TECHNICAL DOCUMENTATION

DOCUMENTATION TECHNIQUE

TECHNISCHE DOKUMENTATION

DOCUMENTACION TECNICA

DOCUMENTAÇAO TECNICA

DOCUMENTAZIONET E C N I C A

PHINSTRUCTIONS B

USE OF THE SMC 085 MICROPROCESSOR-BASEDCONTROL SYSTEM FOR PH PRESSES

PH 339.85.089 Rev. 00 Date 10.12.01

ENGLISH

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PH 339.85.089 Rev. 00 Date 10.12.01

Written by : Leoni Luca Written on : December 10, 2001

Last revised :

Revised by : Alberto Tassoni, ing. Program version :

Title : Number of pages : 133

Use of the SMC 085 Service code : 9512microprocessor-based control systemfor PH Presses Identification no. : PH 339.85.089

SACMI SHALL NOT BE HELD RESPONSIBLE FOR MACHINE FAILURE DUE TO UNAUTHORIZEDMODIFICATIONS.

ANY CHANGES THAT ALTER THE CONSTRUCTION OR THE WORKING CYCLE OF THEMACHINE MUST BE CARRIED OUT OR AUTHORIZED BY SACMI’S AFTER-SALES DEPT.

SACMI RESERVES THE RIGHT TO MAKE ANY CHANGES TO THE MACHINE DESCRIBEDHEREIN AT ANY TIME WITHOUT NOTICE.

IF THERE ARE ANY PRINTING OR OTHER ERRORS, CORRECTIONS WILL APPEAR IN THESUBSEQUENT VERSION OF THE MANUAL.

SACMI SHALL BE HELD RESPONSIBLE ONLY FOR THE TEXT IN THE ORIGINAL ITALIANVERSION.

THIS MANUAL IS PROPERTY OF SACMI. ONLY THE PURCHASER OF THE MACHINE ISAUTHORIZED TO USE IT.

IT IS NOT TO BE COPIED OR REPRODUCED IN ANY FORM WITHOUT PRIOR CONSENTFROM SACMI. FAILURE TO DO SO WILL ENTITLE SACMI TO TAKE LEGAL ACTION.

COPIES OF THIS MANUAL ARE AVAILABLE FROM THE AFTER-SALES SERVICE DEPT.

PH 13.09.01.7TRPH 11.19.01.7TRPH 10A.16.01.7TRPH 10.22.01.7TRPH 09.20.01.7TRPH 08.27.01.7TR

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PH 339.85.089 Rev. 00 Date 10.12.01

SAFETY PRECAUTIONS TO BE OBSERVEDWHEN OPERATING THE MACHINE

Copies of this manual should be given to all personnel in charge of machine maintenanceand operation. It is essential that the manual is read carefully in its entirety and fullyunderstood, as it provides important instructions on how to operate the machine properlyand safely.

The machine must be used only for the tasks it was expressly designed for. Performingjobs other than those recommended is hazardous.SACMI shall not be held responsible for damage to the machine or injuries to personnelresulting from mishandling, improper use or unauthorized modifications.Any modifications made to the machine’s structure and/or work-cycle must be performedor authorized by SACMI’s Service Dept.

The persons in charge of supervising and servicing the machine must read and fullyunderstand the operating instructions contained in the documentation provided.Maintenance can be performed and the electrical parts and devices accessed only bycompetent well-trained personnel.The machine’s work-cycle can be set and controlled only by the persons in charge, orthose 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 personin charge without delay.If the personnel in charge find faults which could endanger the operators, the machinemust be shut off immediately and restarted only after it has been repaired.

Always unplug the machines from the electricity supply before setting up or servicingthem if operations which may endanger personnel are to be performed. Failure to doso may result in severe injury to personnel. Whenever carrying out maintenance of anytype, always shut off the machine and block all parts before starting. This must be doneeven when minor jobs are performed.

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PH 339.85.089 Rev. 00 Date 10.12.01

1 INTRODUCTION

Device Connection State LED indication

Pushbutton N.O. Pressed Led onReleased Led off

N.C. Pressed Led offReleased Led on

Selector switch Closed in pos. x Led onOpen in pos. x Led off

Miniature switch N.O. Energized Led onDe-energized Led off

N.C. Energized Led offDe-energized Led on

Proximity switch N.O. Energized Led onDe-energized Led off

ScannerPhotocell N.O. Triggered Led on

Untriggered Led offReflector/ Triggered Led offDetector unit Untriggered Led on

Contactors-relays N.O. Energized Led onDe-energized Led off

N.C. Energized Led offDe-energized Led on

Level controlPressure switchFlowmeterThermostat N.O. Above the threshold Led on

Below the threshold Led offN.C. Above the threshold Led off

Below the threshold Led on

Vacuum meter N.O. Above the set pressure Led offBelow the set pressure Led on

N.C. Above the set pressure Led onBelow the set pressure Led off

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PH 339.85.089 Rev. 00 Date 10.12.01

2 WARNINGS

MAINTENANCE

- To replace the microprocessor system cards:see INSTRUCTIONS C -

- To replace the EPROMs which store the machine program:see INSTRUCTIONS C -

- Before welding, disconnect the machine from the electrical cabinets by unplugging the cables.

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PH 339.85.089 Rev. 00 Date 10.12.01

3 MAIN FEATURES OF THE ELECTRIC SYSTEM

The electric system basically consists of three parts:1) The microprocessor system that controls and monitors machine operation2) The switchboard that supplies power to the main points of use3) Machine wiring

1) Microprocessor system for controlling and monitoring machine operationThis system controls and monitors plant operation.Its function is to control and monitor all the parts that make up the machine.

The microprocessor system consists of a number of cards, each of which is provided to carry outa specific task.

Power Supply Card (AL):This card supplies power to the various parts inside the system as well as outside to the sensors.

CPU Card:This card stores the main microprocessor and the machine program to be run.

Miscellaneous Card (VA)This is the CPU card support; it is used to dialog with the operator keyboards. It stores the set work-cycle programs.

Encoder/Analog Input Card (EIA)It serves for the dual task of reading the encoders located along the axes as well as the pressuresand temperatures present.

Analog Input Card (IA):It is used to read the pressures and temperatures.

Encoder Input Card (IE):It is used to read the encoders located along the axes.

Digital Input Cards (IDM):The function of these cards is to acquire the state of the limit switches and proximity sensors.

Digital Output and Relay Output cards (OD, OR):These cards are used to pilot the machine actuators.

