Professional Documents
Culture Documents
T E C N I C A
PH
INSTRUCTIONS B
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇAO TECNICA
LISH
ENG
PH 339.85.089 Rev. 00 Date 10.12.01
Last revised :
PH 13.09.01.7TR
PH 11.19.01.7TR
Revised by : Alberto Tassoni, ing. Program version : PH 10A.16.01.7TR
PH 10.22.01.7TR
PH 09.20.01.7TR
PH 08.27.01.7TR
SACMI SHALL NOT BE HELD RESPONSIBLE FOR MACHINE FAILURE DUE TO UNAUTHORIZED
MODIFICATIONS.
ANY CHANGES THAT ALTER THE CONSTRUCTION OR THE WORKING CYCLE OF THE
MACHINE MUST BE CARRIED OUT OR AUTHORIZED BY SACMI’S AFTER-SALES DEPT.
SACMI RESERVES THE RIGHT TO MAKE ANY CHANGES TO THE MACHINE DESCRIBED
HEREIN AT ANY TIME WITHOUT NOTICE.
IF THERE ARE ANY PRINTING OR OTHER ERRORS, CORRECTIONS WILL APPEAR IN THE
SUBSEQUENT VERSION OF THE MANUAL.
SACMI SHALL BE HELD RESPONSIBLE ONLY FOR THE TEXT IN THE ORIGINAL ITALIAN
VERSION.
COPIES OF THIS MANUAL ARE AVAILABLE FROM THE AFTER-SALES SERVICE DEPT.
3
PH 339.85.089 Rev. 00 Date 10.12.01
Copies of this manual should be given to all personnel in charge of machine maintenance
and operation. It is essential that the manual is read carefully in its entirety and fully
understood, as it provides important instructions on how to operate the machine properly
and safely.
The machine must be used only for the tasks it was expressly designed for. Performing
jobs other than those recommended is hazardous.
SACMI shall not be held responsible for damage to the machine or injuries to personnel
resulting from mishandling, improper use or unauthorized modifications.
Any modifications made to the machine’s structure and/or work-cycle must be performed
or authorized by SACMI’s Service Dept.
The persons in charge of supervising and servicing the machine must read and fully
understand the operating instructions contained in the documentation provided.
Maintenance can be performed and the electrical parts and devices accessed only by
competent well-trained personnel.
The machine’s work-cycle can be set and controlled only by the persons in charge, or
those who are duly authorized.
Only well-trained personnel can operate, set-up and service the machine.
The machine can be started up only after all the safety devices have been activated.
Periodically inspect all the safety devices installed in the machine (stop pushbuttons,
interlocks, proximity switches, limit switches, safety guards, etc..) for proper functioning.
Occasionally check to see whether the machine is still efficiently grounded.
If any faults are found while the machine is being run, they must be reported to the person
in charge without delay.
If the personnel in charge find faults which could endanger the operators, the machine
must be shut off immediately and restarted only after it has been repaired.
Always unplug the machines from the electricity supply before setting up or servicing
them if operations which may endanger personnel are to be performed. Failure to do
so may result in severe injury to personnel. Whenever carrying out maintenance of any
type, always shut off the machine and block all parts before starting. This must be done
even when minor jobs are performed.
4
PH 339.85.089 Rev. 00 Date 10.12.01
1 INTRODUCTION
Scanner
Photocell N.O. Triggered Led on
Untriggered Led off
Reflector/ Triggered Led off
Detector unit Untriggered Led on
Level control
Pressure switch
Flowmeter
Thermostat N.O. Above the threshold Led on
Below the threshold Led off
N.C. Above the threshold Led off
Below the threshold Led on
5
PH 339.85.089 Rev. 00 Date 10.12.01
2 WARNINGS
MAINTENANCE
- Before welding, disconnect the machine from the electrical cabinets by unplugging the cables.
6
PH 339.85.089 Rev. 00 Date 10.12.01
The microprocessor system consists of a number of cards, each of which is provided to carry out
a specific task.
CPU Card:
This card stores the main microprocessor and the machine program to be run.
All the electronic cards are tested at 60°C for not less than 48 hours.
An emergency circuit is also provided in the control system. This circuit controls all the safety devices
independently, i.e. safety bar, shutdown button located on the machine control keyboard, external
shutdown buttons, etc..
2) Switchboard that supplies power to the main points of use
This part houses all the devices that control the electric motors.
The controls for the motors are protected with magnetic thermal cut-outs (for power outputs less than
11 kW) with mixed coordination (Ir, type 2, Iq type 1).
Y-D starters are used with power outputs greater than 15 kW.
All the power components are mounted on a bus bar.
7
PH 339.85.089 Rev. 00 Date 10.12.01
8
PH 339.85.089 Rev. 00 Date 10.12.01
The controller comes equipped with a 25 line, 80 character 10-inch display unit. This display shows
all information and parameters required to operate the machine. Use the keyboard provided to enter
data for new work cycles.
1) “DATA” PAGE
The following data is provided:
- data regarding the work-cycle which has just been completed;
- data recorded by the transducers installed in the machine;
- production data (partial and total).
9
PH 339.85.089 Rev. 00 Date 10.12.01
10
PH 339.85.089 Rev. 00 Date 10.12.01
More than 220 self-diagnostic messages can be displayed including scheduled maintenance
messages (in this case, the messages are shown to inform the operator that the maintenance
operation has to be performed).
Example:
REGULATORS
The program automatically corrects the pressure in the cylinder.
This regulator controls the length of the press-stroke so that the set pressure is reached. The
temperature of the die-sets is controlled by a PI type regulator.
TELE-SERVICE
The keyboard for setting and displaying data is remote controlled when tele-service is used.
Any data item can be set/displayed with this service, for example a new set of parameters can be
entered (pressures, times, temperatures, etc.).
All the data transmitted to the machine’s display are shown (including fault messages).
When the remote control is activated, the machine keyboard for setting data is disabled whereas
the display remains active.
This feature allows technical support to be provided to Sacmi engineers on the customer’s premises
from Imola when starting up the machine or troubleshooting it on site when it is being repaired/tested.
11
4
12
MACHINE CONTROL KEYBOARD
17 18 25 26
+5
I R I R
MAN +
SET UP AUT
WD
0 1 2 3 8 9 10 11 16 SL
SC
27 I 29
28
P
A1
I A2 19-23 –
24 4 5 6 7 12 13 14 15 20 21 22 30 31
SMC 085-11-442
PH 339.85.089 Rev. 00 Date 10.12.01
PH 339.85.089 Rev. 00 Date 10.12.01
Note:
* Use key F8 on the computer terminal to select the type of work-cycle.
+ wo keys need to be used for most operations. However, some of them can be performed by
pressing only one key. In these cases, the number of the key which has to be pressed appears
in the column marked “2ND KEY”.
(1) Operation not possible with 4-cylinder S.P.E.
(2) Operation possible with 2-cylinder S.E. only
(3) Operation not possible in proportional presses
(4) Available only with version 13.01.01 or later versions
(5) ONLY FOR PROPORTIONAL PHs
The following conditions must be satisfied: filler-box hooked up, safety bar down, limit switch for
end of filler-box’s return stroke triggered (input SQ59 off), die-set down, plunger raised with
encoders zero set.
(6) The following data items must be set as indicated: DIE-SET LOCKED = NO and DIE-SET
DISASSEMBLY = 2. The following conditions must be satisfied: safety bar up, limit switch for
end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the self-
learning procedure for SPE 2 + 2 carried out.
(7) The following data items must be set as indicated: DIE-SET SECURED = NO and DIE-SET
DISASSEMBLY = 3. The following conditions must be satisfied: safety bar up, limit switch for
end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the “DIE-
SET ENCODER NOT RESET MESSAGE” displayed.
(8) The following data items must be set as indicated: DIE-SET SECURED = NO and DIE-SET
DISASSEMBLY = 2. The following conditions must be satisfied: safety bar up, limit switch for
end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the self-
learning procedure for SPE 2 + 2 carried out.
(9) The following data items must be set as indicated: DIE-SET SECURED = NO and DIE-SET
DISASSEMBLY = 3. The following conditions must be satisfied: safety bar up, limit switch for
end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the “DIE-
SET ENCODER NOT RESET MESSAGE” displayed.
(10) The following data items must be set as indicated: DIE-SET LOCKED = NO and DIE-SET
DISASSEMBLY = 1. The following conditions must be satisfied: safety bar up, limit switch for
end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders not blocked, “DIE-
SET ENCODER NOT RESET MESSAGE” displayed and die-set down.
(11) ONLY WITH VERSION PH 13.xx.yy
The “FILLER-BOX ENCODER NOT RESET” should not be displayed when the filler-box is in
the reset position.
From version PH13.08.01 onwards, the user can reset the encoder zero-point offset for the filler
box by performing the procedure below:
Press keys 25, 30 and 8 with the mode selector turned to SET-UP and the PUMP OFF. Once
this operation has been completed, the filler box will stop exactly when the encoder emits the
zero-set pulse.
(12) ONLY FOR PROPORTIONAL PHs
The following conditions must be satisfied: filler-box hooked up, safety bar down, limit switch for
end of filler-box’s return stroke triggered (SQ59) and the plunger raised with the encoders zero
set. YV303 is de-energized and YV32 is fully opened during the downstroke if MOTION
UPSTROKE, 1ST DEAERATION = 0, YV32 is fully opened during the upstroke if MOTION
UPSTROKE, 1ST DEAERATION = 100. In the mean time, YV318 is opened to an extent equal
to a % of the value set for 1ST PRESS-STROKE SPEED.
Once 5 sec. have gone by, YV32 is brought back to the middle position (closed) and YV318 is
closed.
(13) With a proportional rod-type lift (optional), the upstroke is interrupted in SET-UP mode as soon
as one of the two keys is released.
With the SPE and the AX axis-control card, the die-set upstroke is allowed only when the die-
set is completely down.
14
PH 339.85.089 Rev. 00 Date 10.12.01
(14) With a proportional rod-type lift (optional), the downstroke in SET-UP mode is interrupted as
soon as one of the two keys is released.
Downstroke with the mode selector turned to MAN:
- 2-downstroke cycle
use keys 30 and 13 for the 1st die-set downstroke
use keys 31 and 13 for the last die-set downstroke
- 3-downstroke cycle
use keys 26 and 13 for the first die-set downstroke
use keys 30 and 13 for the second die-set downstroke
use keys 31 and 13 for the last die-set downstroke
(15) With the SPE and the AX card, the proportional valves open (during upstroke and downstroke)
to an extent proportional to the upstroke and downstroke speed.
(16) If a double plunger encoder is provided, and the “SEMI-AUTOMATIC PRESS CYCLE - MAN”
cycle has been selected, it will be possible to raise or lower the safety bar and execute the semi-
automatic pressing cycle after performing the loading operations in semi-automatic mode
(safety bar down).
15
PH 339.85.089 Rev. 00 Date 10.12.01
R Reset
WD Watch-dog
A1
A2
} Keyboard address (both of them on —> first keyboard)
16
PH 339.85.089 Rev. 00 Date 10.12.01
5 COMPUTER TERMINAL
SMC 085-11-409
PAG
PAG
ON
WRITE
QUIT
H
D
OFF
HOME
END
SCREEN
CHAR
LINE
+5
R
WD
SL
SC
B
A1
A2
DEL
DEL
G
E
F
+
-
R
E
E
T
5.1 DESCRIPTION
9
3
.
luminescent display
7
B Function keys
C
C Numeric keypad
in
G Deletes last line typed in
F7
H Cursor keys
F6
F5
F4
F3
F2
F1
A
17
PH 339.85.089 Rev. 00 Date 10.12.01
R Reset
WD Watch-dog
A1
A2
} Keyboard address (both on —> first keyboard)
18
PH 339.85.089 Rev. 00 Date 10.12.01
Information about machine operations is given on the display. A number of pages are provided.
1 2 3
4 5
1 -Fault messages
2 -No. of the operating program
3 -Date and time
4 -Description of the work-cycle
5 -Machine status
6 -Data input and read-out
7 -Description of the function keys
Items 1, 2, 3, 4 and 5 appear on every page whereas items 6 and 7 change from page to page. The
first page displayed (DATA) is given as an example.
19
PH 339.85.089 Rev. 00 Date 10.12.01
20
PH 339.85.089 Rev. 00 Date 10.12.01
This number indicates the program the press is being run on. If an asterisk (*) appears to the right
of the number, it means that changes have been made to the program which have not been saved
yet.
If the number of the operating program is ø, it means that this program has not been saved yet (this
may happen when the system is turned on for the first time or when the operating program has been
deleted).
21
PH 339.85.089 Rev. 00 Date 10.12.01
YEAR 00 ENTER
MONTH 1 ENTER
HOUR 15 ENTER
MINUTE 28 ENTER
SECOND 0 ENTER
In this way the following is obtained: DATE 01/24/00 JANUARY 24, 2000
TIME 15:28:00
22
PH 339.85.089 Rev. 00 Date 10.12.01
The F8 key is used to select the type of work-cycle when the machine is started (press keys 28 and
2 on the machine control keyboard).
This can be done only if the key switch is turned to AUT and the press is not in automatic mode or
being reset.
The standard cycle is the automatic one. In this case the following items appear at the beginning
of the second line on the display.
If the F8 key is pressed, the following will appear after one second:
If the F8 key is pressed again, the following will appear after one second:
If the F8 key is pressed again, the system will go back to the standard work-cycle.
If a double plunger encoder is provided, and the “SEMIAUTOMATIC PRESS CYCLE - MAN” cycle
has been selected, it will be possible to raise or lower the safety bar and to execute the
semiautomatic pressing cycle after performing the loading operations in semi-automatic mode
(safety bar down).
23
PH 339.85.089 Rev. 00 Date 10.12.01
The state of the press is indicated on the right-hand side of the second line displayed. The various
modes in which the machine can operate are described below:
NOTE: If the key switch (on the keyboard) is turned during RESETTING or CYCLE, the press will
stop running.
24
PH 339.85.089 Rev. 00 Date 10.12.01
As already mentioned, the DATA page is displayed when the system is turned on. To shift to other
pages, press a function key (e.g. to shift from the DATA to the PROGRAMS page, press the F2 key).
The operating and production data for the press is given on the pages which appear on the left-hand
side of the diagram above. The pages on the right side show the values entered for the machine
cycle. These settings can be changed if necessary. The help key (F1) can be used with any page
active. By pressing this key, the user can gain access to the “Help” page on which the following
information is provided: a list of the pages provided (similar to the one shown above) is given at the
top of the page - the title of the page currently in use flashes.
In addition, useful information for the operator is given at the bottom of the page. The user can gain
access only to the pages which (in the list of the pages provided) are joined together by a straight
line.
Press one of the ↑ ↓ ← → keys to change the page whose title is flashing. To access another
page by using the Help page, press the keys mentioned above until the title of the required page
flashes. After doing this, press ENTER or the F1 key.
25
PH 339.85.089 Rev. 00 Date 10.12.01
The STOPPAGES page can be accessed from the HELP page. The list of the faults that can be set
by the operator is given on this page. This feature allows the operator to enter the amount of time
the machine stops for the reasons listed below and obtain a detailed report regarding the causes
of machine stoppages in the form of statistical charts.
26
PH 339.85.089 Rev. 00 Date 10.12.01
The contents of the pages (except for the first and second lines) are described below:
5.9.1 “DATA”
The DATA video-page is the first one displayed.
a) The data related to the work-cycle which has just been completed appears in the first square on
the left. The title shows the size of the tiles being produced (to change these three settings, gain
access to the FITTINGS page).
b) The data related to the transducers installed in the machine is shown in the square to the right.
This data is updated in real time.
27
PH 339.85.089 Rev. 00 Date 10.12.01
c) The production data is shown in the bottom square. The TOTALS cannot be reset whereas the
PARTIAL values can. To do this, turn the key switch to “ON” and press the F6 key. The system
will then ask the operator to CONFIRM the operation. If key “1” is pressed, all the partial values
will be set to zero.
28
PH 339.85.089 Rev. 00 Date 10.12.01
Press the F7 key (INFO) to go from “DATA” to “INFORMATION AND LANGUAGE SELECTION”.
The typical parameters of the press are displayed here. They are divided into two parts. The
hydraulic and mechanical settings appear on the left-hand side while the electronic ones are shown
on the right.
29
PH 339.85.089 Rev. 00 Date 10.12.01
At this point the messages are displayed in the language selected by simply pressing any function
key (except F1).
30
PH 339.85.089 Rev. 00 Date 10.12.01
This page is shown in some machine. Press F5 from INFO to go to this page.
The ENCODERS RESET function is used to reset some of the encoders on the press.
To RESET AN ENCODER means determining the end stop position of the axis (plunger etc..)
ENCODER NO. = XX
This indicates the number of the encoder to be reset.
