CATALOGUE 159.

16

CATALOGUE

159.16.A02
INSTRUCTION MANUAL

PH 1600 - PH 2000 - PH 2500

HYDRAULIC PRESS

1
 CATALOGUE 159.16
CATALOGUE

159.16.A02
INSTRUCTION MANUAL

PH 1600 - PH 2000 - PH 2500

HYDRAULIC PRESS

VERSIONS: PH 164.00.000/001 PH 200.00.000 PH 250.00.000

• This manual is supplied with the machine and must be kept with the utmost care. Therefore it should
be read carefully in order to become familiar with the safety procedures required for servicing and
operating the machine.
• This machine must be used only for the tasks it was designed for. Use of the machine for tasks other
than those specified herein is hazardous. The Manufacturer shall not be held responsible for
damage caused by improper and erraneous usage.
• The Manufacturer shall be held responsible only for the machine as it was at the time of delivery.
• Any modifications to its construction and work-cycle must be performed or authorized by Sacmi’s
Engineering Dept.
• Sacmi shall not be held responsible for troubles due to the use of non-original spare parts.

• The Manufacturer reserves the right to make any modifications to the specifications contained in this manual without giving
prior notice. The corrections of any printing or other errors will appear in the revised versions of this manual.
• The Manufacturer shall be held responsible only for the Italian version of this manual. No discrepencies in the translation
will be accepted.
• This manual and related drawings are property of SACMI, therefore they must not be reproduced in any form. Failure to
do so will entitle the Manufacturer to take legal action.
• Additional copies of this manual are available from the SACMI’s After-Sales Service Dept..

2
 CATALOGUE 159.16
Table of contents

1 SPECIFICATIONS
1.1 MACHINE DESCRIPTION
1.2 TECHNICAL DETAILS
1.3 DIMENSIONS
1.4 HYDRAULIC SYSTEM DIAGRAM
1.5 DIAGRAMS SHOWING PRESS USAGE

2 SAFETY PRECAUTIONS
2.1 GENERAL PROCEDURES
2.2 SPECIAL PROCEDURES
2.2.1 General
2.2.2 Safety guards for the operator
2.2.3 Operating procedures

3 INSTALLATION
3.1 MACHINE POSITIONING
3.2 ELECTRICAL HOOK-UP AND CONNECTIONS

4 MACHINE START-UP
4.1 GENERAL
4.2 CHECK-OUT PROCEDURES
4.3 ADJUSTMENT OPERATIONS
4.3.1 SMU knockout adjustment
4.3.2 Hydraulic system preliminary adjustment
4.3.3 Filler-box speed adjustment
4.3.4 Plunger braking adjustment
4.3.5 Setting the plunger travel
4.3.6 Press-cycle set-up
4.3.7 Die-set protection system (in the event of lack of powder)
4.3.8 Adjusting the plunger shock absorbers
4.3.9 Automatic cycle set up
4.3.10 Use of the controller to keep the set speeds unvaried

5 OPERATING INSTRUCTIONS
5.1 CONTROL EQUIPMENT
5.1.1 Controller
5.1.2 Electrical enclosure
5.2 START-UP AND SHUTDOWN PROCEDURES

6 MACHINE OPERATION
6.1 COMPRESSED AIR SUPPLY
6.2 FAST HEATING
6.3 HEAT EXCHANGER SYSTEM
6.4 OIL-LEAK COLLECTOR CIRCUIT
6.5 MAIN PUMP ON - SAFETY BAR ACTIVATED
6.6 PRESSURE TRANSDUCERS - DATA INPUT
6.7 SAFETY BAR OFF
6.8 ENCODER RESET
6.9 DIE-SET CONTROL CIRCUIT
6.10 CYCLE START
6.11 SFS CYCLE: UPPER FORMING DIE
6.12 MOVING DIE
6.13 DIE OVERTRAVEL
6.14 BRUSH OPERATION
6.15 MANUAL MOVEMENTS

3
 CATALOGUE 159.16
7 CHECK AND ADJUSTMENT PROCEDURES
7.1 VARIABLE-DISPLACEMENT PUMP ADJUSTMENT
7.2 SETTING AND RESETTING THE POSITION ENCODER
8 MAINTENANCE
8.1 PERIODIC MAINTENANCE
8.2 SPECIAL MAINTENANCE
8.3 BOLT-AND-NUT TORQUE SETTINGS
8.4 MAINTENANCE OF THE HEAT EXCHANGER

4
 CATALOGUE 159.16
1 SPECIFICATIONS SPECIFICATIONS 1

1.1 MACHINE DESCRIPTION

The PH2000 is a fully-automatic press specially designed to compact clay powder in tile making processes.
The distinctive feature of the machine is that hydraulic power is used to fill the die set, compact the material, extract and
eject the pressed workpieces.
The machine consists of the following assemblies:
(refer to relevant ASSEMBLY DRAWING)

- MACHINE CONSTRUCTION
The machine framework (1) basically consists of four columns, a press-bed and a crosshead (3). A hydraulic cylinder
is incorporated in the crosshead. A double-acting piston (4) moves inside the cylinder and is connected to a plunger,
thus acting as its drive unit.
The crosshead upper part contains the hydraulic fluid required for operation. The plunger (2) runs on wear-resistant
bronze bushings which are mounted on the press columns. The plunger is driven by the main hydraulic cylinder.
Two spring recoil devices (17) lift the plunger during deaeration.

- HYDRAULIC SYSTEM
A set of pressure boosters (7) is mounted inside the upper part of the crosshead. It generates sufficient pressure within
the cylinder in order to perform the programmed pressing cycles.

A set of mounting plates are on the machine body near the various points of use. They hold the valves which control
and monitor the operating pressures as well as the logic elements that control the working parts of the machine.

The mounting plates installed are:

- The mounting plate (20) which holds the logic elements for controlling and monitoring the working pressure required
to perform the pressing cycle.
- The mounting plate (21.1) for the accumulators. It is used to control the upward and downward movements of the
machine. In addition, the plate holds a braking unit (21.2) for reducing the speed of the plunger while the die-set is being
closed.
- The mounting plate (22) for the auxiliary equipment is used to control the knockout and the filler-box.

The hydraulic power unit (27) delivers a sufficient amount of hydraulic fluid to drive the actuators, control the fluid
temperature and filter the fluid itself.
A variable-displacement axial-piston pump draws the oil from the reservoir and delivers it to the hydraulic circuit at the
pressures and flow rates required.
The hydraulic circuit is pressurized in order to prevent highly abrasive ceramic dust from entering.
The oil/water heat exchanger, installed in the hydraulic power unit and interlocked with a thermal-expansion valve,
keeps the fluid temperature within normal operating values. The related circuit is fitted with a cooling motor-and-pump
unit (28) for circulating the fluid through the heat-exchanger.
The hydraulic hook-up (18) comes complete with all the fittings, pipes and flexible hoses necessary to connect the
various parts.
The oil-leak collector (19) is used to collect oil leaks at ambient pressure and to circulate them in the pressurized tank
with the aid of the oil-leak pump mounted on the hydraulic power unit.

- FILLER BOX
The function of the filler box is to fill the die-set with powder and eject the pressed tiles. One section of the filler box is
fastened to the press-bed (mount 9 and geared motor 14). This section supports and guides a moving assembly which
forms the filler box body (10). The moving assembly carries a powder hopper (11) which can be fed directly from the
main hopper or through a homogenizer system. The hydraulic geared motor is connected to the stationary assembly
and transmits motion to the mobile assembly through a crank mechanism, thereby converting the rotary motion into a
straight reciprocating motion. The length of travel, the speed of the mobile assembly and the point the hydraulic motor
stops at are fully adjustable.

5
 CATALOGUE 159.16
SPECIFICATIONS 1

- REMOVABLE POWDER BOX-FEEDER(optional)

The press can be equipped with a removable powder infeed system which replaces the spray-dried powder infeed of
the fixed type.
The equipment comes with a frame with caster wheels and bearings for the movement of the box-feeder (mobile
assembly). This allows easy access to the press from the rear side when the die-set is to be changed. In this phase a
maximum travel speed of ≤ 10 mm/sec is automatically set. Thus, the speed of the machine’s moving parts is lower
than the limit established by the regulations in force, i.e. 10 mm/sec., in order to fully protect the operator from dangerous
situations.
All the devices which link the press to the feeder have quick couplers (electrical, hydraulic, pneumatic or mechanical).
The removable infeed system does not require any adjustments to align the box with the moving part of the die-set and
with the sliding plate.
The sliding plate is fixed to the rear part of the die.
The removable floating grid rests on the sliding plate.
The sole function of the box (mobile assembly) is to drive the grid.
The floating grid can be easily removed if the form of the tile is to be changed or cleaning operations are to be carried
out. It consists of a frame complete with gaskets and steel bars which can be adjusted on a vertical or horizontal plane.
The above described equipment can be fitted with a special pneumatically-driven hopper that enables the operator to:
- vary the gate opening.
- enter the opening time into the controller from the keyboard.
- adjust the load width by means of internal deflectors. Therefore, the feed hopper can be used to load any type of die
box, eliminating the need to replace the die set when tile form is to be changed.

- CONVENTIONAL HYDRAULIC KNOCK-OUT

(to be used as an alternative to the SMU hydraulic knock-out, only on the PH 1600)
The unit includes two hydraulic cylinders which lift the mobile part of the die-set at the end of each press stroke. It is
used to remove the pressed tiles from the die-set. The tile is then brought to the same level as the die-box and ejected
from the filler-box. The lower punches move down thus creating the cavity required to receive the working material. The
depth of the cavity can be adjusted manually or automatically after the desired tile thickness has been set. The two
single-action cylinders are controlled by separate solenoid valves. A hydraulic device comes into action to bring them
back into their initial position.

- HYDRAULIC KNOCKOUT , SMU TYPE

(included in the standard equipment of the PH2000 and PH2500, supplied as as alternative to the CONVENTIONAL
knock-out on the PH1600)
The SMU consists of a bottom plate, a punch holder and a built-in tile knockout system.
The function of the system is to remove the compacted material from the die.
Once the tiles have been brought to the same height as the die, they are ejected by the filler box.
The lower punches are then moved down so as to form the cavity necessary to receive the powder to be pressed. The
depth of the cavity can be adjusted manually from the controller.
This adjustment procedure is automatically performed after the desired tile thickness value is entered into the controller.
Two separate solenoid valves control the two cylinders for the first pressing stage and the four cylinders for the second
pressing stage.
The overtravel control is a device that enables the die box to be positioned below the lower punches. It is operated by
a solenoid valve. It is used for cleaning the lower punches and facilitates the lower punch replacement procedures.

- DIE-SET AIR TRANSFER AND FILTERING CIRCUIT

The air which enters and comes out of the lower part of the die-set during the knockout operation is transferred to a
filtering unit.

6
 CATALOGUE 159.16
SPECIFICATIONS 1
ASSEMBLY DRAWING

1 Framework
2 Plunger
3 Crosshead and hydraulic 7 •
cylinder
4 Hydraulic cylinder
5 Die set air transfer and filtering
20 •
unit
19 •
7 Pressure booster 3 •
8 Hydraulically-operated
knockout (SMU)
9 Filler box mount
10 Filler box • 4

32 • • 2
• 31
• 35
34 27
17 • •
• • •
•

• 28
1 •
15

8 30

11 Hopper
• 21.1
14 Filler box geared motor
• 15 Mechanical lock, safety guards
21.2
16 Suction hoods
17 Spring recoil system
18 18 Hydraulic hook-up
19 Oil-leak collector
33 • 20 Logic element mounting plate
21.1 Accumulator mounting plate
29 21.2 Brake unit
16 22 Filler box and knockout control
• • 14 27 Hydraulic power pack
10 28 Cooling motor-and-pump unit
• • 29 Guards
• 30 Electrical wiring
31 Controller - microprocessor
11 system
32 Electrical enclosure
22 • • 5 33 Plunger positioning control
34 Die-set
35 Control keyboard

• 9

C0289

7
 CATALOGUE 159.16
SPECIFICATIONS 1

- GUARDS AND SUCTION HOODS

The mechanical lock (15) is especially designed to prevent the plunger from falling accidentally while the die set is being
cleaned or serviced. A set of covers protects the moving machine parts (29).
The suction hoods (16) draw the dust out of the work area.

- MICRO-PROCESSOR BASED CONTROLLER

The electronic controller (31) is used to program the whole work-cycle that the press will automatically have to carry out.

The controller consists of the following parts:

- control keyboard;
- a computer terminal to display the set parameters, operating data, messages to the operator and fault messages;
- a set of electronic cards.
The controller is connected to:
- The plunger positioning control (33).
The latter contains a linear encoder which records the position of the plunger and transmits the data to the controller.
- Electrical wiring (30).
This includes all of the electrical and electro-mechanical equipment found in the press, i.e. microcontacts, proximity
sensors and related cams, leads, terminals, etc.

- ELECTRICAL ENCLOSURE
The electrical enclosure (32) contains the electrical equipment needed to start up and shut off all the press drive motors,
the transformers for the heating elements on the dies, contactors, thermal relays, fuses, etc.

- DIE SET
The die (34) is used to give the desired shape to the pressed powder. It is made up of two separate parts.
The lower part, which is fixed to the press-bed, comprises the die supported by a number of mounts and the lower forming
punches connected to the hydraulic knockout.
The upper part, fixed to the plunger, includes a punch holder.
The lower and upper punches and the die are warmed up by heating elements in order to prevent the pressed powder
from sticking.
Three temperature probes constantly monitor the temperature of the punches and die, thereby allowing three separate
pieces of equipment to control and monitor them.
However, the temperature in the accessible parts never exceeds 65°C.