Digital and Analog Output Cards (ODA)The function of these cards is to pilot the proportional valves that control the positions and speedsof the axes along with certain machine actuators.

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 devicesindependently, i.e. safety bar, shutdown button located on the machine control keyboard, externalshutdown buttons, etc..

2) Switchboard that supplies power to the main points of useThis 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 than11 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.

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PH 339.85.089 Rev. 00 Date 10.12.01

3) Electric wiring of the machineThe electric wiring of the machine has been studied in depth and is designed to satisfy installationand maintenance requirements. Connectors are used for each individual part so that they can beeasily unplugged/plugged in when the machine is installed at the customer’s factory and whenmaintenance needs to be carried out.All the materials employed for machine wiring have been carefully examined and selected takinginto account the aggressive agents found in the work area (oil, dust, etc..).

The entire electric system is tested according to current safety regulations.The entire electric system has been designed and developed in compliance with current interna-tional electrical codes and regulations regarding safety of machinery.

MAIN LAWS AND SAFETY STANDARDS USED AS REFERENCES

European Standard CENELEC HD 420Auxiliary control equipment for voltages that do not exceed 1000 V -General prescriptions

Italian Standard CEI EN 60204-1 (CEI 44-5)European Standard CENELEC EN 60204International Standard IEC 204-1

Safety of machinery- Electric equipment of machinery

Italian Standard CEI 64-8European Standard CENELEC HD 384International Standard IEC 364

Electric systems that use a rated voltage that does not exceed 1000 Valternating current and 1500 V direct current.

European Standard EN954-1Safety of machinery- Parts regarding the safety devices in the controlsystem (being approved).

European Standard EN292-1Safety of machinery - Terminology, Basic methods

European Standard EN292-2Safety of machinery - Specifications and technical principles

European Directive 89/392/EECMachine directive

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PH 339.85.089 Rev. 00 Date 10.12.01

MACHINE FEATURES OF THE SACMI PLC/MICROPROCESSOR CONTROL SYSTEM

The controller comes equipped with a 25 line, 80 character 10-inch display unit. This display showsall information and parameters required to operate the machine. Use the keyboard provided to enterdata for new work cycles.

The following pages are shown on the display:

1) “DATA” PAGEThe 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).

2) “INFORMATION AND LANGUAGE SELECTION” PAGEThe machine parameters are displayed: mechanical, hydraulic and electronic.The screensaver function can either be enabled or disabled (for terminal versions starting from 2.0)and the language in which all the messages are displayed can be changed. It is also possible to resetany absolute encoders installed on the machine.

3) “ACTUAL LOADING DATA” PAGEAll the data regarding the cycle that has just been completed is shown here:- length of the various cycle stages;- temperature of the die-sets.

4) “ACTUAL PRESS CYCLE DATA” PAGEAll the data regarding the cycle that has just been completed is shown here:- length of the various cycle stages;- pressures, speeds and positions reached

5) “ACTUAL DIE-SET DATA” PAGEAll the operating data related to the proportional ejector (optional) is given on this page.

6) “PROGRAMS” PAGEThe list of the programs stored in the system is shown on this page (a “program” consists of all themachine operating data). Up to 128 programs can be stored in the computer’s memory. Eachprogram is identified by a name (consisting of: number of the set size, maximum pressure andthickness set).Operations can be performed with the stored programs (write, read, cancel).

7) “LOADING SET UP” PAGEThe values for the following items related to the automatic cycle can be displayed and set from thispage:- positions and speed of the filler-box;- positions and delay times for die-set downstrokes.

8) “PRESS CYCLE SET UP” PAGEThe values for the following items of the automatic cycle can be displayed and set from this page:- positions and speed of the plunger;- number of press-strokes;- de-aerations;- pressures (and everything concerning the press-cycle);- times (length of various cycle stages, delay times, ...).

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PH 339.85.089 Rev. 00 Date 10.12.01

9) “DIE-SET SET UP” PAGEThe values for the following items of the automatic cycle can be displayed and set from this page:- the size and production batch;- die-set blowing;- SFS control- temperatures of the die-sets.- the limit switches and the speed of the proportional ejectors (optional)

10) “FITTINGS SET UP” PAGEThe values for the following items of the automatic cycle can be displayed and set from this page:- ALM control- brush control;- internal synchronizer (allows the press to be run at a predetermined number of cycles per minute);- external synchronizer (allows the press to be synchronized with an external device).

11) “PRINT ROUTINE”Regardless of the page actually being displayed, the production data, set data, fault messages andsome of the actual values can be printed out at any time.

12) “HELP” PAGEThe Help page, which provides the following information, is displayed when the HELP <F1> key ispressed with any page active:- a scheme of the pages will appear on the top of the display and the title of the page currently active

will flash;- some useful information for the operator is given at the bottom of the display.The cursor can be moved to access the page indicated by the flashing cursor by using the keys onthe terminal keyboard.

13) “I/O PAGE” (INPUTS/OUTPUTS)The inputs and outputs, along with their current state, are shown on this page.

14) “STATE OF EXECUTION” PAGEThe current operating state of all the machine axes are displayed here.

15) “STATISTICS” PAGESome historical machine data regarding the amount of time the machine stopped, number of timesthe machine stopped, pressure, thickness, time taken by the filler-box to carry out the strokes andthe setting reached during the die-set upstroke is shown here in histogram form.

16) “FAULTS” PAGEThe last 20 fault messages displayed are shown here in chronological order. The followinginformation is provided:- date;- time;- message.

17) “PRODUCTION DATA” PAGEProduction data is shown here in the following form:- daily data- weekly data- monthly data- production batch data

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PH 339.85.089 Rev. 00 Date 10.12.01

More than 220 self-diagnostic messages can be displayed including scheduled maintenancemessages (in this case, the messages are shown to inform the operator that the maintenanceoperation has to be performed).Example:

2044 OIL LEVEL (SL1) (machine shut-down)

Input SL1 has stayed off for 6 s. The pump is stopped.Check the oil level in the reservoir.Check level sensor SL1, the INPUT card (when the oil is above the level, Led SL1 must beon) and the cables/connectors.

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. Thetemperature 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 beentered (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 whereasthe display remains active.

This feature allows technical support to be provided to Sacmi engineers on the customer’s premisesfrom Imola when starting up the machine or troubleshooting it on site when it is being repaired/tested.