The numbers are given in the list of the encoders the press is provided with shown on the
display. These may be:
1 - PLUNGER
4 - PROP. KNOCKOUT (only with proportional rod-type knockout)
To reset the plunger axis move the plunger fully up (to the mechanical end stop), raise the safety
bar, turn the mode selector to SET UP and set ENCODER NUMBER = 1.
NOTE
The press or the auxiliary equipment that is installed on it may be provided with encoders which
have to be RESET in a different way.
For information concerning the RESET procedure for an encoder refer to the chapter
ADJUSTMENTS in the USER’S MANUAL for the press.
31
PH 339.85.089 Rev. 00 Date 10.12.01
Press the F3 key (LOAD.) to go from the “DATA” page to the “ACTUAL LOADING DATA” page.
a) The temperatures of the die-sets are displayed in the top block. The set value is shown to the right
(SET). If a flashing square appears to the right of SET it means the corresponding heater is on.
In addition, the time (expressed in percentage) each heater for the die-set stays on is shown for
the HEAT-UP TIME data item.
b) The operating times for the different steps into which the filler-box stroke is subdivided are shown
in the left-hand block. The times were measured at the end of the previous cycle. These times
are calculated only during the automatic or semi-automatic loading cycles.
c) With the rod-crank mechanism filler box: the gains for the filler-box valve opening (forward and
return strokes respectively) are displayed in the right block. In addition, the two OFFSET values
(i.e. the minimum values required to move the filler-box) for the forward and return strokes are
given on the right-hand side of this block. If a linear filler-box is employed, along with the OFFSET
value for the return stroke (in the middle and to the right), some other filler-box data items cannot
be modified.
d) The filler-box encoder setting at the end of the first die-set downstroke (during the work-cycle just
performed) and the length of the downstroke are shown in the square below. The latter is divided
into two parts: the first is the time from when the solenoid valve is de-energized and sensor SQ3
is inactivated; the second is from when SQ3 is inactivated and SQ6 is activated. Only one time
is given when a proportional knockout is employed.
e) The actual operating state of the brush is shown at the bottom.
Press the F2 key (DATA) to go from this page back to the “DATA” page; press the F4 key (PRESS
CY.) to shift to the “ACTUAL PRESS CYCLE DATA” page or press the F5 key (DIE-SETS) to go
to the “ACTUAL DIE-SET DATA” page.
32
PH 339.85.089 Rev. 00 Date 10.12.01
To go to the “ACTUAL PRESS CYCLE DATA” page from the “DATA” page, press the F4 key
(PRESS CYCLE).
a) The times and the pressures (expressed in ms and bar respectively) for each individual work-
cycle stage are displayed in the left-hand square. These values were measured at the end of the
cycle which has just been performed. In addition, the TILE THICKNESS value is shown in the
THICK. column. This value is measured at the end of the first press-stroke, the end of the second
press-stroke and at the end of the third one, if performed.
With “proportional” presses, the first number on the left represents, for each press-stroke, the time
taken to reach half the set pressure (if mode = 1 or = 2) or the time to reach the thickness set for
S1/P1 (if mode = 0).
With “proportional” presses only, the number which appears on each Deaeration line and in the
THICKNESS column is the plunger stroke performed during deaeration.
b) Some data items related to plunger braking are displayed on the top right-hand side.
- For “conventional” presses only - setting of the brake logic-element stem: “40” and “470”
correspond to the maximum and minimum braking forces applied respectively. To change
these settings, press keys 26 or 31 and 7 on the machine control keyboard provided that:
SPEED CONTROL ON = NO
(on the PRESS CYCLE SET UP page)
- The pressure in the plunger upstroke chamber (expressed in bar) is given in real time for
“proportional” presses.
- plunger speed at the end of the downstroke measured at the IMPACT POSITION.
- speed after the plunger has passed the point where the brake is applied during the upstroke
(only if braking during upstroke is selected on the PRESS CYCLE SET UP page)
- maximum speed reached by the plunger during the previous upstroke or downstroke.
- Max. speed the plunger has reached. The downstroke speed appears to the left; the upstroke
speed appears to the right (only from version PH13.09.01 onwards).
33
PH 339.85.089 Rev. 00 Date 10.12.01
d) The amount of material (expressed in sq.m) or number of tiles to be produced in order to complete
the current production batch is given in the square below.
For “proportional” presses, the proportional solenoid valves offset values determined during the
self-learning procedure are displayed on the bottom of the page on the right side as follows: YV32
offset to perform the plunger downstroke, YV32 offset to keep the plunger stationary, YV32 offset
to perform the plunger upstroke, YV318 offset.
To go to the “DATA” page from this page press the F2 key (DATA), press the F3 key (LOAD.) to go
to the “ACTUAL LOADING DATA” page or press the F5 key (DIE-SETS) to go to the “ACTUAL DIE-
SET DATA” page.
34
PH 339.85.089 Rev. 00 Date 10.12.01
The “ACTUAL DIE-SET DATA” page can be accessed from the “ACTUAL LOADING DATA” and
“ACTUAL PRESS CYCLE DATA” pages by pressing the F5 key (DIE SETS) - if the press is equipped
with a proportional knockout.
35
PH 339.85.089 Rev. 00 Date 10.12.01
With the SPE, the following data is displayed in the bottom section:
AXIS CONTROL CARD ERROR= fault code from axis control card
CONTROL = Analog datum signal from axis control card to proportional solenoid valve, side A and
B: from 0 (max. datum signal during downstroke) to 4095 (max. reference signal during upstroke)
(only with AX card)
DIE SETTING = encoder setting as seen from axis control card (only with axis control card AP210)
SPEED BTW PUNCHES = SPE average speed during upstroke between the punches measured
by the axis control card (only with AP210 axis control card)
PUSH = pushing force (expressed in bar) measured by the two SPE pressure transducers (only with
AX card)
ZERO POSITION - each time the die-set encoder is reset the following is displayed:
distance between the “zero-set” signal and end-stop for side A, side B and cycle counter. The data
provided during the penultimate reset procedure are displayed on the line underneath.
OFFSET = offset indicated by the SPE proportional valves expressed in % of max. opening (only
with AX card)
SPOOL = Position of SPE proportional solenoid valve spools, side A and B. The value can range
from -100.0% (max. opening during downstroke) to 100.0% (max. opening during upstroke) (only
with AX card)
UPSTROKE CHAMBER PRESSURE = pressure transducer (set in bar) for the SPE bottom
chambers (only with card AX)
DOWNSTROKE = pressure transducer (set in bar) for SPE top chambers (only with AX card)
36
PH 339.85.089 Rev. 00 Date 10.12.01
This page can be accessed from the “DATA” page by pressing the F5 key and then F3.
The values of all the PLC inputs are displayed here.
SL4
Digital input (ON-OFF)
A symbol ( ) appears next to the identification number of the input to indicate that the input is closed.
The symbol is not shown if the input is open.
37
PH 339.85.089 Rev. 00 Date 10.12.01
YV32S
Digital output (ON-OFF)
A symbol ( ) appears next to the identification number of the output to indicate that it is on. The
symbol is not shown if the input is off.
YV20A = XXXX
Analog output (proportional valve)
A number XXXX that ranges from 0 to 255 is shown next to the identification number of the output.
“0” indicates that the solenoid valve is off. Numbers 1 to 255 indicate the valve is on. The values of
the individual outputs the electronic equipment has turned on in that precise moment are also given.
NOTE: Numbers 1 to 255 represent the output current (0-20 mA) that the card supplies to the
corresponding channel.
The number ranges from 0 to 4095 in some analog outputs.
38
PH 339.85.089 Rev. 00 Date 10.12.01
This page can be accessed from the DATA page by pressing the F5 key and then F4.
The last 20 faults which caused machine shutdown or stoppage are shown here. The date and time
are given with each one.
39
PH 339.85.089 Rev. 00 Date 10.12.01
These pages can be accessed from the DATA page by pressing F5 and then F5 again.
Bar charts that illustrate some statistics regarding the production run are given on these pages.
The number of cycles taken into consideration in drawing up the graphs is given on the next to last
line, on the right.
To zero set the data, turn the WRITE key to ON and then press F6. When the system asks the
operator to CONFIRM, press “1”.
Press the PAG↓ or PAG↑ keys to scroll the pages.
To print out the graphs displayed, press the F7 key (a CENTRONICS type printer has to be parallel
connected to the output on the back of the card rack and the WRITE key needs to be turned to ON).
40
PH 339.85.089 Rev. 00 Date 10.12.01
The first chart displayed shows the ten causes of machine stoppage or shutdown which resulted in
the most downtime (shown in order of time).
Note:
- The complete straight line represents the machine downtime before the alarm was reset.
- The lines which are cut off represent the machine downtime after the alarm was reset.
41
PH 339.85.089 Rev. 00 Date 10.12.01
The second chart displayed shows the ten causes of machine stoppage or shutdown which resulted
in the greatest number of stoppages (shown in the order of number of stoppages).
42
PH 339.85.089 Rev. 00 Date 10.12.01
The third chart represents the percentage of defective pieces in relation to the total number
produced for each thickness error band.
The central bar represents the pieces whose thickness error is less than 10 hundredths of a
millimeter.
43
PH 339.85.089 Rev. 00 Date 10.12.01
The fourth chart shows the percentage of pieces in relation to the total number produced that fall
within each pressure error band.
The central bar represents the pieces whose pressure deviates by less than 4 bar.
44
PH 339.85.089 Rev. 00 Date 10.12.01
The fifth chart represents the percentage of cycles in relation to the total number performed for each
error band regarding the time taken by the filler-box to carry out the forward stroke.
The middle bar represents the cycles with errors that are less than 20 ms.
45
PH 339.85.089 Rev. 00 Date 10.12.01
The sixth chart shows the percentage of cycles in relation to the total number performed for each
error band regarding the time taken by the filler-box to carry out the return stroke.
The middle bar represents the cycles with errors that are less than 20 ms.
If the machine is equipped with a proportional knockout, the related statistics are provided. The
following is shown:
- graph showing the errors of cylinder A found after the die-set has completed its upstroke;
- the same for cylinder B.
If three downstrokes are carried out or with a four-cylinder S.P.E. the following is shown:
- graph showing the errors of cylinder A found after the die-set has completed its first downstroke;
- the same for cylinder B.
46
PH 339.85.089 Rev. 00 Date 10.12.01
This page can be accessed from the DATA page by pressing F5 and then F6.
The state of execution of the program is shown on this page in numeric form.
The numbers for each machine axis increase while the cycle is being carried out.
In the event of machine shut down, the numbers are decoded and a fault message is displayed in
the block so that the operator can understand what the machine was doing at the time of shut down.
NOTE: The message is cleared as soon as the Reset button is pressed.
47
PH 339.85.089 Rev. 00 Date 10.12.01
FILLER-BOX 0 X X X X H
{
1st 2nd 3rd
1st) Coding of the main stage
01 = RETURN STROKE IN MANUAL
02 = FORWARD STROKE IN MANUAL
0A = RESETTING
1E = START OF AUTOMATIC CYCLE
20 = AUTOMATIC CYCLE IN PROGRESS
DIE SETS 0 X X X X H
{
48
PH 339.85.089 Rev. 00 Date 10.12.01
PLUNGER 0 X X X X H
{
1st 2nd 3rd
1st) Coding of the main stage
01 = SLOW UPSTROKE
02 = SLOW DOWNSTROKE
03 = UPSTROKE
04 = DOWNSTROKE
0A = RESETTING
14 = SEMI-AUTOMATIC PRESS-CYCLE
1E = START OF AUTOMATIC CYCLE
20 = AUTOMATIC CYCLE IN PROGRESS
POWDER LOADING 0 X X X X H
{
ALM 0 X X X X H
{
49
PH 339.85.089 Rev. 00 Date 10.12.01
BRUSH 0 X X X X H
{
1st) Coding of the main stage
1st 2nd 3rd
50
PH 339.85.089 Rev. 00 Date 10.12.01
This page can be accessed from the “DATA” page by pressing the F5 key and then F7.
The production data is shown in the following forms:
Day: current value along with that of the day before;
Week: current value along with that of the week before;
Month: current value along with that of the month before;
Batch: current value along with that of the previous batch;
51
PH 339.85.089 Rev. 00 Date 10.12.01
To go to the “PROGRAMS” page from the “DATA” page, press the F2 key (PROGRAM).
This page provides a list of the programs stored in the computer’s memory. A “PROGRAM” refers
to all the machine operating data. Up to 128 programs can be stored in the computer’s memory. Each
program is identified by a name. For example, program 4 has three exits for 330 mm x 330 mm tiles
which are 10 mm thick while the maximum pressure for the press-cycle is set at 200 bar.
The name of the program can be displayed in full. To do this, press the “←” or “→” key.
To perform operations with the stored programs, press the F7 key after turning the key switch on
the computer terminal to ON.
52
PH 339.85.089 Rev. 00 Date 10.12.01
The functions which can be selected are given on the last line:
WRITE
This function is used to store the data of the operating program. Press the F2 key. The following
appears on the bottom of the display:
Now type in the number of the program. The latter will be the back-up copy of the program being
used (in the example above, the program in use is one deriving from program 32). If 26 is keyed in
and the ENTER key is pressed, the program being used will be assigned number 26. As a result,
the operating program will be the one numbered 26.
53
PH 339.85.089 Rev. 00 Date 10.12.01
READ
This function is used to run the machine with the data for a program stored in the memory. This
function cannot be used when the press is cycling in automatic mode. The following message will
appear when the F3 key is pressed.
Key in the number of the program required (e.g. 4) and then press the ENTER key. The following
question will be displayed:
This allows the operator to save the old operating program (26 in the example) before loading the
one required (4 in the example).
CLEAR
This function is used to delete a program. To do this, press the F4 key. The following message will
appear:
54
PH 339.85.089 Rev. 00 Date 10.12.01
To go to the “LOADING SET UP” page from the “PROGRAMS” page press the F3 key (LOAD.).
This page shows the settings related to the press loading cycle.
The top half of the page will show one of the following displays:
1) With program version PH13.xx.yy and linear filler-box:
the end of the two filler-box strokes (END OF RETURN STROKE and FORWARD) must be set
(in mm) in relation to the zero setting of encoder BQ2. The FILLER-BOX CONTROL ON data item
should only be set to YES if a fault is to be signaled when the traveling time error exceeds 5%
in relation to the set FILLER-BOX FORWARD STROKE TIME and the FILLER-BOX RETURN
STROKE TIME.
FILL.-BOX APPROACH POS.: if a value greater than the END OF RETURN STROKE is entered
for this data item, the trigger pulse for the plunger downstroke is provided as soon as the filler-
box has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once
the filler-box reaches the END OF RETURN STROKE during the press-cycle the ALM cycle will
start. After the grid has been loaded, the filler-box starts traveling again at the speed set for
SPEED until the value set for FILL.-BOX APPROACH POS. is reached.
The filler-box strokes are divided into steps - or zones - (a maximum of 5 steps for the forward
stroke and 5 for the return stroke). The filler-box speed in each of these zones can also be set.
For the forward stroke enter:
- end of zone 1 position
- end of zone 2 position
- end of zone 3 position
- end of zone 4 position (the end of zone 5 position is the same as the End of Forward Stroke)
- speed for the 5 forward stroke zones
55
PH 339.85.089 Rev. 00 Date 10.12.01
end of zone positions during return stroke = 1000 685 520 430
return stroke speed = 70 85 80 70 60
This means that:
zone 1) from the end of the forward stroke up to 1000 mm the filler-box travels at 70% of its full speed
zone 2) from 1000 mm up to 685 mm the filler-box travels at 85% of its full speed
zone 3) from 685 mm up to 520 mm the filler-box travels at 80% of its full speed
zone 4) from 520 mm up to 430 mm the filler-box travels at 70% of its full speed
zone 5) from 430 mm up to the end of the return stroke the filler-box travels at a 60% of its full speed
When in the mode selector is turned to MAN, the filler-box travels at a constant speed which equals
that set for SPEED IN MANUAL MODE.
If the value entered for FILL.-BOX APPROACH POS. is greater than the END OF RETURN
STROKE value, the following cycle will be carried out:
- without ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box
has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. At the same
time, the APPROACH DELAY TIME starts to elapse. Once the filler-box reaches the END OF
RETURN STROKE, during the press-cycle, it stops for the amount of time set for the
APPROACH DELAY TIME data item. After this time has elapsed the filler-box starts traveling
again at the speed set for the SPEED data item until the value set for FILL.-BOX APPROACH
POS. is reached;
- with ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box
has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once the
filler-box reaches the END OF RETURN STROKE, during the press-cycle, the ALM cycle will
start. After the grid has been loaded, the filler-box starts traveling again at the speed set for
SPEED until the value set for FILL.-BOX APPROACH POS. is reached.