8
 CATALOGUE 159.16
SPECIFICATIONS 1

1.2 SPECIFICATIONS
PH 1600 PH 2000 PH 2500
MACHINE PERFORMANCE
Max. soft clay filling height with SMU 200 mm 50 50 50
with SMU 162 mm 35 35 35
Max. plunger travel mm 140 140 140
Column diameter mm 320 350 390
Width between the columns mm 1450 1500 1430
Distance between press-table and plunger mm 600 600 600
Max. knockout force kN 90 90 90
Max. pressing force kN 16000 20000 25000
Max. cylinder pressure bar 350 350 350
Cycles/minute up to 24 22 21
Press-strokes/cycle 1-2-3 1-2-3 1-2-3

ELECTRICAL SYSTEM
Voltage: auxiliary circuits V ac 110 110 110
die-set heating V ac 50 50 50
solenoid valves (rectified) V 24 24 24
Power: drive motor (50 Hz) kW 55 75 75
exchanger pump motor (50 Hz) kW 2.2 2.2 2.2
die-set heating (standard punches) (50 Hz) kW 10+10 10+10 10+10
die (50 Hz) kW 4 4 4
controller (50 Hz) kW 1 1 1
oil-leak collecting pump (50 Hz) kW 0.18 0.18 0.18

HYDRAULIC SYSTEM
Hydraulic fluid: system capacity l 800 1050 1050
viscosity at 40°C cSt 32 32 32
viscosity index higher than 110 110 110
FZG test 11 11 11
Max. operating pressure of hydraulic power unit bar bar 170 180 180
Accumulators main circuit: capacity l 20+20 20+20+20 20+20+20
- pre-filling pressure bar 110 110 110
aux. equipment circuit: capacity l 12 12 12
pilot valve circuit l 1 1 1
- pre-charging pressure bar 110 110 110
Main filter: filtering capacity µ 10 10 10
Reservoir filter element: filtering capacity µ 60 60 60
Plate-mount filter element: filtering capacity µ 10 10 10
Cooling: heat dissipation kcal/h 32000 35000 35000
water consumption at 20° l/min 30 35 35
water pipe connection (dia.) 1"1/2 1"1/2 1"1/2
rubber hose connection (inside dia.) mm 40 40 40
max. pressure bar 4 4 4
Pressurization: max. pressure (with plunger raised) bar 1.5 1.5 1.5

9
 CATALOGUE 159.16
SPECIFICATIONS 1

PH 1600 PH 2000 PH 2500

EJECTOR
Gear-box lubrication: Oil, EP viscosity (ISO VG 320) (ISO VG 320) (ISO VG 320)

WEIGHTS
Weight press body kg 38500 49000 52000
hydraulic power unit kg 890 890 890
ancillaries (controller, electrical enclosure, filler box, etc.) kg 2800 2800 2800

10
 CATALOGUE 159.16
SPECIFICATIONS 1
1.3 DIMENSIONS 1700

Ø1500

1000
870

G
200

6000
5000

H
MAX 140

PH 1600

3500
A

B
600
C
D

E F

SCHEMA CONVENTIONAL
PER ESTRATTORE HYDRAULIC KNOCK-OUT
OLEODINAMICO TIPODIAGRAM
TRADIZIONALE
Min. service space required (in(in
alternative to all'estrattore
alternativa the SMU type hydraulic knock-out,
oleodinamico tipo SMU only
solo for
perthe
PH PH1600)
1600)
N
I

D
L

810
P

1900

450
1600

PH 1600 PH 2000 PH 2500

A 4160 4660 4860
B 3830 4160 4260
C 770 800 800
D 330 500 600
E 2270 2450 2450
F 900 930 930
G 820 935 935 Min. space for ejection
H 4650 5040 5140
I 1000 1150 1150
L 2200 2250 2250
M 2350 2600 2600
N 890 1380 1380
O 1620 2060 2060
P 1350 1200 1200
C0422

11
 CATALOGUE 159.16
SPECIFICATIONS 1

1.4 HYDRAULIC SYSTEM

A block diagram is used to illustrate the hydraulic system and clearly show the distinct sections it is composed of.
The hydraulic and pneumatic parts on the machinery are numbered in a way which is used both to identify the parts and
codify the related functions.

Block diagram:

A PRE-FILLING TANK
B HOPPER GATE CONTROL
C PRESS-CYCLE CONTROL UNIT
D CONTROL UNIT, PLUNGER UPSTROKE-DOWNSTROKE-BRAKING AND PRESSURE
E BRUSH CONTROL (OPTIONAL)
F SMU DIE LIFT
G LIFT CONTROL & FILLER BOX
H HYDRAULIC POWER UNIT

12
 CATALOGUE 159.16
SPECIFICATIONS 1

HYDRAULIC SYSTEM SCHEMATIC: PH1600 - PH2000 - PH2500

71 PRESS-CYCLE CONTROL UNIT

75
72 73 220
74
➞
PRE-FILLING TANK 219

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125
P

124 CONTROL UNIT, PLUNGER

UPSTROKE-DOWNSTROKE-BRAKING
AND PRESSURE
123 27 18A 18

122 132 90 115

A 92
101
101
109 108
B
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A B

273
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275 A B A B

P P
277 YV31D YV31S

223 222
HOPPER GATE
CONTROL
➞

221

SQ50A
E
192 MOBILE BRUSH 144
CONTROL
(OPTIONAL)
194
224

SQ60 M2
SQ61
225
A B

YV99 P
185
➞
DIE SET LIFT 112

YV129S (SMU) M3
54 84 87
85
KNOCK-OUT SFS 184 184
86 SL4
105
130 SL3
SQ3
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2ª 180 181 181 180
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56 58 BT4

79
SP3

189 189 M1
42 SQ59

HYDRAULIC
POWER UNIT

LIFT CONTROL
AND FILLER BOX 24

249 10
YV20A 12
67
YV11R
142 145 23
YV193 YV172
141 62
252 112A
338 SP4 BP2
169 11
143 242 66 1
251 183
337
339
253 61 YV64
A
13
YV170 250 YV135 YV21 YV22

336 YV129 65

248

C0423

13
 CATALOGUE 159.16

A PRE-FILLING TANK

C PRESS-CYCLE CONTROL UNIT

D CONTROL UNIT, PLUNGER UPSTROKE-DOWNSTROKE-BRAKING AND PRESSURE

B HOPPER GATE CONTROL

E MOBILE BRUSH CONTROL (OPTIONAL)

KNOCK-OUT

F DIE-SET LIFT (SMU)

G LIFT CONTROL & FILLER-BOX

H HYDRAULIC POWER UNIT

14
 CATALOGUE 159.16
SPECIFICATIONS 1

LOGIC ELEMENT ASSEMBLY

YV38
YV70
SP2
BP1

YV19
• YV40
YV41

• •
•
•
•
•
120
•
119 •
118
•
117
•
116
131

BRAKE SYSTEM ASSEMBLY

YV31D
• YV31S

•
115 • •
• •
M15

174
YV47
109
108
YV32S
YV53 YV32D
C0316
C0318

15
 CATALOGUE 159.16
SPECIFICATIONS 1

SMU & FILLER BOX CONTROL ASSEMBLY

YV78
YV21
YV22
YV64

YV11R •
•
•
•
•
•
YV20A

66

C0317

16
 CATALOGUE 159.16
SPECIFICATIONS 1

1.4 LIST OF HYDRAULIC PARTS FOR CERAMIC PRESSES

005 Check valve, auxiliary equipment circuit 192 Solenoid valve, brush drive
010 Pilot-operated valve, pressure control (low pressure) 194 Pressure reducer, brush drive
012 Accumulator, auxiliary equipment (filler box lifting and 219 Check valve, pilot-element accumulator
control) 220 Accumulator, Logic element mounting plate pilots
013 Pump pressure gauge with cock 221 Air solenoid-valve, powder hopper gate control
018 Accumulator, press upstroke 222 Flow regulator, gate control cylinder with silencer
018A Accumulator, press upstroke 223 Flow regulator, gate control cylinder with silencer
023 Flow regulator 224 Gate control cylinder
024 Flow regulator, fast filler box speed 225 Brush lifting cylinder
027 Accumulator, press upstroke 242 Twin restrictor valve, 2nd downstroke
036 Cylinder pressure gauge with cock 247 Check valve, cylinder downstroke
042 Hydraulic motor, filler box 248 Hydraulic system draining cock
048 Heat exchanger 250 Restrictor, SFS accumulator
049 Suction filter, main pump 251 Die, hydraulic-release check valve
054 Check valve, oil-leak collector pump 252 Proportional filter, 10 µm
055 Cylinder, 1st die-set downstroke and ejection 253 Die pressure reducer
056 Cylinder, 2nd knock-out downstroke 254 Quick coupling, Oil filling-discharge
058 Main pump 255 Thermostatic valve, cooling water
061 Restrictor, non-return valve 272 Air cleaner, hopper assembly
062 Restrictor and pilot-operated check valve 273 Reducer, hopper assembly
065 OR valve, auxiliary equipment shutoff 275 Pressure gauge, hopper assembly
066 Logic element, auxiliary equipment shutoff 277 Oiler, hopper assembly
067 Aux. equipment pressure gauge with cock 336 Pressure reducing valve
072 Air filter, pressurization circuit 337 Accumulator, SFS circuit
073 Air flow reducer, pressurization circuit 338 Pressure gauge, SFS circuit
074 Air check valve, pressurization circuit 339 Drain cock, SFS circuit
075 Air pressure gauge, pressurization circuit BP1 Transducer, cylinder pressure
078 Filtering pump BP2 Transducer, auxiliary equipment pressure
079 Delivery filter, recirculation system BP3 Transducer, braking position
084 Coupling (oil-leak collector pump) BT4 Thermocouple, hydraulic power unit reservoir
085 Oil-leak collector pump M1 Main pump motor
086 Suction filter, oil-leak collector pump M11 Recirculation pump motor
087 Oil-leak collector filter M15 Motor, brake control
090 Flow regulator, slow upstroke speed M2 Brush motor
092 Pressure-relief valve, brake system M3 Motor, oil-leak collector pump
101 Plunger spring recoil device SL3 Oil-leak minimum level
105 Oil-leak collector reservoir SL4 Oil-leak maximum level
108 Logic element, upstroke SP1 Pressure switch, main filter clogged
109 Logic element, downstroke SP2 Pressure switch, cylinder
111 Pressure-relief valve SP3 Pressure switch, air pressurization
112 Pilot valve, line pressure SP4 Pressure switch, filter clogged, filler box valve
112A Circuit safety valve SQ3 Sensor, die-set raised
115 Logic element, press-cycle accumulator shutoff SQ50A Safety microswitch, suction cock
116 Logic element, booster, 1st press-stroke SQ59 Safety microswitch, filler box backward
117 Logic element, cylinder pressure SQ6 Sensor, die-set lowered
118 Logic element, cylinder drain SQ60 Sensor, hopper gate open
119 Logic element, pressure booster drain SQ61 Sensor, hopper gate closed
120 Logic element, pressure booster YV11R Solenoid valve, quick oil heating
122 Plunger YV19 Pilot-operated solenoid-valve, 2nd press-stroke (direct
123 Rod press-stroke)
124 Cylinder YV20A Solenoid valve, filler box
125 Pressure booster assembly YV22 Solenoid valve, 1st die-set downstroke
126 Pre-filling tank YV31D Solenoid valve, slow downstroke
131 Logic element, booster, 2nd press-stroke YV31S Solenoid valve, slow upstroke
132 Flow regulator, plunger brake system YV32D Solenoid valve, plunger downstroke
136 Cylinder, Knock-out rod clamping YV32S Solenoid valve, plunger upstroke
141 Accumulator, “Mirror-finish” die YV38 Pilot-operated solenoid valve, pressure booster
142 Pressure gauge, “Mirror-finish” die YV40 Pilot-operated solenoid valve, flow-rate booster, 1st
143 Drain cock, “Mirror-finish” die press-stroke
144 Cock, main pump intake pipe YV41 Solenoid valve, booster feeding, 2nd press-stroke
145 Restrictor, “Mirror-finish” die non-return valve YV47 Solenoid valve, brake system
146 Cylinder, Die-set return stroke YV53 Solenoid valve, accumulator shutoff
169 Twin restrictor, 3rd downstroke YV64 Pilot-operated solenoid valve, aux. equipment
174 Logic element, brake system accumulator shutoff
179 Cylinder, die-set overtravel YV70 Solenoid valve, main cylinder drain
180 Cylinder, SMU knockout YV99 Solenoid valve, pump regulator drain
181 Loading control cylinder (2nd SMU downstroke) YV129 Solenoid valve, die overtravel control
183 Pilot-operated check valve, “Mirror-finish” die YV170 Solenoid valve, 3rd die-set downstroke (optional)
184 SFS cylinder YV172 Solenoid valve, cylinder drain, SFS die-set
185 Flow regulator, filler-box cylinder return YV193 Solenoid valve, SFS punch return
189 Cylinder, Extra downstroke control
17
 CATALOGUE 159.16
SPECIFICATIONS 1

1.5 DIAGRAM ILLUSTRATING THE USES OF THE PRESS

LOAD-PRESSURE GRAPH (PH1600)

The total thrust of the press is obtained from the central cylinder thrust (F). The pressure value of the central cylinder
is shown in the column (P) and by drawing a horizontal line, it is possible to read the corresponding thrust value (F)
in the left-hand column. Once the total thrust force (F) has been found, the value must be written in the ordinates
of the diagram. If the size of the unfired tile and the number of the die cavities are known, the total surface area to
be pressed (S) is obtained. The value expressed in cm2 must be written in the X-coordinates of the graph.The straight
line cutting through the point, whose coordinates are represented by the values previously found, indicates the
specific pressure applied on the pressed product.

4-275 x 275 9-110 x 220

7-150 x 300 5-220 x 330

4-275 x 275 3-330 x 330 4-275 x 275

5-210 x 315 2-440 x 440

4-220 x 440
7-150 x 150 5-220 x 220 3-360 x 360
F (kN) 1-650 x 650 P (bar)
16000 318

00 00 00 00
50 45 40 35
14000 278
q 0
N/cm 300

12000 238
2500

10000 198

2000

8000 159

1500

6000 119

4000 79
S (cm2)
1000

1500

2000

2500

3000

3500

4000

4500

5000

Cylinder cross-section = cm2 5026

C0424

18
 CATALOGUE 159.16
SPECIFICATIONS 1

LOAD-PRESSURE GRAPH (PH2000)

The total thrust of the press is obtained from the central cylinder thrust (F). The pressure value of the central cylinder
is shown in the column (P) and by drawing a horizontal line, it is possible to read the corresponding thrust value (F)
in the left-hand column. Once the total thrust force (F) has been found, the value must be written in the ordinates
of the diagram. If the size of the unfired tile and the number of the die cavities are known, the total surface area to
be pressed (S) is obtained. The value expressed in cm2 must be written in the X-coordinates of the graph.The straight
line cutting through the point, whose coordinates are represented by the values previously found, indicates the
specific pressure applied on the pressed product.

4-275 x 275 9-110 x 220

7-150 x 300 5-220 x 330

4-275 x 275 3-330 x 330 4-275 x 275

5-210 x 315 2-440 x 440

4-220 x 440
7-150 x 150 5-220 x 220 3-360 x 360
F (kN) 1-650 x 650 P (bar)
20000 352

18000 318

16000 283

00 00 00 00
50 45 40 35
14000 247
q 0
cm 0
N/ 30

12000 211
2500

10000 178

2000

8000 140

1500

6000 104

4000 71
S (cm2)
1000

1500

2000

2500

3000

3500

4000

4500

5000

Cylinder cross-section = cm2 5674

C0293

19
 CATALOGUE 159.16
SPECIFICATIONS 1

LOAD-PRESSURE GRAPH (PH2500)

The total thrust of the press is obtained from the central cylinder thrust (F). The pressure value of the central cylinder
is shown in the column (P) and by drawing a horizontal line, it is possible to read the corresponding thrust value (F)
in the left-hand column. Once the total thrust force (F) has been found, the value must be written in the ordinates
of the diagram. If the size of the unfired tile and the number of the die cavities are known, the total surface area to
be pressed (S) is obtained. The value expressed in cm2 must be written in the X-coordinates of the graph.The straight
line cutting through the point, whose coordinates are represented by the values previously found, indicates the
specific pressure applied on the pressed product.
4-275 x 275 9-110 x 220

7-150 x 300 5-220 x 330

4-275 x 275 3-330 x 330 4-275 x 275

5-210 x 315 2-440 x 440

4-220 x 440
7-150 x 150 5-220 x 220 3-360 x 360
F (kN) 1-650 x 650 P (bar)
25000 352

24000 338

22000 310

20000 282

18000 254

16000 226

00 00 00 00
50 45 40 35
14000 197
q
cm 00
N/ 30

12000 169
2500

10000 141

2000

8000 113

1500

6000 85

4000 56
S (cm2)
1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

Cylinder cross-section = cm2 7088

C0336

20
 CATALOGUE 159.16
2 SAFETY PRECAUTIONS SAFETY PRECAUTIONS 2

2.1 GENERAL PROCEDURES

INSTALLATION
Install the machine by following the instructions provided by the manufacturer and observing the recommended safety
precautions. It is essential that the machine is hooked-up to a suitable and efficient ground connection. Improper
installation may cause injuries to personnel and damage to equipment, for which Sacmi shall not be held responsible.

