PH283.85.066 02.en PDF

D O C U M E N TA Z I O N E
T E C N I C A
PH 283.85.066
USE OF THE CONTROL SYSTEM FOR PH PRESSES
WITH PROFIBUS WITHOUT INTERFACE PC
PH 283.85.066 Rev. 02 Date 12.11.2013
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACIÓN TÉCNICA
DOCUMENTAÇÃO TÉCNICA
LISH
ENG
PH 283.85.066 Rev. 02 Date 12.11.2013
Written by : Mr. Matteo Monduzzi Written on : 29.04.2011

Last revised : 12.11.2013
Revised by : Eng. Alberto Tassoni Program version : PH 19.16.01.12SK/A
PH 21.04.01.12SK/A
PH 26.03.01.12SK/A
(compliance with
"EC STANDARD" excluded)
Title: Number of pages : 252
Service code : CCE12V
Use of the control system for PH presses with profibus
without interface pc Code : PH 283.85.066
GENERAL INFORMATION
INTRODUCTION
Carefully read the entire Instructions Manual before working on the machine and/or the packaging of the various parts.
The Instructions Manual contains important information for safeguarding all personnel who work on the machine as
well as the machine itself.
The company using the machine must always assure all operators have completely read and become familiar with
the operating instructions.
Notwithstanding the machine is equipped with active and passive safety devices, all risks resulting from incorrect
use cannot be avoided.
SACMI shall not be held responsible for failure to heed to safety precautions and accident prevention rules and stan-
dards specified throughout this manual and property damage and personal injury caused by unintended, inappropriate
and erroneous use of the machine.
Any changes to the machine must be duly authorized by SACMI in advance.
Only properly trained personnel are authorized to work on the machine (maintenance, adjustments, repairs, cleaning)
closely following the directions contained in this manual.
SACMI reserves the right to make technical changes to the machine and this manual without giving prior notice.
Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.
Copyright. All rights reserved.
This publication or parts of it are valuable trade secrets and must not be copied, stored, reproduced, disclosed,
transferred or translated into any language, spoken or computer, in any form or by any means without the express
written consent of SACMI.
Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.
SACMI guarantees the contents of this publication.It is severely forbidden to use this publication for other purposes,
whatever they may be, that are extraneous to operation of the machine for which this publication has been drawn up.
The information contained herein is guaranteed as being correct only if the user carefully follows all the guidelines
and instructions provided in this publication.
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PH 283.85.066 Rev. 02 Date 12.11.2013
WHERE TO KEEP THE MANUAL
E0004
IMPORTANT INFORMATION!
The manual and supplements:

- are to be considered an essential part of the machine and must be kept along with it even if the machine is sold;
- must always be kept within easy reach near the machine and protected against environmental agents that may ruin
or damage them;
- must always be available and close by so that operators are able to consult them rapidly at any time.
HOW TO LOCATE AND CONSULT THE INFORMATION
The information and instructions provided in this manual are grouped together organized in chapters, subchapters
and paragraphs. The subject of interest can be easily located by consulting the table of contents.
Information provided with alert, warning or danger symbols must be carefully read.
Notes fundamental for the safety or health of operators are given inside a block pointed out by alert, warning and/or
danger symbols and written in italics, as shown below.
E0004
Carefully read the parts regarding SAFETY EQUIPMENT AND PRECAUTIONS several times as they contain
important safety information and warnings for the operators.
USERS OF THE MANUAL
Machine operators are defined as follows in this manual:

- operator: person responsible for supervising and operating the machine.
- maintenance worker: person responsible for performing routine maintenance.
The exact definition of these operators is given in the OPERATOR TRAINING paragraph in chapter 3 (SAFETY
EQUIPMENT AND PRECAUTIONS) in the INSTRUCTIONS manual.
E0004
The term “operator” is also generically used to identify a person who has to work on the machine: operator,
maintenance worker, etc.
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PH 283.85.066 Rev. 02 Date 12.11.2013
SAFETY EQUIPMENT AND PRECAUTIONS
SAFETY DEVICES & GUARDS
The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard the op-
erators and the machine itself.
It is severely forbidden to alter, tamper with or lock out in any way the safety system provided in the machine. Some
illustrations provided in the manual show the machine, or parts of it, without the guards or with the guards removed
for added clarity.
Never use the machine without the safety devices or with the safety devices shut off or locked out.
Warning signs are provided on the machine to indicate any hazards in the zone where the sign is attached. In addi-
tion, plates with important safety information and/or pictograms that advice on correct and safe machine operation
are provided. Always take all necessary safety precautions and follow the guidelines when working on the machine.
SACMI shall not be held responsible for any personal injury or property damage resulting from tampering or failure
to use the safety devices provided. The presence of safety devices does not exempt the operators from exercising
extreme caution during work, avoiding actions that may endanger him/herself or damage the machine at all times. In
particular, the workers must never come into contact with moving machine parts.
SAFETY DEVICES INSTALLED
- Shutdown devices
The shutdown devices signal any malfunctioning and stop the machine or prevent it from being started up.
- Shutdown signals
Each time a fault arises causing the machine to shut down, the operator is informed by the flashing beacon on top of
the electrical cabinet. The cause of the fault which caused the machine to shut down is shown on the keyboard screen.
The fault messages are described in detail in the INSTRUCTIONS B manual.
- Operator protective devices

The machines are generally provided with movable safety guards connected to electrical shutdown devices. In addi-
tion, there are fixed mechanical guards which prevent the operator from accidentally coming into contact with moving
parts or other dangerous components such as live or hot parts.
- Emergency stop buttons

Emergency stop buttons are provided.
These buttons need to be pressed and cause the machine to shutdown immediately.
E0004
If SACMI does not supply the entire assembly which the machine is to be incorporated in the end user is
responsible for connecting the emergency shutdown circuit of the machine dealt with in this manual to the
emergency shutdown circuit of the line in which it is installed.
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PH 283.85.066 Rev. 02 Date 12.11.2013
MACHINE GUIDELINES
E0004
Before attempting to carry out any work on the machine, all the operators must:
- make sure the machine cannot be accidentally started up by shutting off all the power supplies (electrical power, air
supply, etc..) with personal locks (for example pad locks) stamped with the name of the worker who put it on;
- remove and personally hold on to the keys to the locks.
E0007
The electrical control cabinets, like the junction boxes on-board the machine contain parts that may be live. Specific
tools need to be used to access as per the requirements in standard EN 60204-1. Only qualified personnel authorized
to access live parts should be given this tool. When the electrical control cabinet is energized, qualified personnel can
only re-arm the protective devices for the electric circuit.
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.
E0007
Some safety devices may have to be temporarily removed or made in operative to carry out certain maintenance
operations and/or to adjust parts. Always put these devices back into place after maintenance and/or adjustments
have been completed before attempting to start up the machine.
6
PH 283.85.066 Rev. 02 Date 12.11.2013
E0007
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 (replace if damaged) and the efficiency of the grounding connection.
E0004
Never take plates and signs off the machine. The user must keep clean and restore the markings (on wires, terminals,
devices, etc…) plates and labels when no longer legible.
E0004
Never use the machine if any of the safety devices are malfunctioning under any circumstances. Immediately shutdown
the machine cutting off all the power sources. Turn the machine back on only when all the safety devices work efficiently.
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PH 283.85.066 Rev. 02 Date 12.11.2013
1 OPERATION OF THE DEVICES AND SENSORS
Device Connection Physical condition Led signal
Push-button N.O. Pressed LED on

Available LED off
N.C. Pressed LED off
Available LED on
Selector switch Closed in pos. x LED on

Open in pos. x LED off
Miniature switch N.O. Activated LED on

Deactivated LED off
N.C. Activated LED off
Deactivated LED on
Proximity
sensor N.O. Activated LED on
Deactivated LED off
Scanner
photocell N.O. Triggered LED on
Untriggered LED off
Reflector / Triggered LED off
detector unit Untriggered LED on
Contactors-relays N.O. Energized LED on

De-energized LED off
N.C. Energized LED off
De-energized LED on
Level sensor
Pressure switch
Flow meter
Thermostat N.O. Above threshold LED on
Below the threshold LED off
N.C. Above threshold LED off
Below the threshold LED on
Vacuum control N.O. Above pressure limit LED on

Below pressure limit LED off
N.C. Above pressure limit LED off
Below pressure limit LED on
8
PH 283.85.066 Rev. 02 Date 12.11.2013
2 WARNINGS
MAINTENANCE PROCEDURES
- When welding, disconnect the machine from the electrical cabinets by unplugging the connecting cables.
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PH 283.85.066 Rev. 02 Date 12.11.2013
3 MAIN FEATURES OF THE ELECTRICAL SYSTEM
The electric system basically consists of:

1) Electrical cabinet
2) Display/control keyboard
3) Wiring
1) ELECTRICAL CONTROL CABINET
The cabinet is divided into 3 parts:

1.1) The left module contains the power components used for die-set heating.
1.2) The middle module contains all the devices that control the electric motors.
The controls for the motors are protected with magnetic thermal cut-outs (for power outputs less than 11 kW)
with mixed co-ordination (Ir, type 2, Iq type 1).
Y-D starters are used with power outputs greater than 15 kW.
All the power components are mounted on a bus bar.
1.3) The right module contains the automation PC with Profibus master card, interface PC and relative UPS for
correct shutdown in the event of a black out.
It also contains the emergency circuit that controls all the safety devices, such as mobile safety guards in the press
front, emergency stop button on the control keyboard, external emergency stop buttons, etc.. separately from the
electronic section.
2) VISUAL DISPLAY UNIT/CONTROL KEYBOARD
The top section has a 15 inch color monitor with alphanumeric keyboard; transponder key for operator login connected
to the central unit through a remote control device (only with PC interface).
The bottom section has a machine control keyboard connected to the central unit through a field bus.
3) WIRING
Field bus wiring is used. A Profibus-DP bus is employed.

The layout includes:
1 master located in the automation PC in the electrical control cabinet.
2 segments connected to one another by a repeater located in box 1 on-board the press:
The first segment runs from the master and terminates in box 1 on-board the press.
The second segment runs from the repeater and ends in the cabinet on-board the filler-box.
Along with the Profibus cable where data run, power cables are used and the inputs/outputs are connected to the
adjacent slaves.
The wiring meets all installation and maintenance requirements.
All the single parts are hooked up using connectors so that they can be quickly disconnected/connected.
All the materials employed for machine wiring have been carefully examined and selected taking into account the
aggressive agents found in the work area.
However, it is advisable to always keep the boxes/electrical cabinets closed.
The entire electric system is tested according to current safety regulations.

The entire electric system has been designed and developed in compliance with current international electrical codes
and regulations regarding safety of machinery.
10
4
25 26
0 1 2 3 8 9 10 11 16 17 18
PH 283.85.066 Rev. 02 Date 12.11.2013
27 28 29
19-23
24 4 5 6 7 12 13 14 15 20 21 22 30 31
MACHINE CONTROL KEYBOARD
25 26
0 1 2 3 8 9 10 11 16 17 18
27 28 29
19-23
24 4 5 6 7 12 13 14 15 20 21 22 30 31
(Keyboard provided with DIP)
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PH 283.85.066 Rev. 02 Date 12.11.2013
4.1 DESCRIPTION OF THE KEYS
OPERATION 1ST KEY 2ND KEY + KEY PUMP

Pump start Ø
Alarm reset 1
Led and lamp test 26+31 1 MAN/SET-UP
Automatic cycle start 28* 2 AUT ON
Start of semi-automatic loading 28* 2 AUT ON
Start of semi-automatic press-cycle 28* 2 AUT ON
Start of semi-automatic press-cycle in manual ( ) 20
28* 2 AUT ON
SQ59 learning for filler-box encoder control ( ) 40
28 2 AUT ON
Plunger upstroke 25 3 MAN/AUT ON
Plunger downstroke 30 3 MAN ON
Slow plunger upstroke 25 3 SET-UP ON
Slow plunger downstroke 30 3 SET-UP ON
Manual column lubrication cycle start (optional) 28 3
Pump stop 4
Repositioning 28 5 AUT ON
Automatic cycle stop 6
Braking force increase (3) 26 12 MAN/AUT
Braking force decrease ( ) 3
31 12 MAN/AUT
Braking force decrease beyond the limit switch ( ) 3
31 12 SET-UP
Braking force increase beyond the limit switch ( ) 3
26 12 SET-UP
Assign analog braking input offset (3) 25 12 SET-UP
Assign analog braking input gain (3) 30 12 SET-UP
Booster upstroke ( )45
25 12 MAN
Booster downstroke ( ) 45
30 12 MAN
Request to set maximum pressure ( ) 13
28 7 SET-UP ON
YV99 self-learning procedure ( ) 14
28 7 SET-UP ON
YV99 pressure check ( ) 15
28 7 SET-UP ON
YV32/YV318/YV70D self-learning procedure ( ) 18
28 7 MAN ON
YV100 self-learning procedure (19) 28 7 MAN ON
External booster drainage ( ) 12
28 7 MAN ON
External booster encoder reset ( ) 5
28 7 MAN ON
YV21P self-learning procedure ( ) 22
28 7 MAN ON
YV21P offset reset ( ) 23
28 7 SET-UP OFF
Proportional valve YV32/318/70D cleaning (11) 28 7 MAN ON
SPE proportional valve cleaning with oil (32) 28 7 SET-UP ON
SPE proportional valve cleaning without oil ( ) 33
28 7 SET-UP ON
Knockout prop. valve YV21P cleaning ( ) 32
28 7 SET-UP ON
DCP filler-box proportional valve cleaning ( ) 4
28 7 MAN ON
Force SPE encoders not reset ( ) 34
28 7 SET-UP
CFM: Magnetic lock card setting ( ) 42
28 7 SET-UP OFF
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PH 283.85.066 Rev. 02 Date 12.11.2013
DIP: Berger Lahr setting (39) 28 7 SET-UP OFF

Cylinder pressure transducer adjustment (41) 28 7 SET-UP OFF
Check DCP filler-box proportional solenoid valve 28 7 MAN OFF
operation (38)
Check SPE knockout proportional solenoid valve 28 7 SET-UP OFF
operation (37)
Check pressing proportional solenoid valve 28 7 MAN ON
operation (36)
Filler-box forward 29 8 MAN ON
Filler-box reverse 27 8 MAN ON
In-line filler-box forward stroke beyond limit switch 26 8 MAN ON
(21)
In-line filler-box return stroke beyond limit switch 31 8 MAN ON
(21)
Upper punches in 25 9 MAN/SET-UP ON
Upper punches out 30 9 MAN/SET-UP ON
Diff. stroke booster forward (optional) 29 10 MAN ON
Diff. stroke booster back (optional) 27 10 MAN ON
Lower die up (optional) ( ) 44
25 10 MAN/SET-UP ON
Lower die down (optional) ( ) 44
30 10 MAN/SET-UP ON
Upper die up (optional) ( ) 44
25 10 MAN/SET-UP ON
Upper die down (optional) (44) 30 10 MAN/SET-UP ON
Upper die-set released ( ) 43
31 11 SET-UP
Upper die-set locked 26 11 SET-UP
Isostatic/differentiated encoder reset request (35) 28 7 MAN ON
Thickness increase (1) 26 12 MAN/AUT
Thickness decrease (1) 31 12 MAN/AUT
Oil leak recovery pump start/stop ( ) 25
28 12 MAN
Selected valves control in manual mode ( ) 30
28 12 MAN
Locks in/out for SMU die-set change ( ) 2
28 12 SET-UP
Die-sets up/overtravel (16) 25 13 MAN/SET-UP ON
Die-sets down ( ) 17
30 13 MAN/SET-UP ON
SPE die-set lift 2+2 ( ) 6
25 13 SET-UP ON
SPE emergency upstroke 2+2 ( ) 7
25 13 SET-UP ON
Downstroke after SPE lifting 2+2 ( ) 8
30 13 SET-UP ON
SPE emergency downstroke 2+2 ( ) 9
30 13 SET-UP ON
SPE self-learning procedure 2+2 (10) 28 13 SET-UP ON
Lower punch holder released (optional) 31 14 SET-UP
Lower punch holder locked (optional) 26 14 SET-UP
Lower die-set released 31 15 SET-UP
Lower die-set locked 26 15 SET-UP
Proportional knockout locked 28 16 SET-UP ON
Proportional knockout release 28 16 SET-UP ON
Lift rod release 28 16 SET-UP ON
ALM in semi-automatic mode 28 17 AUT ON
ACP in semi-automatic mode 28 18 AUT ON
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PH 283.85.066 Rev. 02 Date 12.11.2013
Powered suction hood up 25 20

Powered suction hood down 30 20
ALM forward 29 17 MAN ON
ALM reverse 27 17 MAN ON
ALM forward stroke beyond limit switch ( ) 21
26 17 MAN ON
ALM return stroke beyond limit switch ( )
21
31 17 MAN ON
ACP in manual mode 27 or 29 18 MAN ON
Left ACP beyond limit switch ( )
21
26 18 MAN ON
Right ACP beyond limit switch ( ) 21
31 18 MAN ON
Shutdown 24
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PH 283.85.066 Rev. 02 Date 12.11.2013
DIP
Photocells SQ38-SQ39 set-up cycle (24) 28 7 MAN ON
Damaged tile ejection (26) 28 8 AUT ON
Filler-box forward in manual mode (27) (steady speed) 29 8 MAN ON
Filler-box reverse in manual mode (28) (steady speed) 27 8 MAN ON
Filler-box forward in manual mode (opened loop) (29) 26 8 MAN ON
(steady speed)
Filler-box reverse in manual mode (opened loop) (29) 31 8 MAN ON
(steady speed)
Roller conveyor A forward in manual mode (steady 29 17 MAN ON
speed)
Roller conveyor A reverse in manual mode (steady 27 17 MAN ON
speed)
Roller conveyor B forward in manual mode (steady 29 18 MAN ON
speed)
Roller conveyor B reverse in manual mode (steady 27 18 MAN ON
speed)
Roller conveyor C forward in manual mode (steady 29 21 MAN ON
speed)
Roller conveyor C reverse in manual mode (steady 27 21 MAN ON
speed)
ACD
Color ACP manual operation 27 or 29 21 MAN ON
Color ACP beyond limit switch (left) 26 21 MAN ON
Color ACP beyond limit switch (right) 31 21 MAN ON
Color ACP semiautomatic mode 28 21 AUT ON
MDR2 slow continuous rotation 26 or 31 22 MAN ON
MDR2 1 step rotation (60 degrees) 27 or 29 22 MAN ON
MDR2/DAC semiautomatic mode 28 22 AUT ON
Mobile grid beyond limit switches (forward)(31) 26 12 MAN ON
Mobile grid beyond limit switches (return) (31) 31 12 MAN ON
Mobile grid forward (31) 29 12 MAN ON
Mobile grid return (31) 27 12 MAN ON
Mobile grid encoder reset 28 5 AUT ON
MDR2 encoder reset 28 5 AUT ON
FAST DIE-SET CHANGE
A key called 'Continuous action button' identified with SB11 is provided on the left side of the page.
Plunger upstroke SB11 25 SET-UP ON
Plunger downstroke SB11 30 SET-UP ON
Beam piston upstroke SB11 25 SET-UP ON
Beam piston downstroke SB11 30 SET-UP ON
Beam forward (open-loop) SB11 26 SET-UP ON
Beam forward SB11 29 SET-UP ON
Beam return (open-loop) SB11 31 SET-UP ON
Beam return SB11 27 SET-UP ON
Upp. control assembly magnetization SB11 + SA8 11 SET-UP ON
Low. control assembly magnetization SB11 + SA8 15 SET-UP ON
Upp./low. control assembly magnetization SB11 + SA8 11 or 15 SET-UP ON
Upp. control assembly released SB11 + SA8 11 SET-UP ON
Low. control assembly release SB11 + SA8 15 SET-UP ON
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PH 283.85.066 Rev. 02 Date 12.11.2013
Upp./low. control assembly release SB11 + SA8 11 or 15 SET-UP ON

Phase 1 engagement SB11 16 SET-UP ON
Phase 1 disengagement SB11 16 SET-UP ON
Automatic mold installation SB11 28 SET-UP ON
Automatic mold removal SB11 28 SET-UP ON
Reset, Beam piston divider SB11 25 or 30 SET-UP ON
Beam piston drainage SB11 25 or 30 SET-UP ON
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PH 283.85.066 Rev. 02 Date 12.11.2013
Notes:
* Use key F12 on the computer terminal to select the type of work-cycle.
+
Two keys need to be used for most operations. However, some of them can be performed by pressing only
one key. In these cases, the number of the key which has to be pressed appears in the column marked “2ND
KEY”.
(1 ) Operation possible only with SMU/LIFT.

Set solenoid valves in manual mode” (YV MAN) = 35
(2 ) Set "solenoid valves in manual mode” (YV MAN) = 36
(3 ) Operation possible only in presses with non-proportional hydraulics.

Set “solenoid valves in manual mode” (YV MAN) = 34
It is possible to increase/decrease only if data item SPEED CONTROL ON = NO.
(4 ) Only for filler-boxes with crank-connecting rod mechanism. SPECIAL OPERATION = 26 has to be set (with
PC interface, go to the "Special operations" page). The plunger should be raised with the encoder reset. The
mobile safety guards of the pressing zone should be closed (in work position) with safety module AJ101 armed.
The die-set should be down and the filler-box encoder has to have already been reset.
(5 ) SPECIAL OPERATION = 12 has to be set (with PC interface, go to the "Special operations" page). The mobile
safety guards of the pressing zone should be closed (in work position) with safety module AJ101 armed. The
filler-box should be back.
(6 ) The following data items must be set as indicated: DIE-SET FASTENED = NO and DIE-SET DISASSEMBLY =
2. The safety guards of the pressing zone should be open; the filler-box should be back; the die-set encoders
should be blocked and the self-learning procedure for SPE 2+2 carried out.
should be blocked and the "DIE-SET ENCODER NOT RESET” message displayed.
should be blocked and the self-learning procedure for SPE 2+2 carried out.
should be blocked and the "DIE-SET ENCODER NOT RESET” message displayed.
(10) The following data items must be set as indicated:DIE-SET FASTENED = NO and DIE-SET DISASSEMBLY = 1.
The safety guards of the pressing zone should be open; the filler-box should be back; the die-set encoders should
not be blocked and the "DIE-SET ENCODER NOT RESET” message not displayed. The die-set should be down.
(11) Operation possible only in presses with proportional hydraulics. SPECIAL OPERATION = 21 has to be set
(with PC interface, go to the "Special operations" page). The plunger should be raised with the encoders reset.
The mobile safety guards of the pressing zone should be closed (in work position) with safety module AJ101
armed. The filler-box should be back. The die-set should be down.
(12) SPECIAL OPERATION = 19 has to be set (with PC interface, go to the "Special operations" page).
Encoder BQ12 for the booster must be reset. It takes approximately 10 minutes to drain the booster. This
procedure can be interrupted at any time with the mode selector.
(13) Available only in PCH. SPECIAL OPERATION = 1 has to be set (with PC interface, go to the "Special operations" page).
The circuit pressure reaches a value equal to the pressure set for the FINAL PRESSURE data item on the
Press-cycle set-up page.
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PH 283.85.066 Rev. 02 Date 12.11.2013
(14) Available only in PCH. SPECIAL OPERATION = 2 must be set (with PC interface, go to the "Special operations" page).
(15) Available only in PCH. SPECIAL OPERATION = 3 must be set (with PC interface, go to the "Special operations" page).
(16) When a proportional rod lift system is used, the upstroke in SET-UP mode is interrupted as soon as one of the
two keys is released.
Set PUNCH OVERTRAVEL = YES to perform the overrun.
With SPE:
- With the key turned to MAN, the die-sets can be moved up only with the die-set down (this is not true when
the key is turned to SET-UP with card AXP).
- With the safety guards of the pressing zone open and key turned to MAN the die-set cannot move.
With SMU or lift system:
(17) When a proportional rod lift system is used, the downstroke in SET-UP mode is interrupted as soon as one of
the two keys is released.
Downstroke with the mode selector turned to MAN:
with a 2-downstroke cycle:
the first die-set downstroke is executed by pressing keys 30 and 13;
the last die-set downstroke is executed by pressing keys 31 and 13.
with a 3-downstroke cycle:
the first die-set downstroke is executed by pressing keys 26 and 13;
the second die-set downstroke is executed by pressing keys 30 and 13;
the last die-set downstroke is executed by pressing keys 31 and 13.
With SPE:
- The following operations take place with the key turned to MAN:
first downstroke
second downstroke, if performed
last downstroke
upstroke up to the position in which the first downstroke takes place
and so on
- The following operations take place with the key turned to SET-UP:
first downstroke
last downstroke
With SMU or lift system:
- The following operations take place with the key turned to MAN or to SET-UP:
first downstroke
last downstroke
upstroke up to the position in which the first downstroke takes place
and so on
(18) SPECIAL OPERATION NO. = 10 must be set (with PC interface, go to the "Special operations" page).
The filler-box must be hooked up, the mobile safety guards of the pressing zone should be closed (in work
position), the filler-box should be back, the die-set should be down and the plunger raised with the encoders
zero set.
(19) Available only for differentiated press-cycles. SPECIAL OPERATION = 11 must be set (with PC interface, go
to the "Special operations" page).
The filler-box must be hooked up and encoder BQ11 for the differentiated booster zero set.
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PH 283.85.066 Rev. 02 Date 12.11.2013
(20) If SEMI-AUTOMATIC PRESS-CYCLE IN MANUAL has been selected and two encoders are mounted for the
plunger, once a semi-automatic loading cycle has been completed, if the safety guards of the pressing zone
are closed (in work position) the pressing zone guards can be opened and closed and a semi-automatic press-
cycle can be carried out.
(21) Operation possible with in-line filler-box, ALM or ACP with absolute encoders (even if they are not zero set yet).
If an SPE is used, the filler-box can operate only if the die-set is locked.
(22) Available only with proportional rod lift system. SPECIAL OPERATION NO. = 14 must be set (with PC interface,
go to the "Special operations" page).
The safety guards of the pressing zone should be closed (in work position), the filler-box should be back, the
die-set encoder should be down and the plunger raised with the encoders zero set.
(23) Available only with proportional rod lift system. SPECIAL OPERATION = 15 must be set (with PC interface, go
to the "Special operations" page).
If problems arise during the YV21P self-learning procedure which prevent the correct offset values from being
determined or the values found do not allow for proper upward movement, the values can be assigned manually.
This is accomplished by setting the value in valve points of the downstroke and upstroke for the DOWNSTROKE
and UPSTROKE items.
(24) Available only with DIP. SPECIAL OPERATION = 5 has to be set (with PC interface, go to the "Special opera-
tions" page). The DIP encoder must be reset, the safety guards of the pressing zone should be closed (in work
position) with safety module AJ101 armed. A tile should be present (SQ43 triggered).
(25) Set "solenoid valves in manual mode” (YV MAN) = 11
(26) The movement can be performed if no faults are present, if the encoder is zero set, if damaged tile ejection
cycle = yes and sensor SQ43 is activated.
The cycle consists of bringing the tile under the PH obviously without performing the press-cycle.
At the end of the cycle, the data item that enables the cycle is automatically set to = no.
(27) The movement can be performed if no faults are present, if the encoder is zero set, if the plunger and die-sets
are raised.
Movement is interrupted either when the end of forward stroke limit switch is reached or the keys are released.
(28) The movement can be performed if no faults are present, if the encoder is zero set, if the plunger and die-sets
are raised.
If a cycle with die-set downstroke has been set, the front band and knockout are automatically raised.
Movement is interrupted either when the end of return stroke limit switch is reached or the keys are released.
(29) The filler-box moves at a very low speed that cannot be set without taking into consideration the position read
by the encoder and set end of the strokes. The movement is limited by the end–stop.
Release the keys to interrupt the movement.
The movement can be carried out even when the encoder is not reset.
(30) After selecting the valve in question, press the keys to energize and de–energize it sequentially (ON –> OFF
–> ON –> OFF, etc...). The led indicates whether or not the selected valve is currently energized.
(31) Set “solenoid valve in manual mode” (YVMAN) = 20.
(32) Only for SPE 2 + 2 or knockouts with proportional rods. SPECIAL OPERATION = 22 must be set (with PC
interface, go to the "Special operations" page).
The die-set should be down. The safety guards of the pressing zone should be closed (in work position) and
the plunger up with the encoders reset. The filler-box should be back.
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(33) For SPE 2 + 2 and 4 piston SPE. SPECIAL OPERATION = 23 must be set (with PC interface, go to the "Special
operations" page).
The die-set should be down. The safety guards of the pressing zone should be closed (in work position) and
the plunger up with the encoders reset. The filler-box should be back.
(34) Set SPECIAL OPERATION = 24 (with PC interface, go to the "Special operations" page).
The die-set should be down.
(34) Set SPECIAL OPERATION = 13 (with PC interface, go to the "Special operations" page).
(36) Set SPECIAL OPERATION = 6 (with PC interface, go to the "Special operations" page). For more detailed
information, see the SPECIAL OPERATION paragraph.
(42) Set SPECIAL OPERATION = 31/32/33 (with PC interface, go to the "Special operations" page). For more de-
tailed information, see the SPECIAL OPERATION paragraph.
(43) The upper magnetic lock can be unlocked only if the safety guards of the pressing zone are closed (in work
position) and the plunger is not up.
(44) In program versions 21.xx.yy / 23.xx.yy / 26.xx.yy and later, keep the keys pressed to complete the slow SET-
UP movement. The SET-UP movement does not occur for the other program versions. However, if the keys
are pressed for 10 seconds, an alarm is displayed and oil is restored.
(45) Only for Imola presses. Set “solenoid valve in manual” (YV.MAN) = 9.
4.2 DESCRIPTION OF THE LEDS
+5 Keyboard supply (+5V)
R Reset
WD Watch-dog
SL Serial line (lights up if connection between the keyboard and Profibus network is down)
SC Scan control (this LED comes on to signal key malfunctioning)
B Comes on when a key is pressed
}
A1
Keyboard address (both of them on → first keyboard)
A2
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5 PROGRAMMING KEYBOARD
A Display
B Function keys (F1, F2, ..., F12)
C CTRL key
D Number keys (1, 2, ..., 0)
E: Mouse
F: Leds signaling the following:
Power: PC power-on
B: Buttons pressed
Caps: Letters entered in upper case
Scroll: Enables Scroll
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6 PAGE LAY-OUT
Information about machine operation is given on a number of video pages.
Page layout is shown below:
1 2 3
4 5
1 - Fault messages
2 - No. of the operating program
3 - Date and time
4 - Description of the work-cycle
5 - Machine status
6 - Data input and read-out
7 - Description of the function keys
Items 1, 2, 3, 4, 5 appear on all the pages. Items 6 and 7 change from page to page.
The first page displayed is given as an example: the DATA page.
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6.1 OPERATING PROGRAM NUMBER
This number indicates the program the press is being run on.
If an asterisk (*) appears to the right of the number, it means that changes have been made to the program which
have not been saved yet.
If the number of the operating program is ø, it means that this program has not been saved yet (this may happen when
the system is turned on for the first time or when the operating program has been deleted).
If symbol + appears to the left of the operating program it means that besides the fault message actually displayed to
the left other messages are present. Go to the “faults page” to read these messages.
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6.2 DATE AND TIME
If the DATE and TIME are not correct, follow the directions given below:
1) LOG IN (see relative paragraph)
2) go to the INFORMATION AND LANGUAGE SELECTION page (INFO)
3) press key F10 (DATA)
4) answer the software-generated question that appears on the bottom left-hand side:
Question Response (example)
YEAR 08 <ENTER>
MONTH 11 <ENTER>
DAY OF MONTH 30 <ENTER>
HOUR 16 <ENTER>
MINUTE 8 <ENTER>
SECOND 0 <ENTER>
5) the set date and time will now appear (on top right-hand side).
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6.3 DESCRIPTION OF THE WORK CYCLE
Key F12 serves to set up the type of cycle executed when the cycle is started (press keys 28 and 2 on the machine
control keyboard).
This can be done only if the key selector is turned to position AUT and the press is not running in automatic mode or
being reset.
The automatic cycle is the standard one and in this case, the following appears on the second line of the display screen:
CYCLE = AUTOMATIC (LOADING + PRESS-CYCLE)
The following appears if key F12 is pressed:
CYCLE = 1 CYCLE (LOADING + PRESS-CYCLE)
To be used to perform a single cycle.
If F12 is pressed again the following appears:
CYCLE = SEMIAUTOMATIC LOADING
If F12 is pressed again the following appears:
CYCLE = SEMIAUTOMATIC PRESS CYCLE)
Press F12 again to go back to the standard cycle.
If SEMI-AUTOMATIC PRESS-CYCLE IN MANUAL has been selected and two encoders are mounted for the plunger,
once a semi-automatic loading cycle has been completed, if the safety guards of the pressing zone are closed (in work
position), press F12 twice to open and close the pressing zone guards and to carry out a semi-automatic press-cycle.
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6.4 MACHINE STATUS
Press status appears on the right hand side of the second line. The various states are described below:
MAN key on keyboard turned to position MAN

SET UP key on keyboard turned to position SET UP
AUT key on keyboard turned to position AUT
REPOSITIONING automatic reset cycle in progress (key turned to AUT)
CYCLE press performing automatic cycle (key turned to AUT)
CYCLE (flashing) press going to stop (key turned to AUT)
NOTE: If the key switch (on the keyboard) is turned during RESETTING or CYCLE, the press will shutdown
6.4.1 LOGIN
If nothing appears to the right of machine status and “LOGIN” is given for the description of key F11, it means the data
can be read but not set. It is necessary to log in order to set the data:
• Press key F11.
• Type the password (the default password is “11111111”).
Data can be set if “LOGIN” appears to the right of machine status.

Log out to end the data input session:
• Press key F11.
CHANGE PASSWORD
Press key F11.

When LOGIN ******** = appears press Enter.
Type the old password (example 11111111).
Enter the new password (it must consist of at least 4 characters) and press ENTER (NOTE: if the new 8-character
password is entered, do not press ENTER).
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7 LIST OF THE PAGES
The following pages regarding press operation are provided:
As already mentioned, the DATA page is displayed when the system is turned on. To go to other pages, press any
function key, for example, to go from PROGRAMS to DATA , press the F2 key.
The pages given on the left-hand side of the screen, contain the operating and production data for the press. On the
other hand, the pages on the right-hand side show the settings for the machine cycle. These settings can be changed
if necessary.
The Help key (F1) can be used with any page displayed. When this key is pressed, the “Help” page that contains the
following information is displayed: the list of the pages provided (similar to the one shown above) is given on the top
of the page, the title of the video-page selected will flash.
In addition, useful information for the operator is given on the bottom of the page.
The user can gain access only to the pages which (in the list of the pages provided) are joined together by a straight line.
Press one of keys ↑ ↓ ← → to change the page whose title is highlighted. To go to another page through the Help
page, press these keys until the title of the required page appears then press ENTER or F1.
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The ALARMS page can be accessed from the HELP page. The list of alarms the operator can set which stop the
machine is given on this page. This allows the operator to know machine downtime due to one of the causes listed.
As a result, a detailed report with charts illustrating the causes of machine shutdown is provided.
Use the arrow keys ↑ ↓ to select the cause.

To make the selection operative use the ← or → arrow keys.
Note: the causes of press shutdown can be selected only if there are no faults present and the machine is not run-
ning in automatic mode. If a stoppage message is shown, the new cause of machine shutdown can be set by using
the functions given above.
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8 OPERATING DATA DISPLAY
The contents of the pages, except for the first and second lines, are given below.
8.1 DATA
DATA is the first page displayed.
a) Data regarding the cycle that has just been completed are given in the first box to the left. The top of the page
shows the tile size being produced (to change these three values, go to the FITTINGS page).
b) Data recorded by the transducers installed in the machine appear in the right box. These values are refreshed
in real time.
A value expressed in bar that represents the applied offset value appears to the right of the CYLINDER PRES-
SURE. For example, if the cylinder pressure is 3 and the offset value is 2 it means that the value read by pres-
sure transducer BP1 is 1 bar.
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c) The machine production data are given in the box at the bottom. The TOTAL values cannot be zeroed while
the PARTIAL values can. In this case, log in and press key F6. The system asks you to CONFIRM. If key “1”
is pressed, all the partial data are zeroed.
Press either key “0” or F6 if you do not want to zero the data.
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8.2 INFORMATION AND LANGUAGE SELECTION PAGE
Press the F7 key (INFO) to go from “DATA” to the “INFORMATION AND LANGUAGE SELECTION” page.
Typical press parameters divided into two parts are shown here: mechanical and hydraulic parameters are shown to
the left, while electronic parameters appear to the right.
These parameters are constant.

Press the F2 key to return to the “DATA” page.
8.2.1 SCREEN SAVER FUNCTION
Press key F6 to enable the screen saver function. When the screen saver function is activated, the screen automati-
cally switches off displaying the SACMI logo ten minutes after a key on the computer keyboard was last pressed. This
function extends the service life of the screen.
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8.2.2 LANGUAGE SELECTION
This page allows the operator to change the local language used for all the messages. Press the F3 key.
The following page appears:
Use keys ↑ ↓ to select the language.

Select with key → or ← or Enter.
INSTRUCTIONS FOR SELECTING ITALIAN AS THE LANGUAGE

Go to page DATA (if you do not know the procedure, simply shut off and turn the controller back on, DATA is the first
page displayed) and press F7 then F3, press → reaching the first line at the top, press →.
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8.2.3 SELECT LOAD TYPE
Press F4 with the pump shut off to go to the following page:
When the mode selector is turned to SET UP the type of filler-box controlled by the controller can be changed by se-
lecting from amongst the ones indicated to the right of the setting. The number shown to the right of SELECT LOAD
TYPE is the actual type of loading selected.
NOTE The system needs to be shut off and turned back on when this data item is changed.
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8.2.4 SPECIAL OPERATIONS AND ENCODER RESET PAGE
Press key F5 from the INFO page to go to this page.

Data items that can be set on this page:
SPECIAL OPERATION
Type of adjustments to be made on the press (see paragraph DESCRIPTION OF THE KEYS as well):
0 = no operation
1 = CHECK ACCUMULATOR PRESSURE

Available only for PCH.
2 = YV99 LEARNING
3 = CHECK YV99 LEARNING

5 = DIP: SET UP SQ38 ... SQ39

Available only with DIP type filler-box.
This is an automatic procedure to set sensors SQ38 (rear tile corner check) and sensors SQ39 (front tile
corner check).
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6 = CHECK YV32/YV318
Available only with proportional hydraulic system.
This procedure is carried out to test the pressing and proportional plunger drive solenoid valves. More
precisely, a command is sent to YV32 that equals the value set for YV32 COMMAND and a command is
sent to YV318 that equals the value set for YV318 COMMAND without moving the plunger. This condition
persists for 10 sec during which it is advisable to check the I/O page to verify if the command (SET) and
relative feedback (SPOOL) of the proportional valves follow the command given.
9 = CHECK YV22A/YV22B or CHECK YV21P

Available only with proportional knockout.
This procedure is carried out to test the proportional knockout drive solenoid valves.
SPE:
An upstroke command is sent to YV22A and B equal to the value set for SPEED – DIE-SET UPSTROKE
without moving the die-set. This condition remains for 10 seconds. At this time, it is advisable to go to the
ACTUAL DIE-SET VALUES page to verify if the command and relative feedback (SPOOL) of the propor-
tional valves follow the commands received. A downstroke command is then sent to YV22A and B equal to
the value set for FIRST DIE-SET DOWNSTROKE SPEED.
This condition remains for 10 seconds. At this time, it is advisable to go to the ACTUAL DIE-SET VALUES
page to verify if the command and relative feedback (SPOOL) of the proportional valves follow the com-
mands received.
EJECTOR WITH RODS:
An upstroke command is sent to YV21P that equals the maximum opening without moving the die-set.
This condition remains for 10 seconds. At this time, it is advisable to go to the I/O page to verify if the
command (SET) and relative feedback (SPOOL) of YV21P follow the commands received. A downstroke
command is then sent to YV21P that equals the maximum opening.
This condition remains for 10 seconds. At this time, it is advisable to go to the I/O page to verify if the com-
mand (SET) and relative feedback (SPOOL) of YV21P follow the commands received.
10 = YV32/YV318 LEARNING
This automatic procedure determines the offset values of the proportional solenoid valves for driving the
plunger and pressing. The operations are performed in the following order:
1. The command to be sent to YV32 to keep the plunger still is acquired.
2. The minimum command that opens YV318 is acquired.
3. The minimum command to be sent to YV32 to lower the plunger is acquired.
4. The minimum command to be sent to YV32 to raise the plunger is acquired.
Some conditions must be satisfied in order to perform the self-learning procedure for the proportional
solenoid valves; one of the fault messages given below may be displayed if one of these conditions is not
satisifed:
904 FILLER-BOX NOT BACKWARD

Move the filler-box fully back.
906 DIE-SET ENCODER NOT RESET
Reset the die-set encoder.
908 DIE-SETS UP
Move the die-set fully down.
911 SAFETY GUARDS OF THE PRESSING ZONE OPEN/(AJ101)
Closer the safety guards of the pressing zone and make sure safety module AJ101 is reset.
912 PLUNGER ENCODER NOT RESET
Reset the plunger encoder.
913 BOOSTER ENCODER NOT RESET
Reset the encoder for the external booster.
914 PLUNGER NOT FULLY UP
Move the plunger fully up.
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11 = YV100 LEARNING
Available only with differentiated press-cycle.
This automatic procedure determines the offset values of the proportional solenoid valves for the isostatic
pads/differentiated pressing unit. The operations are performed in the following order:
1. The command to be sent to YV100 to keep the booster still is acquired.
2. The minimum command to be sent to YV100 in order for the booster to perform its return stroke is ac-
quired.
3. The minimum command to be sent to YV100 in order for the booster to perform its forward stroke is
acquired.
13 = BOOSTER ENCODER RESET

Available only with differentiated press-cycle.
This automatic procedure determines the zero value of the encoder for the isostatic pads/differentiated
pressing unit. The operations are performed in the following order:
1. Booster backed up.
2. Zero position assigned.
3. Booster moved forward.
4. Booster repositioned.
14 = YV21P LEARNING
Available only with rod type proportional knockout.
This automatic procedure determines the offset values of the proportional solenoid valves for the proportional
knockout with rods.
The operations are performed in the following order:
1. knockout moved fully down
2. knockout moved up to determine the minimum upstroke speed
3. knockout moved down to determine the minimum downstroke speed
15 = RESET OFFSET YV21P

Available only with rod type proportional knockout.
The value set for RESET OFFSET YV21P is given to the downstroke offset value for the proportional solenoid
valves of the proportional knockout with rods: D and the value is set for S for the upstroke.
21 = CLEAN YV32/YV318 PROPORTIONAL VALVES

This automatic procedure moves the spool of the proportional solenoid valves for driving the plunger and press-
ing repeatedly without moving the plunger.
22 =
CLEAN SPE PROPORTIONAL VALVES (OIL) / YV21P
Available only with SPE 2+2 or rod type proportional knockout.
SPE 2+2:
This automatic procedure moves the spool of the proportional solenoid valves for driving the knockout repeatedly
without moving the die-set but supplying oil while opening towards the downstroke.
Rod:
without moving the die-set.
23 = CLEAN SPE PROPORTIONAL VALVES

Available only with SPE type knockout.
without moving the die-set.
24 = DIE-SET ENCODER NOT RESET

Available only with SPE type knockout.
This procedure allows the reset procedure for the die-set encoders to be repeated without having to shut off and
turn the electrical cabinet back on.
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25 = CHECK YV20
Available only with DCP type filler-box.
This procedure allows the proportional solenoid valves that drive the filler-box to be tested.
More precisely, a command is sent to YV20 that is equal to the value set for YV20 COMMAND without moving
the filler-box. This condition remains for 10 seconds. At this time, it is advisable to go to the I/O page to verify if
the command (SET) and relative feedback (SPOOL) of YV20 follow the commands received.
26 = CLEAN YV20 PROPORTIONAL VALVES

Available only with DCP type filler-box.
This automatic procedure moves the spool of the proportional solenoid valves for driving the filler-box repeatedly
without moving the filler-box.
28 = DIP: BERGER LAHR SETTINGS

Available only with DIP type filler-box and centering devices on board.
This procedure is performed to set the parameters for driving the centering device motor. This is done for all the
motors present in the DIP.
29 = FILLER-BOX POSIT. LEARNING-SQ59

Available only with DCL or DIP type filler-box.
A control monitors operation of the filler-box encoder. If fault “2265 FILLER-BOX NOT IN PLACE (xxx)” appears
for the DCL or “2284 FILLER-BOX NOT IN PLACE (xxx)” is displayed for the DIP, perform the self-learning pro-
cedure for the positions of the filler-box at which limit switch SQ59 is activated and deactivated. This procedure
consists of a semiautomatic loading cycle. As a result, the system saves the positions of the filler-box encoder at
which sensor SQ59 switches during the forward and return cycles. This procedure should be repeated is sensor
SQ59 is moved, if the zero position of the encoder is changed or if the filler-box speeds are changed near the
sensor.
The control system verifies sensor SQ59 always switches in the same position during each cycle.
30 = CYLINDER PRESSURE TRANSDUCER ADJUSTMENT

This procedure allows an offset value to be automatically assigned to the value read by the cylinder pressure
transducer (BP1). If the operation is not successfully completed (fault message 2016) it means that the pressure
error is too high. The applied offset value (in bar) is shown to the right of the CYLINDER PRESSURE
(for example if CYLINDER PRESSURE = 2 and 2 appears to the right, it means that the value given by the
transducer is 0 bar).
31 = Setting the first profibus current control channel

When this operation is carried out, the system calculates the electrical resistance value of the magnetic
lock’s circuit windings (upper magnetic lock). During regular press operation, the system uses this as a
reference value and calculates the estimated current each and every second taking into consideration
temperature and voltage variations. This value is then compared to the current actually read thereby al-
lowing fault diagnosis.
This operation should be carried out only at machine start-up, when the die-set or just the pads to be
magnetized or reader AP610 is replaced.
- When this operation is required, it is necessary to answer some queries called:

Setting data before performing setup operations
- Is it the first time setting? Has the die-set been changed? (YES/NO)
If the answer is YES, the system does not check the old electrical resistance value saved that is overwritten
with the new value. On the other hand, if NO is entered, the system attempts to find an electrical resistance
value as close to the previously saved value as possible. If the difference is greater than + or – 0.5 ohm
the new value is not saved and a message is displayed informing the user the system has not been set.
This prevents the system from being set when an alarm signaling an electric fault that causes the current
to drop is given which would otherwise eliminate the alarm but not the problem. As this query has to be
answered, it is understandable that the operator may have some questions (why is a set-up procedure
necessary if the die-set has not been changed? Why has the current changed? Is a fault present that the
system correctly detected?) and will therefore perform this procedure only if truly required.
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- Die-set temperature? ( C)
This question is asked only if data item “Thermocouple presence, first current control channel = no”
Set the temperature of the die-set or windings of the magnetic lock connected to the first channel (upper
punches) when the set-up procedure is performed. The system uses this value to correctly calculate the
electrical resistance value of the windings.
It is also used during regular press operation together with an algorithm to determine the estimated tem-
perature of the die-set and therefore the reference current to be compared to the one actually read.
- Ambient temperature? ( C)
This question is asked only if data item “Thermocouple presence, first current control channel = no”
Set the ambient temperature (press zone) when the set-up procedure is performed. The system uses this
value to correctly calculate the electrical resistance value of the windings.
32 = Setting the second profibus current control channel

lock’s circuit windings (lower magnetic lock). During regular press operation, the system uses this as a

This question is asked only if data item “Thermocouple presence, second current control channel = no”
Set the temperature of the die-set or windings of the magnetic lock connected to the second channel (lower
This question is asked only if data item “Thermocouple presence, second current control channel = no”
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33 = Setting the third profibus current control channel

lock’s circuit windings (lower magnetic lock). During regular press operation, the system uses this as a

This question is asked only if data item “Thermocouple presence, third current control channel = no”
Set the temperature of the die-set or windings of the magnetic lock connected to the third channel (lower
This question is asked only if data item “Thermocouple presence, third current control channel = no”
35 = booster positioning (only for Imola presses)

Used to bring the booster to the position set in “BOOST.POS.”.
To read the key of operations available, press key F8.
If key F9 (KEY) is pressed after data item SPECIAL OPERATION has been set, a help page opens that contains
instructions to start the selected operation.
For example:
• the main pump must be running
• the mode selector must be turned to position SET UP
• press keys 28 and 7 at the same time (for the location of the keys, see the MACHINE CONTROL KEYBOARD
paragraph) to start the set operation.
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TYPE OF PLUNGER SPEED SETTING DURING THE UPSTROKE WITH BRAKING (only for proportional column)
It is possible to select if the plunger’s upstroke with braking is set according to speed (unit of measure mm/s)
or extent to which proportional solenoid valve YV32 opens (unit of measure %).
FLANGE FLUSHING CYCLES

Set flange flushing: set the number of intervals between one flushing cycle (oil + air) and the next.
MAN YV
Set which solenoid valve is energized and de-energized with the key on the keyboard.
Press key F10 to view a key.
Once the solenoid valve has been tested, set to 0.
SLOW MOVE.COLLISION CONTROL

If set to YES, the plunger cannot move down at low speed if the filler-box is not back. In addition, the filler-box cannot
go beyond the forward end stop unless the plunger is raised.
If set to NO, the following movements can take place: plunger downstroke at low speed with filler-box forward, die-set
upstroke in Set Up with filler-box forward, linear filler-box/DIP with open loop forward with plunger down, linear filler-
box/DIP with open loop with plunger down, filler-box with open loop back/forth with lower die down.
BP99
Set the end scale value of “jolly” pressure transducer marked BP99
LOGOUT TIME
If a number other than 0 is entered, automatic logout is enabled. For example, if 5 is entered, whenever the log in
procedure is carried out (see paragraph MACHINE STATUS) the log out procedure is automatically performed after
5 minutes.
This serves so that the machine is not accidentally left in the mode in which data can be set.
LENGTH OF PRINTED PAGE

Set the number of lines on each print out (see paragraph PRINT MENU for more information about printing).
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ENCODER RESET
Enter the required number for ENCODER NUMBER to reset one of the absolute encoders installed in the machine.
When an encoder is reset, it means the end of travel position of the parts (plunger, filler-box, etc) is permanently de-
termined, i.e. if the system is shut off and turned back on, the reset procedure does not need to be performed again.
Enter the number of the encoder to be reset (the key appears on the screen) for data item ENCODER NUMBER with
the mode selector turned to Set up.
1 - plunger: move the plunger fully up (end of travel) (with the only exception being in the case of pneumatic
lock with wedges disengaged the safety guards of the pressing zone have to be open).
4 - rods: only with proportional rod-type lift system; move the knockout completely down (against end-stop)
(only if the safety guards of the pressing zone are open).
5 - filler-box or DIP: move the axis into the desired position (only if the safety guards of the pressing zone are
open).
8 - ALM: move the axis into the desired position (only if the safety guards of the pressing zone are open).
9 - ACP: only with ACP with encoder, move the axis into the desired position (only if the safety guards of the
pressing zone are open).
10 - ACP2: only with Sacmi double loading, move the axis into the desired position (only if the safety guards of
the pressing zone are open).
13 - BQ13 die-set forward beam (only if the safety guards of the pressing zone are open).
14 - BQ31 filler-box lifting, Right side (only if the safety guards of the pressing zone are open).
15 - BQ32 filler-box lifting, Left side (only if the safety guards of the pressing zone are open).
16 - BQ34 ALM hopper lifting (only if the safety guards of the pressing zone are open).
NOTE
Encoders RESET differently may be installed on the press or accessories.
For more detailed information concerning the encoder RESET procedure, consult the ADJUSTMENTS chapter
in the USER’S MANUAL that deals with the press.
OPERATION WITH 1 PLUNGER ENCODER

If the press has more than 1 plunger encoder, machine operation can be tested using only the encoder marked BQ6
(be entering 1) or encoder BQ7 (by entering 2).
Use this procedure only in the event of plunger encoder failure.
Just one test cycle can be carried out in automatic mode.
FILLER-BOX ENCODER REVERSE

If the value of the DIP or FILLER-BOX ENCODER on the DATA page counts down at start-up
(i.e. the number decreases while the filler-box approaches the press or vice versa),
change the setting of this data item.
KA501 - 508
8 programmable relays marked KA501 .... KA508 are housed in the electrical control cabinet (not present in PHC).
These data items can be used to determine how and when they are activated.
Select which part is assigned to the relay in column MODE.
Enter the value of the part at which the relay is activated in column ON.
Enter the value of the part at which the relay is deactivated in column OFF.
Examples:
1) To activate relay KA501 when the plunger reaches 10 mm during its downstroke and deactivate it at 100 mm, enter
MODE = 0, ON = 5, OFF = 100.
2) To activate relay KA501 when the linear filler-box reaches 1000 mm during its return stroke and deactivate it at
500 mm, enter MODE = 1, ON = 1000, OFF = 500.
If a filler-box with connecting rod - crank mechanism (DCP) is used, the filler-box position is intended as the value
that starts from 0 reaches 1000 at the end of the forward stroke and returns to 0.
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Example:
1) To activate relay KA501 at half the forward stroke and deactivate it at the end of the forward stroke, enter MODE
= 1, ON = 500, OFF = 1000.
2) To activate relay KA501 at the beginning of the return stroke and deactivate it halfway through the return stroke
enter MODE = 1, ON = 1000, OFF = 500.
With DIP the relays KA507-KA508 (in the electrical cabinet) are not controlled like the other relays but are a copy of
relays KA310/KA2310 and KA400D/KA2400D found in the DIP cabinet.
8.2.5 YV99 SELF-LEARNING PROCEDURE (ONLY FOR PCH)
Press keys F5 and F4 from page INFO to go to this page.