56
PH 339.85.089 Rev. 00 Date 10.12.01
The filler-box strokes are divided into set steps - or zones - (a maximum of 5 steps for the forward
stroke and 5 for the return stroke). The filler-box speed in each of these zones can also be set. For
the forward stroke enter:
- end of zone 1 position
- end of zone 2 position
- end of zone 3 position
- end of zone 4 position (the end of zone 5 position is the same as the End of Forward Stroke)
- speed for the 5 forward stroke zones
For the return stroke enter:
- end of zone 1 position
- end of zone 2 position
- end of zone 3 position
- end of zone 4 position (the end of zone 5 position is the same as the End of Return Stroke)
- speed for the 5 return stroke zones
When the mode selector is turned to MAN, the filler-box travels at a constant speed which equals
that set for the first zone of the forward stroke.
The filler-box strokes are divided into set steps - or zones - (a maximum of 5 steps for the forward
stroke and 5 for the return stroke). The filler-box speed in each of these zones can also be set.
If a value between 0 and 76% is set the filler box travels at low speed (YV20B off). If a value
between 77 and 100% is set the filler box will travel at high speed (YV20B on). For the forward
stroke enter:
- end of zone 1 position
- end of zone 2 position
- end of zone 3 position
- end of zone 4 position (the end of zone 5 position is the same as the End of Forward Stroke)
- speed for the 5 forward stroke zones
For the return stroke enter:
- end of zone 1 position
- end of zone 2 position
- end of zone 3 position
- end of zone 4 position (the end of zone 5 position is the same as the End of Return Stroke)
- speed for the 5 return stroke zones
When the mode selector is turned to MAN, the filler-box travels at a constant speed which equals
that set for the first zone of the forward stroke.
57
PH 339.85.089 Rev. 00 Date 10.12.01
4) With program version PH11.xx.yy or earlier and connecting rod-crank mechanism filler-
box with proportional solenoid valve:
The illustration above shows the set-points relating to the filler-box strokes, the encoder position
for the end of the return stroke and the filler-box speed during the 8 forward steps and 8 return
steps. Enter the following:
FILLER-BOX CONTROL ON = YES
Also enter the length of time required for the filler-box forward and return strokes for F-B
FORWARD RUN TIME and F-B RETURN TIME respectively. In this way the filler-box speed is
automatically controlled according to the set operating times.
When this control has been activated, check the F-STROKE GAIN
and RET. STROKE GAIN settings which are found on the “ACTUAL LOADING DATA” page.
These settings must fall between 140 and 160. If they do not, change the setting for GAIN (RP2)
until the desired values are reached.
If the value entered for FILL.-BOX APPROACH POS. is greater than “0”, the filler-box approach
cycle will be carried out:
- without ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box
has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. At the same
time, the APPROACH DELAY TIME starts to elapse. Once the filler-box reaches the end of
its return stroke, it stops for the amount of time set for the APPROACH DELAY TIME data item.
After this time has elapsed the filler-box starts traveling again at the speed set for the
APPROACH SPEED data item until the value set for FILL.-BOX APPROACH POS. is
reached;
- with ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box
has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once the
filler-box reaches the end of its return stroke, the ALM cycle will start. After the grid has been
loaded, the filler-box starts traveling again at the speed set for SPEED.
Finally, the GAIN (RP2) data item is used to control the speed of hydraulic filler-box operated by
the proportional solenoid valve.
58
PH 339.85.089 Rev. 00 Date 10.12.01
5) With program version PH11.xx.yy or earlier and connecting rod-crank mechanism filler-
box without proportional solenoid valve:
Set FILLER-BOX CONTROL ON = NO. If a value between 0 and 76% is set for the 16 steps, the
filler box travels at low speed. If a value between 77 and 100% is set, the filler box will travel at
high speed. Set FILL.-BOX APPROACH POS. = 0.0%. The GAIN (RP2) setting has no effect.
59
PH 339.85.089 Rev. 00 Date 10.12.01
SERVICE BLOCK
SERVICE PRESSURE: this value is entered for the aux. equipment circuit through the use of
solenoid valve YV64. NOTE: with certain types of PH (when the control assembly is not provided
with pressure transducer BP2 and the related control for the aux. equipment YV64) “0” needs to be
entered to inactivate the aux. equipment pressure control.
SERVICE PRESS. 2nd RECHARGING: if YES is entered, the pressure is recuperated at the
beginning of the last de-aeration if it was below the minimum set threshold (a fault signal is given
before the die-set upstroke). With the linear filler-box or double-loading filler-box, the pressure in the
auxiliary equipment is recuperated during the filler-box stroke.
EJECTION DURING STOPPAGE: if YES is entered, the tiles are ejected at the end of the press stop
cycle.
DIE-SET BLOCK
1st DOWNSTROKE POSITION: this is the position the filler-box reaches during its forward stroke
when the first downstroke is performed.
With a three-downstroke cycle and filler box NOT designed for double loading, the user can set the
position of the filler box for the 2nd downstroke (GLAZE FALL POSITION).
This setting can be entered if the glaze must fall during the forward (0) or return (1) stroke.
FILLER-BOX/PLUNGER BLOCK
60
PH 339.85.089 Rev. 00 Date 10.12.01
1) First of all move the cursor next to the data item to be modified by pressing one of the following
keys:
↓ to shift to the next data item
PAG ↓ to shift to the next data block
END to shift to the last data item on the page
↑ to shift to the previous data item
PAG ↑ to shift to the previous data block
HOME to shift to the first data item on the page
2) The set points can be changed in two ways:
a -enter a new value by using the following keys:
0, 1, 2, 3, 4, 5, 6, 7, 8, 9
- to indicate a negative number
. to indicate decimal points
DEL CHAR to delete the last number entered
DEL LINE to delete the entire data item entered
ENTER to make the data operative
b -By using the “-” and “+” keys found above the ENTER key:
- keep it pressed to decrease the value
+ keep it pressed to increase the value
3) The second to last line on the display provides all the information necessary to enter the data:
a) MIN = 0.0 MAX. = 40.0
These items indicate the minimum and maximum settings for the data item pointed out by the
cursor.
b) +/-
If this symbol appears, it means that the data item pointed out by the cursor can be changed
in the same way as directed for “b” given at point 2) above.
c) FILLER-BOX ENCODER = 0.0%
Useful information on how to change the data item pointed out by the cursor is displayed. In
the example above, the filler-box encoder setting is shown. This value is useful to set the end
of the filler-box’s return stroke.
If no messages appear on the second to last line, it means that the data item cannot be changed
because the WRITE key switch is turned to OFF.
With the WRITE key turned to OFF, changes can be made to the functions below by following the
directions given for “b” at point 2) above:
MOULD UPSTROKE DELAY/DIE UPSTROKE DELAY
The FILL.-BOX APPROACH POS. data item can be modified only if the mode selector is turned to
SET-UP.
61
PH 339.85.089 Rev. 00 Date 10.12.01
To go to the “PRESS CYCLE SET UP” page from “PROGRAMS” press the F4 key (PRESS CY.).
The data set for the press cycle is given on this page.
a) The following information is displayed in the first square on the left-hand side:
Some important settings for the plunger stroke and three data items regarding tile thickness: The
tiles are produced according to the TILE THICKNESS setting.
Perform the following steps to enter the required settings:
- enter the maximum allowable value for the IMPACT POSITION data item, e.g. 140.00 mm;
- enter the maximum allowable value for the THICKNESS SETTING data item, e.g. 40.00 mm;
- lower the plunger in manual mode until it rests on the powder contained in the die-set;
- with the cursor on the IMPACT POSITION data item, read the actual setting of the plunger
encoder given on the second to last line on the screen;
- enter a value which is lower than that of the encoder for the IMPACT POSITION data item:
For example: if the PLUNGER ENCODER = 106.80 mm, set IMPACT POSITION to 105.00
mm. Also set PRESSING START POS. to 105.00 mm ;
- allow the machine to perform one press-cycle;
- with the cursor on the SHUTDOWN POSITION data item
read the value given for the MAX. PLUNGER STROKE data item and enter a value greater
than it for the SHUTDOWN POSITION data item;
- do the same for the SHUTDOWN POSITION 1ST data item;
- with the cursor on the THICKNESS CALIBRATION data item, read the value displayed for the
TILE THICKNESS data item given on the second to last line on the screen;
- measure the actual thickness of the tile;
- enter the same value as the measured one for the THICKNESS CALIBRATION data item;
62
PH 339.85.089 Rev. 00 Date 10.12.01
- enable the automatic thickness gauge by entering a value higher than 0 for THICKNESS CTRL
COEFF.
- enter a value which corresponds to the desired thickness for the TILE THICKNESS data item.
NOTE: This procedure must be performed whenever the die-set is replaced!
NOTE: If a program is called up after the die-set has been replaced, perform this procedure after
reading the program!
Automatic thickness control:
- With a SMU system having a conventional lift mechanism or 2-cylinder S.E.:
The recommended value for THICKNESS CONTROL PULSE is 200. If the press has to
perform too many cycles in order to reach the thickness set for the TILE THICKNESS data item,
increase the setting, e.g. to 300.
If the thickness of the tiles produced is not always the same, decrease the value, for example
to 100.
- With a 4-cylinder S.P.E.
Enter a value greater than 0 in THICKNESS CTRL COEFF.
The recommended value is 50%; if the press needs too great a number of cycles to reach the
thickness set in TILE THICKNESS increase the value.
If the thickness is unstable, decrease the value.
PLUNGER UP POSITION is the position the plunger reaches when it completes its upward
movement during the automatic cycle. The plunger reaches its mechanical end-stop during the
semi-automatic cycle or when the machine is stopped.
END STOP PRECISION is used to more precisely position the plunger at the value set for
PLUNGER UP POSITION. If Ø is entered, minimum precision is obtained. On the other hand, if
100 is entered, the plunger positioning is extremely precise while the production output is reduced
(because the plunger slows down to a greater extent).
PRESSING START POS. when this plunger setting is reached, the first press-stroke delay time
starts to elapse (DEL. in ms). When the delay time has elapsed, the first press-stroke starts. If
the first press-stroke is to stop at the set thickness, enter PRESS STROKE START THICKNESS,
which is the thickness of the soft filling height at which the first press-stroke should start.
TOLERANCE: enter the tolerance for the pressure of the last press-stroke to the right of the symbol
±. If zero is entered for the tolerance, the last press-stroke will finish when the final pressure is
reached. If, on the other hand, the tolerance is 5 bar, the last press-stroke will finish when the
tile thickness is reached; as long as the pressure is between “final pressure - tolerance” and final
pressure + tolerance” (see figure 1).
- The PLUNGER PARALLELISM data item may appear in some machines. This value, expressed
in mm, represents maximum plunger inclination during the press-cycle.
THICKNESS LIMIT FAULT: this indicates the thickness limit beyond which the press stops working
(recommended value = 0.40 mm)
63
PH 339.85.089 Rev. 00 Date 10.12.01
c) Press cycle:
The press-stroke parameters are entered here.
PRESS-STROKE MODE: (0=to thickness, 1 = to pressure, 2 = to set time) this data item can only
be set when the machine is in SET-UP mode; type O can only be used for the first press-stroke.
Type O: the press-stroke finishes when the soft filling height set in the SP/PR column is reached.
Type 1: the press-stroke finishes when the cylinder pressure has reached the setting in the SP/
PR column. Type 2: the press-stroke finishes after a time controlled by the control system, in order
to obtain cylinder pressure equal to the setting in the SP/PR column, has elapsed.
PRESS-STROKE TREND: S1/P1 = thickness/pressure at the first point on the line shown on the
graph (this can only be set for type 0; otherwise it is fixed at half the set pressure). T1 = first time
at which the pressure, as shown on the line, reaches value S1/P1. T2 = total length of pressure
trend. Example 1 (see figure 2): 1st press-stroke set to type 0 with THICKNESS AT START OF
PRESS-STROKE = 15.00, SP/PR = 12.00, S1/P1 = 13.00, T1 = 2000, T2 = 3000. This means
that the press-stroke starts when the soft filling height reaches 15 mm. The press will adjust
YV318 in order to reach a soft filling height of 13 mm in 2 seconds and then 12 mm in another
second. Example 2 (see figure 3): last press-stroke set to type 1 with FINAL PRESSURE = 250
bar, S1/P1 = 125, T1 = 2000, T2 = 3000. This means that the press will adjust YV318 in order to
reach a cylinder pressure of 125 bar in 2 seconds and then 250 bar in the next second.
- Select whether the press-stroke is to be performed without the booster (in this case it is
performed with the direct press-stroke solenoid valve).
- Delay time before first press-stroke.
PRESS-STROKE SPEED: this is the extent to which YV318 opens during the press-stroke,
expressed as a percentage. YV318 controls the delivery rate to the press-cycle control assembly.
d) The data items regarding deaeration should be set in the right-hand block.
DEAERATION block:
MOTION UPSTR.: the speed for the deaeration upstroke should be entered here. Enter Ø to
perform the upstroke at a slow constant speed (through YV31S), enter 100 to perform a fast
upstroke (through YV32).
STROKE: the deaeration upstroke is set here.
DURAT.: set the amount of time the deaeration setting should last
SPE. DOWNSTR: set the speed of the downstroke after deaeration.
64
PH 339.85.089 Rev. 00 Date 10.12.01
Soft filling
height Fig. 1
Final thickness
Tolerance Tolerance
Thickness
Fig. 2
Thickness at
start of press-
stroke
S1/P1
SP/PR
T1 T2 time
65
PH 339.85.089 Rev. 00 Date 10.12.01
Pressure
Fig. 3
SP/PR or final
pressure (=PR)
PR/2
T1 T2 time
66
PH 339.85.089 Rev. 00 Date 10.12.01
a) The following information is displayed in the first square on the left-hand side:
Some important settings for the plunger stroke and three data items regarding tile thickness: The
tiles are produced according to the TILE THICKNESS setting.
Perform the following steps to enter the required settings:
- enter the maximum allowable value for the IMPACT POSITION data item, e.g. 140.00 mm;
- enter the maximum allowable value for the THICKNESS SETTING data item, e.g. 40.00 mm;
- lower the plunger in manual mode until it rests on the powder contained in the die-set;
- with the cursor on the IMPACT POSITION data item, read the actual setting of the plunger
encoder given on the second to last line on the screen;
- enter a value which is lower than that of the encoder for the IMPACT POSITION data item:
For example: if the PLUNGER ENCODER = 106.80 mm, set IMPACT POSITION to 105.00
mm. Also set PRESSING START POS. to 105.00 mm ;
- allow the machine to perform one press-cycle;
- with the cursor on the SHUTDOWN POSITION data item
read the value given for the MAX. PLUNGER STROKE data item and enter a value greater
than it for the SHUTDOWN POSITION data item;
- do the same for the SHUTDOWN POSITION 1ST data item;
- with the cursor on the THICKNESS CALIBRATION data item, read the value displayed for the
TILE THICKNESS data item given on the second to last line on the screen;
- measure the actual thickness of the tile;
- enter the same value as the measured one for the THICKNESS CALIBRATION data item;
- enable the automatic thickness gauge by entering a value higher than 0 for THICKNESS CTRL
COEFF.
- enter a value which corresponds to the desired thickness for the TILE THICKNESS data item.
NOTE: This procedure must be performed whenever the die-set is replaced!
NOTE: If a program is called up after the die-set has been replaced, perform this procedure after
reading the program!
67
PH 339.85.089 Rev. 00 Date 10.12.01
PLUNGER UP POSITION is the position the plunger reaches when it completes its upward
movement during the automatic cycle. The plunger reaches its mechanical end-stop during the
semi-automatic cycle or when the machine is stopped.
- The PLUNGER PARALLELISM data item may appear in some machines. This value, expressed
in mm, represents maximum plunger inclination during the press-cycle.
THICKNESS LIMIT FAULT: this indicates the thickness limit beyond which the press stops working
(recommended value = 0.40 mm)
c) Press cycle:
The press-stroke parameters are entered here.
- pressure for each intermediate press-stroke
- select whether the press-stroke is to be performed without accumulators (separate)
- select whether the press-stroke is to be performed without booster (in this case it is performed
with the direct press-stroke solenoid valve)
- delay time before the first press-stroke (for presses with piloted de-aeration also enter the
delay time before the second and third press-strokes).
d) The length of time each deaeration stroke lasts is set in the right-hand block.
e) In some types of press, the CYLINDER PRESSURE REGAINED data item is set in the block at
the bottom of the screen. This function allows energy to be saved.
With this page active, press F2 (PROGRAMS) to go back to the PROGRAMS page.
The data should be input in the same way as described for the LOADING SET-UP page. Also note
the following:
with the WRITE key switch turned to OFF, the following data items can be modified using method
b) described in point 2) above:
1ST PRESS-STROKE
DEAERATION LENGTH
68
PH 339.85.089 Rev. 00 Date 10.12.01
To go to the “DIE-SET SET UP” page from “PROGRAMS” press the F5 key (DIE-SETS).