SAFETY DEVICES
The machines are equipped with electrical and/or mechanical safety devices which safeguard the operator and the
machine. Therefore, these devices must not be removed or altered. Sacmi declines all responsability for damage due
to tampering or failure to activate the devices.

CHECKS, REPAIRS AND MAINTENANCE

Do not check, repair or carry out any maintenance operations while the machine parts are running.
All operating personnel must be warned of possible danger by placing clearly visible warning signs.
Before carrying out any operations, disconnect the machine from the mains electricity supply by using the master switch.
The master switch can be provided with a pad lock to lock it in "off" position in to prevent the machine from being
accidentally started up.
In order to ensure trouble-free operation, it is important to follow the instructions provided by the manufacturer and carry
out maintenance at the stated intervals. It is advisable to periodically check all safety devices for proper functioning.
Check that the electrical cables are well insulated. Damaged cables must be replaced.

LIVE ELECTRICAL PARTS

Do not work on or near live electrical parts. The electrical enclosure doors must be kept locked and be provided with
warning signs and alert symbols. Before opening the electrical enclosure or gaining access to the switchboard, turn the
power OFF by means of the master switch.

EXPERT PERSONNEL
Assembly, disassembly and maintenance procedures must be carried out by qualified personnel by using suitable
equipment and following the recommended instructions.

MACHINE NOT USED

When the machine is no longer being used, it is advisable to make it inoperative by disconnecting the power leads from
the electricity supply and applying the required safety devices.

21
 CATALOGUE 159.16
SAFETY PRECAUTIONS 2

2.2 SPECIAL SAFETY PROCEDURES FOR PRESSES

2.2.1 GENERAL
The machine (described in this manual) possesses adequate safety features which fully comply with the design and
construction of the machines.
In order to safely work on the machine, perform the following procedures:
• become familiar with the operation of the driving system as well as the safety devices installed on the machine;
• perform all cleaning, servicing and adjustment procedures properly;
• never work on the machine during operation;
• do not alter or modify the safety devices installed on the machine;
• use personal safety equipment, when required.

2.2.2 SAFETY GUARDS FOR THE OPERATOR

The machine comes with fail-safe devices especially designed to safeguard the operator when working in hazardous
areas. The following safety devices and guards are provided:
- Safety bar with flexible guard. This device is interlocked with the microprocessor-based control system: when it is not
activated (safety bar lowered), the operator cannot reach the working area during the pressing cycles. The safety
distance has been calculated according to the relevant current Regulations in force.
When the safety bar is activated (bar raised), two mechanically-operated side locks are applied to prevent the plunger
from lowering.
In addition the single parts of the die-set can be removed so that the routine cleaning operations can be carried out.
- Fixed guards on the filler box
- Side guards in the column area; these consist of a door which can be opened with a special tool provided and a fixed
guard that allows the operator to visually control the press while it is operating.
- Fixed guards on the driving elements of the powder feeder (ACP). The adjustment of the feeder travel must be
performed with the machine turned off.
- Suction hoods on the front and rear side of the press, which remove the dust from the pressing area.

2.2.3 OPERATING PROCEDURES

2.2.3.1 Maintenance, Adjustment operations, etc.

Before performing any maintenance and adjustment operations, etc.:
- Bring the plunger fully up by using the push-buttons (25 & 3) on the control keyboard.
- Raise the safety bar and simultaneously operate the side lever.
- Press the stop button.
- Discharge the auxiliary equipment accumulator (12) by manually energizing the die-set solenoid valves (YV22) until
the knockout stops.
- Discharge the upper accumulators by manually energizing solenoid valve (YV19) “cylinder pressure” and/or solenoid
valves YV32s and YV32d “upward and downward movements”.
- Turn off the press by using the master switch.

2.2.3.2 Cleaning
The cleaning operations must be performed only with the machine turned off.
- Raise the plunger fully up by using the push-buttons (25 & 3) located on the control keyboard.
- Raise the safety bar and simultaneously operate the side lever.

22
 CATALOGUE 159.16
3 INSTALLATION INSTALLATION 3

3.1 MACHINE PLACEMENT

To correctly place the press, refer to the foundation plan supplied beforehand.

To hoist the machine, proceed as

shown in the diagram.

PH 1600 kg 39,000

PH 2000 kg 50,000

PH 2500 kg 52,000

C0434

3.2 CONNECTIONS

The connections are to be performed by expert personnel by following the directions supplied by the manufacturer.

3.2.1 EARTH CONNECTION

Earth the machine at “C” and join the plunger to the

crosshead (at “A” and “B”). In addition, connect the earth
conductors (D and E) as shown in the diagram. 3.2 - DIE A
CONNECTION SCHEMATIC.
B
Any paint which is on the parts of the machine where the
earth wires are to be attached must be removed before
tightening the respective screws in order to ensure
perfect electrical continuity.

The machine may be gravely damaged and the operator C

seriously injured if the parts indicated are not properly
earthed. C0202

23
 CATALOGUE 159.16
INSTALLATION 3

3.2.2 DIE-SET HEATER CONNECTIONS

If these connections are not properly made, the columns and the cylinder may be severely damaged. For this reason,
the following precautions should be observed:
• Never reverse the wires between the upper and lower heaters.
• Both of the wires for the upper heater are to be connected to the die-set. Do not attach one to the die-set and the other
to the plunger.
• Do not earth the transformer’s secondary conductor of the die-set heater.
• Make sure the earth cables have been properly connected.

3.2.3 CONNECTING THE MAGNETIC LOCK FOR THE DIE-SET (Optional)

• Connect the cables and related connector (XJ6) as shown in figure 3.2. - DIE CONNECTION SCHEMATIC.

WARNING!
Never reverse one or more wires as this may cause serious damage to the machine.

3.2 - DIE CONNECTION SCHEMATIC

HEATING MAGNETIC LOCK

510-511 Upper punch leads 911-912 Lower plate leads
514-515 Lower die leads 921-922 Connector XJ 6 (upper plate lead)
516-517 Lower punch leads

VERSION WITH TRADITIONAL LIFT SYSTEM

922
XJ6
921
510
511 D
514
515
912
516
911
517

C0523

VERSION WITH SMU LIFT SYSTEM

922
XJ6
921

510
511 D
E
514
515 912
516
911
517

C0524

24
 CATALOGUE 159.16
4 MACHINE START-UP MACHINE START-UP 4

4.1 GENERAL

Once the press, the filler box and the die-set have been properly installed, the plunger and the safety bar will be raised.

4.2 CHECK-OUT PROCEDURES

The numbers identifying the hydraulic parts in the following descriptions refer to the Press Hydraulic Diagram and can
be found in the list provided. The push-buttons and selector switches refer to the figures in the “OPERATING
INSTRUCTIONS” chapter.

4.2.1 CHECK:
- that the die-set heating elements are properly connected;
- that the selector switch “punch magnetic lock” is in its proper position: make sure that the selector key is not inserted.
- that the press body has been properly joined to the workshop electrical mains; also check that the cables connecting
the plunger to the crosshead are in good condition.
- that the oil level in the upper tank of the press.
- that the pressure of the hydraulic system is within the values indicated in paragraph 1.2 “TECHNICAL DETAILS”.
- that the electrical cables of the tile thickness control device are properly connected.
- that the connection and switching point of the limit switches of the filler-box and safety bar are correct.
- that the warning device “filter clogged” is properly connected.
- that the “powder lack” detector, which is found on the filler box feeding hopper works properly.
- make sure that the controller and the pressed product collectors located after the press are properly interlocked (start-
up and shutdown conditions).

4.2.2 MOTOR M3
Start the motor (M3) that drives the “oil-leak collector” pump by using the push-button (14) located on the electrical
enclosure. Make sure that the motor rotates in the proper direction.

4.2.3 MOTOR M11

Start the motor (M11) of the oil cooling pump by pressing the push-button (13) located on the electrical enclosure. Make
sure that the motor rotates in the proper direction.

4.2.4 DRIVE MOTOR M1

After the pump M11 has worked for at least three minutes, completely loosen the knob of the safety valve (111) and
start-up the drive motor (M1) by pressing the push-button (12) located on the electrical enclosure. Stop the motor after
about two seconds by pressing the push-button (15). Check the direction of rotation of the motor while it is running.
Wait for the drive motor to completely stop, then start the motor (M11) again for a short while and stop it. Operate the
motor intermittently for several times and keep the motor running if no trouble is found. Let the motor idle for a few minutes
in order to bleed all pipes and plates. Then, keeping the push-button (28) pressed, tighten the knob of the valve (111)
progressively to increase the circuit pressure up to 100 bars approx; check that no oil leaks from the flexible hose
connections.

4.2.5 SETTING THE PUMP PRESSURE

With the safety valve (111) set to about 100 bar, tighten the adjustment screw of the main pressure-relief valve (112)
which is located on the pump. Then, keeping the push-button (28) pressed, tighten the safety valve (111) progressively
until the pressure gauge (14) reads 230 bar approx.
Loosen and tighten the lock nut.
Keeping the push-button (28) pressed, loosen the adjustment screw of the pressure-relief valve (112) until the desired
pressure value is read (e.g. 170 bar at first). Fully tighten the adjustment screw.

25
 CATALOGUE 159.16
MACHINE START-UP 4

4.2.6 TOP DEAD CENTER

To bring the plunger to its top dead center position, press the push-buttons (3 & 25) located on the control switchboard.
The main cylinder should reach its top dead center, while the pressure in the hydraulic power unit should increase, as
shown on pressure gauge (14), until the factory-preset value of 180 bar is reached.

4.2.7 SAFETY GUARDS

The filler box is able to move when the safety bar is lowered. Before performing any other functions, check the
emergency push-buttons (24) for proper operation.

4.2.8 AUXILIARY EQUIPMENT PRESSURE

Set a working pressure of 140 bar into the controller, on the “SET-UP FILLING video-page.

4.2.9 FILLER BOX

Gain access to the “SET-UP FILLING” video-page and set the filler-box control to “0”.
Before starting the filler box tighten the flow regulator (24) completely, set RP2 (potentiometer located inside the
controller) to its maximum value and set the speed of the 16 filler-box steps (from the 1st forward step to the 8th return
step) to 100%.
Start the filler box by pressing the push-buttons (8, 27 & 29) simultaneously, then gradually open the flow regulator (24)
until the filler box reaches a sufficiently high speed. This speed should be greater than the normal operating one, but
should not be at a level (i.e. too high) which may cause damage to the gearmotor or the filler box.
Lock the flow regulator in this position. Set RP2 to value 5 and start the filler-box running so that the air bubbles, if any,
can be bled from the hydraulic circuit. Perform some complete operating cycles in semi-automatic mode (after having
selected semi-automatic filling) by pressing the F8 key and then the push-buttons (28 & 2) simultaneously.
Make sure that the filler box is completely backwards (at the end of its stroke), so that the safety limit switch is kept
pressed. The setting displayed for the filler box encoder should be less than the setting for the backward limit switch
(usually a few millimeters).
Under the conditions described above (speed = 100 and RP2 = 5) the speed of the filler box must be at least equal to
the max. speed required to form the desired tile size. If this is not the case, increase RP2 until the required speed is
reached.

26
 CATALOGUE 159.16
MACHINE START-UP 4

4.3 ADJUSTMENT OPERATIONS

4.3.1 SMU ADJUSTMENT (NORMALIZED MULTIPLE SYSTEM)

Regulate the pressure of the die supporting cylinders by means of the pressure reducing valve (253). The pressure
should be set to about 80 bar in presses with a die with entering punches or about 50 bar in presses with a mirror-finish
die. The valve setting is read on pressure gauge (142).
Adjust the knockout speed by means of the restrictor plate (61). To adjust the speed of the first downstroke of the die-
set, operate the restrictor (23) until the desired speed is obtained.
Adjust the speed of the second downstroke of the die-set by means of the restrictor plate (242) until the die-set rests
on the lower plate without bumping it. Check that the first downstroke of the die-set is properly performed by pressing
the push-buttons (13 & 30) once or twice, so that the lower punch reaches its second downstroke position. Measure
the distance between the lower punch and the upper surface of the die. If this is not the desired value, rest the die-set
on the press-table and press the push-buttons (13 & 30) and the push-buttons (26 or 31, with pushbutton 12 pressed)
in order to either increase or decrease the soft filling height to the desired value.

4.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM

The press is factory-preset. However, the following data is provided to see if the preliminary adjustments have been
changed.

MOUNTING PLATE, LOGIC ELEMENTS

Part No. activated by preliminary adjustment

120 YV38 fully open less 1/2 turn

119 YV70 open by about 2 turns
118 YV70 fully open less 1/2 turn
117 YV18 fully open less 1/2 turn
116 YV40 open by 4 turns
131 YV41 open by 6 turns

MOUNTING PLATE, ACCUMULATORS

Part. No. activated by preliminary adjustment

115 YV53 fully open less 1/2 turn

100 YV32S fully open less 5 turns
109 YV32D fully open less 1 turn
174 YV47 fully open less 6 turns

MOUNTING PLATE, AUXILIARY EQUIPMENT

Part. No. activated by preliminary adjustment

66 YV64 open by 1/2 turn

27
 CATALOGUE 159.16
MACHINE START-UP 4

4.3.3 FILLER-BOX SPEED ADJUSTMENT

4.3.3.1 Setting
After checking that the filler box works properly, the speed levels for each of the 8+8 steps the filler box stroke is divided
into. These speed levels, expressed from 0% to 100%, represent the extent to which the control valve is opened in
relation to its maximum opening.
A curve is thus defined which shows the optimum speeds required for a particular product to be pressed. To load the
powder, enter the filler box setting for the die-set to perform its first downstroke. Simulate filler-box operation in semi-
automatic mode. Press the pushbuttons (8 & 27) at the same time to check for proper functioning before loading the
powder.

4.3.3.2 Powder infeed

Two different methods can be used:

FILLER BOX WITH HOPPER AND ACP

After properly setting the ACP device (see relevant manual), put some powder into the filler box feeding hopper.

FILLER BOX WITH CONTROLLED-OPENING HOPPER GATE AND ACP

Properly set the ACP device (see relevant manual).
The hopper gate should open when the filler box is completely backward). It should close before the rear part of the filler
box grid leaves the hopper during the forward stroke. Enter increasing values, so that the amount of powder in the grid
increases. Make sure that no powder falls off the grid.
Enter “0” or “1” depending on the opening required or whether the hopper gate is to be left opened or closed, when
the machine is not working.
Move the filler box fully backward and put the powder into the feeding hopper. Perform some die-set filling cycles with
the machine set to semi-automatic mode and make any adjustments, if necessary. Leave the die cavities full of powder.

4.3.4 PLUNGER BRAKING ADJUSTMENT

To check the brake setting for the plunger, make sure that the brake logic element is set to around 80. If it is not, allow
the plunger to rest on the powder. Press the pushbuttons (7 & 26) at the same time to increase the setting; pushbuttons
(7 & 31) to decrease it. Perform this operation until 80 (approx) is shown.
At the beginning, inactivate the brake control (brake control set to “0”) and enter a sufficient braking space (braking
space = 90.00) in order to ensure safe braking. After filling the die-set with powder, allow the system to perform a few
downward strokes and adjust the braking space and force by changing the setting of the braking logic element until the
best results are obtained. After the machine has been started up, switch-on the brake control device. To do this, make
sure that the braking space is ≥ 70.00 (if less than 70.00 the braking control cannot be turned on). After carrying out a
loading cycle, read the impact speed of the punches on the powder (which should be suitable for the press-cycle), set
the brake control to “1” and key-in the impact speed (previously read).
From now on, the controller will automatically correct the braking parameters in order to keep the preset punch impact
speed unvaried.