A chart illustrating the pressure curve, in bar, recorded by the pump pressure transducer (BP4) is relation to the per-
centage of the pump’s proportional pressure control valve (YV99) is provided.
This curve is obtained during the YV99 self-learning procedure (see data item SET UP OPERATION and the DE-
SCRIPTION OF THE KEYS paragraph).
The pump pressure measured with the maximum reference applied to the proportional pressure control solenoid valve
is shown on the top right side of the page.
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8.2.6 PROFIBUS HELP PAGE (LIVE LIST)
Turn the mode selector to Set Up and press key F5 and F5 on page INFO to access this page.
This page can also be reached from the I/O page by pressing key F5.
This page allows the user to check operation of the Profibus network that governs the machine inputs and outputs.
Note regarding PROFIBUS network operation:

the Profibus network consists of a control unit (Master) and a series of peripheries (Slaves) with addresses.
Correct communication between the Master and the Slaves only occurs if the Slave addresses correspond directly to
the addresses saved in the Master.
How the PROFIBUS HELP page is displayed:
The page is divided as shown in the figure below:
2 3
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ZONE DESCRIPTION
1. Slave / Modules box.

This area shows the results obtained from the Live list operation (see the following paragraph for
further details regarding the operations that can be performed on this page).
This area shows the results obtained from the Extended Diagnostic operation (see the following
paragraph for further details regarding the operations that can be performed on this page).
2. Profibus Master State box

The following data regarding the state of the PROFIBUS Master is displayed.
• firmware version mounted on the PROFIBUS Master card in the automation PC (DPM symbol =
profibus-DP Master).
• DPM STATE = DPM card status; it must be “Operate” i.e. operative.
• DPM MODE = must be "Synchronous Host Controlled".
• STORAGE FORM.= must be "Little Endian".
• GLOBAL BIT = usually 0. If it is not 0, a network error is indicated (value expressed in hexadecimal
format).
• ERR.REM.ADR = address of faulty slave (expressed as a hexadecimal; example 12H corresponds
to slave 18).
• ERR.EVENT = number of the Master error (expressed in hexadecimal format).
• HOST FLAGS = state of communication between the DPM (DEVICE) card and the program
(HOST) expressed in hexadecimal format: it can vary continuously during communication.
• DEV.FLAGS = state of communication between the program (HOST) and the DPM (DEVICE)
card expressed in hexadecimal format: it can vary continuously during communication.
• BUS.ERR.COUNT = serious error counter on the bus (expressed in hexadecimal format).
Note: if contacting Sacmi Customer Service the information given above must be quoted.
Slave box
3. The list of Slave addresses included in the PROFIBUS network are displayed (as set-up in the DP
Master card):
READY Address on a green background. The Slave operates correctly.
FAULT Address on a red background. There is an error in the Slave.
DEACTIVATED Address on a light blue background. The Slave is deactivated (for ex-
ample, this may be a slave that corresponds to optional devices that
are not provided with the machine).
Profibus Operation box.

4. Area used for setting necessary data and performing diagnostic functions (see the following para-
graph for details regarding the operations that can be performed on this page).
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Permitted operations:
Live List
This function allows the user to view a scheme illustrating the addresses available in the PROFIBUS network.
Turn the mode selector to SET UP and shut off the pump to start it.
Press F4 to start network scanning.
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Reading the results:

The table in area 1 of the page is updated at the end of the operation (see previous paragraph).
The numeric table can be interpreted according to the following legend:
NOT PRESENT Gray address. Indicates that the address is not assigned to any device in the
PROFIBUS network.
MASTER Master address on a blue background (usually is number 1).
OK Address on green background. Indicates that a Slave address is operating cor-

rectly.
REAL Address on a yellow background. Indicates the address of a Slave present in the
network, but not configured.
Example:
The Slave does not have the correct address, check for the correct address and
set it.
CONF Address on an orange background. Indicates the address of a Slave with a struc-
ture error.
Example:
one of the modules that make up the Slave is faulty;
one of the modules that make up the Slave is not configured as required.
CARD Address on a red background. Indicates that the Slave with the address given
does not respond or does not respond in the correct manner
Example:
Slave not energized;
PROFIBUS network cable does not reach the Slave;
address set in the Slave is not correct;
a PROFIBUS cable connector is On (termination) before this Slave.
DEACTIVATED Address on a LIGHT BLUE background: indicates one of the Slave addresses is
operating correctly, but is deactivated.
Red address on a LIGHT BLUE background: indicates one of the Slave addresses
is not present, but is deactivated.
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Error messages:
ERROR 40 - command execution error

ERROR 41 - command execution error:
ERROR 48 - timeout
Extended Diagnostics
This function allows the user to view the modules present in the selected Slave.
Press key F5.Enter the SLAVE number that indicates the address at which the operation is to be carried out in the
Profibus Operation box.
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Once the operation has been started, the contents of area 1 on the page are updated at the end of the scan (see
previous paragraph).
The numeric table can be interpreted according to the following legend:
OK Gray numeric position. Indicates that there is a module correctly operating at the numeric
position given.
DIAG Numeric position on a red background. It indicates that a module with internal diagnostics
is present in the specified numeric position.
FAULT Numeric position on a yellow background. It indicates that a faulty module is present in
the specified numeric position.
WRONG Numeric position on an orange background. It indicates that the wrong module is present
in the specified numeric position.
MISSING Numeric position on a light blue background. It indicates a missing or faulty module is
present in the specified numeric position.
Note: "Numeric position" represents a module position inside the Slave, counted starting from the next module to the
PROFIBUS interface module (the one with the dip-switch).
Some additional information may be given in the Extended Diagnostic box:
DIAG AVAILABLE (3)
This means that there are 3 additional diagnostic notices regarding the individual modules.
Press the <Down arrow> or <Up arrow> keys to view the information.
The information is given on the underlying line.
Example:
2-Module no.12 Channel no. 1 Error no. 6 = Line/Wire Break

| | | |
| | | number of error and description
| | number of channel inside the module
| module number inside Slave
Information number
The example given above indicates that the cable of the thermocouple connected to the first input of the 12th Slave
for which extended diagnostics has been requested is broken.
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INTERRUPT
In this case, it means some additional diagnostic information arriving directly from the I/O modules of the slave in
question is present.
The progressive number is given in parenthesis.
The number indicating the position of the module that signaled the problem is also provided.Counting starts from the
coupler (IM151-1 ...) excluding it from the count.
The description of the malfunction is given to the right.

Example:
INTERRUPT ( 1) Module no. 3, Pending Channel no. 1 Error Open circuit

| | | | |
| | | | error description
| | | number of channel inside the module
| | alarm status
| module position
progressive number
The example given of the first interrupt that occurred regards the I/O module in position 3, alarm still pending (i.e. not
remedied yet), related to the first channel of the module; the problem is that the cable is broken.
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Error messages:
ERROR 80 - send request error (example: request made to the Master / and a Slave that is not present);
ERROR 81 - send request error (example: request made to a configured Slave that is not present or to a deactivated
Slave that is not present);
ERROR 83 - incorrect Slave type;
ERROR 84 - diagnostics not possible.
For example:
“two modules missing“;
‘“Slave terminator missing”;
“PROFIBUS network interface module missing (or broken) (module containing the dip-switches)”
“wrong bus backplane (or broken)”.
If this error appears, the results are still available, but their interpretation cannot be certain. All the modules may ap-
pear as faulty (in other words, in a color other than white). This does not mean that they are all malfunctioning, but,
rather, that there are 2 or more faulty modules in the station.
ERROR 88 - timeout.
Common Data
This function allows additional information useful for Profibus network diagnostics to be obtained if hard-to-trace
problems are present.
Press F3 (COM.D) to activate this function.

A page containing the required data is accessed.
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Information about the Master and all the Slaves present is given.
Master:
Master d1
D.Ex.Failed
d2
d1 = address of Master (normally 1)

d2 = counter (master level) for failed Data Exchange messages, i.e. the number of data exchange messages between
the master and slaves not successfully completed. This number should be 0 if the network functions properly.
Slave:
The number of ‘retry’ operations and “disconnections” are given for each slave.
Retry refers to the number of times the Profibus master card had to send the pack back to the slave in question (be-
cause it did not arrive correctly): a retry operation does not cause the network to signal an alarm however, after a few
consecutive retries (every 3 consecutive retries on the average) the slave is declared disconnected from the Profibus
Master and the Profibus network signals a fault is present.
In particular, the number of retry operations can be used to point out ongoing problems in the hardware such as wrong
termination resistors, short circuits, voltage fluctuations, etc..
By analyzing the number of retry operations, it is possible to verify if there are problems in the network before the
network signals an alarm. The peak number of retry operations gives a rough indication as to where the problem is
located: the slaves with the highest number of retry operations are generally physically closer to the problem.
Slave d1
Retry = d2
Discon.= d3
d4
d1 = Slave address; the color indicates the status of the Slave (formore information about the status, see the Slave box).
d2 = counter for number of retry operations for each Slave; retry refers to the number of telegrams that master had
to send more than once due to problems in the line.
d3 = counter for number of disconnections for the Slave (each disconnection is accompanied by an alarm that shuts
down the machine).
d4 = description / location of the Slave.
Data refresh:
The data are refreshed only when key F5 (REFRESH) is pressed.
Notes:
1) Data D.Ex.Failed, Retry, Discon. are reset whenever the automation PC is shutdown and the Warm Restart pro-
cedure is performed.
2) The Retry data are automatically reset when 65535 is exceeded
3) The Discon. data are automatically reset when 255 is exceeded.
Warm Restart
This function allows the Master PROFIBUS card to be restarted without shutting off the system's power supply.
Activate this operation only when a PROFIBUS fault has been signaled.
Press F6 to restart the card.
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File Slave.mem
This function allows the user to export the PROFIBUS master card set-up data in a file.
Press key F7 to obtain the SLAVE.MEM file.
ASSISTED DIAGNOSTICS
This is the feature (standard in presses) which sees that the control system automatically opens this page when a
PROFIBUS error is present. Two cases may arise:
1. if there is a slave with a set-up error (indicated in black on an orange background in the Live List box), therefore
an error inside the slave, the extended diagnostics page for the slave in question automatically opens;
2. in all the other cases the page is automatically opened with Live List.
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8.3 ACTUAL LOADING DATA
Press the F3 key (LOAD.) to go from the “DATA” to the “ACTUAL LOADING DATA” page.
a) The box at the top contains:
the number of cycles completed with the actual die-set while the number of cycles remaining before the die-set is
to be changed is given at the bottom (the life of the die-set is set on the DIE-SET SET-UP page).
b) The times employed to travel the steps included in the filler-box stroke are given in the box on the bottom left side
of the page. These times were measured at the end of the previous cycle. These times are calculated only during
the automatic or semiautomatic loading cycle (with a filler-box with crank-rod mechanism they are also calculated
in manual mode).
The LOADING time expressed in sec. is calculated from when the filler-box starts (excluding any approach strokes)
until the end of the return stroke is reached (only during automatic or semiautomatic loading). If a linear filler-box
or DIP is used, it also includes the wait time at the end of the forward stroke (RETURN DELAY) and the time it
waits for the mobile brush to move down before the filler-box starts, times that are not included in the respective
total times.
NOTE If the time given in an area is 0, it means that the system was not able to execute that area. This happens
for example if the area limit is too close to the filler-box limit switch or if a speed change excessive for the space
set for that area is required. In this case, change the limits of the areas and/or speeds.
If the filler-box for double loading is equipped with the optional mobile grid, the times taken to travel the 3 steps
included in the mobile grid’s stroke are given at the bottom of the box. These times were measured at the end of
the previous cycle.
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c) With rod-crank mechanism filler-box: the gains for the filler-box valve opening (forward and return strokes respec-
tively) are displayed in the right block. In addition, the two OFFSET values (i.e. the minimum values required to
move the filler-box) for the forward and return strokes along with the maximum length of the acceleration and
deceleration ramps are given underneath.
d) Underlying box: filler-box encoder setting at the end of the first die-set downstroke, during the previous work-cycle
(if a filler-box with connecting rod-crank mechanism is used this value is expressed both as a percentage of the
stroke and in degrees, if the degrees are higher than 180 it means that the downstroke was completed with the
filler-box performing the return stroke). With a DCL type filler-box, an arrow -> appears to the right of the number
of the first downstroke was completed during the forward stroke, <- if the first downstroke was finished during the
filler-box return stroke.
1st D.STR. DURATION: If a SMU or knockout is used, it is divided into two parts: the first is between de-energizing
of the solenoid valve and sensor SQ3 deactivation; the second is from when SQ3 is deactivated and SQ6 is acti-
vated.
e) The actual operating state of the brush is shown at the bottom.
Press the F2 key (DATA) to go from this page back to the “DATA” page; press the F4 key (PRESS-CY.) to go to
the “ACTUAL PRESS-CYCLE DATA” page press F5 (DIE-SETS) to go to the “ACTUAL DIE-SET DATA” page. If
the die-set heater is present, press F5 to go to the relative page (°C symbol).
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8.4 ACTUAL PRESS-CYCLE DATA
To go to the “ACTUAL PRESS-CYCLE DATA” page from the “DATA” page, press the F4 key (PRESS-CYCLE).
8.4.1 PRESSES WITH PROPORTIONAL HYDRAULIC SYSTEM
a) The times and pressures (expressed in ms and bar respectively) for each individual work-cycle stage are displayed
in the left-hand square. These values were measured at the end of the cycle which has just been performed. In
addition, the TILE THICKNESS value is shown in the THICK. column at the end of each press-stroke.
The first number on the left represents, for each press-stroke, the time taken to reach half the set pressure (if mode
= 1 or = 2) or the time to reach the thickness set for S1/P1 (if mode = 0).
The number shown on each deaeration line and in the THICK. column is the plunger stroke completed during
deaeration.
b) Data regarding plunger braking are given on the top right side of the page.
- BP99 value (jolly transducer)
- real-time pressure in plunger upstroke chamber expressed in bar
- minimum pressure in upstroke chamber to raise plunger
- plunger speed at the end of the downstroke measured in the IMPACT POSITION
- plunger speed at the end of the upstroke section in which the brake is applied (only if braking is enabled during
the upstroke on the PRESS-CYCLE SET UP page)
- maximum speed reached by the plunger, the value reached during the downstroke appears to the left, the one
reached during the upstroke is given to the right.
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c) The following items are given in the square below:

- maximum stroke carried out by the plunger during the cycle which has just been performed and, on the right
(optional) the same value measured by the 2nd encoder BQ7 and the one measured by the 3rd BQ8 (optional)
underneath
- distance between the upper and lower punches
- plunger speed during loading cycle
- difference between the thickness measured during the cycle which has just been performed and the set point
(TILE THICKNESS on the PRESS-CYCLE SET UP page).
- only when more than 1 plunger encoder is present: maximum plunger parallelism error during the automatic or
semiautomatic cycle.
d) The amount of material (expressed in sq.m) or number of tiles to be produced in order to complete the current
production batch is given in the square below.
e) The current pump pressure setting is indicated here.
- If an external booster is used: booster reset position.
The proportional solenoid valves offset values determined during the self-learning procedure are displayed on the
bottom of the page on the right side as follows: YV32 offset to perform the plunger downstroke, YV32 offset to
keep the plunger stationary, YV32 offset to perform the plunger upstroke, YV318 offset.
The offset for centered YV32 may vary during the automatic cycle if proportional presses equipped with YV104 are
used. The value given in parenthesis is the one determined during the last self-learning procedure performed.
To go to the “DATA” page from this page press the F2 key (DATA). Press the F3 key (LOAD.) to go to the “ACTUAL
LOADING DATA” page or F5 (DIE-SETS) to go to the “ACTUAL DIE-SET DATA” page.
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8.4.2 PRESSES WITH NON-PROPORTIONAL HYDRAULIC SYSTEM
a) The times and pressures (expressed in ms and bar respectively) for each individual work-cycle stage are displayed
in the left-hand square. These values were measured at the end of the cycle which has just been performed. In
addition, the TILE THICKNESS value is shown in the THICK. column at the end of each press-stroke. The number
shown on each deaeration line and in the THICK. column is the plunger stroke completed during deaeration.
b) Data regarding plunger braking are given on the top right side of the page.
- BP99 value (jolly transducer)
- setting of braking logic element needle, 40 corresponds to maximum braking force, 470 minimum.
To change this value, see the DESCRIPTION OF THE KEYS paragraph.
- plunger speed at the end of the downstroke measured in the IMPACT POSITION
- plunger speed at the end of the upstroke section in which the brake is applied (only if braking is enabled during
the upstroke on the PRESS-CYCLE SET UP page)
- maximum speed reached by the plunger, the value reached during the downstroke appears to the left, the one
reached during the upstroke is given to the right.
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c) The following items are given in the square below:

- maximum stroke carried out by the plunger during the cycle which has just been performed and, on the right
(optional) the same value measured by the 2nd encoder BQ7 and the one measured by the 3rd BQ8 (optional)
underneath
- distance between the upper and lower punches
- plunger speed during loading cycle
- difference between the thickness measured during the cycle which has just been performed and the set point
(TILE THICKNESS on the PRESS-CYCLE SET UP page).
- only when more than 1 plunger encoder is present: maximum plunger parallelism error during the automatic or
semiautomatic cycle.
d) The amount of material (expressed in sq.m) or number of tiles to be produced in order to complete the current
production batch is given in the square below.
e) The current pump pressure setting is indicated here.
To go to the “DATA” page from this page press the F2 key (DATA). Press the F3 key (LOAD.) to go to the “ACTUAL
LOADING DATA” page or F5 (DIE-SETS) to go to the “ACTUAL DIE-SET DATA” page.
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8.5 ACTUAL DIE-SET DATA
The “ACTUAL DIE-SET DATA” page can be accessed from the “ACTUAL LOADING DATA” and “ACTUAL PRESS-
CYCLE DATA” pages by pressing the F5 key (DIE-SETS) only if the press is equipped with a proportional knockout.
With a four-piston S.P.E. or 2 + 2 piston the following data are provided:

- The values of die-set encoders BQ4 and BQ5 are refreshed in real time for the DIE-SET SETTING data item.
- The soft filling height (FILLING HEIGHT) along with the ratio between the thickness of the tiles and that of the soft
filling (TILE THICKNESS/FILLING HEIGHT), expressed in percentage, are also displayed.
- Furthermore the movements of the knockout are shown in terms of time (ms) and speed (mm/s).
With an electronic rod-type lift system the following are also provided:
- offset values for YV21P upward and downward movement
(for example, downstroke offset = 40 equals 1.95% of max. opening during downward movement).
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With SPE, the following data are given at the bottom:
CONTROL = analog reference from axes card to proportional valve on side A and B; it ranges from - 100% (maximum
downstroke ref.) to 100% (maximum upstroke ref.).
SPOOL = position of the spool of the SPE proportional solenoid valve on side A and B; it may range from -100.0%
(maximum opening during downstroke) to 100.0% (maximum opening during upstroke).
OFFSET = offset value measured for the SPE proportional valves expressed in % of maximum opening; it is measured
during the die-set encoder reset procedure.
ZERO POSITION = whenever the die-set encoder is reset the following information is displayed: distance between
mechanical end-stop and zero pulse for side A, side B and the cycle counter. Data regarding the next to last reset
procedure performed are given on the underlying line.
Generally speaking, the zero values fall within 2 and 3 mm.
If -1.00 mm appears, it means the zero pulse of that encoder has not been read.
Only with AXP card provided with firmware (version 1.02 or higher) two lines are displayed above those described above.
The distance from encoder zero mark is shown with a bar-graph both for encoder BQ4 (A) and for BQ5 (B).
They are used for the correct installation of the SPE encoders:
if the encoder is exactly on the zero mark, the middle area of the bar-graph is displayed (in red) and the green squares
more distant from the middle light up as the zero mark becomes more distant.
Also the encoder value recommended in order to have the zero mark 2.5 mm away from the end-stop is displayed
in brackets to the right.
STATE = axis card status code.
ERROR = error code from axis card.
CMD = command to axis card.
MOV = axis card movement.
SET POINT = final position of movement being performed expressed in mm, to the left for side A and to the right for
side B.
SPEED = speed of movement in progress expressed in mm/s.
UPSTROKE CHAMBER PRESSURE = SPE lower chamber pressure transducer, expressed in bar.
DOWNSTROKE = SPE upper chamber pressure transducer, expressed in bar.
PUSH = upstroke force, in bar, measured by the 2 SPE pressure transducers. If the plunger upstroke with braking is
performed with the upstroke help unit (optional unit) the knockout force in the section in which the plunger upstroke
with the help is activated appears in brackets.
Press the F2 key (DATA) to go from this page back to the “DATA” page. Press F3 (FILL) to go to the ACTUAL FILLING
DATA page or F4 (PRESS-CY.) to go to the “ACTUAL PRESS-CYCLE DATA” page. If the die-set heater is provided,
press F5 to go to the relative page.
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8.6 “DISPLAY” PAGE
Press the F5 key and then F2 to go to this page from the “DATA” page.
The thickness and pressure are shown in large digits so that the user can easily read them even when far away from
the machine. The data is updated every work-cycle.
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8.7 I/O PAGE
The values of all the inputs are displayed here.
The state of the inputs is displayed here.
SL4
Digital input (ON-OFF)
A symbol ( ) appears next to the identification number of the input to indicate that the input is closed. The symbol
is not shown if the input is open.
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Press F4 to go to the output page.
The state of the outputs is displayed.
YV32S
Digital output (ON-OFF)
A symbol ( ) appears next to the identification number of the output to indicate that it is on.The symbol is not shown
if the input is off.
NOTE: Press the F4 key to go to the second output page.
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The second output page contains the analog outputs used for the inverters and proportional valves.
-SET: command to proportional valve; the first number, called “valve points” may range from -27.648 to +27.648.
The values expressed in % and Volt appear to the right, which could be measured at the proportional
valve input.
-SPOOL: the feedback value, expressed in % and Volt may be given for some proportional valves which could
be measured at the proportional valve output.
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8.7.1 GRAPH PAGE
To access this page, log in and then press F8 on the second output status page.
Two machine variables can be plotted on this page.
CHANNEL1: value that can be selected to be plotted in channel 1

MIN (CH1): minimum value of value to be displayed to scale channel 1
MAX (CH1): maximum value of value to be displayed to scale channel 1
CHANNEL2: value that can be selected to be plotted in channel 2

MIN (CH2): minimum value of value to be displayed to scale channel 2
MAX (CH2): maximum value of value to be displayed to scale channel 2
TIME BASE: time between signal sampling.
As in a true graph, it is possible to define a trigger and see a signal only if the signal at the selected CHANNEL TRIG-
GER goes over or below (depending on whether the rising edge or falling edge is selected for data item TRIGGER
EDGE) the value set for TRIGGER LEVEL.
RUN/HOLD:
YES = continuous sampling and video refresh
NO = sampling of new data stopped and video not refreshed
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8.8 FAULTS PAGE
The most recent fault messages that caused the machine to shutdown or stop are shown. The date and time at which
they occurred are given on the left-hand side of each message.
The 26 most recent messages are given on the first page.
Press key F4 to go to another page that contains another 26 fault messages, previously saved.
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8.8.1 CURRENT FAULTS PAGE
Press key F5 on the FAULT MESSAGES PAGE to go to this page.
The alarms actually present, divided into 6 categories, are displayed on this page (the categories are described in
the FAULT MESSAGES chapter).
Top: ACTIVE
The active alarm is shown for each category.
Use the <Up arrow> or <Down arrow> keys to move the cursor to modify the visualization filter of the bottom part,
confirming with the <Right arrow> key.
If xxxx is selected, all the alarms simultaneously active (CAT. NO. 0) will be displayed at the bottom.
If 1xxx is selected, all the shutdown messages simultaneously active (CAT NO. 1) will be displayed at the bottom.
The same takes place for the other categories.
Bottom: OTHER CATEGORY NO. ALARMS
The filtered alarms appear at the top.
Press key F7 to refresh the alarms displayed.
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8.9 “STATISTICS” PAGES
These pages can be accessed from the DATA page by pressing F5 and then F5 again.
Bar charts that illustrate some statistics regarding the production run are given on these pages.
The number of cycles taken into consideration in drawing up the graphs is given on the bottom right side.
To zero set the statistics, log in and press key F6. When the system asks the operator to CONFIRM, press “1”.
Press the PAG ↑ or PAG ↓ keys to scroll the pages.
To print out the graphs displayed, press the F7 key. (The log in procedure has to have been performed and a printer
has to be parallel connected to the output on the back of the automation PC).
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The first chart displayed shows the ten causes of machine stoppage or shutdown which resulted in the longest down-
time (shown in order of time).
Note:
- The complete straight line represents the machine downtime before the alarm was reset.
- The lines which are cut off represent the machine downtime after the alarm was reset.
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The second chart displayed shows the ten causes of machine stoppage or shutdown which resulted in the greatest
number of stoppages (shown in the order of number of stoppages).
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The third chart represents the percentage of defective pieces in relation to the total number produced for each thick-
ness error band.
The central bar represents the pieces whose thickness error is less than 10 hundredths of a millimeter.
Percentage of each band

Set value in relation to total cycles
Deviation from set value Percentage in relation to Total number of cycles

(mm) total cycles performed
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The fourth chart shows the percentage of pieces in relation to the total number produced that fall within each pres-
sure error band.
The central bar represents the pieces whose pressure deviates by less than 4 bar.

Deviation from set value Percentage in relation to Total number of cycles

(mm) total cycles performed
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The fifth chart represents the percentage of cycles in relation to the total number performed for each error band re-
garding the time taken by the filler-box to carry out the forward stroke.
The middle bar represents the cycles with errors that are less than 20 ms in relation to the total time set on the LOAD-
ING SET-UP page.

Deviation from set value Percentage in relation to Total number of

(mm) total cycles cycles performed
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The sixth chart shows the percentage of cycles in relation to the total number performed for each error band regarding
the time taken by the filler-box to carry out the return stroke.
The middle bar represents the cycles with errors that are less than 20 ms in relation to the total time set on the LOAD-
ING SET-UP page.

Deviation from set value Percentage in relation to Total number of

(mm) total cycles cycles performed
If the machine is equipped with a proportional knockout, the related statistics are provided. The following is shown:
- graph showing the errors of piston A found after the die-set has completed its upstroke;
- the same for piston B.
- graph showing the errors of piston A found after the die-set has completed its first downstroke;
- the same for piston B.
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8.10 PRODUCTION
This page can be accessed from the “DATA” page by pressing the F5 key and then F7.
The production data are shown in the following formats:
Day: current value along with yesterday’s;
Week: current value along with last week’s;
Month: current value along with last month’s;
Batch: current value along with that of the last batch.
PRODUCTION YIELD - Percentage that represents the number of cycles completed divided by the number of cycles
the press would have performed if it had worked constantly. It is calculated every day at midnight.
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9 SETTING THE DATA ITEMS
9.1 PROGRAMS
To go to the “PROGRAMS” page from the “DATA” page, press the F2 key (PROGRAM).
This page provides a list of the programs stored in the computer’s memory. A “PROGRAM” refers to all the machine
operating data.
NOTE: all settable data items are saved in the PROGRAM with the exception of:
“SPEED IN MANUAL”
“LOCK LOWER DEMAGNETIZATION”
“LOCK UPPER DEMAGNETIZATION”
“PUNCH OVERTRAVEL”
“PUNCH OVERTRAVEL LENGTH”
“DIE-SET FASTENED”
“HEAT EXCHANGER”
Up to 128 programs can be stored in the computer’s memory. Each program is identified by a name. For example,
program 4 has three exits for 330 mm x 330 mm tiles which are 10 mm thick while the maximum pressure for the
press-cycle is set at 200 bar.
The name of the program has an extension. To view it, press the “←” or “→” key.
To view the other programs press the PAG ↓ or PAG ↑ keys.
To perform operations with the stored programs, press the F7 key after logging in.
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The functions that can be carried out are given on the last line:
WRITE
This function is used to store the data of the operating program. This cannot be done if the press is set to automatic
mode. Press the F2 key. The following appears on the bottom of the page:
Now type in the number of the program. The latter will be the back-up copy of the program being used (in the example
above, the program deriving from program 4 is operative). If 26 is keyed in and the ENTER key is pressed, the program
being used will be assigned number 26. As a result, the operating program will be the one numbered 26.
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READ
This function is used to run the machine with the data for a program stored in the memory. This cannot be done if the
press is set to automatic mode.
The following message will appear when the F3 key is pressed.
READ PROGRAM NUMBER ?
Type the number of the program required (e.g. 4) and then press the ENTER key.
The following question will be displayed:
SAVE PROGRAM NUMBER 26 (Ø = no, 1 = yes)?
If “1” is pressed, the old operating program (26 in the example) is saved before loading the desired one (4 in the
example).
If “0” is pressed, the desired one is loaded directly.
CLEAR
This cannot be done if the press is set to automatic mode.
To delete a program, press the F4 key.The following message will appear:
CANCEL PROGRAM NUMBER ?
Type in the number and then press the ENTER key.

If the back-up copy of the operating program is deleted, the new program will be identified by ø.
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9.2 LOADING SETTINGS
To go to the “LOADING SET-UP” page from the “PROGRAMS” page press the F3 key (LOAD.).
This page shows the settings related to the press loading cycle.
The top half of the page may appear in one of the following manners:
1) With linear filler-box
The ends of the filler-box movement (END OF FORWARD/RETURN STROKES), expressed in mm and referred
to the encoder BQ2, need to be set.
MIN = safety end stop for the end of the linear filler-box and DIP return stroke. If the encoder falls below this value,
the press shuts down and a message is displayed. It is set in Set Up mode. A value that is at least 20 mm less
than the end of the return stroke should be used.
MAX = safety end stop for the end of the linear filler-box and DIP forward stroke. If the encoder goes over this
value, the press shuts down and a message is displayed. It is also the maximum allowable value that can be set
for the END OF THE FORWARD STROKE.
It is set in Set Up mode. A value that is at least 20 mm higher than the end of the forward stroke should be used.
TIME CONTROL should be set to YES only if a fault message is to be displayed when the time taken to complete
the forward and return strokes exceeds the time set for the FILLER-BOX FORWARD TIME or FILLER-BOX RE-
TURN TIME data items by more than 5%.
Set data item FILL.-BOX APPROACH POSITION to a value greater than the value set for END OF BACK STROKE
if the following cycle is to be selected:
- once the FILL.-BOX APPROACH POS. has been passed during the filler-box return stroke, the trigger pulse
is provided for the plunger to move down. When the filler-box reaches the END OF BACK STROKE position
during the press-stroke, the ALM cycle starts. After the grid has been loaded, the filler-box starts traveling again
at the speed set for APPROACH SPEED until the value set for FILL.-BOX APPROACH POS. is reached.
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When in MAN mode the filler-box travels at a constant speed which equals that set for SPEED IN MANUAL MODE.
FORWARD STOP PRECISION: set the degree to which the linear filler-box has to be precisely positioned at the
forward end-stop.
0% = minimum precision and high reverse speed: this mode assures the maximum press production rate.
100% = maximum precision and low reverse speed: this mode assures maximum reverse value precision.
RETURN DELAY: a time, expressed in ms, for delaying the filler-box return stroke can be set for linear filler-boxes.
The limits of the filler-box steps and its speed when in these zones (5 forward steps and 5 return steps at most)
need to be set. The following are to be set for the forward stroke:
- end of 1st step
- end of 2nd step
- end of 3rd step
- end of 4th step (the end of the 5th forward step corresponds to the end of the forward stroke)
- speed of the 5 forward steps.
The following are to be set for the return stroke:
- end of 1st step
- end of 2nd step
- end of 3rd step
- end of 4th step (the end of the 5th return step corresponds to the end of the return stroke)
- speed of the 5 return steps.
Example of linear filler-box:
end of return stroke = 175 mm, approach value = 430 mm and end of forward stroke = 1185 mm
end of forward step = 520 700 700 1050
forward speed = 35 55 55 85 70
Description:
the filler-box runs at the approach speed from the end of the return stroke to the filler-box approach position
step 1) the filler-box runs at a speed of 35% from the approach position to 520 mm
step 2) the filler-box runs at a speed of 55% from 520 mm to 700 mm
step 4) the filler-box runs at a speed of 70% from 1050 mm to the end of the forward stroke
end of return step = 1000 685 520 430

return speed = 70 85 80 70 60
Description:
step 1) the filler-box runs at a speed of 70% from the end of the forward stroke to 1000 mm
step 5) the filler-box runs at a speed of 60% from 430 mm to the end of the return stroke
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2) With rod-crank mechanism filler-box:
The end of the filler-box return stroke, expressed as a %, needs to be set.

FILLER-BOX CONTROL ON = YES should be set only if the filler-box speed needs to be automatically regulated
according to the times set for the FILLER-BOX FORWARD TIME and FILLER-BOX RETURN TIME data items.
Once this function has been activated, check the F-STROKE GAIN and RET. STROKE GAIN settings which are
found on the “ACTUAL LOADING DATA” page. These settings must fall between 140 and 160. If the forward gain
is less than 140, increase all the speeds set for the forward stroke steps until the forward gain is about 150. Do
the same for the return stroke.
Set data item FILL.-BOX APPROACH POSITION to a value greater than the value set for END OF BACK STROKE
if the following cycle is to be selected:
- without ALM: once the FILL.-BOX APPROACH POS. has been passed during the filler-box return stroke, the
trigger pulse is provided for the plunger to move down. Once the filler-box reaches the value set for END OF
RETURN STROKE during the press-cycle, it waits until the APPROACH DELAY TIME has elapsed. After this
time has elapsed the filler-box starts traveling again at the speed set for APPROACH SPEED until the value
set for FILL.-BOX APPROACH POS. is reached.
- with ALM: once the FILL.-BOX APPROACH POS. has been passed during the filler-box return stroke, the trigger
pulse is provided for the plunger to move down. When the filler-box reaches the END OF BACK STROKE posi-
tion during the press-stroke, the ALM cycle starts. After the grid has been loaded, the filler-box starts traveling
again at the speed set for APPROACH SPEED until the value set for FILL.-BOX APPROACH POS. is reached.
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When the mode selector is turned to position MAN, the filler-box runs at a steady speed equal to the set for SPEED
IN MANUAL mode.
The limits of the filler-box steps and its speed when in these zones (5 forward steps and 5 return steps at most)
need to be set, in order for the filler-box to operate in automatic or semiautomatic mode.
The following are to be set for the forward stroke:
- end of 1st step
- end of 2nd step
- end of 3rd step
- end of 4th step (the end of the 5th forward step corresponds to the end of the forward stroke)
- speed of the 5 forward steps.
The following are to be set for the return stroke:
- end of 1st step
- end of 2nd step
- end of 3rd step
- end of 4th step (the end of the 5th return step corresponds to the end of the return stroke)
- speed of the 5 return steps.
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OTHER DATA
EJECT.WHEN STOPPING: if set to YES tiles are ejected at the end of the press stop cycle.
DOWNSTROKE BOX
1st D.STROKE POS.: point of the filler-box forward stroke at which the 1st die-set downstroke is carried out.
1st DOWNSTROKE POSITION LIMIT: this setting refers to the filler-box position during the return stroke beyond which
the press stops if the die-set has not finished the first downstroke. The relative fault messages is number 2028.
With 3-downstroke cycle (see data item set on page “ SPE die-set set-up”) and filler-box NOT for double loading, it is
possible to set the position the filler-box is in during the 2nd downstroke (GLAZE POSITION).
It is also possible to set whether the downstroke takes place during the forward (0) or return (1) stroke with the DIE-
SET DOWNSTROKE SEL. data item.
If the second filler box is present (DAF-DXP type) data item 2ND FILLER-BOX START POSITION is present: enter
the value of the filler-box during the forward stroke at which the second filler-box starts operating; if 0 is entered, the
second filler-box is disabled.
Press the F2 (PROGR.) key to go back to the PROGRAMS page.
Instructions on how to change the set data are given below:
1) First of all move the cursor next to the data item to be modified by pressing one of the following keys:
↓ to go to the next data item
PAG DOWN to go to the next data block
END to go to the last data item on the page
↑ to go back to the previous data item
PAG UP to go back to the previous data block
HOME to go to the first data item on the page.
2) The set points can be changed in two ways:

a - enter a new value by using the following keys:
0, 1, 2, 3, 4, 5, 5, 6, 7, 8, 9
- to indicate a negative number
. to indicate decimal points
BACK SPACE to delete the last number entered
ENTER to make the entry operative
b - By using the “-” and “+” keys found above the ENTER key:
- keep it pressed to decrease the value
+ keep it pressed to increase the value
3) The second to last line on the display provides all the information necessary to enter the data:
a) MIN = 0.0 MAX = 40.0
These items indicate the minimum and maximum settings for the data item pointed out by the cursor.
b) +/-
If this symbol appears, it means that the data item pointed out by the cursor can be changed in the same way
as directed for “b” given at point 2) above.
c) FILLER-BOX ENCODER = 0.0%
Useful information on how to change the data item pointed out by the cursor is displayed. In the example above,
the filler-box encoder setting is shown. This value is useful to set the end of the filler-box’s return stroke.
If no messages appear on the second to last line, it means that the data item cannot be changed because the log in
procedure has not been performed.
The following data items:

FILL.-BOX APPROACH POS.
can be changed only if the mode selector is turned to SET-UP.
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9.2.1 OTHER LOADING DATA
Press the F3 key to go to this page from the “LOADING SET-UP” page.
If RETURN REVERSE POS. = 0, the cycle with “steps” is not performed and the other data regarding the “steps” are
not displayed.
If a linear filler-box is used, the cycle with “steps” is enabled if data item RETURN REVERSE POS. > 0 (only if the
mode selector is turned to SET-UP).
In this case, once the set reverse position is reached during the filler-box’s return stroke, the filler-box moves forward
(step) reaching the value set for END OF RET. REVERSE POS.
At this point, the regular return stroke restarts.
The forward step can be divided into 3 zones. The filler-box speed can be set for each of these zones.
The same goes for the return step.
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If a Sacmi filler-box for double loading (optional) is used, the following page is displayed.
DOUBLE LOADING PAGE (ACD)
• DOUBLE L. = YES/NO
It is possible to select if the double loading device is installed on the filler-box.
If YES is entered, all the other data items on the page are enabled.
• FEEDER TYPE = 0/1/2/3

It is possible to select the type of feeder mounted on the color ACP (double loading)
0 = feeder not present
1 = micronizer
2 = MDR (mixer with rotary diaphragm)
3 = DAC (gate feeder)
• REVERSE POS. FOR RETURN (mm)

If a value greater than 0 is entered, the filler-box can move forward (second filler-box stroke).
This is the value at which the filler-box stops during the second forward stroke to restart the return stroke.
• END OF RET. REVERSE POS. (mm)

This data item is provided only if reverse position for return is set to a value greater than 0.
This is the value at which the filler-box stops during the second forward stroke and restarts the return stroke.
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• FORW.STEP ZONES (mm)

The forward stroke can be divided into 3 steps so that three different speeds can be set.
• STEP SPEEDS (%)

Set the 3 speeds for the 3 steps set.
• STEP RET. ZONES (mm)

The return stroke can be divided into 3 steps so that three different speeds can be set.
• STEP SPEEDS (%)

MOBILE GRID BOX
• MOBILE GRID INSTALLED = YES/NO

It is possible to select whether or not the mobile grid is present on the filler-box.
If YES is entered, all the other data items in this box are enabled.
• MOBILE GRID STOPPED = YES/NO

It is possible to select that the mobile grid remains stationary even if it is installed. Basically speaking if YES is entered,
the cycle performed is the same as the one carried out when the mobile grid is not present.
The grid is kept at the value set for the end of the return stroke.
• END OF RETURN STROKE (mm)

This is the position the mobile grid reaches when it is closest to the press (encoder homing sensor side).
• END OF FORWARD STROKE (mm)

This is the position the mobile grid reaches when it is furthest away from the press (side opposite the encoder hom-
ing sensor).
• DOUBLE REV. CYCLE TYPE = 1/2

This item is used to select the type of mobile grid cycle in cycle with steps.
1 = cycle that takes advantage of mobile grid movement when loading the base (slower system)
2 = cycle that takes advantage of the main part when loading the base (faster system)
• SPEED IN MANUAL MODE (%)

Speed of the grid when operating in manual mode.
• FORWARD VALUE (mm)

The forward stroke can be divided into 3 steps so that three different speeds can be set.
• FORWARD SPEED (%)

• RETURN SPEED (%)

Set the speed for the return stroke. Only one speed can be entered.
When 0 is entered, the grid performs the return stroke tracking the filler-box speed assuring that it does not go back
to the cavity already loaded thereby optimizing the times to the best extent possible.
If the value entered for the speed is greater than 0 and therefore filler-box tracking is not enabled, a check is made
to assure the grid is not operating too fast in relation to the filler-box.
HOLE BOX (YV601)
• CYCLE TYPE = -1/0/1/2

Selects the type of hole cycle: -1 = always closed
0 = opens during forward stroke, closes during return stroke
1 = opens during forward stroke, closes during next forward stroke
2 = opens during forward stroke, closes during forward step
(settable only if the step is enabled)
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• CLEANING/SHAKING = YES/NO
Used to enable the cleaning cycle. When the filler-box reaches the end of the return stroke the hole is opened 3 times
fast and closed 3 times fast to clean it.
• ON POS. - OFF POS. (mm)

Set the ON and OFF values for the hole in relation to the filler-box position.
BOX ACP2
• CYCLE TYPE = 0/1/2/3/4

This data item is used to select the type of ACP2 cycle:
0 = standard movement (complete stroke from one end stop to the other end stop).
1 = speed change during travel up to a maximum of 8 settable steps that are not the mirror image of one another
in the two directions of travel.
2 = speed change during travel up to a maximum of 8 settable steps that are the mirror image of one another in
the two directions of travel.
3 = during travel it stops in eight spots for the set times.
4 = start conditioned by SL24 (powder level in upper color hopper).
• SPEED (%)
ACP movement speed.
• No. OF ACP MOVEMENTS (1……50)

Number of ACP movements per cycle.
(1 = one movement, 2 = two movements, 3 = three movements - 50 = non-stop movement)
• START-UP DELAY (s)

Time ACP start-up is delayed compared to when the filler-box reaches the end of the return stroke.
If CYCLE TYPE = 4 set the time start up is delayed after SL24 is activated.
If CYCLE TYPE = 4 set the time shut down of ACP2 is delayed after SL24 is deactivated and the delay time for start-
ing the micronizers after input SL24 goes off.
• START M121 ONLY WITH SL24 ON = YES/NO

If set to YES, the ACP2 starts running only if level SL24 is on.
• LH/RH (mm)
Set the end of the right and left strokes.
DISTRIBUTOR IMPELLER
• CYCLE TYPE = 0/1/2/3

Impeller cycle selection
0 = impeller not present
1 = rotation in one direction
2 = rotation in opposite direction
3 = rotation in one direction during one cycle and the opposite direction during next cycle.
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• SPEED (%)
Impeller rpm.

The time set cannot be longer than the delay time for ACP2 start up.
If the times (ACP2 start up delay and impeller start-up delay) are the same, the impeller starts along with ACP2. If
the impeller start up delay time is shorter than the one for ACP2, start-up is advanced in relation to ACP2 start-up the
difference between the two set times.
Obviously the impeller cannot start running after ACP2.
FITTINGS BOX
• OPENING TIME (s)

Time fixed hopper gate YV603 opens. The system waits for the gate to close before the filler-box performs the forward
stroke and ACP2 starts running.
• ALL CYCLES ON = YES/NO

It is possible to select if the gate is to be opened all the cycles (when the filler-box reaches the end of the return stroke)
or if it opens only when the mobile hopper level control (SL26) detects it needs to be filled.
• WAIT ACP2 STOP = YES/NO

If the filler-box reaches the end of the return stroke and ACP2 has not stopped yet, it is possible to decide whether or
not to wait for ACP2 to stop before opening the gate (YV603).
This data item is insignificant if ACP2 = 50 (non stop movement) is set.
ON YV604/2 FORW.STEP D.STROKE = YES/NO

If set to YES, the mobile hopper is opened and the second downstroke is performed during the forward step. If NO
is entered, the mobile hopper is opened and the second downstroke is performed during the return stroke before the
step forward stroke is carried out.
• YV604 ON POS. / OFF POS. (mm)

Set the ON and OFF positions for YV604.
The ON position always refers to the return stroke, the OFF position refers either to the return stroke or forward stroke
of the step.
• YV602 ON POS. / OFF POS. (mm)

Up to 3 ON and 3 OFF values can be entered for YV602 (STIRRER) during the filler-box stroke.
• YV604V ON POS. / OFF POS. DUR. FORW. (mm)

Enter an ON and OFF value for mobile hopper vibration during the filler-box forward stroke.
• YV604V ON POS. / OFF POS. DUR. RET. (mm)

Enter an ON and OFF value for mobile hopper vibration during the filler-box return stroke.
• YV603V ON POS. (mm)

Enter an ON value for fixed hopper vibration during the filler-box return stroke.
• LENGTH OF SHAKING (YV603V) (s)

Enter the time the fixed hopper has to vibrate (YV603V).
Press key F4 for the other settable double loading data items.
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COLOR FEEDER PAGE (MICRONIZED)
• YV624V OPERATING TIME (s)

Unloader vibrator ON time during color ACP movement.
• YV624V STOP TIME (s)

Unloader vibrator OFF time during color ACP movement.
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COLOR FEEDER PAGE (ROTARY DIAPHRAGM MIXER “MDR”)
• MDR2 SPEED (%)

MDR disk speed.

Start up delay after a pause because funnel is full (level probe SL24).
• STOP TIME 1/2/3/4/5/6 (s)

Disk stop time at each unloading position (every 60°).
• YV24 OPENS CONTINUOUSLY = YES/NO

This data item determines if the gate for YV24 stays open continuously.
• OPENING POSITION 1 YV24 (°)

• CLOSING POSITION 1 YV24 (°)
• OPENING POSITION 2 YV24 (°)
• CLOSING POSITION 2 YV24 (°)
If continuous opening is not enabled, two values for opening and two for closing the gate regarding YV24 can be set
in relation to the disk position.

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COLOR FEEDER PAGE (“DAC” GATE FEEDER)
• GATE 1 STAGE (YV25) = YES/NO

The system performs 5 stages each of which for a set time. Set which gate is to open for each stage.
• DURATION (SEC.) (s)

Set the times for the 5 phases.

Delay time for starting loading from the moment in which the level is no longer high.
• SIMULTANEOUS STOP = YES/NO

It is possible to select if the stage in progress is to be completed or if all the gates are to be closed simultaneously
once the desired level is reached.
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• VARIABLE STAGE REPETITION = YES/NO

It is possible to select if the stages are to be executed in order (1-2-3 etc...) or in random order (2-4-5-1 etc...).