The set points related to the die-set are displayed on this page.
a) The following items appear in the SIZE block along with the three size parameters:
TYPE OF BATCH: enter Ø to set the production batch in m2, enter 1 to set it in terms of the number
of tiles produced.
PRODUCTION BATCH: as soon as the press has produced the tiles which correspond to the
set value, the press will stop and BATCH COMPLETED will appear on the display.
TILE CODE indicates the type of product.
SHRINKAGE: this specific pressure is calculated by referring to the unfired tiles. Kiln production
(sq.m produced) is determined by referring to the shrinkage (difference btw die cavity and fired
tiles expressed in %)
b) Die-set temperature:
To turn off a heater, enter ø for the related set point.
c) SFS BLOCK:
DIE-SET TYPE: enter - 1 if a SFS upper die-set is installed, 0 if the lower die is fixed or 1 if the
lower die is mobile.
DOUBLE EFFECT: enter YES if there is a double-acting die-set or NO if it is single-acting.
PUNCHES INSIDE: enter 1 to move the upper punches back in when the filler-box starts, 2 to
move them in when the filler-box is at the end of its forward-stroke and 3 to move them in when
the filler-box is at the end of its return stroke.
WAIT LOWER DIE: enter YES to enable the “lock/unlock die” operation when the lower mobile
die remains locked in its low position at the end of the press-cycle. After the plunger has moved
back up again - performing a movement equal to PLUNGER TRAVEL, DIE-SETS UP - the lower
punch upstroke is performed. After the MOULD UPSTROKE DELAY time has elapsed (LOAD-
ING SET-UP page) the lower die is unlocked and moves up to the upper end-stop thus energising
the 2 sensors SQ63A/B.
69
PH 339.85.089 Rev. 00 Date 10.12.01
d) Two data items regarding maintenance of the die-sets are given in this block along with the type
of material the punches are constructed in.
First of all, the operator has to enter the expected service life of the die-set for the “NO. OF
CYCLES DIE-SET LIFE” data item.
Each time the die-set is changed as the production cycle is modified jot down the value given
for the “CYCLES PERFORMED WITH DIE-SET” data item shown on the “ACTUAL LOADING
DATA” page regarding the die-set being removed. Once the die-set has been installed, enter
the value for “NO. OF CYCLES PERFORMED”. As soon as the die-set reaches the number of
cycles entered for “NO. OF CYCLES DIE-SET LIFE” the following message appears: “RE-
PLACE DIE-SET”.
e) Two data items regarding the upper and lower die-sets are given in the MAGNETIC LOCK block.
Enter YES if the related magnetic lock is provided on the press. Two other data items are
provided for demagnetizing the die-sets: enter YES before demagnetizing the die-set (these
settings are operative ONLY with program version PH 11.01.01.7TR or later).
If the press is provided with the magnetic lock set UPP. = YES and LOW. = YES.
Magnetising procedure: with the key switch turned to SET UP press the “magnetisation” keys
(see chap. DESCRIPTION OF KEYS) and make sure the related leds come on. Adjust the
current control device of the magnetism (AJ1 and AJ2) (see INSTRUCTIONS FOR ADJUSTING
THE ELECTRICAL EQUIPMENT); turn the key switch to MAN.
Demagnetising procedure: with the key switch turned to SET UP set DEMAGNETISATION
UPP. = YES AND LOW. = YES, press the related keys (see DESCRIPTION OF KEYS) and
make sure the related leds go out (they flash for more than a minute).
To release a magnetic lock, first demagnetise it and then set UPP. = NO (or LOW. = NO).
The two data items LOW. 1, which relate to the magnetic lock of the bottom punch holder
(optional), appear at the bottom.
f) As far as DIE-SET BLOWING is concerned, the operator can set the stages in which the solenoid
valve (YV173) for die-set blowing is activated. Set DURING PRESS. = YES to operate the
blower during the press-0cycle.
Enter the plunger encoder value at which blowing is terminated during the upstroke for the OFF
POS. data item.
Enter the blowing value for the SFS pusher to clean the mobile die (YV178) on the line below.
It is energized during the plunger downstroke at the value set for ON. POS. and is de-energized
at the value set for OFF POS.
If a linear filler-box is used, the DOUBLE-ROW BLOWER data item is also provided. If a value
> 0 is entered, YV175 is energized when the filler-box starts running and is de-energized once
the filler-box has exceeded the set value.
Two additional data items, NO. CYCLES and LENGTH have been added to the DIE-SET
BLOWING block for the PH 4200. These data items concern YV 174 (PH 4200 base blowing).
This solenoid valve is energized for two seconds whenever the automatic cycle is started and
periodically every n cycles, where n = NO. CYCLES. The length is the value entered for the
LENGTH data item.
Press the F2 key (PROGRAM) to go back to the PROGRAMS page from this page.
Follow the directions given on the LOADING SET UP page to set the following data items.
ENABLE SPS
WAIT LOWER DIE
UPP. MAGNETIC LOCK
LOW. MAGNETIC LOCK
UPP. DEMAGNETIZATION
LOW. DEMAGNETIZATION
DIESET SELF-LEARNING
END STOP (UP) A
END STOP (UP) B
KNOC.
These data items can be modified only if the mode selector is turned to SET-UP.
71
PH 339.85.089 Rev. 00 Date 10.12.01
The “S.P.E. DIE-SET SET-UP” page can be accessed from the “DIE-SET SET-UP” page by
pressing F5 (S.P.E.).
This page (which is optional) shows the proportional knockout setpoints.
a) Settings:
First of all, enter the number of SPE downstrokes (which can be changed only in SETUP mode
and with the die-set down)
- 2-downstroke cycle
die-set setting
time
die-set first die-set last die-set
upstroke downstroke downstroke
72
PH 339.85.089 Rev. 00 Date 10.12.01
- 3-downstroke cycle
die-set setting
upper end
stop glaze thickness
time
die-set first die-set second die-set last die-set
upstroke downstroke downstroke downstroke
73
PH 339.85.089 Rev. 00 Date 10.12.01
d) Movements of the knockout which are timed with the FILLER BOX.
The knockout can perform up to five movements during the filler box return stroke starting from
the 1st downstroke position. For each movement set the following: the filler box setting when it
starts moving, the extent the die-set moves, the filler box return stroke setting at the point where
1st downstroke takes place, the die-set travel speed.
An explanatory diagram is given below:
die-set stroke
With a 4-cylinder S.P.E. the speed of each movement can be calculated automatically so as to
smooth the powder in such a way as to give it a “wedge” shape instead of a “step” shape (AUT =
YES).
Die-set setting
RETURN
From this page it is possible to go back to the PROGRAMS page by pressing F2 (PROGRAM.)
74
PH 339.85.089 Rev. 00 Date 10.12.01
As far as data set-up is concerned, refer to the paragraph regarding the LOADING SETUP page.
The following data items:
NO. OF DOWNSTROKES
END STOP
FILLING HEIGHT
BASE THICKNESS
GLAZE THICKNESS
KNOC.
DIE-SET SECURED
DIESET DISASSEMBLY
PUNCH EXTRARUN
MAX. MISALIGNMENT (B - A)
NO. CORRECTIONS
AUT
can only be changed if the Mode selector is turned to SET-UP.
With the WRITE key switch turned to OFF the following data item can only be modified with keys
-/+ on the keyboard:
BASE THICKNESS
75
PH 339.85.089 Rev. 00 Date 10.12.01
To go to the FITTINGS SET UP page from the PROGRAMS page, press the F6 key (FITTINGS).
The remaining set points are shown on this page.
a) The INSIDE synchronization data item allows the press to be run at a preset speed (expressed
in CYCLES PER MINUTE). The second CYCLES PER MINUTE data item allows the strokes of
the press to be “halved” with synchronized operation. For example, the press is synchronized and
carries out 12 cycles per minute, if the input that pilots inside synchronization (KA301) is activated
the press performs 6 cycles per minute.
OUTER synchronization allows the press to be timed with an external device.
b) As far as the ACP is concerned, enter the number of movements to be performed during each
work cycle. The numbers range from 1 to 49, with 0 = Off, 50 = ACP operating continuously. In
addition, a delay time can be set between one movement and another
The following is to be set if the loading operations are to be performed through an ALM mobile
hopper:
76
PH 339.85.089 Rev. 00 Date 10.12.01
Only set OPEN W/ MCH. STOPPED = YES if the gate is to be opened at the end of the automatic
cycle.
77
PH 339.85.089 Rev. 00 Date 10.12.01
d) If the Enea Cooling system is provided (optional), the user can select whether to enable or disable
the heat exchanger or cooling fans (only if the Enea Cooling system is controlled by SACMI).
e) MDR BLOCK (optional and available for program version PH12.xx.yy and later versions)
Basic MDR CYCLE TYPE:
0 = MDR disabled,
1 = rotation always clockwise,
2 = rotation always counter-clockwise,
3 = rotation clockwise, counter-clockwise.
MDR SPEED: speed (expressed as a %) of the mixer with rotating diaphragm installed on the
ACP.
To go to the “PROGRAMS” page from this one, press the F2 key (PROGRAM).
To enter the data, follow the instructions given for the “LOADING SET UP” page.
78
PH 339.85.089 Rev. 00 Date 10.12.01
The PRINT ROUTINE is displayed (regardless of the page currently being shown) by pressing the
<SCREEN> key on the terminal (see chapter 4 “COMPUTER TERMINAL”). The following data can
be printed out at any time.
- PRODUCTION DATA
- SET DATA
- FAULTS
- ACTUAL DATA
While the data is being transmitted to the printer, a dotted line which flashes will appear.
Press ESC (key <5>) to go back to the current page.
NOTE:
In order to print out the data, a printer with a Centronics type parallel input must be connected to the
output on the back of the card rack (marked ST). It is advisable to use the printer installation kit (not
supplied). A4 continuous form paper should be used.
NOTE:
A BMOS v. 1.8 operating system or later version is required (see INFO page).
79
PH 339.85.089 Rev. 00 Date 10.12.01
The fault messages are displayed in the area of the display illustrated in the figure.
Each message is identified by a four digit number (the first digit indicates the category the message
belongs to). The messages are divided into five different categories:
1) SHUTDOWN MESSAGES
These messages are displayed when the machine immediately shuts down. Once the trouble
has been remedied, clear them by pressing the Reset key.
4) INFORMATION MESSAGES
These messages do not affect the work-cycle or manual operations. Press the Reset key to clear
them.
5) MAINTENANCE MESSAGES
These messages do not affect the work-cycle or manual operations. Press the Reset key to clear
them.
NOTE: In some cases, messages are displayed by the operating system. When this happens, the
video is completely cleared and the machine shuts down. A detailed description of these
messages is given in the following chapter.
NOTE: - Some of the messages recommend checking one or more cards for proper functioning
(e.g. check the EIA card). Consult the Hardware Manual for the card in question, in
particular the TROUBLESHOOTING chapter.
- For further information regarding the sensors/actuators consult the LIST OF DEVICES
handbook.
- The location of the sensors/actuators indicated in the fault messages is given in the
SPARE PARTS Manual.
80
PH 339.85.089 Rev. 00 Date 10.12.01
Read the message shown on the first line at the top of the display and then refer to the FAULT
MESSAGES chapter for information regarding what caused the shutdown or stoppage. In some
cases the identification symbol of the device that detected the fault is given next to the message.
In these cases, check the state of the device in question. If everything is as required, check the
electric connections regarding the input in question.
ALWAYS TAKE DOWN ALL THE INFORMATION MENTIONED ABOVE SO THAT IT CAN BE
READILY QUOTED WHEN CONTACTING SACMI’s SERVICE DEPARTMENT.
MACHINE MALFUNCTIONING CANNOT BE PROPERLY DIAGNOSED IF THIS INFORMATION
IS NOT AVAILABLE.
If AJ1 or AJ2 does not appear to the right of the fault message the magnetic lock is enabled
but it has not yet been magnetized (see chapter 5.9.16, paragraph “e” in this manual).
- (AJ1): The input card has not received the feedback signal that the upper punch locks are
magnetized.
Check the setting of current control device AJ1 and check the wiring/operation of the upper
magnetic lock. Also inspect the input and output cards (see NOTE).
- (AJ2): The input card has not received the feedback signal that the lower punch locks are
magnetized.
Check the setting of current control device AJ2 and check the wiring/operation of the lower
magnetic lock. Also inspect the input and output cards (see NOTE).
NOTE: For presses using an earlier program version than PH12.01.01, there is only one
feedback input signal (the contacts of AJ1 and AJ2 are series connected). This means that,
even if the fault message PUNCHES NOT FIXED (AJ1) appears, the operator must check
whether the fault is in the upper or lower magnetic lock. Then make the required checks.
If this message appears when the machine is started up or after the CPU card has been
replaced, check all of the set data.
If the message appears at any other time, check the battery for proper functioning (located
on the POWER SUPPLY card).
If it works properly, replace the CPU card and check all of the settings.
NOTE: The message can be deleted (with the key switch on the control keyboard turned
to SET UP) by pressing the Reset button.
The key on the machine control keyboard was turned during RESETTING, CYCLE or SEMI-
AUTOMATIC operation.
If the key was not turned, check selector SA9, its connection to the machine keyboard and
the keyboard power lead.
If the lead is properly plugged in and is not broken, replace the control keyboard.
If the keyboard works properly, replace the MISCELLANEOUS card.
82
PH 339.85.089 Rev. 00 Date 10.12.01
The second encoder/analog card (EIA) in location 10 is malfunctioning. Shut off the
controller and replace the card.
If the trouble persists, replace the CPU card.
If the problem still cannot be resolved, contact SACMI to check the configuration (check the
ENCODER data item).
NOTE: this message only appears when a program version earlier than PH12.01.01 is being
used.
This fault message is displayed just before the power to the electrical cabinet is cut off. This
happens because a fault has been detected in one of the die-set heaters (“n” indicates the
heater which is malfunctioning):
- output KMn is off and the corresponding input KMn is on.
- the temperature measured by thermocouple BTn is higher than 110°C (80°C if the punches
are made of rubber).
- the temperature measured by BTn is lower than 0°C and output KMn is on.
In all these cases, the pumps are stopped after 5 minutes and then power to the electrical
cabinet is cut off.
With program versions earlier than PH12.01.01: check thermocouple BTn, its input
module, the EIA card in location 6/7 and the related leads/connectors. If the problem is the
first possibility mentioned, check the output card, contactor KMn, feedback relay KAn in the
electrical cabinet and the input card.
With program version PH12.01.01 or later: check thermocouple BTn, its conversion card
in box 38, the IA card and the related leads/connectors. If the problem is the first possibility
mentioned, check the output card, contactor KMn, feedback relay KAn in the electrical
cabinet and the input card.
The OD and ODA cards have a control device which checks that the current supplied from
each digital output is correct.
If one of these cards detects a faulty output, this message appears.
Disconnect the output for YVn from the controller and make sure there are no short circuits
in solenoid valve YVn or in the leads/connectors.
If there are no shorts in the cable or solenoid valve, check to see whether there is a +24 V
supply for the solenoid valves. To do this, check the respective Led on the power supply (see
INSTRUCTIONS C - paragraph 3.1) and the AL Led on the card which has the short circuited
output.
Make sure there are no false contacts in the power supply for the YVn output card.
If the short-circuited output is part of the first ODA card, check filler-box limit switches SQ59,
SQ53 (Roller conveyor on), SQ66, SQ66A (Filler-box on), SQ51, SQ52 (Safety bar),
contact SA9 of the mode selector as well as contacts AJ101, KA102 and KA103. Also check
circuit breaker FS101.
If the problem persists replace the output card.
83
PH 339.85.089 Rev. 00 Date 10.12.01
The maximum operating pressure for the press cylinder has been exceeded. If “(SP2)”
appears to the right of the fault message this means the problem has been detected by
pressure switch SP2: check the pressure switch and the ID card (if the pressure is within
the set limits led SP2 should always be on) as well as the leads/connectors.
If nothing appears to the right of the fault message this means the problem has been
detected by pressure transducer BP1. In this case the message appears when the
transducer detects pressure which is 20 bar above the maximum allowable. Check
transducer BP1, the leads/connectors and
With program versions earlier than PH12.01.01: the input module of transducer BP1
(AP301) and the EIA card in location 6/7.
With program version PH12.01.01 or later: check the IA card in location 7.
The IE card does not work. Turn off the controller and replace the card. If the problem
persists replace the CPU card.
The IA card does not work. Turn off the controller and replace the card. If the problem
persists, replace the CPU card.
Input KM11 has remained inactivated for 30 seconds. The pumps are stopped.
Check the thermal cutout and contactors of the fan and filtering unit motors (KM4 and
KM11).
Check the input card (Led KM11 must be on when the motors are running) and the leads/
connectors.
Check the output card (Led KM11 must come on when the motors have to run) and the
leads/connectors.