28
 CATALOGUE 159.16
MACHINE START-UP 4

4.3.5 SETTING THE PLUNGER TRAVEL

Determine the setting required to start the press cycle (punches on the powder), by slowly lowering the plunger until
the punches are brought into contact with the powder. Read the plunger encoder setting (expressed in mm, end of the
upper stroke). Then enter the setting for the beginning of the stroke. With the key selector turned to the WRITE position,
enter a very high temporary value for “lack of powder” (140.000), which practically makes the control inoperative. Enter
the value for the end of the plunger upstroke. This value must allow the filler box to pass under the plunger. If necessary,
enter the value for braking and end of braking during the plunger upstroke, if equal to zero the brakes will not come into
action. With the machine set to manual mode and the die-set cavities full of powder, allow the plunger to perform some
upstrokes and downstrokes.

4.3.6 PRESS-CYCLE ADJUSTMENT

Input the press-cycle data. Enter the number of press-strokes for each cycle, the pressure for the first, second and third
(if required) strokes, the delay time (in milliseconds) for the 1st press stroke, the 1st and 2nd (if required) de-aeration
- which must be suitable for the size of the tiles and material to be pressed. Refill the die set in semiautomatic mode
as indicated in par. 4.3.3.2. After making sure that the powder has been evenly distributed in the cavities, perform a
press-stroke in semi-automatic mode (press the F8 key and then pushbuttons 28 and 2 to select the semiautomatic
press-cycle). Repeat the loading operations and press-cycles about ten times in order to allow the air in the hydraulic
system to be be let out. The automatic pressure control devices will thus be able to perform the required corrections.
When the tile appears to be correctly pressed, measure its thickness and adjust the soft filling height by pressing
pushbuttons 26 (+) or 31 (-) while keeping the pushbutton (12) pressed (with the die set lowered) until the desired
thickness is obtained. After setting the thickness control device (+) to Ø, (the displayed thickness should be equal to
that measured). Perform a few additional press-cycles in semi-automatic mode and make sure that the measured
thickness is the same as the displayed one. If they are, the automatic thickness correction device can be activated
(-) (thickness control = 1 and tile thickness = desired thickness).

4.3.7 DIE-SET PROTECTION SYSTEM IN THE EVENT OF POWDER LACK

After checking that the automatic thickness control is working properly, keep in mind that the die-set can be damaged
if the tiles are too thin. Stop the plunger in the same position as when powder is lacking and enter the max allowable
stroke for the plunger. The plunger should be able to move down an additional 0.5 mm (approx.) in relation to the desired
tile thickness.
After having entered this value, make sure that a fault message appears on the display when the plunger goes below
this setting.

4.3.8 ADJUSTING THE PLUNGER SPRING SHOCK ABSORBER

With the plunger at the end of its upstroke and the safety guards raised, loosen the lock nut and lower the pads for the
spring shock absorber (101). Load the die-set with new powder, allow the punches to rest on the powder, raise the pads
until they come into contact with the plunger.
Bring the cylinder to the end of its upstroke, lift up the safety-bar, raise the pads by approx. half a turn and then fit the
pads in place by using the locknuts provided.

NOTE: It is necessary to adjust the height of the shock absorbers each time the punches or die-set are replaced.

29
 CATALOGUE 159.16
MACHINE START-UP 4

4.3.9 ADJUSTING THE AUTOMATIC CYCLE

Check the oil level with the plunger lowered and make sure that the die-sets have reached the proper temperature
(observe the displayed die-set temperatures).
Make sure that the die-set can freely move at the preset temperatures.
Thoroughly clean the die and start up the automatic cycle by pressing the push-buttons (28 and 2) at the same time.
It is important to keep happens the work area under control during the first press-cycles so that the emergency push-
buttons (24) can be immediately pressed if necessary.
If everything is working properly, let the machine run for a few minutes.
Press push-button (6) to stop the work-cycle. Check the pressed product and make any necessary corrections. If the
tiles are to be ejected even during the last cycle set ejection during shutdown = 1, if not, set ejection during shutdown
= 0.

NOTE: The adjustments which have to be carried out on the press body or on the filler box must be performed with
the machine stopped. The adjustments regarding the data entered in the controller or the hydraulic parts can be done
with the machine running.

If the quality of the product is satisfactory, make a backup copy of the program (see par. 4.2.3.3 Instructions B) and
make any improvements which will increase productivity.

4.3.10 USE OF THE CONTROLLER TO KEEP THE SET SPEEDS UNVARIED

The press is equipped with an electronic device that energizes the valve YV20A to eleminate anything which alters the
speeds set for the powder loading device. When the press is started up, this device must be turned off (filler box control
= 0) .
After the press has been started up and the tiles have been found properly pressed (which means that the die-set has
been correctly loaded) the controller should be turned on (filler box control = 1). The filler-box forward and return stroke
times should be the same as those measured during the last stroke. Make sure that the gain for the forward and return
strokes is between 145 and 155. If it is not, turn RP2 (located inside the controller) until the required value is obtained.

30
 CATALOGUE 159.16
5 OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS 5

5.1 CONTROL EQUIPMENT

The parts used to control and run the press are:

- CONTROLLER
This is equipped with all the controls necessary to operate the press and all the keys to program the work cycles.

- ELECTRICAL ENCLOSURE
This contains all the switches to start up all the driving motors.

ELECTRICAL ENCLOSURE CONTROLLER

RACK PLC
• KEYBOARD

C0295

IMPORTANT!
All the information regarding CYCLE PROGRAMMING and MACHINE OPERATION are
found in the INSTRUCTIONS B manual: “Use of the microprocessor-based control
system”.

IMPORTANT
- “CYCLE PROGRAMMING” refers to the all information necessary to perform an automatic work cycle.
- Programming mode can be activated only by inserting the key provided in the key-switch found on the controller
keyboard.
- The programming procedures should be performed only by authorized personnel because improper data may
seriously damage the machine.
- It is advisable to keep written records of stored programs by using the files supplied.

31
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

5.1.1 CONTROLLER
This is a microprocessor-based programmable logic controller.
It allows:
- set up of the work cycle by using a keyboard, independent monitoring of the various process stages even when the
press is running;
- display of the messages and typical variables;
- all the parameters of each pressing cycle selected can be stored and retrieved whenever needed;
- automatic diagnostics;
- automatic operating pressure control;
- automatic tile thickness gauging;
- automatic machine control in case of malfunctioning.

C0295
KEYBOARD

+5
R WRITE
WD OFF ON
SL
SC
P
A1
7 8 9 – A2

4 5 6 + SCREEN HOME PAG

1 2 3 E DEL QUIT
CHAR
N
T
0 . E
R
DEL
LINE
END PAG

N1 N2 N3 N4 N5 N6 N7 N8

+5
I R I R
MAN +
SET UP AUT 25 26
WD
0 1 2 3 8 9 10 11 16 17 18
SL
SC I
P 27 28 29
A1
24 I A2 23 –
4 5 6 7 12 13 14 15 20 21 22 30 31

C0350

32
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

KEYBOARD

Machine Control Keys

Keys

0 Hydraulic power unit pump start

1 Reset (fault conditions)
2 Start, Automatic/semi-automatic cycle, semi-automatic loading, press-cycle
3 Plunger, Manual movements
4 Stop, Hydraulic power unit pump & filtering unit pump
5 Automatic repositioning of plunger and filler box
6 Automatic cycle stop
7 Manual plunger brake adjustment
8 Filler box, Manual movements
9 SFS punches, Manual movements
10 Not used
11 Not used
12 Powder filling height adjustment (manual mode)
13 Die set, Manual movements
14 Not used
15 Not used
16 Not used
17 Not used
18 Semiautomatic powder loading (1 re-positioning cycle)
20 Not used
21 Not used
22 Powder loading (manual mode)
23 AUTOMATIC/MANUAL/SET UP Key switch (functions with interlocks inactivated)
24 Stop button
25 Upstroke
26 Increment
27 Backwards
28 Automatic/semi-automatic cycle enable
29 Forward
30 Downstroke
31 Decrement

33
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

DISPLAY UNIT

The press comes with a 25 line x 80 column luminous display unit which provides the user with the following information:
- fault messages
- machine data
- production data
- actual settings
- program list
- set-points (display and modification)

The fault messages appear on the first line of the display. Different types of messages are shown depending on whether
the machine has blocked, stopped or if they are only general messages for the operator. Approximately 130 different
messages are provided.
All the other information is given on other video-pages. The data is shown in figure 1. The procedure to shift from one
page to another is also provided.

ACTUAL DATA SET UP

FILLING FILLING

SET UP
INFORMATION DATA PROGRAMS PRESSING

ACTUAL DATA SET UP

PRESSING FITTINGS

Fig. 1

Each time the machine is turned on, the “DATA” video-page will appear on the display (see figure 2).
The data related to the press-cycle which has just been completed appear in the first block on the left.
The data related to the transducers found on the machine is shown in the right-hand block. Some production data is
displayed in the bottom block. Some data items can be reset (those in the “PARTIAL” column) while others cannot (those
in the “TOTAL” column).
→
→

To reset any of these data items, press the F6 key, the cursor and , “0” and the “ENTER” key. To complete the
production data reset procedure, press the F6 key.
It is possible to shift from the “DATA” video-page to “ACTUAL DATA FILLING” (by pressing the F3 key), “ACTUAL DATA
PRESSING” (pressing the F4 key), “INFORMATION”, which shows the machine data, (pressing the F7 key) or to the
“PROGRAMS” video-page (by pressing the F2 key), as shown in figure 1.

34
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

OUTER SHUTDOWN PUSHBUTTON

CYCLE = AUTOMATIC (FILLING + PRESSING) MANUAL
3 OUTPUTS 300 mm x 300 mm ACTUAL DATA
CYCLES PER MINUTE = 18.0
CYLINDER PRESSURE = 0 bar
TILE THICKNESS = 9.90 mm
SERVICE PRESSURE = 150 bar
PRESSURE = 320 bar
OIL TEMPERATURE = 26 °C
SPECIFIC PRESSURE = 595 kg/cm2
PLUNGER ENCODER = 1.20 mm
MAX. FORCE = 16083 kN
FILLER-BOX ENCODER = 0.5 %
F-B FORWARD RUN TIME = 749 ms
= 34.9 °
F-B RETURN TIME = 878 ms

PRODUCTION DATA

PARTIAL TOTAL
PUMP OPERATING TIME = 0 h
PRESS WORKING TIME = 0 min 0 h
NO. OF CYCLES CARRIED OUT = 0 0
MATERIAL OUTPUT = 0 m2 0 m2
POWDER CAUSE STOP TIME = 30 min
PRESS CAUSE STOP TIME = 0 min
DRIER CAUSE STOP TIME = 0 min

HELP PROGRAM. FILLING PRESSING RESET INFO CYCLE

Fig. 2

The F1 and F8 have the same functions on all the video-pages. Pressing the F1 key will cause the previously displayed
page and some help functions to appear. The F8 key is used to change the functions of the cycle start key (key 2 on
the control keyboard). For example, when the F8 key is pressed, “CYCLE=SEMIAUTOMATIC LOADING” appears on
the second line of the display unit. When the keys (28 & 2) on the control keyboard are pressed at the same time, with
the key switch turned to “AUT”, the press will perform only one powder loading cycle. To change-over to automatic, press
the F8 key twice.

35
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

OUTER SHUTDOWN PUSHBUTTON

CYCLE=AUTOMATIC (FILLING + PRESSING) AUTOMATIC
PROGRAM LIST
1 3 OUT - 300 x 300 - SP 10.00 - PR 320 17
2 18
3 19
4 20
5 21
6 22
7 23 2 OUT - 400 x 400 - SP 11.00 - PR 300
8 24
9 25
10 26
11 27
12 28
13 29
14 30
15 31
16 32

HELP DATA FILLING PRESSING FITTINGS WRITE READ CYCLE

Fig. 3

The “PROGRAMS” video-page (see figure 3) shows the list of the stored programs. The stored programs are
accompanied with a title indicating the size, thickness of the tiles and the max. pressure provided. Press the HELP (F1)
key to obtain other useful information.
Press the F6 key to make a back up copy or to cancel one; press the F7 key to call up a program.
Press the F2 key to shift from the “PROGRAMS” to the “DATA” video-page. It is also possible to gain access to one of
the set up video-pages (display and modification of the set points). Press the F3 key to gain access to “FILLING”, F4
to “PRESSING” and F5 to “FITTINGS”.
“SET UP FILLING” will now be examined, as shown in figure 4.

36
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

OUTER SHUTDOWN PUSHBUTTON

CYCLE= AUTOMATIC (FILLING + PRESSING) MANUAL
FILLER-BOX
BACK STROKE END STOP = 5.0 % INS. FILLER-BOX CONTROL ON = 1
F-B FORWARD RUN TIME = 1000 ms F-B RETURN TIME = 1150 ms
FORWARD 1st ZONE = 50 % RETURN 1st ZONE = 50 %
FORWARD 2nd ZONE = 50 % RETURN 2nd ZONE = 50 %
FORWARD 3rd ZONE = 50 % RETURN 3rd ZONE = 50 %
FORWARD 4th ZONE = 50 % RETURN 4th ZONE = 50 %
FORWARD 5th ZONE = 50 % RETURN 5th ZONE = 50 %
FORWARD 6th ZONE = 50 % RETURN 6th ZONE = 50 %
FORWARD 7th ZONE = 50 % RETURN 7th ZONE = 50 %
FORWARD 8th ZONE = 50 % RETURN 8th ZONE = 50 %

AUX. EQUIPMENT 2nd FILLER-BOX

SERVICE PRESSURE = 140 bar ENABLE = 0
EJECTION WHEN STOPPING = 0

MOULDS HOPPER GATE

MOULD UPSTROKE DELAY = 500 ms CLOSING POSITION = 50.0%
OPENING POSITION = 50.0%
MOULD 1st FALL POSITION = 70.0 % OPENING WHEN STOPPING = 0

MIN = 0.0 MAX = 40.0 FILLER-BOX ENCODER = 0.5 %

HELP PROGRAM. FILLING PRESSING RESET INFO CYCLE

Fig. 4

→
→

To move the cursor, press the “ ” key. Press the “ ” key to shift to the last data item. Press the “PAG “ to shift
→
→

to the next block, “PAG “ to the last one. Press the “END” key to shift to the last data item on the video-page, “HOME”
to the first one.
The min. and max. allowable values for the data item indicated by the cursor and any information useful to modify the
set points appear on the next to last line on the display unit.

Two methods can be used to modify the set points:

1) Keep the -1 key pressed to decrease the data item; the +1 key to increase it.

2) It is possible to directly enter the desired setting by pressing the keys from 0 to 9 (To correct any errors, press the
DEL CHAR key; the last number input will be deleted. Use the DEL LINE key to delete all the keyed-in numbers).
Press the ENTER key.

The set points can be changed only if the key switch is turned to the “ON” position.
With MOULD UPSTROKE DELAY,MOULD 1ST FALL POSITION, 1ST PRESSING and 1ST DEAERATION, which can be
altered as explained at 1, it is possible to make the modifications with the key switch turned to the “OFF” position.