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PH 339.85.089 Rev. 00 Date 10.12.01

4 MACHINE CONTROL KEYBOARD

RI

I

I

I

+ –

MA

NS

ET

UP

AU

TW

D

SL

SC P A1

A2R+5

10

23

89

1011

16

1718

19-2

3

244

56

712

1314

1520

2122

2526

2927

28 3031

SMC 085-11-442

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PH 339.85.089 Rev. 00 Date 10.12.01

4.1 DESCRIPTION OF THE KEYS

1ST KEY 2ND KEY+ KEY SWITCH PUMP

Ø1

28* 2 AUT ON28* 2 AUT ON28* 2 AUT ON25 3 MAN/AUT ON30 3 MAN ON25 3 SET-UP ON30 3 SET-UP ON

26+31 3 MAN ON27+29 3 MAN ON

428 5 AUT ON

626 7 MAN/AUT31 7 MAN/AUT

28 and 31 7 SET-UP26 and 28 7 SET-UP25 and 26 7 SET-UP30 and 31 7 SET-UP

28 7 SETUP OFF29 8 MAN ON27 8 MAN ON

26+31 8 SET-UP ON25 9 MAN/SET-UP ON30 9 MAN/SET-UP ON31 11 SET-UP26 11 SET-UP26 12 MAN/AUT31 12 MAN/AUT25 13 MAN/SET-UP ON27 13 SET-UP ON29 13 SET-UP ON30 13 MAN/SET-UP ON25 13 SET-UP ON25 13 SET-UP ON30 13 SET-UP ON30 13 SET-UP ON28 13 SET-UP ON31 14 SET-UP26 14 SET-UP31 15 SET-UP26 15 SET-UP28 16 SET-UP ON28 16 SET-UP ON28 17 AUT ON28 18 AUT ON

2029 21 MAN ON27 21 MAN ON

27 or 29 22 MAN24

FUNCTION

Pump startAlarm resetAutomatic cycle startSemi-automatic loading startSemi-automatic press-cycle start (16)Plunger upstrokePlunger downstrokePlunger upstroke at low speedPlunger downstroke at low speedSelf-learning for plunger upstroke/downstroke+press-cycle(5)YV32 and YV318 operation check(12)Pump stopResetAutomatic cycle stopBraking force increaseBraking force decreaseBraking force decrease beyond the limit switch(3)(4)Braking force increase beyond the limit switch(3)(4)Assign analog braking input offset(3)(4)Assign analog braking input gain(3)(4)Control of the SPE proportional solenoid valves (15)Filler-box forwardFiller-box reverseFiller-box encoder mechanical zero setting,Crank connecting rod(11)Punches inPunches outUpper die-set de-magnetizedUpper die-set magnetizedThickness increase(1)Thickness decrease(1)Die-sets up (13)YV21 de-energized, Last dieset downstroke(2)YV21 energized, Last dieset downstroke(2)Die-sets down (14)SPE die-set lift 2+2(6)SPE emergency upstroke 2+2(7)Downstroke after SPE lifting 2+2(8)SPE emergency downstroke 2+2(9)SPE self-learning procedure 2+2(10)Bottom punch holder assembly de-magnetised (optional)Bottom punch holder assembly magnetised (optional)Lower die-set de-magnetizedLower die-set magnetizedEngage proportional knockoutRelease proportional knockoutALM in semi-automatic modeC.P. in semi-automatic modeOil leak recovery pump Start/StopALM forwardALM reverseC.P. in manual modeShutdown

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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 appearsin 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 forend of filler-box’s return stroke triggered (input SQ59 off), die-set down, plunger raised withencoders zero set.

(6) The following data items must be set as indicated: DIE-SET LOCKED = NO and DIE-SETDISASSEMBLY = 2. The following conditions must be satisfied: safety bar up, limit switch forend 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-SETDISASSEMBLY = 3. The following conditions must be satisfied: safety bar up, limit switch forend 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-SETDISASSEMBLY = 2. The following conditions must be satisfied: safety bar up, limit switch forend 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-SETDISASSEMBLY = 3. The following conditions must be satisfied: safety bar up, limit switch forend 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-SETDISASSEMBLY = 1. The following conditions must be satisfied: safety bar up, limit switch forend 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.yyThe “FILLER-BOX ENCODER NOT RESET” should not be displayed when the filler-box is inthe reset position.From version PH13.08.01 onwards, the user can reset the encoder zero-point offset for the fillerbox by performing the procedure below:Press keys 25, 30 and 8 with the mode selector turned to SET-UP and the PUMP OFF. Oncethis operation has been completed, the filler box will stop exactly when the encoder emits thezero-set pulse.

(12) ONLY FOR PROPORTIONAL PHsThe following conditions must be satisfied: filler-box hooked up, safety bar down, limit switch forend of filler-box’s return stroke triggered (SQ59) and the plunger raised with the encoders zeroset. YV303 is de-energized and YV32 is fully opened during the downstroke if MOTIONUPSTROKE, 1ST DEAERATION = 0, YV32 is fully opened during the upstroke if MOTIONUPSTROKE, 1ST DEAERATION = 100. In the mean time, YV318 is opened to an extent equalto 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 isclosed.

(13) With a proportional rod-type lift (optional), the upstroke is interrupted in SET-UP mode as soonas 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.

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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 assoon 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 downstrokeuse keys 31 and 13 for the last die-set downstroke

- 3-downstroke cycleuse keys 26 and 13 for the first die-set downstrokeuse keys 30 and 13 for the second die-set downstrokeuse 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).

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PH 339.85.089 Rev. 00 Date 10.12.01

4.2 DESCRIPTION OF THE LEDs

+5 Keyboard supply (+5V)

R Reset

WD Watch-dog

SL Serial line (comes on if the keyboard is not hooked up to the PLC)

SC Scan control (comes on to indicate that a key is malfunctioning)

B Comes on when a key is pressed

A1Keyboard address (both of them on —> first keyboard)

A2}

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PH 339.85.089 Rev. 00 Date 10.12.01

5.1 DESCRIPTION

A 25 line x 80 column electro-luminescent display

B Function keys

C Numeric keypad

D Write key switch

E Print routine display

F Deletes last character typedin

G Deletes last line typed in

H Cursor keys

5 COMPUTER TERMINAL

0

98

7 4 12

365

OF

FO

NW

RIT

E+5 R

WD

SL

SC B A1

A2

E N T E R-

.