COLOR FEEDER PAGE: 2nd LOADING - ACP2 ZONES
The following data items need to be set in the ACP2 box (color) that is provided with all feeders:
• 16 steps included in the ACP2 stroke: 8 steps with 8 speeds can be set with these 16 data items.
In addition, 8 clean contacts that refer to the 16 settings are provided: KA551,KA552,KA553,KA554,KA555,KA55
6,KA557,KA558.
• SPEEDS: speeds used to travel the 8 steps (used only when ACP2 CYCLE TYPE is set to 1 or 2)
• STOP TIMES: stop times to be used when the values of the first column are reached (ON VALUE) (used only when
ACP2 CYCLE TYPE is set to 3).
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9.2.2 FILLER-BOX/PLUNGER
This page is reached from the LOADING SET-UP page by pressing key F9 (SYNC).
NOTE In the event of AXES SYNCHRONIZATION (optional) consult the relative User’s manual.
FILLER-BOX/PLUNGER BOX
FILLER-BOX SETTING-PLUNGER START (ONLY with linear filler-box or DIP)

During the linear filler-box’s return stroke, the plunger starts moving down at the set value as long as miniature switch
SQ59 is activated otherwise a fault will be signaled. If a mobile die is used, the value should be set so that the grid
is out of the die. Enter 0 to inactivate this function. The data item can be edited only with the mode selector turned
to SET-UP.
SAFETY FILL-BOX SETTING (ONLY in proportional presses with DIP, double loading or linear filler-boxes)
When the value set for PLUNGER UP POS. - FILL-BOX START ADVANCE is exceeded during the plunger upstroke,
the filler-box will start operating. As soon as the filler-box reaches the value set for SAFETY FILL-BOX SETTING,
the system checks that the plunger has moved fully up to the set value otherwise the filler-box shuts down and the
“FILLER-BOX/PLUNGER COLLISION” message is displayed.
Set FILL-BOX START ADVANCE = 0 to inactivate this function.
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9.3 “PRESS-CYCLE SET-UP” PAGE
To go to the “PRESS CYCLE SET-UP” page from “PROGRAMS” press the F4 key (PRESS-CY.).
The data set for the press-cycle are shown on this page.
9.3.1 PRESSES WITH PROPORTIONAL HYDRAULIC SYSTEM
a) The following information is displayed in the first box on the left-hand side:
Some important settings for the plunger stroke and three data items regarding tile thickness: The tiles are produced
according to the TILE THICKNESS setting.
Perform the following steps to enter the required settings:
- enter the maximum allowable value for the IMPACT POSITION data item, e.g. 140.00 mm;
- enter the maximum allowable value for the THICKNESS SETTING data item, e.g. 40.00 mm;
- lower the plunger in manual mode until it rests on the powder contained in the die-set;
- with the cursor on the IMPACT POSITION data item, read the actual setting of the plunger encoder given on
the second to last line on the screen;
- enter a value which is lower than that of the encoder for the IMPACT POSITION data item:
Example: if the PLUNGER ENCODER = 106.80 mm, set IMPACT POSITION to 105.00 mm; set PRESSING
START POS. to 105.00 mm for proportional presses as well;
- allow the machine to perform one cycle;
- with the cursor on the SHUTDOWN POSITION (NO POWDER) data item read the value given for the MAX.
PLUNGER STROKE data item and enter a value greater than it for the SHUTDOWN POSITION (NO POWDER)
data item;
- do the same for the SHUTDOWN POSITION IN 1st PRESS-STROKE;
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- with the cursor on the THICKNESS CALIBRATION data item, read the value displayed for the TILE THICK-
NESS data item given on the second to last line on the screen;
- measure the actual thickness of the tile;
- enter the same value as the measured one for the THICKNESS CALIBRATION data item;
- enable the automatic thickness gauge by entering a value higher than 0 for THICKNESS CTRL COEFF.
- enter a value which corresponds to the desired thickness for the TILE THICKNESS data item.
NOTE This procedure must be performed whenever the die-set is replaced!
NOTE If a program is called up after the die-set has been replaced, perform this procedure after reading the program!
Automatic thickness control:
- With a SMU/conventional lift mechanism:
If THICKNESS CONTROL PULSE is set to 200 and the press has to perform too many cycles in order to reach
the thickness set for the TILE THICKNESS data item, increase the setting, e.g. to 300.
If the thickness of the tiles produced is not always the same, decrease the value, for example to 100.
- With S.P.E.
Enter a value greater than 0 in THICKNESS CTRL COEFF.
The recommended value is 50%; if the press needs too great a number of cycles to reach the thickness set in
TILE THICKNESS increase the value.
If the thickness is instable, decrease the value.
PLUNGER UP POSITION is the position the plunger reaches when it completes its upward movement during the
automatic cycle. The plunger reaches its mechanical end-stop during the semi-automatic cycle or when the ma-
chine is stopped.
END STOP PRECISION is used to more precisely position the plunger at the value set for PLUNGER UP POSITION.
If Ø is entered, minimum precision is obtained. On the other hand, if 100 is entered, the plunger positioning is
extremely precise while the production output is reduced (because the plunger slows down to a greater extent).
IMPACT POSITION: position of plunger at which braking stops during the downstroke.
PRESSING START POS. when this plunger setting is reached, the 1st press-stroke DELAY TIME starts to elapse.
When the delay time has elapsed, the first press-stroke starts. If the first press-stroke is to stop at the set thick-
ness, enter PRESS-STROKE START THICKNESS, which is the thickness of the soft filling height at which the
first press-stroke should start.
THICKNESS FAULT THRESHOLD: thickness error over which the press shuts down (recommended value = 0.40 mm).
The PLUNGER PARALLELISM data item may appear in some machines. This value, expressed in mm, represents
maximum plunger inclination during the press-cycle.
b) The following are shown in the box at the top right side of the page:
- selection of plunger braking during the first press-stroke: if BRAKING DURING PRESS CYCLE = NO, when
the plunger reaches the value set for the PRESS-STROKE START POS. YV32 opens during the downstroke to
reboot the plunger, vice versa opening of end of braking is maintained throughout the entire first press-stroke;
- plunger downstroke speed to reach IMPACT POSITION;
- selection of braking during upstroke setting: if enabled, braking starts when the plunger is on the tile and ends
when the plunger has traveled the distance set for BRAKING DISTANCE DURING UPSTROKE.
In addition, set the plunger speed in the area where the brake is applied, expressed in mm/s or % to which
proportional solenoid valve YV32 opens (to change the type of setting, see par. 8.2.4).
Only for presses with proportional hydraulic and braking during plunger upstroke enabled (BRAKING DUR.
UPSTROKE = YES), if UPSTROKE SPEED BRAKE is set to a value ranging from 18 to 49 mm/s (these values
may differ slightly from the ones indicated) it is possible to set the way in which upstroke with braking takes
place:
if BOOSTER FREE UPSTROKE = YES it takes place with the booster’s free upstroke (YV38 activated);
if BOOSTER FREE UPSTROKE = NO it takes place while the booster is moving up at a speed limited by a
logic element (YV38 deactivated).
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- UPSTROKE HELP STROKE (only with hydraulic unit for “plunger lightening “): if this value is different from
zero, it represents the plunger upstroke with the help activated (it is lower than the upstroke with brake applied)
if upstroke with braking is enabled.
FINAL PRESSURE: set the pressure for the last press-stroke;
TOLERANCE: enter the tolerance for the pressure of the last press-stroke to the right of the symbol ±. If zero is
entered for the tolerance, the last press-stroke will finish when the final pressure is reached. If, on the other
hand, the tolerance is ≥ 5 bar, the last press-stroke will finish when the tile thickness is reached - as long as
the pressure is between “final pressure - tolerance” and final pressure + tolerance” (see figure 1).
PRECISION: the final precision during the last press-stroke can be set in some machines: 100% equals maximum
precision but causes the cycle to slow down slightly; 0% equals minimum precision but maximum production
speed.
Number of press-strokes per cycle.
NO. OF PRELIMINARY CYCLES: the number of strokes performed whenever the cycle is started can be set. En-
ter “0” to disable this function. The maximum value that can be entered is 100 cycles. During these cycles the
press performs the number of press-strokes set for data item “NUMBER OF PRESS-STROKES” found on the
line below “NO. OF PRELIMINARY CYCLES”. Once these cycles have been completed, the press automati-
cally goes back to the number of cycles set for data item “NUMBER OF PRESS-STROKES” found over “NO.
OF PRELIMINARY CYCLES”.
Option DECOMPRESSION WITH BOOSTER allows the cylinder to be decompressed by the external booster to
recover part of the stroke used during the previous press-stroke. The number of press-strokes per cycle should
be more than 2.
c) Press-cycle:
The press-stroke parameters are entered here.
PRESS-STROKE MODE : (0 = to thickness, 1 = to pressure, 2 = to set time) this data item can only be set when
the machine is in SET-UP mode; type 0 can only be used for the first press-stroke. Type 0: the press-stroke
finishes when the soft filling height set in the TH/PR column is reached. Type 1: the press-stroke finishes when
the cylinder pressure has reached the setting in the TH/PR column. Type 2: the press-stroke finishes after a
time controlled by the control system, in order to obtain cylinder pressure equal to the setting in the TH/PR
column, has elapsed.
Thickness of pressure SET POINT of each intermediate press-stroke (TH/PR).
PRESS-STROKE TREND: S1/P1 = thickness/pressure at the first point on the line shown on the graph
T1 = first time at which the pressure, as shown on the line, reaches value S1/P1.
T2 = total length of pressure trend.
Example 1 (see figure 2): 1st press-stroke set to type 0 with THICKNESS AT START OF PRESS-STROKE =
15.00, TH/PR = 12.00, S1/P1 = 13.00, T1 = 2000, T2 = 3000. This means that the press-stroke starts when the
soft filling height reaches 15 mm. The press will adjust YV318 in order to reach a soft filling height of 13 mm in
2 seconds and then 12 mm in the next second.
Example 2 (see figure 3): last press-stroke set to type 1 with FINAL PRESSURE = 250 bar, S1/P1 = 125, T1 =
2000, T2 = 3000. This means that the press will adjust YV318 in order to reach a cylinder pressure of 125 bar
in 2 seconds and then 250 bar in the next second.
- PSM = Used to select if the press-stroke is performed without the booster (in this case, the solenoid valve for
the direct press-stroke is used).
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PRESS-STROKE SPEED: this is the extent to which YV318 opens during the press-stroke, expressed as a per-
centage. YV318 controls the delivery rate to the press-cycle control assembly.
d) The data items regarding deaeration should be set in the right-hand block.
DEAERATION block:
MOTION UPSTROKE: the speed for the deaeration upstroke should be entered here. Enter Ø to perform the up-
stroke at a slow constant speed (through YV31S), enter 100 to perform a fast upstroke (through YV32).
STROKE: the deaeration upstroke is set here.
DURAT.: set the amount of time deaeration takes place.
DOWNSTROKE SPEED: set the speed of the downstroke after deaeration.
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Soft filling
height Fig. 1
Final
thickness
Tolerance Tolerance
Final pressure Cyl. pressure
Thickness
Fig. 2
Thickness at start
of press-stroke
S1/P1
SP/PR
T1 T2 time
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Pressure
Fig. 3
TH/PR or final pres-

sure (=PR)
S1/P1
T1 T2 time

To set the data items, follow the instructions given on the LOADING SET-UP page with the following exceptions: the
following data items can be changed even if the LOG IN procedure has not been performed in mode b) given at step 2):
TH/PR of the 1st press-stroke
Length of 1st deaeration

MODE
can be modified only if the mode selector is turned to SET-UP.
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9.3.2 Presses with non-proportional hydraulic system
a) The following information is displayed in the first box on the left-hand side:
Some important settings for the plunger stroke and three data items regarding tile thickness: The tiles are produced
according to the TILE THICKNESS setting.
Perform the following steps to enter the required settings:
- enter the maximum allowable value for the IMPACT POSITION data item, e.g. 140.00 mm;
- enter the maximum allowable value for the THICKNESS SETTING data item, e.g. 40.00 mm;
- lower the plunger in manual mode until it rests on the powder contained in the die-set;
- with the cursor on the IMPACT POSITION data item, read the actual setting of the plunger encoder given on
the second to last line on the screen;
- enter a value which is lower than that of the encoder for the IMPACT POSITION data item:
Example: if the PLUNGER ENCODER = 106.80 mm, set IMPACT POSITION to 105.00 mm;
- allow the machine to perform one cycle;
- with the cursor on the SHUTDOWN POSITION (NO POWDER) data item read the value given for the MAX.
PLUNGER STROKE data item and enter a value greater than it for the SHUTDOWN POSITION (NO POWDER)
data item;
- do the same for the SHUTDOWN POSITION IN 1st PRESS-STROKE;
- with the cursor on the THICKNESS CALIBRATION data item, read the value displayed for the TILE THICK-
NESS data item given on the second to last line on the screen;
- measure the actual thickness of the tile;
- enter the same value as the measured one for the THICKNESS CALIBRATION data item;
- enable the automatic thickness gauge by entering a value higher than 0 for THICKNESS CTRL COEFF (THICK-
NESS CONTROL PULSE for SMU or lifting).
- enter a value which corresponds to the desired thickness for the TILE THICKNESS data item.
NOTE This procedure must be performed whenever the die-set is replaced!
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NOTE If a program is called up after the die-set has been replaced, perform this procedure after reading the program!
Automatic thickness control:
- With a SMU/conventional lift mechanism:
If THICKNESS CONTROL PULSE is set to 200 and the press has to perform too many cycles in order to reach
the thickness set for the TILE THICKNESS data item, increase the setting, e.g. to 300.
If the thickness of the tiles produced is not always the same, decrease the value, for example to 100.
- With S.P.E.
Enter a value greater than 0 in THICKNESS CTRL COEFF.
The recommended value is 50%; if the press needs too great a number of cycles to reach the thickness set in
TILE THICKNESS increase the value.
If the thickness is instable, decrease the value.
PLUNGER UP POSITION is the position the plunger reaches when it completes its upward movement during the
automatic cycle. The plunger reaches its mechanical end-stop during the semi-automatic cycle or when the
machine is stopped.
IMPACT POSITION: position of plunger at which braking stops during the downstroke.
DELAY BEFORE FIRST PRESS-STROKE (in presses with piloted de-aeration the delay time prior to the second
press-stroke/next ones is also set).
THICKNESS FAULT THRESHOLD: thickness error over which the press shuts down (recommended value = 0.40
mm).
The PLUNGER PARALLELISM data item may appear in some machines. This value, expressed in mm, represents
maximum plunger inclination during the press-cycle.
b) The following are shown in the box at the top right side of the page:
- plunger braking during the first press-stroke;
- braking space for the last part of the plunger downstroke;
- speed control when the plunger is moving down and relative speed at the IMPACT POSITION.
- selection of braking during upstroke setting: if enabled, braking starts when the plunger is on the tile and ends
when the plunger has traveled the distance set for BRAKING DISTANCE DURING UPSTROKE.
- Upstroke help stroke (only with hydraulic unit for “plunger lightening “): if this value is different from zero, it rep-
resents the plunger upstroke with the help activated (it is lower than the upstroke with brake applied) if upstroke
with braking is enabled.
- FINAL PRESSURE: set the pressure for the last press-stroke;
- number of press-strokes per cycle;
- NO. OF PRELIMINARY CYCLES: the number of strokes performed whenever the cycle is started can be set.
Enter “0” to disable this function. The maximum value that can be entered is 100 cycles. During these cycles
the press performs the number of press-strokes set for data item “NUMBER OF PRESS-STROKES” found on
the line below “NO. OF PRELIMINARY CYCLES”. Once these cycles have been completed, the press auto-
matically goes back to the number of cycles set for data item “NUMBER OF PRESS-STROKES” found over
“NO. OF PRELIMINARY CYCLES”.
c) Press-cycle:
The press-stroke parameters are set here:
- pressure during each intermediate press-stroke (PRES.)
- whether the press-stroke is carried out without accumulators (SEPARATE)
- whether the press-stroke is carried out without the booster (in this case, the solenoid valve for the direct press-
stroke is used (PSM).
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d) The length of each deaeration stage is set in the right-hand box.

The mode for deaeration upstroke can be selected in data item UPSTROKE:
0 = the solenoid valve for plunger slow upstroke is used. The stroke can be set up to 3.5 mm;
100 = fast upstroke; stroke cannot be set.
When setting data, the same information given on the LOADING SET-UP page is valid with the following additions:
The following data items can be changed in mode b) at step 2) even if the log out procedure has been performed:
1st PRESS-STROKE
1st DEAERATION LENGTH
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9.4 DIE-SET SET-UP
To go to the “DIE-SET SET-UP” page from “PROGRAMS” press the F5 key (DIE-SETS).
The set points related to the die-set are displayed on this page.
a) Three parameters that identify the size being handled are set in the SIZE box.
If data item TILE LENGTH cannot be set, go to the Axis synchronization page (SYNC) and change data item P.
In addition:
TYPE OF BATCH: enter Ø to obtain the production batch in m2, enter 1 to obtain it according to the number of tiles
produced.
PRODUCTION BATCH: when the press has produced the number of tiles set for the batch, it will stop and mes-
sage “BATCH COMPLETED” will be displayed.
TILE CODE identifies the type of product.
SHRINKAGE: the specific pressure is calculated with the data for the unfired tile; whereas the kiln production (m2
produced) is calculated using shrinkage (difference between die-set cavity and fired tile in %)
b) This box contains two data items regarding die-set maintenance.

First of all the operator should set the estimated service life of the die-set for “NO. OF CYCLES DIE-SET LIFE”
(“NO. OF DIE-SET CYCLES”).
Whenever the die-set is changed for production change write down the value given for data item “CYCLES PER-
FORMED WITH DIE-SET” present on the ACTUAL LOADING VALUES page regarding the die-set being removed.
Once the die-set has been installed, set data item “NO. OF CYCLES PERFORMED”. When the die-set reaches
the number of cycles that equals the “NO. OF CYCLES DIE-SET LIFE” (“NO. OF DIE-SET CYCLES”) data item,
message CHANGE DIE-SET appears.
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c) Two data elements regarding the upper and lower die-sets are given in the MAGNETIC LOCK window. Enter YES
if the press is equipped with a magnetic lock. There are 2 other data items for releasing the die-set lock. Enter
YES before releasing the die-set’s magnetic lock.
If the press is equipped with a magnetic lock enter UPPER = YES and LOWER = YES.
Magnetization procedure: with the key switch turned to SET UP press the “magnetization” keys (see DESCRIPTION
OF KEYS paragraph) and make sure the related leds come on. Adjust the current control device of the magnet
(AJ1 and AJ2) (see the INSTRUCTIONS FOR SETTING ELECTRIC DEVICES manual) and turn the key switch
to MAN.
Demagnetizing procedure: with the key switch turned to SET UP set UPPER DEMAGNETIZATION = YES and
LOWER DEMAGNETIZATION = YES. Press the related keys (see DESCRIPTION OF KEYS paragraph) and make
sure the related leds go out (they flash for more than a minute).
To release a magnetic lock, first demagnetize it and then set UPPER = NO (or LOWER = NO).
Two data elements LOWER PUNCH HOLDER that regard the magnetic locks for the lower punch holders (optional)
may appear at the bottom of the window.
If the magnetic lock control card (CFM) is used, press F7 to view all the other data regarding the magnetic lock.
d) Window to the right:
DIE-SET TYPE: enter - 1 if an SFS upper die-set is used, 0 if the lower die is fixed and 1 if a mobile lower die is
employed.
DOUBLE EFFECT: enter YES if there is a double-acting die-set or NO if it is single-acting.
PUNCHES IN: enter 1 to move the upper punches back in when the filler-box starts, 2 to move them in when the
filler-box is at the end of its forward-stroke and 3 to move them in when the filler-box is at the end of its return
stroke.
SFS STOPPED (SFS SHUTDOWN): if an SFS is used (double action) this data item enables SFS shutdown when
raised so that it acts as return punches.
4 SENSORS: if an SFS is used, this data item enables control of the outside punches with 4 sensors (2 series
connected pairs) instead of the 2 sensors traditionally used (1 series connected pair).
PUNCH EJECTION DELAY (only with SFS type upper die-sets):

with WAIT LOWER DIE (WAIT LOWER DIE-SET) = NO; the time starts from the end of the last press-stroke.
with WAIT LOWER DIE-SET = YES; the time starts from the beginning of the last press-stroke.
WAIT LOWER DIE (WAIT LOWER DIE-SET): YES to enable the “die block/release” cycle in which the mobile
lower die is blocked when down at the end of the press-cycle the lower punches move up after the plunger has
moved up a stroke equal to PLUNGER TRAVEL, DIE-SETS UP (DIE-SET UPSTROKE PLUNGER STROKE).
When the plunger has traveled the PLUNGER TRAVEL, DIE-SETS UP (DIE-SET UPSTROKE PLUNGER
STROKE) + DIFFERENCE DIE UPWARD VALUE (DIE UPSTROKE VALUE DIFFERENCE) the lower die is
released (through YV298), which moves all the way up, activating sensors SQ63A/B. If it takes the die a long
time, the command can be advanced in relation to the knockout by setting a negative value for DIFFERENCE
DIE UPWARD VALUE (DIE UPSTROKE VALUE DIFFERENCE).
If an SFS or mobile lower die is used, it is possible to set independently during each de-aeration if the lower
die needs to be blocked by setting DIE STOPPED = YES; enter NO to allow the lower die to move.
DIE-SET UP DELAY (ms)

- with WAIT LOWER DIE (WAIT LOWER DIE-SET) = NO; if a SMU or traditional knockout is used, the time starts
from the beginning of the last press-stroke; if a proportional knockout is used, the time starts from the end of
the last press-stroke.
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e) Regarding DIE-SET BLOWING it is possible to set the stages during which the solenoid valve die-set blowing
(YV173) is activated:
DURING PRESS-CYCLE:
0 = blower solenoid valve YV173 is not energized during the press-strokes
-1 = the blower operates during the press-strokes but not during de-aeration. Data item POS. OFF needs to
be set: if a value equal to the maximum plunger stroke is entered, the blower does not operate during the
plunger upstroke; if a value lower than the maximum plunger stroke is entered, the blower restarts when
the plunger begins the upstroke and stops when plunger encoder BQ6 reaches the set value.
1 = according to time: it starts at the beginning of the first press-stroke and stops after the time set for “LENGTH”
(in seconds) has elapsed.
If the time set is very long, the blower will stop in any case at the end of the filler-box forward stroke.
POS. OFF:
Set the value of the plunger encoder at which die-set blowing (YV173) stops during the upstroke; enter the maxi-
mum value to disable the blower during the plunger upstroke.
Enter blowing of the SFS pusher to clean the mobile die (YV178) on the underlying line: it is energized during the
plunger downstroke at the value set for ON POS. and is deactivated at the value set for OFF POS.
If a linear filler-box is used, data item DOUBLE-ROW BLOWER: if a value greater than 0 is entered, YV175 is
energized when the filler-box starts running and is de-energized once the filler-box has exceeded the set value
during the forward stroke.
The two items given have been added to window DIE-SET BLOWING in the PH4600:
NO. OF CYCL. and LENGTH: these regard YV174 (base blowing): it is energized for two seconds whenever the
automatic cycle is started and periodically every n cycles where n = NUMBER OF CYCLES for the time set for
LENGTH.

If the die-set heater is present, press F5 to go to the relative page.
When setting data, the same information given on the LOADING SET-UP page is valid.
DIE UPSTROKE DELAY can be modified with +/- even if the log out procedure has been performed.
UPPER MAGNETIC LOCK

LOWER MAGNETIC LOCK
MAGNETIC LOCK, LOWER PUNCH HOLDER
UPPER DEMAGNETIZATION
LOWER DEMAGNETIZATION
DEMAGNETIZATION, LOWER PUNCH HOLDER
DIE-SET TYPE
WAIT LOWER DIE-SET
DIE LOCK
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9.4.1 Die-set heater
All the data items regarding the die set heater are given on this page: both the die-set temperatures and the set values.
Box DIE-SET TEMPERATURES has a line for each area the die-set heater is divided into.
• NO. - the first number to the left identifies the area.
• SYMBOL (ID NO.) - the number of the thermocouple that read the temperature is given to the right.
• CONNECTED TO: - indicates the part of the die-set connected to the thermocouple: for example if 1 is set in col-
umn PHS, it means that the thermocouple is connected to the upper punches.
• TEMP. - temperature measured by the thermocouple.
• SET - temperature set for the particular heater. If set to 0 the heater in that area is disabled. As soon as a tem-
perature different from zero is set, the heater is enabled as long as the mode selector is not turned to SET-UP.
• OUTPUT - If a red dot lights up it means that the heater in that area is on.
• OUTPUT HEAT-UP TIME (ON TIME) - indicates the percentage of time in which the heater in that area is on.
More precisely, it is the time the heater is on (i.e. red light in OUTPUT) divided by the time in which the heater was
enabled to work (i.e. key turned to MAN or AUT, SET higher than 0, no faults).
To reset these data items, reset the statistics as directed in chapter STATISTICS PAGES (all the charts are suitable
except foe the CHARTS SHOWING NUMBER OF STOPS OR DOWNTIMES).
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Only if the die-set heater is fed the mains voltage:
• DIE-SET HEATER ENABLE - Set to YES to enable the heaters. If the system detects a fault, for example if a power
connector is detached from the die-set, this data item is automatically set to NO. The operator therefore has to
reconnect the connector, press the Reset key and set the data item to YES.
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9.4.2 Die-set magnetic lock
Press F7 on the die-set set-up page to access this page that contains all the data regarding the magnetic lock only if
the magnetic lock control card (CFM) is present.
The following items can be set for each group of electromagnetic locks marked AJ1 / AJ2 / AJ3:
THERMOCOUPLE PRES.
- Thermocouple presence, first current control channel (yes/no)
To more accurately control the magnetic lock’s current value, the operating temperature of the windings has to
be taken into consideration. In fact, the current is affected by the winding’s resistance value and therefore the
temperature.
It is possible to select if the thermocouple that reads the temperature of the upper punch (BT5) is to be as-
sociated to the first channel of the magnetic lock’s current control system. “YES” should be selected only if the
first current control channel measures the current value of the upper punch’s magnetic lock, as shown in the
machine’s original wiring diagram. If the thermocouple is not in a position in which it can efficiently read the
temperature of the upper magnetic lock’s windings, enter “NO”.
If “NO” is selected, the system does not take into consideration the temperature read by the thermocouple. In
fact, in order to effectively control the current value it simulates how the winding heats up over time accord-
ing to a set theoretical algorithm. If the type of operation is changed, i.e. this data item is modified, the set-up
procedure for the first channel has to be carried out (see the special operations page).
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- Thermocouple presence, second current control channel (yes/no)

temperature.
It is possible to select if the thermocouple that reads the temperature of the lower punch (BT8) is to be associ-
ated to the second channel of the magnetic lock’s current control system. “YES” should be selected only if the
first current control channel measures the current value of the lower punch’s magnetic lock as shown in the
temperature of the lower magnetic lock’s windings, enter “NO”.
- Thermocouple presence, third current control channel (yes/no)

temperature.
It is possible to select if the thermocouple that reads the temperature of the lower punch (BT8) is to be associ-
ated to the third channel of the magnetic lock’s current control system. “YES” should be selected only if the
first current control channel measures the current value of the lower punch’s magnetic lock as shown in the
temperature of the lower magnetic lock’s windings, enter “NO”.
PUNCH DETACH CONTROL ENABLE

- Enabling of the punch detachment control, Channel 1 (yes/no)
The system performs 2 types of checks, one called electrical fault and the other punch detachment.
The one referred to as electrical fault is always active whereas the punch detach control can be turned on or
off.
Electrical fault: current delta 10% greater/less than the estimated current (calculated) for more than 1 sec
Punch detach: current delta 40% greater/less than the estimated current (calculated) for more than 100 mil-
liseconds

off.
liseconds

off.
liseconds
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The following data items are given underneath:
- Current (A)
The current value of the magnetic lock connected to the selected channel is displayed in real time.
- Voltage (V)
The voltage value of the magnetic lock connected to the selected channel is displayed in real time.
- Estimated die-set temperature ( C)

The temperature of the die-set regarding the selected channel which the system estimated based on current fluc-
tuations and the die-set and ambient temperatures set when the set-up procedure is performed is shown here.
This data item is displayed only if thermocouple presence = no
- Calculated reference current (A)

Estimated current value of the selected channel which is constantly compared to the one actually read to diagnose
any malfunctions. The system calculates it based on the values obtained during the set-up procedure and the
voltage and temperature values read each and every second.
- Difference btw reference and measured current (A)

This is the difference between the calculated reference current value and the one actually read by the instrument
for the selected channel obtained in real time.
Punch detach: current delta 40% greater/less than the estimated current (calculated) for more than 100 milliseconds
- Resistance calculated at temp. of 0 °C (ohm)

This is the electrical resistance value of the windings of the magnetic lock’s control circuit for the selected channel
based on the values obtained during the set-up procedure in relation to a temperature of 0 °C.
- Resistance calculated at measured temperature (ohm)

This is the electrical resistance value of the windings of the magnetic lock’s control circuit for the selected channel
based on the measured or estimated temperature of the die-set.
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9.4.3 DE-AIR
This page, which can be accessed by pressing F9 on the Die-set set-up page (only with integrated De-Air die-set),
contains all the data related to the device.
CYCLE ENABLED WITH DE-AIR DEVICE

Cycle with DE-AIR device enabled.
NEEDLE OUT DELAY, PLUNG.UPSTR START

Delay for switching ON YV325 (needles out) from when the plunger starts moving up (msec)
TIME NEEDLES OUT

YV325 ON time (time needles out) (msec)
NO. CYCLES BETWEEN CLEAN.

Number of press-cycles between needle cleaning cycles.
NEEDLE CLEANING TIME

Time compressed air is blown to clean the needles by activating valves YV326A-B-C.... for the set time.
Cleaning takes place by activating one valve at a time (one each press-cycle) and not all together in order not to
completely discharge the pressure accumulators.
The valves which are energized depend on the number of outputs and set product size.
The counter starts counting the number of cycles between cleaning cycles only when all the valves have been ener-
gized (msec).
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9.5 S.P.E. DIE-SET SET-UP
Press key F8 (S.P.E.) to go from the DIE-SET SET-UP PAGE to the S.P.E. DIE-SET SET-UP PAGE.
The data items for the proportional knockout are set on this page.
a) Settings:
First of all, set the number of SPE downstrokes (they can be changed only in SET-UP mode with the die-set low-
ered)
- 2-downstroke cycle
die-set value
soft filling
limit switch height
up
time
die-set first die- last die-
upstroke set down- set down-
stroke stroke
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- 3-downstroke cycle
die-set value
base thickness
limit switch
up glaze thickness
time
die-set first die- second last die-
upstroke set down- down- set down-
stroke stroke stroke
BALANCING = downstroke in mm to be carried out before balancing (0 = standard cycle) is set only with SPE and
optional “press-cycle with balancing”.
b) Set the speeds of the various die-set movements.
c) Set:
If ejection is to take place between punches, enter KNOCK.= value other than Ø (only with SPE)
Enter the ejection for expressed in bar for data item KNOCK.0 = upstroke between punches disabled.
Enter DIE-SET SECURED = YES only if the die-set has been locked.
DIE-SET DISASSEMBLY (0/1/2/3) [only with S.P.E. 2 + 2 pistons]
Set the type of movement to be performed when assembling/disassembling the die-set; enter 0 unless the opera-
tions for die-set installation described in paragraph DESCRIPTION OF THE KEYS need to be performed.
0 = No operation for die-set installation movements

1 = Self-learning procedure required
2 = Raise die-set – Lower after die-set has been raised
3 = Emergency upstroke – Emergency downstroke
The data can be set only if the mode selector is turned to SET-UP.
Some conditions have to be satisfied in order to carry out the movements given above; one of the messages listed
below will be displayed if one of the conditions is not satisfied:
901 PERFORM DIE-SET SELF-LEARNING

The self-learning procedure has to be carried out (DISASSEMBLY OPERATION NUMBER = 1)
902 DIE-SET ENCODER NOT BLOCKED
Block the die-set encoders.
903 SAFETY GUARDS OF THE PRESSING ZONE CLOSED
The safety guards of the pressing one should be opened
904 FILLER-BOX NOT BACKWARD
Move the filler-box fully back.
905 DIE-SET ENCODER RESET
Set the system to the condition in which the die-set encoder is not reset.
906 DIE-SET ENCODER NOT RESET
Reset the die-set encoder.
907 DIE-SET ENCODER BLOCKED
Release the die-set encoders.
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908 DIE-SETS UP
Move the die-set fully down.
909 DIE-SET ENCODER NOT RESET, FEELER STROKE > 15
One of the two encoders has detected the die-set has traveled more than 15mm while moving up.
910 EMERGENCY MOVEMENT NOT ALLOWED. Reset.
One of the two encoders has detected movement of more than 1 mm during the emergency upstroke.
915 LEARNING NOT COMPLETED
The self-learning procedure has not been successfully completed.
To perform the punch overtravel, set PUNCH OVERTRAVEL = YES and move the die-sets up (see the DESCRIP-
TION OF THE KEYS paragraph); the value beyond the upwards overtravel the die-set reaches during the over
travel can also be set (only with SPE).
With SPE, if the die-set is not level with the die on both sides when fully up, a different setting for piston A and
piston B of the S.P.E. may be set. For example if piston cylinder A is level with the die but piston B is beneath it
set MAX. MISALIGN. (B - A) = 0.20 mm (example).
With electronic rod-type lift systems (optional), set the IDLE STROKE (distance in mm between the mechanical
end stop and the lower end stop with the die-set installed and locked in place) data item. First zero the die-set
encoder at the end of the stroke (see paragraph RESETTING THE AXES), install and lock the die-set, perform
the downstroke in SET-UP and then enter the value read with the die-set fully down at its IDLE STROKE + 1 mm
(for example, if 12.00 is read, enter 13.00 mm). When at the END OF THE UPSTROKE, enter the dead stroke +
the required stroke (for example, to travel 30 mm enter 30 + 13 = 43 mm).
d) ejection with die.

ENABLE EJECTION WITH DIE
enables or disables the ejection with die phase
ENABLE MOBILE DIE
enables or disables mobile die operation (only with ejection with lower die).
DOUBLE DIE EFFECT
Set to YES is lower die pressing is desired. Set to NO if upper die pressing level with punches is desired. (only for
extraction with upper die)
DIE DOUBLE MOVEMENT
enables or disables the die upstroke/downstroke for cleaning the plates (only for extraction with upper die)
LOWER DIE
top lower die (1 = when the filler-box starts, 2 = when the filler-box is forward, 3 = when the filler-box is back) (only
for ejection with upper die)
DIE PLUNGER DOWNSTROKE
when the plunger completes its upstroke, the upper die downstroke command is given (only for ejection with upper
die)
DIE UPSTROKE DELAY
die upstroke control delay (only for ejection with upper die)
DIE DOWNSTROKE DELAY
die downstroke control delay (only for ejection with lower die)
FINAL DECOMPRESSION PRESSURE
controlled decompression final pressure for the cylinder
PLUNGER POSITION FOR PUNCH CLEANING
plunger position for cleaning the upper punches (only for ejection with upper die)
e) Knockout operation timed with FILLER-BOX.

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: degree to which the die-set moves, value of filler-box when the steps starts
(1), filler-box return value at the previous setting (1), die-set speed during movement.
To correct die-set pistons A and B differently during the filler-box return stroke, movements of the SPE to the left
(LH) and right (RH) can be set separately.
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See the example given below:
When S.P.E. is used, the speed can be automatically calculated to even out the powder in such a way as to give it a
“wedge” shape instead of a “step” shape (AUT = YES).
filler-box
Die-set value return stroke
die-set stroke
END OF RE- END START END OF FOR- Filler-box

TURN STROKE WARD STROKE value
lastdown- RETURN SPEED

stroke
Data element TYPE OF CORRECTIONS serves to select the filler-box steps corrections are based on.
Die-set value
END OF RE- END START END OF FOR- Filler-box

TURN STROKE WARD STROKE value
RETURN
Note:
(1) If a filler-box for double loading not manufactured by SACMI is used, this data item is set on the filler-box display
and operation is triggered by KA309.
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NUMBER OF DOWNSTROKES
END STOP (TOP LIMIT SWITCH)
SOFT FILLING THICK.
BASE THICKNESS
KNOCK.
DIE-SET SECURED
DIE-SET DISASSEMBLY
PUNCHES EXTRARUN
MAX. MISALIGN. (B - A)
NO. OF CORRECTIONS
CORRECTION TYPE
AUT
The data item can be modified only with the -/+ keys on the keyboard even if the log out procedure has been performed:
BASE THICKNESS/SOFT FILLING THICK.(only if THICKNESS CONTROL COEFFICIENT = 0).
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9.6 FITTINGS SET-UP
To go to the FITTINGS SET-UP page from the PROGRAMS page, press the F6 key (FITTINGS).
The remaining set points are shown on this page.
a) As far as the ACP is concerned, the number of movements performed during each cycle can be set. The setting
may range from 1 to 49 where 0 = off and 50 = ACP runs non-stop. In addition, a delay time can be set between
one step and the next.
ACP with encoder and inverter (optional): the following can be set in the order given: Speed in %, end of stroke to
left in mm, end of stroke to right in mm.
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b) Concerning the mobile hopper (ALM), 4 types of cycles can be set with data element CYCLE TYPE:
MOBILE ALM (enter Ø)
FIXED ALM WITH LOADING DURING FORWARD STROKE (enter 1)
FIXED ALM WITH LOADING DURING RETURN STROKE (enter -1)
FIXED/MOBILE ALM (enter 2) (only if a cycle with approaching has been set)
MOBILE ALM
When this is selected, the grid is loaded through ALM movement when the filler-box is at a standstill at the end of its
return stroke.
The following items need to be set in the ALM box:
• Type of ALM cycle = Ø i.e. MOBILE ALM
• Double row die-set loading set-up
• Delay time for starting loading
• End of BACK and FORWARD strokes
• MAX = highest allowable setting for BACK STROKE END ST (END OF RETURN STROKE), i.e. the maximum
stroke the ALM can perform. It is set in Set Up mode.
• ALM gate closing position and (with double-row loading) next re-opening and closing
• Speed in manual mode and travel out of the zones and during the ALM return stroke
• Speed percentage in the five zones (the zone is divided into 5 parts included from the end of the return stroke and
first closing value and the zone included between the second opening value and second closing value)
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Description of the cycle:

The gate opens and after the time set for LOADING DELAY has elapsed, the ALM starts the loading stroke. It travels
at the set speed % during the loading stroke. the gates closes in the position set for closing. The ALM moves fully
forward and reverses reaching the end of the return stroke at the speed % set for repositioning. If 2 row loading is
performed, during the loading stroke the gate opens in the second opening position and closes definitively in the
second closing position.
The settings for the data elements in the other boxes do not change and will therefore be dealt with only once further
on in this manual.
FIXED ALM WITH LOADING DURING FORWARD STROKE
When this is selected, the grid is loaded by movement of the filler-box during the forward stroke, the ALM hopper
remains stationary in the set loading position.
• Type of ALM cycle = 1 i.e. FORWARD FIXED ALM
• If the filler-box does not approach, gate opening can be set:
Ø = It opens when the filler-box reaches the end of the return stroke, i.e. RIGHT AWAY
1 = It opens when the filler-box starts running
• DELAYED START FILLER-BOX

Filler-box does not approach
If HOPPER OPENING = 0: delay time for opening gate in relation to when the filler-box reaches the end of its
return stroke.
If HOPPER OPENING = 1: time filler-box start-up is delayed after the gate opens
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Delay time for starting approach in relation to when the gate opens
• The ALM loading position (the ALM does not move out of this position)
• Position of filler-box in which the gate closes
• Speed of the ALM for manual movements and repositioning

• APPROACH POS. = 0 and HOPPER OPENING = 0
The hopper remains stationary in the loading position:when the filler-box reaches the end of its return stroke,
the gate opens (after a time that equals the delay time for opening the gate). The gate closes when the filler-box
reaches the position in which it closes during the forward stroke.
During the first cycle, the gate opens and waits the time set for OPENING DELAY (only if < 1000 ms).
• APPROACH POS. > 0

The grid is loaded during the filler-box approach stroke. The ALM remains stationary in its loading position. First
of all the gate opens and, after the delay time for filler-box start up has elapsed, the filler-box starts the approach
stroke. The gate closes when the filler-box reaches the position in which it closes.
• APPROACH POS. = 0 and HOPPER OPENING = 1

The hopper remains stationary in the loading position: when the plunger reaches the value set for “plunger up” the
gate opens and the filler-box starts running after the time set for “filler-box start-up delay” elapses.
The gate closes when the filler-box reaches the position in which it closes during the forward stroke.
During the first cycle, the gate opens and waits the time set for DELAYED START FILLER-BOX (FILLER-BOX
START-UP DELAY) (not more than 1 sec.) before the filler-box starts running.
on in this manual.
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FIXED ALM WITH LOADING DURING RETURN STROKE
When this is selected, the grid is loaded by movement of the filler-box during the return stroke, the ALM hopper remains
stationary in the set loading position.
• Type of ALM cycle = -1 i.e. return fixed ALM
• The ALM loading position (the ALM does not move out of this position)
• Position of filler-box in which the gate opens during the filler-box return cycle
• Position of filler-box in which the gate closes during the filler-box return cycle
• Speed of the ALM for manual movements and repositioning
on in this manual.
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FIXED AND MOBILE ALM
This cycle can be selected only if the cycle with filler-box approach has been set.
When this is selected, the grid is loaded by movement of the filler-box during the approach stroke.If this is not suf-
ficient, the ALM finishes loading the grid.

• Type of ALM cycle = 2 i.e. MIXED ALM
All the other data items are the same as those set for ALM = 0 (MOBILE ALM).
Loading using both fixed/mobile ALM should be used when the CAF stroke is not sufficient to load the entire grid with
the ALM stationary.

A) Once the die-set has been loaded, the filler-box brings the front of the grid under the ALM.
B) The ALM gate opens and stays open.
C) The filler-box advances reaching the maximum position allowed by the die-set dimensions (approach value) with
the ALM at a standstill and then stops after the time set for DELAYED LOADING has elapsed.
D) The ALM backs up keeping the gate open until the grid has been completely loaded with the filler-box stopped.
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c) MDR BOX (optional)

CYCLE TYPE MDR (of base):
0 = MDR off;
1 = revolves to right;
2 = revolves to left;
3 = right/left rotation.
SPEED MDR: speed (percentage) of the mixer with rotary diaphragm installed on the ACP.
d) The INSIDE (INTERNAL) synchronizer allows the press to be run at the set speed (CYCLES PER MINUTE). The
second value in CYCLES PER MINUTE permits the strokes of the press to be “halved” with synchronized opera-
tion. Example: the press operates at 12 cycles/minute in synchronous mode. If the input which controls internal
synch.(KA301) is activated, the press will operate at a rate of 6 cycles/minute.
Several speed levels can be obtained using a second digital input (KA301A):
If set to INSIDE SYNCHRONIZATION = NO:
1. If KA301 = OFF and KA301A = OFF ==>
the press is asynchronous (at max. allowable speed)
2. If KA301 = ON and KA301A = OFF ==>
the press is synchronized with number of cycles = first value set for CYCLES PER MINUTE (at intermedi-
ate speed)
3. If KA301 = OFF and KA301A = ON ==>
ate speed)
4. Se KA301 = ON e KA301A = ON ==>
the press is synchronized with number of cycles = second value set for CYCLES PER MINUTE (at low
speed)
If set to INSIDE SYNCHRONIZATION = YES:
1. If KA301 = OFF ==>
ate speed)
2. If KA301 = ON ==>
the press is synchronized with number of cycles = second value set for CYCLES PER MINUTE (at low speed)
The OUTER (EXTERNAL) synchronizer allows the press to be timed with an external device.
e) If Enea cooling (optional) is provided, the additional heat exchanger or cooling fans can be enabled or disabled.
OIL TEMPERAT. OFF YV279/ON

Set the oil temperature (measured by BT4) at which solenoid valve YV279 comes on (water shut off, also called
YV280 – drainage of water arriving from cooling unit) and the temperature at which it shuts off.
The temperatures for controlling YV278 (additional cooling kit water shut off) are these temperatures decreased
4 degrees.
OIL TEMP. LOW-HIGH SPEED EXCH. (M11)

It is the temperature for M11 speed exchange.
The setting range is within 40 and 50 degrees and applies to the shift from low to high. A value which is 2 de-
grees smaller than the set value applies to the shift from high to low.
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f) The following settings can be entered for the brush:

- whether or not the brush is provided
- whether the brush is fixed or mobile
- if the brush is mobile the following can be set:
1) whether the brush has to clean the lower or the upper die-set
2) the point of the filler-box stroke at which the brush moves down
3) the point of the filler-box stroke at which the brush moves up
- brush rotation: if this function is enabled, the following modes of operation can be selected:
CLOCKWISE rotation (REVERSE ROTATION = NO, C.WISE ROTATION = YES);
COUNTER-CLOCKWISE rotation
(REVERSE ROTATION = NO, C.WISE ROTATION = NO)
Reverse rotation every h cycles
(REVERSE ROTATION = YES, CYCLES BTW REVERSALS = h).
The ROTATION ON data item allows the following to be selected:
NO = rotation off
1 = rotation on only during filler-box forward stroke
2 = rotation on only during filler-box return stroke
3 = rotation constantly on
- With linear filler-box:

If a linear filler-box is used, it is possible to set the distance in mm the filler-box travels from when brushing
starts to the point at which brushing ends in box BRUSH.
In addition, the brush reverses during the forward stroke at the value set for REVERSE ROT. (only if ROTATION
ON = 3, i.e. if it turns both during the forward and return strokes).
CONSUMPTION and MAX (only for proportional presses)

If CONSUMPTION is set to > 0, the end of the plunger upstroke is lowered to automatically compensate for brush
wear and obtain perfect cleaning. The operator sets specific wear of the brush, i.e. the number of cycles during
which the brush radius decreases is 1 1/100 of mm. In addition, maximum allowable consumption (MAX) can also
be set. When this consumption is reached, the machine shuts down and “REPLACE BRUSH” is displayed. The
procedure starts again if the reset procedure is performed.
NOTE When this function is used, the degree to which the die-set opens may be reduced gradually until the filler-
box is no longer able to pass!
g) WAIT FOR AUTO RESTART (AUTOMATIC RESTART HOLDING) box
ARA
For program versions PH 21.01.01 and later: this data item can be set only if the optional Automatic restart
holding function is present. It is used to enable/disable the Automatic restart holding function.
ARA.M
Used to enable/disable the wait for automatic restart when powder is missing (input SL2 off). This cycle oper-
ates only after a special change.
For program versions 16,18,19,20,22,24,25: if the cycle is set and it goes in standby mode for lack of powder,
the program remains in standby waiting for start trigger pulse. Stop the cycle, then start it again.
PUMP OFF DELAY (0=ON) only in presses with proportional hydraulics
Delay time during Automatic restart holding after which the pump shuts off to save energy.
0 = energy savings not enabled.
This data item can be set even if the optional Automatic restart holding function is not present, provided that
movement of the pneumatic lock’s wedges is independent from that of the bands.
KA300 DELAY, 1ST DOWNSTROKE X ENERGY SAVINGS.

Time interval that starts elapsing from the first die-set downstroke within which an external stop signal does not
trigger the Automatic restart holding cycle with energy savings.
Press the F2 (PROGRAMS) key to go back to the PROGRAMS page.

CYCLE TYPE
can be set only in SET-UP mode.
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9.7 LINE SET-UP
To go to the LINE SET-UP page from the PROGRAMS page, press the F9 key (LINE).
This page is used to control the roller-type press collection unit (RPR) which is optional equipment.
The following settings can be entered:
TURNER OPERATION ENABLE

(YES-NO) (settable only in SET-UP mode)
Enable RPR tuner operation with digital output KM5014 (tuner operating motor).
TURNER ROLL. CONV. STOP ENABLE

Enable operation of RPR turner roller conveyor with incoming tile only
- if = yes is set, check the sensor SQ5041 (turner input photocell) to start the turner roller conveyor motor
- if = is set, check whether the roller conveyors are running
TURNER ROLL. CONV. STOP DELAY

(sec)
It is the stoppage delay of the turner roller conveyors (and, consequently, of rotation start) from the de-activation of
the sensor SQ5041 (turner input photocell). The value should be set so that the roller conveyors stop when the tile
is entirely inside the turner.
ROLL. CONV. MULTISPEED ENABLE

Enable the setting of inverter multispeed for RPR roller conveyors from the press
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ROLL. CONV. MULTISPEED TYPE

Select inverter multispeed for RPR roller conveyors from the press
The control of roller conveyors inverter multispeed acts on digital outputs KA5161, KA5162, KA5163 = trigger pulses
for the selection of inverter multispeed for roller conveyors.
RPR TURNER REPOSITION.

(YES-NO) (not settable if the press is cycling)
Request for repositioning the RPR turner (it is useful only if the RPR turner remains still halfway and booth supply is
cut off). It allows a full rotation of the turner or the completion of an interrupted rotation.
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10 “PRINT ROUTINE”
After logging in, the PRINT ROUTINE is displayed, regardless of the page currently being shown, by pressing key “S”
(with CAPS on, if not press key <CAPS LOCK>). The following data can be printed out at any time.
- SET DATA (as they appear on the various data set-up pages)
- ACTUAL DATA (most important data items)
- PRODUCTION DATA (the same ones that appear on the DATA page)
- FAULTS (the fault history is shown on the FAULTS page)
Press key <9> to go back to the current page.
NOTE:
In order to print out the data, a printer with parallel input must be connected to the output on the back of the automa-
tion PC. A4 continuous form paper should be used.
To set the length of the paper used to print, see page RESETTING THE AXES.
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11 WHAT TO DO WHEN THE MACHINE STOPS DUE TO MALFUNCTIONING
Machine stoppage due to a fault
The machine immediately stops running when a shutdown message is displayed.
When a "stoppage" message appears the machine stops after completing the cycle in progress.
Read the message shown on the first line on the top of the display and then refer to the FAULT MESSAGES chapter
for information regarding what caused the shutdown or stoppage. In some cases, the symbol of the device that de-
tected the fault is shown next to the message. In this case, check the state of the device. If everything is ok, check
the electric connections for the input involved.
Further information regarding the machine is provided on the following pages:
I/O
All the machine inputs are displayed as well. Information useful if an axis or accessory fails to move is given on this
page. The state of the outputs is shown in order to check which outputs should have been active.
All the machine inputs are displayed as well. Consistency between the physical inputs (measuring the card's input
voltage: 0V input not energized, 24V input energized) and the inputs read by the controller can be checked. If the
actual state does not coincide with the one shown, replace the input card.
ALWAYS TAKE DOWN ALL THE INFORMATION MENTIONED ABOVE SO THAT IT CAN BE READILY QUOTED
WHEN CONTACTING SACMI’S SERVICE DEPARTMENT.
MACHINE MALFUNCTIONING CANNOT BE PROPERLY DIAGNOSED IF THIS INFORMATION IS NOT AVAILABLE.
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12 OPERATION OF THE SINGLE PILZ PNOZMULTI SAFETY MODULE
It is a safety PLC with 20 inputs (I0-I19), 2 signal outputs (O4-O5) and 4 safety outputs (O0-01-02-03).
The installed software adequately governs the inputs and outputs to prevent dangerous machine devices from operating.
The system controls the following safety devices:

• inputs I0-I1 Emergency stop buttons SB1 (keyboard) - SB1E (behind machine) - SB2E (foreseen but not installed)
• inputs I2-I3 Set-up/manual-automatic mode selector SA9 (keyboard)
• inputs I4-I5 Filler-box detector SQ66-SQ66A
• inputs I6-I7 Position of r.h. safety guards, Pressing zone SQ11A-SQ11C
• inputs I8-I9 Position of tile collector rollers SQ53A-B
• inputs I10-I11 Position of filler-box gates SQ69-SQ70
• inputs I12-I13 Position of l.h. safety guards, Pressing zone SQ11B-SQ11D
In addition to these devices, the system also governs watch dog signal KT100 (input I15)
The 4 safety outputs are controlled in the following manner:

Outputs O0-O1 are controlled according to the status of the emergency stop buttons and watch dog
(outputs OFF = emergency stop button pressed or watch dog signal not present)
Outputs O2-O3 are controlled according to the status of all the other safety devices
(outputs OFF = outputs O0 and O1 off or one of the safety devices is not in its work position or the mode selector is
turned to set-up)
The 2 signal outputs (O4 and O5) tell the machine P.C. inputs AJ100 e AJ101) the status of the safety outputs (O0-01-
02-03) taking into consideration the state of the feedbacks of contactors KA100-KA101 (input I17) and KA102-KA103
(input I18) which the safety outputs control.
Outputs ON = safety outputs ON and relative contactors ON (i.e. feedback inputs OFF)
Description of operation:
The device is rearmed at the falling edge of the reset signal (input I16). Outputs O0 and O1 are reset at the first reset
pulse while outputs O2 and O3 are reset at the second pulse.
If the outputs are not reset and the led indicators do not signal malfunctions it means that the inputs are not able to
reset the device (example: emergency stop button pressed or guard opened)
The system does not need the reset signal to go back to manual/automatic mode from set-up.
The system makes a number of checks at the inputs of the safety devices (emergency stop buttons, microcontacts,
etc...):
- the poles must not be reversed, the voltages supplied by the device (terminals T0-T1-T2-T3) should be con-
nected to the inputs observing the poles given in the drawing.
(I fault signal)
- if two inputs for the same safety device are short circuited, the system detects the problem
(I fault signal).
- (I fault signal).the system checks if inputs for the same device switch from off to on and vice versa simultane-
ously, the maximum allowable time is approximately 3 sec.
This check is disabled for inputs I4 and I5 (SQ66/66A). (I fault signal)
The device resets the safety outputs only if the feedback of the contactors (KA100-101 and KA102-103) are ON (i.e.
contactors OFF). When the system is reset, the inputs of the feedbacks must switch OFF (i.e. contactors ON) (O fault
signal) within approximately 1 sec.
Outputs O0 and O1 → feedback KA100-KA101 (I17)
Outputs O2 and O3 → feedback KA102-KA103 (I18)
In addition, the device resets safety outputs O0-O1 and O2-O3 only if the contactors that feed the filler-box are OFF
(input I19 ON). As regards outputs O0–O1, this is not required when the filler-box is not present, I4 and I5 (SQ66-
SQ66A) OFF.
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The device switches over to safe conditions keeping all the outputs OFF whenever an alarm arises.
Meaning of led indicators:

- OA0: power at terminals 24V and 0V of XT2
(the led indicators for terminals A1-A2 24V-0V stay off even when power is present)
- Power: device energized
- Run: program running without any problems
- Diag: serial connection to a p.c. on
- Fault: device failure, the program does not run (check the chip-card, if the program is installed and is correct)
- I-fault: the status of the inputs is not consistent (see the description of operation)
- O-fault: the status of the outputs is not consistent (see the description of operation)
The led indicators on the inputs and outputs simply signal power is present at the relative terminal.
In order to reset a I-fault or O-fault condition, either switch over the inputs and outputs involved with the problem or
shut off the device and then turn it back on.
Photograph 1 shows the status of the device’s led indicators before being reset with all the safety devices in their work
positions and the mode selector turned to manual or automatic.
Photograph 1
Photograph 2 shows the status of the led indicators when the device is regularly reset.
Photograph 2
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13 FAULT MESSAGES
The fault messages are displayed in the area of the display illustrated in the figure.
Each message is identified by a four-digit number (the first figure represents the category of message). Five message
categories are provided.
1) SHUTDOWN MESSAGES
These messages are displayed when the machine immediately shuts down.
These messages can be cleared by pressing the Reset key after the cause of the shutdown has been removed.
2) PARTIAL SHUTDOWN MESSAGES

These messages are displayed when the machine immediately shuts down.
These messages can be cleared by pressing the Reset key after the cause of the shutdown has been removed.
3) STOPPAGE MESSAGES
These messages appear when the machine stops at the end of the work cycle in progress. Manual operations
are still enabled. These messages can be cleared by pressing the Reset key after the cause of the shutdown
has been removed.
4) FAULTS (MESSAGES WHICH REQUIRE MANDATORY ACTIONS)

These types of messages to the operator do not influence cycle execution, however, the operator is required
to act immediately.
5) INFORMATION MESSAGES
These messages do not affect the work-cycle or manual operations. Press the Reset key to clear them.
6) MAINTENANCE MESSAGES
These messages do not affect the work-cycle or manual operations.
Press the Reset key to clear them with the key turned to SET-UP.
NOTE: In some cases, operating system messages are displayed. A detailed description of these messages is given
in the following chapter.
NOTES: - For further information regarding the sensors/actuators consult the LIST OF DEVICES handbook.
- The location of the sensors/actuators indicated in the fault messages is given in the SPARE PARTS
Manual.
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NOTES ON HOW TO REPLACE THE CARDS:

• The set data are stored in the automation PC’s buffer RAM but can be copied in the recipes that reside in the
interface PC’s memory.
If the mother board or automation PC’s buffer RAM card needs to be replaced, save the work recipe and call
it up after replacing the device.
• The configuration data (serial number, type of press, type of filler-box, etc…) reside in a file saved in the auto-
mation PC.
• The “total” production data reside in a file saved in the automation PC.
• The automation PC’s buffer RAM contains other data that are lost if the mother board or buffer RAM card is
replaced.
The main data along with instructions on what to do if they are lost are given below:
PLUNGER ENCODER HAS BEEN RESET:

If the “PLUNGER ENCODER NOT RESET” fault message is displayed, go to the page used to reset the encoder.
DIE-SET LOCKING ACTIVE:

If the “PUNCHES NOT FIXED” fault message is displayed, first of all carry out the procedure to lock them.
PROPORTIONAL SOLENOID VALVE SELF-LEARNING PROCEDURE COMPLETED:

This information is given only in proportional presses. If the “PERFORM PLUNGER LEARNING (YV32)” fault
message is displayed, perform the self-learning procedure for the plunger upstroke/downstroke.
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13.1 OPERATING SYSTEM MESSAGES
0001 DIVIDE ERROR INTERRUPT (Operating system)
The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears.
0002 NON-MASKABLE INTERRUPT (Operating system)
0003 OVERFLOW INTERRUPT (Operating system)
0004 UNUSED OPCODE INTERRUPT (Operating system)
0005 KEYBOARD ERROR /PE/OE/FE (Operating system)
Communication problem with the machine control keyboard. Shut off the electrical power and then turn it
on again.
Parameter: PE (parity error), OE (overrun error), FE (framing error).
0006 INVALID MEMORY (Operating system)
The program is not valid. Shut off the power supply, make sure the card located on the CPU is properly
plugged in and then turn the power supply back on. If the trouble persists, contact SACMI quoting the alpha-
numeric code stamped on the card.
0007 POWER SUPPLY/FUSES nnV (Operating system)
0008 DIVIDE ERROR PROG n LINE nn (Operating system)
A division has been made by 0. The problem cannot be solved by the customer. Contact SACMI quoting
the message as it appears.
0009 OVERFLOW PROG n LINE nn (Operating system)
An instruction has been improperly executed; its result exceeds the set limits. The problem cannot be solved
by the customer. Contact SACMI quoting the message as it appears.
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0010 PROG n PC nnnn:nnnn COD nn (Operating system)
An instruction not acknowledged was executed. The version of the operating system is probably prior to the
one required by the program. The problem cannot be solved by the customer. Contact SACMI quoting the
message as it appears and the version of the operating system.
0011 OVERFLOW STACK PROG nLINE nn (Operating system)
The stack pointer is not within the allowable range.

The problem cannot be solved by the customer.
Contact SACMI quoting the message as it appears.
0012 OUT OF PROGRAM (Operating system)
A SKIP instruction has been executed that caused the program counter to exit the program. Contact SACMI
Customer Service Department.
0013 INVALID LICENSE CODE (Operating system)
An appropriate Profibus master card is not installed. Contact SACMI Customer Service Department.
0014 FLOAT ERROR (Operating system)
The mathematic coprocessor has executed an instruction with invalid parameters. Contact SACMI Customer
Service Department.
0015 NO SUCH FILE (Operating system)
This fault appears if the BMOS.EXE is executed with a parameter name of a non-existent file.
Contact SACMI customer service.
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13.2 SHUTDOWN MESSAGES
1001 SHUTDOWN PUSH-BUTTON (shutdown)
The emergency stop button on the keyboard has been pressed.

If the push-button has not been pressed, check the keyboard power leads.
If the cord is properly plugged in and is not broken, try replacing the control KEYBOARD.
1002 EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E) (shutdown)
One of the external shutdown pushbuttons has been pressed.