If KM11A, KM13 or KM14 are indicated in the fault message, check the additional heat
exchanger.
Input KM1D has stayed off for 30 seconds with the main pump running or the input signal
has remained on for 2 seconds while the main pump is being turned off. The main pump is
stopped.
Check the thermal cutout and contactor KM1D.
Check the input card (Led KM1D must be on when the motor is running) and the leads/
connectors.
Check the output card (Led KM1 must be on when the motor has to run) and the leads/
connectors.
84
PH 339.85.089 Rev. 00 Date 10.12.01
Input SP3 has stayed off for 6 seconds. The main pump is stopped.
Check the main pump suction filter for efficiency.
Check pressure switch SP3, the input card (Led SP3 must be on when the operating
pressure is within the allowable range) and the leads/connectors.
Input SL1 has stayed off for 6 seconds. The pumps are stopped.
Check the oil level in the reservoir.
Check level sensor SL1, the input card (Led SL1 must come on when the oil exceeds the
maximum level mark) and the leads/connectors.
The machine will shutdown when this message appears and the main pump will stop
running.
Make sure the thermocouple for the oil is properly connected.
With program versions earlier than PH12.01.01:check the input module of thermocouple
BT4 (AP304) and the EIA card in location 6/7.
With program version PH12.01.01 or later: check conversion card APBT4 (control unit
box) and the IA card.
The oil temperature has remained at a temperature which is too low (less than 2° C) for 30
seconds. The main pump is stopped.
Check the thermocouple for proper functioning (replace it if necessary).
If it works properly, find out what is causing the temperature to be too low.
With program versions earlier than PH12.01.01:check the input module of thermocouple
BT4 (AP304) and the EIA card in location 6/7.
With program version PH12.01.01 or later: check conversion card APBT4 (control unit
box) and the IA card.
The oil has remained at a temperature which is too high (over 55° C) for 30 seconds. The
main pump is stopped.
Check the thermocouple for proper functioning (replace it if necessary).
If it works properly, find out what is causing the temperature to be too high.
With program versions earlier than PH12.01.01: check the input module of thermocouple
BT4 (AP304) and the EIA card in location 6/7.
With program version PH12.01.01 or later: check conversion card APBT4 (control unit
box) and the IA card.
The temperature level reached appears to the right of the fault message.
The input of pressure switch SP11 has stayed off for 6 sec. while motor control KM11 was
on. The pumps are stopped. Check the input card (Led SP11 must be on when motor M11
is running) and the leads/connectors.
85
PH 339.85.089 Rev. 00 Date 10.12.01
Input SP1 has remained inactivated and the oil temperature is above 30°C. The main pump
is stopped.
Replace the filter in the hydraulic power unit as it is clogged.
If the message is still displayed even after the filter has been replaced, check pressure
switch SP1, the input card (Led SP1 must be on when the filter is not clogged) and the leads/
connectors.
Input SL4 has stayed off for 40 seconds. The main pump is stopped.
Check the oil leak level in the oil recovery tank.
Check level sensor SL4, the input card (Led SL4 must come on when the oil is below the
low level mark) and the leads/connectors.
With the safety bar raised, the pressure in the cylinder exceeds 6 bar. The main pump is
stopped.
Check all the logic elements and solenoid valves of the pressing unit and make sure no faults
are present.
If there is no pressure in the cylinder, set the pressure transducer of the cylinder (see
NOTE).
If the problem persists, replace pressure transducer BP1.
With program version earlier than PH12.01.01:check the input module of transducer
BP1 (AP301) and the EIA card in location 6/7.
With program version PH12.01.01 or later: check the IA card in location 7.
NOTE: With program version 12.01.01 or later, cylinder pressure = 2 bar is displayed when
the machine is turned on if digital input SP3 is on (air pressurization approx. 1.5 bar) and
the pressure detected by transducer BP1 is between -3 bar and +7 bar.
To set the transducer, it is necessary to eliminate pressurization, turn off the controller and
then turn it on again. At this point the pressure displayed is that read by the transducer and
the operator can therefore proceed with the setting procedure: see the INSTRUCTIONS
FOR SETTING THE TRANSDUCERS Manual.
Input SP6 has stayed off for 60 seconds and the oil temperature is higher than 30°C.
The ENEA COOLING filter needs to be replaced as it is clogged.
If the message continues to be shown after the filter has been replaced, check pressure
switch SP6 and the input card (with the filter not clogged led SP6 should be on) and the
related leads/connectors.
86
PH 339.85.089 Rev. 00 Date 10.12.01
Input ST1 has stayed off for 6 sec. The main pump is stopped. Check the flywheel bearings
to see if they are properly lubricated. Make sure the bearings work properly.
During the automatic cycle, SQ62 has not been energised within 0.5 seconds of the moment
when the plunger arrived at the top end stop.
Check limit switch SQ62 and the related leads/connectors.
Check the input card (Led SQ62 must be on when the punches are out). Also check solenoid
valve YV193, the leads/connectors and related output card.
SQ61 has not been energized within one second of YV221 being de-energized during gate
closing.
Check solenoid valve YV221 for proper operation.
Check proximity switch SQ61, the input card (with the hopper closed, switch SQ61 must be
energized) and the leads/connectors.
Check the output card (Led YV221 must go off when the gate has to close) and the leads/
connectors.
During the last die-set downstroke SQ6 was de-energised (see NOTE).
Check solenoid valve YV21 for proper functioning.
Check proximity switch SQ6, the ID card in location 11(when the die-set is lowered, Led SQ6
must be on) and the leads/connectors.
Check the OD card in location 16 (during the last die-set downstroke, Led YV21 must go
out) and the leads/connectors.
NOTE: SQ6 must be activated once the die-set has completed the first downstroke and
must remain activated during all the other downstrokes as well as during the press-cycle.
With 2-cylinder proportional knockout: if the value of encoder A or B is not lower than
2 mm within 8 seconds from when the signal for the last downstroke was sent:
Check proportional solenoid valves YV22A/22B, axis cards AP204/205, the related ODA
card, synchronization card AP203, encoder interface module AP206 installed on the SMU,
encoders BQ4/5 and:
- With program version earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01 or later: the IA card and the IE card in location 9.
If the message is displayed during the press-cycle, it means encoders BQ4/5 have not read
a value less than 0.5 mm during the press-strokes. Shut off the controller and then turn it
back on and reset the encoders.
With 4-cylinder proportional knockout: if the value of encoder A or B is not lower than
0.8 mm within 8 seconds from when the signal for the last downstroke was sent:
Check proportional solenoid valves YV22A/22B, axis cards AP210, the encoder interface
card AP207, the serial interface card AP208, the OD card in location 14, the ID card in
location 13, encoders BQ4/5 and
- With program version earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01 or later: the IE card in location 9.
If the message is displayed during the press-cycle, it means encoders BQ4/5 have not read
a value less than 0.5 mm during the press-strokes. Shut off the controller and then turn it
back on and reset the encoders.
87
PH 339.85.089 Rev. 00 Date 10.12.01
The plunger is below the value set for its upper-most position when the die-sets begin to
move up.
The filler box is not completely back when the die-set starts moving up
If “(SQ59)” appears to the right of the fault message, this means the fault has been
diagnosed by upper input SQ59. In this case, check filler box safety switch SQ59 and the
IDM card in location 11.
If nothing appears to the right of the message, this means that the fault has been detected
by the filler box encoder. In this case, check the filler-box encoder setting. If the latter does
not correspond to the actual position of the filler box:
With program version earlier than PH12.01.01:check the EIA card in locations 6/7.
With program version PH12.01.01 or later: check the IE card in location 9.
The position of the second filler-box or LB type filler-box is not correct when the die-sets start
their upstroke. Check the trigger pulse for the plunger downstroke (KA302) and the related
input card.
Proximity switch SQ3 is not energized during the die-set upstroke (see NOTE).
Check solenoid valves YV21/22 and the related hydraulic lines for proper functioning.
Check proximity switch SQ3, the ID card in location 11 (when the die-sets are raised,
proximity switch SQ3 must be energized) and the leads/connectors.
Check the OD card in location 16 (while the die-sets are moving up, Leds YV21/22 must
come on) and the leads/connectors.
Check solenoid valve YV64 and the pressure in the service circuit.
With a 2-cylinder proportional knockout: if the setting of encoder A or B does not reach
the upper end-stop setting less 2 mm within 8 seconds from when the signal for the die-set
upstroke was sent:
Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis cards AP204/
205 and related ODA card, synchronization card AP203, encoder interface module AP206
installed on the SMU, encoders BQ4/5 and
- With program version earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01 or later: the IA card and the IE card in location 9.
With 4-cylinder proportional knockout: if the setting of encoder A or B does not reach
the upper end-stop setting less 0.8 mm within 8 seconds of the signal for the die-set upstroke
being sent:
Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis card AP210,
the encoder interface card AP207, the serial interface card AP208, the OD card in location
14, the ID card in location 13, encoders BQ4/5 and
- With program version earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01 or later: the IE card in location 9.
NOTE: SQ3 should be energized when the die-sets move up (YV21 and YV22 ON) for a
max. time of 8 seconds. SQ6 should be de-energised within this time and should be
energized when the die-set performs its first downstroke.
88
PH 339.85.089 Rev. 00 Date 10.12.01
Proximity switch SQ3 is not de-energized or proximity switch SQ6 is not energized within
1 second of the first downstroke signal (see NOTE).
Check solenoid valve YV22 and related hydraulic lines for proper functioning.
Check proximity switches SQ3/SQ6, the ID card in location 11 (after the first downstroke,
SQ6 should be energized and SQ3 de-energized) and the leads/connectors.
Check the OD card in location 16 (Led YV22 should go out after the first downstroke) and
the leads/connectors.
With a 2-cylinder proportional knockout:
2-downstroke cycle: if the setting of encoder A or B is not lower than FCA/2 (FCA = Upper
end-stop) within 8 seconds from when the signal for the first downstroke was sent,
3-downstroke cycle: if the first downstroke setting (with 0.4 mm tolerance) has not been
reached within 8 seconds from when the signal for the first downstroke was sent:
check proportional solenoid valves YV22A/22B, axis cards AP204/205 and related ODA
card, synchronization card AP203, encoder interface card AP206 installed on the SMU,
encoders BQ4/5 and
- With program version earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01 or later: the IA card and the IE card in location 9.
With 4-cylinder proportional knockout: if the first downstroke setting (with 0.8 mm
tolerance) has not been reached within 8 seconds from when the signal for the first
downstroke was sent:
Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card
AP207, serial interface card AP208, the OD card in location 14, the ID card in location 13,
encoders BQ4/5 and
- With program version earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01 or later: the IE card in location 9.
NOTE: SQ6 should be energized when the first die-set downstroke has been performed and
should remain energized for the rest of the downstrokes and during the press-cycle. SQ3
should be energized as soon as the die-set starts to move down.
SQ60 has not been energized within 1 second of YV221 being energized during gate
opening.
Check solenoid valve YV221 for proper functioning.
Check proximity switch SQ60, the input card (with the hopper open, proximity switch SQ60
must be energized) and the leads/connectors.
Check the output card, (Led YV221 must come on when the gate has to open) and the leads/
connectors.
Digital input KA304 has not come on within 15 seconds from when the signal for starting the
2nd filler-box cycle was sent (KA401).
Make sure the second filler box/filler-box for double loading works properly.
Check the trigger pulse contact for the intermediate die-set downstroke (KA304), the input
card (Led KA304 must be on when the trigger pulse is provided) and the leads/connectors.
89
PH 339.85.089 Rev. 00 Date 10.12.01
During the second die-set downstroke (in a 3-downstroke cycle) SQ6 has been de-
energized for more than 1 second.
Check proximity switch SQ6, the ID card in location 11 (LED SQ6 should be on) and the
leads/connectors.
Check solenoid valve YV170 and related hydraulic lines for proper functioning.
Check the OD card in location 16 and the leads/connectors.
With a 2-cylinder proportional knockout:
3-downstroke cycle: if the first downstroke setting less 0.4 mm has not been reached within
8 seconds from when the signal for the second downstroke was sent:
(Note: If the set glaze thickness is lower than 0.8 mm, the fault message is not shown)
check proportional solenoid valves YV22A/22B, axis cards AP204/205 and related ODA
card, synchronization card AP203, encoder interface card AP206 installed on the SMU,
encoders BQ4/5 and
- With program version earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01 or later: the IA card and the IE card in location 9.
With 4-cylinder proportional knockout: if the second downstroke setting (with 0.8 mm
tolerance) has not been reached within 8 seconds of the signal for the second downstroke
being sent:
Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card
AP207, serial interface card AP208, the OD card in location 14, the ID card in location 13,
encoders BQ4/5 and
- With program version earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01 or later: the IE card in location 9.
Digital input KA302 has not come on within 15 seconds of the second die-set downstroke.
Check that the second filler box functions and moves properly.
Check the trigger pulse contact for the last die-set downstroke (KA302), the input card (Led
KA302 must be on when the last die-set downstroke is triggered) and the leads/connectors.
SQ63 has not been energized within 0.5 seconds from when = the plunger reached its
uppermost position.
Check sensor SQ63 and the leads/connectors.
Check the input card (with the die up, Led SQ63 must be on).
Check solenoid valve YV172, the leads/connectors and related output card.
Digital input SP5 is off and the oil temperature is higher than 30°C.
The knockout filter must be replaced as it is clogged.
If the message is still displayed after the filter has been replaced, check pressure switch
SP5, the ID card in location 12 (when the filter is not clogged, Led SP5 should be on) and
the leads/connectors.
90
PH 339.85.089 Rev. 00 Date 10.12.01
An excessive difference was found between the value of the right-hand side and the left-
hand side while the proportional knockout was moving.
With 2-cylinder proportional knockout:
1) When moving down cylinder B has exceeded cylinder A by more than 2.5 mm (setting
A > setting B).
Cylinder A shut down; check proportional valve A.
2) When moving down cylinder A has exceeded cylinder B by more than 2.5 mm (setting
B > setting A).
Cylinder B shut down; check proportional valve B.
3) When moving up cylinder A has exceeded cylinder B by more than 2.5 mm (setting A >
setting B).
Cylinder B shut down; check proportional valve B.
4) When moving up cylinder B has exceeded cylinder A by more than 2.5 mm (setting B >
setting A).
Cylinder A shut down; check proportional valve A.
5) A misalignment of more than 10.5 mm has been detected between the two cylinders
(YV22S is de-energized).
Proportional valve malfunctioning; check the Moog and ODA cards.
Encoder stopped or not working.
With 4-cylinder proportional knockout:
0) A misalignment of more than 5 mm has been detected between the two cylinders.
91
PH 339.85.089 Rev. 00 Date 10.12.01
At the filler-box start, the difference between the value measured by one of the two encoders
and the upper end-stop is > 0.4 mm. The values measured for cylinders A and B of the
proportional knockout are indicated in brackets.
Try reducing the setting for UPSTROKE SPEED.
With 2-cylinder proportional knockout: Check solenoid valve YV22S, proportional
solenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronization
card AP203, encoder interface card AP206 installed on the SMU, encoders BQ4/5 and
- With program version earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01 or later: the IA card and the IE card in location 9.
With 4-cylinder proportional knockout: Check solenoid valve YV22S, proportional
solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial
interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/
5 and
- With program version earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01 or later: the IE card in location 9.
Perform the die-set self-learning procedure. See the DIE-SET SET UP page.
A fault has been detected in one of the die-set encoders (the difference between the analog
value and the digital one is > 1 mm). Check the encoder interface card AP206 installed on
the SMU, encoders BQ4 and BQ5 and
With program version earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
With program version PH12.01.01or later: the IA card and the IE card in location 9.
93
PH 339.85.089 Rev. 00 Date 10.12.01
During the die-set learning procedure one of the two encoders has reached the value set
for UPPER END STOP ± 2 mm.
Check the proportional solenoid valves of the die-set for proper functioning.
Check solenoid valve YV64, YV225 and the pressure of the service circuitry.
Otherwise reduce the UPPER END STOP setting A or B.
The control used to perform the die-set upstroke (or the first downstroke in the case of a 3-
downstroke cycle) is too far up.
Try performing a die-set self-learning procedure.
(See the DIE-SET SET-UP page).
If the problem persists replace the solenoid valves in the die-set.
The card which controls the proportional knockout has emitted a fault signal. Make sure
there are no faults in the die-set (excessive friction, etc...). Check to see whether the die-
set encoders work properly.
0) Check signal KA 1006 and the IDM card in location 13. If the problem persists, replace
axis card control AP210 in the controller.
1) The die-set is blocked. Try moving down the die-set with the key switch turned to Set Up
and make sure there are no obstacles which prevent the die-set from moving. If the die-
set is still blocked, try moving the die-set upwards in Set Up mode.
2) The AX card does not work. Check the first module.