- +S

CR

EE

NH

OM

E

DE

LC

HA

R

DE

LL

INE

EN

D

QU

IT

PAG

PAG

A B

C

D

E F G

H

F1

F2

F3

F4

F5

F6

F7

F8

SMC 085-11-409

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PH 339.85.089 Rev. 00 Date 10.12.01

5.2 DESCRIPTION OF THE LEDs

+5 Keyboard supply (+5 V)

R Reset

WD Watch-dog

SL Serial line (comes on if the keyboard is not hooked up to the PLC)

SC Scan control (comes on to indicate that a key is malfunctioning)

B Comes on when a key is pressed

A1Keyboard address (both on —> first keyboard)

A2}

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PH 339.85.089 Rev. 00 Date 10.12.01

5.3 PAGE LAY-OUT

Information about machine operations is given on the display. A number of pages are provided.

The following items appear on each page:

1 2 34 5

7

6

1 -Fault messages2 -No. of the operating program3 -Date and time4 -Description of the work-cycle5 -Machine status6 -Data input and read-out7 -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. Thefirst page displayed (DATA) is given as an example.

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PH 339.85.089 Rev. 00 Date 10.12.01

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PH 339.85.089 Rev. 00 Date 10.12.01

5.4 NO. OF THE OPERATING PROGRAM

This number indicates the program the press is being run on. If an asterisk (*) appears to the rightof the number, it means that changes have been made to the program which have not been savedyet.If the number of the operating program is ø, it means that this program has not been saved yet (thismay happen when the system is turned on for the first time or when the operating program has beendeleted).

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PH 339.85.089 Rev. 00 Date 10.12.01

5.5 DATE AND TIME

If DATE and TIME need to be corrected, proceed as directed below:1) turn the key on the computer terminal to “ON”;2) switch off the system and then turn it on again;3) press the DEL CHAR key while DATE and TIME are displayed;4) respond to the software-generated questions as they appear:

QUESTION RESPONSE (example)

YEAR 00 ENTER

MONTH 1 ENTER

DAY OF MONTH 24 ENTER

HOUR 15 ENTER

MINUTE 28 ENTER

SECOND 0 ENTER

In this way the following is obtained: DATE 01/24/00 JANUARY 24, 2000TIME 15:28:00

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PH 339.85.089 Rev. 00 Date 10.12.01

5.6 DESCRIPTION OF THE WORK-CYCLE

The F8 key is used to select the type of work-cycle when the machine is started (press keys 28 and2 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 orbeing reset.The standard cycle is the automatic one. In this case the following items appear at the beginningof the second line on the display.

CYCLE = AUTOMATIC (LOADING + PRESS CYCLE)

If the F8 key is pressed, the following will appear after one second:

CYCLE = SEMI-AUTOMATIC LOADING

If the F8 key is pressed again, the following will appear after one second:

CYCLE = SEMI-AUTOMATIC PRESS CYCLE

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” cyclehas been selected, it will be possible to raise or lower the safety bar and to execute thesemiautomatic pressing cycle after performing the loading operations in semi-automatic mode(safety bar down).

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PH 339.85.089 Rev. 00 Date 10.12.01

5.7 MACHINE STATUS

The state of the press is indicated on the right-hand side of the second line displayed. The variousmodes in which the machine can operate are described below:

MAN Key switch (on the keyboard) turned to MANSET UP Key switch (on the keyboard) turned to SET UPAUT Key switch (on the keyboard) turned to AUTRESETTING The machine is being automatically reset (key switch turned to AUT)CYCLE Press running in automatic mode (key switch turned to AUT)CYCLE (flashing) Press being stopped (key switch turned to AUT)

NOTE: If the key switch (on the keyboard) is turned during RESETTING or CYCLE, the press willstop running.

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PH 339.85.089 Rev. 00 Date 10.12.01

5.8 LIST OF PAGES

The pages related to press functioning are listed below:

As already mentioned, the DATA page is displayed when the system is turned on. To shift to otherpages, 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-handside of the diagram above. The pages on the right side show the values entered for the machinecycle. These settings can be changed if necessary. The help key (F1) can be used with any pageactive. By pressing this key, the user can gain access to the “Help” page on which the followinginformation is provided: a list of the pages provided (similar to the one shown above) is given at thetop 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 gainaccess only to the pages which (in the list of the pages provided) are joined together by a straightline.Press one of the ↑ ↓ ← → keys to change the page whose title is flashing. To access anotherpage by using the Help page, press the keys mentioned above until the title of the required pageflashes. After doing this, press ENTER or the F1 key.

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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 setby the operator is given on this page. This feature allows the operator to enter the amount of timethe machine stops for the reasons listed below and obtain a detailed report regarding the causesof machine stoppages in the form of statistical charts.

Use the ↑ ↓ arrow keys to select the cause of machine stoppage.To make the item selected operative use the ← or → keys.NOTE: It is possible to select the cause of the stoppage only if there is no shutdown. If a stoppagemessage is displayed, it is possible to enter a new cause of the stoppage by using the functionsdescribed above.

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PH 339.85.089 Rev. 00 Date 10.12.01

5.9 DATA INPUT & READ-OUT

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 onthe left. The title shows the size of the tiles being produced (to change these three settings, gainaccess 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.

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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 thePARTIAL values can. To do this, turn the key switch to “ON” and press the F6 key. The systemwill then ask the operator to CONFIRM the operation. If key “1” is pressed, all the partial valueswill be set to zero.

If the data does not need to be reset, press “0” or F6.

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5.9.2 “INFORMATION AND LANGUAGE SELECTION” PAGE

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. Thehydraulic and mechanical settings appear on the left-hand side while the electronic ones are shownon the right.

These parameters will not change.Press the F2 key to return to the “DATA” page.Press the F6 key to activate the screensaver function. This is extremely useful as the screen willautomatically be switched off after the keyboard has not been used for fifteen minutes thusprolonging its service life. To turn the screen back on, simply press any key.The language used to display all the messages can be changed from this page.Press the F3 key.

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At this point the messages are displayed in the language selected by simply pressing any functionkey (except F1).

INSTRUCTIONS FOR SELECTING ITALIANGo to the DATA page (if the procedure is not known, then simply turn the controller off and then onagain: the DATA page will be the first to appear) then press F7 followed by F3 and finally by F2.

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5.9.3 AXES CONFIGURATION RESET

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. = XXThis 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 thedisplay. These may be:

1 - PLUNGER4 - 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 safetybar, turn the mode selector to SET UP and set ENCODER NUMBER = 1.

NOTEThe press or the auxiliary equipment that is installed on it may be provided with encoders whichhave to be RESET in a different way.For information concerning the RESET procedure for an encoder refer to the chapterADJUSTMENTS in the USER’S MANUAL for the press.