If this is not the case, check the connector blocks of the external shutdown buttons and related wiring con-
nections. Also check the input card (Led SB1E must be on when the machine has not shutdown) and the
leads/connectors.
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1003 PROFIBUS ERROR: ADDRESS y (shutdown)
A fault has been detected in the slave whose address is equal to y in the machine’s profibus network.
Check the electric diagram or the I/O page for the exact location of the station in question and check its state.
Check the state of the bus connector, correct setting of the address and terminal inside the connector.
Restart the profibus master card from the Live list page with function “Warm restart”.
Some stations have profibus interface module -DP with 3 led indicators called SF, BF, ON. A general indica-
tion of the meaning of the various cases that can occur follows:
LED Event
Cause Action
SF BF ON
off off off There is no voltage in the interface mod- Switch on the DC 24V power supply in
ule, or the interface module has a hard- the interface module.
ware defect.
* * on Voltage is present in the interface mod- ---
ule.
* flashing on Interface module design is missing or - check the interface module
incorrect. The Master DP and interface - check the configuration and param-
module do not exchange data. eter settings
Causes: - check the PROFIBUS address
- incorrect PROFIBUS address
- configuration error
- parameter setting error
* on on Search for transmission speed, PROFI- Set a valid PROFIBUS address (1-125)
BUS address not allowed, lower code for the interface module or check the
selector (PROFIBUS address) not in the bus configuration.
"OFF" position. - Make sure the bus connector is insert-
Causes: ed correctly.
- the call-up control time has elapsed - Make sure the bus cable to the Master
- bus communication with the interface DP is not disconnected.
module through PROFIBUS DP is in- - Turn the DC 24V power supply of the
terrupted. interface module off and then back on.
The established ET 200S configuration Check ET200S configuration to deter-
does not correspond to the real one. mine if a module is missing or defec-
tive one or if a non-configured one is
inserted.
Check the project (for ex. con COM-
PROFIBUS or STEP7) and eliminate
the parameter setting error.
on * on Periphery module error or defective in- Replace the interface module or contact
terface module. your Siemens partner.
off off on Data exchange between the Master DP ---
and ET 200S is in progress.
The preset configuration and the actual
ET 200S configuration coincide.
* Not relevant
See if there is an error in the configuration: run the Live List (see the chapter that deals with Profibus network
diagnosis). Verify if the faulty slave is shown in orange, i.e. CONF.
In this case, the indications provided by the leds may be different from those previously described; follow
the directions given below.
Errors in the configuration and ET 200S peripheral device are signaled on the interface module by LEDs for
cumulative errors SF (red) and bus errors BF (red).
The LED that signals the error provides information about the cause. The LED flashes to signal the error
after which the type of error and then the location and code are displayed.
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The LED that signals errors in the configuration and settings

• is active both with POWER ON and during operation
• it has priority over all the other states displayed by the SF and BF LEDS
• it stays on until the cause of the error has been cleared.
After the configuration of the ET 200 S has been modified, it may be necessary to turn the interface module
OFF/ON.
Sequence Description
1 LEDS SF and BF flash 3 times at 0.5 Hz Signals the type of error
2 LED BF flashes at 1 Hz Displays the type of error (decimal)
3 LEDS SF and BF flash 3 times at 2 Hz Signals the error location/code
4 LED SF flashes at 1 Hz Displays the tens (decimal) of the error location/code
5 LED BF flashes at 1 Hz Displays the unit (decimal) of the error location/code
6 1 through 5 are repeated until the cause of the error has been cleared
Error indication
Type of BF er- Error location (SF/ Cause Action

ror BF)
1 01-63 Communication down Check ET 200S
(connector socket) The first connector socket from which no periph- configuration.
eral module is found is displayed.
• A peripheral module with POWER ON is not
present or several peripheral modules are not
present during operation
• Interruptions in backplane bus
• Short circuit in backplane bus (“01” is dis-
played as the connector socket)
• Closing module not present
If the closing module is not present, the num-
ber of peripheral modules plugged in + 1 are
displayed (if the default configuration is not
present).
2 01-63 Closing module not found Install the clos-
(connector socket) This type of error is signaled if a default configu- ing module
ration is present and the connector socket from
which the peripheral modules are not longer
found is equal to (number of default configuration
modules + 1).
3 01-63 Peripheral module Verify if a mod-
(connector socket) The established ET 200S configuration does ule is missing in
not correspond to the real one. The first connec- the design and/
tor socket that indicates a configuration error c or configuration
(module missing, wrong module, error in module) of the ET 200S
is displayed. or if an incorrect
This error is displayed only if parameter “Opera- or faulty module
tion if default configuration <> from actual one” is present.
is blocked.
The following errors may occur only if the ET 200S is used in a third party master or with GSD file.
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Type of BF Error location (SF/ Cause Action

error BF)
4 01 Design error Future extensions Modify design.
Future extension parameters have been set
without designing the relative power module.
02-63 Future extension parameters have been set
(connector socket) more power modules than necessary have
been foreseen. The connector socket for the
second power module with future extensions
is displayed.
5 01 General setting error Make required cor-
The number of parameters blocks of the rections.
module in the telegram does not correspond
to that of the identifications in the configura-
tion telegram.
02 The address area (inputs and outputs) of the
interface module has been exceeded.
03 Structure of parameter telegram incorrect.
If the problem persists, contact the Customer Service Department - SACMI IMOLA quoting the data that ap-
pear on the Live list / extended diagnostic pages and the status of the 3 led indicators previously described.
1004 PUNCHES NOT FIXED (AJ1/AJ2/AJ3) (shutdown)
If (AJ1), (AJ2) or (AJ3) does not appear to the right of the fault message the magnetic lock is enabled but it
has not yet been magnetized (see the MAGNETISM paragraph in this manual).
(AJ1):
The input card has not received the feedback signal that the upper punch locks are magnetized.
Check the setting of current control device AJ1 and check the wiring/operation of the upper magnetic lock.
Also inspect the digital input module with input AJ1 and the relay output module with output KA201.
(AJ2):
The input card has not received the feedback signal that the lower punch locks are magnetized.
Check the setting of current control device AJ2 and check the wiring/operation of the lower magnetic lock.
(AJ3):
The input card has not received the feedback signal that the lower punch locks are magnetized.
Check the setting of current control device AJ3 and check the wiring/operation of the lower magnetic lock.
(AJ1GE):
Electrical fault present in magnetic locking circuit AJ1, signaled by card CFM (Magnetic lock control), pres-
ent in the electrical cabinet.
This may be due to: very low current or voltage or calculated current and resistance values = 0 for at least
250 msec (0 appears to the right). Current delta 10% higher/lower than the set-point for more than 1 sec (the
error between the current read and the reference one, expressed in hundredths of Ampere, at the moment
in which the alarm occurred is given to the right).
(AJ1DP):
Punches detached from magnetic lock AJ1, signaled by card CFM (Magnetic lock control), present in the
electrical cabinet. Current delta 40% higher/lower than the set-point for more than 100 msec (the error be-
tween the current read and the reference one, expressed in hundredths of Ampere, at the moment in which
the alarm occurred is given to the right).
(AJ2GE):
Same description as for (AJ1GE) but regarding magnetic lock AJ2
(AJ2DP):
Same description as for (AJ1DP) but regarding magnetic lock AJ2
(AJ3GE):
Same description as for (AJ1GE) but regarding magnetic lock AJ3
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(AJ3DP):
Same description as for (AJ1DP) but regarding magnetic lock AJ3
1005 CHECK PRESET DATA (shutdown)
If this message appears when the machine is started up or after the automation PC has been replaced,
check all of the set data.
If the message appears at any other time, make sure the Profibus master card FBM mounted on the PCI
bus of the automation PC is secured in place.
NOTE: To clear the message, turn the key switch on the machine control keyboard to “SET-UP” and press
the Reset key.
1006 SAFETY MODULE (AJ100) (shutdown)
With two PNOZ X3 devices:

Input AJ100 is not present. Press the Reset key. If the message is not cleared, check safety module AJ100.
If power is not being supplied, check the module it has to feed, the leads/connectors and fuse.
If power is being delivered but the LED indicators for the two channels are not both on check all the emer-
gency stop buttons, the leads/connectors and that the reset signal reaches the device.
If power is being delivered and the LED indicators for the channels are on, check the safety module that
may be faulty.
With single PNOZmulti device:
Input AJ100 is not present even if the inputs for the emergency stop buttons are OK. This input corresponds
to output O4 of module AJ100 that indicates the status of the outputs (O0 and O1) regarding the emergency
stop buttons. Press the reset key.If the message is still displayed, check safety module AJ100 (see the
chapter that describes operation of device PNOZmulti).
1007 MODE SELECTOR (shutdown)
The key on the machine control keyboard was turned during RESETTING, CYCLE or SEMI-AUTOMATIC
operation.
If the key was not turned, check selector SA9, its connection to the machine keyboard and the keyboard
power lead.
If the lead is properly plugged in and is not broken, replace the control keyboard.
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1008 PROFIBUS ERROR: MASTER GB x EV y (shutdown)
A problem has been detected in the Profibus network.

If the problem persists, contact the Customer Service Department - SACMI IMOLA quoting the data that
appear on the Live list page and the status of the led indicators present on the front of the Profibus master
card in the automation PC.
Profibus Master card front lay-out
PC connection
(9-pin male connector)
HL1: Status (yellow)

HL2: Error (red)
HL3: Ready (yellow)
HL4: Run (green)
Profibus connection
(9-pin female connector)
Card FBM: Field Bus Master
Note: with operating system versions BMOS v.03.01, v.03.02, v.03.03, v.03.04, if parameter y = 220, the
Ethernet connection between the automation PC and interface PC may be down; in this case, check the
Ethernet cables/connectors, and (if present) the HUB AP414 device and the relative power supply.
Value x is an additional diagnostic tool called Global Bits
It indicates the following:
1st bit (*): CONTROL ERROR = parameter setting error.
2nd bit: AUTO CLEAR ERROR = the Profibus master card has interrupted communication to all the slaves
and has reached condition “fine auto clear”.
3rd bit: NON EXCHANGE ERROR = at least one station has not reached the "data exchange" state and no
data has been exchanged with this station.
4th bit: FATAL ERROR = due to a serious bus error no further bus communication is possible.
5th bit: EVENT ERROR = the PROFIBUS master card has detected a short circuit in the bus. The bit is set
when the first short circuit is detected and will not be reset again.
6th bit: HOST NOT READY NOTIFICATION = indicates if the program is in "operating" condition. If this bit
= 1, it means the program is not able to communicate.
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7th bit: TIMEOUT ERROR = the Profibus master card has detected a timeout as Profibus messages have
been refused. This indicates there is a short circuit on the bus while the master interrupts communication.
The bit is set when the first short circuit is detected and will not be reset again.
8th bit: reserved
(*) the 1st bit is the one from the right of value x expressed as a binary value.
Example:
If it is GB 4, as 4 in binary form is written as 00000100, the problem is NON EXCHANGE ERROR.
If it is GB 5, as 5, in binary form is written as 00000101, the problem is NON EXCHANGE ERROR along
with CONTROL ERROR.
Value Y is an additional diagnostic tool called Error event.
It indicates the following:
0 no error
50 contact customer service department
54 no parameters in master: a “download” is required
55 wrong value in master parameters: contact customer service department
56 no parameters in slave: a “download” is required
57 wrong value in slave parameters: contact customer service department
58 a double address has been detected in the slaves
59 data have been set to an address beyond limit 0-255
60 data have been received from an address beyond limit 0-255
61 overlapping in the data areas of the slaves being transmitted
62 overlapping in the data areas of the slaves being received
63 error in “warm start” parameters
110 BUS OFF status reached due to a short circuit in the bus.
The bus short circuit counter (BUS.ERR.CNT on Live List page) increases
212 database read error: a “download” is required
220 software watchdog error
221 program failed to perform “handshake” within allowable time
222 master in “auto clear” state as a slave does not respond
Refer to the type C manual for the card for further information.
1009 MAIN SWITCH TRIPPING (BTn or KMn) (shutdown)
This fault message is displayed just before the power to the electrical cabinet is cut off. This happens because
a fault has been detected in one of the die-set heaters (“n” indicates the heater which is malfunctioning):
- output KMn of the relay output module is off and the corresponding input KMn of the digital input module
is on (for example a contact is stuck);
- the temperature measured by thermocouple BTn is higher than 75°C.
In all these cases, the pumps are stopped after 5 minutes and then power to the electrical cabinet is cut off.
Check thermocouple BTn, the analog input module and the related leads/connectors. In the first case, check
the relay output module, contactor KMn, feedback relay KAn in the electrical cabinet and the digital input
module.
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1010 PROFIBUS ERROR: HOST FLAG x (shutdown)
A problem has been detected in the Profibus network.

A problem has been detected in data exchange between the program (Host) and the master Profibus card.
PC connection

HL2: Error (red)
HL3: Ready (yellow)
HL4: Run (green)
Profibus connection
Value x is an additional diagnostic tool called HostFlags.

It means:
1st bit (*): irrelevant
2nd bit (*): irrelevant
3rd bit (*): irrelevant
4th bit: ERR; if 1 it means there is a communication error with a network device
5th bit (*): irrelevant
6th bit: COM (if 1); if 0 it means there is I/O exchange with a network device
7th bit: RUN (if 1); if 0 it means that the Profibus master card is not communicating
8th bit: READY (if 1); if 0 it means that the Profibus master card has not completed the initialization procedure
(*)1ø bit to the right of the binary value
Example:
If x = 232, as the binary value is written as 11101000, the master card status is ERR;
If x = 160, as the binary value is written as 10100000, the master card status is not in RUN.
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1011 PRESSURE SWITCH (SP2) ... bar (shutdown)
The maximum operating pressure for the pressing cylinder has been exceeded. The problem has been
detected by pressure switch SP2. If no problems are found, check the pressure switch, relative digital input
card (if the pressure is within the set limits, the input should be on) as well as the cables/connectors.
1012 PROFIBUS ERROR: WATCH DOG (shutdown)
A Watch dog error has been detected in the master Profibus card.
If the problem persists, replace the master Profibus card in the automation PC.
PC connection

HL2: Error (red)
HL3: Ready (yellow)
HL4: Run (green)
Profibus connection
1013 CONFIG. (shutdown)
This message is for SACMI personnel only.

The press cannot perform any movements.
If this message appears when no SACMI engineer is working on the press, contact the After-sales Service
Dept. - SACMI, IMOLA
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1014 PROFIBUS ERROR: COMMUNICATION (shutdown)
A problem has been detected in the PROFIBUS network of the machine.

Check which stations are in error on the Live List page. Observe cabling if the stations in the wiring diagram
and make the checks that appear in red on the Live List page, from the first to the last one:
check the status of the bus connectors and make sure the selector switch (On/Off) present on each con-
nector is correctly set.
If the problem persists, contact Customer Service - SACMI IMOLA providing all the information given on
the Live list page and the status of the led indicators present on the front of the master profibus card in the
automation PC and any numbers that appear to the right of the message.
PC connection

HL2: Error (red)
HL3: Ready (yellow)
HL4: Run (green)
Profibus connection
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1015 FILE ERROR: x (shutdown)
Contact the After-sales Service Dept. - SACMI, IMOLA

An error has been found when reading a automation PC file.
x indicates the following:
00001H Operation not permitted
00002H No such file or directory
00003H No such process
00004H Interrupted function call
00005H Input/output error
00006H No such device or address
00007H Argument list too long
00008H Exec format error
00009H Bad file descriptor
0000AH No child processes
0000BH Resource temporarily unavailable
0000CH Not enough space
0000DH Permission denied
0000EH Bad address
00010H Resource device
00011H File exists
00012H Improper link
00013H No such device
00014H Not a directory
00015H Is a directory
00016H Invalid argument
00017H Too many open files in system
00018H Too many open files
00019H Inappropriate I/O control operation
0001BH File too large
0001CH No space left on device
0001DH Invalid seek
0001EH Read only file system
0001FH Too many links
00020H Broken pipe
00021H Domain error
00022H Result too large
00024H Resource deadlock avoided
00026H Filename too long
00027H No locks available
00028H Function not implemented
00029H Directory not empty
0002AH Illegal byte sequence
1016 SAFETY GUARDS OPEN (AJ101) (shutdown)
The guards opened while the press was cycling. The fault was detected by digital input AJ101 coming from
safety module AJ101.
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1017 PROFIBUS ERROR: PDACK-PDCOM (shutdown)
A problem has been detected in the PROFIBUS network of the machine.

More specifically, the handshake mechanism to time the program with the bus has taken a time out.
Check data items DPM SET MODE and SYNCHRONOUS on the Live List page.
PC connection

HL2: Error (red)
HL3: Ready (yellow)
HL4: Run (green)
Profibus connection
1018 KEYBOARD ERROR: SCAN CONTROL ##° (shutdown)
A fault has been detected in the machine’s profibus keyboard card.

The number to the right of the fault indicates the key with the problem (button pressed for over 120 sec).
Refer to the keyboard shown in the relevant chapter at the beginning of this manual for the number legend.
Make sure the keys are efficient and the connectors on the card are attached correctly.
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1019 CHECK 24 Volt (parameter)° (shutdown)
If the parameter is (24 Vev-1):

Input 24 VEV1 is not present. No 24 V solenoid valves branch 1 (wire 939). Check power supply TS102.
If the parameter is (24 Vev-2):
Input 24 VEV2 is not present. No 24 V solenoid valves branch 2 (wire 0939). Check power supply TS102.
If the parameter is (24 Vev-1-2):
Inputs 24 VEV1 and 24VEV2 are not present. No 24 V solenoid valves in branch 1 and branch 2 (wires 939
and 0939). Check power supply TS102.
If the parameter is (24VSEN):
Input 24 VSEN is not present. Sensors 24 V provided by power supply TS101 not present.
There may be a short circuit in sensors 24 V.
If there is a short circuit breaker FS120 also trips.
If the parameter is (24VEV):
Input 24 VEV is not present. Solenoid valve 24 V provided by power supply TS102 not present.
There may be a short circuit in solenoid valve 24 V.
If there is a short a circuit breaker (FS100 or FS102 or FS103 or FS107 or FS108 or FS111 or FS112) also
trips.
1020 PLUNGER SHUTDOWN (KA312) (shutdown)
Plunger downstroke / pressing during automatic cycle stopped by external system (input KA312 off).
NOTE If there is no external device that shuts down the press, place a jumper on input KA312 in the electri-
cal cabinet (slave 3).
1026 PROFIBUS CONFIGURATION (slave N1, module N2) (shutdown)
The device that controls the input/output modules has detected an error.
More precisely, the module in position N2 (second alarm parameter) in the slave with address N1 (first alarm
parameter) is not correct.
NOTE: Counting of the position of the modules starts from the coupler (IM151-1 ...) excluding it from the count.
1027 PRESSURE IN CYLINDER TOO HIGH (BP1) (shutdown)
The maximum operating pressure for the pressing cylinder has been exceeded. The problem has been de-
tected by pressure switch BP1. The latter has measured a pressure in the upper cylinder that is more than
20 bar higher than the maximum allowable pressure. If no problems are found, check pressure transducer
BP1, the relative analog input card as well as the cables/connectors.
1028 EXTERNAL SHUTDOWN PUSH-BUTTON (SB5E) (shutdown)
The external shutdown push-button SB5E has been pressed (filler-box keyboard).
If the button has not been pressed, check the connector block of the shutdown push-button and related
wiring connections.
Also check the digital input card (Led SB5E must be on when the machine has not shutdown) and related
wiring connections.
1029 SET PASSWORD (shutdown)
The press has been stopped. Set the password provided by Sacmi in settable data item PASSWORD to
start it again. The related page can be reached by pressing F8 twice on INFO page.
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1030 CHECK (SB11/KA111A-B) (shutdown)

(Fast die-set change)
A fault is present in inputs KA111A-KA111B; with button SB11 pressed, the inputs should be KA111A OFF,
KA111B ON, with button SB11 not pressed, the inputs should be KA111A ON, KA111B OFF. These two
conditions (the only possible conditions) have not been checked.
Outside fast die-set change (settable data item), the button SB11 has been depressed more than 10 seconds
without starting other movements. Check the inputs KA111A-KA111B, the button SB11, the digital input card
in question and related wiring connections.
1031 CHECK (SB10/KA110A-B) (shutdown)

A fault is present in inputs KA10A-KA10B; with button SB10 pressed, the inputs should be KA10A OFF,
KA10B ON, with button SB10 not pressed, the inputs should be KA10A ON, KA10B OFF. These two condi-
tions (the only possible conditions) have not been checked.
The button SB10 has been depressed more than 10 seconds without starting other movements of the filler-
box regarding fast die-set change. Check the inputs KA10A-KA10B, the button SB10, the digital input card
in question and related wiring connections.
1032 RPR TRIP WIRE (SQ5032) (shutdown)

(RPR)
The digital input SQ5032 is off and indicates that the trip wire has been pulled.
If this is not the case, check the sensor SQ5033 and related wiring connections.
1033 RPR TURNER DOOR (SQ5033) (shutdown)

(RPR)
The digital input SQ5033 is off and indicates that the turner door has been opened.
If this is not the case, check the door limit switch SQ5033 and related wiring connections.
1034 CHECK (KA104A-B) (shutdown)
The system has found an inconsistency between the state of the input that controls the contactors KA104A.
KA104B and the conditions for which they should be energized or de-energized (filter time is 2 sec).
Contactors should be energized in the following conditions: with the selector SA11 for control with continu-
ous action in position "on" or when emergency stop buttons are not pressed and machine guards are closed
(operating position).
Check the contactors KA104A-KA104B, the selector SA11, the contactors KA111A-B, the module AJ100
and the related expansions, the limit switches of the mobile guards, the connecting cables and connectors.
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13.3 PARTIAL SHUTDOWN MESSAGES
2001 FAN/FILTERING UNIT (KM11) (pump shutdown)
If KM11 is indicated in the message.

Input KM11 has remained inactivated for 30 seconds. The pumps are stopped.
Check the thermal cut-out and contactors of the fan and filtering unit motors (KM4 and KM11).
Check the digital input card (Led KM11 must be on when the motors are running) and the leads/connectors.
Check the relay output card (Led KM11 must come on when the motors have to run) and the leads/connectors.
If KM11A is indicated in the fault message, check the additional heat exchanger.
2002 HYDR.UNIT PUMP (KM1D) (pump shutdown)
Input KM1D has stayed off for 30 seconds with the main pump running or the input signal KM1D has remained
on for 2 seconds while the main pump is being turned off. The main pump is stopped.
Check the thermal cut-out and contactor KM1D.
Check the digital input card (Led KM1D must be on when the motor is running) and the leads/connectors.
Check the relay output card (Led KM1 must be on when the motor has to run) and the leads/connectors.
2003 LOW PRESSURIZATION (SP3) (pump shutdown)
Input SP3 has stayed off for 6 seconds. The main pump is stopped.
Check the main pump suction filter for efficiency.
Check pressure switch SP3, the digital input card (Led SP3 must be on when the operating pressure is
within the allowable range) and the leads/connectors.
2004 OIL LEVEL (SL1) (pump shutdown)
Input SL1 has stayed off for 6 seconds. The pumps are stopped.
Check the oil level in the reservoir.
Check level sensor SL1, the digital input card (Led SL1 must come on when the oil exceeds the maximum
level mark) and the leads/connectors.
2005 OIL THERMOCOUPLE DISCONNECTED (BT4) (pump shutdown)
The oil temperature measured is less than or equal to 0 °C.

The machine will shutdown when this message appears and the main pump will stop running.
Make sure the thermocouple for the oil is properly connected.
Check conversion card APBT4 (control unit box) and the analog input card.
2006 TEMP. TOO LOW (BT4) (pump shutdown)
The oil temperature has remained at a temperature which is too low (less than 2° C) for 30 seconds. The
main pump is stopped.
Check the thermocouple for proper functioning (replace it if necessary).
If it works properly, find out what is causing the temperature to be too low.
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2007 TEMP. TOO HIGH (BT4) > x °C (pump shutdown)
The oil has remained at a temperature which is too high (over 55° C) for 30 seconds. The main pump is
stopped.
Check the thermocouple for proper functioning (replace it if necessary).
If it works properly, find out what is causing the temperature to be too high.
The temperature threshold reached appears to the right of the message.
2008 TEMP. TOO HIGH (ST4) (pump shutdown)
The oil temperature is too high. Input ST4 (oil thermostat) has detected the problem as it stayed off for 30
seconds.
Check the digital input card (when the temperature is below the threshold set for the thermostat, led indicator
ST4 should be on) and the leads/connectors.
2009 REPLACE FILTER (SP1) (pump shutdown)
Input SP1 has remained inactivated and the oil temperature is above 30°C. The main pump is stopped.
Replace the filter in the hydraulic power unit as it is clogged.
If the message is still displayed even after the filter has been replaced, check pressure switch SP1, the digital
input card (Led SP1 must be on when the filter is not clogged) and the leads/connectors.
2010 OIL LEAK LEVEL (SL4) (pump shutdown)
The oil in the recovery tank is at the highest allowable level.

Input SL4 has stayed off for 40 seconds. The main pump is stopped.
Check the oil level in the oil recovery tank.
Check level sensor SL4, the digital input card (Led SL4 must come on when the oil is below the min. level
mark) and the leads/connectors.
2011 OIL COCK CLOSED (SQ50) (pump shutdown)
If the message regards SQ50, the main oil cock is in question.

The pumps are stopped.
If this message appears when the oil cock is open, check limit switch SQ50 (which opens the oil passage),
the leads/connectors and the digital input card (Led SQ50 must be on when the cock is open).
If SQ501 is indicated, the message regards the cock used to change the filters and not the main oil cock.
2012 HIGH PRESSURE IN THE CYLINDER (pump shutdown)
With the safety guards of the pressing zone open (or, in the case of pneumatic lock and guards disengaged,
with wedges in) and pump operating, the pressure in the cylinder exceeds 6 bar (measured with pressure
transducer BP1).
The main pump is stopped.
Check all the logic elements and solenoid valves of the pressing unit and make sure no faults are present.
If there is no pressure in the cylinder, set the pressure transducer of the cylinder (see NOTE).
If the problem persists, replace pressure transducer BP1.
Check the analog input card.
NOTE: if digital input SP3 is on at start-up (air pressure approximately 1.5 bar) and the pressure measured
by transducer BP1 falls within -3 bar and +7 bar, cylinder pressure = 2 bar is displayed.
To set the transducer, it is necessary to eliminate pressurization, turn off the controller and then turn it on
again. At this point the pressure displayed is that read by the transducer and the operator can therefore
proceed with the setting procedure: see the INSTRUCTIONS FOR SETTING THE TRANSDUCERS Manual.
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2013 REPLACE FILTER (SP6) (pump shutdown)
Input SP6 has stayed off for 60 seconds and the oil temperature is higher than 30°C.
The ENEA COOLING filter needs to be replaced as it is clogged.
2014 OIL HEATING PUMP (pump shutdown)
(KM180/KA180)
When the additional oil heater pump motor (output KM180 on) and additional oil heater (output KM19 on)
are enabled, input KM180 (additional oil heater pump motor feedback + thermostat) is off.
(KM19)
When the additional oil heater pump motor (output KM180 on) and additional oil heater (output KM19 on)
are enabled, input KM19 (additional oil heater feedback) is off.
2015 PRESSURE SWITCH (SPn) (pump shutdown)
The pressure switch test was not successfully passed. Check the indicated pressure switch, its connections
and the input module.
2016 PRESSURE TRANSDUCER (BPn) (pump shutdown)
The pressure measured is less than – 20 bar (– 5 bar for BP1). Make sure the pressure transducer indicated
in the fault message is properly connected.
The main pump cannot start running.
Only if the parameter is (BP1):
the value read by the cylinder pressure transducer (without applying the offset value) is higher than 17 bar
(15 bar without pressurization) or too negative when the control system started up.
If the error appears while special operation number 30 (cylinder pressure transducer adjustment) is being
performed it means that the value expressed in bar read by the cylinder pressure transducer (without ap-
plying the offset value) is either too high or too negative therefore it cannot be corrected by the procedure.
If the error appears when the pump is shut off, it means that the value expressed in bar read by the cylinder
pressure transducer (without applying the offset value) is either higher than 17 bar or too negative.
In all these cases, replace pressure transducer BP1.
2017 PUMP PRESSURE (SP10) (pump shutdown)
The normally closed contact of pressure switch SP10, mounted on the pump delivery line has opened.
The power unit motor is shut down.
Pressure in filtration line high.
If the message persists, check the digital input module which SP10 (screw pump pressure switch) is con-
nected to.
2018 CHECK HEAT EXCHANGER (KM11A) (pump shutdown)
With heat exchanger enabled and oil cooling/filtering pump active (digital output OKM11 or OKM11L), the
digital input KM11A sent by the heat exchanger is low.
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2021 PUNCHES IN (SQ62) (die-set shutdown)
If (SQ62) appears to the right:

During the automatic cycle, SQ62 has not been energized within 0.5 seconds of the moment when the
plunger arrived at the top end stop.
Check limit switch SQ62 and the related leads/connectors.
Check the digital input card (Led SQ62 must be on when the punches are out).
Also check solenoid valve YV193 (when the punches are out, the led should be on), the leads/connectors
and related digital output card.
If (SQ64) appears to the right:
At the beginning of the plunger downstroke, when the upper punches should be in, input SQ64 is off.
Otherwise, when the upper punches should be in, input SQ64 is off after the delay time for moving out the
punches has elapsed.
Check input SQ64 that has sensors SQ64A and SQ64B series connected activated when the SFS punches
are out; if these sensors are not provided, set “4 SENSORS” = NO.
2022 HOPPER CLOSING (SQ61) (die-set shutdown)
SQ61 has not been energized within one second of YV221 being de-energized during gate closing.
Check operation of solenoid valve YV221.
Check proximity switch SQ61, the digital input card (with the hopper closed, switch SQ61 must be energized)
and the leads/connectors.
Check the digital output card (Led YV221 must go off when the gate has to close) and the leads/connectors.
2023 LAST DIE-SET D.STROKE (die-set shutdown)
With SMU/lift system.

During the last die-set downstroke SQ6 was de-energized (it must be activated once the die-set has com-
pleted the first downstroke and must remain activated during all the other downstrokes as well as during
the press-cycle).
Check proximity switch SQ6, the digital input card (when the die-sets are lowered, Led SQ6 must be on)
Check the digital output card (during the last die-set downstroke, Led YV21 must go out) and the leads/
connectors.
With 4 or 2 + 2-piston proportional knockout
If the value of encoder A or B is not lower than 0.8 mm within 8 seconds from when the signal for the last
downstroke was sent:
Check proportional solenoid valves YV22A/22B, the axis card and encoders BQ4/5.
If the message is displayed during the press-cycle, it means encoders BQ4/5 have read a value less than-
0.5 mm during the press-strokes. Shut off the controller and then turn it back on and reset the encoders.
2024 PLUNGER DOWN DUR. DIE-SET UPSTR. (die-set shutdown)
The plunger is below the value set for its upper-most position when the die-sets begin to move up.
2025 F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59) (die-set shutdown)
The filler-box is not fully back when the die-sets begin to move up.
If (SQ59) appears to the right of the fault message, the fault was detected by the input SQ59. Check the
limit switch/sensor SQ59 and the digital input card.
If no additional parameters appear to the right of the fault message, the fault was detected by the filler-box
encoder.
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2026 FILLER-BOX NOT BACKWARD (KA302) (die-set shutdown)
The position of the DIP filler-box or double loading filler-box is not correct when the die-sets start their up-
stroke. Check the trigger pulse for the plunger downstroke (KA302) and the digital input card.
2027 DIE-SET UPSTROKE (SQ3) (die-set shutdown)

Proximity switch SQ3 was not energized with the die-sets up (YV21 and YV22 ON) within the maximum
allowable time of 8 seconds. SQ6 should be de-energized within this time.
Check solenoid valves YV21/22 and the related hydraulic lines for proper functioning.
Check proximity switch SQ3, the digital input card (when the die-sets are raised, proximity switch SQ3 must
be energized) and the leads/connectors.
Check the digital output card (while the die-sets are moving up, Leds YV21/22 must come on) and the leads/
connectors.
Check the pressure in the service circuit.
With 2 + 2 or 4-cylinder proportional knockout: if the setting of encoder A or B does not reach the upper
end-stop setting less 0.8 mm within 8 seconds of the signal for the die-set upstroke being sent:
Check solenoid valve YV22S, proportional solenoid valves YV22A/22B and the axis card.
2028 1ST DIE-SET D.STROKE (SQ3/SQ6) (die-set shutdown)

Proximity switch SQ6 is not energized within 1 second of the first downstroke signal within which SQ3 has
to be deactivated.
Check solenoid valve YV22 and related hydraulic lines for proper functioning.
Check proximity switches SQ3/SQ6, the digital input card (after the first downstroke, SQ6 should be ener-
gized and SQ3 de-energized) and the leads/connectors.
Check the digital output card (Led YV22 should go out after the first downstroke) and the leads/connectors.
With 2 + 2 or 4-cylinder proportional knockout: if the first downstroke setting (with 0.8 mm tolerance) has
not been reached within 8 seconds from when the signal for the first downstroke was sent.
NOTE: If the fault message appears when the first downstroke is not triggered, it means the program is
blocked before the first downstroke signal arrived late, i.e. the filler-box (DCL or DCP) has already passed
the value set for the first downstroke and the die-set is not properly loaded.
2029 HOPPER OPEN (SQ60) (die-set shutdown)
SQ60 has not been energized within 1 second of YV221 being energized during gate opening.
Check proximity switch SQ60, the digital input card (with the hopper open, proximity switch SQ60 must be
energized) and the leads/connectors.
Check the digital output card, (Led YV221 must come on when the gate has to open) and the leads/connectors.
2030 2ND F-BOX TRIGGER P. (KA304) (die-set shutdown)
Digital input KA304 has not come on within 15 seconds from when the signal for starting the 2nd filler-box
cycle was sent (KA401).
Make sure the second filler-box/filler-box for double loading works properly.
Check the trigger pulse contact for the intermediate die-set downstroke (KA304), the digital input card (Led
KA304 must be on when the trigger pulse is provided) and the leads/connectors.
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2031 2ND DIE-SET D.STROKE (SQ6) (die-set shutdown)

Proximity switch SQ6 is not energized within 1 second of the second downstroke signal (in a 3-downstroke
cycle) (YV170 ON).
Check proximity switch SQ6, the digital input card (LED SQ6 should be on) and the leads/connectors.
Check solenoid valve YV170 and related hydraulic lines for proper functioning.
Check the digital output card and the leads/connectors.
With 2 + 2 or 4-cylinder proportional knockout: if the second downstroke setting (with +/- 0.8 mm toler-
ance) has not been reached within 8 seconds from when the signal for the second downstroke was sent.
2032 2ND F-BOX TRIGGER P. (KA302) (die-set shutdown)
Digital input KA302 has not come on within 15 seconds of the second die-set downstroke.
Check that the second filler-box functions and moves properly.
Check the trigger pulse contact for the last die-set downstroke (KA302), the digital input card (Led KA302
must be on when the last die-set downstroke is triggered) and the leads/connectors.
2033 DIE DOWN (SQ63) (die-set shutdown)
SQ63 has not been energized within 0.5 seconds from when the plunger reached its uppermost position.
Check sensor SQ63 and the leads/connectors.
Check the digital input card (with the die up, Led SQ63 must be on).
Check solenoid valve YV298, the leads/connectors and related digital output card.
2034 REPLACE FILTER (SP5) (die-set shutdown)
Digital input SP5 is off and the oil temperature is higher than 30°C.
The knockout filter must be replaced as it is clogged.
2035 DIE-SET DEVIATION > 2 mm (die-set shutdown)
With 2 + 2 or 4-cylinder proportional knockout: during their upstroke one or two of the proportional knock-
out pistons have exceeded the setting for UPPER END-STOP (DIE-SET SET-UP page) by more than 2 mm.
Try reducing the UPSTROKE SPEED. Check solenoid valve YV22S, proportional solenoid valves YV22A/22B,
the axis card and encoders BQ4/5.
2036 DIE-SET PARALLELISM ERROR (die-set shutdown)
no. 0) Misalignment between two pistons exceeding 5 mm has been found during movement of the propor-
tional knockout. Check proportional solenoid valves YV22A/22B, the axis card and encoders BQ4/5.
no. 1) The AX card has detected a parallelism error and has shut down the die-set; try performing a die-set
downstroke with the key turned to Set-Up and make sure nothing is interfering with the die-set. If
the problem is not solved after performing the downstroke, carry out an upstroke in Set-Up. Check
proportional solenoid valves YV22A/22B, the axis card and encoders BQ4/5.
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2037 DIE-SET UP.ERROR (A=..., B=...) (die-set shutdown)
At the filler-box start, the difference between the value measured by one of the two encoders and the up-
per end-stop is > +/- 0.4 mm. The values measured for pistons A and B of the proportional knockout are
indicated in brackets. If a proportional rod lift system is used, the value measured by encoder BQ4A of the
proportional knockout is given in parenthesis.
Try reducing the setting for UPSTROKE SPEED.
With 2 + 2 or 4-cylinder proportional knockout: Check solenoid valve YV22S, proportional solenoid valves
YV22A/22B, the axis card and encoders BQ4/5.
With proportional rod lift system: Check operation of solenoid valves YV21H/YV21G, proportional solenoid
valve YV21P and encoder BQ4A.
2038 DIE-SET ENCODER RESET (die-set shutdown)
WITH ROD-TYPE KNOCKOUT

In this case, the fault message indicates that the absolute encoder for the rod-type knockout (BQ4A) has to
be reset: see paragraph AXES RESET PAGE (CONFIG:).
WITH SPE:
The die-set encoder was not properly reset.
The reset procedure consists of a number of upward steps carried out 1 mm at a time. Once the limit is
reached, the die-set is pulled down to the end of the stroke.
Check the proportional solenoid valves (YV22A, YV22B) for the die-set.
Make sure there is pressure in the service circuit. Make sure pressure reaches SPE (solenoid valves YV22S,
YV25).
Check the axes card and encoders BQ4 and BQ5.
no. 1) When moving the first 1 mm up, the encoder on side A failed to read 0.5 mm movement.
no. 2) When moving the first 1 mm up, the encoder on side B failed to read 0.5 mm movement.
no. 3) A parallelism error occurred when moving the first 1 mm up.
no. 4) When moving up, the encoder on side A failed to read 0.5 mm movement per step.
no. 5) When moving up, the encoder on side B failed to read 0.5 mm movement per step.
no. 6) A parallelism error occurred when moving up.
no. 7) The die-set moved up too quickly.
no. 8) After the reset procedure was completed, one or both encoders failed to read a value that falls
within +0.5 mm and - 0.5 mm.
no. 9) The zero-set pulse of one of the encoders was not read. To locate where the problem lies, see
the “Zero position” data item on the die-set data display page.
no. 10) A parallelism error was detected during the downstroke.
Make sue the hydraulic system has been thoroughly bled.
Make sure the die-set moves freely on both sides.
no. 12) With the SPE encoder not yet reset as soon as YV25 is energized (YV22S in 4 piston SPE),
the die-set has moved up more than 2.5 mm to deliver oil to the SPE.
YV25 and YV22S are then de-energized.
BP6/BP7) Pressure transducer BP6 for the upstroke chamber or BP7 for the downstroke one is either
not connected or the pressure in the upstroke chamber is too high. Make sure the pressure
transducers are not reversed.
BP7<130) The pressure in the downstroke chamber is too low: the auxiliary equipment pressure may be
low.
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2039 DIE-SETS DOWN AT FILLER-BOX START (die-set shutdown)
With axes synchronization enabled from when the filler-box starts and the first die-set downstroke is per-
formed, the filler-box has reached the value in which the cavity starts but the lower die-set has not reached
the end of the upstroke yet.
Check the values set on the Axes synchronization page (SYNC), more precisely values E, P and L.
If allowed for when the piece is removed, try to increase the speed at which the die-set moves up or decrease
the delay time for the die-set upstroke.
If this is not possible, decrease the value set for “Synch efficiency dur. forw. stroke”.
2040 SPE MOVEMENT NOT COMPLETED (die-set shutdown)
When the downstroke begins with the key turned to MAN or AUT and the knockout at a value greater than 2
mm, card AXP detects that the previous SPE movement was not completed. Verify that there is not exces-
sive friction that prevents regular movement of the die-set.
2041 PERFORM SELF-LEARNING (YV21P) (die-set shutdown)
SE with rods:
If a proportional knockout with rods is used, perform the YV21p offset self-learning procedure (see DE-
SCRIPTION OF THE KEYS).
2042 AXIS CARD ERROR (parameter) (die-set shutdown)
The fault is in the card that controls movement of the proportional knockout.
If the parameter equals 1: card AXP does not work. If card AX the first module may be faulty.
If the parameter equals 2: card AXP does not work. The second module may be faulty.
2043 SPE FAULTY VALVE (parameter) (die-set shutdown)
YV22A) When YV25 is energized (YV22S in the 4-piston SPE) to deliver oil to the SPE, the AX card
has detected a problem in proportional solenoid valve A spool (left side).
Proportional valve A blocked; check the AX card, check the spool signal.
YV22B) When YV25 is energized (YV22S in the 4-piston SPE) to deliver oil to the SPE, the AX card
has detected a problem in proportional solenoid valve B spool right side).
2044 DIE-SET ENCODER BLOCKED (SQ4) (die-set shutdown)
The proportional knockout cannot be moved because the encoders are blocked. Release them.
If the message continues to appear, check the two sensors SQ4 and SQ5, the wiring and digital input card.
2045 RESET SPE PRESSURE (die-set shutdown)
While the proportional knockout pressure was being reset, one of the two encoders read a value greater
than 0.6 mm (the die-set was not fully down and therefore the reset procedure was not performed).
Make sure the die-set can reach the zero setting. Check encoders BQ4/5 and the axis card.
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2046 KNOCKOUT UPSTROKE TIME OUT (die-set shutdown)
The knockout with rods has failed to complete the upstroke within the maximum allowable time.
Check YV25S (slow movement of the knockout with rods), YV21G/YV21H (knockout solenoid valve) and
YV21P (proportional solenoid valve for knockout with rods).
Check the relative digital and analog output cards.
Check linear absolute encoder BQ4A (position of knockout with rods) and relative connections.
2047 LOWER DIE DOWNSTR. (SQ340A/SQ340B) (die-set shutdown)
Digital input SQ340 (Series of sensors SQ340A and SQ340B) was not activated within 5 seconds from when
the signal for the lower die downstroke (YV340D) was transmitted.
Check YV340D (lower die downstroke) and YV341 (lower die downstroke during balancing).
Check sensors SQ340A and SQ340B, the digital input card and cables/connectors.
2048 LOWER DIE UPSTR. (SQ63A/SQ63B) (die-set shutdown)
Digital input SQ63 (series of sensors SQ63A and SQ63B) was not activated within 5 seconds from when
the signal for the lower die upstroke (YV340S) was transmitted.
Check YV340S (lower die upstroke) and YV341 (lower die upstroke during balancing).
Check sensors SQ63A and SQ63B, the digital input card and cables/connectors.
2049 EJECTOR DOWNSTR.TIMEOUT (die-set shutdown)
The rod knockout did not complete its downstroke within the maximum allowable time.
Check YV25D (rod knockout slow downstroke), YV21G/YV21H (knockout safety solenoid valve) and YV21P
(rod knockout proportional solenoid valve).
Check the relative digital and analog output cards.
2050 WRONG KNOCKOUT MOVEMENT (BQ4A) (die-set shutdown)
The rod knockout has moved in the wrong direction.

Proportional valve YV21P may be jammed.
Check YV21P (rod knockout proportional solenoid valve) and the analog output card.
2051 DIE-SET LEARNING (YV21P) (die-set shutdown)
The self-learning cycle for calculating the offset values for the proportional valves for the knockout with rods
has been stopped in an incorrect manner. The various cases are examined below.
The various cases, identified by the number that appears to the right of the message, are examined below:
1 The mode selector switch has been turned from the MAN position during slow downward movement
or the lift system has failed to move completely down (dead stroke) within 60 seconds.
Check YV25D and the OD card. As an alternative, try setting a higher value for the DEAD STROKE.
2 The mode selector switch has been turned from the MAN position while searching for the offset value
for upward movement or the lift system has failed to move completely up within 60 seconds. Check
YV21P, encoder BQ4A and YV21G/YV21H.
3 The mode selector switch has been turned from the MAN position while searching for the offset value
for downward movement or the lift system has failed to move completely down (DEAD STROKE)
within 60 seconds. Check YV21P, encoder BQA and YV21G/YV21H.
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4 The offset search procedure was not completed within 2 minutes.

Check YV21P.
If problems arise during the YV21P self-learning procedure that prevent the correct offset values from
being determined, perform the procedure to assign the recommended values.
To start the procedure set SET-UP OPERATION NO. = 15. The following conditions have to be sat-
isfied in order to reset the offset values: mode selector turned to SET-UP and pump shut off. Press
keys 28 and 7.
2052 VALVE FAULT (YV…) (plunger shutdown)
A proportional solenoid valve is malfunctioning. The cases are examined below:

(YV318): during a stage in which the proportional solenoid valve for the press-cycle should be
closed the analog feedback signal has detected the solenoid valve is not closed. Or,
when the type of solenoid valve installed is automatically recognized, with a command
equal to 60%, the feedback signal does not correspond to any of the cases with a
tolerance of -+20%.
Check the electrical connections of the feedback signal and the analog input card.
If no problems are found, check the control signal and relative analog output card. If
everything works correctly, check the proportional solenoid valve.
(YV32): before the plunger has started moving, the analog feedback signal has detected the
proportional solenoid valve is not closed. Or, when the type of solenoid valve installed
is automatically recognized, with a command equal to 60%, the feedback signal does
not correspond to any of the cases with a tolerance of -+20%. Check the electrical
connections of the feedback signal and the analog input card. If no problems are
found, check the control signal and relative analog output card. If everything works
correctly, check the proportional solenoid valve.
(YV70D): before the drain was opened, the analog spool signal has detected the proportional
solenoid valve that regulates the degree to which the drain is opened, is not closed
or opened during the press-cycle. Check the electrical connections of the feedback
signal and the analog input card.
If no problems are found, check the control signal and relative analog output card. If
everything works correctly, check the proportional solenoid valve.
(SPOOL-YV22A): while SPE balancing was taking place, the analog spool signal has detected pro-
portional solenoid valve YV22A failed to open during upward movement. Check the
electrical connections of the spool signal and the AX card. Go to the INFO page to
make certain the software version is at least 3.00. If everything works correctly, check
the proportional solenoid valve.
(SPOOL-YV22B): same as for YV22A but regarding the other proportional solenoid valve of the SPE.
(YV22A): encoder BQ4 has detected the die-set has moved more that 0.5 mm up during SPE
balancing.
(YV22B): encoder BQ5 has detected the die-set has moved more that 0.5 mm up during SPE
balancing.
(YV303): at the end of plunger repositioning (after receiving an axes repositioning request or
cycle start signal) or when the automatic cycle is stopping at the end of the plunger
upstroke YV303 was closed, YV32 was opened during downward movement and the
plunger moved down at a speed higher than 15 mm/s.
Check YV303 that may be stuck open or the output card of YV303.
(SQ303): after the plunger has moved down 5 mm, YV303 is closed (input SQ303 is high).
Or YV303 is already opened before the plunger is moved down (input SQ303 low).
Or, when the plunger was brought back up or when the automatic cycle is stopping at
the end of the plunger upstroke with the command to YV303 de-energized the latter
is opened (input SQ303 down).
Or while the plunger’s proportional valves are being cleaned with YV303 deactivated
it is still open (input SQ303 low).
Check YV303 and sensor SQ303.
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(SPOOL-YV21P): During rod knockout balancing, the analog feedback signal has detected that pro-
portional solenoid valves YV21P failed to open when moving up. Check the electric
connections of the feedback signal. If no problems are found, check proportional
solenoid valve YV21P.
(YV21P): During rod knockout balancing, the die-set has moved more than 0.8 mm up as de-
tected by encoder BQ4A.
2054 ENCODER FAULTY (id number) (plunger shutdown)
A fault has been detected in the system which monitors the setting of a plunger encoder (the name of the
encoder is specified in brackets).
Check the encoder, connecting lead and relative encoder input card for proper functioning.
2055 PUNCHES OVERTRAVEL/LIFT RODS (plunger shutdown)
Data item PUNCH OVERTRAVEL = YES has been set on the S.P.E. die-set set-up page.
Enter NO for this setting.
2056 DIE-SET CHANGE DEVICE ON (SQ68/SQ67) (plunger shutdown)
The device for changing the die-set is activated (it is out). If this is not the case, check sensors SQ68A,
SQ68B, SQ67A, SQ67B (when the hook is in, sensors SQ67 are energized and SQ68 de-energized, whereas
when the hook is out sensors SQ67 are de-energized and SQ68 energized). Check the relative digital input
card and the leads/connectors.
2057 REPLACE FILTER (SP4) (filler-box shutdown)
Input SP4 has stayed off for 0.5 seconds with the oil temperature higher than 30°C.
Replace the filter located on the proportional solenoid valve in the filler-box as it is clogged.
2058 PLUNGER ENCODER/ACTUATOR (plunger shutdown)
Approx. 300 msecs. have elapsed since the plunger downstroke began and the plunger speed is still null.
In “proportional” PHs, this fault message may be displayed during the first few plunger downstrokes just
before reaching the impact position. In this case, try restarting the machine because during each attempt
the control system tries to soften the brake ramp.
Check the plunger encoder, its lock and the leads/connectors.
Make sure the plunger can reach the PRESS-STR, START POS. setting when it moves down.
Check solenoid valve YV32D for the on/off PH, YV303 for the proportional ones and the related hydraulic
lines for proper functioning.
Check filler-box backward sensor SQ59, circuit breaker FS101, contactors KA102/102A, KA103/103A, mode
selector SA9 and safety module AJ101.
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2059 F-BOX ENCODER/ACTUATOR (filler-box shutdown)
200 msecs. have elapsed since the filler-box forward stroke signal was sent but the filler-box encoder value
has not changed.
Check encoder BQ2, its mount and the leads/connectors.
With rod-crank mechanism filler-box: check proportional solenoid valve YV20 (see NOTE), the related
electrical wiring and hydraulic lines for proper functioning. Check the pressure in the service circuit, solenoid
valve YV20S and related electrical wiring.
If solenoid valve YV20S does not work, also check circuit breaker FS101, mode selector SA9 and contac-
tors KA102/102A, KA103/103A.
NOTE: if proportional valve YV20 is not installed, check solenoid valve YV20A and the related electrical wiring;
If the proportional solenoid valve is installed, YV20A becomes YV20S
With linear filler-box: check digital output KA20E (LED on = filler-box moving), the related electrical wiring,
relays KA20E/20I, inverter U20 and motor M20.
2060 PWD FEED SHUTOFF AT... mm (BQn) (plunger shutdown)
There is no powder in the die-set. The plunger has reached a value higher than the one set for the STOP-
PAGE NO POWDER data item. Alternatively, the plunger has reached a value higher than that set for the
STOPPAGE NO POWDER 1ST data item during the first press-stroke. The setting of the plunger encoder
which caused the alarm is indicated in the message. If a filler-box without ALM or with ALM but with a fixed
ALM cycle, this message signals the cycle has stopped because the filler-box’s return stroke is too slow.
Increase the speed of the return stroke. If a filler-box with rod and crank mechanism is used and FILLER-
BOX SPEED CONTROL ON has been selected, decrease the set return time. The number of the encoder
(example BQ6) that detected the fault is given to the right.
2061 FILLER-BOX RETURN STROKE (filler-box shutdown)
The filler-box failed to complete its return stroke within the maximum allowable time.
With rod-crank mechanism filler-box:
Check proportional solenoid valve YV20 and the related hydraulic lines for proper functioning. If the propor-
tional solenoid valve is not provided, check solenoid valve YV20A.
Check encoder E2, its mount and the leads/connectors.
Check the output card (when the solenoid valve has to operate, Led YV20A must come on) and the leads/
connectors.
With a filler-box for double loading (non Sacmi), check signals KA302 and SQ59 coming from the filler-
box itself (when the filler-box is fully back, led KA302 should come on). Also check the digital input card and
the KA59 relay.
If a filler-box without ALM or with ALM but with a fixed ALM cycle, this message signals the cycle has stopped
because the filler-box’s return stroke is too slow. Increase the speed of the return stroke. If a filler-box with
rod and crank mechanism is used and FILLER-BOX SPEED CONTROL ON has been selected, decrease
the set return time.
2062 FILLER-BOX FORWARD STROKE (filler-box shutdown)
The filler-box failed to complete its forward stroke within the maximum allowable time.
With rod-crank mechanism filler-box:
Check proportional solenoid valve YV20 and the related hydraulic lines for proper functioning. If the propor-
tional solenoid valve is not provided, check solenoid valve YV20A.
Check encoder E2, its mount and the leads/connectors.
Check the output card (Led YV20A must come on when the solenoid valve has to operate) and the leads/
connectors.
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With a filler-box for double loading (non Sacmi), check signals KA302 and SQ59 coming from the filler-box
itself (when the filler-box starts running, led KA302 should go off). Also check the digital input card and the
KA59 relay.
2063 F-BOX ENCODER RESET (filler-box shutdown)
The filler-box encoder reset procedure has failed.