3) The AX card does not work. Check the second module.
4) When solenoid valve YV25 is energised (YV22S in the 4-cylinder SPE) to deliver oil to
the SPE, the AX card indicates that there are problems with the feedback of proportional
solenoid valve A (left-hand side). Solenoid valve YV25 or YV22S is de-energised.
Proportional valve A stuck. Check the AX card and the spool signal.
5) When solenoid valve YV25 (YV22S in 4-cylinder SPE) is energised to deliver oil to the
SPE, the AX card indicates that there are problems with the feedback of proportional
solenoid valve B (right-hand side).
Solenoid valves YV25 and YV22S are de-energised.
Proportional valve B has got stuck. Check the AX card and the spool signal.
The proportional knockout cannot be moved because the encoders are blocked.
Release them.
If the message continues to appear, check the two sensors SQ4 and SQ5, the wiring and
IDM card in location 13.
While the proportional knockout pressure was being reset, one of the two encoders read a
value greater than 0.6 mm (the die-set was not fully down and therefore the reset procedure
was not performed). Make sure the die-set can reach the zero setting. Check encoders BQ4/
5, the IE card in location 9 and axis card AP210.
94
PH 339.85.089 Rev. 00 Date 10.12.01
Check BQ4A = position of rod-type knockout (linear absolute encoder) and the related
electrical wiring.
Check card IE, location 9.
The rod-type knockout has not completed its upward movement within the preset time.
Check YV25S = slow upward movement of the rod-type knockout, YV21G/YV21H=
knockout interlock solenoid valve, YV21P = proportional solenoid valve to control rod-type
knockout.
Check card OD, location 14, card OD, location 16, and card ODA, location 17.
Check BQ4A = position of rod-type knockout (linear absolute encoder) and card IE, location
9.
The rod-type knockout has not completed its downward movement within the preset time.
Check YV25D = slow downward movement of rod-type knockout, YV21G/YV21H= knockout
interlock solenoid valve, YV21P= proportional solenoid valve to control the rod-type
knockout.
Check card OD (location 14) card OD (location 16) card ODA (location 17).
Check BQ4A= position of the rod-type knockout (linear absolute encoder) and card IE,
location 9.
95
PH 339.85.089 Rev. 00 Date 10.12.01
A fault has been detected in the system which monitors the setting of a plunger encoder (the
name of the encoder is specified in brackets).
Check the encoder, connecting lead and the encoder card (IE) in location 9 for proper
functioning. Try turning off the control system, removing the IE card and putting it back in
and then turning the system on again.
The lift rod or punch over-travel selectors have been turned on.
If neither of these selectors have been turned on, check the input card in location 12 (Led
SA1 must be on if no contacts are energized) and the leads/connectors.
With 4-cylinder proportional knockout: data item PUNCH OVERTRAVEL = YES has
been set on the S.P.E. die-set set-up page. Enter NO for this setting.
The device for changing the die-set is activated (it is out). If this is not the case, check
sensors SQ68A, SQ68B, SQ67A, SQ67B (when the hook is in, sensors SQ67 are
energized and SQ68 de-energized, whereas when the hook is out sensors SQ67 are de-
energized and SQ68 energized). Check the ID cards and the leads/connectors.
Input SP4 has stayed off for 0.5 seconds with the oil temperature higher than 30°C.
Replace the filter located on the proportional solenoid valve in the filler-box as it is clogged.
If the message is still displayed even after the filter has been replaced, check pressure
switch SP4, the ID card in location 11 (Led SP4 must be on when the filter is not clogged)
and the leads/connectors.
Approx. 300 msecs. have elapsed since the plunger downstroke began and the plunger
speed is still lower than 4mm/sec.
In “proportional” PHs, this fault message may be displayed during the first few plunger
downstrokes just before reaching the impact position. In this case, try restarting the machine
because during each attempt the control system tries to soften the brake ramp.
Check the plunger encoder, its mount and the leads/connectors.
Make sure the plunger can reach the START PRESS STROKE setting when it moves down.
Check solenoid valve YV32D and the related hydraulic lines for proper functioning.
The first ODA card has to be energized while the plunger is moving down (19th led of the
card should be on). If it is not, check filler box limit switch SQ59, circuit breaker FS101,
contactors KA102/102A, KA103/103A, mode selector SA9, safety module AJ101 and
With program version earlier than PH12.01.01: check the EIA card in location 6/7 if an
incremental encoder is installed or the IE card in location 9 if an absolute encoder is
installed.
With program version PH12.01.01 or later: check the IE card in location 8.
96
PH 339.85.089 Rev. 00 Date 10.12.01
200 msecs. have elapsed since the filler-box forward stroke signal was sent but the filler-
box encoder value has not changed.
Check encoder BQ2, its mount and the leads/connectors.
With rod-crank mechanism filler-box: check proportional solenoid valve YV20 (see
NOTE), the related electrical wiring and hydraulic lines for proper functioning. Check the
pressure in the service circuit.
Check solenoid valve YV20S and related electrical wiring. Also inspect YV20 control card
AP201 and the OD card in location 16.
If solenoid valve YV20S does not work, also check circuit breaker FS101, mode selector
SA9 and contactors KA102/102A, KA103/103A.
NOTE: if proportional valve YV20 is not installed, check solenoid valve YV20A and the
related electrical wiring;
If the proportional solenoid valve is installed, YV20A becomes YV20S
- With program version earlier than PH12.01.01: check the EIA card in locations 6/7.
- With program version PH12.01.01 or later: check the IE card in location 10.
With linear filler-box: check digital output KA20E on the ODA card (LED on = filler-box
moving) and the related electrical wiring. Check relays KA20E/20I, inverter U20 and motor
M20.
- With program version earlier than PH12.01.01: check the EIA card in locations 6/7.
- With program version PH12.01.01 or later: check the IE card in location 10.
Check proportional solenoid valve YV20 and the related hydraulic lines for proper functioning,
including card VT11023. If the proportional solenoid valve is not provided, check solenoid
valve YV20A.
Check encoder E2, its mount, the EIA card and the leads/connectors.
Check the output card (when the solenoid valve has to operate, Led YV20A must come on)
and the leads/connectors. Check the pressure in the service circuit.
With a filler box for double loading, check signals KA302 and SQ59 coming from the filler
box itself (when the filler box is fully back, led KA302 on the ID card should come on and
led SQ59 should go out). Also check the ID card and the KA59 relay.
Check proportional solenoid valve YV20 and the related hydraulic lines for proper functioning,
including card VT11023. If the proportional solenoid valve is not provided, check solenoid
valve YV20A.
Check encoder E2, its mount, the EIA card and the leads/connectors.
Check the output card (Led YV20A must come on when the solenoid valve has to operate)
and the leads/connectors.
Check the pressure in the service circuit.
With a filler box for double loading, check signals KA302 and SQ59 coming from the filler
box itself (when the filler box starts moving, led KA302 on the ID card should go out and led
SQ59 should come on). Also check the ID card and the KA59 relay.
97
PH 339.85.089 Rev. 00 Date 10.12.01
The plunger is below the value set for its upper-most position when the filler-box begins its
forward/return strokes.
If an absolute encoder is installed, check that the value read by the encoder when the
plunger is against the end-stop is 0. If this is not the case, repeat the plunger encoder reset
procedure (see AXES RESET page). If the fault persists, try replacing the IE card in location
8.
When the automatic or semi-automatic cycle is started, the filler-box for double loading is
not fully back. When the filler-box is fully back, input SQ59 should be off and input KA302
should come on. Check cards ID in locations 11 and 13.
The signal for the first die-set downstroke sent from the PLC controlled filler-box was not
received within 15 seconds of the filler-box start.
Check the connection for the first die-set downstroke signal and the input card in location
13 (when the request is provided Led KA305 must come on).
The signal for the third die-set downstroke was not received from the filler-box for double
loading.
Check the connection for the third die-set downstroke signal and the input card (when the
request is provided Led KA306 must come on).
98
PH 339.85.089 Rev. 00 Date 10.12.01
Digital inputs SQ59 and KA302 have not changed over within 15 seconds of the last
downstroke (when the filler-box arrives at the rear end-stop, led SQ59 should go out and
led KA302 should come on).
Make sure that the digital input cards in location 11 and 13 receive the filler-box forwards/
backwards signals SQ59 and plunger down trigger pulse KA302. Also check contactor
KA59 and the related press/filler-box leads/connectors.
One of the two limit switches for the safety bar is faulty.
Check the two limit switches, the ID card in location 11 and the related leads/connectors
(when the safety bar is down Leds SQ51 and SQ52 for the input card must be on).
After checking, push the safety bar up and press the Reset button.
Check solenoid valve YV20S and its monitoring device (SQ20S) for proper functioning.
When the filler-box is operating (output YV20S energized), input SQ20S must be off
whereas when the filler-box is stopped (YV20S de-energized) input SQ20S must be on.
Check the ID input card in location 12.
The ejector cylinder is malfunctioning. Check the sensor indicated in the fault message and
the ID input card in location 13 (when the sensor is activated the corresponding Led of the
card must be on) and the leads/connectors.
Press the Reset button. If the message remains on the screen, check safety module AJ101.
If no power is delivered (“NETZ” Led off or “POWER” off) check magnetic-thermal cutout
FS100. If power is being delivered but the two signals (S1 and S2) are different or they are
both off, check limit switches SQ51, SQ52 and SQ66/SQ66A as well as sensors SQ53A/
SQ53B, which monitor the roller conveyor (optional), for secure mounting and proper
operation. If Leds S1 and S2 stay on and the message remains on the screen, check the
input card (Led AJ101 must be on when the safety bar is down) and the leads/connectors.
99
PH 339.85.089 Rev. 00 Date 10.12.01
The value of one or both die-set encoders has exceeded the Upper End Stop (FCA) setting
by more than 0.5 mm or has fallen below it by more than 1 mm during the filler-box forward
stroke (up until the first downstroke).
Refer to fault message 2037 for trouble-shooting instructions.
One of the 2 sensors that detect when the roller deck is in front of the press is malfunctioning.
Check the 2 sensors, the ID card in location 13 and the leads/connectors (when the roller
deck is connected Leds SQ53 and SQ54 on the ID card must be off). After checking, move
the roller deck back and press the Reset key.
Digital inputs SQ59 and KA302 failed to change-over within 30 sec. from the moment in
which the start signal was sent to the PLC controlled filler-box from contact KA20A (when
the filler-box begins to move, led SQ59 should light up and led KA302 should go out).
Make sure the start signal from KA20A reaches the filler-box controller (led YV20S on card
OD in location 16 ON = filler-box start). In addition, check contactors KA102/102A, KA103/
103A, relay KA20A and the leads/connectors for the relative press/filler-box.
Make sure the digital input cards in locations 11 and 13 receive the filler-box forward/back
signals from SQ59 and the signals for the plunger downstroke from KA302. In addition,
check contactor KA59 and the leads/connectors for the relative press/filler-box.
The linear filler-box has exceeded the safety position (set for the FILLER-BOX SAFETY
SETTING data item on the LOADING SET- UP page) and the plunger is lower than the value
set for PLUNGER UP (PRESS CYCLE SET-UP page). Decrease the value set for F.BOX
START ADVANCE.
If this is not enough to solve the problem, try reducing the value set for PLUNGER UP or
adjust the UPPER END-STOP PRECISION data item.
Digital input KM22 has not come on within 300 msecs. of the KM22A signal being sent.
Check the thermal cutout and ACP contactor KM22A for proper functioning.
Check the input card (Led KM22 must be on when the motor is running) and the leads/
connectors.
Check the output card (Led KM22A must be on when the motor has to run) and the leads/
connectors
Digital input SQ21 has not come on within 20 seconds of the KM21A signal being sent.
Check the thermal cutout and the ACP contactor.
Check sensors SQ21 and SQ22 (when KM21A is energized SQ21 has to be activated) and
the related input card.
Check the output card (when the motor has to run, Led KM21A must be on) and the leads/
connectors.
100
PH 339.85.089 Rev. 00 Date 10.12.01
Digital input KM22 has not come on within 300 msecs. of the KM22B signal being sent.
Check the thermal cutout and ACP contactor KM22B for proper functioning.
Check the input card (Led KM22 must be on when the motor is running) and the leads/
connectors.
Check the output card (Led KM22B must be on when the motor has to run) and the leads/
connectors.
Digital input SQ22 has not come on within 20 secs. of the KM12B signal being sent.
Check the thermal cutout and the ACP contactor.
Check sensors SQ21 and SQ22 (when KM21B is energized SQ22 has to be activated).
Check the output card (when the motor has to run, Led KM21B must be on) and the leads/
connectors.
ALM with encoder: if the ALM does not reach the setting for the end of the backstroke within
15 seconds;
check ALM encoder BQ10, the IE card in location 10 and the leads/connectors.
ALM with sensors: if limit switch sensor SQ23 is not energised within 15 seconds (the ALM
should be near the press).
Check sensor SQ23 and the input card (with the ALM near the press, led SQ23 should be
on).
Check contactor KM23A and the OR output card (when the ALM moves near the press, led
KM23A should be on) and the leads/connectors.
- With the fixed ALM, limit switch SQ23 is not energized at the filler-box start (the ALM
should be near the press).
Make sure that digital input SQ23 on the ID card in location 12 is on.
- Limit switch SQ24 has not been energised within 15 seconds during a manual operation
or ALM reset procedure.
Try increasing the ALM speed.
101
PH 339.85.089 Rev. 00 Date 10.12.01
Sensor SQ25 was not activated during the ALM loading cycle.
Check sensor SQ25, the input card and the leads/connectors.
Check the related cam: SQ25 must be energized before the ALM activates SQ24.
This fault message is provided with 2-LINE LOADING of the ALM when the second cam for
SQ25 or limit switch SQ24 is activated before the time set for OPENING DELAY for the gate
has elapsed.
Decrease the value set for the OPENING DELAY data item found on the FITTINGS SET
UP page.
Sensor SQ24S was activated while the ALM was being moved back in manual mode or
being reset. Check sensor SQ24S and the input card (when the ALM is at the end of its
backwards overtravel stroke, Led SQ24S must be on) and the leads/connectors.
If the return stroke of the filler-box is to be carried out in manual mode, move the ALM to the
end of its backwards overtravel position with the manual control for the back stroke before
carrying out the operation. If a semi-automatic loading cycle is required, move the ALM
forwards before carrying out the operation.
If the ALM has to be moved back in manual mode or be reset, move the filler-box fully back
before carrying out the operation.
- With the fixed ALM, the value read by the ALM encoder BQ10 differs from the rear end-
stop value by more than 20 mm.
Check encoder BQ10, the IE card in location 9 and the leads/connectors.
- The ALM has not reached the rear end-stop position within 25 seconds during a manual
operation or while being reset.
Try increasing the ALM speed.
- With an ALM with sensors, make certain limit switches SQ23 and SQ24 are not activated
at the same time. Check the ID card in location 12.
102
PH 339.85.089 Rev. 00 Date 10.12.01
- The position of the ALM during the filler-box return stroke, with the filler-box nearly at the
end of the backstroke, is not correct (reset sensor SQ10 should be energized).
- Reset sensor SQ10 was not energized within 25 seconds while the ALM was being
operated in manual mode or was being reset.
Try increasing the ALM speed, check reset sensor SQ10, the IE card in location 9 and
the leads/connectors.
- The ALM encoder zero-point was not found with reset sensor SQ10 energized.
Check the ALM encoder BQ10 and the leads/connectors.
The ALM encoder value has not changed after 0.75 secs. following the signal for the ALM
to move.
Check the encoder for proper functioning, check the ODA card in location 18, the OR card
in location 20 (when the ALM needs to move, one of outputs KM23A/KM23I should be
energized), relays KA23A/KA23I, the IE card in location 10, inverter U23, motor M23 and
the leads/connectors.
With the pump running, mode selector SA9 in the manual or automatic position and safety
modules AJ100 and AJ101 in operating mode, digital input U24 is off.
Make sure inverter U24 is in operating mode and check the ID card in location 12 (with
inverter U24 in operating mode, digital input U24/KM22AB should be on) and the leads/
connectors.
The pressure measured by transducer BP1 before the plunger begins its downstroke is
more than 20 bar.
Check pressure transducer BP1, the leads/connectors and
With program versions earlier than PH12.01.01: check the input module of transducer
BP1 (AP201) and the EIA card in locations 6/7.
With program version PH12.01.01 or later: check the IA card in location 7.
103
PH 339.85.089 Rev. 00 Date 10.12.01
- If the plunger encoder value does not reach the IMPACT POSITION setting within 8
seconds during a downstroke in manual mode;
- if the plunger encoder value does not reach the IMPACT POSITION - BRAKING SPACE
setting (both data items can be set) within 8 seconds in automatic mode;
Check that the setting for IMPACT POSITION can be reached. Also check solenoid valve
YV32D and related hydraulic lines for proper operation, inspect the plunger encoder and
make sure it is securely mounted, check the leads/connectors, the ODA card (when
solenoid valve YV32D is energised, the corresponding green LED should be on) and
With program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if the
incremental encoder is installed or the IE card in location 9 if the absolute encoder is
installed.