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5.9.4 “ACTUAL LOADING DATA” PAGE

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 forthe HEAT-UP TIME data item.

b) The operating times for the different steps into which the filler-box stroke is subdivided are shownin the left-hand block. The times were measured at the end of the previous cycle. These timesare 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 andreturn 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 aregiven on the right-hand side of this block. If a linear filler-box is employed, along with the OFFSETvalue for the return stroke (in the middle and to the right), some other filler-box data items cannotbe modified.

d) The filler-box encoder setting at the end of the first die-set downstroke (during the work-cycle justperformed) and the length of the downstroke are shown in the square below. The latter is dividedinto two parts: the first is the time from when the solenoid valve is de-energized and sensor SQ3is inactivated; the second is from when SQ3 is inactivated and SQ6 is activated. Only one timeis 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 (PRESSCY.) to shift to the “ACTUAL PRESS CYCLE DATA” page or press the F5 key (DIE-SETS) to goto the “ACTUAL DIE-SET DATA” page.

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5.9.5 “ACTUAL PRESS CYCLE DATA” PAGE

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 thecycle which has just been performed. In addition, the TILE THICKNESS value is shown in theTHICK. column. This value is measured at the end of the first press-stroke, the end of the secondpress-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 timetaken to reach half the set pressure (if mode = 1 or = 2) or the time to reach the thickness set forS1/P1 (if mode = 0).

With “proportional” presses only, the number which appears on each Deaeration line and in theTHICKNESS 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 changethese 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).

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c) The following items are given in the square below:- maximum stroke carried out by the plunger during the cycle which has just been performed

and, on the right (optional) the same value measured by the 2nd encoder BQ7- distance between the upper and lower punches- difference between the thickness measured during the cycle which has just been performed

and the set point (TILE THICKNESS on the PRESS CYCLE SET UP page).

d) The amount of material (expressed in sq.m) or number of tiles to be produced in order to completethe current production batch is given in the square below.

e) The current pump pressure setting is indicated here.

For “proportional” presses, the proportional solenoid valves offset values determined during theself-learning procedure are displayed on the bottom of the page on the right side as follows: YV32offset to perform the plunger downstroke, YV32 offset to keep the plunger stationary, YV32 offsetto 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 goto the “ACTUAL LOADING DATA” page or press the F5 key (DIE-SETS) to go to the “ACTUAL DIE-SET DATA” page.

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5.9.6 “ACTUAL DIE-SET DATA” PAGE

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 equippedwith a proportional knockout.

With a two-cylinder S.E. the data is as follows:The values of the two die set encoders are updated in real time and given for the DIE SETTING dataitem. The corresponding analog values are given for the ANALOG data item. The length of theupstroke is shown below the latter. The soft filling height (FILLING HEIGHT) along with the ratiobetween the thickness of the tiles and that of the soft filling (TILE THICKNESS / FILLING HEIGHT),expressed in percentage, are also displayed.

With a four-cylinder S.P.E. or 2 + 2 cylinders the data is as follows:The values of the two die set encoders BQ4 and BQ5 are updated in real time and given for the DIESETTING data item. The soft filling height (FILLING HEIGHT) along with the ratio between thethickness of the tiles and that of the soft filling (TILE THICKNESS / FILLING HEIGHT), expressedin percentage, are also displayed.Furthermore the movements of the knockout are shown in terms of time (ms) and speed (mm/s)

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With the SPE, the following data is displayed in the bottom section:

STATE = Axis control card code

AXIS CONTROL CARD ERROR= fault code from axis control card

CONTROL = Analog datum signal from axis control card to proportional solenoid valve, side A andB: 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 measuredby the axis control card (only with AP210 axis control card)

PUSH = pushing force (expressed in bar) measured by the two SPE pressure transducers (only withAX 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 dataprovided during the penultimate reset procedure are displayed on the line underneath.

CMD = Axis card control (only with AX card)

STEP = Axis control card step (only with AX card)

OFFSET = offset indicated by the SPE proportional valves expressed in % of max. opening (onlywith AX card)

SPOOL = Position of SPE proportional solenoid valve spools, side A and B. The value can rangefrom -100.0% (max. opening during downstroke) to 100.0% (max. opening during upstroke) (onlywith AX card)

UPSTROKE CHAMBER PRESSURE = pressure transducer (set in bar) for the SPE bottomchambers (only with card AX)

DOWNSTROKE = pressure transducer (set in bar) for SPE top chambers (only with AX card)

Press the F2 key (DATA) to go back to the “DATA” page.

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5.9.7 “I/O” PAGE

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.

The state of the inputs is displayed here.

SL4Digital input (ON-OFF)A symbol ( ) appears next to the identification number of the input to indicate that the input is closed.The symbol is not shown if the input is open.

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Press F4 to go to the output page.

The state of the outputs is displayed.Two types of solenoid valves are provided.

YV32SDigital output (ON-OFF)A symbol ( ) appears next to the identification number of the output to indicate that it is on. Thesymbol is not shown if the input is off.

YV20A = XXXXAnalog 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 ofthe 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 thecorresponding channel.The number ranges from 0 to 4095 in some analog outputs.

NOTE: Press the F4 key to go to the second output page.

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5.9.8 “FAULTS” PAGE

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 timeare given with each one.

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5.9.9 “STATISTICS” PAGES

These pages can be accessed from the DATA page by pressing F5 and then F5 again.Bar charts that illustrate some statistics regarding the production run are given on these pages.The number of cycles taken into consideration in drawing up the graphs is given on the next to lastline, on the right.To zero set the data, turn the WRITE key to ON and then press F6. When the system asks theoperator 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 parallelconnected to the output on the back of the card rack and the WRITE key needs to be turned to ON).

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The first chart displayed shows the ten causes of machine stoppage or shutdown which resulted inthe 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.

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The second chart displayed shows the ten causes of machine stoppage or shutdown which resultedin the greatest number of stoppages (shown in the order of number of stoppages).

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The third chart represents the percentage of defective pieces in relation to the total numberproduced for each thickness error band.The central bar represents the pieces whose thickness error is less than 10 hundredths of amillimeter.

Percentage of each band inrelation to total cycles

Total numberof cyclesperformed

Percentage in relationto total cycles

Deviation from setvalue (mm)

Set value

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The fourth chart shows the percentage of pieces in relation to the total number produced that fallwithin each pressure error band.The central bar represents the pieces whose pressure deviates by less than 4 bar.

Percentage of each band inrelation to total cycles

Total numberof cyclesperformed

Percentage in relationto total cycles

Deviation from setvalue (bar)

Set value

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The fifth chart represents the percentage of cycles in relation to the total number performed for eacherror 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.