37
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

(CONTROLLER)
SELECTOR SWITCHES AND INDICATOR LIGHTS

CONTROLLER

C0295

27 17 18 28 29 19 20

30 21 22 23 31

C0313

17 HL201 Indicator light, upper punches magnetized

18 HL203 Indicator light, upper punches de-magnetized
19 HL202 Indicator light, lower punches magnetized
20 HL204 Indicator light, lower punches de-magnetized
21 SA201 Key switch, Magnetic upper punch locking
22 SA203 SFS On/Off switch
23 SA202 Key switch, magnetic lower punch locking
27 HL301 Red indicator light
28 HL205 Off indicator light
29 HL206 On indicator light
30 SA300 Selector switch, automatic start (optional)
31 SA1 Selector switch, punch overtravel

38
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

(CONTROLLER)
SYSTEM CARDS

RACK - PLC

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

EN

IN
AL CPU VA
AN

C0295

POWER SUPPLY
ALIMENTAZIONE PROCESSING
ELABORAZIONE INPUTS
INGRESSI OUTPUTS
USCITE
C0297

SYSTEM CONFIGURATION
Location of the cards

1-4 AL POWER SUPPLY (rectified supply voltages)

5 CPU Central processing unit
6 ENCODER ANALOG INPUT
7 VA MISCELLANEOUS
8-9-10 (not used)
11-12 I D DIGITAL INPUT (detection of 24 Vdc incoming signals)
13 OR RELAY OUTPUTS
14-15 OD DIGITAL OUTPUTS, energize the 24 Vdc outputs
16 ODA DIGITAL AND ANALOG OUTPUTS
17-18-
19-20-21 (not used)

This configuration is for reference purposes only. For a detailed description, see INSTRUCTIONS B, chap. 2,
“SYSTEM CONFIGURATION”.

39
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

5.1.2 ELECTRICAL ENCLOSURE

The power switchboard provides power to the electric motors on the hydraulic power unit and on the press as well as
power for heating the die-set.

ELECTRICAL ENCLOSURE

C0295

C0435

24 25 VISUAL AND AUDIBLE SIGNALS

V A
1 HL2 Warning light, oil below min. level
2 HL12 Warning light, motor overload cutouts
4 HL8 Indicator light, lower punch heating
1 2 3 4 5 6 7
5 HL7 Indicator light, lower die heating
8 9 10 11 6 HL6 Indicator light, upper die heating (optional)
7 HL5 Indicator light, upper punch heating
12 13 14 8 HL1 Pilot light, hydraulic power unit drive motor
9 HL11 Pilot light, oil filtering unit motor
15 16 10 HL3 Pilot light, oil-leak recovery motor
11 HL4 Pilot light, heat-exchanger fan motor

SELECTOR SWITCHES
12 SB3M Push-button, motor run (M1)
26 13 SB11M Push-button, motor run (M11)
14 SB3P Push-button, manual motor run (M3)
15 SB3A Push-button, motor shutoff (M1)
16 SB11A Push-button, motor shutoff (M11)
24 Voltmeter
25 Ammeter
26 Master switch

40
 CATALOGUE 159.16
OPERATING INSTRUCTIONS 5

5.2 START-UP AND SHUTDOWN PROCEDURES

DAILY START-UP

The machine can be started up either from the electrical enclosure or from the controller keyboard.
There are two pairs of pushbuttons on the electrical cabinet for the main motor (12) and (15) and for the motor driving
the recirculating pump (13) and (16).
On the controller, a single push-button (0) first starts the circulating pump and then the main motor.

WARNING: Do not press the “Enable” button (28) on the controller while starting up the machine.

MACHINE SHUTDOWN

The machine can be shut down in three different ways:

- Using key 6 found on the controller;
- from a timing circuit (KA301);
- from an external shutdown circuit (KA300).

41
 CATALOGUE 159.16
6 MACHINE OPERATION MACHINE OPERATION 6

Refer to the diagrams:

- 1.4 HYDRAULIC SCHEMATIC
- INSTRUCTIONS B MANUAL - 5 PHOTO-CELL ARRANGEMENT

6.1 COMPRESSED AIR SUPPLY

The circuit consists of a filter (72), a pressure reducer (73) a check valve (74) and a pressure gauge (75).
The compressed air is used to pressurize the reservoir and exert constant pressure on the hydraulic fluid.
The pressure reducer should be properly set-up, so that a pressure of 1-1.2 bar is produced inside the reservoir (126).
A safety valve (71) is used to relieve possible overpressures which may arise inside the hydraulic reservoir.
The valve is properly set-up and sealed during machine inspection.
A pressure switch (SP3) for the pressurization control is located near the suction pipe of the pump (58). In case of
insufficient air pressure inside the circuit, the pressure switch will not allow the main pump to start, and a relevant fault
message will appear on the display.
A special unit consisting of a filter (272), a pressure reducer (273), a pressure gauge (275), an oiler (277) and the
solenoid valve (YV221) controls the cylinder (244) operating the feed hopper gate (if provided).

6.2 FAST HEATING

In order for the press to function properly, the oil temperature should be as close as possible to 40°.
When the press is started up, the oil is at room temperature and must be heated to at least 30° before starting the
machine in automatic mode; however, it is possible to start the press, if desired.

NOTE: For temperatures below 5°, the use of an external heating system is recommended.

To warm up the oil, start the pump with the safety bar raised. If the temperature is lower than 30°, the pump circulates
the oil at a pressure of 100 bar (as set for the valve 112A), thus dissipating electric power which is transformed into heat.
The power dissipated by the pressure-relief valve (112A) warms up the whole amount of oil in a short time (10-15 minutes
approx.).
If the oil temperature is found to be ≤ 0°C, the controller prevents the drive motor (M1) from starting.

6.3 HEAT EXCHANGER CIRCUIT

The system consists of a motor & pump assembly (M11-78) and a plate-type heat exchanger (48).
The oil contained in the reservoir of the hydraulic power unit is drawn by the pump (78) and sent to the heat exchanger
(48) from which, after being cooled down, it returns to the reservoir.
The flow rate of the cooling water is controlled by a thermostatic valve (255) according to the temperature desired.
If the motor (M11) stops, the drive motor (M1) and consequently the press automatic cycle will stop.
To start the drive motor (M1), the exchanger unit must first be started if the motors are operated from the electrical
enclosure. If the motors are started by means of the push-button (0) on the switchboard, the controller will start the
motors in sequence.
The hydraulic coupling (254) allows the filling of the tank or the oil to be changed by means of a motor-pump-filter
assembly supplied with the machine. It is good practice to use this assembly every time the oil is to be changed or added.

42
 CATALOGUE 159.16
MACHINE OPERATION 6

6.4 OIL-LEAK COLLECTOR CIRCUIT

Hydraulic oil-leaks which come from the seal of the main cylinder rod (124), the hydraulic motor (42) (driving the filler
box) and the logical elements (117, 115, 108) are collected in the tank (105).
The solenoid valve (YV185) located on the line coming from the hydraulic motor (42) shuts off the oil delivered in case
of power failure. A level gauge called “first level control” (SL3) is located inside the hydraulic tank (105). When the
maximum level is reached, the motor-and-pump unit (M3-85) will be started.
The oil drawn by the pump through the filter (86) flows into the reservoir of the hydraulic power unit. A check valve (54)
is used to prevent the oil from going back to the tank (105). When the min. level is reached, the pump will stop working.
If the oil cannot flow into the reservoir of the hydraulic power unit (e.g. due to the breakage of the joint between the motor
and the pump, suction filter (86) clogged, overload cutout of motor M3, etc.) the “second level control” (SL4) inside the
tank (105) transmits a signal which, processed by the microprocessor-based control system, automatically stops the
machine.

6.5 MAIN PUMP ON - SAFETY BAR UP

When the motor control panel is activated by using the master switch, the microprocessor-based control system is also
activated.
By pressing the key (0), the following units are started in sequence:
- fan motor on the soundproof housing (if provided);
- motor-and-pump assembly of the heat-exchanger (M11-78);
- drive motor-and-pump assembly (M1-58).

The assembly (M1-58) is started up according to the given sequence under no-load conditions, as solenoid valve
YV99 controls the drainage of the pump pressure regulator in this phase.

The filter (49) and the pressurization system pressure switch (SP3) are located on the pump suction line (58). The
pressure switch is also used to check if the filter (49) is clogged. Should this occur, there will be a drop in pressure inside
the pump suction line which will immediately be detected by the pressure switch (SP3). The latter will transmit a signal
to the microprocessor-based control system and will shut down the drive motor-pump assembly. A relevant fault
message will be displayed.
The filter (79) and the pressure switch (SP1) are located on the pump delivery line (58). The pressure switch detects
if the filter (79) is clogged. The pressure in the circuit at this point is about 20 bar (see description regarding the operation
of the variable-displacement pump. When the solenoid valve (YV22) is de-energized, the oil is forced into the upper
chamber of the SMU cylinders (180) and as a result, the lower punches come down.
When the solenoid valve (YV221) is energized, compressed air is sent to the hydraulic cylinder (224) which opens the
powder infeed hopper gate.

43
 CATALOGUE 159.16
MACHINE OPERATION 6

6.6 PRESSURE TRANSDUCERS - DATA INPUT

The encoders are digital position transducers which detect the position of the plunger and the filler box every second.
The machine will perform the pre-determined operations according to the data entered into the microprocessor control
system and the program selected. In order for this operation to be carried out, the plunger and filler box positions
(sensed by the transducers) must coincide with the input data.

The following is a list of some data which can be entered for encoder 1 (plunger position).
(See Instructions B - 4.2.2.3):
- Plunger blocked due to lack of powder.
- Plunger down (press-cycle start enable).
- Braking space.
- Plunger up in automatic cycle.
- Plunger up with machine stopped.
- Plunger upstroke, End of braking.

Encoder 1 is reset, when the sensor (SQ1) is activated by the cam integral with the encoder slide. Reset for the encoder.
Encoder 2 (filler-box position) is reset when it reaches the end of its backward stroke.

The following data can be entered for the filler box cycle (see Instructions B - 4.2.2.1 and 4.2.2.3):
- Filler box backward
- Time taken to perform the forward stroke
- Time taken to perform the return stroke
- Filler box speed during the forward stroke
- Filler box speed during the return stroke
- First die-set downstroke position

The sensors (SQ3) and (SQ6) detect when the die set is raised or lowered. All of the inputs, outputs, solenoid valves,
miniature switches, sensors, contactors, etc., are displayed with indicator lights (LEDs) on the rack of the microprocessor-
based control system. The lights indicate the condition of the above items while the machine is operating.

6.7 SAFETY BAR OFF (LOWERED)

Lowering the safety bar, the limit switch (SQ51) is triggered and sends a signal to the microprocessor-based control
system, which energizes the solenoid valve (YV99). At this point, the pressure in the circuit will correspond to the
pressure of the relief valve (112) which is set to 180 bar, as shown on the pressure gauge (13). The valve (111), with
the pressure value for 112A set to 230 bar, acts as a hydraulic safety device.
It is important to remember that once the safety and relief pressure valves have been set to the proper value, it is good
practice to lock the adjusting pins of the two valves (by means of lock nuts). This should be done in order to prevent the
adjusting pins from loosening (the vibrations produced while the machine is functioning may cause this to happen) as
this will change the set pressure.
The pressure setting of valve (112) is known as line pressure.

6.8 ENCODER RESET

To perform this operation press the keys (28) and (5) at the same time. It is important to reset the encoder each time
the microprocessor-based control system is turned off. To start up the machine in automatic cycle, the encoders have
to be reset. “Encoder reset” will be shown on the display of the microprocessor-based control system when this operation
has to be performed. Once the plunger encoder has been reset, the filler box encoder will also be reset.

44
 CATALOGUE 159.16
MACHINE OPERATION 6

6.9 DIE-SET CONTROL CIRCUIT

By pressing the buttons (25) and (13), the solenoid valves (YV22) and (YV21) will be energized. The solenoid valve
(YV22) will cause the oil to be delivered to the lower part of the lower punch lifting cylinders (180); at the same time the
upper part of the cylinders (180) will be drained through YV22. To adjust the upstroke speed, work on the flow regulator
(61) located under the solenoid valve (YV22). The solenoid valve (YV21) delivers oil to the die-set upstroke cylinders
(181) through the flow regulator (242) which then allows the speed of the last downstroke to be adjusted. In this way,
the lower punches are raised to the same level as the die.

6.10 CYCLE START

6.10.1 FILLER BOX START

Pressing the two cycle start keys (28) and (2) at the same time will energize the solenoid valve (YV20a). The oil supplied
from the pump (58) and from the auxiliary equipment accumulator (12) flows to the proportional flow control valve
(YV20a) and starts the hydraulic motor (42). The latter drives the filler box through gears. It is possible to choose eight
different speeds for the forward stroke and eight speeds for the return stroke by using the microprocessor-based control
system.The limit switch (SQ59) located on the filler box fixed mount, must be de-energized after the filler box has moved
forward a few millimeters, thus preventing the plunger from lowering until the switch is pressed by the filler box during
its return stroke, a few millimeters before it stops in the initial starting position (i.e. when the encoder reaches the value
set for C24).
It is important that the point at which YV20a is de-energized and the point at which the crank stops working are within
the operating range of the limit switch (SQ59) (see the diagram).

6.10.1 - ASYNCHRONOUS OPERATION

C Crank travel
T Tolerance, Filler-box backward
0 Filler box backward (theoretical)
C24 Max. allowable limit, Filler box backward

T
SQ59
TRIGGERED
PREMUTO
0%
FC
C

SQ59
NOT TRIGGERED
NON PREMUTO

100%

C0351

45
 SQ3
SQ6
YV38
YV40
YV41
YV70
YV53
YV19
YV47
YV21
YV22
YV64
YV99

SQ61
SQ60
SQ59
YV221

YV32S
YV20A

YV32D
FILLER BOX START
HOPPER GATE OPENING

FIRST DIE-SET DOWNSTROKE START

CYCLE DIAGRAM

END OF FIRST DOWNSTROKE

solenoid valve energized

HOPPER GATE CLOSING

START OF SECOND FILLER BOX SPEED

END OF FILLER BOXSTROKE-DOWNSTROKE START

END OF SECOND DIE-SET DOWNSTROKE

END OF AUX. EQUIPMENT REFILLING

solenoid valve enrgized if relevant options have been selected

START OF BRAKING

ARRIVAL ON THE POWDER

T1
START OF FIRST PRESS-STROKE

END OF FIRST PRESS-STROKE

DECOMPRESSION-DEAERATION
T2

END OF DEAERATION
START OF DIRECT PRESS-STROKE
T8

END OF DIE-SET UPSTROKE DELAY

CATALOGUE

START OF PRESS-STROKE WITH PRESSURE BOOSTER

END OF SECOND PRESS-STROKE

UPSTROKE START
END OF DIE-SET UPSTROKE
END OF BRAKING, UPSTROKE
MACHINE OPERATION
6

C0302
END OF UPSTROKE
159.16

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 CATALOGUE 159.16
MACHINE OPERATION 6

6.10.2 POWDER INFEED

The powder can be fed in the following ways:
- a fixed-opening hopper: the powder is fed by gravity and there are no driven parts that come into action during the
machine cycle.
- a hopper with controlled and adjustable opening: the hopper gate stays open when the filler box starts and remains
open according to the setting entered into the controller (“FILLING” video-page). The solenoid valve (YV221) is then
de-energized and the hydraulic cylinder (224) closes the gate which will then be re-opened during the return stroke by
YV221 (when energized again).
In this way, the operator can regulate the amount of powder loaded onto the moving grid of the filler box during its stroke,
by altering the infeed hopper gate settings provided.