With rod-crank mechanism filler-box: the encoder zero-point has not been found within 8 seconds of the
signal to reset the filler-box.
Check the encoder for proper functioning. Check proportional solenoid valve YV20 (see NOTE), its electri-
cal wiring and related hydraulic lines, the service circuit pressure, solenoid valve YV20S and related wiring.
If solenoid valve YV20S is not energized check circuit breaker FS101, mode selector SA9 and contactors
KA102/102A, KA103/103A.
NOTE: if proportional valve YV20 is not installed, check solenoid valve YV20A and the related electrical wiring;
If the proportional valve is installed, YV20A will be identified as YV20S.
2064 PLUNGER DOWN AT FILLER-BOX START (filler-box shutdown)
The plunger is below the value set for its upper-most position when the filler-box begins its forward/return
strokes.
If an absolute encoder is installed, check that the value read by the encoder when the plunger is against the
end-stop is 0. If this is not the case, repeat the plunger encoder reset procedure (see AXES RESET page).
2065 FILLER-BOX NOT BACKWARD (KA302/SQ59) (filler-box shutdown)
When the automatic or semi-automatic cycle is started, the filler-box for double loading is not fully back.
Check the conditions of the input SQ59 and of the input KA302 (they should be on with filler-box back).
2066 1st DOWNSTROKE SIGNAL (KA305) (filler-box shutdown)
The signal for the first die-set downstroke was not received within 15 seconds of the filler-box start.
Check the connection for the first die-set downstroke signal and the input card (when the request is provided
Led KA305 must come on).
2067 3rd DOWNSTROKE SIGNAL (KA306) (filler-box shutdown)
The signal for the third die-set downstroke was not received from the filler-box for double loading.
Check the connection for the third die-set downstroke signal and the input card (when the request is provided
Led KA306 must come on).
2068 WAIT FOR F-BOX TO GO BACK (KA302) (filler-box shutdown)
Digital inputs SQ59 and KA302 have not changed over within 15 seconds of the last downstroke (when the
filler-box arrives at the rear end-stop, led KA302 should come on).
Make sure that the digital input cards receive the filler-box forwards/backwards signals SQ59 and plunger
down trigger pulse KA302. Also check contactor KA59 and the related press/filler-box leads/connectors.
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2069 SAFETY GUARD LIMIT SWITCHES, PRESS-CYCLE ZONE (SQ11A/B/C/D) (filler-box shutdown)
One of the limit switches for the press-cycle zone safety guards is faulty.
Check the limit switches and the related leads/connectors (when the press-cycle zone safety guards are
closed, the two leds for the input card must be off).
After checking, open the the safety guards of the press-cycle zone and press the Reset button.
If a mechanical lock is used (column presses), the alarm parameter is “(SQ51/SQ52)” and indicates to check
the two bar limit switches SQ51 and SQ52.
If a pneumatic lock is used, the alarm parameter is "(SQ11A/B/C/D)" and indicates to check limit switches
SQ11A, SQ11B, SQ11C and SQ11D.
For PHC the alarm parameter is "(KA51/KA52)" and indicates to check the 2 sensors of the safety bars
KA51 and KA52.
2070 DCP FAULTY VALVE (parameter) (die-set shutdown)
A fault has been detected in the filler-box with rod and crank mechanism. Depending on the parameter
indicated in the message, follow the instructions given below:
(SQ20S) Check solenoid valve YV20S and its monitoring device (SQ20) for proper functioning.
When YV20S is activated to move the filler-box, input SQ20S must be off while when YV20S
is deactivated to stop the filler-box, input SQ20S must be on. Check the digital input card for
SQ20S, the digital output card for YV20S and related connections.
(YV20S) Check solenoid valve YV20S and its monitoring device (SQ20S) for proper functioning.
Check operation of solenoid valve YV20S. When YV20S is deactivated to stop the filler-box,
the filler-box actually continues operating which is why YV20S is blocked when open or check
the digital output card for YV20S and its connections.
(YV20) Check solenoid valve YV20S and its monitoring device (SQ20S) for proper functioning.
Check operation of proportional solenoid valve YV20. The fault message may be displayed if:
before the filler-box starts moving, the spool signals an opening greater than 20% or:
if the movement is not completed within 10 sec. at most, the spool signals the opening is 20%
smaller than the expected one.
Check the analog input card for YV20 spool, the analog output card for YV20 and the related
connections.
2071 FILLER-BOX NOT IN PLACE (filler-box shutdown)
The filler-box is not in the correct position while the mobile grid is moving.
2072 FAULT, FILLER-BOX DRIVE (U20) (filler-box shutdown)
Digital input U20 is not energized.

The converter that drives the linear filler-box is malfunctioning or is not energized.
Check the two miniature switches SQ20A and SQ20I which, when triggered, shut off the power supply to
the converter.
Check the converter and consult the Instruction Manual to locate what is causing the fault. If the converter is
not faulty, check the input card (when the converter is running, Led U20 must be on) and the leads/connectors.
2073 SAFETY MODULE (AJ101) (filler-box shutdown)
With two PNOZ X3 devices:

Press the Reset button. If the message remains on the screen, check safety module AJ101. If no power is
delivered (“NETZ” Led off or “POWER” off) check magnetic-thermal cut-out FS100. If power is being deliv-
ered but the two signals (S1 and S2) are different or they are both off, check limit switches SQ11A/B/C/D,
SQ66/SQ66A and SQ53A/SQ53B, which monitor the roller conveyor (optional), for secure mounting and
proper operation. If Leds S1 and S2 stay on and the message remains on the screen, check the input card
(Led AJ101 must be on when the safety bar is down) and the leads/connectors.
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If the filler-box is not manufactured by SACMI, this fault message may mean that the filler-box’s safety
guards have been opened.
With single PNOZmulti device:
Input AJ101 is not present even if the inputs for the relative safety devices (mode selector – guide limit
switches– etc.) are OK. This input corresponds to output O5 of module AJ100 that indicates the status of
the outputs (O2 and O3) regarding the machine safety devices. Press the reset key.If the message is still
displayed, check safety module AJ100 (see the chapter that describes operation of device PNOZmulti).
2074 WRONG DIE-SET OP. (A=…, B=…) (filler-box shutdown)
The value of one or both die-set encoders has exceeded the Upper End Stop (FCA) setting by more than
0.5 mm or has fallen below it by more than 1 mm during the filler-box forward stroke (up until the first down-
stroke). When a proportional rod lift system is used, the value read by encoder BQ4A for the proportional
knockout is given in parenthesis.
Refer to fault message 2037 for trouble-shooting instructions.
2075 SAFETY GUARD LIMIT SWITCHES, PRESS-CYCLE ZONE (SQ11ABCD) (filler-box shutdown)
The alarm is displayed only if the two digital inputs of the safety guards in the press-cycle zone are different:
SQ11AB high indicates that both safety guards are open, whereas
SQ11CD low indicates that both safety guards are in work position (closed).
2076 FILLER-BOX DID NOT START (KA302/SQ59) (filler-box shutdown)
Digital inputs SQ59 and KA302 failed to change-over within 30 sec. from the moment in which the start signal
was sent to the filler-box from contact KA20A (when the filler-box begins to move, led KA302 should go out).
Make sure the start signal from KA20A (ON = filler-box start) reaches the filler-box controller. In addition,
check contactors KA102/102A, KA103/103A, relay KA20A and the leads/connectors for the relative press/
filler-box.
Make sure the digital input cards receive the filler-box forward/back signals from SQ59 and the signals for
the plunger downstroke from KA302. In addition, check contactor KA59 and the leads/connectors for the
relative press/filler-box.
2077 PLUNGER/F-BOX COLLISION (FORWARD STROKE) (filler-box shutdown)
One of the following numbers may appear to the right of the message.
(1): during the filler-box forward stroke / plunger upstroke, the front end of the filler-box was too close to
the plunger / upper die-set.
If the problem occasionally occurs, make sure the press-cycle / plunger drive cycle is correctly repeated.
To do this, keep the total press-cycle time (displayed on the PRESS-CYCLE DISPLAY page) under
control; if the time is constant after each and every cycle (i.e. the difference between two consecutive
cycles is less than 100 ms) and a much longer cycle suddenly takes place, this fault message may be
displayed.
In this case, trace the problems that prevent the press-cycle from being correctly repeated and remedy.
If this cannot be done, try one of the following solutions:
A) if the filler-box approach stroke is performed, reduce its speed: decrease the value set for data item
‘Max. approach speed’ given on the axes timing page (see the Use of axes timing manual);
B) if the filler-box approach stroke is performed, disable the approach stroke (set ‘Approach value'
= 0) and increase the ‘Maximum pre-impact speed’ on the axes timing page (see the Use of axes
timing manual);
C) reduce synchronism efficiency during the forward stroke on the axes timing page (see the Use of
axes timing manual), even if the machine speed is negatively affected.
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(2): When the cycle started, the system discovered the axis synchronization data were not correctly set.
More precisely, the difference between “plunger encoder at edge of die when up” and “PLUNGER UP”
is less than value H2. Check the settings for “A”, “H2” and “PLUNGER UP” (see the axis synchroniza-
tion manual).
(3): The linear filler-box has gone beyond the safety position (set for SAFETY FILL-BOX SETTING on
the LOADING CYCLE SET-UP PAGE) and the plunger is lower than the value set for PLUNGER UP
POS. (PRESS-CYCLE SET-UP page). Decrease the value set for FILL-BOX START ADVANCE.
If the trouble persists, decrease the value set for PLUNGER UP POS. or modify TOP LIMIT SWITCH
ACCUR.
2079 DIRECTION OF OPERATION REVERSED (M20) (filler-box shutdown)
The filler-box encoder is counting backwards.

Reverse the value set for data item “filler-box encoder reverse” on the set-up page.
2080 PLUNGER / DIE DOWN (KA410) (shutdown)
Signal KA410 was de-energized while the filler-box for double loading was carrying out its stroke for one of
the following reasons:
the plunger has moved down more than 2.5 mm in relation to the position it should be in when fully raised.
the lower die has moved down (SQ63 de-energized).
2081 MIXER (KM24A) (ACP shutdown)
Digital input U24 has not come on within 300 msecs. of the KM24A signal being sent.
Check the thermal cut-out and ACP contactor KM24A for proper functioning.
Check the input card (Led U24 must be on when the motor is running) and the leads/connectors. Check the
output card (Led KM24A must be on when the motor has to run) and the leads/connectors.
2082 HOMOGENIZER (ACP shutdown)
We will now examine the various cases:

(KM21A)
Output KM21A is activated while input U21 that is the parallel of the spools of contactors KM21A and KM21B
is low. Overload cut-out QM21 may have tripped.
(KM21B)
Output KM21B is activated while input U21 that is the parallel of the spools of contactors KM21A and KM21B
is low. Overload cut-out QM21 may have tripped.
(SQ21/SQ22)
SQ21 and SQ22 are both ON.
A sensor may be broken causing the input to stay ON.
(U21)
The digital signal sent from the ACP inverter (U21) indicates inverter failure.
(RH)
ACP movement towards the RH end stroke set in mm has not been completed within the 45 sec. time out.
(KM21A/SQ21)
Digital input SQ21 has not come on within 45 seconds of the KM21A signal being sent.
Check the thermal cut-out and the ACP contactor.
Check sensor SQ21 (when KM21A is energized SQ21 has to be activated) and the related input card.
Check the output card (when the motor has to run, output KM21A must be on) and the leads/connectors.
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2083 MIXER (KM24I) (ACP shutdown)
Digital input U24 has not come on within 300 msecs. of the KM24I signal being sent.
Check the thermal cut-out and ACP contactor KM24I for proper functioning.
Check the input card (Led U24 must be on when the motor is running) and the leads/connectors.
Check the output card (Led KM24I must be on when the motor has to run) and the leads/connectors.
2084 HOMOGENIZER (ACP shutdown)
We will now examine the various cases:

(LH)
ACP movement towards the LH end stroke set in mm has not been completed within the 45 sec. time out.
(KM21B/SQ22)
Digital input SQ22 has not come on within 45 seconds of the KM21B signal being sent.
Check the thermal cut-out and the ACP contactor.
Check sensor SQ22 (when KM21B is energized SQ22 has to be activated).
Check the output card (when the motor has to run, output KM21B must be on) and the leads/connectors.
2085 MOBILE HOPPER (KM23I) (ACP shutdown)
The ALM failed to complete its loading stroke correctly.

If the ALM does not reach the setting for the end of the forward stroke within 25 secs.
If the ALM accidentally performs an overtravel beyond the setting for end of backstroke and does not return
to the end of backstroke setting within 25 seconds,
Check ALM encoder BQ10 and the leads/connectors.
Check contactor KM23I and the output card (when the ALM moves away from the press, led KM23I should
be on) and the leads/connectors.
2086 MOBILE HOPPER (KM23A) (ACP shutdown)
If the ALM does not reach the setting for the end of the backstroke within 25 seconds:
Check ALM encoder BQ10 and the leads/connectors.
Check contactor KM23A and the OR output card (when the ALM moves near the press, led KM23A should
2087 ALM ENCODER NOT RESET (ACP shutdown)
Either a reset cycle or a semiautomatic loading cycle is in progress but the ALM encoder has not been zero
set. To zero set, see page AXES RESET.
2088 MOBILE HOPPER (U23) (ACP shutdown)
Digital input U23 is not energized.

The inverter which drives the ALM is malfunctioning.
Check inverter U23, the input card (Led U23 must be on when the inverter is running) and the leads/connectors.
2092 FILLER-BOX FORWARD (ACP shutdown)
If the ALM has to be moved back in manual mode or be reset, move the filler-box fully back before carrying
out the operation.
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2093 MOBILE HOPPER (ACP shutdown)
With the fixed ALM, the value read by the ALM encoder BQ10 differs from the rear end-stop value by more
than 20 mm.
Check encoder BQ10 and the leads/connectors.
The ALM has not reached the rear end-stop position within 25 seconds during a manual operation or while
being reset.
Try increasing the ALM speed.
2094 ALM RETURN (ACP shutdown)
The cycle has been interrupted because the ALM repositioning time is too long.
Increase the ALM repositioning speed.
2095 ACTUATOR/ENCODER (ACP) (ACP shutdown)
After movement of the ACP, the value of encoder ACP (BQ21) failed to change after 0.75 sec. Check opera-
tion of the encoder.
Check the analog output card for U21, relay output card for KM21A and KM21B (when the ACP has to move,
one of outputs KM21A/KM21B should be on), relays KA21A/KA21B, inverter U21, motor M21 as well as
the cables/connectors.
2096 MOBILE HOPPER (ACP shutdown)
The position of the ALM during the filler-box return stroke, with the filler-box nearly at the end of the back-
stroke, is not correct.
The encoder was not zeroed within 25 seconds while the ALM was being operated in manual mode or was
being reset.
Try increasing the ALM speed, check encoder BQ10 and the leads/connectors.
2097 ALM ACTUATOR/ENCODER (ACP shutdown)
After movement of the ALM, the value of encoder ALM (BQ10) failed to change after 0.75 sec.
Check operation of the encoder. Check the analog output card for U23, relay output card for KM23I and
KM23A (when the ALM has to move, one of outputs KM23I/KM23A should be on), relays KA23I/KA23A,
inverter U23, motor M23 as well as the cables/connectors.
2098 FAULT, MDR DRIVE (U24) (ACP shutdown)
With the pump running, mode selector SA9 in the manual or automatic position and safety modules AJ100
and AJ101 in operating mode, digital input U24 is off.
Make sure inverter U24 is able to work. Check digital input card U24 (when inverter U24 is able to work,
digital input U24/KM22AB should be on) and the leads/connectors.
2101 CARRY OUT LOADING (plunger shutdown)
A press-cycle has been attempted before carrying out a loading cycle.
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2102 CYLINDER PRESSURE TRANSDUCER (BP1) (plunger shutdown)
The pressure measured by transducer BP1 before the plunger begins its downstroke is more than 10 bar.
Check pressure transducer BP1 and the leads/connectors.
In presses with external booster, the pressure in the cylinder was over 10 bar before the booster was re-
positioned.
2103 PLUNGER DOWNSTROKE (plunger shutdown)
If the plunger encoder value does not reach the IMPACT POS. setting within 8 seconds during a downstroke
in manual mode.
If the plunger encoder value does not reach the IMPACT POS. - BRAKING SPACE setting (both data items
can be set) within 8 seconds in automatic mode.
Check that the setting for IMPACT POS. can be reached.
In presses that are not proportional check solenoid valve YV32D and related hydraulic lines for proper op-
eration, inspect the plunger encoder and make sure it is securely mounted and check the leads/connectors.
In proportional presses, check proportional solenoid valve YV32, solenoid valve YV303 and potentiometer
card AP32.
This message may be displayed because the press has started an upward movement when a signal for
downward motion has been provided. In this case, replace YV32 and/or the analog output card (YV32S or
YV32D for presses that are not “proportional”).
In proportional hydraulic presses, if the message appears when the YV32/YV318 self-learning or repositioning
procedures start, check YV303 and relative logic element (the plunger moves down with YV303 deactivated).
In presses with proportional hydraulic system, this message may indicate that the speed at which the plunger
came into contact with the power was too high (more than 60 mm/s compared to the set impact speed).
2104 EXCESSIVE BRAKING (plunger shutdown)
The plunger encoder value does not reach the setting for IMPACT POS. while the plunger is moving down.
The plunger encoder value does not reach the setting for PLUNGER UP while the plunger is moving up.
Check that the setting for IMPACT POS. can be reached.
Check solenoid valves YV32D and YV32S and related hydraulic lines for proper operation. Also check the
plunger encoder and make sure it is securely mounted. Check the leads/connectors.
In proportional presses, check solenoid valve YV303 and proportional solenoid valve YV32.
If it happens during the upstroke in proportional presses, decrease the value set for END OF UPSTROKE
PRECISION.
2105 CYLINDER DECOMPRESSION NOT COMPLETED (plunger shutdown)
In the case of PHs with ejection with upper die, the cylinder pressure did not fall to the value set in FINAL
DECOMPRESSION PRESSURE within the time out (3 sec) at the end of the final cylinder press stroke in
controlled decompression.
Check the cylinder (BP1) transducer pressure and:
in the case of column presses:
- check operation of proportional solenoid valve YV70D (if provided);
- check operation of proportional solenoid valve YV70P (if provided).
In the case of Imola/Power series presses:
- check operation of proportional solenoid valve YV318
Cylinder decompression was not completed within the time out (10 sec.) in the PCH.
Check operation of proportional solenoid valve YV32 and cylinder pressure transducer BP1.
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2106 DIE-SETS UP (SQ3/SQ6) (plunger shutdown)
The die-set is not down when the plunger begins its downstroke.
When the SMU/lift system is used, proximity switch SQ6 is inactivated or SQ3 is activated.
Check proximity switch SQ6, the input card (Led SQ6 must be on when the die-sets are down) and the
leads/connectors. Do the same for SQ3.
The same fault message will appear on the display when the filler-box is moved manually and the PRO-
PORTIONAL KNOCKOUT is 0.4 mm higher than the set value.
In this case move the die-set manually so as to bring it into the correct position.
2107 F-BOX FORW. DUR. PLUNGER DOWNSTROKE (plunger shutdown)
The filler-box is not all the way back when the plunger begins to move down. Check the filler-box encoder set-
ting which should be lower than the REAR LIMIT SWITCH. Try increasing the REAR LIMIT SWITCH setting.
2108 F-BOX SAFETY SW. (SQ59) (plunger shutdown)
The filler-box is not all the way back when the plunger begins to move down (with axis synchronization
enabled, the check is performed at the beginning of the last press-stroke).
Check sensor SQ59, its mount, the input card and the leads/connectors.
2109 2ND F-BOX SAFETY SW. (KA302) (plunger shutdown)
When the plunger begins its downstroke the trigger pulse from the double loading filler-box is not provided.
Check the signal for plunger downstroke KA302, its lock, the input card (Led KA302 must be on when the
double loading filler-box is fully back) and the leads/connectors.
2110 PLUNGER UPSTROKE (plunger shutdown)
In manual mode: the manual upstroke keys have been kept pressed for more than 8 seconds.
In automatic mode: if upstroke with braking has been selected and plunger encoder has not reached the
“end of braking during upstroke” setting. Check that the setting for END OF BRAK., UPSTR. can be reached.
In presses that are not proportional, check operation of solenoid valves YV32S and YV47 and related hy-
draulic lines for proper functioning. Check the plunger encoder, its mount and the leads/connectors.
In proportional presses, check proportional solenoid valve YV32, YV303 and potentiometer card AP32.
This message may be displayed because the press has started an downward movement when a signal for
upward motion has been provided. In this case, replace YV32 (YV32D or YV32S for presses that are not
“proportional”). From when the signal to start the plunger upstroke was provided a half a second passed
and the plunger has moved up less than 0.50 mm. This may be caused by YV32 malfunctioning (YV32S in
presses that are not proportional). As an alternative, the die-set may have jammed during the press-cycle
and the plunger upstroke was stopped to avoid ripping out the upper die-set screws.
In presses with proportional hydraulic system, if the fault message is displayed when repositioning starts,
YV32/YV318 self-learning starts or when the automatic cycle is stopping at the end of the plunger upstroke,
check operation of YV303 and the relative logic element (plunger moved up with YV303 de-energized).
2111 PLUNGER ENCODER RESET (plunger shutdown)
Zero set the plunger encoder (see set up page). The causes may be:
If just one encoder is installed: with the safety guards of the pressing zone open, the encoder value is < - 8 mm.
If 2 or 3 encoders are installed: the difference between the relative values of the two encoders is > 5 mm.
YV31D (slow downstroke) was activated when plunger repositioning started and the encoder failed to count.
Check the plunger encoder, its lock and the leads/connectors.
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2112 PRESS-STROKE NOT COMPLETED – FLOW BOOSTER (1) (plunger shutdown)
The first press-stroke with flow booster was not completed within the maximum allowable time (4 sec).
In the case of column presses:
Check operation of solenoid valve YV40, the relative hydraulic circuit and pressure transducer BP1. In the
case of a press with proportional hydraulics, check operation of proportional solenoid valve YV318 and
the relative hydraulic circuit. In the case of a press with proportional hydraulics, if the problem persists, try
increasing the set pressing speed.
In the case of a Power/Imola series press:
Check operation of solenoid valve YV348/YV350, the relative hydraulic circuit and pressure transducer
BP1. Check operation of proportional solenoid valve YV318 and the relative hydraulic circuit. If the problem
persists, try increasing the set pressing speed.
2113 RAISE SAFETY BAR (plunger shutdown)
Raise the safety bar so that the control system can check efficiency of the limit switches triggered by the bar.
2114 PLUNGER/F-BOX COLLISION (RETURN STROKE) (plunger shutdown)
One of the following numbers may appear to the right of the message:
(1): during the filler-box return stroke/plunger downstroke, the upper punches were too close to the mobile
part of the filler-box. Try reducing the set efficiency during the return stroke.
(2): the plunger downstroke enable signal was not received from the axis synchronization controller. Check
the set axis synchronization data. If no problems are found, try reducing the value set for “sync. efficiency
dur. return”.
(3): the plunger has started its downstroke (encoder BQ6 has detected downward movement greater than
1 mm) but the filler-box is still in the way of the plunger. Try speeding up the filler-box return stroke. As an
alternative, try reducing the value set for “sync. efficiency dur. return”.
See the axis synchronization manual.
2115 PRESS-STROKE NOT COMPLETED – PRESSURE BOOSTER (n) (plunger shutdown)
The ……th press stroke has not been completed within the maximum allowable time (4 sec): the direct stage
of the press-stroke has been completed therefore the stage with the pressure booster has not been finished.
Check operation of solenoid valves YV41 and YV38, the relative hydraulic circuit and pressure transducer
BP1. In the case of a press with proportional hydraulics, check operation of proportional solenoid valve
YV318 and the relative hydraulic circuit. In the case of a press with proportional hydraulics, if the problem
persists, try increasing the set pressing speed.
Check operation of solenoid valves YV349/YV351, the relative hydraulic circuit and pressure transducer
BP1. Check operation of proportional solenoid valve YV318 and the relative hydraulic circuit. If the problem
persists in presses try increasing the set pressing speed.
2116 PRESSURE NOT RECUPERATED (plunger shutdown)
The press was not able to restore the correct pressure.

If the cylinder pressure is not lower than the pump pressure + 30 bar (the set pump pressure is approx. 200
bar) within 2 seconds after the end of the press-stroke.
Check solenoid valve YV19 and the related hydraulic lines for proper functioning. Check pressure transducer
BP1 and the leads/connectors and for proportional press-strokes, solenoid valve YV318 and the related
hydraulic lines.
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2117 SENSORS FOR DIE-SET CHANGE DEVICE (SQ67/SQ68) (plunger shutdown)
Sensors SQ67A/B and SQ68A/B have remained de-energized for more than 5 seconds.
The die-set changer has not been correctly activated or inactivated.
Check pneumatic valve YV292 and proximity sensors SQ67A/B, SQ68A/B: when the hook is used, only
sensors SQ68A/B must be activated, when the hook is not used only sensors SQ67A/B have to be activated.
Check the input card and the leads/connectors.
2118 PRESS-STROKE NOT COMPLETED - DIRECT (n) (plunger shutdown)
The ……th press stroke has not been completed within the maximum allowable time (4 sec): the direct
press-stroke has not been completed.
Check operation of solenoid valve YV19, the relative hydraulic circuit and pressure transducer BP1. In the
case of a press with proportional hydraulics, check operation of proportional solenoid valve YV318 and
the relative hydraulic circuit. In the case of a press with proportional hydraulics, if the problem persists, try
increasing the set pressing speed.
If n = 1, check operation of solenoid valves YV350/YV351, the relative hydraulic circuit and pressure trans-
ducer BP1. If n > 1, check operation of solenoid valves YV349/YV351, the relative hydraulic circuit and
pressure transducer BP1.
Check proportional solenoid valve YV318 and related hydraulic lines for proper functioning.
If the problem persists, try increasing the set pressing speed.
2119 POWDER UNDER DIE-SET (plunger shutdown)
With 2 + 2 or 4-cylinder proportional knockout: the value of one or both encoders is > 0.6 mm during
the press-cycle.
Check the axis card and encoders BQ4/5.
With rod lift system, check encoder BQ4A and the setting for the DEAD STROKE.
2120 INCORRECT PLUNGER PARALLELISM: ... mm (BQ6-7) (plunger shutdown)
The max. difference (value to be entered in INCORRECT PLUNGER PARALLELISM on the PRESS-CYCLE
SET-UP page) on the diagonal of the plunger has been exceeded. Check loading.
The detected value is the difference between encoders BQ6 and BQ7.
The pair of encoders that detected the difference is indicated to the right:
e.g. BQ6-7 indicates that the difference was detected between encoders BQ6 and BQ7. In addition, when
a positive value is given for the left value it means that the plunger has moved further down on side BQ6
whereas a negative value indicates the plunger has moved down more on side BQ7.
2121 REPLACE FILTER (SP7) (plunger shutdown)
With the oil temperature higher than 30°C, digital input SP7 has stayed off.
Replace the filter of the control line of proportional solenoid valves YV32 and YV318 as it is clogged. If the
message is still displayed on the screen after the filter has been replaced, check pressure switch SP7 and
the input card (LED SP7 should be on if the filter is not clogged) and the leads/connectors.
2122 LOW ACCUMULATOR PRESSURE (BP3) (plunger shutdown)
The pressure measured by the pressure transducer of the PCH’s secondary circuit is below 200 bar.
No signal is accepted.
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2123 PERFORM LEARNING (YV32 or YV318 or YV70D) (plunger shutdown)
For presses with columns:

The self-learning cycle for calculating the offset values for proportional valves (YV32, YV318) has been
stopped in an incorrect manner. The various cases are examined below.
The number that appears on the right side of the message is given.
1. The mode selector switch has been turned from the MAN position or the plunger has not moved down
1 mm with YV31D energized. Check the solenoid valve for the slow downstroke and the relative cables.
If the plunger moves down but the encoder does not count, check plunger encoder BQ6.
2. The mode selector switch has been turned from the MAN position or the plunger has not moved down
15 mm with YV318 open 35%. Check proportional solenoid valve YV318 and the relative cables.
Check the solenoid valves for the booster downstroke: solenoid valve YV32M (it should be energized
during this stage), solenoid valve YV40 (it should be energized during this stage) and solenoid valve
YV70/71 (it should be energized during this stage).
3. The mode selector switch has been turned from the MAN position or the plunger has not reached the
IMPACT POS. - 40 mm with YV31D energized.
Check the value set for the IMPACT POS. data item on the press-cycle set-up page.
Check the solenoid valve for the slow downstroke and the relative cables.
4. During the stage in which the offset value for YV32 is determined, the cylinder pressure has exceeded
10 bar to keep the plunger stationary. Check proportional solenoid valve YV318 (it should be closed
during this stage) and the relative cables. Check the solenoid valve used to put the cylinder under pres-
sure: solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should
be closed during this stage), solenoid valve YV40 (it should be de-energized during this stage), logic
element 116 (it should be closed during this stage), solenoid valve YV41 (it should be de-energized
during this stage), logic element 131 (it should be closed during this stage), solenoid valve YV38 (it
should be de-energized during this stage), logic element 120 (it should be closed during this stage),
solenoid valve YV70 (it should be de-energized during this stage) and logic element 118 (it should be
opened during this stage).
5. During the stage in which the offset value for YV32 is determined, the mode selector switch was turned
from the MAN position to keep the plunger stationary or the plunger did not move down with YV31D
energized. Decrease the value set for the IMPACT POS. data item on the press-cycle set-up page.
from the MAN position to keep the plunger stationary or the plunger did not move up with YV31S
energized. Check the solenoid valve for the slow upstroke and the relative cables.
7. The mode selector switch was turned from the MAN position or the plunger did not move up with
YV31S energized.
The plunger should move up to 0 mm. Check the solenoid valve for the slow upstroke and the relative
cables.
8. If the mode selector was not turned, it means the plunger did not move down with YV31D energized.
Check the solenoid valve for the slow upstroke and the relative cables.
11. At the end of the stage in which the offset value for YV318 is determined, the command to the solenoid
valve is either too high or null.
Check proportional solenoid valve YV318 and the relative cables. Check the solenoid valves used to
charge the upstroke chamber during this stage; solenoid valve YV19 (it had to be energized during
this stage) and solenoid valve YV70 (it had to be energized during this stage).
12. During the stage in which the offset value for YV32 (downstroke) is determined, the plunger has
reached the IMPACT POS. - 10 mm. Increase the value entered for the IMPACT POS. data item
on the press-cycle set-up page. Otherwise check proportional solenoid valve YV32 and the relative
cables. Check solenoid valve YV303 used for plunger movement (it should be energized during this
stage).
13. During the stage in which the offset value for YV32 (downstroke) is determined, the pressure in the
cylinder has exceeded 10 bar.
Check proportional solenoid valve YV318 (it should be closed during this stage) and the relative
cables.
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Check the solenoid valve used to put the cylinder under pressure: solenoid valve YV19 (it should be
de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid
valve YV40 (it should be de-energized during this stage), logic element 116 (it should be closed dur-
ing this stage), solenoid valve YV41 (it should be de-energized during this stage), logic element 131
(it should be closed during this stage), solenoid valve YV38 (it should be de-energized during this
stage), logic element 120 (it should be closed during this stage), solenoid valve YV70 (it should be
de-energized during this stage) and logic element 118 (it should be opened during this stage).
14. The mode selector switch was turned from the MAN position or the plunger did not reach the IMPACT
POS. - 20 mm with YV31D energized. Check the value set for the IMPACT POS. data item on the
press-cycle set-up page. Check the solenoid valve for the slow downstroke and the relative cables.
15. During the stage in which the offset value for YV32 (upstroke) is determined, the plunger has reached
19 mm. Check proportional solenoid valve YV32 and the relative cables. Check solenoid valve YV303
used for plunger movement (it should be energized during this stage). Try lowering the IMPACT POSI-
TION on the press cycle set-up page.
16. During the stage in which the offset value for YV32 (upstroke) is determined, the pressure in the
Check proportional solenoid valve YV318 (it should be closed during this stage) and the relative
cables.
Check the solenoid valve used to put the cylinder under pressure: solenoid valve YV19 (it should be
de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid
valve YV40 (it should be de-energized during this stage), logic element 116 (it should be closed dur-
ing this stage), solenoid valve YV41 (it should be de-energized during this stage), logic element 131
(it should be closed during this stage), solenoid valve YV38 (it should be de-energized during this
stage), logic element 120 (it should be closed during this stage), solenoid valve YV70 (it should be
de-energized during this stage) and logic element 118 (it should be opened during this stage).
17. The mode selector switch was turned from the MAN position or the plunger did not reach the me-
chanical end-stop at the end of the self-learning cycle. The booster may not have moved up. Make
sure the solenoid valves allow upward movement: solenoid valve YV32M (it should be de-energized
during this stage) and solenoid valve YV71 (it should be de-energized during this stage).
18. The self-learning procedure has been interrupted because YV32 has jammed either during the up-
stroke or downstroke (with YV303 energized and the trigger pulse is sent to YV32 to have the centers
closed, the plunger travels at a speed higher than 40 mm/s).
19. When determining the lowest value that opens drain (YV70D), either the mode selector was turned
to a different position or the plunger failed to move down with YV31D energized.
20. When determining the lowest value that opens drain (YV70D), the maximum closing signal was pro-
vided with the pressure in the upstroke chamber (BP5) increased 50 bar.
21. When determining the lowest value that opens drain (YV70D), the cylinder pressure has gone over
10 bar or the plunger has moved too far down.
22. The YV70D offset value is too high.
43. The centering offset value of YV32 is too high (more than 250 valve points): check YV303 and the
power supply to the output card of YV303.
Check proportional solenoid valve YV32 and the output card.
44. The downstroke offset value of YV32 is too high (more than 250 valve points): check YV303 and the
45. The upstroke offset value of YV32 is too high (more than 250 valve points): check YV303 and the
47. If the mode selector was not turned, it means the plunger failed to reach the end stop with YV31S
48. While determining of the offset value for YV318, the plunger has reached the IMPACT POSITION
-20 mm. Try increasing the value set for the IMPACT POS. data item on the press-cycle set-up page.
Check logic element YV303 which should be opened.
49. During the stage in which the offset value for YV318 is determined, the signal sent to the solenoid
valve has exceeded the maximum allowable value (4095 valve points). Check proportional solenoid
valve YV318 and the relative cables.
Check the solenoid valves used to charge the upstroke chamber during this stage; solenoid valve
YV19 (it should be energized during this stage) and solenoid valve YV70 (it should be energized dur-
ing this stage).
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50. During the stage in which the offset value for YV318 is determined, the pressure in the cylinder has
exceeded 20 bar. Check proportional solenoid valve YV318 and related wiring. Check the solenoid
valves used to charge the upstroke chamber during this stage; solenoid valve YV19 (it should be en-
ergized during this stage) and solenoid valve YV70 (it should be energized during this stage). Check
logic element YV303 which should be opened.
For PCH or Power presses:

The self-learning cycle for calculating the offset values for proportional valve YV32 has been stopped in an
incorrect manner.
The number that appears on the right side of the message is given.
1. Not used.
2. Not used.
3. The mode selector switch has been turned from the MAN position or the plunger has not reached the
IMPACT POS. - 40 mm with YV31D energized. Check the value set for the IMPACT POS. data item
on the press-cycle set-up page. Check the solenoid valve for the slow downstroke and the relative
cables.
4. During the stage in which the offset value for YV32 is determined, the cylinder pressure has exceeded
10 bar to keep the plunger stationary. Check the solenoid valve used to put the cylinder under pressure:
solenoid valve YV307 (it should be de-energized during this stage), solenoid valve YV70 (it should
be de-energized during this stage) and logic element 118 (it should be open during this stage).
from the MAN position to keep the plunger stationary or the plunger did not move down with YV31D
energized. Decrease the value set for the IMPACT POS. data item on the press-cycle set-up page.
from the MAN position to keep the plunger stationary or the plunger did not move up with YV31S
7. The mode selector switch was turned from the MAN position or the plunger did not move up with
YV31S energized.
The plunger should move up to 30 mm. Check the solenoid valve for the slow upstroke and the rela-
tive cables.
8. If the mode selector was not turned, it means the plunger did not move down with YV31D energized.
Check the solenoid valve for the slow upstroke and the relative cables.
9. When determining the lowest value that opens YV318 during the press-stroke, the signal sent to the
solenoid valve has exceeded the maximum allowable value (4095 valve points). Check proportional
solenoid valve YV318 and related wiring. Check solenoid valves YV350 and YV351 which should be
energized and logic elements 346 and 347 that should be opened.
10. When determining the lowest value that opens YV318 during the press-stroke, either the cylinder pres-
sure has exceeded 10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional
solenoid valve YV318 and related wiring.
Check solenoid valves YV350 and YV351 which should be energized and logic elements 346 and
347 that should be opened. Check YV303 that should be de-energized.
11. At the end of the stage in which the lowest value that opens YV318 during the press-stroke is deter-
mined, the signal sent to YV318 is either too high or null. Check proportional solenoid valve YV318
and related wiring. Check solenoid valves YV350 and YV351 which should be energized and logic
elements 346 and 347 that should be opened.
12. During the stage in which the offset value for YV32 (downstroke) is determined, the plunger has
reached the IMPACT POS. - 10 mm. Increase the value entered for the IMPACT POS. data item on
the press-cycle set-up page. Otherwise check proportional solenoid valve YV32 and related wiring.
Check solenoid valve YV303 used for plunger movement (it should be energized during this stage).
13. During the stage in which the offset value for YV32 (downstroke) is determined, the pressure in the
Check the solenoid valve used to put the cylinder under pressure: solenoid valve YV307 (it should
be de-energized during this stage), solenoid valve YV70 (it should be de-energized during this stage)
and logic element 118 (it should be open during this stage).
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14. The mode selector switch was turned from the MAN position or the plunger did not reach the IMPACT
POS. - 20 mm with YV31D energized. Check the value set for the IMPACT POS. data item on the
press-cycle set-up page. Check the solenoid valve for the slow downstroke and the relative cables.
15. During the stage in which the offset value for YV32 (upstroke) is determined, the plunger has reached
4 mm. Check proportional solenoid valve YV32 and the relative cables. Check solenoid valve YV303
used for plunger movement (it should be energized during this stage).
16. During the stage in which the offset value for YV32 (upstroke) is determined, the pressure in the
Check the solenoid valve used to put the cylinder under pressure: solenoid valve YV307 (it should
be de-energized during this stage), solenoid valve YV70 (it should be de-energized during this stage)
and logic element 118 (it should be open during this stage).
17. The mode selector switch was turned from the MAN position or the plunger (encoder BQ6) did not
reach the mechanical end-stop at the end of the self-learning cycle.
18. The self-learning procedure has been interrupted because YV32 has jammed either during the up-
stroke or downstroke (with YV303 energized and the trigger pulse is sent to YV32 to have the centers
closed, the plunger travels at a speed higher than 40 mm/s).
19. When determining the lowest value that opens drain (YV70D), either the mode selector was turned
to a different position or the plunger failed to move down with YV31D energized.
20. When determining the lowest value that opens drain (YV70D), the maximum closing signal was pro-
vided with the pressure in the upstroke chamber (BP5) increased 50 bar.
21. When determining the lowest value that opens drain (YV70D), the cylinder pressure has gone over
10 bar or the plunger has moved too far down.
22. The YV70D offset value is too high.
23. When determining the lowest value that opens YV318 during the press-stroke, the signal sent to the
solenoid valve has exceeded the maximum allowable value (4095 valve points). Check proportional
solenoid valve YV318 and related wiring. Check solenoid valves YV350 and YV351 which should be
energized and logic elements 346 and 347 that should be opened.
24. When determining the lowest value that opens YV318 during the press-stroke, either the cylinder pres-
sure has exceeded 10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional
solenoid valve YV318 and related wiring.
Check solenoid valves YV350 and YV351 which should be energized and logic elements 346 and
347 that should be opened. Check YV303 that should be de-energized.
25. At the end of the stage in which the lowest value that opens YV318 during the press-stroke is deter-
mined, the signal sent to YV318 is either too high or null. Check proportional solenoid valve YV318
and related wiring. Check solenoid valves YV350 and YV351 which should be energized and logic
elements 346 and 347 that should be opened.
26. When determining the lowest value of YV318 during holding), the signal sent to the solenoid valve
has exceeded the minimum allowable value (10 valve points).
Check proportional solenoid valve YV318 and related wiring.
27. When determining the lowest value of YV318 during holding, either the cylinder pressure has exceeded
10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional solenoid valve
YV318 and related wiring.
28. At the end of the stage in which the lowest value for YV318 during holding is determined, the signal
sent to YV318 is either too high or null. Check proportional solenoid valve YV318 and related wiring.
29. When determining the lowest value of YV318 during decompression, the signal sent to the solenoid
valve has exceeded the minimum allowable value (10 valve points).
30. When determining the lowest value of YV318 during decompression, either the cylinder pressure has
exceeded 10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional solenoid
valve YV318 and related wiring.
31. At the end of the stage in which the lowest value for YV318 during decompression is determined, the
signal sent to YV318 is either too high or null. Check proportional solenoid valve YV318 and related
wiring.
32. When determining the lowest value of YV318 during holding, the plunger failed to move down 10 mm
with YV31D energized.
33. When determining the lowest value of YV318 during holding, the plunger failed to move up 10 mm
with YV31S energized.
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34. PCH: the plunger failed to reach the end stop with YV31S energized
35. PCH: when determining the lowest value of YV32 during the press-stroke, the signal sent to the so-
lenoid valve has exceeded the minimum allowable value (10 valve points).
36. PCH: when determining the offset value for YV32 during the press-stroke, the pressure in the cylinder
has exceeded 15 bar.
37. PCH: during the stage in which the offset value for YV32 (press stroke) is determined, the plunger
has exceeded the IMPACT POS. - 10 mm.
38. PCH: when determining the lowest value for YV32 during the press-stroke, the signal sent to YV32
is too high.
39. PCH: the plunger has not reached the IMPACT POS. - 20 mm with YV31D energized.
40. PCH: when determining the lowest value of YV32 during decompression, the signal sent to the sole-
noid valve has exceeded the minimum allowable value (4095 valve points).
41. PCH: when determining the offset value for YV32 during decompression, the pressure in the cylinder
has exceeded 15 bar. Check proportional solenoid valve YV32 and related wiring.
42. PCH: when determining the lowest value for YV32 during decompression, the plunger has moved
fully up.
43. The centering offset value of YV32 is too high (more than 250 valve points): check YV303 and the
44. The downstroke offset value of YV32 is too high (more than 250 valve points): check YV303 and the
45. The upstroke offset value of YV32 is too high (more than 250 valve points): check YV303 and the
46. PCH: when determining the lowest value for YV32 during decompression, the signal sent to YV32 is
too high. Check proportional solenoid valve YV32 and related wiring.
2124 PERFORM LEARNING PROCEDURE (YV99) (plunger shutdown)
The self-learning procedure for proportional valve YV99 needs to be executed. For PC interface, go to the
"SPECIAL OPERATIONS" page - SET-UP OPERATION NO. = 2 with the key turned to Set-up and then
press keys 28 and 7. The procedure takes a few minutes. Once the procedure has been completed, press
Reset to clear the message.
2125 PRESS-STR.START POS. NOT REACHED (plunger shutdown)
During its downstroke the plunger has exceeded the value set for IMPACT POS. but has failed to reach the
PRESS-STR. START POS. (or PRESS-STROKE START THICKNESS) - 5 mm within 5 sec.
See whether the value set for PRESS-STR.START POS. can actually be reached (for example, something
may be inside the die-set or soft filling that prevents the plunger from moving down).
2126 PERFORM LEARNING PROCEDURE (YV32) (plunger shutdown)
Before running the press in automatic or semi-automatic mode, the self-learning procedure must be performed
for the proportional solenoid valves (see “Self-learning for plunger upstroke/downstroke” in the DESCRIP-
TION OF THE KEYS paragraph).
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2127 CLEAN PROPORTIONAL VALVES (n) (plunger shutdown)
A problem has been detected while cleaning proportional solenoid valves YV32/YV318/YV70D. Parameter
n identifies the type of problem:
1) Pressure in cylinder over 10 bar.
2) Plunger moved down (encoder BQ6 has exceeded 5 mm).
3) Mode selector not turned to position MAN or filler-box back sensor (SQ59) no longer triggered, or the
machine is no longer in a safe condition (AJ101 off) as the safety guards in the press-cycle zone are
open, the filler-box is disconnected or the roller conveyor in front of the press is not connected.
6) External booster moved more than 10 mm.
7) The filler-box has shifted while valve YV20 was being cleaned.
8) See parameter 3.
2128 HIGH ACCUMULATOR PRESSURE (BP3) (plunger shutdown)
PCH: the accumulator pressure measured by pressure transducer BP3 is more than 30 bar higher than the
required pressure. The plunger is blocked.
2129 WEDGES NOT OUT (SQ12A/B) (plunger shutdown)
When a signal is provided for the wedges to come out (solenoid valve YV313 energized), they failed to come
out within a 3 s timeout as input SQ12AB is high (i.e. at least 1 wedge is not out).
As an alternative, the wedges failed to come out when the slow plunger downstroke was started from the
keyboard in SET-UP mode as input SQ12AB is high (i.e. at least 1 wedge is not out).
NOTE Input SQ12AB is parallel with SQ12A (microswitch on right wedge/hook) and SQ12B (microswitch
on left wedge/hook).
The microswitches should be triggered when the wedges/hooks are in their work position, i.e. completely out.
As soon as the wedge/hook is no longer completely out, the microswitch should not be triggered any more.
2130 WEDGES NOT IN (SQ12C/D) (plunger shutdown)
When a signal is provided for the wedges to retract (solenoid valve YV313 de-energized), they failed to
retract within a 3 s timeout as input SQ12CD is low (i.e. at least 1 wedge is not in).
NOTE Input SQ12CD is in series with SQ12C (microswitch on right wedge/hook) and SQ12D (microswitch
on left wedge/hook).
2131 BOOSTER RESET (BQ12) (booster shutdown)
A fault arose during the reset procedure for the external flow/pressure booster. The booster was not reset
after reaching its mechanical end-stop.
2132 BOOSTER UPSTROKE (YV103) (booster shutdown)
If “(YV103)” appears it means the external flow/pressure booster failed to complete half its upstroke during
the repositioning stage. If parameter (YV103) does not appear it means the booster has moved up more
than 40 mm during the direct press stroke.
2133 BOOSTER DOWNSTROKE (YV102) (booster shutdown)
If “(YV102)” appears it means the external flow/pressure booster failed to complete half its downstroke dur-
ing the repositioning stage. If parameter (YV102) does not appear it means the booster has moved down
more than 40 mm during the direct press stroke.
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2134 BOOSTER NOT REPOSITIONED (booster shutdown)
The external flow/pressure booster failed to complete its repositioning stroke when the plunger started its
downstroke.
2135 PRESSURE IN UPSTROKE CHAMBER HIGH (BP5) (booster shutdown)
The pressure in the upstroke chamber (BP5) increased 80 bar during the booster downstroke.
2136 FAULTY VALVE (YV486) (booster shutdown)
The proportional solenoid valve YV486 (for booster upstroke) is malfunctioning.

The position of the solenoid valve spool deviates more than -/+ 20% in relation to the command received.
Check the electrical connections of the feedback signal and the analog input card regarding YV486. If no
problems are found, check the control signal and relative analog output card regarding YV486. If everything
works correctly, check the proportional solenoid valve.
2137 TIMEOUT, BOOSTER STROKE RECOVERY (booster shutdown)
The booster has not completed the stroke recovery during press-cycle within the timeout.
Check operation of linear absolute encoder BQ12 and the electric connections.
Check proportional solenoid valve YV318 and relative wiring. The valve should be fully open towards the
drain (-100 %) during this stage.
Check proportional solenoid valves YV102, YV349, YV351, YV350 that control booster downstroke.
2138 BOOSTER MOV. DURING OIL HEATING (BQ12) (booster shutdown)
Booster movement has been detected during oil heating. The booster should instead remain at the limit
switch (encoder BQ12 = 0).
Oil heating is interrupted.
2141 PAD PRECHARGE TIMEOUT (BQ11) (diff. press-cycle shutdown)
The pad precharge cycle was not completed within the maximum allowable time (30 seconds). Booster
BQ11 has not reached the precharge position.
Check proportional solenoid valve YV100 and the valves in question.
Check linear absolute encoder BQ11 and the electric connections.
2142 LEARNING PROCEDURE (YV100) (diff. press-cycle shutdown)
The self-learning cycle for calculating the offset values for proportional valve YV100 has been stopped in
an incorrect manner. The various cases, identified by the number that appears to the right of the message,
are examined below:
1. During syringe repositioning (back up), the booster failed to complete the maximum stroke - 10 mm
- within 30 seconds.
2. During syringe repositioning (advancing), the booster failed to complete the maximum stroke - 5 mm
- within 120 seconds.
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3. While the offset values used for the return stroke and to keep the booster for YV100 in place were
being established, the speed of the booster failed to drop below 0.2 mm/s within 120 seconds.
4. While the offset values used for the return stroke and to keep the booster for YV100 in place were
being established, the booster moved either completely back or forward.
5. Once the offset values used for the return stroke and to keep the booster for YV100 in place were
determined, the booster failed to reach the end of its return stroke 5 mm within 120 seconds while
being repositioned.
6. While the offset value for the forward stroke of YV100 was being established, the speed of the booster
failed to drop below 6 mm/s within 120 seconds.
7. While the offset value for the forward stroke of YV100 was being established, the booster reached
the end of its forward stroke.
8. Once the offset value for the forward stroke of YV100 was determined, the booster failed to reach the
end of its forward stroke - 5 mm within 120 seconds while being repositioned.
9. Not used.
10. Not used.
11. The booster did not reach the cycle start position while being repositioned for the return stroke within
120 seconds.
12. The booster did not reach the cycle start position while being repositioned for the forward stroke within
120 seconds.
2143 BOOSTER REPOSITIONING (BQ11) (diff. press-cycle shutdown)
The booster either failed to reach its initial position during the repositioning procedure within 120 seconds
or the precharge position within 60 seconds.
2144 CHECK PAD PRECHARGE (BP203) (n). (diff. press-cycle shutdown)
1. During pad decompression, the pad pressure (BP203) failed to drop below 0.3 bar within 60 seconds.
2. During pad precharging or while precharging is being checked, the pad pressure (BP203) is higher
than the maximum allowable isostatic precharge pressure.
3. While checking precharge, the pad pressuyre (BP203) is higher than the maximum allowable isostatic
precharge pressure.
Check pressure transducer BP203 and wiring.
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2145 LOW CYL.PRESS DUR. DIFF. CYCLE (diff. press-cycle shutdown)
During the differentiated press-cycle, the cylinder pressure (BP1) dropped below the value set for CYLINDER
PRESS.AT DIFF. CYCLE START - 5%.
The pad may be damaged.
2146 PLUNGER UPSTR.EXCESSIVE DUR. DIFF. CYCLE (diff. press-cycle shutdown)
While the pad pistons are put under pressure during the differentiated press-cycle, make sure the plunger
does not move more than 0.5 mm up in relation to the maximum value reached when the pressure was
discharged from the pistons.
The pad may be damaged.
2147 PRESSURE IN PADS HIGH (BP204) (diff. press-cycle shutdown)
(1) The booster pressure (BP204) exceeded 100 bar (or settable value in the case of generic pads) during
pad precharing.
(2) The booster pressure (BP204) exceeded 450 bar during the last press-stroke.
(3) The booster pressure (BP204) exceeded 20 bar during the oil change cycle. This means that the oil
pushed by the booster is not able to flow out.
Check operation of proportional solenoid valve YV100 along with the valves in question.
2148 PISTON POS. UNDER PRESS.NOT REACHED (diff. press-cycle shutdown)
While the pad pistons were put under pressure during the differentiated press-cycle, the booster (BQ11)
failed to reach the value calculated according to the set piston stroke within 5 seconds.
2149 REPLACE FILTER (SP8) (diff. press-cycle shutdown)
Digital input SP8 stayed off and the oil temperature is higher than 30 °C.
Change the filter of the pressure switch for proportional valve YV100 as it is clogged.
If the message is still displayed even after the filter has been changed, check pressure switch SP8, the rela-
tive input card (when the filter is not clogged, led SP8 should be on) and the cables/connectors.
2150 PERFORM LEARNING PROCEDURE (YV100) (diff. press-cycle shutdown)
The self-learning procedure for proportional valve YV100 needs to be executed. For PC interface, go to
the "SPECIAL OPERATIONS" page - SET-UP OPERATION NO. = 11 with the key turned to Man and then
press keys 28 and 7. The procedure takes a few minutes. Once the procedure has been completed, press
Reset to clear the message.
2151 PAD DECOMPRESSION TIMEOUT (BP204/BP203) (diff. press-cycle shutdown)
The pressure inside the pad (BP204) is checked at the end of the first press-stroke. For piston pads, this is
the pressure detected by BP204 pressure transducer. For general pads, it is detected by BP203 pressure
transducer. If it is higher than 3 bar, the cylinder is kept at the first press-stroke pressure as long as the
pressure in the pad does not fall below 4 bar. As a result, the pad pistons surely move all the way down
(this procedure is performed whenever the cycle starts and the oil is changed). If it stays below 4 bar for 20
sec, a fault is signaled.
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2152 OIL LEAK LEVEL (SL11) (diff. press-cycle shutdown)
Input SL11 has remained deactivated for 40 sec. This input is the maximum oil leak level control of the active
isostatic/differentiated pressing unit.
2161 DRIVE FAULT (U28) (DIP shutdown)
U28:
With the inverter energized and reset, input U28 (slave 20) failed to come on.
Check inverter U28 to see if it works properly.
Check the input card (module ID) and all the leads/connectors.
U2028:
2162 CHECK (SQ41) (DIP shutdown)
SQ41:
With DIP running in automatic mode, roller conveyor A running and the upstream signal (KA310) on, photocell
SQ41 has been activated for more than 10 consecutive seconds.
Make sure photocell SQ41 is in the correct position and works properly. Check the input card (module ID)
(slave 20) and all the leads/connectors.
SQ2041:
With DIP running in automatic mode, roller conveyor A running and the upstream signal (KA310) on, photocell
SQ2041 has been activated for more than 10 consecutive seconds.
Two checks are made:

With the machine running in automatic mode, roller conveyors A and B running, photocell SQ42 has been
activated for more than 10 consecutive seconds.
During the automatic cycle, from the moment in which SQ41 is deactivated, SQ42 failed to change over (on
if it was off and off if it was on) within 6 seconds. Make sure photocell SQ42 is in the correct position and
works properly. Check the input card (module ID) (slave 20) and all the leads/connectors.
U27:
Check input card AP651 (module ID) and all the leads/connectors.
U2031:
Check input card AP651 (module ID) and all the leads/connectors.
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U29:
U2029:
Three checks are made:

With DIP in its loading position, roller conveyor B running and SQ43 activated, none of photocells SQ44
have been activated yet after 5 sec. Most likely photocell SQ43 was activated even when a tile is not pres-
ent, it may be dirty or faulty.
With all tiles correctly positioned in the box (SQ44 enabled = ON) and the DIP still at the BACK LIMIT
SWITCH, photocell SQ43 was not activated.
Throughout the entire DIP stroke, photocell SQ43 was not inactivated, it may be dirty or faulty.
2167 INCREASE M29 DEC. DELAY AFTER SQ43 ON (DIP shutdown)
The moment in which the tiles change over from the running speed to the stop speed, photocell SQ42 was
not inactivated (still activated by a tile).
Increase the space for delaying M29 deceleration after SQ43 has come on.
If the problem persists, it means there is not enough space between photocell SQ42 and the front band for
the size of the tiles being produced.
Make sure photocells SQ42 and SQ43 are in the correct position and work properly. Check the input card
(module ID) (slave 20) and all the leads/connectors.
2168 FAST TILE-BAND IMPACT (DIP shutdown)
Roller conveyor B is still at the operating speed at the moment in which the first SQ44 photocell is activated
(it should be at the stop speed).
This may be due to:
The space for delaying roller conveyor deceleration is too large.
The tiles are not aligned, the tile on the side of photocell SQ43 is considerably further behind the other tiles.
Photocell SQ43 fails to detect tiles for some reason.
Increase the space for delaying roller conveyor B deceleration.
Make sure the times are correctly aligned when they reach photocell SQ43. Make sure photocell SQ43 is
in the correct position and works properly. Check the input card (module ID) (slave 20) and all the leads/
connectors.
2169 FILLER-BOX RETURN STROKE (DIP shutdown)
The DIP failed to complete its stroke (manual or automatic) within the maximum allowable time (from 10 to
30 seconds depending on the type of stroke in progress).
Check encoder BQ30, encoder input card (module IE1), relay KA30E, drive U30, relay output card (OR
module) and all the leads/connectors in question.
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2170 FILLER-BOX FORWARD STROKE (DIP shutdown)
The DIP failed to complete its stroke (manual or automatic) within the maximum allowable time (from 10 to
30 seconds depending on the type of stroke in progress).
Check encoder BQ30, encoder input card (module IE1), relay KA30E, drive U30, relay output card (OR
module) and all the leads/connectors in question.
2171 SIDE BANDS OPEN (SQ2060A/M628) (DIP shutdown)
When the DIP reaches the end of the forward stroke or the overrun value, the side bands should be closed.
This conditions is not satisfied as either sensor SQ2060A, that detects when the bands are opened, is ac-
tivated or the position of motor M628 indicates the bands are opened.
Make sure sensor SQ2060A, motor M628, solenoid valve YV2060, the input card (ID module) (slave 21)
and output card (OD module) (slave 21) are in the correct position and work properly. In addition, check all
the cables/connectors.
2172 PLUNGER DOWN AT FILLER-BOX START (DIP shutdown)
During the forward stroke (manual, automatic and damaged tile ejection cycle), the system checks that the
plunger is up.
Make sure the plunger is in the correct position, i.e. at the end of its upstroke the moment in which the
forward stroke begins.
2173 DIP FAULT (M30/M2030) (...) (DIP shutdown)
The system detected a fault while the DIP was moving; the part does not perform the desired movement. A
number is given in parenthesis that aids in understanding the cause of the problem.
1 = end-stop outside range
2 = final position outside limits
3 = peak speed outside range
4 = acceleration null
5 = peak acceleration outside range
6 = ramp soft coefficients outside range
7 = movement too long (> ’30 sec.)
8 = movement cannot be performed
50 = excessive tracking error
51 = emergency shutdown as end of stroke is reached
52 = speed of part too high (> max speed + 20%)
54 = position of part not allowed
Check drive U30 or U2030 if indicated in the message. Make sure there are no obstacles and that the forward
and return strokes can be completed in a trouble-free manner.
Check all the data set or the part (forward-return stroke limit switch, speed, etc...) verifying that the required
movement can be carried out.
Only for SACMI personnel during start-up: make sure all the parameters for this part are properly set
(recommended values).
2174 FILLER-BOX OUTSIDE RANGE (.....) (DIP shutdown)
This check is made in different ways and at different times of the cycle.
While waiting for the tile to reach the loading position, the DIP has failed to reach the end of its return stroke,
i.e. in the position in which it receives tiles. As precision is not absolutely fundamental, the fault is signaled
with errors > + - 5 mm.
The DIP failed to reach the value for the END OF THE FORWARD STROKE. In this case, precision is ex-
tremely important and the fault is signaled with errors > + - 0.5 mm.
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The DIP failed to reach the value for the END OF THE RETURN STROKE. In this case, less precision is
required and the fault is signaled with errors > + - 2 mm. While being repositioned, the DIP failed to reach
the value for the END OF THE RETURN STROKE. In this case, the fault is signaled with errors > + - 2 mm.
Try increasing the value set for positioning on the filler-box page.
Check encoder BQ30, encoder input card (module IE), relay KA30E, drive U30, relay output card (module
OR) and all the leads/connectors in question.
Make certain the filler-box is able to move in a trouble-free manner.
Only for SACMI personnel during start up: make sure all the parameters for filler-box movement are properly set.
2175 FILLER-BOX REPOSIT. (DIP shutdown)
Repositioning was not completed with the maximum allowable time of 30 seconds.
Check encoder BQ30, encoder input card (module IE), relay KA30E, drive U30, relay output card (module
OR) and all the leads/connectors in question.
2176 CHECK (SQ2065A) (DIP shutdown)
Sensor SQ2065A has not detected that the evener of the fixed centering device is raised.
Sensor SQ2065A was not activated within 1.5 sec from the moment in which solenoid valve YV2065 was
activated.
Make sure sensor SQ2065A, solenoid valve YV2065, the input card (DI module) (slave 21) and the output
card (DO module) (slave 21) are in the right position and work properly. Check all the connecting cables/
connectors.
2177 CHECK (.....) (DIP shutdown)
This message identifies a fault in a photocell. The group of photocells with the problem but not the photocell
that caused shutdown is given in parenthesis.
• (SQ44A/B/C/D…): One of these photocells is faulty.
During the forward stroke, all enabled photocells should change over from ON to OFF. This did not happen
as at least one photocell did not shut off.
Roller conveyor B failed to stop within 3 seconds from when the rear band closed, one of enabled photocells
SQ44 may not be activated.
Make sure photocells SQ44A/B/C... work properly and are in the correct position. Check the input card
• (SQ38A/B/C/D…): One of these photocells is faulty.
If the photocells are located at the back of the tile, all the photocells should change over from ON to OFF
during the return stroke. This did not happen as at least one photocell did not shut off.
After performing the procedure to set the photocells, the system checked operation and negative results
were obtained.
• (SQ39A/B …): One of these photocells is faulty.
After performing the procedure to set the photocells, the system checked operation and negative results
were obtained.
2178 TILE NOT IN PRESS. POS. (SQ38 - SQ39) (DIP shutdown)
Once the die-sets have completed the downstroke, before starting the return stroke, one of enabled photo-
cells SQ38 or SQ39 stayed activated. This most likely indicates the tile did not fall into the cavity correctly
or the photocell is faulty or not in the right position.
(module ID) (slave 20 or slave 21) and all the leads/connectors.
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2179 DIRECTION OF OPERATION REVERSED (M30/2030) (DIP shutdown)
This check is made during all movements.