Percentage of each band inrelation to total cycles

Total numberof cyclesperformed

Percentage in relationto total cycles

Deviation from setvalue (ms)

Set value

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The sixth chart shows the percentage of cycles in relation to the total number performed for eacherror 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. Thefollowing 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.

Percentage of each band inrelation to total cycles

Total numberof cyclesperformed

Percentage in relationto total cycles

Deviation from setvalue (ms)

Set value

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5.9.11 “STATE OF EXECUTION” PAGE

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 inthe 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.

The meaning of each digit is given on the following pages:

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FILLER-BOX 0 X X X X H

1st 2nd 3rd

1st) Coding of the main stage01 = RETURN STROKE IN MANUAL02 = FORWARD STROKE IN MANUAL0A = RESETTING1E = START OF AUTOMATIC CYCLE20 = AUTOMATIC CYCLE IN PROGRESS

2nd) Not used.

3rd) Coding of operation in progress0 = FORWARD STROKEF = RETURN STROKE

DIE SETS 0 X X X X H

1st 2nd 3rd

1st) Coding of the main stage01 = UPSTROKE02 = DOWNSTROKE03 = UPPER PUNCHES IN04 = UPPER PUNCHES OUT05 = OVERTRAVEL0A = RESETTING14 = LOADING IN SEMI-AUTOMATIC15 = PRESS-CYCLE IN SEMI-AUTOMATIC1E = START OF AUTOMATIC CYCLE1F = END OF RESETTING DURING AUTOMATIC CYCLE20 = AUTOMATIC CYCLE IN PROGRESS

2nd) Coding of filler-box operation in progress1 = FILLER-BOX FORWARD STROKE2 = FILLER-BOX RETURN STROKE3 = 2ND FORWARD STROKE (Optional)4 = 2ND RETURN STROKE (Optional)

3rd) Coding of the secondary stage1 = START OF LAST PRESS-STROKE2 = START OF DELAY TIME FOR DIE-SET UPSTROKE3 = END OF REMOVAL4 = SYNCHRONIZATION5 = END OF SYNCHRONIZATION6 = FILLER-BOX START7 = FIRST DIE-SET DOWNSTROKE8 = LAST DIE-SET DOWNSTROKE9 = THICKNESS CONTROL STARTA = SECOND DIE-SET DOWNSTROKE

{{

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PLUNGER 0 X X X X H

1st 2nd 3rd

1st) Coding of the main stage01 = SLOW UPSTROKE02 = SLOW DOWNSTROKE03 = UPSTROKE04 = DOWNSTROKE0A = RESETTING14 = SEMI-AUTOMATIC PRESS-CYCLE1E = START OF AUTOMATIC CYCLE20 = AUTOMATIC CYCLE IN PROGRESS

2nd) Coding of the secondary stage1 = PLUNGER DOWNSTROKE2 = BRAKING DURING PLUNGER DOWNSTROKE3 = DE-AERATION4 = START OF PRESS-STROKE5 = END OF PRESS-STROKE6 = DELAY TIME FOR PLUNGER UPSTROKE7 = PLUNGER UPSTROKE

3rd) Coding of number of press-strokes0 = FIRST PRESS-STROKE1 = SECOND PRESS-STROKE2 = THIRD PRESS-STROKE

POWDER LOADING 0 X X X X H

1st 2nd 3rd

1st) Coding of the main stage01 = IN MANUAL MODE02 = IN SEMI-AUTOMATIC MODE03 = IN AUTOMATIC MODE

2nd) Not used.

3rd) Coding of type of operation0 = LEFT-HAND MOVEMENTF = RIGHT-HAND MOVEMENT

ALM 0 X X X X H

1st 2nd 3rd

1st) Coding of the main stage01 = IN AUTOMATIC MODE02 = IN SEMI-AUTOMATIC MODE03 = RESETTING

2nd) Not used.

{{

{

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3rd) Coding of secondary stage1 = HOPPER GATE OPENING2 = LOADING3 = HOPPER GATE CLOSING4 = ALM FORWARD

BRUSH 0 X X X X H

1st 2nd 3rd

1st) Coding of the main stage00 = BRUSH PROGRAM NOT BEING EXECUTEDFF = BRUSH PROGRAM BEING EXECUTED

2nd) Coding of secondary stage1 = STOP BEFORE REVERSING2 = REVERSE ROTATION

3rd) Coding of type of operation0 = COUNTER-CLOCKWISE OPERATIONF = CLOCKWISE OPERATION

{

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5.9.11 “PRODUCTION DATA” PAGE

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;

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5.9.12 “PROGRAMS” PAGE

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” refersto all the machine operating data. Up to 128 programs can be stored in the computer’s memory. Eachprogram is identified by a name. For example, program 4 has three exits for 330 mm x 330 mm tileswhich 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 display other programs press the PAG↓ or PAG↑ keys.

To perform operations with the stored programs, press the F7 key after turning the key switch onthe computer terminal to ON.

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The functions which can be selected are given on the last line:

WRITEThis function is used to store the data of the operating program. Press the F2 key. The followingappears 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 beingused (in the example above, the program in use is one deriving from program 32). If 26 is keyed inand the ENTER key is pressed, the program being used will be assigned number 26. As a result,the operating program will be the one numbered 26.

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READThis function is used to run the machine with the data for a program stored in the memory. Thisfunction cannot be used when the press is cycling in automatic mode. The following message willappear when the F3 key is pressed.

READ PROGRAM NUMBER?

Key in the number of the program required (e.g. 4) and then press the ENTER key. The followingquestion will be displayed:

SAVE PROGRAM NUMBER 26 (Ø = no, 1 = yes)?

This allows the operator to save the old operating program (26 in the example) before loading theone required (4 in the example).

CLEARThis function is used to delete a program. To do this, press the F4 key. The following message willappear:

CANCEL PROGRAM NUMBER?

Type in the number and then press the ENTER key.If the back-up copy of the operating program is deleted, the new program will be identified by ø.