6.10.3 FIRST DIE-SET DOWNSTROKE

While the filler box is moving forward, the encoder detects the loading position (the setting of which can be entered into
the microprocessor-based control system) by using the first downstroke setting as reference. At this point, YV22 is
de-energized causing the oil to flow from the pump (58) and the accumulator (12) to the upper part of the cylinders (180).
At the same time, the oil from the lower part of the cylinders (180) is drained through YV22 and the pilot-operated check
valve (62) allows the cylinders to move down quickly.
The lowering speed can be adjusted by using the flow regulator (23) located in line with the piping. At the end of their
stroke, the lower punches are stopped by the cylinders (181), as YV21 remains energized during this stage.
In this way the die-set can perform its first downstroke, as the cavity needed for the downstroke is formed and filled
with the powder contained in the grill of the filler box. The first downstroke setting is therefore extremely important, as
it determines when the powder is to be dropped into the lower cavities until they are filled.
Other parameters affect the first downstroke of the die-set, e.g. the filler box travel speed which is regulated by the
propotional flow-rate control valve (YV20a). The sensor SQ3 must be de-activated during this phase (lower punches
up) and the cam has to be positioned in front of the sensor (SQ6). If this is not the case, the machine will shut down and
the relevant fault message will appear on the display.

6.10.4 FILLER BOX DRIVE

The encoder detects the position of the filler box during its stroke. The speed at which the filler box must travel can be
selected by entering the set points for the 8 + 8 steps for the forward and return stroke (1), respectively. By turning the
potentiometer (RP2) - located inside the microprocessor-based control system (2) - it is possible to proportionally
change all of the speeds. The proportional valve (YV20a) will regulate the flow rate from the accumulator (12) to the
motor (42) according to the values entered for the set-points and the position of the potentiometer. The flow regulator
(24) limits the max. speed.

NOTE:
(1) The set points are values which range from 0 to 100% and give the relative speed range for each step.
(2) The potentiometer acts on the live output of the microprocessor-based control system by increasing or
decreasing the value for the valve proportionally to the input.

6.10.5 SECOND DIE-SET DOWNSTROKE

The filler box reaches the end of its backward stroke and the solenoid valve (YV21) is now de-energized. The OFFSET
value is assigned to solenoid valve YV20a. When it is de-energized, the line of the second downstroke cylinders (181)
is joined to the drain line. When the solenoid valve (YV22) is de-energized, it controls the oil pressure in the die-set return
cylinder (180). As a result, the pressure exerted on the cylinder (181) forces the oil through the flow regulator (242) and
YV21, thereby causing the die-set to perform its second downstroke. These movements can be regulated by working
on the plate-mount flow regulator (242). It is very important that the sensor SQ6 remains activated by the respective
cam. Otherwise, as said before, the press will automatically stop working and the relevant fault message will appear
on the display (see instructions type B). The setting for end of backward stroke will cause the filler box to stop in its rest
position. Before the machine stops running, the filler box has to press the limit switch (SQ59) and the corresponding
indicator light (LED) on the front panel of the microprocessor-based control system (KA59) will come on.

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 CATALOGUE 159.16
MACHINE OPERATION 6

6.10.6 ADDITIONAL DIE-SET DOWNSTROKE (OPTIONAL)

The lower punches stop halfway to allow for a double-layer load. The punches first rest on the cylinders (189) thus
performing the first downstroke. Under these conditions, the cavities are filled another time as the punches rest on the
cylinders (189). At this point the solenoid valve (YV170) is de-energized, but YV21 remains energized. Under these
conditions, the second layer of powder is formed. When the solenoid valve (YV21) is de-energized, the punches rest
on the press table. The additional downstroke speed is regulated by using the plate-type flow regulator (169).
The cavity can be filled a second time by means of a second box which, at the end of its cycle, triggers the start of the
press cycle.

6.10.7 FAST DOWNSTROKE

The following conditions must be satisfied for the plunger to begin its downstroke:
- Sensor SQ6 energized (lower punches down)
- Limit switch SQ59 triggered by the filler box when backward.

With the above mentioned conditions satisfied, an electric signal is sent from the microprocessor-based control system
to the magnet of the valve (YV32d) which, in turn, removes the pressure from the rear part of the cone of the descent
logic element (109). At this point, the weight of the cylinder-plunger assembly and the pressure exerted by the air in the
pre-filling tank (126) produce pressure on the ring-shaped chamber of the cylinder, which then opens the logic elements
(174) and (109), by overcoming the force exerted by the spring.
The oil can flow from the ring chamber to the drain. Consequently, the main cylinder begins its downstroke as the air
forces the oil in the pre-filling tank through the ports of the pressure booster bushing in the main cylinder.
The speed of this first stage can be adjusted by using the adjusting pins provided for the opening of the logic element
cone (109). However, as this operation brings the upper punches closer to the powder to be pressed, it is important to
maintain the maximum speed according to the machine’s capabilities.

6.10.8 DOWNSTROKE WITH BRAKE APPLIED

As soon as the plunger exceeds the brake setting, solenoid valve (YV47) is energized. As a result, the oil under pressure
flows from the accumulators (27, 18, 18a) (on the PH 1600, only accumulators 27 & 18 are provided) to the rear part
of the logic element cone (174), thus causing the cone to close within a time defined by the spray nozzle located under
the YV47 pressure line. The oil is forced through the power-operated flow regulator (132) which due to its small
dimensions (DM=15) produces a backpressure during braking and reduces the plunger downstroke speed.
The relief valve (92) is a safety device which relieves pressure and must not be used to adjust the brake system.
To adjust the speed at which the upper punches come into contact with the powder contained in the cavities, it is
necessary to enter the desired value into the microprocessor-based control system (speed control = 1, impact speed
= desired value expressed in mm/sec).
The controller program is complete with a punch speed correction system. When activated, it detects the impact speed
of the punches and compares it with the set speed value, modifying the opening of the flow regulator (132) accordingly
by means of the motor (M15).
The braking speed control can be inactivated by setting speed control to 0.

6.10.9 FIRST PRESS-STROKE DELAY

The plunger keeps on lowering at the braking speed until the upper punches come into contact with the powder
contained in the die cavities.
While the upper punches move closer to the powder, the encoder reaches the value set for “press-stroke start” just
before the upper punches come into contact with the powder contained in the die cavities.
This moment corresponds to the beginning of the first press-stroke delay time. Braking is inactivated by de-energizing
the solenoid valve (YV47) so that the plunger can freely move downwards. The delay time is entered into the
microprocessor-based control system. As long as this delay time lasts, the powder contained in the die cavities is
pressed under the weight of the cylinder, the plunger and under the pressure exerted by the air used for pressurization.
The powder is thus compacted for the first time and a certain amount of air can escape. Consequently, this operation
is very important in order to achieve proper de-aeration during the following phases.

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 CATALOGUE 159.16
MACHINE OPERATION 6

6.10.10 FIRST PRESS-STROKE

The first press-stroke begins once the first press-stroke delay time has elapsed. The desired pressure value is entered
in the controller and is measured by the pressure transducer (BP1).
The microprocessor-based control system checks the pressure value reached, compares it with the setting and corrects
it if necessary.
The following is a description of what happens in the hydraulic circuit.
The microprocessor-based control system sends a signal to the first press-stroke solenoid valve (YV40) which is
energized, thus allowing the logic element (116) to open. Once opened, the logic element allows the oil coming from
the pump (58) and from the accumulators (18), (18A) and (27) to reach the boosters (125). The oil flowing speed, and
therefore the pressing speed, can be regulated by means of the logic element adjusting pin (116).
The accumulators (18) and (27) are connected to the pressure line by means of the logic element (115) which is opened
when the solenoid valve (YV53) is de-energized.
The pressure produced by the flow-rate booster cylinder during the plunger downstroke, is exerted directly on the oil
which fills the cylinder chamber and is applied to the plunger through the main cylinder.
This pressure value can be read on the display unit of the microprocessor-based control system. Remember that the
exact pressure value is indicated on the display, which is more precise than the mechanical pressure gauge. The
mechanical pressure gauge (36) should always be disconnected during the normal press operation and must be used
only to check or set the values shown on the display.

6.10.11 FIRST DIRECT PRESS-STROKE WITH AND WITHOUT ACCUMULATORS

Setting 1st P. STROKE W/O BOOST = 1, the machine will perform a type of press-stroke which, from a hydraulic stand
point, is different from the one described above.
A fixed time during which the solenoid valve (YV40) is energized is preset in the controller, as described in the previous
paragraph. Once this time has elapsed, the solenoid valve (YV40) is de-energized and YV19 is energized, thus allowing
the logic element (117) to open.
Now, as the line pressure is greater than the pressure present in the section connecting the logic element (117) to the
cylinder, the oil will flow naturally to the cylinder. In this way, the press-stroke is completed without the booster coming
into action again, thus saving oil.
This type of first press-stroke is to be used only when a lot of oil is required to perform the first press-stroke (installation
of the SFS die or other optional equipment, very thick tiles made with dry-ground mix).

6.10.12 FIRST SEPARATE PRESS-STROKE

The function of the first press-stroke is to remove the air from the powder which is to be pressed.
If the first press-stroke is performed quickly and a lot of pressure is exerted, part of the air may not escape, thus causing
the resulting pressed tiles to be defective (grooves in the tiles).
For this reason, it may sometimes be necessary to perform the first press-stroke at a slower speed, and apply the
pressure more gradually. This system is called “first separate press-stroke”. To do this, set NUMBER OF PRESSINGS
= 1.
The selection of the type of first press-stroke to be performed depends on the characteristics of the powder to be
pressed.
After the delay time for the 1st press-stroke has elapsed, the magnet of the valve (YV40) is energized, thus causing the
logic element (116) to open. At the same time, the magnet of the valve (53) is also energized, and causes the logic
element (115) to close and consequently the accumulators (18), (18A) and (27) are shut off.
The press-stroke is completed when the cylinder reaches the set pressure. With the accumulators shut-off, the cylinder
moves slowly and steadily thus allowing the air in the powder to come out. This type of press-stroke ensures less power
consumption, as the pressure in the pump has the same values (from 0 to the max. setting) as the pressure in the
cylinder. On the contrary, if the accumulators are used, the pressure in the pump is always equal to the maximum setting.

6.10.13 FIRST (AND SECOND) SEPARATE PRESS-STROKE (MACHINE REMAINS UNDER PRESSURE)
If it is difficult to remove the air from the powder being pressed, proceed as directed above.
This operation can be performed only by modifying the hydraulic circuit, i.e. by replacing the pressure control valve (112)
with a proportional valve (YV111) supplied on request.
The following phases take place in the hydraulic circuit: the magnet of the valve (YV40) is energized, thus causing the
logic element (116) to open. At the same time the magnet of the valve (53) is also energized and causes the logic element
(115) to close and the accumulators (18), (18A) and (27) to be shut-off.
49
 CATALOGUE 159.16
MACHINE OPERATION 6

When the pressure set points for the 1st press-stroke are reached, the set time for the 1st press-stroke starts elapsing
and the cylinder is kept under pressure for the whole preset time. At this point the proportional relief valve (YV111) will
cause the regulator of the pump (58) to be set so that the line pressure can remain (entered by means of the
microprocessor-based control system) unvaried for the whole time set.

6.10.14 DE-AERATION
The de-aeration process occurs when the upper punches are raised from the powder which was just pressed, so that
the air inside the die cavities can be released.
Once the first press-stroke has finished, the time set (length of de-aeration) will start elapsing. This time can be entered
into the microprocessor-based control system.
The solenoid valve (YV40) which causes the logic element (116) to close and the solenoid valve (YV70) for draining
are de-energized at the same time.
YV70 allows the logic elements (118) and (119) to open. The former releases the pressure for the first press-stroke from
the main cylinder, by joining it to the reservoir (126).
The logic element (119) allows the oil inside the flow-rate booster to be drained into the reservoir (126).
At this point the two spring recoil devices (101) placed under the plunger and priorly compressed during the first press-
stroke push the plunger up, thus lifting the upper punches up away from the powder. Therefore, the air can escape from
the cavity through the open spaces in the die-set.
De-aeration is controlled by the combination of the time set and the space left by the plunger (this space, expressed
in millimeters, can be varied by adjusting the spring recoil devices). The correct adjustment is obtained when de-aeration
is carried out in the shortest possible time, remembering that the pressed tiles must not have any faults.

6.10.15 SECOND PRESS-STROKE (LAST PRESS-STROKE)

The last press-stroke consists of two separate stages which can be called:

- SECOND DIRECT PRESS-STROKE

- PRESS-STROKE WITH PRESSURE BOOSTER

During the first phase, a max pressure of 150 bar can be reached. The second phase has to be performed if higher
pressures are to be reached.

6.10.16 SECOND DIRECT PRESS-STROKE

Once the de-aeration time has elapsed, the coil of the valve (YV70) is energized, thus causing the logic elements (118
& 119) to close. The solenoid valve (YV19) is then energized allowing the line pressure to open the logic element (117).
A direct connection between the accumulators and the main cylinder is thus established. If the pressure set is < 150
bar, the second press-stroke will finish once the set point is reached.
If the pressure set is greater than 150 bar, when BP1 has sensed that the optimum pressure (according to the controller)
has been reached, YV19 is de-energized thereby closing the connection with the accumulators and starting the press-
stroke with the pressure booster.

6.10.17 SECOND SEPARATE PRESS-STROKE

When it is necessary to perform a slower and more gradual second press-stroke, it is possible to disconnect the
accumulators (18, 18A and 27) from the line by entering NO. OF SEPARATE PRESS. = 2 in the microprocessor-based
control system. When YV19 starts working, the magnet of the accumulator shut-off valve (which closes logic element
115) is energized.
The latter prevents the oil found in the accumulators (18, 18A and 27) from draining into the pressure lines. As a result,
only the oil coming from the main pump (58) will fill the main cylinder.
The solenoid valve (YV53) is de-energized when the operating time for YV19 has elapsed. If the value for the pressure
to be reached in the main cylinder is higher than the line pressure, it is necessary to use the pressure booster as well
as the accumulators.
This type of press-stroke is saves energy, as the pressure in the pump and the the cylinder is the same. It does not reach
its maximum value as when the cylinder is connected to the accumulators.

50
 CATALOGUE 159.16
MACHINE OPERATION 6

6.10.18 PRESS-STROKE WITH PRESSURE BOOSTER

The first part of the press-stroke is performed as described in paragraph 6.10.16 “Second direct press-stroke”. When
the pressure in the main cylinder is the same as in the microprocessor-based control system, YV19 is de-energized,
thus closing the logic element (117). YV38 and YV41 are energized, allowing the logic elements (120 and 131) to open.
Through these elements the oil under pressure in the pump and accumulators (18A, 18 and 27) reaches the flow-rate
and pressure booster (125).
The max. pressure which can be set for the main cylinder is 350 bar.
If the max. pressure setting in the main cylinder circuit is exceeded for any reason, pressure switch SP2 (set and sealed
during machine inspection) comes into action stopping the cycle. The relevant fault message will appear on the display
of the microprocessor-based control system.