The direction of operation has been reversed. Basically speaking, the encoder has detected a 15 mm move-
ment in the direction opposite the one the part is working in.
If no faults are present, this fault message should appear only at first time start-up, after the motor, drive or
encoder have been replaced or if hardware maintenance jobs have been performed (wires may have been
reversed).
M30:
Make certain motor M30 and drive U30 work properly and are correctly connected. Check the analog output
module (slave 20).
Make sure encoder BQ30 works properly and is correctly connected. Check the encoder input module
(slave 20).
M2030:
Make certain motor M2030 and drive U30 work properly and are correctly connected. Check the analog
output module (slave 21).
Make sure encoder BQ30 works properly and is correctly connected. Check the encoder input module
(slave 21).
U30:
With the drive energized and reset, input U30 (slave 20) is not on.
Make sure drive U30 works efficiently.
U2030:
With the drive energized and reset, input U2030 (slave 21) is not on.
Make sure drive U2030 works efficiently.
2181 SIDE BANDS OPEN (SQ2061A) (DIP shutdown)
Sensor SQ2061A has not detected that the mobile centering device’s side bands opened.
activated.
card (DO module) are in the right position and work properly. Check all the connecting cables/connectors.
2182 SIDE BANDS CLOSED (SQ2061A) (DIP shutdown)
Sensor SQ2061A is still activated even when the mobile centering device’s side bands should be closed.
Sensor SQ2061A was not deactivated within 1.5 sec from the moment in which solenoid valve YV2061 was
deactivated.
card (DO module) are in the right position and work properly. Check all the connecting cables/connectors.
SQ48A:
Sensor SQ48A has not detected the rear band opened.
Sensor SQ48A was not activated within 1.5 seconds from the moment in which solenoid valve YV48 was
deactivated.
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Make sure sensor SQ48A and solenoid valve YV48 work efficiently and are in the correct position. Check
the input card (module ID) (slave 20) and output card (module OD) (slave 20) and all the leads/connectors.
SQ2062A:
Sensor SQ2062A has not detected the rear band opened.
Sensor SQ2062A was not activated within 1.5 seconds from the moment in which solenoid valve YV2062
was deactivated.
2184 CHECK (SQ48C) (DIP shutdown)
SQ48C:
Sensor SQ48C has not detected the rear band closed.
Sensor SQ48C was not activated within 1.5 seconds from the moment in which solenoid valve YV48 was
activated.
Make sure sensor SQ48C and solenoid valve YV48 work efficiently and are in the correct position. Check
SQ2062B:
Sensor SQ2062B has not detected the rear band closed.
Sensor SQ2062B was not activated within 1.5 seconds from the moment in which solenoid valve YV2062
was activated.
Make sure sensor SQ48C and solenoid valve YV2062 work efficiently and are in the correct position.Check
SQ49A-B:
Sensors SQ49A and SQ49B (series connected) did not detect roller conveyor B is raised (position in which
the roller conveyor runs, rollers not idling).
Sensor SQ49A or SQ49B was not activated within 1.5 seconds from the moment in which solenoid valve
YV49 was activated. Make sure sensors SQ49A/SQ49B and solenoid valve YV49 work efficiently and are
in the correct position. Check the input card (module ID) (slave 20) and output card (module OD) (slave 20)
and all the leads/connectors.
SQ2049A-B:
Sensors SQ2049A and SQ2049B (series connected) did not detect roller conveyor B is raised (position in
which the roller conveyor runs, rollers not idling).
Sensor SQ2049A or SQ2049B was not activated within 1.5 seconds from the moment in which solenoid valve
YV2049 was activated. Make sure sensors SQ2049A/SQ2049B and solenoid valve YV2049 work efficiently
and are in the correct position. Check the input card (module ID) (slave 21) and output card (module OD)
SQ49C-D:
Sensors SQ49C and SQ49D (series connected) did not detect roller conveyor B is lowered (position in which
the roller conveyor is stationary, rollers idling).
Sensor SQ49C or SQ49D was not activated within 1.5 seconds from the moment in which solenoid valve
YV49 was deactivated.
Make sure sensors SQ49C/SQ49D and solenoid valve YV49 work efficiently and are in the correct posi-
tion. Check the input card (module ID) (slave 20) and output card (module OD) (slave 20) and all the leads/
connectors.
SQ2049C-D:
Sensors SQ2049C and SQ2049D (series connected) did not detect roller conveyor B is lowered (position
in which the roller conveyor is stationary, rollers idling).
Sensor SQ2049C or SQ2049D was not activated within 1.5 seconds from the moment in which solenoid
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valve YV2049 was deactivated.

Make sure sensors SQ2049C/SQ2049D and solenoid valve YV2049 work efficiently and are in the correct
position. Check the input card (module ID) (slave 21) and output card (module OD) (slave 21) and all the
leads/connectors.
Sensor SQ55A has not detected the ejector is raised.

activated.
Sensor SQ55C has not detected the ejector is lowered.

deactivated.
SQ56A:
Sensor SQ56A has not detected the front band opened.
activated.
SQ2056A:
Sensor SQ2056A has not detected the front band opened.
Sensor SQ2056A was not activated within 1.5 seconds from the moment in which solenoid valve YV2056
was activated.
SQ56C:
Sensor SQ56C has not detected the front band closed.
deactivated.
SQ2056C:
Sensor SQ2056C has not detected the front band closed.
Sensor SQ2056C was not activated within 1.5 seconds from the moment in which solenoid valve YV2056
was inactivated.
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2191 DAMAGED TILE (SQ…. ) (DIP shutdown)
This message indicates the tile is broken.

The photocell that detected the fault is given in parenthesis.
Photocells SQ39 always signal when the tile is chipped at the front, photocells SQ38 signal either the front
or back of the tile is chipped, depending on where they are installed.
The checks are made with the bands closed before the filler-box starts running and at the forward end stop
before the die-sets move down.
Make sure sensors SQ38 or SQ39 work efficiently and are in the correct position. Check the input cards
(modules ID) and leads/connectors.
Sensor SQ2065C has not detected the evener of the fixed centering device is down.
Sensor SQ2065C was not activated within 1.5 sec from the moment in which solenoid valve YV2065 was
deactivated.
Make sure sensor SQ2065C, solenoid valve YV2065, the input card (DI module) (slave 21) and the output
connectors.
2193 TILE TOO FAR FORWARD (SQ38/SQ39) (DIP shutdown)
This check is made only in a cycle without die-set downstrokes.

While the DIP was performing the return stroke, one of enabled photocells SQ39, or if placed at the front
SQ38 as well, was inactivated in the space between the END OF THE FORWARD STROKE and value set
for END OF TILE TOO FAR FORWARD CONTROL POS.
Check the value set for END OF TILE TOO FAR FORWARD CONTROL POS. SQ45. Take into consideration
that the higher the filler-box speed the less accurate the control procedure is (tolerance from 1 to 5 mm,
according to the speed) due to the rate at which the photocell is read (about 2.5 ms).
Basically speaking, this check is made only to detect when the tile shifts from 1 to 5 mm. Lesser movements
cannot be detected.
Make sure sensors SQ39 and SQ38 work efficiently and are in the correct position. Check input card (module
ID) (slave 20) and the leads/connectors.
2194 TILE TOO FAR BACK (DIP shutdown)
This check is made only in a cycle without die-set downstrokes.

While the DIP was performing the return stroke, one of enabled photocells SQ39 or if placed at the front SQ38
as well, was still activated 30 mm after the value set for END OF TILE TOO FAR BACK CONTROL POS.
Check the value set for END OF TILE TOO FAR BACK CONTROL POS. Take into consideration that the
higher the filler-box speed the less accurate the control procedure is (tolerance from 1 to 5 mm, according
to the speed) due to the rate at which the photocell is read (about 2.5 ms).
Basically speaking, this check is made only to detect when the tile shifts from 1 to 5 mm. Lesser movements
cannot be detected.
Make sure sensors SQ38 and SQ39 work efficiently and are in the correct position. Check input card (module
ID) (slave 20) and the leads/connectors.
2195 TILE IN PRESSING ZONE (DIP shutdown)
The tile just pressed may not be completely removed from the pressing zone (front roller conveyor at standstill
due to its own problems, because the drier has shutdown or the DIP ejector is not long enough).
This check prevents the tile from being pressed between the lower and upper die during the next cycle.
To prevent this from happening, the system has two overruns that see that the tile is completely ejected
even when the front roller conveyor is stopped.
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The first system, enabled by setting overrun during cycle > 0, sees that the set overrun cycle is carried out
each cycle.In this case, the problem cannot arise therefore this check is disabled.
The second system, enabled by setting overrun during stoppage > 0, sees that the set overrun cycle is per-
formed only if there was an external shutdown (KA300 OFF) during the forward stroke. This overrun cycle
assures the tile is completely ejected while the overrun time is not loaded during each cycle. If the outer
shutdown occurs when the DIP is already at a standstill at the end of the forward stroke or when the return
stroke has just started, the system will shutdown as it is no longer possible to perform the overrun cycle.
The tile may not have left the pressing zone.
The control therefore is active only if overrun during stoppage > 0 is set.
Normally, simply remove the tile and restart the line.
2196 PLUNGER/FILLER-BOX/ COLLISION (KA410) (DIP shutdown)
This fault message is displayed when the filler-box reaches the collision safety position (set on the filler-box
page) while performing the forward stroke before KA410 came on (press plunger full up).
If a time for starting the filler-box in advance has been set, make sure it is no too long causing the filler-box to
reach the safety position before the plunger has reached the limit switch for the end of the upward movement.
Obviously, the collision safety position should be correct set, if it is too close to the limit switch for the end
of the return stroke, the message may be displayed.
2197 DIP OUTSIDE ALLOWABLE RANGE (parameter) (DIP shutdown)
BQ30 or BQ2030
This fault message is displayed if the DIP reaches position outside the limits of the allowable stroke.
These limits can be set only by operators who have the enabled password.
Check the limits. If they are not correct, make the necessary corrections (the minimum one must be at least
10 mm less than the end of the return stroke while the maximum one should be greater than the end of the
forward stroke + an overrun that is at least 10 mm). If the settings are correct, make sure the part is able to
move in a trouble-free manner and above all that encoder BQ30 reads the position correctly.
SQ2030A
The DIP has moved fully forwards activating sensor SQ2030A. If this is not the case, check the efficiency
of the sensor, its wiring and the relative digital input module.
SQ2030I
The DIP has moved fully back activating sensor SQ2030I. If this is not the case, check the efficiency of the
sensor, its wiring and the relative digital input module.
2198 TILES NOT ALIGNED (SQ2047A,B,C, etc) (DIP shutdown)
Maximum allowable misalignment between tiles reaching SQ2047A,B,C.. is 200 mm.

If the distance between the first incoming tile and the last one is more than 200 mm this shutdown occurs.
Make sure sensors SQ2047A,B,C, etc.. and the input card (DI module) (slave 21) are in the right position
and work properly. Check all the connecting cables/connectors. Make sure the devices placed before the
DIP are set to send the tiles aligned.If they are not, adjust these machines to solve the problem.
2199 TILES TOO CLOSE TOGETHER (DIP shutdown)
In order for the cycle to be correctly performed, the incoming tiles should not be less than 150 mm away
from one another (distance between rows). Use photocells SQ2047A,B,C. etc to check.
Make sure sensors SQ2047A,B,C, etc.. and the input card (DI module) (slave 21) are in the right position and
work properly. Check all the connecting cables/connectors. Make sure the devices placed before the DIP are
set to send tiles at rates higher than 150 mm. On the contrary adjust these machines to solve the problem.
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2200 CHECK (M2031/SQ2031A) (DIP shutdown)
The pallet did not reach the up end-stop (SQ2031A) or during the automatic cycle the sensor that detects
when the pallet is up was deactivated even if a signal for pallet downward movement was not given.
Sensor SQ2031A has to be activated within 1.5 sec. from the moment in which pallet upward movement is
triggered.
Make sure sensor SQ2031A, motor M2031, the input card (DI module) (slave 21) and the output card (RO
and AO modules) (slave 21) are in the right position and work properly. Check all the connecting cables/
connectors.
The fault may have arisen because the table stayed up for more than 3 seconds.
2201 ACP2 LEFT TRAVEL (KA121B-U121) (ACD shutdown)
The color ACP failed to move to the left within the set time (60 sec.).
Check relay KM121B, inverter U121 and encoder BQ121.
Check the output card (module OR), encoder input card and all the leads/connectors.
2202 ACP2 RIGHT TRAVEL (KA121A-U121) (ACD shutdown)
The color ACP failed to move to the right within the set time (60 sec.).
Check relay KM121A, inverter U121 and encoder BQ121.
2203 CHECK U121/U26/U25 (ACD shutdown)
With the inverter energized and reset, either input U121 (slave 19), input U26 (slave 19) or input U25 (slave
19) failed to come on.
Check operation of inverter U121/U26/U25.
2204 ACTUATOR/ENCODER (ACP2) (ACD shutdown)
After a signal has been provided to move the color ACP, no movement was performed within the set time.
Check relays KM121A - KM121B, inverter U121 and encoder BQ121.
2205 CHECK (SQ...) (ACD shutdown)
This message signals that after a signal was sent to a gate, the relative sensor that monitors the end of the
stroke was not activated.
If the following are signaled:
SQ601C or SQ601A the fault regards the hatch
SQ603C or SQ603A the fault regards the color hopper gate
SQ604C or SQ604A the fault regards the mobile color case gate
SQ624C or SQ624A the fault regards the color feeder gate
SQ625C or SQ625A the fault regards color pipe 1 gate
Depending on which sensor is indicated, check the position and operation of the sensor, the relative control
valve, the input card (module ID) and all the leads/connectors.
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2206 ENCODER FAILURE (BQ121) (ACD shutdown)
The system has detected a fault in encoder BQ121.

Check the encoder and encoder input card.
2207 FIXED COLOR HOPPER LEVEL TIMEOUT (SL25) (ACD shutdown)
The system verifies powder is present in the fixed hopper before the fixed hopper’s gate (YV603) opens
to let out powder in the mobile device. If the level probes (SL25) do not detect powder is present within 20
sec. max., the machine shuts down.
The check is made each cycle.
Check operation of level probes SL25.
Check the input card (module ID), when the level is correct the input should be high and the leads/connectors.
2208 MOBILE COLOR HOPPER LEVEL TIMEOUT (SL26) (ACD shutdown)
Level probe (SL26) in the mobile hopper was not activated with 1.5 sec. after gate YV603 closed.
The check is made each cycle.
Check operation of level probes SL26.
Check the input card (module ID), when the level is correct the input should be high and the leads/connectors.
2209 RESET MDR2 ENCODER (ACD shutdown)
The reset procedure for encoder BQ25 was not successfully completed within 30 seconds.
Check encoder BQ25, the encoder input card and the leads/connectors.
2210 CHECK (M25-U25) (ACD shutdown)
While the color MDR’s disk was turning, the next value (from 0 to 60 degrees, from 60 to 120 degrees, from
120 to 180 degrees, etc..) was not reached within the allowable timeout (8 sec.).
The disk may not have turned or the encoder may not have detected movement. Check motor M25, inverter
U25, encoder BQ25, the encoder input and relay output cards and the leads/connectors.
2211 DIRECTION OF OPERATION REVERSED (M25) (ACD shutdown)
The MDR disk is running in reverse. When looking at the disk from the top, it should turn clockwise.
Check the connections of the motor. If the disk runs in the right direction the encoder may be detecting it is
running in reverse. Make sure the encoder is properly connected and works correctly.
2241 MOBILE GRID RETURN (ACD shutdown)
Fault message displayed only if the mobile grid is installed.

Whenever the mobile grid performs a return stroke (repositioning, return stroke in manual mode, return
stroke during automatic cycle, acceleration and deceleration ramps), the system checks that the movement
takes place within the maximum allowable time after which the machine shuts down.
The control times cannot be changed and vary according to the type of movement to be performed.
The causes may be one of the following:
The mobile grid failed to start, stopped during the stroke, failed to perform the entire stroke within the
maximum allowable time, the acceleration and deceleration ramps were not completed within the maximum
allowable time.
Check inverter U40, encoder BQ40, the encoder input card, the relay output card and all the leads/connectors.
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2242 MOBILE GRID FORWARD (ACD shutdown)

Whenever the mobile grid carries out forward strokes (repositioning, forward stroke in manual mode, forward
stroke during automatic cycle, acceleration and deceleration ramps), the system checks that the movement
takes place within the maximum allowable time after which the machine shuts down.
The control times cannot be changed and vary according to the type of movement to be performed.
The causes may be one of the following:
The mobile grid failed to start, stopped during the stroke, failed to perform the entire stroke within the
maximum allowable time, the acceleration and deceleration ramps were not completed within the maximum
allowable time.
Check inverter U40, encoder BQ40, the encoder input card, the relay output card and all the leads/connectors.
2243 MOBILE GRID FORWARD (SQ40) (ACD shutdown)

If sensor SQ40 is activated during the mobile grid’s encoder reset procedure it is deactivated and then ac-
tivated again to reset the encoder.
If sensor SQ40 is already deactivated, it is directly activated to reset the encoder. Shutdown may occur in
one of the two conditions:
If it is already activated and is not deactivated within the time out (SQ40 OFF).
If not already activated the sensor fails to be activated within the timeout and therefore the system is not reset.
Check operation of the transfer device, sensor SQ40, the direction in which motor M40 runs and drive U40.
Check the input card (module ID) (when the sensor is activated, input SQ40 should be on) and the leads/
connectors. Check the relay output card (when motor M40 has to work, led KA40E should come on) and
the leads/connectors.
2244 MOBILE GRID NOT IN PLACE (ACD shutdown)

If the mobile grid is installed but the cycle with the mobile grid stationary has been set, before starting the
filler-box return stroke, the system verifies the mobile grid is at a standstill at the set value + or - the toler-
ance (5 mm). If this condition is not satisfied, the machine shuts down.
Check drive U40, motor M40 and relay KA40E that should be activated to maintain motor M40 torque.
Check all the leads/connectors.
2245 GRID REPOSIT. TOO FAST (ACD shutdown)

The mobile grid reached the end of the return stroke during the filler-box return stroke. During this stroke
the grid should not move over the cavity as it may ruin loading. This happens if the speed of the grid is too
high compared to the filler-box speed.
Decrease the speed of the mobile grid or increase the filler-box speed.
2246 GRID REPOSIT. TOO SLOW (ACD shutdown)

The mobile grid performed the forward stroke and stopped in relation to the die-set during the filler-box
forward stroke. If it moves too slowly, the grid may go back over the cavity ruining the load.
Decrease the speed of the filler-box or increase the mobile grid speed.
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2247 CHECK (U40) (ACD shutdown)

With the inverter energized and reset, input U40 on the input card (module IUD) failed to come on.
Check the input card and leads/connectors.
2248 ACTUATOR/ENCODER (BQ40) (ACD shutdown)
After the grid has moved, no movement was detected within the set time.
Check relay KA40E, inverter U40 and encoder BQ40.
2261 FILLER-BOX OUTSIDE ALLOWABLE STROKE (parameter) (filler-box shutdown)
BQ2
The reading received from encoder BQ2 for the linear filler-box is either higher than the MAX value or lower
than the MIN value. These values can be seen/edited on the LOADING SET-UP page. If the settings are
correct, make sure the axis moves properly and that encoder BQ2 reads the position correctly.
SQ20AI
The linear filler-box reached the limit switch and energized sensor SQ20A (forward limit switch) or sensor
SQ20I (rear limit switch).
If this is not the case, check the efficiency of the sensor, its wiring and the relative digital input module.
2262 AXIS CONTROL FAULT (M20) (n) (filler-box shutdown)
The program that controls the linear filler-box (driven by motor M20) has detected a fault. Number n given
in parenthesis indicates the cause:
1 end-stop outside range
2 final position outside limits
3 peak speed outside range
4 acceleration null
5 peak acceleration outside range
6 ramp soft coefficients outside range
7 movement too long (> 30 sec.)
8 movement cannot be performed
50 excessive tracking error
51 emergency shutdown as end of stroke is reached
52 speed of part too high (> max speed + 20%)
54 position of part not allowed
Check drive U20. Make certain there are no obstacles or other interferences present that stop the forward
and return strokes from being properly performed.
Check all the data set or the part (forward-return stroke limit switch, speed, etc...) verifying that the required
movement can be carried out.
Only for SACMI personnel during start-up: make sure all the parameters for this part are properly set
(recommended values).
2263 FILLER-BOX REPOSIT. (filler-box shutdown)
The linear filler-box (driven by motor M20) has failed to reach the position set for the end of its return stroke
within 50 seconds.
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2264 HOLDING FOR PRESS-CYCLE START (KA306) (filler-box shutdown)
During the DIP automatic/semiautomatic cycle 50 seconds have elapsed from when the die-set completed
the downstroke and the DIP has not provided the signal for the plunger to move down. This occurs when
the DIP encoder (BQ30) detects a value less than the position set for the end of the return stroke (or less
that the approach position, if set).
2265 FILLER-BOX NOT IN PLACE (#) (filler-box shutdown)
Explanation of message:
The program checks the DCL filler-box’s encoder using microswitch/sensor SQ59. During the learning
cycle started by the operator, the value at which SQ59 is deactivated is saved during the filler-box forward
stroke. On the other hand, during the return stroke the position in which it is triggered is saved. During the
automatic cycle, it verifies that this value is observed within a tolerance of a few millimeters. As a result, if
the encoder does not read correctly the machine detects it and shuts down. The number given in brackets
to the right of the message indicates the error expressed in mm. If, for example, the parameter equals -35
and appears at the end of the filler-box return stroke, it means that: at the moment in which the filler-box
back was detected (SQ59), the filler-box encoder measured a value 35 mm lower than the one measured
during the learning procedure (in other words further back).
Actions to be taken:
Perform the ”SQ59 value learning procedure for filler-box encoder control” (see the “Description of the keys”
paragraph”).
This procedure must always be repeated if SQ59 is moved, if the encoder’s home position is changed or if
the speed of the filler-box is changed when near SQ59.
If the trouble persists, replace contactor KA59 and/or microswitch/sensor SQ59 and/or encoder BQ2 for
the filler-box.
2266 ENCODER FAILURE (BQ...) (filler-box shutdown)
A fault has been detected in the system which monitors the setting of a plunger encoder (the name of the
encoder is specified in brackets).
Check the encoder, connecting lead and relative encoder input card for proper functioning.
"BQ13" = absolute encoder, Die-set forward beam
"BQ31" = absolute encoder, Filler-box lifting, Right side
"BQ32" = absolute encoder, Filler-box lifting, Left side
"BQ34" = absolute encoder, ALM lifting
2267 ACTUATOR/ENCODER (BQ13) (filler-box shutdown)
1 sec. has elapsed since the beam movement signal was sent but the beam encoder value has not changed.
Check the encoder BQ13, its lock and the leads/connectors.
Check digital output KA12A (LED on = plunger moving), the related electrical wiring, inverter U12 and mo-
tor M12.
2281 CHECK (M2031/SQ2031B) (DIP shutdown)
The pallet did not reach the down end-stop (SQ2031B) or during the automatic cycle the sensor that detects
when the pallet is down was deactivated even if a signal for pallet upward movement was not given.
Sensor SQ2031B has to be activated within 1.5 sec. from the moment in which pallet downward movement
is triggered.
Make sure sensor SQ2031B, motor M2031, the input card (DI module) (slave 21) and the output card (RO
and AO modules) (slave 21) are in the right position and work properly. Check all the connecting cables/
connectors.
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2282 CHECK (M62X/Y) (DIP shutdown)
A fault has arisen in one of the motors employed to center the tiles (M622-M623-M624-M625-M626-M627-
M628).
The number of the motor is indicated for X. The value of Y indicates the type of fault that occurred:
1 = timeout to reach a new position
2 = tile centering timeout SQ2047
3 = drive set-up timeout
4 = alarm reset through the process channel timeout
5 = alarm reset timeout + ON through the process channel
6 = positioner software end-stop
Make sure the motor (M622-623, etc....) works properly and that there are no mechanical faults. In addition,
check all the cables/connectors.
2283 DRIVE FAILURE (M62X/Y/Z) (DIP shutdown)
A fault has arisen in one of the drives that actuate the motors employed to center the tiles (M622-M623-
M624-M625-M626-M627-M628).
The number of the motor is indicated for X. The value of Y indicates the type of fault that occurred:
1 = error inside positioner
2 = error outside positioner
3 = positioner warning
The value of Z is another indication provided by the drive.
If 0 it indicates a generic fault.
If other than 0 consul the specific manual that deals with the drive.
Make sure the motor (M622-623....) and all the cables/connectors work properly.
2284 FILLER-BOX NOT IN PLACE (#) (DIP shutdown)
Explanation of message: the program checks the DIP filler-box’s encoder using sensor SQ59. During the
learning cycle started by the operator, the value at which the sensor is deactivated is saved during the filler-
box forward stroke. On the other hand, during the return stroke the position in which it is triggered is saved.
During the automatic cycle, it verifies that this value is observed within a tolerance of a few millimeters. As
a result, if the encoder does not read correctly the machine detects it and shuts down. The number given
in brackets to the right of the message indicates the error expressed in mm. If, for example, the parameter
equals -35 and appears at the end of the filler-box return stroke, it means that: at the moment in which the
filler-box back sensor was activated (SQ59), the filler-box encoder measured a value 35 mm lower than the
one measured during the learning procedure (in other words further back).
Actions to be taken: perform the ”SQ59 value learning procedure for filler-box encoder control” (see the
“Description of the keys” paragraph”). If the trouble persists, replace contactor KA59 and/or sensor SQ59
and/or encoder BQ30 for the DIP.
2285 INCORRECT SETTING SQ2047 (M62x) (DIP shutdown)
Photocells SQ2047A-B-C, etc,, are not correctly assigned to motors M622-623, etc… The system is not
able to understand how to operate the motors to correctly center the tiles. An example may be: in a DIP
with 4 motors and set for 4 outputs, photocell SQ2047A was associated with more than one motor. This is
not possible.
Check the setting that determines how photocells SQ2047A-B-C, etc.. are associated to motors M622,623,etc…,
the number of motors enabled and set number of outputs.
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2286 SIDE BANDS OPEN (SQ2060A) (DIP shutdown)
Sensor SQ2060A has not detected that the mobile centering device’s side bands opened.
activated.
connectors.
2287 SIDE BANDS CLOSED (SQ2060A) (DIP shutdown)
Sensor SQ2060A is still activated even when the mobile centering device’s side bands should be closed.
Sensor SQ2060A was not deactivated within 1.5 sec from the moment in which solenoid valve YV2060 was
deactivated.
connectors.
2288 CHECK (SQ2047A-B-C-D....) (DIP shutdown)
The setting cycle for photocells SQ2038-2039 starts only when SQ2047 are deactivated (digital input off).
2301 DIE-SET NEEDLES NOT RETRACTED (SP13) (die-set shutdown)
Digital input SP13 (needle retraction pressure switch) is not ON with needle solenoid valve OFF (needles in).
2302 DIE NEEDLES NOT OUT (SP12) (die-set shutdown)
Digital input SP12 (needle extended pressure switch) is not ON with needle solenoid valve ON (needles out).
2303 UPPER DIE UPSTROKE (SQ341A/B) (die-set shutdown)
The upper die did not perform its upstroke by the timeout (5 sec).
Check the sensors that detect whether or not the upper die is up (SQ341A/B).
2304 UPPER DIE DOWNSTROKE (SQ344A/B) (die-set shutdown)
The upper die did not perform its downstroke by the timeout (5 sec).
Check the sensors that detect whether or not the upper die is down (SQ344A/B).
2305 UPPER DIE NOT DOWN (SQ344A/B) (die-set shutdown)
The upper die is not down.

Check the sensors that detect whether or not the upper die is down (SQ344A/B).
2306 UPPER DIE NOT UP (SQ341A/B) (die-set shutdown)
The upper die is not up.

Check the sensors that detect whether or not the upper die is up (SQ341A/B).
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2307 MOLCONTROL ERROR (die-set shutdown)
The Molcontrol device failed to complete its cycle by the end of the filler-box return stroke and therefore
before the next pressing stage with output KA421 high (die-set piston movement request). In fact, input
KA422 (die-set piston movement completed) is low.
2308 DIE-SET LOCK UPSTROKE NOT PERFORMED (die-set shutdown)
The upstroke of the main SPE pistons for securing the lock box has not been completed for one of the fol-
lowing reasons:
• excessive parallelism error between SPE right and left sides
• the encoder BQ4 does not indicate any movements or a movement smaller than 0.5 mm
The upstroke of the main SPE pistons for opening the lock box has not been completed for one of the fol-
lowing reasons:
2309 DIE-SET LOCK DOWNSTROKE NOT PERFORMED (die-set shutdown)
The downstroke of the main SPE pistons for adding thickness has not been completed for one of the fol-
lowing reasons:
The downstroke of the main SPE pistons for removing the pistons from the lock boxes has not been com-
pleted for one of the following reasons:
2310 SPE MOVEMENT DURING PLUNGER UPSTROKE (die-set shutdown)

SPE knockout has moved up by 2 mm during slow plunger upstroke.
2321 ADJUST WEDGE LIMIT SWITCHES (plunger shutdown)
Adjust wedge limit switches. With plunger up, input SQ12AB is high and input SQ12CD is low.
With wedges in, input SQ12AB is usually high and input SQ12CD is high.
With wedges out, input SQ12AB is usually low and input SQ12CD is low.
2322 OPEN THE SAFETY GUARDS OF THE PRESS-CYCLE ZONE (plunger shutdown)
Open the safety guards (bands) of the press-cycle zone so that the control system can check efficiency of
the sensors triggered by the mobile guard.
2323 INCORRECT WEDGE POSITION (SQ12ABCD) (plunger shutdown)
The alarm is displayed only if the two digital inputs of the plunger wedges are different:
SQ12AB is high, i.e. at least one wedge is not out, whereas SQ12CD is low, i.e. at least one wedge is not in.
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2324 COMMAND FOR OPENING YV513 GIVEN BUT SQ513 IS CLOSED (plunger shutdown)
The command for opening the logic element on the flange of the main piston (YV513) was given, but the
feedback (SQ513) indicates that the logic element is closed.
2325 COMMAND FOR CLOSING YV513 GIVEN BUT SQ513 IS OPEN (plunger shutdown)
The command for closing the logic element on the flange of the main piston (YV513) was given, but the
feedback (SQ513) indicates that the logic element is open.
2326 HIGH PRESSURE IN THE CYLINDER (plunger shutdown)
Cylinder pressure detected during oil heating (by means of pressure transducer BP1) is greater than 6 bar.
Oil heating is interrupted.
2341 SLID. PLATE NOT LOCKED (SQ331/2..) (fast die-set change shutdown)
At least one of the plate locking cylinders is not closed, therefore the sliding plate is not locked.
Check the sensors and the relative digital inputs.
For cylinder number 1:
SQ331A (cylinder 1 sensor open = plate unlocked)
SQ331C (cylinder 1 sensor closed = plate locked)
2342 SLID. PLATE NOT FORWARD (SQ33A) (fast die-set change shutdown)
The sliding plate is not close to the press.

Check the forward limit switch sensor (sliding plate SQ33A) and the relative digital input (input high = sliding
plate close to the press).
2343 SLID. PLATE NOT LOCKED (SP33) (fast die-set change shutdown)
Air not detected in the locking branch of the sliding plate.

The digital input SP33 is off (SP33 = pressure switch for checking the presence of air in the locking branch
of the sliding plate).
If air is present, check the pressure switch and the relative digital input.
2344 FILLER-B. LIFT. OUTSIDE RANGE (0.1 mm) (fast die-set change shutdown)
The height of the filler-box frame (detected by the absolute encoder BQ31 - filler-box lifting (right side) or
by the absolute encoder BQ32 - filler-box lifting, (left side) deviates by more than 0.1 mm from the relative
set-point for filler-box lifting value.
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2345 DIE-SET DETACHMENT (KA221/223) (fast die-set change shutdown)
The control unit of the magnetic lock with permanent magnets indicates the die-set has been detached.
The input KA221 is off or the input KA223 is off.
2346 HOPP. LIFT. OUTSIDE RANGE (1 mm) (fast die-set change shutdown)
The height of the ALM hopper frame (detected by the absolute encoder BQ34 - ALM hopper lifting) deviates
by more than 1 mm from the relative set-point for ALM hopper lifting value.
2347 MAGNET/DEMAGNET OF FAST DIE-S. CHANGE NOT COMPLETED (fast die-set change shutdown)
With fast die-set change and mode selector in AUT or MAN or if FAST DIE-SET CHANGE has not been set,
the magnetization/demagnetization of fast die-set change plate has not been completed.
2348 DIE-SETS NOT MAGNETIZED (KA221/223) (fast die-set change shutdown)
With fast die-set change device and the following conditions:

upper and lower plates magnetized, mode selector to AUT or MAN, or NO STEP OF QUICK DIE-SET
CHANGE-OVER set, one or more digital inputs that activate the plunger KA221–KA223 (signals coming
from the control unit for magnetic lock) are not on.
Check the control unit for magnetic lock AP800, try to demagnetize and magnetize the die-set top and bot-
tom. Check the connecting cables and connectors.
If the problem persists, contact Sacmi customer service department.
2349 UPPER DIE-SET NOT PRESENT (KA225) (fast die-set change shutdown)
With fast die-set change and mode selector in AUT or MAN or if FAST DIE-SET CHANGE has not been
set, with upper plate magnetized, the input KA225 (upper die-set present, signal coming from the control
unit of the magnetic lock) is low. The input KA227 (die-set detachment, signal coming from the control unit
of the magnetic lock) is low.
2350 LOWER DIE-SET NOT PRESENT (KA226) (fast die-set change shutdown)
with lower plate magnetized, the input KA226 (lower die-set present, signal coming from the control unit of
the magnetic lock) is low. The input KA227 (die-set detachment, signal coming from the control unit of the
magnetic lock) is low.
2351 CONTR.UN. FAILURE, DIE-SET MAGN. PLATE (KA224) (fast die-set change shutdown)
With fast die-set change and mode selector in AUT or MAN or if FAST DIE-SET CHANGE STAGE has not
been set, the input KA224 (general failure in the control unit of the magnetic layers) is low.
2352 BEAM NOT AT THE END OF RETURN STROKE (BQ13) (fast die-set change shutdown)
With fast die-set change if FAST DIE-SET CHANGE has not been set, the beam is not in home position
(detected by BQ13 beam absolute encoder).
2353 BEAM PISTONS OT FULLY DOWN (SQ72AB) (fast die-set change shutdown)
With fast die-set change if FAST DIE-SET CHANGE has not been set, the lifting pistons are not down (de-
tected by input SQ72AB = sensor for die-set lifting pistons. The die-set is down).
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2354 UPPER DIE-SET NOT MAGNETIZED (fast die-set change shutdown)
the upper plate is not magnetized.
2355 LOWER DIE-SET NOT MAGNETIZED (fast die-set change shutdown)
the lower plate is not magnetized.
2356 FILLER-BOX GUIDES UNLOCKED (fast die-set change shutdown)
With fast die-set change if FAST DIE-SET CHANGE has not been set, "FILLER-BOX GUIDES UNLOCKED"
= YES.
2357 DIE-SET ON SUPPORTS (SQ71A/B) (fast die-set change shutdown)
With fast die-set change, the die-set is on the supports (detected by input SQ71AB = die-set on beam, the
input is high) and the lower plate is magnetized.
2358 SEL. FOR MAG./DEMAG ENABLED (SA8) (fast die-set change shutdown)
With fast die-set change, the input SA8 (selector to enable plate mag.- demag. for fast die-set change) is
low, e.g. mag/demag enabled.
2359 CHECK CONTACTORS KA105A/B (fast die-set change shutdown)
The system has found an inconsistency between the state of the input that controls the contactors KA105A.
KA105B and the conditions for which they should be energized or de-energized (filter time is 2 sec).
Contactors should be energized in the following conditions: with the selector SA8 for magnetization/demag-
netization to "on" and output KA216A energized (a magnetization/demagnetization procedure has been
requested).
Make sure these contactors are not energized when a magnetization/demagnetization procedure is not in
progress and with the quick die-set change-over device set to NO.
Check the contactors KA105A-KA105B, the selector SA8, the relay KA216A, the module AJ100 and the
related expansions, the connecting cables and connectors.
2360 REPEAT UPP. MAGNETIZATION (KA224A) (fast die-set change shutdown)

upper plate magnetized, mode selector to AUT or MAN or no step of quick die-set change-over set,
the digital input KA224A (signal coming from the control unit for magnetic lock) is not on.
Check the control unit for magnetic lock AP800, try to demagnetize and magnetize the die-set top. Before
magnetization, try also to turn the control unit off and on. Check the connecting cables and connectors.
2361 CONTACTS STUCK IN CONTACTOR, RPR ROLLER CONVEYOR (KM5012) (RPR shutdown)
The feedback of roller conveyor motor is active (digital input KM5012 high) with motor control de-activated
(relay OKM5012 output is off).
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2362 RPR ROLLER CONVEYOR NOT WORKING (KM5012) (RPR shutdown)
The feedback of roller conveyor motor is not active (digital input KM5012 low) with motor control active
(relay OKM5012 output is on).
2363 CONTACTS STUCK IN CONTACTOR, RPR ROLLER CONVEYOR (KM5013) (RPR shutdown)
The feedback of roller conveyor motor for the turner is active (digital input KM5013 high) with motor control
de-activated (relay OKM5013 output is off).
2364 RPR ROLLER CONVEYOR NOT WORKING (KM5013) (RPR shutdown)
The feedback of roller conveyor motor for the turner is not active (digital input KM5013 low) with motor control
active (relay OKM5013 output is on).
2365 CHECK INPUT SENSOR, RPR TURNER (SQ5041) (RPR shutdown)
The turner input sensor (digital input SQ5041) has been active for too long.
2366 ROTATION TIMEOUT, RPR TURNER (KM5014/SQ5008) (RPR shutdown)
RPR turner rotation was not completed within the maximum allowable time.
If rotation does not take place, check the turner rotation motor, controlled by relay OKM5013 output.
If rotation takes place, check the turner rotation sensor (digital input SQ5008 should be on when the turner
is horizontal).
2367 SAFETY DEVICE OF OVERLOAD CUTOUT TRIGGERED (QM5032) (RPR shutdown)
The control on the safety device of the overload cutout has been activated. Check the digital input QM5032
(safety device of the overload cutout) that turns off in case of faults.
2381 REPEAT LOWER MAGNETIZATION (KA224B) (fast die-set change shutdown)

lower plate magnetized, mode selector to AUT or MAN or no step of quick die-set change-over set,
the digital input KA224B (signal coming from the control unit for magnetic lock) is not on.
Check the control unit for magnetic lock AP800, try to demagnetize and magnetize the die-set bottom. Be-
fore magnetization, try also to turn the control unit off and on. Check the connecting cables and connectors.
2382 UPP. DIE-SET DETACHMENT/DIE-SET NOT PRESENT (KA225) (fast die-set change shutdown)
With the upper die-set magnetized, the magnetization/demagnetization control unit has found a die-set
detachment (magnetic flow control), even very short, or the sensor that detects die-set is off.
This faulty condition is transferred to the system with the trigger pulse KA225: this digital input is off.
This control is active with the mode selector turned to MAN or AUT and when the quick die-set change-over
device set to NO.
Check the magnetization/demagnetization control unit AP800, try to demagnetize and magnetize the up-
per die-set. Check the connecting cables and connectors. If the problem persists, contact Sacmi customer
service department.
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2383 LOW. DIE-SET DETACHMENT/DIE-SET NOT PRESENT (KA226) (fast die-set change shutdown)
With the lower die-set magnetized, the magnetization/demagnetization control unit has found a die-set de-
tachment (magnetic flow control), even very short, or the sensor that detects die-set is off.
This faulty condition is transferred to the system with the trigger pulse KA226: this digital input is off.
This control is active with the mode selector turned to MAN or AUT and when the quick die-set change-over
device set to NO.
Check the magnetization/demagnetization control unit AP800, try to demagnetize and magnetize the lower
die-set. Check the connecting cables and connectors.
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13.4 STOPPAGE MESSAGES
3001 DIE-SET HEATER NOT ENERGIZED (EHn) (stoppage)
The heater for a part of the die-set is on but the spool is deactivated. The faulty heater is given in brackets.
Example: (EH5) means that relay output KM5 is on but digital input KM5 is off.
Check the contacts of the contactor for the faulty heater (KM5 in the example) that may not close correctly.
If the heater is fed at the mains voltage, along with checking the contacts of the contactor for the faulty
heater (KM5L in the example), check the automatic switch (FS5L in the example) and the connector on the
die-set (XJ5EH in the example).
3005 CONTACTS STUCK IN CONTACTOR (KMn) (stoppage)
The heater is off but feedback is on. The identification number of the faulty feedback is given in parenthesis.
Example: (KM5) means that relay output KM5 is off but digital input KM5 is on.
Check the contactor of the faulty heater (KM5 in the example) whose contacts may not open correctly.
If the heater is fed at the mains voltage, check the contactor of the faulty heater (KM5L in the example). The
main switch for the press electrical cabinet trips 5 minutes after this fault message is displayed.
3009 DIE-SET TEMP.TOO HIGH > 75°C (BTn) (stoppage)
One of the thermocouples that reads the die-set temperature has found that the temperature is too high,
over 75°C. The identification number of the thermocouple is given in parenthesis.
If the temperature is not actually so high, try replacing the thermocouple and/or analog input module con-
nected to the thermocouple. The main switch for the press electrical cabinet trips 5 minutes after this fault
message is displayed.
3011 POWDER LEVEL SENSORS DEACTIVATED (stoppage)
ACP has moved too often without activating the powder level sensor in the hopper during the wait cycle for
automatic restart when powder is missing and while waiting for ACP movement to be completed.
For program versions 21,23,26: make sure input 7 of digital input module AP603A_(ID01) is not jumped (in
the cabinet).
3012 REMOTE CYCLE STOPPAGE (stoppage)
'Formula' has given the remote command for stopping the cycle.
3013 BRUSH NOT WORKING (KM2A/KM2B) (stoppage)
Feedback digital input KM2 is off after a signal for brush rotation has been sent (KM2A or KM2B = ON).
Check the thermal cut-out and contactors KM2A and KM2B.
Check the input card (input KM2 must be closed when the motor is running) and the leads/connectors.
Check the output card (Led KM2A or KM2B must be on when the motor has to run) and the leads/connectors.
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3014 LACK OF POWDER IN HOPPER (stoppage)
Digital input AD1 or AD2 (SL2 in the case of filler-box for double loading or in the case of trigger pulse from
color loading that goes to a digital input (SL2) in the cabinet) is off.
Check the powder level in the hopper.
Check level sensor SL2, the input card (Led AD1/2 must come on when the powder exceeds the maximum
level) and the leads/connectors.
With DCP type filler-box, if the powder is over the level and led AD1/2 is off, adjust sensitivity of the powder
detector amplifier (AD1).
3015 EXTERNAL STOP (KA300) (stoppage)
Digital input KA300 is off.

The line after the press has stopped.
Check signal KA300.
If the line after the press has not stopped, check the input card (when the line is running Led KA300 must
3016 STOP PUSH-BUTTON (stoppage)
The automatic cycle stop push-button (located on the keyboard) has been pressed.
If it has not, check the keyboard power cord.
If the cord is properly plugged in and is not broken, try replacing the control KEYBOARD.
3017 STOP.DUE TO EXT. SYNCH. (KA301) (stoppage)
The outer synchronization contact has remained closed (when the filler-box starts its travel) for more than
the maximum allowable time (2 minutes).
Check contact KA301, the input card (Led KA301 must be off when the press is running) and the leads/
connectors.
3018 BATCH COMPLETED (stoppage)
The production batch has been completed as set for the “PRODUCTION BATCH” data item.
3019 PLUNGER UPSTR.HELP STROKE NOT REACHED (stoppage)
During plunger lightening, the plunger stopped (its speed is equal to 0 mm/s) before completing the set
“PLUNGER UPSTROKE HELP STROKE” but the die-set did not reach the top; this means that the pressure
relief valve (482) is not properly set therefore the die-set is not able to push the plunger up.
The lightening cycle is interrupted.
Check plunger lightening solenoid valve YV481 and the setting of upstroke chamber pressure relief valve 482.
3020 DECREASE FILLER-BOX FORWARD SPEED (stoppage)
Decrease the speeds set for the forward steps of the filler-box. This needs to be done because in order to
reach the set forward time the GAIN for opening the filler-box’s proportional valve (shown on the ACTUAL
LOADING VALUES page) has dropped to a value that is 45 less.
If the problem persists, check proportional valve for the filler-box YV20.
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3021 INCREASE FILLER-BOX FORWARD SPEED (stoppage)
Increase the speeds set for the forward steps of the filler-box. This needs to be done because in order to
LOADING VALUES page) has gone over 255.
3022 PLUNGER LEAKS (stoppage)
The plunger has moved down more than 5 mm (2 mm if DIP or double loading are used) in relation to the
value set for PLUNGER UP during the loading cycle. YV31S is energized to move the plunger back up. If
the message is displayed when the cycle is NOT in progress it means YV104 is faulty or plunger leakage
is no longer remarkable.
3023 THICKNESS ERROR (stoppage)
Incorrect tile thickness has been detected with the automatic thickness control.
If the thickness measured does not correspond to the actual thickness, check the plunger encoder, its mount
With SMU: Check the automatic filling height control, motor M9 and contactors KM9A/KM9B, the relay
output card (either output KM9A or KM9B has to be activated when the filling height is adjusted) and the
leads/connectors.
With 2 + 2 or 4-cylinder proportional knockout: Check the axis card and encoders BQ4/5.
3024 CHECK THERMOCOUPLE (BTn) (stoppage)
The die-set heater is on but the temperature read does not increase.
The identification number of the faulty thermocouple that reads the die-set temperature is given in parenthesis
Check the connections of the thermocouple (if it reads the room temperature it may have slipped out of the
die-set, or the 2 thermocouple wires may have shorts) or the 2 thermocouple wires may be reversed. Make
sure the heating elements are properly fed. Make sure that 2 thermocouples have not been reversed.
3025 WRONG DIE-SET OP.(A=..., B=...) (stoppage)
At the filler-box start the value of one or both die-set encoders has exceeded the top limit switch setting
(FCA) by more than 0.4 mm or has fallen below the FCA setting by more than 0.6 mm. When a proportional
rod lift system is used, the value read by encoder BQ4A for the proportional ejector is given in parenthesis.
3026 DIE-SET THERMOCOUPLE DISCONNECTED (BTn) (stoppage)
One of the thermocouples that read the die-set temperature is not connected. The identification number of
the faulty thermocouple is given in parenthesis.
3027 DECREASE FILLER-BOX RETURN SPEED (stoppage)
Decrease the speeds set for the return steps of the filler-box. This needs to be done because in order to
LOADING VALUES page) has dropped to a value that is 45 less.
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3028 INCREASE FILLER-BOX RETURN SPEED (stoppage)
Increase the speeds set for the return steps of the filler-box. This needs to be done because in order to
LOADING VALUES page) has gone over 255.
3029 RPR ROLLER CONVEYOR NOT WORKING (stoppage)
RPR roller conveyors are still.