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5.9.13 “LOADING SET UP” PAGE

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 itemshould 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 RETURNSTROKE TIME.FILL.-BOX APPROACH POS.: if a value greater than the END OF RETURN STROKE is enteredfor 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. Oncethe filler-box reaches the END OF RETURN STROKE during the press-cycle the ALM cycle willstart. After the grid has been loaded, the filler-box starts traveling again at the speed set forSPEED 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 forwardstroke 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

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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 zonesExample with linear filler-box:end of return stroke = 175 mm, approach setting = 430 mm and end of forward stroke = 1185 mmend of zone positions during forward stroke = 520 700 700 1050forward stroke speed = 35 55 55 85 70This means that:from the end of the return stroke to the approach setting, the filler-box travels at the approach speed.zone 1) from the approach setting up to 520 mm the filler-box travels at 35% of its full speedzone 2) from 520 mm up to 700 mm the filler-box travels at 55% of its full speedzone 3) from 700 mm up to 1050 mm the filler-box travels at 85% of its full speedzone 4) from 1050 mm up to the end of the forward stroke the filler-box travels at 70% of its full speed

end of zone positions during return stroke = 1000 685 520 430return stroke speed = 70 85 80 70 60This means that:zone 1) from the end of the forward stroke up to 1000 mm the filler-box travels at 70% of its full speedzone 2) from 1000 mm up to 685 mm the filler-box travels at 85% of its full speedzone 3) from 685 mm up to 520 mm the filler-box travels at 80% of its full speedzone 4) from 520 mm up to 430 mm the filler-box travels at 70% of its full speedzone 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 equalsthat set for SPEED IN MANUAL MODE.

2) With program version PH13.xx.yy and connecting rod-and-crank mechanism filler-boxwith proportional solenoid valve:Set the end of the filler-box return stroke as a percentage. FILLER-BOX CONTROL ON shouldonly be set to YES if the filler-box speed is to be automatically controlled according to theoperating times set for F-B FORWARD RUN TIME and F-B RETURN TIME.Once this function has been activated, check the F-STROKE GAINand 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 the END OF RETURNSTROKE 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 sametime, the APPROACH DELAY TIME starts to elapse. Once the filler-box reaches the END OFRETURN STROKE, during the press-cycle, it stops for the amount of time set for theAPPROACH DELAY TIME data item. After this time has elapsed the filler-box starts travelingagain at the speed set for the SPEED data item until the value set for FILL.-BOX APPROACHPOS. is reached;

- with ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-boxhas passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once thefiller-box reaches the END OF RETURN STROKE, during the press-cycle, the ALM cycle willstart. After the grid has been loaded, the filler-box starts traveling again at the speed set forSPEED until the value set for FILL.-BOX APPROACH POS. is reached.

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The filler-box strokes are divided into set steps - or zones - (a maximum of 5 steps for the forwardstroke and 5 for the return stroke). The filler-box speed in each of these zones can also be set. Forthe 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 zonesFor 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 equalsthat set for the first zone of the forward stroke.

3) With program version PH13.xx.yy and connecting rod-and-crank mechanism filler-boxwithout proportional solenoid valve:Set the end of the filler-box return stroke as a percentage. Set FILLER-BOX CONTROL ON = NO.The values set for F-B FORWARD RUN TIME and F-B RETURN TIME are only used for theSTATISTICS PAGES. Set FILL.-BOX APPROACH POS. = 0.0%. GAIN (RP2) has no relevance.

The filler-box strokes are divided into set steps - or zones - (a maximum of 5 steps for the forwardstroke 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 valuebetween 77 and 100% is set the filler box will travel at high speed (YV20B on). For the forwardstroke 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 zonesFor 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 equalsthat set for the first zone of the forward stroke.

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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 positionfor the end of the return stroke and the filler-box speed during the 8 forward steps and 8 returnsteps. Enter the following:FILLER-BOX CONTROL ON = YESAlso enter the length of time required for the filler-box forward and return strokes for F-BFORWARD RUN TIME and F-B RETURN TIME respectively. In this way the filler-box speed isautomatically controlled according to the set operating times.When this control has been activated, check the F-STROKE GAINand 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 approachcycle 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 sametime, the APPROACH DELAY TIME starts to elapse. Once the filler-box reaches the end ofits 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 theAPPROACH SPEED data item until the value set for FILL.-BOX APPROACH POS. isreached;

- with ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-boxhas passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once thefiller-box reaches the end of its return stroke, the ALM cycle will start. After the grid has beenloaded, 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 bythe proportional solenoid valve.

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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, thefiller box travels at low speed. If a value between 77 and 100% is set, the filler box will travel athigh speed. Set FILL.-BOX APPROACH POS. = 0.0%. The GAIN (RP2) setting has no effect.

6) With program version PH11.xx.yy or earlier and linear filler-box:The following data should be entered in the FILLER-BOX block:The data items END OF RETURN STROKE and FORWARD represent the two filler-box strokesin mm in relation to the zero setting of the encoder. The FILLER-BOX CONTROL ON data itemis used to select whether a fault is to be signaled when the traveling time error exceeds 5% inrelation to the set TIME.FILL.-BOX APPROACH POS.: if a value greater than “0” is entered for this data item, the triggerpulse for the plunger downstroke is provided as soon as the filler-box has passed the value setfor FILL.-BOX APPROACH POS. during its return stroke. Once the filler-box reaches the end ofits return stroke, the ALM cycle will start. After the grid has been loaded, the filler-box startstraveling again at the speed set for SPEED until the value set for FILL.-BOX APPROACH POS.is reached. In manual mode the filler-box moves at a speed set for SPEED IN MANUAL MODE.In automatic or semi-automatic mode, the filler-box travels at the set speeds. If the value set forFILL.-BOX APPROACH POS. is greater than “0”, the steps go from the FILL.-BOX APPROACHPOS. to the END OF FORWARD STROKE. The last part of the return stroke is performed at thesame speed as that set for the eighth step of the return stroke.If the FILL.-BOX APPROACH POS. = 0, the steps start from the end of the return stroke and goto the end of the forward stroke. All the steps have the same length.

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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 ofsolenoid valve YV64. NOTE: with certain types of PH (when the control assembly is not providedwith pressure transducer BP2 and the related control for the aux. equipment YV64) “0” needs to beentered to inactivate the aux. equipment pressure control.

SERVICE PRESS. 2nd RECHARGING: if YES is entered, the pressure is recuperated at thebeginning of the last de-aeration if it was below the minimum set threshold (a fault signal is givenbefore the die-set upstroke). With the linear filler-box or double-loading filler-box, the pressure in theauxiliary 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 stopcycle.

DIE-SET BLOCK

DIE-SET UPSTROKE DELAY TIME:- with WAIT FOR LOWER DIE-SET = NO: if the die-set is provided with a SMU device or a

conventional Knockout, this time starts from the beginning of the last press-stroke. If the die-setis provided with a proportional knockout, the time starts from the end of the last press-stroke.