With program versions from PH12.01.01 onwards, check card IE in location 8.
In proportional presses, check proportional solenoid valve YV32, card ODA (location 17),
potentiometer card AP32. This problem may arise when the press has started moving up
after receiving a downstroke signal. In this case, replace YV32 and/or card ODA - location
17 (YV32D or YV32S with non-proportional presses).
- The plunger encoder value does not reach the setting for IMPACT POSITION while the
plunger is moving down.
- The plunger encoder value does not reach the setting for PLUNGER UP while the plunger
is moving up.
Make sure that the setting for IMPACT POSITION can be reached. Check solenoid valves
YV32D and YV32S and related hydraulic lines for proper operation. Also check the plunger
encoder and make sure it is securely mounted, check the leads/connectors, the ODA card
(when solenoid valve YV32D is energised, the green LED should be on) and
With program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if the
incremental encoder is installed or the IE card in location 9 if the absolute encoder is
installed.
With program version PH12.01.01 or later: check the IE card in location 8.
If this problem arises during the upstroke with a proportional press, decrease the value set
for UPPER END-STOP PRECISION.
Make sure that the braking space set is sufficient so that the solenoid valve can work
properly.
Check solenoid valve YV47 and the related hydraulic lines for proper functioning. Inspect
the plunger encoder, its mount, card EIA and the leads/connectors.
Check the output card (when the solenoid valve has to operate, Led YV47 must come on)
and the leads/connectors.
The die-set is not down when the plunger begins its downstroke. Proximity switch SQ6 is
inactivated or SQ3 is activated.
Check proximity switch SQ6, the input card (Led SQ6 must be on when the die-sets are
down) and the leads/connectors. Do the same for SQ3.
The same fault message will appear on the display when the filler box is moved manually
and the PROPORTIONAL KNOCKOUT is 0.4mm higher than the set value. In this case
move the die-set manually so as to bring it into the correct position.
104
PH 339.85.089 Rev. 00 Date 10.12.01
The filler-box is not all the way back when the plunger begins to move down. Check the filler
box encoder setting which should be lower than the REAR END STOP. Try increasing the
REAR END STOP setting. If the problem persists check YV20 and card VT 11023.
The filler-box is not completely back when the plunger begins its downstroke.
Check limit switch SQ59, its mount, the input card (Led SQ59 must be off when the filler-
box is fully back) and the leads/connectors.
If limit switch SQ59 is working correctly, check the filler box encoder.
When the plunger begins its downstroke the trigger pulse from the 2nd filler-box or the LB
type filler-box is not provided. Check limit switch KA302, its mount, the input card (Led
KA302 must be on when the 2nd filler-box or LB type filler-box is fully back) and the leads/
connectors.
In manual mode: the manual upstroke keys have been kept pressed for more than 8
seconds.
In automatic mode: if upstroke with braking has been selected and plunger encoder has not
reached the “end of braking during upstroke” setting;
check that the setting for END OF BRAKING DURING UPSTROKE can be reached, check
solenoid valves YV32S and YV47 and related hydraulic lines for proper functioning.
Check the plunger encoder, its mount and the leads/connectors. Also check the OD card
in location 16 (when solenoid valve YV32S is energised, the related green LED should be
on) and
With program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if the
incremental encoder is installed or the IE card in location 9 if the absolute encoder is
installed.
With program versions from PH12.01.01 onwards: check card IE in location 8.
In proportional presses, check proportional solenoid valve YV32, card ODA (location 17),
potentiometer card AP32. The problem may arise when the press has started moving down
after receiving an upstroke signal. In this case, replace YV32 and/or card ODA - location 17
(YV32D or YV32S with non-proportional presses).
105
PH 339.85.089 Rev. 00 Date 10.12.01
The ejector cylinder is forward (SQ58 inactivated) when the plunger begins its downstroke.
Check sensor SQ58, the ID input card in location 13 (when the ejector cylinder is back, Led
SQ58 must be on) and the leads/connectors.
106
PH 339.85.089 Rev. 00 Date 10.12.01
Sensors SQ67A/B and SQ68A/B have remained de-energised for more than 5 seconds.
The die-set changer has not been correctly activated or inactivated.
Check pneumatic valve YV292 and proximity sensors SQ67A/B, SQ68A/B:
when the hook is used, only sensors SQ68A/B must be activated, when the hook is not used
only sensors SQ67A/B have to be activated.
Check the input card and the leads/connectors.
The plunger has carried out a stroke which is longer than the allowable one.
Reset the plunger encoder (see the USER’S MANUAL).
107
PH 339.85.089 Rev. 00 Date 10.12.01
With 2-cylinder proportional knockout: the difference between the analog and digital
values during the press-cycle is greater than 1 mm and the encoder value is > 0.6 mm.
Check encoder interface card AP206 installed on the SMU for proper operation. Also check
encoders BQ4/5 and
- With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01 and later: the IA card and the IE card in location 9.
With 4-cylinder proportional knockout: the value of one or both encoders is > 0.6 mm
during the press-cycle.
Check axis card AP210, encoder interface card AP207, serial interface card AP208,
encoders BQ4/5 and
- With program versions earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01 and later: the IE card in location 9.
With the oil temperature higher than 30°C, digital input SP7 has stayed off for more than 2.5
seconds.
Replace the filter of the control line of proportional solenoid valves YV32 and YV318 as it
is clogged. If the message is still displayed on the screen after the filter has been replaced,
check pressure switch SP7 and the input card (LED SP7 should be on if the filter is not
clogged) and the leads/connectors.
While the accumulators were being re-charged, the line pressure is less than the pressure
of the accumulators or the pressure of the accumulators has not reached the required value
within 5 sec. Make sure there is no pressure loss in the main hydraulic circuit line or line for
the accumulators. Check pressure transducers BP2 and BP4, the cables and IA card. Carry
out the self-learning procedure for YV309 again (see message 2124).
108
PH 339.85.089 Rev. 00 Date 10.12.01
2. The mode selector switch has been turned from the MAN position or the plunger has
not moved down 15 mm (19 mm for P1-14200) with YV318 open 35%. Check
proportional solenoid valve YV318, the relative cables and OD card in location 17.
Check the solenoid valve for the booster downstroke: solenoid valve YV32M (it should
be energized during this stage), solenoid valve YV40 (it should be energized during this
stage) and solenoid valve YV70/71 (it should be energized during this stage).
3. The mode selector switch has been turned from the MAN position or the plunger has
not reached the IMPACT POSITION - 40 mm with YV31D energized.
Check the value set for the IMPACT POSITION data item on the press-cycle set-up
page. Check the solenoid valve for the slow downstroke, the relative cables and OD card
in location 16.
4. During the stage in which the offset value for YV32 is determined, the cylinder pressure
has exceeded 10 bar to keep the plunger stationary. Check proportional solenoid valve
YV318 (it should be closed during this stage), the relative cables and ODA card in
location 17. Check the solenoid valve used to put the cylinder under pressure: solenoid
valve YV19 (it should be de-energized during this stage), logic element 117 (it should
be closed during this stage), solenoid valve YV40 (it should be de-energized during this
stage), logic element 116 (it should be closed during this stage), solenoid valve YV41
(it should be de-energized during this stage), logic element 131 (it should be closed
during this stage), solenoid valve YV38 (it should be de-energized during this stage),
logic element 120 (it should be closed during this stage), solenoid valve YV70 (it should
be de-energized during this stage) and logic element 118 (it should be opened during
this stage).
5. During the stage in which the offset value for YV32 is determined, the mode selector
switch was turned from the MAN position to keep the plunger stationary or the plunger
did not move down with YV31D energized. Decrease the value set for the IMPACT
POSITION data item on the press-cycle set-up page. Check the solenoid valve for the
slow downstroke, the relative cables and OD card in location 16.
6. During the stage in which the offset value for YV32 is determined, the mode selector
switch was turned from the MAN position to keep the plunger stationary or the plunger
did not move up with YV31S energized.
Check the solenoid valve for the slow upstroke, the relative cables and OD card in
location 16.
7. The mode selector switch was turned from the MAN position or the plunger did not move
up with YV31S energized. The plunger should move up to 26 mm (30 mm for P1-14200).
Check the solenoid valve for the slow upstroke, the relative cables and OD card in
location 16.
8. The mode selector switch was turned from the MAN position or the plunger did not move
1 mm down with YV31D energized. The plunger should move up to 26 mm (30 mm for
P1-14200). Check the solenoid valve for the slow downstroke, the relative cables and
OD card in location 16.
9. During the stage in which the offset value for YV318 is determined, the command to the
solenoid valve has exceeded the maximum allowable value (4095 valve points, given
on page 110). Check proportional solenoid valve YV318, the relative cables and ODA
card in location 17. Check pressure transducer BP5 for the upstroke chamber, the
relative cables and IA card in location 7. Check the solenoid valves used to charge the
upstroke chamber during this stage: solenoid valve YV19 (it should be energized during
this stage), solenoid valve YV70 (it should be energized during this stage).
10. During the stage in which the offset value for YV318 is determined, the pressure in the
cylinder has exceeded 10 bar or the plunger has reached the IMPACT POSITION - 10
mm. In the latter case increase the value entered for the IMPACT POSITION data item
on the press-cycle set-up page. Otherwise check proportional solenoid valve YV318,
the relative cables and ODA card in location 17. Check pressure transducer BP5 for the
upstroke chamber, the relative cables and IA card in location 7. Check the solenoid
valves used to charge the upstroke chamber during this stage: solenoid valve YV19 (it
should be energized during this stage), solenoid valve YV70 (it should be energized
during this stage). If the pressure in the cylinder has exceeded 10 bar and the plunger
109
PH 339.85.089 Rev. 00 Date 10.12.01
has reached the material, decrease the value entered for the IMPACT POSITION data
item on the press-cycle set-up page. Check logic element YV303 which should be open
during this stage.
11. Once the stage in which the offset value for YV318 is determined has been completed,
the command to the solenoid valve is either too high or null. Check proportional solenoid
valve YV318, the relative cables and ODA card in location 17. Check pressure
transducer BP5 for the upstroke chamber, the relative cables and IA card in location 7.
Check the solenoid valves used to charge the upstroke chamber during this stage:
solenoid valve YV19 (it should be energized during this stage), solenoid valve YV70 (it
should be energized during this stage).
12. During the stage in which the offset value for YV32 (downstroke) is determined, the
plunger has reached the IMPACT POSITION - 10 mm. Increase the value entered for
the IMPACT POSITION data item on the press-cycle set-up page. Otherwise check
proportional solenoid valve YV32, the relative cables and ODA card in location 17.
Check solenoid valve YV303 used for plunger movement (it should be energized during
this stage) and ODA card in location 17.
13. During the stage in which the offset value for YV32 (downstroke) is determined, the
pressure in the cylinder has exceeded 10 bar. Check proportional solenoid valve YV318
(it should be closed during this stage), the relative cables and ODA card in location 17.
Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19
(it should be de-energized during this stage), logic element 117 (it should be closed
during this stage), solenoid valve YV40 (it should be de-energized during this stage),
logic element 116 (it should be closed during this stage), solenoid valve YV41 (it should
be de-energized during this stage), logic element 131 (it should be closed during this
stage), solenoid valve YV38 (it should be de-energized during this stage), logic element
120 (it should be closed during this stage), solenoid valve YV70 (it should be de-
energized during this stage) and logic element 118 (it should be opened during this
stage).
14. The mode selector switch was turned from the MAN position or the plunger did not reach
the IMPACT POSITION - 20 mm with YV31D energized. Check the value entered for
the IMPACT POSITION data item on the press-cycle set-up page. Check the solenoid
valve for the slow downstroke, the relative cables and OD card in location 16.
15. During the stage in which the offset value for YV32 (upstroke) is determined, the plunger
has reached 19 mm (23 mm for P1-14200). Check proportional solenoid valve YV32,
the relative cables and ODA card in location 17. Check solenoid valve YV303 used for
plunger movement (it should be energized during this stage) and ODA card in location
17.
16. During the stage in which the offset value for YV32 (upstroke) is determined, the
pressure in the cylinder has exceeded 10 bar. Check proportional solenoid valve YV318
(it should be closed during this stage), the relative cables and ODA card in location 17.
Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19
(it should be de-energized during this stage), logic element 117 (it should be closed
during this stage), solenoid valve YV40 (it should be de-energized during this stage),
logic element 116 (it should be closed during this stage), solenoid valve YV41 (it should
be de-energized during this stage), logic element 131 (it should be closed during this
stage), solenoid valve YV38 (it should be de-energized during this stage), logic element
120 (it should be closed during this stage), solenoid valve YV70 (it should be de-
energized during this stage) and logic element 118 (it should be opened during this
stage).
17. The mode selector switch was turned from the MAN position or the plunger did not reach
the mechanical end-stop at the end of the self-learning cycle. The booster may not have
moved up. Make sure the solenoid valves allow upward movement: solenoid valve
YV32M (it should be de-energized during this stage) and solenoid valve YV71 (it should
be de-energized during this stage).
18. The self-learning procedure has been interrupted because solenoid valve YV32 has got
stuck during the upstroke or downstroke (with solenoid valve YV303 energised and a
signal sent to YV32 so that the valve over-center is closed, the plunger travels at a speed
> 40 mm/s).
110
PH 339.85.089 Rev. 00 Date 10.12.01
16. During the stage in which the offset value for YV32 (upstroke) is determined, the
pressure in the cylinder has exceeded 10 bar. Check the solenoid valves used to put
the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this
stage), logic element 117 (it should be closed during this stage), solenoid valve YV307
(it should be de-energized during this stage), solenoid valve YV70 (it should be de-
energized during this stage) and logic element 118 (it should be opened during this
stage).
17. The mode selector switch was turned from the MAN position or the plunger (encoder
BQ6) did not reach the mechanical end-stop at the end of the self-learning cycle.
The self-learning procedure for proportional solenoid valve YV309 needs to be carried out.
Set NO. OP. SETTING = 2 (on PC page N) with the key turned to Set-up and then press keys
28 and 7. The procedure takes a few minutes. Once completed, press the Reset key to clear
the message.
During its downstroke the plunger had exceeded the IMPACT POSITION setting but has
not reached the START OF PRESS-STROKE POS. (or START OF PRESS-STROKE
THICKNESS) - 5 mm - within 5 seconds.
Check that the value set for START OF PRESS-STROKE POS. can be reached (for
example it could be something in the die-set or soft filling that is preventing the downstroke
from being performed).
The proportional solenoid valve self-learning procedure must be performed before switching
the press over to automatic or semi-automatic mode (refer to the “self-learning for plunger
upstroke/downstroke...” item in the DESCRIPTION OF THE KEYS).
The heater is turned on (OUT KM5 and KM5B = ON) but feedback input KM5 is off.
Check the contacts on contactors KM5 and KM5B (optional) for heating the upper punches
as they fail to close.
Check the contact on contactor KM6 for heating the upper die as it fails to close.
Check the contact on contactor KM7 for heating the lower die as it fails to close.
Check the contacts on contactors KM8 and KM8B (optional) for heating the lower punches
as they fail to close.
112
PH 339.85.089 Rev. 00 Date 10.12.01
The heater is off (OUT KM5 and KM5B = OFF) but feedback input KM5 is on.
Contactor KMn does not work; its contacts fail to open.
The temperature measured by thermocouple BTn is higher than 110°C (80°C if the punches
are made of rubber).
The temperature is too high.
Check the thermocouple for proper functioning (replace it if necessary).
If it works properly, find out what is causing the overtemperature.
If it does not work properly, (even after the thermocouple has been replaced), check the
input module of the thermocouple and then try replacing the analog card.
NOTE: n = 5 upper punches
n = 6 upper die
n = 7 lower die
n = 8 lower punches
113
PH 339.85.089 Rev. 00 Date 10.12.01
Feedback digital input KM2 is off after a signal for brush rotation has been sent (KM2A or
KM2B = ON).
Check the thermal cutout and contactors KM2A and KM2B.
Check the input card (input KM2 must be closed when the motor is running) and the leads/
connectors.
Check the output card (Led KM2A or KM2B must be on when the motor has to run) and the
leads/connectors.
The automatic cycle stop push-button (located on the keyboard) has been pressed.
If the push-button has not been pressed, check the keyboard lead.
If the lead is properly connected and is not broken, try replacing the control KEYBOARD.
If the keyboard works properly, try replacing the MISCELLANEOUS card.
The outer synchronization contact has remained closed (when the filler-box starts its travel)
for more than the maximum allowable time (2 minutes).
Check contact KA301, the input card (Led KA301 must be off when the press is running)
and the leads/connectors.