The line after the press has stopped or the rate of the tiles feeding the turner is greater than the time required
to complete its rotation, or the selector SA5001 is not in running position.
Check signal KA300.
Switch the selector SA5001 to start the roller conveyors.
3030 PUMP STOP PUSH-BUTTON (stoppage)
The pump stop button on the keyboard has been pressed.

If it has not, check the keyboard power cord. If the cord is properly plugged in and is not broken, try replac-
ing the control KEYBOARD.
3031 LOW PRESSURIZATION/FILTER (SP3) (stoppage)
Digital input SP3 is off.

Check the suction filter of the main pump.
Make sure the pressurization pressure is sufficient.
Check the digital input card and the leads/connectors.
3032 CLEANING (stoppage)
Machine stopped by the operator from the STOPS page.
3033 DIE-SET CHANGE (stoppage)
3034 SCHEDULED MAINTENANCE (stoppage)
3035 UNSCHEDULED MAINTENANCE / REPAIRS (stoppage)
3036 CHECK TILE/ADJUST MACHINE (stoppage)
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3037 PAUSE/WORKSHIFT CHANGE (stoppage)
3038 OTHER CAUSES (stoppage)
3040 DIE-SET NOT DOWN (stoppage)
One of the die-set cylinders moved more than 2 mm while the proportional knockout was being hooked.
Repeat the procedure for hooking the proportional knockout.
3041 PLUNGER LEAKS (stoppage)
The plunger moved by more than 2 mm while the proportional knockout was being engaged.
3042 OIL LEAK RECOVERY (KM3) (stoppage)
Output KM3 is energised but feedback digital input KM3 is off.

The oil leak recovery motor has failed.
Input KM3 must be closed when the motor is running.
Check the input card and the leads/connectors.
Check the output card (when the motor has to run, output KM3 must be activated) and the leads/connectors.
3043 FILLER-BOX NOT BACK (stoppage)
The filler-box is further back than the value set for the END OF THE RETURN STROKE when the plunger
starts to move down or the ALM begins its forward stroke. Bring the filler-box into the correct position.
3044 FILL.-BOX NOT IN AUTO./NO POWDER (SL2) (stoppage)
Input SL2 is off.

This may be the powder level signal arriving from the filler-box not provided by Sacmi or an indication that
the filler-box not provided by Sacmi is not in automatic mode.
3045 REPLACE BRUSH (stoppage)
The brush bristles have worn down to the maximum allowable extent set on the FITTINGS SET-UP page.
Change the brush, press Reset and restart the machine.
3046 FILLER-BOX SENSOR (SQ59) (stoppage)
If the fault message is displayed at cycle start, the limit switch/sensor SQ59 is not active after the filler-box
has been repositioned. When the filler-box is fully forward (after the first downstroke, if a double loading
filler-box is used) during the automatic or semi-automatic cycle, limit switch/sensor SQ59 is activated. Check
the limit switch/sensor for filler-box backward and the relative digital input card.
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3047 OIL CHANGE TIMEOUT (stoppage)
The oil in the pad was not changed within 180 seconds.
3048 PAD PISTONS FULLY DOWN (stoppage)
The pressure in the booster (BP204) failed to reach 90% of the pressure reached during the previous cycle
while waiting to reach the CYLINDER PRESS.AT DIFF. CYCLE START value.
3049 FILLER-BOX FORWARD CYCLE TIME (stoppage)
The time taken for the forward stroke of the linear filler-box differs by more than 10% from the set time (more
than 20% of the set time in the case of a DCP filler-box).
Set the correct time for the filler-box forward stroke. If the press does not have to shut down, enter FILLER-
BOX CONTROL ON = NO or TIME CONTROL = NO.
3050 TEMPERATURE TOO HIGH (ST115)/AIR CONDITIONER FAULT (stoppage)
Thermostat ST115 (or series-connected thermostats) have detected the temperature inside one of the elec-
trical control cabinets is too high.
The input may be:
ST114 DCL filler-box electrical control cabinet

ST115 electrical control cabinet
ST116 DIP filler-box electrical control cabinet
ST117 ACD filler-box electrical control cabinet
ST118 DCP filler-box electrical control cabinet
3051 BOOSTER AT END-STOP (n bar, m) (stoppage)
The external flow/pressure booster has reached the end of its stroke. The cylinder pressure and the press-
stroke actually performed at the moment in which the fault arose are indicated in the fault message.
If “REPOS.” is displayed it means the booster may not have been put back into the proper position.
3052 FILLER-BOX RETURN CYCLE TIME (stoppage)
The time taken for the return stroke of the linear filler-box differs by more than 10% from the set time (more
than 20% of the set time in the case of a DCP filler-box).
Set the correct time for the filler-box return stroke. If the press does not have to shut down, enter FILLER-
BOX CONTROL ON = NO or TIME CONTROL = NO.
3054 SPE BALANCING TIMEOUT (stoppage)
During the SPE balancing cycle, the die-set failed to reach the end of its stroke within 10 seconds: encoders
BQ4 and BQ5 have not read a value < 0.8 mm.
3055 LUBRICATION NOT PERFORMED (SP130) (stoppage)
Twenty cycles have been completed without being lubricated.
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3056 OIL LEAK RECOVERY (KM10) (stoppage)
With the oil leak recovery unit motor of the isostatic/differentiated pressing active (OKM10 activated), input
KM10 (oil leak recovery unit motor spool) is deactivated.
3057 MIN. ISOSTATIC PRESS. NOT REACHED (stoppage)
During the last press-stroke, the pressure of the isostatic booster (measured by transducer BP204) has not
reached the set minimum pad pressure 3 times during a period of 10 cycles. Check operation of proportional
solenoid valve YV100 and the valves in question. Check pressure transducer BP204 and wiring.
3058 SLOW PAD DECOMPRESS.-OIL LEAK (stoppage)
Pad decompression was not completed with a timeout of 5 seconds because all the oil inside the pad did
not return to the booster and the latter failed to reach the value the control system determines based on the
set precharge strokes. Check operation of proportional solenoid valve YV100 and the valves in question.
Check encoder BQ11 and relative wiring.
3059 LUBRICATION NOT PERFORMED (SP131) (stoppage)
Plunger guides have not been lubricated on the left side: therefore the cycle is stopped.
If PLUNGER GUIDES are to be LUBRICATED, the sensor SP130 has not detected a sufficient grease flow.
3060 LUBRICATION NOT PERFORMED (SP130/SP131) (stoppage)
Plunger guides have not been lubricated on the left side and on the right side: therefore the cycle is stopped.
If PLUNGER GUIDES are to be LUBRICATED, the sensors SP130/SP131 have not detected a sufficient
grease flow.
3066 SUCTION SYSTEM FAULTY (KA314) (stoppage)
The trigger pulse for suction operation indicates that suction is faulty (digital input KA314 open).
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13.5 ALARMS (MESSAGES WHICH REQUIRE MANDATORY ACTIONS)
6001 SEE PROFIBUS ADDRESS n DIAGNOSTICS (alarm)
The slave with address n has signaled an error.

Communication is not down therefore the machine can continue to run but it is necessary to go to the Profibus
diagnostics page. Select Extended Diagnostic for slave number n, identify the error and take the necessary actions.
Some typical errors that cause this alarm are given below:
Die-set heater thermocouple cable broken, analog input/output cable broken, I/O module not correctly installed.
6002 DIE-SET CHANGE PISTONS DOWN (SQ72A-B) (alarm)
When the absolute encoder BQ13 (die-set forward beam) is to be reset, the die-set lifting pistons are not
down (digital input SQ72AB off). Check the sensors that detect whether the die-set lifting pistons are down.
6003 SEE DIE-SET CHANGE DIAGNOSTICS (alarm)
The fast die-set change system is malfunctioning. Consult the corresponding description on the page for fast die-set change.
6004 SET PASSWORD (alarm)
Set the password provided by Sacmi in settable data item PASSWORD. The related page can be reached
by pressing F8 twice on INFO page.
6005 OPEN THE SAFETY GUARDS OF THE PRESS-CYCLE ZONE (alarm)
When the plunger absolute encoders are to be reset, the wedges are out (in work position) with the control
(YV313) for wedges/hooks movement active (control for wedges out): open the safety guards of the press-
cycle zone so that the wedges can be retracted.
6006 HAVE PLUNGER GUIDES LUBRICATED (SP130/SP131) (alarm)
A given number of cycles has elapsed after the last lubrication of plunger guides (right and left sides), there-
fore a new lubrication is to be performed.
Executed lubrication is detected by the sensors SP130/SP131.
6007 HAVE PLUNGER GUIDES LUBRICATED (SP130) (alarm)
A given number of cycles has elapsed after the last lubrication of plunger guides (right side), therefore a
new lubrication is to be performed.
Executed lubrication is detected by the sensor SP130.
6008 HAVE PLUNGER GUIDES LUBRICATED (SP131) (alarm)
A given number of cycles has elapsed after the last lubrication of plunger guides (left side), therefore a new
lubrication is to be performed.
Executed lubrication is detected by the sensor SP131.
6009 OPERAT.NOT ALLOWED: MOVE PLUNGER DOWN (alarm)
The plunger should be down for magnetization to be performed.
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13.6 INFORMATION MESSAGES
4001 CYCLE TIME GREATER THAN SYNCH.TIME (message)
The time required for the press to perform a complete cycle is greater than the time set for a synchronized
cycle. The number of cycles per minute set cannot be carried out.
4002 WAIT FOR SYNCH.TIME (message)
The press is stationary and is waiting for the internal synchronization time to elapse.
4003 WAIT FOR EXTERNAL SYNCH. (message)
The press is stationary and is waiting for external synchronization contact KA301 to open.
4004 LOADING CORRECTION NOT ALLOWED (message)
Loading cannot be corrected as the die-sets are not down.

On the other hand, if they are down, it means the automatic thickness correction of the base has reached
a saturation value. Make certain the displayed TILE THICKNESS corresponds to the measured one, vice
versa set the thickness as directed on page PRESS-CYCLE SETTINGS.
4005 DIE-SET TEMP.>65°C RISK OF BURNS (BTn) (message)
One of the thermocouples that reads the die-set temperature has found that the temperature is too high, over
65°C. The identification number of the thermocouple is given in parenthesis. The message, which appears
only if the press is not cycling, informs the operator that the temperature measured is considered dangerous
if the part is touched without wearing protective gloves.
4006 CHECK DIE-SET HEATER SETTINGS (n) (message)
The data set for the die-set heater are not consistent. Go to page DIE-SET HEATING and check the data
on the line whose number is given in brackets to the right of the message.
4007 ADJUST CYLINDER PRESS.TRANSDUCER (message)
The reading of the cylinder pressure transducer, expressed in bar, was not correct when the pump shut off.
Perform special operation number 30 (adjust cylinder pressure transducer).
4008 PROPORTIONAL VALVES CLEANING IN PROGRESS (message)
The press will start the automatic cycle as soon as the operation in progress has been completed.
4009 F-BOX FORW.RUN TIME (message)
The time taken for the filler-box to perform its forward stroke differs from the set value (FILL.-BOX FWD
TIME) by more than 5%.
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4010 FILLER-BOX RETURN TIME (message)
The time taken for the filler-box to perform its return stroke differs from the set value (FILLER-BOX RETURN
TIME) by more than 5%.
4011 OIL TEMPERATURE (message)
The temperature of the oil is less than 30°C. If the safety guards in the press-cycle zone are open, under
these conditions, the oil will automatically be heated up by solenoid valve YV11R. It is possible to stop the
oil from being heated by closing the safety guards in the press-cycle zone and pressing the Reset key on
the control keyboard.
In PH3200 oil heating procedure is performed with YV318 and YV19.
In presses with pneumatic lock disengaged, the procedure is enabled also with safety guards closed, pro-
vided the mode selector is in SET-UP.
4012 ERROR FROM AXES CARD (message)
An error was detected when data were exchanged with card AXP. The cases are examined below:
(1) DSP fault: after command = 0, the state is not 0
(2) DSP fault: after command = 4, the state is not 1
(3) DSP fault: after command = 4, the error is not 0
(RD) data reception (side A and side B offset) not completed within max. time of 1 sec.
4013 CYCLE SLOWED DOWN BY (name) (message)
With axis synchronization enabled, this message indicates that the maximum production speed cannot be
reached. The parameter to the right of the message indicates which press axis is in question: the parameter
(name) may be one of the following: DIP, RODS, SMU, SPE, LOWER DIE, SFS.
4014 WAIT FOR END OF MOBILE HOPPER CYCLE (message)
The press is stationary and is waiting for the ALM to stop moving.
4015 THICKNESS ERROR (message)
Incorrect tile thickness has been detected with the automatic thickness control. The error falls within the set
maximum threshold and 63% of the value.
4016 POWDER UNDER DIE-SET (message)
With 2 + 2 or 4-cylinder proportional knockout: the value of one or both encoders is between 0.3 mm
and 0.6 mm during the press-cycle. Check the axis card and encoders BQ4/5.
4017 CHECK PLUNGER SETTING (message)
This message is displayed after a program has been read. Go to the PRESS-CYCLE SET-UP page and
check the data in the square that deals with the PLUNGER.
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4018 OIL HEATING (KM180/19) (message)
The signals to start the motor of the pump that heats up the additional oil (output KM180 on) and the ad-
ditional oil heater (output KM 19 on) are enabled. Wait until the oil temperature is higher than 6 °C before
starting the main pump.
4019 DIE-SET HEATER NOT ON (message)
If the heater feedback (KM5/6/7/8) drops with an ON signal, all the heaters are shut off. To turn them back
on, press the reset button and set DIE-SET HEATING ENABLE = YES. This message indicates that the
heaters were turned off by the program because the data item was set to NO.
4020 FILLER-BOX FORWARD (message)
A semi-automatic ALM cycle was requested with the filler-box forwards. Move the filler-box fully back and
try again.
4021 SAFETY BAR UP (message)
The safety bar has been raised.

If the message appears when the safety bar is down, press the Reset key. If the message remains on the
screen, check limit switches SQ11A/B/C/D for secure mounting and proper operation and the leads/connectors.
This message only appears if the leds for the 2 digital inputs are on with mode selector SA9 turned to
MANUAL or AUTOMATIC.
4022 FILLER-BOX ENCODER NOT RESET (message)
Carry out an automatic resetting cycle to zero set the filler-box encoder.
See the SETTING AND RESETTING DATA page.
4023 DIE-SET ENCODER NOT RESET (message)
Carry out an automatic resetting cycle to zero set the die-set encoder.
4024 PLUNGER ENCODER NOT RESET (message)
Bring the plunger into the desired 0 position (carry out movements with the key turned to SET-UP) and
perform the reset procedure. See the SETTING AND RESETTING DATA page.
4025 FILLER-BOX SAFETY GUARDS (SQ66A) (message)
The filler-box has been moved from its seat. Make sure limit switches SQ66/SQ66A are correctly installed
and efficient.
Check SQ66, the input card (if SQ66 is a lever-type limit switch, the digital input is open with filler-box con-
nected; if SQ66 is magnetic, the digital input is closed with filler-box connected) and the connecting cables/
connectors.
Check safety module AJ101.
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4026 WAITING FOR TILE FROM PRESS (message)
The DIP is waiting to receive the tile from the precompacting press (photocells SQ41, SQ42 and SQ43 are all off).
4027 WAIT FOR AUTO.RESTART (KA300) (message)
The press is in standby ready to start automatically. No trigger pulse has been sent from the next machine
in line (KA300). When the trigger pulse is emitted the machine will restart.
4028 WAITING FOR TILE IN LOADING POS. (message)
The DIP is waiting for the tile to reach the position in which the die-set is loaded.
4029 FILLER-BOX SENSOR (KA59) (message)
During the downward movement of the plunger the outputs are not energized due to back filler-box sensor SQ59.
4030 INCORRECT PRESSING (message)
The pressure reached during the last press-stroke deviates more than 15 bar in relation to the set value. If
the message continues to appear check the solenoid valves for the press-stroke; in non proportional presses
YV19, YV41 and YV38, pressure transducer BP1, the leads/connectors.
In proportional presses, solenoid valve YV318 and the related hydraulic lines.
4031 CHECK HEAT EXCHANGER (message)
HEAT EXCHANGER = NO has been set on the FITTINGS SET-UP page but the feedback digital input
KM11A of the heat exchanger is on.
4032 PLUNGER LEAKS (message)
The plunger is kept up by the automation program’s logic array because otherwise it would move down to
rest on the die-set because of too much leakage.
Check the cylinder seal and the hydraulic lines for the downstroke.
4033 WAIT (message)
Wait before performing any machine operation.
4034 DIE-SET NOT LOCKED (message)
The proportional knockout is not locked.

Lock the die-set.
4035 CENTERING DEVICE ENCODER NOT RESET (M62X) (message)
The encoders of the DIP centering devices (M622-M623-M624 - M628) have to be reset whenever the system
is turned on. The message informs the user that this procedure needs to be carried out.
X indicates the last digit of the number of the motor that needs to be reset.
See the chapter that deals with the keyboard to perform this procedure.
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4036 ALM ENCODER NOT RESET (message)
Zero set the ALM encoder.

4037 ROLLER CONVEYOR SAFETY GUARDS (SQ53) (message)
The roller conveyor has been moved away from the press.
Check miniature switches SQ53A/SQ53B, the relative digital input card (with the roller conveyor in the work
position, digital input SQ53A should be off) and the leads/connectors.
4038 SELF-LEARNING IN PROGRESS (message)
The press is carrying out the self-learning cycle to calculate the offset values for the proportional valves
(YV32, YV318). Turn the mode selector switch to stop the cycle.
4039 YV32 OFFSET VALUE TOO HIGH [O/D/S] (message)
The offset values for YV32, determined during the self-learning procedure, are too high.
If (S) appears on the right side of the message it means the upstroke offset value is too high.
(D) appears to signal the downstroke offset value is too high.
(O) appears to signal the zero offset value is too high.
Carry out the self-learning cycle again with hot oil. If the message is still displayed, replace YV32 (plunger
proportional solenoid valve).
4040 PRESSURE TRANSDUCER (BP5) (message)
While the plunger was moving up, the value, expressed in bar read by the pressure transducer in the upstroke
chamber is < 10 bar, or it is higher than a value expressed in bar calculated by the program (however > 20
bar) at the end of the last press-stroke. Check pressure transducer BP5 and its connections.
4041 BOOSTER ENCODER NOT ZERO SET (BQ11) (message)
Bring the booster to the desired 0 position (with the key turned to SET-UP) and carry out the reset procedure.
4042 BOOSTER ENCODER NOT RESET (message)
Carry out the automatic procedure to reset the encoder for the external flow/pressure booster.
4043 BOOSTER AT END-STOP (message)
The pressure/flow booster has reached the end of the stroke at almost the end of the press-stroke. The
cylinder pressure and the press-stroke actually performed at the moment in which the fault arose are indi-
cated in the fault message.
If “REPOS.” is displayed it means the booster may not have been put back into the proper position.
4044 PERFORM LAST DIE-SET DOWNSTR. (message)
Turn the mode selector to either MAN or SET-UP and carry out a die-set downstroke in manual mode. The
press can be set to automatic or semi-automatic mode only once this has been done.
If the message is still displayed, replace the AX card.
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4045 YV100 OFFSET TOO HIGH [0/A/R] (message)
The offset values for YV100 determined during the self-learning procedure are too high.
If (A) appears to the right of the message it means the offset value for the forward stroke is too high.
If (R) appears it means the offset value for the return stroke is in question.
If (0) appears it means the zero offset is in question.
Carry out the learning procedure with hot oil. If the message is still displayed, replace YV100 (isostatic circuit
proportional solenoid valve).
4046 OIL BEING CHANGED (message)
The oil in the pad is being changed.
4047 PAD DECOMPRESSION IN PROGRESS (message)
The pad decompression cycle is in progress.
4048 WAITING FOR D.I.P. SIGNAL (KA311) (message)
The press is waiting to receive the D.I.P ready trigger pulse KA311.
The press will start cycling as soon as it is received (input KA311 high).
If this does not happen, make sure this signal is provided from the D.I.P.’s electrical cabinet.
4049 YV70D FAULTY VALVE (message)
During decompression at the end of the last press-stroke in which proportional solenoid valve YV70D is
open, its spool that should read 100% (that corresponds to the valve completely open), actually reads a value
below 80%. Check proportional solenoid valve YV70D, the spool signal sent from it and the connections.
4050 YV21P OFFSET TOO HIGH (message)
The offset value calculated during the self-learning procedure for the ejector with rods is too high. If (D) ap-
pears to the right it means the message regards the downstroke offset value, if (S) appears it regards the
upstroke offset value. The ejector with rods may not be working properly.
4051 ACP ENCODER NOT RESET (message)
Zero set encoder ACP on the SETTING AND RESETTING DATA page.
4052 WAITING FOR PRELOAD AT START OF PRESS-STROKE (message)
Wait until pad preloading has been completed.
4053 COLUMN LUBRICATION IN PROGRESS (message)
The grease pump motor has been started (relay output KM130 on).
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4054 CLEAN PROPORTIONAL VALVES (n) (message)
A problem has been detected while cleaning proportional solenoid valves YV32/YV318/YV70D during the
self-learning procedure. Parameter n identifies the type of problem:
1 Pressure in cylinder over 10 bar.
2 Plunger moved down (encoder BQ6 has exceeded 5 mm).
6 External booster moved more than 10 mm.
4055 MODEM CONNECTION (message)
The modem port is hooked up. Remote assistance can be activated.
4056 CYCLE WITHOUT PRESSING (message)
The press allows the tiles coming from the DIP to pass without pressing. To press them, set the relative data
item on the page used to set the DIP data items.
4057 REDUCE PRESS 1 CYCLES (message)
The precompacting press is too fast. Slow it down for example by setting it to synchronized mode.
4058 ADJUST REDUCER 31 (YV307) (message)
The booster’s stroke measured during the 1st press-stroke is more than 40 mm greater than the ideal stroke
for the 1st press-stroke. Adjust reducer 31. To correctly adjust, see data item "BOOSTER STROKE DIF-
FERENCE” shown on the PRESS-CYCLE page.
4059 DIP GUARDS OPENED (SQ69 - SQ70) (message)
SQ69-SQ70:
The DIP guards are opened: input SQ70 (D.I.P. safety barrier interlock) is on or input SQ69 (upstream cen-
tering system safety guards limit switch) is on.
SQ2070:
The DIP guards are opened: input SQ2070 (D.I.P. safety barrier interlock) is on in the case of microswitch
with plug, it is off with a magnetic microswitch.
4060 TILE NOT PRESENT (message)
A request has been made to eject a damaged tile but the tile has not been detected (SQ43 off).
Do not start sensor setting if SQ2047 (or SQ2042) are not active.
4061 WAIT MOBILE GRID REPOSIT. (message)
This message is displayed only if the mobile grid is installed.

When the filler-box is fully back, this fault message is displayed if the mobile grid has not finished moving
back into position.
4062 ENCODER NOT ZERO SET (BQ40) (message)
This message is displayed only if the mobile grid is installed.

The encoder for the mobile grid BQ40 is not reset. Perform the encoder reset procedure (see machine
control keyboard page). When this message is displayed, only slow steady movements can be carried out
(see machine control keyboard page).
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4063 ACP2 ENCODER NOT RESET (message)
The ACP2 encoder is not reset. Perform the encoder reset procedure (see machine control keyboard page).
When this message is displayed, only slow steady movements can be carried out (see machine control
keyboard page). If DOUBLE LOADING = NO this message is not displayed as the system assumes ACP2
is either not present or not used.
4064 ENCODER MDR2 NOT RESET (message)
The MDR2 encoder is not reset. Perform the encoder reset procedure (see machine control keyboard page).
If DOUBLE LOADING = NO or TYPE OF CONTROL VALVE other than 2 is set, this message is not displayed
as the system assumes MDR2 is either not present or not used.
4065 WAITING FOR COLOR HOPPER FILLING (message)
After the filler-box has completed the return stroke, the powder level is checked before the color hopper
gate opens.SL25 should be on. If the correct level is not present the color ACP is given a certain amount of
time (max. 20 sec.) to fill the hopper. This message is displayed during this time.
4066 WAIT FOR ACP2 TO STOP (message)
If WAIT ACP2 STOP = YES is set on the color acp2 page, if the color acp2 has not stopped when the filler-box
reached the end of the return stroke, the machine waits for acp2 to stop before the hopper gate is opened.
4067 PERFORM LEARNING PROCEDURE (SQ59) (message)
The self-learning procedure for the value at which the filler-box back limit switch (SQ59) is activated/deacti-
vated needs to be carried out. Keep in mind that this operation can be selected as“SQ59 value learning for
filler-box encoder control” as described in paragraph “DESCRIPTION OF THE KEYS”.
4068 DCL GUARDS OPENED (SQ54) (message)
The safety guards for the filler-box have been opened: the digital input connected to limit switch SQ54 (filler-
box gate interlocking device) has been de-activated.
Digital input SQ54 is activated with filler-box DCL 667/677/976/422/922/924 provided with mobile guards
and magnetic limit switches.
4069 FAILED LEARNING (n) (message)
The procedure for setting the current control for the magnetic lock has not been successfully completed
as the new calculated resistance differs from the one measured during the previous learning procedure by
more than 0.5 ohm. The resistance that has just been calculated, expressed in ohm, is given in parenthesis.
Make sure the correct response has been entered for “IS IT THE FIRST TIME SETTING THE DEVICE?
HAS THE DIE-SET BEEN CHANGED?” that appears when the procedure is selected.
Check the circuits of the magnetic lock and the connections.
4070 OIL TEMPERATURE HIGH (message)
Thermocouple BT4 has detected that the oil temperature is over 50°C, the press continues working.
In any case, it is not advisable to work at these temperatures.
Make sure the devices that cool down the oil work efficiently.
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4071 ROW STOPPED ON RPR: PUMP NOT STOPPED (message)
The external stop signal (input KA300) arrived between first downstroke start-up and the end of the time set
for KA300 DELAY FROM 1ST DOWNSTROKE X ENERGY SAVINGS on the FITTINGS SETTING page.
It was sent when the first downstroke started. The energy savings cycle is disabled until the next external
stoppage takes place.
4072 WEDGES NOT RETRACTED (message)
The conditions to retract the wedges are satisfied but the machine waits until the plunger is up to prevent
the hook from rubbing against the plunger’s strut throughout its entire movement.
If the message is still displayed after 1 min it means that the wedges could not be inserted because the
plunger is not raised.
Zero set the absolute encoder of die-set forward beam (BQ13).

Zero set the absolute encoder of filler-box lifting (right side) (BQ31).
Zero set the absolute encoder of filler-box lifting (left side) (BQ32).
4077 WAIT FOR AUT. RESTART (SL2) (message)
The wait cycle for automatic restart when powder is missing has been activated and the powder level probe
in the hopper indicates that powder is missing: the optical alarm is activated.
4078 DIE-SET CHANGE-OVER FILLER-BOX IN POSITION (SQ74A/B) (message)
The press does not start in automatic mode when the sensors for the presence of the die-set change-over
filler-box are active.
Zero set the absolute encoder of ALM hopper lifting (BQ34).

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4094 THE FIRST DEAERATION IS DISABLED (message)
Cycle start has been requested but the first deaeration is disabled: the tiles might not be properly formed.
Presses with on/off hydraulic system:

Set DEAERATION PLUNGER STROKE greater than 0.5 mm or set DEAERATION UPSTROKE = 100.
Presses with proportional hydraulic system:

Set DEAERATION PLUNGER STROKE greater than 0.5 mm.
4095 PAD LOADING CYCLE IN PROGRESS/SELECTED (message)
The cycle for pad introduction with DIP has been selected, therefore this message is displayed at cycle start.
4096 PAD ALREADY IN LOADING POSITION (message)
The command for inserting the pad in the DIP roller conveyor was given but the photocells SQ2039 A-B-C...
= ON detect that the pad is already present.
Therefore go to the next step: inserting the pad in the press.
4097 PAD NOT IN LOADING POSITION (message)
The command for inserting the pad in the PH with the DIP was given but the photocells SQ2039 A-B-C... =
OFF and SQ2038 A-B-C... = OFF detect that the pad is not present.
Therefore perform the previous step, i.e. insert the pad in the DIP roller conveyor.
4098 PAD TOO BACK, PERFORM STEP 2 (message)
The command for inserting the pad in the PH with the DIP was given but the photocells SQ2038 A-B-C... =
ON detect that the pad is present but too back.
Therefore the pad should be inserted in the DIP roller conveyor.
4099 REMOTE CONTROL ENABLED (message)
Press automation indicates to 'Formula' that controls and data setting are remote.
4100 REMOTE CYCLE START (message)
'Formula' has given the remote command for starting the cycle.
4101 SAFETY GUARDS OF THE PRESSING ZONE OPEN (message)
The safety guards of the pressing zone are open:

Press the Reset button if the message is displayed with the safety guards of the pressing zone closed (in
work position). If the message remains on the screen, check limit switches SQ11A, SQ11B, SQ11C, SQ11D
for secure mounting and proper operation and the leads/connectors.
This message is displayed if the two digital inputs SQ11AB and SQ11CD are high, with the mode turned to
MAN or AUT.
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4102 PLUNGER NOT FULLY UP (message)
When the plunger absolute encoders are to be reset, the wedges are out (in work position) but the control
(YV313) for wedges/hooks movement is off (control for wedges in).
4103 MOV. NOT ALLOWED IN FAST DIE-SET CHANGE (message)
Movements cannot be performed in fast die-set change.
4104 DCL CHECKS NOT ENABLED IN FAST DIE-SET CHANGE (message)
The press is performing the automatic cycle and the selection of use excludes the checks on the devices
for fast die-set change installed on the filler-box.
4105 BEAM CHECKS NOT ENABLED IN FAST DIE-SET CHANGE (message)
for fast die-set change installed on the press.
4106 BEAM/DCL CHECKS NOT ENABLED IN FAST DIE-SET CHANGE (message)
for fast die-set change.
4107 TILES TOO CLOSE TOGETHER (RPR) (message)
The turner input sensor (digital input SQ5041) is activated with a row of tiles which is still fed or with turner
rotation in progress. The roller conveyors are stopped.
4108 ADJUST. NOT ALLOWED IN PLUNGER DOWNSTROKE (message)
Manual braking adjustment is not allowed during plunger upstroke.
4109 REAR HOOD INEFFICIENT IN QUICK DIE-SET CHANGE-OVER SYSTEM (SP14) (message)
The pressure switch installed on the rear suction hood of the quick die-set change-over system indicates
that the suction system is faulty (digital input SP14 open).
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13.7 LOCAL MESSAGES
0101 WRITE ERROR (message)
An error has been found in file “PROGRAM.MEM” in the automation personal computer.
0102 PROGRAM NOT AVAILABLE (message)
A program number already used has been selected when writing a program.
0103 WRONG PROGRAMMED DATA (message)
An error was found in the program CRC while a program was being written.
0104 INVALID PROGRAM NUMBER (message)
The number selected when reading, writing or cancelling a program is not valid.
0105 BLANK PROGRAM (message)
A blank program has been selected when reading a program.
0110 ERROR DURING PRINTING (message)
Make sure the printer is properly hooked up to the machine controller, power is supplied and that it is ON-LINE.
0111 OPERATION NOT ALLOWED (message)
A program cannot be read if the machine is set to RESETTING or CYCLE
0115 PROFIBUS ERROR: (###) (message)
Error in activating / deactivating the PROFIBUS master card slaves.
The number given in parenthesis may be:

110 = firmware read error
111 = firmware version < 1.090
112 = Profibus Master card not operative
If the message is still displayed after restarting the system, replace the Profibus master card.
If the message appears again, contact the Customer Service Department - SACMI IMOLA.
0116 PROFIBUS ERROR: (RUN.F=0) (message)
Error in booting the Profibus master card. Profibus master card status is not “run”.
Make sure the card is present and installed correctly. If the message is still displayed after restarting the
system, replace the Profibus master card.
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0117 PROFIBUS ERROR: (READY.F=0) (message)
Make sure the card is present and installed correctly. If the message is still displayed after restarting the
system, replace the Profibus master card.
0118 PROFIBUS ERROR: (INIT.F=1) (message)
Make sure the card is present and installed correctly. If the message remains after restarting the system,
replace the PROFIBUS master card.
0119 MISSING FILE. DBM (message)
The profibus file for the selected machine configuration was not found in the automation PC. The parameter
identifies the name of the missing file. For example:
if (10) appears to the right of the message it means file PH10.DBM is missing.
if (0) appears to the right of the message it means the machine configuration is not foreseen.
0120 MEMORY READ (message)
This message appears for a few seconds when the machine is turned on.
0121 INVALID CONFIGURATION DATA (message)
If this message appears when the machine is turned on, contact the CUSTOMER SERVICE DEPT - SACMI
IMOLA.
0122 INVALID DATA AFTER CONFIGURATION READ (message)
IMOLA.
0123 SACMI BMOS V.3.X - MINIMUM BMOS V.3.Y (message)
At least a BMOS v.3.Y operating system has to be installed in order to run the program.
Check the version. If it is earlier than 3.Y, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA. If this
is not the case, shut off the system and then turn it back on.
0124 CHECK CONFIGURATION (message)
IMOLA.
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0125 CARD AX: <parameter> (message)
When the system was turned on a fault was detected in card AXP (located inside box 1 on board the press).
There are several cases, depending on the value of the <parameter> that appears to the right of the message:
(Read) No. (X)
firmware version of card AXP not successfully read within 1 sec.
(Write) No. (X)

card AXP parameters not successfully set within 5 sec. The data item (X) that appears to the right is the
number of the parameter.
WRONG TYPE = (X)

When checking the data arriving from the AXP card the system has detected that the type of module installed
is not correct; the type detected is given in brackets.
If the problem persists after shutting off the machine and then turning it back on, replace the card.
WRONG VERS.= (X)

When checking the data arriving from the AXP card the system has detected that the firmware version is
not correct; the version found is given in brackets.
If the problem persists after shutting off the machine and then turning it back on, replace the card.
MODULE NR. 1/2 WRONG TYPE = (X)

When checking the data arriving from the AX card the system has detected that one of the 2 modules is
wrong; the type detected is given in brackets.
If the problem persists after shutting off the machine and then turning it back on, replace the module.
MODULE NR. 1/2 WRONG VERS.= (X)

When checking the data arriving from the AX card the system has detected that the firmware of one of the
2 modules is wrong; the firmware detected is given in brackets.
If the problem persists after shutting off the machine and then turning it back on, replace the module.
0126 WAIT (message)
The configuration is being written.
0127 ERROR DURING CONFIGURATION WRITE (message)
An error was found when writing the configuration in file “CONFIG.MEM” in the automation personal computer.
0128 CONFIGURATION READ TIMEOUT (message)
Timeout to read configuration from file “CONFIG.MEM” in the automation personal computer.
0129 CONFIGURATION WRITE TIMEOUT (message)
Timeout to write the configuration in file “CONFIG.MEM” in the automation personal computer.
0130 FILE ERROR: x (message)
An error has been found when reading file “config.mem” in the automation personal computer.
For the meaning of parameter x see message 1015.
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0131 RESTART AUTOMATION PERSONAL COMPUTER (message)
Shut off power in order to download the selected new configuration.
0132 AX PROTOCOL (message)
The type of protocol used to exchange data with the AX card needs to be changed.
The following number may appear to the right:
0 protocol compatible with version 1.01 of card AX
1 protocol compatible with version 1.02 of card AX
0133 FIRMWARE FBM V01.081 (message)
When the Profibus master card was booted, the system found that the wrong firmware version is installed.
In fact, at least the version indicated on the line below the message, to the right of “minimum”, must be
installed example MINIMUM V01.208.
If the message is still displayed after restarting the system, replace the Profibus master card.
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13.7.1 LOCAL ALARMS - FAST DIE-SET CHANGE
1 MODE SELECTOR NOT TO AUT
The mode selector is either in MAN or SET-UP position: turn it to AUT.
2 SAFETY MODULE AJ101 OFF
The safety module is not armed: set the safety guards of the press-cycle area to work position and press
the Reset button. The fault is detected by digital input AJ101 (safety module for mobile guards of the press-
cycle area) that is off.
3 AVAILABLE
4 PLATE NOT BACK (SQ33I OFF)
The sliding plate is not back: bring it to the rear end-stop. The fault is detected by digital input SQ33I (rear
end-stop sensor for sliding plate) that is off.
5 MODE SELECTOR NOT IN SET-UP
The mode selector is either in MAN or AUT position: turn it to SET-UP.
6 PUMP OFF
The main pump (driven by M1) is off: run it.
7 DIE-SET CHANGE FILLER-BOX NOT IN PLACE
The die-set change filler-box is not in the correct position: move it until it rests on the press. The fault is
detected by digital input SQ74AB (sensor for die-set change filler-box present) that is off.
8 SPE ENCODERS NOT LOCKED
At least one of the two SPE encoders is not locked: lock the SPE encoders.
The fault is detected by digital input SQ4 (sensor for SPE encoder unlocked, series-connected with SQ5)
that is on.
9 SPE PISTONS ARE NOT DOWN
The pistons of the SPE knockout are not fully down: bring them down. The fault is detected by at least one of
the encoders BQ4 or BQ5. It has detected a value greater than the maximum allowable value with encoders
locked or a value increase greater than the maximum allowable value with encoders not reset.
10 CONTROL FOR DIE-SET CONTIN. ACTION NOT PRESSED
The continuous action button found on the left of the keyboard, identified with SB11, has not been pressed:
press it.
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11 DIE-SET LIFTING PISTONS NOT DOWN
Die-set lifting pistons are not down: move them down.

The fault is detected by digital input SQ72AB (sensor for die-set lifting pistons down) that is off.
12 DIE-SET LIFTING PISTONS NOT UP
Die-set lifting pistons are not up: move them up.

The fault is detected by digital input SQ73AB (sensor for die-set lifting pistons up) that is off.
13 BEAM MOVEMENT FAULTY
The movement of the beam for fast die-set change is faulty. The cause might be: problem in encoder BQ13,
inverter U12 faulty, direction operation of the beam reversed, beam forward/backward limit switch.
14 DIE-SET NOT PRESENT
The die-set is not present (this is detected by the knockout encoder value which exceeds a given limit).
15 PLUNGER ENCODER NOT RESET
The plunger encoder (or the plunger encoders) is not reset: reset plunger encoder.
16 THE PLUNGER HAS MOVED UP
The plunger has moved up in a step of die-set change where it did not have to move up (detected by means
of the value of encoder BQ6).
17 CHECK REQ.-UPP. DIE-SET PRESENCE SENS. (KA228)
During magnetization of the upper die-set, the system requires the sensor for die-set presence to be to
deactivated and activated again for safety reasons. The system requires the check to be performed when
the digital input KA228 is off.
If this is not mechanically possible, reset with the keyboard and repeat the magnetization operation. If the
problem persists (the input KA228 remains off), check the magnetization/demagnetization control unit AP800,
check the trigger pulse KA228, check the connecting cables/connectors.
Contact Sacmi customer service department if the possible causes are not found.
18 CHECK REQ.-LOW. DIE-SET PRESENCE SENS. (KA228)
During magnetization of the lower die-set, the system requires the sensor for die-set presence to be to
deactivated and activated again for safety reasons. The system requires the check to be performed when
the digital input KA228 is off.
If this is not mechanically possible, reset with the keyboard and repeat the magnetization operation. If the
problem persists (the input KA228 remains off), check the magnetization/demagnetization control unit AP800,
check the trigger pulse KA228, check the connecting cables/connectors.
Contact Sacmi customer service department if the possible causes are not found.
19 AVAILABLE
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20 NO AIR (SP33)
No air: this is detected by the digital input SP33 (pressure switch for checking the presence of air in the
locking branch of the sliding plate) that is off.
21 PLATE NOT UNLOCKED (SQ331/2/3/...)
1. The wait phase for sliding plate unlock was too long, and the following digital inputs did not become low:
SQ331C (cylinder 1 sensor, closed = plate locked), SQ332C for cylinder 2, SQ333C for cylinder 3, SQ334C
for cylinder 4, SQ335C for cylinder 5, SQ336C for cylinder 6, SQ337C for cylinder 7, SQ338C for cylinder
8.
2. The plate is locked. This is detected by one of the digital inputs type SQ331C (cylinder 1 sensor, closed
= plate locked) that is closed. The same happens for the following inputs: SQ332C for cylinder 2, SQ333C
for cylinder 3, SQ334C for cylinder 4, SQ335C for cylinder 5, SQ336C for cylinder 6, SQ337C for cylinder
7, SQ338C for cylinder 8.
22 PLATE MOVEMENT MOTOR (KM33)
Failure of the plate movement motor, detected by the digital input KM33 (motor M33 control feedback, sliding
plate movement motor) that is off.
23 PLATE BACK-UP TIMEOUT
1. The wait phase for back movement of filler-box and sliding plate completed was too long, SQ33I (rear
end-stop sensor for sliding plate) is still off.
2. The wait phase for back movement of sliding plate for de-activating the plate forward sensor was too
long, SQ33A (front end-stop sensor for sliding plate) is still high.
24 PISTON DOWNSTROKE TIMEOUT (SQ72A/B OFF)
The wait phase for die-set lifting pistons down was too long with lifting pistons not down, detected by input
SQ72AB (sensor for die-set lifting pistons) that is still low.
25 BEAM FORWARD TIMEOUT
The wait phase for beam forward was too long without seeing any beam movements.
26 PISTON LIFTING TIMEOUT (SQ73A/B OFF)
1. The wait phase for die-set lifting pistons up was too long with lifting pistons not up as SQ73AB (sensor
for die-set lifting pistons, on = die-set up) is still low.
2. The wait phase for pistons up and die-set on supports (during die-set lifting) was too long and lifting
pistons are not up. This is detected by digital input SQ73AB (sensor for die-set lifting pistons, on = die-set
up) that is still low.
27 DIE-SET NOT PRESENT (SQ71A/B OFF)
The wait phase for pistons up and die-set on supports (during die-set lifting) was too long and lifting pistons are
up. This is detected by digital input SQ71AB (die-set present on beam, on = die-set present) that is still low.
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28 BEAM BACKWARD TIMEOUT
The wait phase for beam backward was too long without seeing any beam movements.
29 DIE-SET DOWNSTROKE TIMEOUT (SQ72A/B OFF)
The wait phase for lifting pistons down was too long and lifting pistons are not down. This is detected by
digital input SQ72AB (sensor for die-set lifting pistons, on = die-set down) that is still low.
30 DIE-SET DOWNSTROKE TIMEOUT (SQ71A/B ON)
The wait phase for pistons down and die-set not on supports (during die-set downstroke) was too long and
lifting pistons are up. This is detected by digital input SQ71AB (die-set present on beam, on = die-set pres-
ent) that is still low.
31 WEDGES NOT RETRACTED
The wedges are not retracted.
32 UPP. MAGNETIZATION TIMEOUT (KA217 OFF)
The wait phase for upper magnetization completed was too long and digital input KA217 (feedback of mag-
netized upper plate) is still low.
33 LOW. MAGNETIZATION TIMEOUT (KA219 OFF)
The wait phase for lower magnetization completed was too long and digital input KA219 (feedback of mag-
netized lower plate) is still low.
34 AVAILABLE
35 DIE-SET ON SUPPORTS (SQ71A/B ON)
The die-set is on the supports. This is detected by the digital input SQ71AB (die-set present on beam, on
= die-set present) that is high.
36 DIE-SET NOT ON SUPPORTS (SQ71A/B OFF)
The die-set is not on the supports. This is detected by the digital input SQ71AB (die-set present on beam,
on = die-set present) that is low.
37 BEAM REPOSITIONING TIMEOUT
The wait phase for beam in home was too long without seeing any beam movements.
38 SPE ENCODER ZERO TIMEOUT
The phase, that checks whether the SPE encoder zero was read, was too long and unsuccessful.
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39 BEAM MOVEMENTS FAULTY (U12)
Beam movements are faulty: the digital input U12 (inverter/motor M12 feedback) is off.
40 AVAILABLE
41 DIE-SET NOT UNLOCKED
The data item 'die-set locked' is set to YES.
42 UPP. DEMAGNETIZATION TIMEOUT (KA218 OFF)
The wait phase for upper demagnetization completed was too long and digital input KA218 (feedback of
demagnetized upper plate) is still low.
43 LOW. DEMAGNETIZATION TIMEOUT (KA220 OFF)
The wait phase for lower demagnetization completed was too long and digital input KA220 (feedback of
demagnetized lower plate) is still low.
44 PLATE NOT LOCKED (SQ331/2/3/...)
1. The wait phase for sliding plate piston lock was too long, and the following digital inputs did not become
high: SQ331C (cylinder 1 sensor, closed = plate locked), SQ332C for cylinder 2, SQ333C for cylinder 3,
SQ334C for cylinder 4, SQ335C for cylinder 5, SQ336C for cylinder 6, SQ337C for cylinder 7, SQ338C for
cylinder 8.
2. The plate is not locked. This is detected by one of the digital inputs type SQ331C (cylinder 1 sensor, closed
= plate locked) that is low. The same happens for the following inputs: SQ332C for cylinder 2, SQ333C for
cylinder 3, SQ334C for cylinder 4, SQ335C for cylinder 5, SQ336C for cylinder 6, SQ337C for cylinder 7,
SQ338C for cylinder 8.
45 AVAILABLE
46 PLATE NOT FORWARD (SQ33A OFF)
The sliding plate is not close to the press. This is detected by digital input SQ33A (forward end-stop sensor
for sliding plate) that is low.
47 FILLER-BOX LIFTING MOTOR (KM31)
Failure of filler-box lifting motor: after the activation command for M31 (motor for adjusting filler-box height
on the right side), the digital input KM31 (motor M31 control feedback) is off.
48 FILLER-BOX LIFTING MOTOR (KM32)
Failure of filler-box lifting motor: after the activation command for M32 (motor for adjusting filler-box height
on the left side), the digital input KM32 (motor M32 control feedback) is off.
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49 MAX MISALIGNM.,FILLER-B. LIFTING (15 mm)
The difference between the value of BQ31 (absolute encoder, filler-box lifting on the right side) and of BQ32
(absolute encoder, filler-box lifting on the left side) is greater than 15 mm.
50 HOPPER LIFTING MOTOR (KM34)
Failure of ALM lifting motor: after the activation command for M34 (motor for adjusting ALM height), the
digital input KM34 (motor M34 control feedback) is off.
51 SIMULT. ACTION OF KEYS NOT RESPECTED (SB10)
The continuous action control on the die-set remote control panel has been pressed for more than 3 sec.
and no other buttons have been pressed. Detected by digital inputs KA10A (N.O. contact, button to enable
movements with continuous action, on = button pressed) high and KA10B (N.O. contact, button to enable
movements with continuous action, off = button pressed) low.
52 ENCODER BQ31 DOES NOT COUNT/COUNTS DOWN
After the activation command for M31 (motor for adjusting filler-box height on the right side), the value of
BQ31 (absolute encoder of filler-box lifting on the right side) does not change or counts down.