6.10.19 ACTIVATION OF DIE-SET 1 AND DIE-SET 2

At the start of the second press-stroke, the delay time (for die-set lifting) starts elapsing. The delay time can be entered
into the microprocessor-based control system.
Once the delay time has elapsed, the coils of the valves (YV21 and YV22) are simultaneously energized. The oil under
pressure from the accumulator (12) flows to the lower part of the cylinders (181 and 180), allowing the lower punches
to be raised after the plunger has moved away.
In order for the delay time to be properly set, the punches will be raised at the same time as the plunger (pack-type
ejection). On the other hand, the longer the delay time , the longer the time required for energizing the two solenoid valves
(YV22 and YV21). As a result, the upstroke of the lower punches will be delayed in relation to the plunger upstroke.

6.10.20 CYLINDER PRESSURE RECOVERY

By using the controller, it is possible to select this option which can be used only if the pressure in the cylinder is higher
than the line pressure.
At the end of the last press-stroke, the oil in the cylinder flows into the accumulators (18, 18A and 27), the pressure
of which is lower. YV19 is energized, thus allowing the logic element (117) to open. The oil will be transferred until the
pressure in the cylinder decreases and reaches a level equal to the line pressure + 30 bar.
At this point YV19 is de-energized, closing the logic element (117). YV70 is de-energized. The logic elements (118 and
119) will open, allowing the pressure in the chamber of the cylinder to be eliminated.

6.10.21 UPSTROKE WITH BRAKE APPLIED

To lift the plunger, eliminate the pressure for last press-stroke in the main cylinder.
This is done by de-energizing the solenoid valve (YV70) which opens the logic elements (118 and 119). The logic
element (118) connects the main cylinder to the reservoir (126). At the same time, the magnet of the valve (YV32s) which
opens of the logic element (108), is energized allowing the oil coming from the pump (58) and from the accumulators
(18, 18A and 27) to flow into the chamber for the main cylinder upstroke.
Part of this oil goes into the booster upstroke chamber, allowing the shutter to open. The shutter is opened because
the solenoid valve (YV38) remained energized and therefore the logic element (120) is still opened and thus allows the
pressure in the pressure booster chamber to be released into the reservoir (126).
At this point, the pilot pressure applied to the shutter causes the boost cylinder to move up and the oil in the pressure
booster chamber to flow into the reservoir through the opening created by the shutter.
The oil in the flow booster chamber enters reservoir through the logic element (119) which is activated when the drain
solenoid valve (end of braking during upstroke) (YV70) is de-energized. As the boost cylinder goes up, the ports which
joins the main cylinder to the reservoir are opened. This will allow the pressure exerted in the upstroke chamber of the
logic element (108) (which is opened by solenoid valve YV32s) to raise the main cylinder and the oil in the cylinder can
thus flow into the reservoir.
YV47 is energized at the same time as YV32s. YV47 remains energized until the plunger encoder reaches the pre-set
value. YV47 closes the logic element (174) and the oil coming from the main pump (58) and from the accumulators (18,
27 and 27A) - through the logic element (108) - is forced through the restrictor (90) before reaching the upstroke chamber
of the main cylinder. The braking force can be adjusted by working on this restrictor.

51
 CATALOGUE 159.16
MACHINE OPERATION 6

6.10.22 FAST UPSTROKE

When the position of the plunger (detected by the encoder) is not within the range set for braking, the oil coming from
the logic element (108) can directly flow into the upstroke chamber as soon as YV47 is de-energized. The plunger
continues to move up quickly until the encoder detects the position of the plunger (when raised). The solenoid valve
(YV32s) is de-energized and the logic element (108) is closed. Meanwhile, the solenoid valve (YV38) (de-energized)
causes the logic element (120) to close.
At this point the plunger stops moving.

6.10.23 EJECTION
The solenoid valves (YV21 & YV22) need to be energized so that the tiles formed in the cavities can be ejected. This
will cause the lower punches to be raised as described in the paragraph “DIE-SET LIFTING”. The time at which the
solenoid valves are to be energized can be set by using a timer (die-set upstroke delay) . In this way, it is possible to
choose whether to eject the tiles freely or in packages. When the sensor (SQ3) is activated, i.e. the material previously
pressed has been ejected, the filler box starts working and thus allowing a new cycle to begin.

6.11 SFS CYCLE: UPPER FORMING DIE (OPTIONAL)

The control cylinders for the SFS (184) are located in the upper part of the die-set.
The circuit consists of two three-position solenoid valves (YV193, YV172), an accumulator (137) and a pressure relief
valve (336).
The tiles are ejected by energizing YV193 (after the delay time set in the micro-processor based control system and
measured at the start of the last press-stroke, has elapsed), allowing the oil from the accumulator (137) to flow to the
upper part of the cylinders (184).
The speed is adjusted by using the flow regulator (250) located under the accumulator. The punch return stroke can
be selected by energizing YV172 at the start of the filler box stroke, when the filler box is forward or when the filler box
is at the end of its return stroke.
Energizing YV172 allows the oil from the accumulator to flow to the lower part of the cylinders (184). The speed is
adjusted by using the flow regulator (249).

6.12 MOVING DIE

If a “mirror-finish” die-set is used, the lower die must be able to move in order to bring the upper punches into contact
with the powder.
An accumulator (141) and a reducing valve (253) which controls the maximum downstream pressure form a system that
controls the movement of the die. During the pressing phase, the upper punch which is firmly connected to the plunger,
moves the lower die-set downwards. The oil in the lower part of the cylinders (179) partly flows back to the accumulator
(141) and is partly drained through 253.
Once the pressing cycle is completed, the accumulator (141) supplies the necessary thrust and oil to move the die
upwards. The die upstroke speed can be adjusted by means of the flow regulator (145). If, when the machine is shut
down for a long period of time, there are oil-leaks, the check valve (183) will prevent the die from moving down.

6.13 DIE OVERTRAVEL

The die overtravel is used to clean the lower punches by turning a selector switch located in the microprocessor-based
control system cabinet.
In this way YV178 is energized and causes the oil to flow into the upper part of cylinders (179). It also releases the check-
valve (251), thus allowing the die to lower. Under this condition, the lower punches are raised and their side part is
accessible for cleaning or disassembly operations.

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 CATALOGUE 159.16
MACHINE OPERATION 6

6.14 BRUSH OPERATION (OPTIONAL)

The brush is used to clean the punches and the die. It is operated by an electric motor and a belt drive. It moves forward
together with the filler box.
The brush can be run only if the press is set for automatic operation and “1” has been keyed in. To set the direction
of rotation, type in “1” if the brush is to be rotated in only one direction (clockwise rotation) (KM2A output activated),
type in “0” (counter-clockwise) if the brush is to be reversed (KMB2 energized). The brush can also be reversed from
time to time. To do this, key in “1” and enter the number of cycles between one change of direction and another. Mobile
brushes can also perform up and down movements. As soon as the filler box starts running, the solenoid valve (YV192)
is enegized. As a result, the air cylinder (225) comes into operation to lower the brush close to the lower die. Once the
filler-box encoder has reached the setting entered for the brush (in raised position), the solenoid valve (YV192) is de-
energized and the brush moves up again.
The brush remains up for the remaining part of the cycle.

6.15 MANUAL MOVEMENTS

Many manual movements can be carried out by using the related keys on the control keyboard. In any case, the
movements allowed are not dangerous to the operator.
The movements can be performed only if the mode selector switch on the control keyboard is turned to “MAN”.

Different situations can be encountered:

- Safety bar raised: only the upward and downward movements of the die-set (Push-buttons 25, 30 and 13) and die
are allowed. However, if the lower punches of the die-set are provided with a magnetic lock, the selector switch (SA202)
on the controller is released and the punch overtravel is selected (selector switch SA1 on the controller), the die-set
cannot lower.
- Safety bar lowered and filler box mounted. The following movements are allowed: plunger upward and downward
(push-buttons 25, 30 and 3), filler-box backward and forward (push-buttons 27, 28 and 29) and the die and die-set up
and down (push-buttons 25, 30 and 13).
- Safety bar lowered and CAM not mounted (optional): the upward and downward movements of the plunger can be
performed (push-buttons 25, 30 and 3). However, the strokes of the plunger are controlled by the solenoid valves (YV31s
and YV31d) which allow it to move only at a speed lower than 10 mm/sec (pushbuttons 25, 30 & 13). If the selector
switch is turned to SET UP, the plunger and the die set can move only up and down at slow speed.

53
 CATALOGUE 159.16
7 CHECK AND ADJUSTMENT PROCEDURES ADJUSTMENTS 7

7.1 VARIABLE-DISPLACEMENT PUMP ADJUSTMENT

Refer to figure 7.1.

PUMP START-UP

- Fill the hydraulic system.

- Fill the pump body from the coupler (4) until the pump chamber is completely full.

- Start the motor and run it at a low speed until all the air has been removed.

1 - SETTING THE MAX. PRESSURE FOR THE HYDRAULIC SYSTEM

A pressure-relief valve safeguards the hydraulic system against possible malfunctioning.

This valve (112A + 111) is located on the SMU and the filler-box control plate. To properly set the pressure-relief valve,
proceed as follows:
- Start up the main pump with the bar raised.
- Completely tighten the valve 15 (112) located on the block fixed on the hydraulic power unit frame.
- Completely loosen the valve (112A) to be set.
- Press the pressure control push-button (28) on the microprocessor-based control system: the pressure reaches
approx. 10-20 bar, the YV99 is energized and the pump reaches its maximum displacement (indicator 9 reads 11), so
that all of the fluid is drained.
- Slowly tighten the pressure-relief valve (112A) until 230 bar is read on the pump pressure gauge.
- Lock the valve in the correct position.

2 - SETTING THE MAX. POWER REQUIRED

The variable-displacement pump is provided with a power regulator which limits the maximum power required for
machine operation to a value less than or equal to the motor rating (75 Kw for the PH 2000 & PH 2500 and 55 kW for
the PH 1600).
This is done by adjusting the power regulator (5) in the following way:
- Start up the main pump.
- Make sure that the pressure-relief valve is properly set.
- Keep the push-button (28) of the microprocessor-based control system pressed (YV99 is energized, the pump
delivers oil which is drained by safety valve 111, the pressure reaches 230 bar).
- Attach a portable ammeter to the motor supply wires.
- Turn the screw (6) of the power regulator until 85 A is read for the PH 2000 & PH 2500; 60 A for the PH 16000, which
corresponds to 75 kW and 55 kW respectively. If a portable ammeter is not available, use the ammeter located in the
electrical cabinet.
Remember that 145 A must be read on the ammeter for a 75 kW motor and 155 A for a 55 kW motor. Under these
conditions, as the ammeter is connected to the cabinet line and not to the hydraulic power unit motor, make sure that
all the other equipment is disconnected.

54
 CATALOGUE 159.16
ADJUSTMENTS 7

3 - SETTING THE WORK PRESSURE (180 bar)

(See figure 7.1)

The valve that controls the working pressure (15) in the hydraulic line is located on the block fixed to the hydraulic power
unit frame. To perform this adjustment, the max. pressure must be set to 230 bar, as described above.
The following procedure is to be carried out:
- Start up the main pump.
- To apply pressure, press the push-button (28) of the microprocessor-based control system. The solenoid valve (YV99)
is energized, the pump reaches its max. delivery and the pressure reaches the set value.
- Loosen the pressure control valve 15 (112) by keeping the push-button (28) pressed until a value of 180 bar is read
on the pump pressure gauge.
Once the adjustment has been completed and everything works properly, the pump should not deliver any fluid (indicator
9 must read “10” which corresponds to 0°). Under these conditions, the oil should not be heard draining through
pressure-relief valve (112A).
- Lock the adjusting screw of the pressure-relief valve (15) in position.
- Lock the screw (6) in the correct position.

The working pressure can be set with power ratings different from those indicated in the Specifications.
In this case, consult SACMI’s After-Sales Service Dept.

4 - CHECKING THE OPERATING CONDITIONS

(See figure 7.1)

- Motor off; pump stationary: the displacement meter (9) reads “11”.
- Motor on; pump working; safety bar raised: the displacement meter (9) reads “10”, pump delivers no fluid, line
pressure = 20 bar.
- Press in stand-by mode; motor on; pump working; safety bar lowered: the displacement meter (9) reads “10”, pump
delivery equal to zero; line pressure = 180 bar, i.e. the same as the previously set working pressure.
If pump displacement is zero, it means that oil is leaking in the system (make sure that the pressure-relief valve 112A
has been properly set).
- Press in automatic mode with the use of the accumulators: the power and current required, must be as shown in
diagram 1. In this diagram, when the pressure in the hydraulic line reaches the set value, the power input is limited to
75 kW and reduced to 13 kW. Under these conditions, the pump delivers no fluid when the pressure reaches the set
value.
- Press running automatically in economy mode (see diagram 2): the number of separate press-strokes = 2 and
the setting for the cylinder pressure recovery must be entered into the computer memory.

NOTE: Several readings were taken to draw the graphs below. They are for reference purposes only as they are
influenced by numerous factors:

• number of cycles

• soft filling height

• maximum working pressure

• type of machine

55
 CATALOGUE 159.16
ADJUSTMENTS 7
Diagram 1
PRESS IN AUTOMATIC MODE: USE OF ACCUMULATORS

pot=10.00 KW (/div)
tswp=5.041 Sec points=3531
Replay Menu Active
Frame # 1-1 Diagram 1: WORK-CYCLE WITH ACCUMULATORS X Range [0.06 -
0.40]

1LdData 2SvData 3Commts 4Ca1c 5Retrac 6List 7Title 8Cursor 9Param

10Exit C0303

Diagram 2
PRESS RUNNING AUTOMATICALLY: ECONOMY MODE

pot=10.00 KW (/div)
tswp=5.083 Sec points=2541
Replay Menu Active
Frame # 1-1 Diagram 2: WORK-CYCLE WITH MAX. ENERGY SAVING X Range [0.06 -
0.40]

1LdData 2SvData 3Commts 4Ca1c 5Retrac 6List 7Title 8Cursor 9Param

10Exit C0304

56
 CATALOGUE 159.16
ADJUSTMENTS 7

7.1 - REXROTH VARIABLE-DISPLACEMENT 18 7

8
PUMP
6
1 Displacement control unit
2 Max. displacement limiter screw
3 Min. displacement limiter screw 4
4 Pump casing, Drainage and filling 5
5 Power regulator 2 3
6 Power setting screw
7 Pressure regulator
8 Screw, Min. pressure setting
9 Displacement meter 1
10 “Zero” displacement setting
11 Max. displacement setting 9
12 Pump body
13 Suction line
14 Delivery line
15 Line pressure control valve 12
17 Power regulator mechanism 11
18 Connection to external pilot XD
10

(Pump overhead view) 15° 15°

0
Pos. 11
Pos. 10

C0190
C0197

HYDRAULIC POWER UNIT

YV99 A B

P T
15
10
7
YV11R 112
18

6 5
112A

8
111 17

254
SP1
3 49
12
13 2
58

5 4 1
79
14 13 SP3

M
M1

C0305

57
 CATALOGUE 159.16
ADJUSTMENTS 7

7.2 SETTING AND RESETTING THE POSITION ENCODER

The encoder reset operations must be performed each time the encoder or any of its parts are to be replaced.