The production batch has been completed as set for the “PRODUCTION BATCH” data item.
114
PH 339.85.089 Rev. 00 Date 10.12.01
The service pressure has remained lower than the set value - 5 bar for three consecutive cycles.
Check solenoid valve YV64 for proper functioning.
Check the output card (Led YV64 must come on when the solenoid valve has to operate)
and the leads/connectors.
Check pressure transducer BP2, its input module, the EIA card and the leads/connectors.
See the INSTRUCTIONS FOR SETTING THE PRESSURE TRANSDUCER.
Make sure the SERVICE PRESSURE setting is higher than the operating pressure of the
accumulators.
Decrease the value set for the GAIN (RP2) data item to prevent the gain for opening the filler-
box valve from becoming too low. This value is given on the ACTUAL LOADING DATA
video-page.
If the problem persists check YV20 and card VT 11023.
If the problem persists check the EIA card and the leads/connectors.
Increase the value set for the GAIN (RP2) data item to prevent the gain for opening the filler-
box valve from becoming too high. This value is given on the ACTUAL LOADING DATA
video-page.
If the problem persists check YV20 and card VT 11023.
If the problem persists check the EIA card and the leads/connectors.
The plunger has moved down more than 5 mm during the loading cycle.
A tile thickness deviation greater than 0.4 mm has been indicated. The thickness is
automatically adjusted (the 0.4 mm threshold can be entered).
If the thickness measured does not correspond to the actual thickness, check the plunger
encoder, its mount, the EIA/IE card (EIA if an incremental encoder is installed, IE if an
absolute one is installed) and the leads/connectors.
With SMU and 2-cylinder proportional knockout: Check the automatic filling height
control, motor M9 and contactors KKM9A/KM9B, the OR output card (either output KM9A
or KM9B has to be activated when the filling height is adjusted), the leads/connectors and,
only for 2-cylinder proportional knockout:
- With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01or later: the IA card and the IE card in location 9.
With SMU and 4-cylinder proportional knockout: Check axis card AP210, encoder
interface card AP207, serial interface card AP208, encoders BQ4/5 and
- With program versions earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01or later: the IE card in location 9.
115
PH 339.85.089 Rev. 00 Date 10.12.01
The die-set heater is on (OUT KMn = ON) but the temperature measured by thermocouple
BTn is lower than 1°C.
The temperature measured by a thermocouple for the die-sets is not correct.
Check the connections of the thermocouple indicated in the message.
Check the input module in question.
At the filler-box start the value of one or both die-set encoders has exceeded the setting for
Upper End Stop (FCA) by more than 0.4 mm or has fallen below the setting by more than
0.6 mm.
See whether the thermocouple is properly connected. If the message is not cleared,
With program versions earlier than PH12.01.01: check the input module of thermocouple
BT5 (AP305), the EIA card in locations 6/7 and the leads/connectors.
With program version PH12.01.01or later: check the IA card in location 7 and the leads/
connectors.
See whether the thermocouple is properly connected. If the message is not cleared,
With program versions earlier than PH12.01.01: check the input module of thermocouple
BT6 (AP306), the EIA card in locations 6/7 and the leads/connectors.
With program version PH12.01.01or later: check the IA card in location 7 and the leads/
connectors.
See whether the thermocouple is properly connected. If the message is not cleared,
With program versions earlier than PH12.01.01: check the input module of thermocouple
BT7 (AP307), the EIA card in locations 6/7 and the leads/connectors.
With program version PH12.01.01or later: check the IA card in location 7 and the leads/
connectors.
See whether the thermocouple is properly connected. If the message is not cleared,
With program versions earlier than PH12.01.01: check the input module of thermocouple
BT8 (AP308), the EIA card in locations 6/7 and the leads/connectors.
With program version PH12.01.01or later: check the IA card in location 7 and the leads/
connectors.
Open the controller and turn selector SA293 to engage the proportional knockout.
One of the die-set cylinders moved more than 2 mm while the proportional knockout was
being hooked.
Repeat the procedure for hooking the proportional knockout.
117
PH 339.85.089 Rev. 00 Date 10.12.01
With 2-cylinder proportional knockout: the plunger moved by more than 1 mm while the
proportional knockout was being engaged.
With 4-cylinder proportional knockout: the plunger moved by more than 2 mm while the
proportional knockout was being engaged.
The filler-box is further back than its END OF BACKSTROKE setting when the plunger starts
to move down or the ALM begins its forward stroke. Bring the filler-box into the correct
position.
The maximum allowable brush wear set on the FITTINGS SET-UP page has been reached.
Replace the brush, press Reset and start up again.
Miniature switch SQ59 has been energised (input SQ59 off) at the end of the filler-box
forward stroke (after the first downstroke with a double-loading filler-box) in automatic or
semi-automatic mode.
Check the filler-box back miniature switch and related ID card (with the filler-box forward the
miniature switch should be inactivated an the input should be on).
The time the linear filler box requires to complete its forward and backward stroke deviates
more than 10% from the pre-determined time
Set the correct time for the filler-box forward and return stroke. If the press does not need
to stop, set FILLER BOX CONTROL ON = NO
The time required for the press to perform a complete cycle is greater than the time set for
a synchronized cycle. The number of cycles per minute set cannot be carried out.
118
PH 339.85.089 Rev. 00 Date 10.12.01
The press is stationary and is waiting for the internal synchronization time to elapse.
The press is stationary and is waiting for external synchronization contact KA301 to open.
The time taken for the filler-box to perform its forward stroke differs from the set value (F-
BOX FORW. RUN TIME) by more than 5%.
The time taken for the filler-box to perform its return stroke differs from the set value (FILLER
BOX RETURN TIME) by more than 5%.
The temperature of the oil is less than 30° C. If the safety bar is raised, under these
conditions, the oil will automatically be heated up by solenoid valve YV11R.
It is possible to stop the oil from being heated by lowering the safety bar and pressing the
Reset key on the control keyboard.
119
PH 339.85.089 Rev. 00 Date 10.12.01
The press is stationary and is waiting for the ALM to stop moving.
Tile thickness is wrong. The thickness is automatically adjusted. The deviation falls within
0.25 and 0.4 mm; the max. threshold (0.4 mm) can be entered.
With 2-cylinder proportional knockout: the difference between the analog and digital
values during the press-cycle is more than 1 mm and the encoder value is between 0.3 and
0.6 mm.
Check encoder interface card AP206 installed on the SMU, encoders BQ4/5 and
- With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA
card in location 10.
- With program version PH12.01.01or later: the IA card and the IE card in location 9.
With 4-cylinder proportional knockout: the value of one or both the encoders is between
0.3 mm and 0.6 mm during the press-cycle.
Check axis card AP210, encoder interface card AP207, serial interface card AP208,
encoders BQ4/5 and
- With program versions earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01or later: the IE card in location 9.
This message is displayed after a program has been read. Go to the PRESS CYCLE SET
UP page and check the data in the square that deals with the PLUNGER.
The difference between the value of one or both die-set encoders and the Upper End Stop
is > 0.2 mm.
The upward movement of the proportional knockout is not very precise and it takes it longer
to reach the value set for the UPPER LIMIT data item. To avoid slowing down the cycle, set
the upstroke of the proportional knockout.
120
PH 339.85.089 Rev. 00 Date 10.12.01
An error greater than 0.4 mm was detected after the proportional knockout completed its
first downstroke.
A semi-automatic ALM cycle was requested with the filler-box forwards. Move the filler-box
fully back and try again.
With the proportional knockout carrying out three downstrokes, an incorrect self-learning
value for the encoder of the die-set on the cylinders for the last downstroke (YV21) was
detected. Shut the controller off, turn it back on and then carry out an automatic resetting
cycle.
If the message is not cleared, check the die-set for the last downstroke.
Carry out an automatic resetting cycle to zero set the filler-box encoder.
Carry out an automatic resetting cycle to zero set the die-set encoder.
Carry out an automatic resetting cycle to zero set the plunger encoder.
The filler-box has been moved from its seat. Make sure limit switches SQ66/SQ66A are
correctly installed and efficient.
Check contact SQ66, the input card (Led SQ66 should be on when the filler-box is detached)
and the cables/connectors.
If either a DAF or DXP filler-box is used, check safety module AJ101.
Carry out the self-learning procedure for the die-set. See the DIE SET SET UP chapter.
The press is in standby ready to start automatically. No trigger pulse has been sent from the
next machine in line (KA300). When the trigger pulse is emitted the machine will restart.
121
PH 339.85.089 Rev. 00 Date 10.12.01
During the downward movement of the plunger the ODA card is not energized.
Check the 1st ODA card, the filler box miniature switch SQ59 as well as miniature switches
SQ66, SQ66A, SQ51, SQ52, SQ53A and SQ53B (optional), contactors KA102, KA103,
circuit breaker FS101, mode selector SA9 and safety module AJ101.
The pressure reached during the last press stroke deviates more than 15 bar in relation to
the set value. If the message continues to appear check the solenoid valves (YV19, YV41,
YV38), pressure transducer BP1, the leads/connectors and
With program versions earlier than PH12.01.01: the input module of transducer BP1
(AP301) and the EIA card in locations 6/7
With program version PH12.01.01or later: check the IA card in location 7 and, if the
proportional press-stroke is delivered, solenoid valve YV318, the related hydraulic lines and
the ODA card in location 17.
HEAT EXCHANGER = NO has been set on the FITTINGS SET-UP page but the feedback
digital input KM11A of the heat exchanger is on.
The plunger is kept up by the PLC because otherwise it would move down to rest on the die-
set because of too much leakage.
Check the cylinder seal and the hydraulic lines for the downstroke.
To ensure top performance of the hydraulic joint in the power unit, wait 10 minutes before
starting the pump.
122
PH 339.85.089 Rev. 00 Date 10.12.01
Perform an automatic reset procedure to set the ALM encoder back to zero.
The roller conveyor has been moved away from the press.
Check miniature switches SQ53A/SQ53B, the ID card in location 13 (with the roller
conveyor in the work position, digital input SQ53A should be off) and the leads/connectors.
The press is carrying out the self-learning cycle to calculate the offset values for the
proportional valves (YV32, YV318). Turn the mode selector switch to stop the cycle.
The offset values for YV32, determined during the self-learning procedure, are too high. If
(S) appears on the right side of the message it means the upstroke offset value is too high.
(D) appears to signal the downstroke offset value is too high.
(O) appears to signal the zero offset value is too high.
Carry out the self-learning cycle again with hot oil. If the message is still displayed, replace
YV32 (plunger proportional solenoid valve).
While the plunger is moving up, the value in the upstroke chamber read by the pressure
transducer is < 10 bar. Check pressure transducer BP5, its cables and the IA card in location
7.
Turn the mode selector to MAN or SETUP and allow the die-set to perform the downstroke
in manual mode. Now it is possible to change the press over to automatic or semi-automatic.
If the message does not disappear, replace the AX card.
The press is waiting for a trigger pulse from the D.I.P to indicate that the KA311 is ready to
operate.
As soon as the trigger pulse has been emitted (input KA311 signal high) the press restarts
cycling. If this does not happen, make sure the DIP electrical cabinet disables the signal.
Check the IDM card on the press (location 11) and the cables/wiring connectors.
This message appears for a few seconds when the machine is turned on.
123
PH 339.85.089 Rev. 00 Date 10.12.01
If this message appears when the machine is turned on, contact the CUSTOMER SERVICE
DEPT - SACMI IMOLA.
If this message appears when the machine is turned on, contact the CUSTOMER SERVICE
DEPT - SACMI IMOLA.
A CPU card with at least a BMOS v. 1.Y operating system has to be installed in order to run
the program.
Check the version. If it is earlier than 1.Y, replace the CPU card. If this is not the case, shut
off the system and then turn it back on.
If this message appears when the machine is turned on, contact the CUSTOMER SERVICE
DEPT - SACMI IMOLA.
Make sure the printer is properly hooked up to the machine controller, power is supplied and
that it is ON-LINE.
Remember that the CPU card must have an operating system that is at least BMOS 1.8.
If this message appears, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA.
The user tried to store a back-up copy of the operating program in an area (in the computer’s
memory) which is already occupied by another program. Enter a different program number.
An error was found while a program was being read. Try to read the program again. If the
fault message is not cleared, erase the program.
124
PH 339.85.089 Rev. 00 Date 10.12.01
Make sure the filters in the hydraulic power unit are not clogged.
Check pressure switch SP1 and the input card (with the filters clean, Led SP1 should be on)
and the cables/wiring connectors.
NOTE: to erase the message, turn the key switch on the keyboard to SETUP and press the
RESET key.
The number to the right of the message indicates the number of hours the pump can operate
with the filter clogged.
This message appears after the main pump has operated for 80 hours.
The maintenance operations which are described in the INSTRUCTIONS MANUAL need
to be performed.
NOTE: To clear the message, turn the key switch on the machine control keyboard to “SET
UP” and press the Reset key.
The die-set has already carried out the number of cycles set for the “DIE-SET LIFE IN
CYCLES” data item on the DIE SET SET-UP page. It needs to be replaced. NOTE: The
message is cleared by turning the key on the machine control keyboard to SET UP and
pressing the Reset key.
125
PH 339.85.089 Rev. 00 Date 10.12.01
126
PH 339.85.089 Rev. 00 Date 10.12.01
The machine shuts down and the screen is cleared when these messages are displayed. The list
of messages is given below:
INVALID MEMORY
The program is not valid. Shut off the power supply, make sure the card located on the CPU is
properly plugged in and then turn the power supply back on. If the trouble persists, contact SACMI
quoting the alpha-numeric code stamped on the card.
The protection device on the AL card has come into action or the fuses have blown.
The message provides information about the voltages not provided.
Check the fuses for condition and make sure there are no shorts in the conductors indicated.
An instruction has been executed whose result exceeds the set limits.
The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears.
An instruction not acknowledged was executed. The version of the operating system is probably
prior to the one required by the program.
The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears
and the version of the operating system.
127
PH 339.85.089 Rev. 00 Date 10.12.01
TABLE OF CONTENTS
1 INTRODUCTION ................................................................................................................. 5
2 WARNINGS ......................................................................................................................... 6
128
PH 339.85.089 Rev. 00 Date 10.12.01
131
PH 339.85.089 Rev. 00 Date 10.12.01
132
PH 339.85.089 Rev. 00 Date 10.12.01
T
TEMP. TOO HIGH (BT4) ............................................................................................................................ 85
TEMP. TOO HIGH (BT5) .......................................................................................................................... 114
TEMP. TOO HIGH (BT5): ... °C ................................................................................................................ 119
TEMP. TOO HIGH (BT6) .......................................................................................................................... 114
TEMP. TOO HIGH (BT6): ... °C ................................................................................................................ 119
TEMP. TOO HIGH (BT7) .......................................................................................................................... 114
TEMP. TOO HIGH (BT7): ... °C ................................................................................................................ 119
TEMP. TOO HIGH (BT8) .......................................................................................................................... 114
TEMP. TOO HIGH (BT8): ... °C ................................................................................................................ 120
TEMP. TOO LOW (BT4) ............................................................................................................................ 85
TEMPERATURE TOO HIGH (ST1) ........................................................................................................... 87
THICKNESS ERROR > 0.25 mm ............................................................................................................ 120
THICKNESS ERROR > 0.4 mm .............................................................................................................. 115
THICKNESS ERROR > 25 c.mm ............................................................................................................ 120
THICKNESS ERROR > 40 c.mm ............................................................................................................ 115
TIME-OUT, KNOCKOUT DOWN ............................................................................................................... 95
TIME-OUT, KNOCKOUT UP ..................................................................................................................... 95
TOO MUCH TIME TAKEN TO SET DIE-SET .......................................................................................... 121
TURN SELECTOR SA293 TO ON .......................................................................................................... 118
U
UPPER DIE HEATING (KM6) ................................................................................................................. 113
UPPER PUNCH HEATING (KM5) ........................................................................................................... 113
W
WAIT ....................................................................................................................................................... 123
WAIT FOR AUTO. RESTART (KA300) .................................................................................................... 122
WAIT FOR END OF MOBILE HOPPER CYCLE .................................................................................... 120
WAIT FOR EXTERNAL SYNCH. ............................................................................................................ 119
WAIT FOR F-BOX TO GO BACK (KA302) ................................................................................................ 99
WAIT FOR SYNCH. TIME ....................................................................................................................... 119
WAIT FOR TRIGGER PULSE FROM D.I.P. (KA311) .............................................................................. 123
WRONG DIE-SET OP. (A=..., B=...) ................................................................................................ 100, 116
WRONG KNOCKOUT MOTION (BQ4A) ................................................................................................... 95
WRONG PROGRAMMED DATA ............................................................................................................. 125
Y
YV32 OFFSET VALUE TOO HIGH ·[O/D/S] ............................................................................................ 124
133