After the activation command for M32 (motor for adjusting filler-box height on the left side), the value of BQ32
(absolute encoder of filler-box lifting on the left side) does not change or counts down.
After the activation command for M34 (motor for adjusting ALM height), the value of BQ34 (absolute encoder
of ALM lifting) does not change or counts down.
55 AVAILABLE
56 HOPPER LIFTING END STOP
As BQ34 (absolute encoder for ALM lifting) speed is zero, it is assumed that the end stop for hopper lifting
was reached.
57 SIMULT. ACTION OF KEYS NOT RESPECTED (SB11)
The continuous action control on the control panel has been pressed for more than 3 sec. and no other
buttons have been pressed.
Detected by digital inputs KA111B (N.O. contact, button to enable movements with continuous action, on =
button pressed) high and KA111A (N.O. contact, button to enable movements with continuous action, off =
button pressed) low.
58 BEAM FORWARD LIMIT SWITCH (SQ112A)
During beam movement (M12) the forward limit switch was reached: the digital input SQ112A (limit switch
sensor for die-set change beam, off = forward limit switch) is off.
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59 BEAM BACKWARD LIMIT SWITCH (SQ112I)
During beam movement (M12) the backward limit switch was reached: the digital input SQ112I (limit switch
sensor for die-set change beam, off = backward limit switch) is off.
60 UNLOCK FILLER-BOX GUIDES
The data item 'filler-box guides unlocked' is set to NO.
61 FILLER-BOX NOT IN DIE-SET CHANGE POS.
With DCL:
the filler-box is not IN die-set change position (the encoder value is greater than the value set for 'DCL filler-
box position during fast die-set change).
With DIP:
the DCL (or DIP) filler-box encoder has a value greater than the value for the backward limit switch which
has been set.
62 AVAILABLE
63 LOWER DEMAGNETIZATION NOT PERFORMED
The movement is not allowed as the lower die-set is not demagnetized.
64 BEAM NOT IN ZERO POSITION
The beam is not in zero position: the value of BQ13 (beam absolute encoder) is other than 0.
65 LOWER MAGNETIZATION NOT PERFORMED
The movement is not allowed as the lower die-set is not magnetized.
66 PLUNGER NOT IN DIE-SET CHANGE POS.
The beam is not in die-set change position: the value of the encoder BQ6 is too high.
67 TIMEOUT, HOPPER LIFTING POSITIONING
The wait phase for repositioning ALM lifting was too long.
68 TIMEOUT, FILLER-BOX LIFTING POSITIONING
The wait phase for repositioning filler-box lifting was too long.
69 AIR PRESENCE (SP33)
Compressed air presence: the digital input SP33 (pressure switch for checking the presence of air in the lock-
ing branch of the sliding plate) is high. No compressed air should be present when moving the sliding plate.
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70 TIMEOUT, PLATE FORWARD
The wait phase for moving the sliding plate forward and activate the related sensor was too long and the
sliding plate did not reach PH (SQ33A - the forward end-stop sensor for sliding plate is still low).
71 DIE-SET NOT DOWN
The die-set (as detected by the encoders BQ4 and BQ5) is not down: move it fully down.
72 BEAM NOT ON LIMIT SWITCH
The beam for die-set change is not on one of the two limit switches, as detected by BQ13, beam absolute
encoder.
73 BEAM DIRECTION OF OPERATION REVERSED
After the command for beam movement, the movement occurs in the direction opposite to that expected,
as detected by BQ13 (beam absolute encoder).
74 HEATING CABLES NOT DISCONNECTED
Disconnect the connectors of the die-set heating cables.
75 MAG./DEMAG SELECTOR NOT ENABLED (SA8)
the input SA8 (selector to enable plate mag.- demag. for fast die-set change) is high, e.g. mag/demag disabled.
76 PRESS. IN PLUNGER UPSTROKE CHAMBER > 20 BAR
Pressure in plunger upstroke chamber is high (detected by BP5, pressure transducer for plunger upstroke
chamber).
77 WEDGES NOT OUT
The wedges are not out.
78 UPPER DIE-SET ALREADY MAGNETIZED
The operation is not performed as the upper die-set is already magnetized.
79 LOWER DIE-SET ALREADY MAGNETIZED
The operation is not performed as the lower die-set is already magnetized.
80 UPP./LOW. DIE-SET ALREADY MAGNETIZED
The operation is not performed as the upper and lower die-sets are already magnetized.
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81 UPPER DIE-SET ALREADY DEMAGNETIZED
The operation is not performed as the upper die-set is already demagnetized.
82 LOWER DIE-SET ALREADY DEMAGNETIZED
The operation is not performed as the lower die-set is already demagnetized.
83 UPP./LOW. DIE-SET ALREADY DEMAGNETIZED
The operation is not performed as the upper and lower die-sets are already demagnetized.
84 DIE-SET PROPERLY MAGNETIZED
The magnetization procedure was properly completed.
85 DIE-SET PROPERLY DEMAGNETIZED
The demagnetization procedure was properly completed.
86 MAGNETIZATION IN PROGRESS
The magnetization procedure is in progress.
87 DEMAGNETIZATION IN PROGRESS
The demagnetization procedure is in progress.
88 DIE-SET INSTALLATION IN PROGRESS
The die-set installation procedure is in progress.
89 DIE-SET REMOVAL IN PROGRESS
The die-set removal procedure is in progress.
90 DIE-SET PROPERLY PLACED
The die-set installation procedure was properly completed.
91 DIE-SET PROPERLY REMOVED
The die-set removal procedure was properly completed.
92 DIE-SET LOCKING IN PROGRESS
The die-set locking procedure is in progress.
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93 DIE-SET UNLOCKING IN PROGRESS
The die-set unlocking procedure is in progress.
94 DIE-SET LOCKED
The die-set locking procedure was properly completed.
95 DIE-SET PROPERLY UNLOCKED
The die-set unlocking procedure was properly completed.
96 DIE-SET CHANGE FILLER-BOX IN PROGRESS
The procedure for setting up the automatic die-set change of the filler-box is in progress.
97 HOPPER EMPTYING IN PROGRESS
The hopper emptying procedure is in progress.
98 FILLER-BOX SET-UP COMPLETED
The procedure for setting up the automatic die-set change of the filler-box was properly completed.
99 FILLER-BOX REPOSITIONING IN PROGRESS
The procedure for repositioning the filler-box after die-set change is in progress.
100 FILLER-BOX REPOSITIONING COMPLETED
The procedure for repositioning the filler-box after die-set change was properly completed.
101 PISTON PRESSURE RESET IN PROGRESS
The procedure for resetting piston pressure is in progress.
102 RELEASE THE BUTTON AND DRAIN
Release the continuous action button (SB11) and drain lifting pistons.
103 DIE-SET ALREADY PRESENT (KA226)
The operation cannot be performed because the die-set is already present (KA226 - lower die-set pres-
ence - up).
104 DIE-SET NOT PRESENT (KA226)
The operation cannot be performed because the die-set is not present (KA226 - lower die-set presence - down).
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105 LIFT. PISTONS NOT UP WITH DIE-SET PRESENT
The lifting pistons are not up (detected by the digital input SQ73AB = sensor for die-set lifting pistons up,
sensor off) and the die-set is on the supports (detected by the input SQ71AB, die-set on beam, that is high).
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13.8 MAINTENANCE MESSAGES
5001 REPLACE FILTER (SP1) WITHIN n h (message)
Make sure that the filters in the hydraulic power unit are not clogged.
Check pressure switch SP1, the input card (Led SP1 must be on when the filters are not clogged) and the
leads/connectors. The number given to the right indicates the number of hours in which the pump can con-
tinue running with the filter clogged.
NOTE: To clear the message, turn the key selector on the keyboard to SET-UP and press the RESET key.
The parameter may be SP4 for the DCP filler-box proportional solenoid valve filter, SP5 for the SPE filter,
SP6 for the Enea cooling filter, SP7 for the press-cycle control assembly filter and SP8 for the differentiated
press-cycle filter.
5002 SCHEDULED MAINTENANCE (80 h) (message)
This message appears after the main pump has operated for 80 hours.
The maintenance operations which are described in the INSTRUCTIONS MANUAL need to be performed.
NOTE: To clear the message, turn the key switch on the machine control keyboard to “SET-UP” and press
the Reset key.
See message no. 5002.
5007 REPLACE DIE-SET (message)
The die-set has already carried out the number of cycles set for the “NO. CYCLES DIE-SET DURATION”
data item on the DIE-SET SET-UP page. It needs to be replaced.
NOTE: The message is cleared by turning the key selector on the machine control keyboard to position
SET-UP and pressing the Reset key after entering the values for "NO. OF CYCLES DIE-SET LIFE" and
"NO. OF CYCLES PERFORMED" regarding the die-set installed.
To permanently disable this maintenance message, set NO. CYCLES DIE-SET LIFE = 0.
5008 SCHEDULED MAINTENANCE (6,000,000 CYCLES) (message)
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5010 AT END OF BATCH LOAD PROGRAM NO. (message)
Perform the operation requested by the controller.
5011 GREASE LEVEL LOW (SQ130) (message)
Grease level low sensor SQ130 has detected the grease level is low (digital input SQ130 off) 4 seconds
after the grease pump motor started running (relay output KM130 on).
5012 LUBRICATION NOT PERFORMED (SP130) (message)
Two minutes have gone by since sensor SP130 was activated or sensor SP130 has not been activated for
at least 500 ms or has not been activated at all.
5013 CHECK ALM CABLES (10,000,000 CYCLES) (message)
Change the ALM cables as they may break after numerous cycles have been performed (they are mobile).
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TABLE OF CONTENTS
GENERAL INFORMATION.........................................................................................................................................3
1 OPERATION OF THE DEVICES AND SENSORS.....................................................................................8
2 WARNINGS................................................................................................................................................9
3 MAIN FEATURES OF THE ELECTRICAL SYSTEM................................................................................10
4 MACHINE CONTROL KEYBOARD..........................................................................................................11
4.1 DESCRIPTION OF THE KEYS.................................................................................................................12
4.2 DESCRIPTION OF THE LEDS.................................................................................................................20
5 PROGRAMMING KEYBOARD.................................................................................................................21
6 PAGE LAY-OUT........................................................................................................................................22
6.1 OPERATING PROGRAM NUMBER.........................................................................................................24
6.2 DATE AND TIME.......................................................................................................................................25
6.3 DESCRIPTION OF THE WORK CYCLE..................................................................................................26
6.4 MACHINE STATUS...................................................................................................................................27
6.4.1 LOGIN.......................................................................................................................................................27
7 LIST OF THE PAGES...............................................................................................................................28
8 OPERATING DATA DISPLAY...................................................................................................................30
8.1 DATA.........................................................................................................................................................30
8.2 INFORMATION AND LANGUAGE SELECTION PAGE............................................................................32
8.2.1 SCREEN SAVER FUNCTION..................................................................................................................32
8.2.2 LANGUAGE SELECTION.........................................................................................................................33
8.2.3 SELECT LOAD TYPE...............................................................................................................................34
8.2.4 SPECIAL OPERATIONS AND ENCODER RESET PAGE........................................................................35
8.2.5 YV99 SELF-LEARNING PROCEDURE (ONLY FOR PCH)......................................................................43
8.2.6 PROFIBUS HELP PAGE (LIVE LIST).......................................................................................................44
8.3 ACTUAL LOADING DATA.........................................................................................................................54
8.4 ACTUAL PRESS-CYCLE DATA................................................................................................................56
8.4.1 PRESSES WITH PROPORTIONAL HYDRAULIC SYSTEM....................................................................56
8.4.2 PRESSES WITH NON-PROPORTIONAL HYDRAULIC SYSTEM...........................................................58
8.5 ACTUAL DIE-SET DATA...........................................................................................................................60
8.6 “DISPLAY” PAGE......................................................................................................................................62
8.7 I/O PAGE..................................................................................................................................................63
8.7.1 GRAPH PAGE..........................................................................................................................................66
8.8 FAULTS PAGE..........................................................................................................................................67
8.8.1 CURRENT FAULTS PAGE.......................................................................................................................68
8.9 “STATISTICS” PAGES..............................................................................................................................69
8.10 PRODUCTION..........................................................................................................................................76
9 SETTING THE DATA ITEMS....................................................................................................................77
9.1 PROGRAMS.............................................................................................................................................77
9.2 LOADING SETTINGS...............................................................................................................................80
9.2.1 OTHER LOADING DATA..........................................................................................................................85
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9.2.2 FILLER-BOX/PLUNGER...........................................................................................................................94
9.3 “PRESS-CYCLE SET-UP” PAGE.............................................................................................................95
9.3.1 PRESSES WITH PROPORTIONAL HYDRAULIC SYSTEM....................................................................95
9.3.2 PRESSES WITH NON-PROPORTIONAL HYDRAULIC SYSTEM.........................................................101
9.4 DIE-SET SET-UP....................................................................................................................................104
9.4.1 DIE-SET HEATER...................................................................................................................................107
9.4.2 DIE-SET MAGNETIC LOCK...................................................................................................................109
9.4.3 DE-AIR....................................................................................................................................................112
9.5 S.P.E. DIE-SET SET-UP.........................................................................................................................113
9.6 FITTINGS SET-UP..................................................................................................................................118
9.7 LINE SET-UP..........................................................................................................................................126
10 “PRINT ROUTINE”..................................................................................................................................128
11 WHAT TO DO WHEN THE MACHINE STOPS DUE TO MALFUNCTIONING.......................................129
12 OPERATION OF THE SINGLE PILZ PNOZMULTI SAFETY MODULE.................................................130
13 FAULT MESSAGES................................................................................................................................132
13.1 OPERATING SYSTEM MESSAGES......................................................................................................134
13.2 SHUTDOWN MESSAGES......................................................................................................................136
13.3 PARTIAL SHUTDOWN MESSAGES......................................................................................................150
13.4 STOPPAGE MESSAGES.......................................................................................................................203
13.5 ALARMS (MESSAGES WHICH REQUIRE MANDATORY ACTIONS)...................................................210
13.6 INFORMATION MESSAGES..................................................................................................................211
13.7 LOCAL MESSAGES...............................................................................................................................222
13.7.1 LOCAL ALARMS - FAST DIE-SET CHANGE.........................................................................................226
13.8 MAINTENANCE MESSAGES.................................................................................................................237
LIST OF FAULT MESSAGES.................................................................................................................................241
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LIST OF FAULT MESSAGES
1ST DIE-SET D.STROKE (SQ3/SQ6).................................................................................................................... 154

1ST DOWNSTROKE SIGNAL (KA305)................................................................................................................. 162
2ND DIE-SET D.STROKE (SQ6)........................................................................................................................... 155
2ND F-BOX SAFETY SW.(KA302)......................................................................................................................... 169
2ND F-BOX TRIGGER P. (KA302)......................................................................................................................... 155
2ND F-BOX TRIGGER P. (KA304)......................................................................................................................... 154
3RD DOWNSTROKE SIGNAL (KA306)................................................................................................................. 162
A
ACCUMULATOR PRESSURE HIGH (BP3)........................................................................................................... 177
ACP2 ENCODER NOT RESET.............................................................................................................................. 218
ACP 2 LEFT TRAVEL (KA121A - U121)................................................................................................................. 190
ACP 2 LEFT TRAVEL (KA121B - U121)................................................................................................................ 190
ACP ENCODER NOT RESET................................................................................................................................ 216
ACTUATOR / ENCODER (ACP)............................................................................................................................ 167
ACTUATOR/ENCODER (ACP2)............................................................................................................................ 190
ACTUATOR/ENCODER (ALM).............................................................................................................................. 167
ACTUATOR/ENCODER (BQ13)............................................................................................................................ 194
ACTUATOR/ENCODER (BQ40)............................................................................................................................ 193
ADJUST CYLINDER PRESS.TRANSDUCER....................................................................................................... 211
ADJUST. NOT ALLOWED IN PLUNGER DOWNSTROKE.................................................................................... 221
ADJUST REDUCER 31 (YV307)............................................................................................................................ 217
ADJUST WEDGE LIMIT SWITCHES..................................................................................................................... 197
AIR PRESENCE (SP33)........................................................................................................................................ 232
ALM ENCODER NOT RESET........................................................................................................................ 166, 215
ALM RETURN........................................................................................................................................................ 167
AT END OF BATCH LOAD PROGRAM NO........................................................................................................... 238
AXIS CARD ERROR (PARAMETER)..................................................................................................................... 157
AXIS CONTROL FAULT (M20) (N)......................................................................................................................... 193
AX PROTOCOL...................................................................................................................................................... 225
B
BATCH COMPLETED............................................................................................................................................ 204
BEAM BACKWARD LIMIT SWITCH (SQ112I)....................................................................................................... 232
BEAM BACKWARD TIMEOUT............................................................................................................................... 229
BEAM/DCL CHECKS NOT ENABLED IN FAST DIE-SET CHANGE..................................................................... 221
BEAM DIRECTION OF OPERATION REVERSED................................................................................................ 233
BEAM FORWARD LIMIT SWITCH (SQ112A)........................................................................................................ 231
BEAM FORWARD TIMEOUT................................................................................................................................. 228
BEAM MOVEMENT FAULTY................................................................................................................................. 227
BEAM MOVEMENTS FAULTY (U12)..................................................................................................................... 230
BEAM NOT AT THE END OF RETURN STROKE (BQ13)..................................................................................... 199
BEAM NOT IN ZERO POSITION........................................................................................................................... 232
BEAM NOT ON LIMIT SWITCH............................................................................................................................. 233
BEAM PISTONS OT FULLY DOWN (SQ72AB)..................................................................................................... 199
BEAM REPOSITIONING TIMEOUT....................................................................................................................... 229
BLANK PROGRAM................................................................................................................................................ 222
BOOSTER AT END-STOP..................................................................................................................................... 215
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BOOSTER AT END-STOP (N BAR, M).................................................................................................................. 208

BOOSTER DOWNSTROKE (YV102)..................................................................................................................... 177
BOOSTER ENCODER NOT RESET..................................................................................................................... 215
BOOSTER ENCODER NOT ZERO SET (BQ11)................................................................................................... 215
BOOSTER MOV. DURING OIL HEATING (BQ12)................................................................................................. 178
BOOSTER NOT REPOSITIONED......................................................................................................................... 178
BOOSTER REPOSITIONING (BQ11).................................................................................................................... 179
BOOSTER RESET (BQ12).................................................................................................................................... 177
BOOSTER UPSTROKE (YV103)........................................................................................................................... 177
BRUSH NOT WORKING (KM2A/KM2B )............................................................................................................... 203
C
CARD AX: .............................................................................................................................................................. 224
CARRY OUT LOADING......................................................................................................................................... 167
CENTERING DEVICE ENCODER NOT RESET (M62X)....................................................................................... 214
CHECK (.....)........................................................................................................................................................... 184
CHECK 24 VOLT (PARAMETER) ......................................................................................................................... 148
CHECK ALM CABLES (10,000,000 CYCLES)....................................................................................................... 238
CHECK CONFIGURATION.................................................................................................................................... 223
CHECK CONTACTORS KA105A/B....................................................................................................................... 200
CHECK DIE-SET HEATER SETTINGS (N)........................................................................................................... 211
CHECK HEAT EXCHANGER................................................................................................................................. 214
CHECK HEAT EXCHANGER (KM11A).................................................................................................................. 152
CHECK INPUT SENSOR, RPR TURNER (SQ5041)............................................................................................. 201
CHECK (KA104A-B)............................................................................................................................................... 149
CHECK (M25 - U25)............................................................................................................................................... 191
CHECK (M62X/Y)................................................................................................................................................... 195
CHECK (M2031/SQ2031A).................................................................................................................................... 190
CHECK (M2031/SQ2031B).................................................................................................................................... 194
CHECK PAD PRECHARGE (BP203) (N)............................................................................................................... 179
CHECK PLUNGER SETTING................................................................................................................................ 212
CHECK PRESET DATA.......................................................................................................................................... 140
CHECK REQ.-LOW. DIE-SET PRESENCE SENS. (KA228)................................................................................. 227
CHECK REQ.-UPP. DIE-SET PRESENCE SENS. (KA228).................................................................................. 227
CHECK (SB10/KA10A-B)....................................................................................................................................... 149
CHECK (SB11/KA111A-B)...................................................................................................................................... 149
CHECK (SQ...)....................................................................................................................................................... 190
CHECK (SQ41)...................................................................................................................................................... 181
CHECK (SQ42)...................................................................................................................................................... 181
CHECK (SQ43)...................................................................................................................................................... 182
CHECK (SQ48A).................................................................................................................................................... 185
CHECK (SQ48C).................................................................................................................................................... 186
CHECK (SQ49A).................................................................................................................................................... 186
CHECK (SQ49C).................................................................................................................................................... 186
CHECK (SQ55A).................................................................................................................................................... 187
CHECK (SQ55C).................................................................................................................................................... 187
CHECK (SQ56A).................................................................................................................................................... 187
CHECK (SQ56C).................................................................................................................................................... 187
CHECK (SQ2047A-B-C-D....)................................................................................................................................. 196
CHECK (SQ2065A)................................................................................................................................................ 184
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CHECK (SQ2065C)................................................................................................................................................ 188

CHECK THERMOCOUPLE (BTN)......................................................................................................................... 205
CHECK TILE/ADJUST MACHINE.......................................................................................................................... 206
CHECK (U40)......................................................................................................................................................... 193
CHECK U121/U26/U25.......................................................................................................................................... 190
CLEANING............................................................................................................................................................. 206
CLEAN PROPORTIONAL VALVES (N).......................................................................................................... 177, 217
COLUMN LUBRICATION IN PROGRESS............................................................................................................. 216
COMMAND FOR CLOSING YV513 GIVEN BUT SQ513 IS OPEN....................................................................... 198
COMMAND FOR OPENING YV513 GIVEN BUT SQ513 IS CLOSED.................................................................. 198
CONFIG.................................................................................................................................................................. 144
CONFIGURATION READ TIMEOUT...................................................................................................................... 224
CONFIGURATION WRITE TIMEOUT.................................................................................................................... 224
CONTACTS STUCK IN CONTACTOR (KMN)....................................................................................................... 203
CONTACTS STUCK IN CONTACTOR, RPR ROLLER CONVEYOR (KM5012)................................................... 200
CONTACTS STUCK IN CONTACTOR, RPR ROLLER CONVEYOR (KM5013)................................................... 201
CONTROL FOR DIE-SET CONTIN. ACTION NOT PRESSED............................................................................. 226
CONTR.UN. FAILURE, DIE-SET MAGN. PLATE (KA224).................................................................................... 199
CYCLE SLOWED DOWN BY (NAME)................................................................................................................... 212
CYCLE TIME GREATER THAN SYNCH.TIME...................................................................................................... 211
CYCLE WITHOUT PRESSING.............................................................................................................................. 217
CYLINDER DECOMPRESSION NOT COMPLETED............................................................................................ 168
CYLINDER PRESSURE TRANSDUCER (BP1).................................................................................................... 168
D
DCL CHECKS NOT ENABLED IN FAST DIE-SET CHANGE................................................................................ 221
DCL GUARDS OPENED (SQ54)........................................................................................................................... 218
DCP VALVE FAULT (PARAMETER)...................................................................................................................... 163
DECREASE FILLER-BOX FORWARD SPEED..................................................................................................... 204
DECREASE FILLER-BOX RETURN SPEED........................................................................................................ 205
DEMAGNETIZATION IN PROGRESS................................................................................................................... 234
DIE DOWN (SQ63)................................................................................................................................................. 155
DIE NEEDLES NOT OUT (SP12).......................................................................................................................... 196
DIE NEEDLES NOT RETRACTED (SP13)............................................................................................................ 196
DIE-SET ALREADY PRESENT (KA226)................................................................................................................ 235
DIE-SET CHANGE................................................................................................................................................. 206
DIE-SET CHANGE DEVICE ON (SQ68/SQ67)..................................................................................................... 160
DIE-SET CHANGE FILLER-BOX IN PROGRESS................................................................................................. 235
DIE-SET CHANGE FILLER-BOX NOT IN PLACE................................................................................................. 226
DIE-SET CHANGE-OVER FILLER-BOX IN POSITION (SQ74A/B)...................................................................... 219
DIE-SET CHANGE PISTONS DOWN (SQ72A-B)................................................................................................. 210
DIE-SET DETACHMENT (KA221/223).................................................................................................................. 199
DIE-SET DEVIATION > 2 MM................................................................................................................................ 155
DIE-SET DOWNSTROKE TIMEOUT (SQ71A/B ON)............................................................................................ 229
DIE-SET DOWNSTROKE TIMEOUT (SQ72A/B OFF)........................................................................................... 229
DIE-SET ENCODER BLOCKED (SQ4).................................................................................................................. 157
DIE-SET ENCODER NOT RESET......................................................................................................................... 213
DIE-SET ENCODER RESET................................................................................................................................. 156
DIE-SET FASTENED............................................................................................................................................. 235
DIE-SET HEATER NOT ENERGIZED (EHN)......................................................................................................... 203
243
PH 283.85.066 Rev. 02 Date 12.11.2013
DIE-SET HEATER NOT ON................................................................................................................................... 213

DIE-SET INSTALLATION IN PROGRESS............................................................................................................. 234
DIE-SET LEARNING (YV21P)............................................................................................................................... 158
DIE-SET LIFTING PISTONS NOT DOWN............................................................................................................. 227
DIE-SET LIFTING PISTONS NOT UP................................................................................................................... 227
DIE-SET LOCK DOWNSTROKE NOT PERFORMED........................................................................................... 197
DIE-SET LOCKING IN PROGRESS...................................................................................................................... 234
DIE-SET LOCK UPSTROKE NOT PERFORMED................................................................................................. 197
DIE-SET NOT DOWN.................................................................................................................................... 207, 233
DIE-SET NOT LOCKED......................................................................................................................................... 214
DIE-SET NOT ON SUPPORTS (SQ71A/B OFF)................................................................................................... 229
DIE-SET NOT PRESENT....................................................................................................................................... 227
DIE-SET NOT PRESENT (KA226)......................................................................................................................... 235
DIE-SET NOT PRESENT (SQ71A/B OFF)............................................................................................................ 228
DIE-SET NOT UNLOCKED.................................................................................................................................... 230
DIE-SET ON SUPPORTS (SQ71A/B).................................................................................................................... 200
DIE-SET ON SUPPORTS (SQ71A/B ON)............................................................................................................. 229
DIE-SET PARALLELISM ERROR.......................................................................................................................... 155
DIE-SET PROPERLY DEMAGNETIZED............................................................................................................... 234
DIE-SET PROPERLY MAGNETIZED.................................................................................................................... 234
DIE-SET PROPERLY PLACED.............................................................................................................................. 234
DIE-SET PROPERLY REMOVED.......................................................................................................................... 234
DIE-SET PROPERLY UNLOCKED........................................................................................................................ 235
DIE-SET REMOVAL IN PROGRESS..................................................................................................................... 234
DIE-SETS DOWN AT FILLER-BOX START........................................................................................................... 157
DIE-SETS NOT MAGNETIZED (KA221/223)......................................................................................................... 199
DIE-SETS UP (SQ3/SQ6)...................................................................................................................................... 169
DIE-SET TEMP.>65°C RISK OF BURNS (BTN).................................................................................................... 211
DIE-SET TEMP.TOO HIGH > 75°C (BTN)............................................................................................................. 203
DIE-SET THERMOCOUPLE DISCONNECTED (BTN).......................................................................................... 205
DIE-SET UNLOCKING IN PROGRESS................................................................................................................. 235
DIE-SET UP.ERROR (A=..., B=...)......................................................................................................................... 156
DIE-SET UPSTROKE (SQ3).................................................................................................................................. 154
DIP FAULT (M30/M2030) (...)................................................................................................................................. 183
DIP GUARDS OPENED (SQ69 - SQ70)................................................................................................................ 217
DIP OUTSIDE ALLOWABLE RANGE (PARAMETER)........................................................................................... 189
DIRECTION OF OPERATION REVERSED (M20)................................................................................................. 165
DIRECTION OF OPERATION REVERSED (M25)................................................................................................. 191
DIRECTION OF OPERATION REVERSED (M30/2030)........................................................................................ 185
DIVIDE ERROR INTERRUPT................................................................................................................................ 134
DIVIDE ERROR PROG N LINE NN....................................................................................................................... 134
DRIVE FAILURE (M62X/Y/Z)................................................................................................................................. 195
DRIVE FAULT (U27)............................................................................................................................................... 181
DRIVE FAULT (U28)............................................................................................................................................... 181
DRIVE FAULT (U29)............................................................................................................................................... 182
DRIVE FAULT (U30)............................................................................................................................................... 185
244
PH 283.85.066 Rev. 02 Date 12.11.2013
E
EJECTOR DOWNSTR.TIMEOUT.......................................................................................................................... 158
ENCODER BQ31 DOES NOT COUNT/COUNTS DOWN..................................................................................... 231
ENCODER FAILURE (BQ...).................................................................................................................................. 194
ENCODER FAILURE (BQ121)............................................................................................................................... 191
ENCODER FAULTY (ID NUMBER)........................................................................................................................ 160
ENCODER NOT RESET (BQ13)........................................................................................................................... 219
ERROR DURING CONFIGURATION WRITE........................................................................................................ 224
ERROR DURING PRINTING................................................................................................................................. 222
ERROR FROM AXES CARD................................................................................................................................. 212
EXCESSIVE BRAKING.......................................................................................................................................... 168
EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E)............................................................................................... 136
EXTERNAL SHUTDOWN PUSH-BUTTON (SB5E)............................................................................................... 148
EXTERNAL STOP (KA300).................................................................................................................................... 204
F
FAILED LEARNING (N).......................................................................................................................................... 218
FAN/FILTERING UNIT (KM11)............................................................................................................................... 150
FAST TILE-BAND IMPACT..................................................................................................................................... 182
FAULT, FILLER-BOX DRIVE (U20)........................................................................................................................ 163
F-BOX ENCODER/ACTUATOR............................................................................................................................. 161
F-BOX ENCODER RESET..................................................................................................................................... 162
F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59).............................................................................................. 153
F-BOX FORW. DUR. PLUNGER DOWNSTROKE................................................................................................ 169
F-BOX FORW.RUN TIME...................................................................................................................................... 211
F-BOX SAFETY SW.(SQ59).................................................................................................................................. 169
FILE ERROR: X............................................................................................................................................. 146, 224
FILL.-BOX NOT IN AUTO./NO POWDER (SL2).................................................................................................... 207
FILLER-B. LIFT. OUTSIDE RANGE (0.1 MM)........................................................................................................ 198
FILLER-BOX DID NOT START (KA302/SQ59)...................................................................................................... 164
FILLER-BOX ENCODER NOT RESET.................................................................................................................. 213
FILLER-BOX FORWARD............................................................................................................................... 166, 213
FILLER-BOX FORWARD CYCLE TIME................................................................................................................. 208
FILLER-BOX FORWARD STROKE....................................................................................................................... 183
FILLER-BOX GUIDES UNLOCKED....................................................................................................................... 200
FILLER-BOX LIFTING MOTOR (KM31)................................................................................................................. 230
FILLER-BOX LIFTING MOTOR (KM32)................................................................................................................. 230
FILLER-BOX MICROCONTACT (SQ59)................................................................................................................ 207
FILLER-BOX NOT BACKWARD............................................................................................................................ 207
FILLER-BOX NOT BACKWARD (KA302).............................................................................................................. 154
FILLER-BOX NOT BACKWARD (KA302/SQ59).................................................................................................... 162
FILLER-BOX NOT IN DIE-SET CHANGE POS..................................................................................................... 232
FILLER-BOX NOT IN PLACE................................................................................................................................. 163
FILLER-BOX NOT IN PLACE (#)................................................................................................................... 194, 195
245
PH 283.85.066 Rev. 02 Date 12.11.2013
FILLER-BOX OUTSIDE ALLOWABLE STROKE (PARAMETER).......................................................................... 193

FILLER-BOX OUTSIDE RANGE (.....)................................................................................................................... 183
FILLER-BOX REPOSIT.................................................................................................................................. 184, 193
FILLER-BOX REPOSITIONING COMPLETED...................................................................................................... 235
FILLER-BOX REPOSITIONING IN PROGRESS................................................................................................... 235
FILLER-BOX RETURN CYCLE TIME.................................................................................................................... 208
FILLER-BOX RETURN STROKE........................................................................................................................... 182
FILLER-BOX RETURN TIME................................................................................................................................. 212
FILLER-BOX SAFETY GUARD (SQ66A)............................................................................................................... 213
FILLER-BOX SET-UP COMPLETED..................................................................................................................... 235
FIRMWARE FBM V01.081..................................................................................................................................... 225
FIXED COLOR HOPPER LEVEL TIMEOUT (SL25).............................................................................................. 191
FLOAT ERROR...................................................................................................................................................... 135
G
GREASE LEVEL LOW (SQ130)............................................................................................................................. 238
GRID REPOSIT. TOO FAST.................................................................................................................................. 192
GRID REPOSIT. TOO SLOW................................................................................................................................. 192
H
HAVE PLUNGER GUIDES LUBRICATED (SP130)............................................................................................... 210
HAVE PLUNGER GUIDES LUBRICATED (SP130/SP131)................................................................................... 210
HAVE PLUNGER GUIDES LUBRICATED (SP131) (ALARM)............................................................................... 210
HEATING CABLES NOT DISCONNECTED.......................................................................................................... 233
HIGH PRESSURE IN THE CYLINDER.......................................................................................................... 151, 198
HOLDING FOR PRESS-CYCLE START (KA306)................................................................................................. 194
HOMOGENIZER............................................................................................................................................ 165, 166
HOPPER CLOSING (SQ61).................................................................................................................................. 153
HOPPER EMPTYING IN PROGRESS................................................................................................................... 235
HOPPER LIFTING END STOP.............................................................................................................................. 231
HOPPER LIFTING MOTOR (KM34)...................................................................................................................... 231
HOPPER OPEN (SQ60)........................................................................................................................................ 154
HOPP. LIFT. OUTSIDE RANGE............................................................................................................................. 199
HYDR.UNIT PUMP (KM1D)................................................................................................................................... 150
I
INCORRECT PLUNGER PARALLELISM: ............................................................................................................ 171
INCORRECT PRESSING....................................................................................................................................... 214
INCORRECT SETTING SQ2047 (M62X)............................................................................................................... 195
INCORRECT WEDGE POSITION (SQ12ABCD)................................................................................................... 197
INCREASE FILLER-BOX FORWARD SPEED...................................................................................................... 205
INCREASE FILLER-BOX RETURN SPEED.......................................................................................................... 206
INCREASE M29 DEC. DELAY AFTER SQ43 ON.................................................................................................. 182
INVALID CONFIGURATION DATA......................................................................................................................... 223
INVALID DATA AFTER CONFIGURATION READ................................................................................................. 223
INVALID LICENSE CODE...................................................................................................................................... 135
INVALID MEMORY................................................................................................................................................. 134
INVALID PROGRAM NUMBER.............................................................................................................................. 222
246
PH 283.85.066 Rev. 02 Date 12.11.2013
K
KEYBOARD ERROR: ........................................................................................................................................... 147
KEYBOARD ERROR /PE/OE/FE........................................................................................................................... 134
KNOCKOUT UPSTROKE TIMEOUT..................................................................................................................... 158
L
LACK OF POWDER IN HOPPER.......................................................................................................................... 204
LAST DIE-SET D.STROKE (SQ6)......................................................................................................................... 153
LEARNING (YV100)............................................................................................................................................... 178
LIFT. PISTONS NOT UP WITH DIE-SET PRESENT............................................................................................. 236
LOADING CORRECTION NOT ALLOWED........................................................................................................... 211
LOW ACCUMULATOR PRESSURE (BP3)............................................................................................................ 171
LOW CYL.PRESS DUR. DIFF. CYCLE.................................................................................................................. 180
LOW. DEMAGNETIZATION TIMEOUT (KA220 OFF)............................................................................................ 230
LOW. DIE-SET DETACHMENT/DIE-SET NOT PRESENT (KA226)...................................................................... 202
LOWER DIE DOWNSTR. (SQ340A/SQ340B)....................................................................................................... 158
LOWER DIE-SET ALREADY DEMAGNETIZED.................................................................................................... 234
LOWER DIE-SET ALREADY MAGNETIZED......................................................................................................... 233
LOWER DIE-SET NOT MAGNETIZED.................................................................................................................. 200
LOWER DIE-SET NOT PRESENT (KA226).......................................................................................................... 199
LOWER DIE UPSTR. (SQ63A/SQ63B)................................................................................................................. 158
LOWER MAGNETIZATION NOT PERFORMED................................................................................................... 232
LOW. MAGNETIZATION TIMEOUT (KA219 OFF)................................................................................................. 229
LOW PRESSURIZATION/FILTER (SP3)................................................................................................................ 206
LOW PRESSURIZATION (SP3)............................................................................................................................. 150
LUBRICATION NOT PERFORMED (SP130)................................................................................................. 208, 238
LUBRICATION NOT PERFORMED (SP130/SP131)............................................................................................. 209
LUBRICATION NOT PERFORMED (SP131)......................................................................................................... 209
M
MAG./DEMAG SELECTOR NOT ENABLED (SA8)............................................................................................... 233
MAGNET/DEMAGNET OF FAST DIE-S. CHANGE NOT COMPLETED............................................................... 199
MAGNETIZATION IN PROGRESS........................................................................................................................ 234
MAIN SWITCH TRIPPING (BTN OR KMN)........................................................................................................... 142
MAX MISALIGNM.,FILLER-B. LIFTING (15 MM)................................................................................................... 231
MDR2 ENCODER NOT RESET............................................................................................................................. 218
MDR DRIVE FAULT (U24)..................................................................................................................................... 167
MEMORY READ.................................................................................................................................................... 223
MIN. ISOSTATIC PRESS. NOT REACHED........................................................................................................... 209
MISSING FILE. ...................................................................................................................................................... 223
MIXER (KM24A)..................................................................................................................................................... 165
MIXER (KM24I)...................................................................................................................................................... 166
MOBILE COLOR HOPPER LEVEL TIMEOUT (SL26)........................................................................................... 191
MOBILE GRID FORWARD..................................................................................................................................... 192
MOBILE GRID FORWARD (SQ40)........................................................................................................................ 192
MOBILE GRID NOT IN PLACE.............................................................................................................................. 192
MOBILE GRID RETURN........................................................................................................................................ 191
MOBILE HOPPER.................................................................................................................................................. 167
MOBILE HOPPER (KM23A).................................................................................................................................. 166
MOBILE HOPPER (KM23I).................................................................................................................................... 166
MOBILE HOPPER (U23)........................................................................................................................................ 166
247
PH 283.85.066 Rev. 02 Date 12.11.2013
MODEM CONNECTION......................................................................................................................................... 217

MODE SELECTOR................................................................................................................................................ 140
MODE SELECTOR NOT IN SET-UP..................................................................................................................... 226
MODE SELECTOR NOT TO AUT.......................................................................................................................... 226
MOLCONTROL ERROR........................................................................................................................................ 197
MOV. NOT ALLOWED IN FAST DIE-SET CHANGE.............................................................................................. 221
N
NO AIR (SP33)....................................................................................................................................................... 228
NON-MASKABLE INTERRUPT............................................................................................................................. 134
NO SUCH FILE...................................................................................................................................................... 135
O
OIL BEING CHANGED........................................................................................................................................... 216
OIL CHANGE TIMEOUT........................................................................................................................................ 208
OIL COCK CLOSED (SQ50).................................................................................................................................. 151
OIL HEATING (KM180/19)..................................................................................................................................... 213
OIL HEATING PUMP.............................................................................................................................................. 152
OIL LEAK LEVEL (SL4).......................................................................................................................................... 151
OIL LEAK LEVEL (SL11)........................................................................................................................................ 181
OIL LEAK RECOVERY (KM3)................................................................................................................................ 207
OIL LEAK RECOVERY (KM10).............................................................................................................................. 209
OIL LEVEL (SL1).................................................................................................................................................... 150
OIL TEMPERATURE.............................................................................................................................................. 212
OIL TEMPERATURE HIGH.................................................................................................................................... 218
OIL THERMOCOUPLE DISCONNECTED (BT4)................................................................................................... 150
OPEN THE SAFETY GUARDS OF THE PRESS-CYCLE ZONE.................................................................. 197, 210
OPERATION NOT ALLOWED................................................................................................................................ 222
OPERAT.NOT ALLOWED: MOVE PLUNGER DOWN........................................................................................... 210
OTHER CAUSES................................................................................................................................................... 207
OUT OF PROGRAM.............................................................................................................................................. 135
OVERFLOW INTERRUPT..................................................................................................................................... 134
OVERFLOW PROG N LINE NN............................................................................................................................. 134
OVERFLOW STACK PROG NLINE NN................................................................................................................. 135
P
PAD ALREADY IN LOADING POSITION............................................................................................................... 220
PAD DECOMPRESSION IN PROGRESS............................................................................................................. 216
PAD DECOMPRESSION TIMEOUT (BP204/BP203)............................................................................................ 180
PAD LOADING CYCLE IN PROGRESS/SELECTED............................................................................................ 220
PAD NOT IN LOADING POSITION........................................................................................................................ 220
PAD PISTONS FULLY DOWN............................................................................................................................... 208
PAD PRECHARGE TIMEOUT (BQ11)................................................................................................................... 178
PAD TOO BACK, PERFORM STEP 2.................................................................................................................... 220
PAUSE/WORKSHIFT CHANGE............................................................................................................................. 207
PERFORM LAST DIE-SET DOWNSTR................................................................................................................. 215
PERFORM LEARNING PROCEDURE (SQ59)...................................................................................................... 218
PERFORM LEARNING PROCEDURE (YV21P).................................................................................................... 157
PERFORM LEARNING PROCEDURE (YV32)...................................................................................................... 176
PERFORM LEARNING PROCEDURE (YV99)...................................................................................................... 176
PERFORM LEARNING PROCEDURE (YV100).................................................................................................... 180
PERFORM PLUNGER LEARNING (YV32 OR YV318 OR YV70D)....................................................................... 172
PISTON DOWNSTROKE TIMEOUT (SQ72A/B OFF)........................................................................................... 228
248
PH 283.85.066 Rev. 02 Date 12.11.2013
PISTON LIFTING TIMEOUT (SQ73A/B OFF)........................................................................................................ 228

PISTON POS. UNDER PRESS.NOT REACHED.................................................................................................. 180
PISTON PRESSURE RESET IN PROGRESS...................................................................................................... 235
PLATE BACK-UP TIMEOUT.................................................................................................................................. 228
PLATE MOVEMENT MOTOR (KM33).................................................................................................................... 228
PLATE NOT BACK (SQ33I OFF)........................................................................................................................... 226
PLATE NOT FORWARD (SQ33A OFF)................................................................................................................. 230
PLATE NOT LOCKED (SQ331/2/3/...)................................................................................................................... 230
PLATE NOT UNLOCKED (SQ331/2/3/...).............................................................................................................. 228
PLUNGER / DIE DOWN (KA410).......................................................................................................................... 165
PLUNGER DOWN AT FILLER-BOX START.......................................................................................................... 183
PLUNGER DOWN DUR. DIE-SET UPSTR............................................................................................................ 153
PLUNGER DOWNSTROKE................................................................................................................................... 168
PLUNGER ENCODER/ACTUATOR....................................................................................................................... 160
PLUNGER ENCODER NOT RESET.............................................................................................................. 213, 227
PLUNGER ENCODER RESET.............................................................................................................................. 169
PLUNGER/F-BOX COLLISION (FORWARD STROKE)........................................................................................ 164
PLUNGER/F-BOX COLLISION (KA410)................................................................................................................ 189
PLUNGER/F-BOX COLLISION (RETURN STROKE)............................................................................................ 170
PLUNGER LEAKS................................................................................................................................. 205, 207, 214
PLUNGER NOT FULLY UP.................................................................................................................................... 221
PLUNGER NOT IN DIE-SET CHANGE POS......................................................................................................... 232
PLUNGER SHUTDOWN (KA312).......................................................................................................................... 148
PLUNGER UPSTR.EXCESSIVE DUR. DIFF. CYCLE........................................................................................... 180
PLUNGER UPSTR.HELP STROKE NOT REACHED............................................................................................ 204
PLUNGER UPSTROKE......................................................................................................................................... 169
POWDER LEVEL SENSORS DEACTIVATED....................................................................................................... 203
POWDER UNDER DIE-SET.................................................................................................................................. 212
POWER SUPPLY/FUSES NNV............................................................................................................................. 134
PRESS. IN PLUNGER UPSTROKE CHAMBER > 20 BAR................................................................................... 233
PRESS STR.NOT COMPLETED – PRESSURE BOOST.(N)................................................................................ 170
PRESS-STROKE NOT COMPLETED - DIRECT (N)............................................................................................. 171
PRESS-STROKE NOT COMPLETED – FLOW BOOSTER (1)............................................................................. 170
PRESS-STR.START POS. NOT REACHED.......................................................................................................... 176
PRESSURE IN CYLINDER TOO HIGH (BP1)....................................................................................................... 148
PRESSURE IN PADS HIGH (BP204).................................................................................................................... 180
PRESSURE IN UPSTROKE CHAMBER HIGH (BP5)........................................................................................... 178
PRESSURE NOT RECUPERATED....................................................................................................................... 170
PRESSURE SWITCH (SP2) ... BAR...................................................................................................................... 144
PRESSURE SWITCH (SPN).................................................................................................................................. 152
PRESSURE TRANSDUCER (BP5)........................................................................................................................ 215
PRESSURE TRANSDUCER (BPN)....................................................................................................................... 152
PROFIBUS CONFIGURATION (SLAVE N1, MODULE N2)................................................................................... 148
PROFIBUS ERROR: ..................................................................................... 137, 141, 143, 144, 145, 147, 222, 223
PROG N PC NNNN:NNNN COD NN..................................................................................................................... 135
PROGRAM NOT AVAILABLE................................................................................................................................. 222
PROPORTIONAL VALVES CLEANING IN PROGRESS....................................................................................... 211
PUMP OFF............................................................................................................................................................. 226
PUMP PRESSURE (SP10).................................................................................................................................... 152
PUMP STOP PUSH-BUTTON................................................................................................................................ 206
PUNCHES NOT FIXED (AJ1/AJ2/AJ3).................................................................................................................. 139
PUNCHES OVERTRAVEL/LIFT RODS................................................................................................................. 160
PWD FEED SHUTOFF AT... MM (BQN)................................................................................................................. 161
249
PH 283.85.066 Rev. 02 Date 12.11.2013
R
RAISE SAFETY BAR............................................................................................................................................. 170
REAR HOOD INEFFICIENT IN QUICK DIE-SET CHANGE-OVER SYSTEM (SP14)........................................... 221
REDUCE PRESS 1 CYCLES................................................................................................................................. 217
RELEASE THE BUTTON AND DRAIN.................................................................................................................. 235
REMOTE CONTROL ENABLED............................................................................................................................ 220
REMOTE CYCLE START....................................................................................................................................... 220
REMOTE CYCLE STOPPAGE............................................................................................................................... 203
REPEAT LOWER MAGNETIZATION .................................................................................................................... 201
REPEAT UPPER MAGNETIZATION (KA224A)..................................................................................................... 200
REPLACE BRUSH................................................................................................................................................. 207
REPLACE DIE-SET................................................................................................................................................ 237
REPLACE FILTER (SP1)....................................................................................................................................... 151
REPLACE FILTER (SP1) WITHIN N H.................................................................................................................. 237
RESET MDR2 ENCODER..................................................................................................................................... 191
RESET SPE PRESSURE....................................................................................................................................... 157
RESTART AUTOMATION PERSONAL COMPUTER............................................................................................. 225
ROLLER CONVEYOR LIMIT SWITCHES (SQ53)................................................................................................. 215
ROTATION TIMEOUT, RPR TURNER (KM5014/SQ5008).................................................................................... 201
ROW STOPPED ON RPR: .................................................................................................................................... 219
RPR ROLLER CONVEYOR NOT WORKING........................................................................................................ 206
RPR ROLLER CONVEYOR NOT WORKING (KM5012)....................................................................................... 201
RPR ROLLER CONVEYOR NOT WORKING (KM5013)....................................................................................... 201
RPR TRIP WIRE (SQ5032).................................................................................................................................... 149
RPR TURNER DOOR (SQ5033)............................................................................................................................ 149
S
SACMI BMOS V.3.X - MINIMUM BMOS V.3.Y....................................................................................................... 223
SAFETY BAR LIMIT SWITCHES (SQ11A/B/C/D).................................................................................................. 163
SAFETY BAR UP................................................................................................................................................... 213
SAFETY DEVICE OF OVERLOAD CUTOUT TRIGGERED (QM5032)................................................................. 201
SAFETY GUARD LIMIT SWITCHES, PRESS-CYCLE ZONE (SQ11ABCD)......................................................... 164
SAFETY GUARDS OF THE PRESSING ZONE OPEN......................................................................................... 220
SAFETY GUARDS OPEN (AJ101)........................................................................................................................ 146
SAFETY MODULE (AJ100).................................................................................................................................... 140
SAFETY MODULE (AJ101).................................................................................................................................... 163
SAFETY MODULE AJ101 OFF.............................................................................................................................. 226
SCHEDULED MAINTENANCE.............................................................................................................................. 206
SCHEDULED MAINTENANCE (6,000,000 CYCLES)........................................................................................... 237
SCHEDULED MAINTENANCE (80 H)................................................................................................................... 237
SCHEDULED MAINTENANCE (200 H)................................................................................................................. 237
SCHEDULED MAINTENANCE (500 H)................................................................................................................. 237
SCHEDULED MAINTENANCE (2000 H)............................................................................................................... 237
SCHEDULED MAINTENANCE (4000 H)............................................................................................................... 237
SEE DIE-SET CHANGE DIAGNOSTICS............................................................................................................... 210
250
PH 283.85.066 Rev. 02 Date 12.11.2013
SEE PROFIBUS ADDRESS N DIAGNOSTICS..................................................................................................... 210

SELF-LEARNING IN PROGRESS......................................................................................................................... 215
SEL. FOR MAG./DEMAG ENABLED (SA8)........................................................................................................... 200
SENSORS FOR DIE-SET CHANGE DEVICE (SQ67/SQ68)................................................................................. 171
SET PASSWORD........................................................................................................................................... 148, 210
SHUTDOWN PUSH-BUTTON............................................................................................................................... 136
SIDE BANDS CLOSED (SQ2060A)....................................................................................................................... 196
SIDE BANDS CLOSED (SQ2061A)....................................................................................................................... 185
SIDE BANDS OPENED (SQ2060A)...................................................................................................................... 196
SIDE BANDS OPENED (SQ2061A)...................................................................................................................... 185
SIDE BANDS OPEN (SQ2060A/M628)................................................................................................................. 183
SIMULT. ACTION OF KEYS NOT RESPECTED (SB10)....................................................................................... 231
SIMULT. ACTION OF KEYS NOT RESPECTED (SB11)....................................................................................... 231
SLID. PLATE NOT FORWARD (SQ33A)............................................................................................................... 198
SLID. PLATE NOT LOCKED (SP33)...................................................................................................................... 198
SLID. PLATE NOT LOCKED (SQ331/2..).............................................................................................................. 198
SLOW PAD DECOMPRESS.-OIL LEAK................................................................................................................ 209
SPE BALANCING TIMEOUT................................................................................................................................. 208
SPE ENCODERS NOT LOCKED........................................................................................................................... 226
SPE ENCODER ZERO TIMEOUT......................................................................................................................... 229
SPE FAULTY VALVE (PARAMETER).................................................................................................................... 157
SPE MOVEMENT DURING PLUNGER UPSTROKE............................................................................................ 197
SPE MOVEMENT NOT COMPLETED................................................................................................................... 157
SPE PISTONS ARE NOT DOWN.......................................................................................................................... 226
STOP.DUE TO EXT. SYNCH. (KA301).................................................................................................................. 204
STOP PUSH-BUTTON........................................................................................................................................... 204
SUCTION SYSTEM FAULTY (KA314)................................................................................................................... 209
T
TEMPERATURE TOO HIGH (ST115)/AIR CONDITIONER FAULT....................................................................... 208
TEMP. TOO HIGH (BT4) > X °C............................................................................................................................. 151
TEMP.TOO HIGH (ST4)......................................................................................................................................... 151
TEMP.TOO LOW (BT4).......................................................................................................................................... 150
THE FIRST DEAERATION IS DISABLED.............................................................................................................. 220
THE PLUNGER HAS MOVED UP......................................................................................................................... 227
THICKNESS ERROR..................................................................................................................................... 205, 212
TILE DAMAGED (SQ…)......................................................................................................................................... 188
TILE IN PRESSING ZONE..................................................................................................................................... 188
TILE NOT IN PRESS. POS. (SQ38 – SQ39)......................................................................................................... 184
TILE NOT PRESENT............................................................................................................................................. 217
TILES NOT ALIGNED (SQ2047A,B,C, ETC)......................................................................................................... 189
TILES TOO CLOSE TOGETHER........................................................................................................................... 189
TILES TOO CLOSE TOGETHER (RPR)................................................................................................................ 221
TILE TOO FAR BACK............................................................................................................................................ 188
TILE TOO FAR FORWARD (SQ38/SQ39)............................................................................................................. 188
TIMEOUT, BOOSTER STROKE RECOVERY....................................................................................................... 178
TIMEOUT, FILLER-BOX LIFTING POSITIONING................................................................................................. 232
TIMEOUT, HOPPER LIFTING POSITIONING....................................................................................................... 232
TIMEOUT, PLATE FORWARD............................................................................................................................... 233
251
PH 283.85.066 Rev. 02 Date 12.11.2013
U
UNLOCK FILLER-BOX GUIDES............................................................................................................................ 232
UNSCHEDULED MAINTENANCE/REPAIRS........................................................................................................ 206
UNUSED OPCODE INTERRUPT.......................................................................................................................... 134
UPP. DEMAGNETIZATION TIMEOUT (KA218 OFF)............................................................................................. 230
UPP. DIE-SET DETACHMENT/DIE-SET NOT PRESENT (KA225)....................................................................... 201
UPPER DIE DOWNSTROKE (SQ344A/B)............................................................................................................ 196
UPPER DIE NOT DOWN (SQ344A/B)................................................................................................................... 196
UPPER DIE NOT UP (SQ341A/B)......................................................................................................................... 196
UPPER DIE-SET ALREADY DEMAGNETIZED..................................................................................................... 234
UPPER DIE-SET ALREADY MAGNETIZED.......................................................................................................... 233
UPPER DIE-SET NOT MAGNETIZED................................................................................................................... 200
UPPER DIE-SET NOT PRESENT (KA225)........................................................................................................... 199
UPPER DIE UPSTROKE (SQ341A/B)................................................................................................................... 196
UPP./LOW. DIE-SET ALREADY DEMAGNETIZED............................................................................................... 234
UPP./LOW. DIE-SET ALREADY MAGNETIZED.................................................................................................... 233
UPP. MAGNETIZATION TIMEOUT (KA217 OFF).................................................................................................. 229
V
VALVE FAULT (YV…)............................................................................................................................................. 159
VALVE FAULT (YV70D).......................................................................................................................................... 216
VALVE FAULT (YV486).......................................................................................................................................... 178
W
WAIT............................................................................................................................................................... 214, 224
WAIT FOR ACP2 TO STOP................................................................................................................................... 218
WAIT FOR AUTO.RESTART (KA300).................................................................................................................... 214
WAIT FOR AUT. RESTART (SL2).......................................................................................................................... 219
WAIT FOR END OF MOBILE HOPPER CYCLE.................................................................................................... 212
WAIT FOR EXTERNAL SYNCH............................................................................................................................. 211
WAIT FOR F-BOX TO GO BACK (KA302)............................................................................................................. 162
WAIT FOR MOBILE GRID REPOSIT..................................................................................................................... 217
WAIT FOR SYNCH.TIME....................................................................................................................................... 211
WAITING FOR COLOR HOPPER FILLING........................................................................................................... 218
WAITING FOR D.I.P. SIGNAL ............................................................................................................................... 216
WAITING FOR PRELOAD AT START OF PRESS-STROKE................................................................................. 216
WAITING FOR TILE FROM PRESS...................................................................................................................... 214
WAITING FOR TILE IN LOADING POS................................................................................................................. 214
WEDGES NOT IN (SQ12C/D)................................................................................................................................ 177
WEDGES NOT OUT.............................................................................................................................................. 233
WEDGES NOT OUT (SQ12A/B)............................................................................................................................ 177
WEDGES NOT RETRACTED........................................................................................................................ 219, 229
WRITE ERROR...................................................................................................................................................... 222
WRONG DIE-SET OP.(A=..., B=...)................................................................................................................ 164, 205
WRONG KNOCKOUT MOVEMENT (BQ4A)......................................................................................................... 158
WRONG PROGRAMMED DATA............................................................................................................................ 222
Y
YV21P OFFSET TOO HIGH................................................................................................................................... 216
YV32 OFFSET VALUE TOO HIGH [O/D/S]............................................................................................................ 215
YV100 OFFSET TOO HIGH [0/A/R]....................................................................................................................... 216
252

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

PH 283.85.066 Rev. 02 Date 12.11.2013

Written by : Mr. Matteo Monduzzi Written on : 29.04.2011

WHERE TO KEEP THE MANUAL

The manual and supplements:

HOW TO LOCATE AND CONSULT THE INFORMATION

USERS OF THE MANUAL

Machine operators are defined as follows in this manual:

SAFETY EQUIPMENT AND PRECAUTIONS

SAFETY DEVICES & GUARDS

SAFETY DEVICES INSTALLED

- Operator protective devices

- Emergency stop buttons

1 OPERATION OF THE DEVICES AND SENSORS

Device Connection Physical condition Led signal

Push-button N.O. Pressed LED on

Selector switch Closed in pos. x LED on

Miniature switch N.O. Activated LED on

Contactors-relays N.O. Energized LED on

Vacuum control N.O. Above pressure limit LED on

3 MAIN FEATURES OF THE ELECTRICAL SYSTEM

The electric system basically consists of:

1) ELECTRICAL CONTROL CABINET

The cabinet is divided into 3 parts:

2) VISUAL DISPLAY UNIT/CONTROL KEYBOARD

Field bus wiring is used. A Profibus-DP bus is employed.

The entire electric system is tested according to current safety regulations.

4.1 DESCRIPTION OF THE KEYS

OPERATION 1ST KEY 2ND KEY + KEY PUMP

DIP: Berger Lahr setting (39) 28 7 SET-UP OFF

Powered suction hood up 25 20

Upp./low. control assembly release SB11 + SA8 11 or 15 SET-UP ON

(1 ) Operation possible only with SMU/LIFT.

(2 ) Set "solenoid valves in manual mode” (YV MAN) = 36

(3 ) Operation possible only in presses with non-proportional hydraulics.

(25) Set "solenoid valves in manual mode” (YV MAN) = 11

(31) Set “solenoid valve in manual mode” (YVMAN) = 20.

4.2 DESCRIPTION OF THE LEDS

+5 Keyboard supply (+5V)

SC Scan control (this LED comes on to signal key malfunctioning)

B Comes on when a key is pressed

Information about machine operation is given on a number of video pages.

Page layout is shown below:

6.1 OPERATING PROGRAM NUMBER

6.2 DATE AND TIME

1) LOG IN (see relative paragraph)

2) go to the INFORMATION AND LANGUAGE SELECTION page (INFO)

3) press key F10 (DATA)

6.3 DESCRIPTION OF THE WORK CYCLE

CYCLE = AUTOMATIC (LOADING + PRESS-CYCLE)

The following appears if key F12 is pressed:

CYCLE = 1 CYCLE (LOADING + PRESS-CYCLE)

To be used to perform a single cycle.

If F12 is pressed again the following appears:

CYCLE = SEMIAUTOMATIC LOADING

If F12 is pressed again the following appears:

CYCLE = SEMIAUTOMATIC PRESS CYCLE)

Press F12 again to go back to the standard cycle.

6.4 MACHINE STATUS

MAN key on keyboard turned to position MAN

Data can be set if “LOGIN” appears to the right of machine status.

Press key F11.