7.2.1 FILLER-BOX ENCODER

To reset:
• Move the plunger fully up. 7.2.1 - FILLER-BOX ENCODER
• Raise the safety bar.
1 Encoder
• Switch off the controller. 2 7-pin connector
• Remove the cable from the connector (2) of the encoder 3 Encoder resetting box
(1). 4 Screw-held half-flanges
• Connect the reset box (3). 5 Holes with plugs to reach the coupling
6 Gearmotor
7 Connecting rod 1 22 3
There are two green indicator lights (LEDs) for the
signals (CK1) and (CK2) and a red one (which is CK1
more important) on the box (3). The red light comes 4
on only when the encoder is reset. CK2

5
• Move the connecting rod (7) perpendicularly to the
press, as when the filler-box is in its backward position.
• Loosen the screws which fix the encoder to the half-
flanges (4).
• Reset the encoder by turning the its body until the red 6
led goes on.
• Securely tighten the screws (4).
• Connect the cable from the controller to the connector
(2).
• Mount the safety guard , making sure that the cable is
kept out of the way.
7

If, after performing this operation the encoder has

C0207
not been set, proceed as follows:

• Remove the two plugs (5) of the metal cylinder located

under the encoder.
• Turn the connecting rod (7) until the coupling screw is
in front of the hole.
• Loosen the lower screw on the coupling and position
the connecting rod (7) perpendicularly to the machine,
without turning the encoder coupling.
• Tighten the lower screw.
• Loosen the upper screw and the screws (4) which
secure the encoder to the two half-flanges.
• Remove the encoder.
• Turn the shaft until the red led lights up.
• Re-fit the encoder and tighten all the screws.

58
 CATALOGUE 159.16
ADJUSTMENTS 7

7.2.2 PLUNGER ENCODER

Perform the following procedure to reset the encoder:
• Move the plunger fully up. 7.2.2 - PLUNGER ENCODER
• Raise the safety bar.
8 metal plate
• Turn the power off.
9 sensor SQ1
• Connect the reset box by using a 7 to 9-pin extension. 10 encoder
• Loosen the nut (14) while keeping the rod (13) in 11 slide
position. 12 cover
• Turn the rod until the red led lights up. 13 rod
• Adjust the sensor (SQ1) as required. 14 nut
• Move the slide (11) slightly upwards by further turning 15 threaded section
the rod (13). 16 plunger 8 9
• Fully tighten the nut (14).

If the travel of the threaded bar (15) is too short to

10
make the adjustment, proceed as follows:

• Remove the encoder (10) from the slide (11) after 11

removing the cover (12). 12
• Slightly turn the gear.
• Carefully re-fit the gear and try to perform the reset
operation again.

When moving the plunger (16), make sure that the

slide (11) does not come into contact with the metal
box which holds it.

13
14

15

16

C0208

59
 CATALOGUE 159.16
8 MAINTENANCE MAINTENANCE 8

Maintenance and check-out procedures are described below.

The first operations, as shown in the following table, must be performed at the stated intervals.
The other operations can be carried out at the operator’s discretion.

8.1 PERIODIC MAINTENANCE

INITIAL
PRIME MAINTENANCE
MANUTENZIONI TODA
BEEFFETTUARE
CARRIED OUT IN
OPERATIONS
OPERAZIONI AFTER ...OPERATIONAL
DOPO ORE: HOURS: THEREAFTER
SEGUITO
EVERY
OGNI
8 40 80 200 500 2000 4000
11 - -GENERAL
PULIZIACLEANING
GENERALE DI PRESSA
OF DIE-SET E STAMPO
AND PRESS 88hours
ore
22 - -CHECK THE FELT
VERIFICA FORSTATO
DELLO CONDITION
DI USO DEI FELTRI 80
80hours
ore
33 - -GREASE THE PLUNGERBOCCOLE
LUBRIFICAZIONE BUSHES TRAVERSA 80
80hours
ore
44 - -CHECK OIL LEVELLIVELLO
CONTROLLO IN THE FILLER-BOX GEARED MOTOR
OLIO MOTORID. CARRELLO 80
80hours
ore
55 - -CHECK THE KNOCKOUT SYSTEM (SMU)
CONTROLLO DELL'ESTRATTORE (SMU) 80
80hours
ore
66 - -CHECK THE BOLTS
CONTROLLO & NUTS FOR TIGHTNESS
SERRAGGIO BULLONERIA 2000 hours
2000 ore
77 - -CHANGING THE OIL IN THE HYDRAULIC
CAMBIO OLIO NELLA CENTRALINA POWER UNIT 4000 hours
4000 ore
88 - -CHANGING
CAMBIO THE OILNEL
OLIO IN THE FILLER-BOXDEL
RIDUTTORE REDUCTION UNIT
CARRELLO 4000 hours
4000 ore
99 - -CLEANING THE ELECTRICAL ENCLOSURE INSIDE
PULIZIA INTERNA DELLA CABINA ELETTRICA 2000 hours
2000 ore
10
10 - -REPLACE THE FILTERS
SOSTITUZIONE AND FILTERFILTRANTI
CARTUCCE ELEMENTS DEI FILTRI (*)
(*)
11 - CHECK FOR OIL-LEAKS
11 - VERIFICA TRAFILAMENTI 200
200hours
ore
12
12 - -CHECK THE VARIABLE
CONTROLLO POMPADELIVERY PUMP VARIABILE
A PORTATA 200 hours
200 ore
13
13 - -CHECK THE GROUND
VERIFICA CONNECTIONS
COLLEGAMENTI (**)
ELETTRICI A TERRA (**) 80
80hours
ore

(*)
(*) The operation must
L'operazione be carried
deve essere outeffettuata
only when soltanto
indicated. quando viene segnalata.
(**)
(**) In
Inparticular,
particolarecheck each timealla
verificare the die-set
fine diisogni
changed.
cambio stampo.

1 - GENERAL CLEANING OF THE PRESS, in particular the filler-box, the grid, the sliding plate and the part of the die
which rests on the press-table.

2 - CHECK THE FELT FOR CONDITION. The felt safeguards the bushings on the plunger.

3 - GREASE THE PLUNGER BUSHINGS (to be performed manually, use the grease gun to inject grease through the
fittings provided).

4 - CHECK THE OIL LEVEL IN THE FILLER-BOX GEARMOTOR.

5 - CHECK THE KNOCKOUT (SMU). Make sure that no oil is leaking and that all screws are securely tightened.

6 - CHECK ALL NUTS AND BOLTS FOR TIGHTNESS. See table 8.3.

7 - OIL CHANGE IN THE HYDRAULIC POWER UNIT. Change the oil after removing any deposits which may have
built-up in the reservoir. Use only hydraulic fluids which are indicated in the paragraph “technical details”.

8 - OIL CHANGE IN THE FILLER-BOX REDUCTION UNIT.

9 - CLEANING THE ELECTRICAL ENCLOSURE INSIDE. Clean the internal electrical and electronic equipment by
suction or blowing jets of dry compressed air at low pressure. Clean the contacts with ether.

10 - REPLACING THE FILTERS AND FILTER ELEMENTS. When the filter elements are clogged, indicators SP1 and
SP4 will cause a fault message to appear on the display of the control system.

60
 CATALOGUE 159.16
MAINTENANCE 8

In this case, replace the filter element indicated. When the display shows the message “Filter clogged”, check if the
relevant indicator (252) is red. If it is, change the filter element. If it is green, replace the filter element of the filter (79)
located on the main pressure line.
When “filter clogged SP4” appears on the display, replace the element in the filter (252) located in the filler-box circuit.
Every time a filter element is changed, thoroughly clean the filter body.
The filter (79) on the main line must be replaced along with the filter (49) which is mounted on the reservoir where the
pump (58) sucks hydraulic fluid.
It is important to check the filter seals for condition every time the relevant housing is opened.

11 - CHECK FOR OIL-LEAKS. Check the logic element and valve seats for oil leaks. Check the oil level in the oil-leak
collector.

12 - CHECK THE VARIABLE-DISPLACEMENT PUMP. Check the seals in the pump for wear.
The pump works properly under the following conditions:
Keeping the pressure control push-button pressed, check that the pump displacement meter located on the pump
casing reads “zero” and that the energy consumption of the motor and the pump does not exceed 60-65 A. If this is not
the case, contact SACMI’s After Sales Service Dept..

13 - GROUND CONNECTIONS
Make sure the machine has been properly grounded and that the earth connections have been provided between the
plunger and crosshead. Perform these connections if required.

Earth points:
A - crosshead
B - plunger
C - machine base
A
Make sure the die-set has been properly earthed. (See
fig. 3.2 - DIE CONNECTION SCHEMATIC, Leads D and
E). B

Any paint which is on the parts of the machine where the

earth wires are to be attached must be removed before
tightening the respective screws in order to ensure
perfect electrical continuity. C0202
C
The machine may be gravely damaged and the operator
seriously injured if the parts indicated are not properly
earthed.

8.2 SPECIAL MAINTENANCE

- PLUNGER BUSHING MAINTENANCE

The bushings do not need any adjustments. In fact, they
are made of material which guarantees a long service life
while ensuring perfect sealing. This keeps dust from
coming into contact with the bushings. When assembling,
make sure that the two ends of the bushings form an “O”
and that the ends marked (O) face the center of the
press.
C0306

61
 CATALOGUE 159.16
MAINTENANCE 8

TANK FILLING
PRE-FILLING TANK
The tank is filled with oil by means of a portable pump.
Q
• Loosen the level cap (Q) in the pre-filling tank to allow
the air to escape.
• Open the ball valve (A) on the suction hose.
• Insert the rubber suction hose (B) of the pump into the
oil barrel (C).
• Attach the end of the delivery hose (D) to the quick
coupling (E) on the hydraulic power unit.
• Start the oil delivery pump by turning the switch (F).
• Make sure that the oil filter (G) is not clogged (red on
sight gauge H)

If necessary replace the filter element (10 µm absolute).

• Make sure that the hydraulic unit is completely filled

with oil by checking to see if there is oil present in the
hose (L).

Once the required level has been reached (with plunger

down):

• Stop the pump by using the switch (F).

• Detach the hose from the quick coupling (E).

NOTE: If the optional oil delivery pump is not supplied,

the customer will have to filter the oil coming from the A
barrels by using filters having a 10 µ filtering capacity. C0307

DRAINING THE OIL FROM THE HYDRAULIC POWER HYDRAULIC

UNIT AND HOSES L
POWER UNIT
• Make sure that the ball valve (A) (suction hose) is
open.
• Make sure that the ball valve (M) on the drain hose (D)
supplied is closed.
• Connect the drain hose (D) to the respective quick E
coupling (E), on the hydraulic power unit, and from the
opposite side put the hose into the oil collection barrel.
• Completely drain the system by opening the ball valve M
(M), drain hose.

To completely drain the system, make sure that the drain

end of the hose (D) is lower than the connection (E) on
D C0194
the hydraulic power unit.

OIL DELIVERY PUMP OIL BARREL

WITH FILTER
F (OPTIONAL) B
C

B D

C0195 H G C0196

62
 CATALOGUE 159.16
MAINTENANCE 8

8.3 BOLT-AND-NUT TORQUE SETTINGS

S.R. = Cross section (mm2)

MS = Tightening torque (mkg)
V = Pre-load (corresponding to the tightening torque) (kg)

NOTE: The tightening of 12K-class screws with a torque wrench must be carried out as for 10K-class screws.

Example: a 12-mm dia., 1.75 pitch, 12K class screw is tightened to 12.28 mkg instead of 14.74 kg.

STANDARD THREAD SCREWS

DIAMETER mm. 4 5 6 8 9 10 12 14 16 18 20 22 24

PITCH mm. 0.70 0.80 1.00 1.25 1.25 1.50 1.75 2.00 2.00 2.50 2.50 2.50 3
2
S.R. mm 8.11 13.31 18.68 34.57 45.77 55.28 79.92 110.16 150.49 185.16 236.52 294.16 338

5S MS = Kgm 0.22 0.43 0.73 1.81 2.33 3.23 5.46 8.33 12.72 16.02 24.88 33.10 44.00

V = Kg 227 373 523 978 1282 1548 2238 3084 4214 5184 68.23 84.36 9880

8G MS 0.34 0.69 1.16 2.90 3.73 5.18 8.74 13.32 20.36 25.63 35.81 43.36 60.5

V 363 596 837 1549 2050 2477 3580 4935 6742 8295 10596 13178 15800

10K MS 0.49 0.96 1.64 4.07 5.25 7.28 12.28 18.74 28.63 36.04 50.36 60.97 85.3

V 511 839 1177 2178 2884 3483 5035 6940 9481 11665 14900 18532 21740

12K MS 0.58 1.16 1.96 4.89 6.30 8.73 14.74 22.49 34.36 43.25 60.43 73.16 100.9

V 613 1006 1412 2613 3460 4179 6042 8328 11377 13998 17830 22238 26000

FINE THREAD SCREWS

DIAMETER mm. - - - 8 - 10 12 14 16 18 20 22 24

PITCH mm. - - - 1.00 - 1.00 1.50 1.50 1.50 1.50 1.50 1.50 2

S.R. mm2 - - - 37.14 - 61.87 83.83 119.42 161.29 209.44 263.86 324.58 374.5

5S MS = Kgm - - - 1.92 - 3.52 5.68 8.83 13.37 17.48 27.16 35.81 45.7

V = Kg - - - 1040 - 1732 2347 3344 4516 5864 7688 9388 10800

8G MS - - - 3.08 - 5.63 9.09 14.12 21.39 27.96 38.65 52.10 66.00

V - - - 1664 - 2772 3756 5350 7226 9383 11821 11541 17200

10K MS - - - 4.33 - 7.91 12.78 19.86 30.08 39.32 54.36 73.82 91.00

V - - - 2340 - 3898 5281 7523 10161 13195 16623 21249 24300

12K MS - - - 5.19 - 9.50 15.34 23.83 36.09 47.18 65.23 88.79 110.0

V - - - 2808 - 4677 6338 9005 12194 15834 19948 21538 29200

63
 CATALOGUE 159.16
MAINTENANCE 8

8.4 MAINTENANCE OF THE HEAT EXCHANGER

8.4.1 GENERAL
• Loosen the tie-rod nuts and remove the mobile plate.
• Remove the plates from the frame.
• If the plates are dirty or have build-ups, put them (WITHOUT REMOVING THE GASKETS AND THE NETS) into
hydrochloric acid diluted by approx. 10%. They should remain in this solution for the min. time required to remove the
calcium deposits.
• Thoroughly rinse them in running water.

8.4.2 REPLACING THE GASKET

• Remove the square mesh grid from the plate.
• Pull the gasket out of its housing and clean the edge of the plate, if dirty.

If it is difficult to fit in the new gasket, slightly lift the folded edge of the plate with a spatula.

• Re-fit the turbine making sure that it is correctly placed inside the gasket.

8.4.3 TIGHTENING THE STAY BOLTS nxA

This operation can be carried out without using any

special tools (torque wrench). The value n x A shown in 1 6
the diagram can be exceeded (plate pack more pressed)
without damaging the exchanger (see the chart below).
It is recommended to follow the indications below when 2 7

tightening the stay bolts:

3 8
• Tighten the stay-bolts 1-6-10-5
• Tighten the stay-bolts 2-7-9-4
• Tighten the stay-bolts 3-8. 4 9

Repeat the operations until the desired value is reached.

5 10

C0315

TIGHTENING ONE PLATE

new 1st year of operation minimum
A 3.65 3.5 3.4

NOTE:
- The first value was used when the heat exchanger was constructed.
- The other values indicate the tolerance range.
- The min. tightening value indicates the lowest allowable value, above which the stay bolts are overloaded.
If the exchanger (after these operations) still leaks, there are certainly other faults.
IT IS THEREFORE NECESSARY TO REPLACE THE DEFECTIVE PARTS.

64