- with WAIT FOR LOWER DIE-SET = YES: the data item becomes DIE UPSTROKE DELAY TIMEand the time starts to elapse from when the plunger moves up again according to the settingPLUNGER TRAVEL, DIE-SETS UP

PUNCHES EJECTION DELAY (only with SFS type upper die-set):- with WAIT FOR LOWER DIE-SET = NO: the delay time starts from the end of the last press-

stroke.- with WAIT FOR LOWER DIE-SET = YES: the delay time starts from the beginning of the last

press-stroke.

1st DOWNSTROKE POSITION: this is the position the filler-box reaches during its forward strokewhen the first downstroke is performed.

With a three-downstroke cycle and filler box NOT designed for double loading, the user can set theposition 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

F.BOX SETTING AT PLUNGER START (ONLY with linear filler-box)If miniature switch SQ59 is activated, the plunger will begins its downstroke at the set moment duringthe return stroke of the linear filler-box. Otherwise the press signals a fault. If a mobile die is installed,this setting must be made so that the grid is outside the die itself. Set O to turn off this function.

F.BOX START ADVANCEFILLER-BOX SAFETY SETTING (ONLY with proportional presses and linear filler-box).When the PLUNGER UP - FILLER-BOX START ADVANCE setting is exceeded during the plungerupstroke, the filler-box starts to move. When the filler-box arrives at the FILLER-BOX SAFETYSETTING, check that the plunger has arrived at the setting for the end of its upstroke. Otherwisethe filler-box movement is blocked and the message “F.BOX/PLUNGER COLLISION” is shown. SetFILLER-BOX START ADVANCE = 0 to turn off this function.

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From this page, press F2 (PROGRAM) to go back to the PROGRAMS page.

Instructions on how to change the set data are given below:

1) First of all move the cursor next to the data item to be modified by pressing one of the followingkeys:↓ to shift to the next data itemPAG ↓ to shift to the next data blockEND to shift to the last data item on the page↑ to shift to the previous data itemPAG ↑ to shift to the previous data blockHOME 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 pointsDEL CHAR to delete the last number enteredDEL LINE to delete the entire data item enteredENTER 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 thecursor.

b) +/-If this symbol appears, it means that the data item pointed out by the cursor can be changedin 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. Inthe example above, the filler-box encoder setting is shown. This value is useful to set the endof the filler-box’s return stroke.

If no messages appear on the second to last line, it means that the data item cannot be changedbecause 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 thedirections given for “b” at point 2) above:MOULD UPSTROKE DELAY/DIE UPSTROKE DELAYThe FILL.-BOX APPROACH POS. data item can be modified only if the mode selector is turned toSET-UP.

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5.9.14 “PRESS-CYCLE SET UP” PAGE

To go to the “PRESS CYCLE SET UP” page from “PROGRAMS” press the F4 key (PRESS CY.).The data set for the press cycle is given on this page.

1) Presses with proportional hydraulic system

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: Thetiles 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 105.00mm. 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 greaterthan 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;

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- enable the automatic thickness gauge by entering a value higher than 0 for THICKNESS CTRLCOEFF.

- 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 toperform 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 exampleto 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 thethickness 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 upwardmovement during the automatic cycle. The plunger reaches its mechanical end-stop during thesemi-automatic cycle or when the machine is stopped.

END STOP PRECISION is used to more precisely position the plunger at the value set forPLUNGER UP POSITION. If Ø is entered, minimum precision is obtained. On the other hand, if100 is entered, the plunger positioning is extremely precise while the production output is reduced(because the plunger slows down to a greater extent).

IMPACT POSITION: when this plunger setting is reached, braking finishes.

PRESSING START POS. when this plunger setting is reached, the first press-stroke delay timestarts to elapse (DEL. in ms). When the delay time has elapsed, the first press-stroke starts. Ifthe 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.

FINAL PRESSURE: enter the pressure of the last press-stroke

TOLERANCE: enter the tolerance for the pressure of the last press-stroke to the right of the symbol±. If zero is entered for the tolerance, the last press-stroke will finish when the final pressure isreached. If, on the other hand, the tolerance is 5 bar, the last press-stroke will finish when thetile thickness is reached; as long as the pressure is between “final pressure - tolerance” and finalpressure + tolerance” (see figure 1).

- The PLUNGER PARALLELISM data item may appear in some machines. This value, expressedin 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)

b) The following are shown in the “braking” block:- plunger braking during the first press-stroke;- speed when the plunger is moving down to the IMPACT POSITION;- braking during upstroke; if this function is enabled, braking will start when the plunger rests on

the tile and stops when the value set for END OF BRAKING UPWARDS is reached.Also enter the plunger speed during the part of the stroke with braking.

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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 onlybe 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 orderto obtain cylinder pressure equal to the setting in the SP/PR column, has elapsed.

Pressure or thickness SET-POINT for each intermediate press-stroke.

PRESS-STROKE TREND: S1/P1 = thickness/pressure at the first point on the line shown on thegraph (this can only be set for type 0; otherwise it is fixed at half the set pressure). T1 = first timeat which the pressure, as shown on the line, reaches value S1/P1. T2 = total length of pressuretrend. Example 1 (see figure 2): 1st press-stroke set to type 0 with THICKNESS AT START OFPRESS-STROKE = 15.00, SP/PR = 12.00, S1/P1 = 13.00, T1 = 2000, T2 = 3000. This meansthat the press-stroke starts when the soft filling height reaches 15 mm. The press will adjustYV318 in order to reach a soft filling height of 13 mm in 2 seconds and then 12 mm in anothersecond. Example 2 (see figure 3): last press-stroke set to type 1 with FINAL PRESSURE = 250bar, S1/P1 = 125, T1 = 2000, T2 = 3000. This means that the press will adjust YV318 in order toreach 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 fastupstroke (through YV32).

STROKE: the deaeration upstroke is set here.DURAT.: set the amount of time the deaeration setting should lastSPE. DOWNSTR: set the speed of the downstroke after deaeration.

e) The CYLINDER PRESSURE REGAINED function allows energy to be saved.

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Thickness

Thickness atstart of press-

stroke

T1

Fig. 2

S1/P1

SP/PR

T2 time

Soft fillingheight

Final thickness

Tolerance Tolerance

Final pressure Cylinder pressure

Fig. 1

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Pressure

SP/PR or finalpressure (=PR)

T1

Fig. 3

PR/2

T2 time

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2) Presses with traditional hydraulic system

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: Thetiles 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 105.00mm. 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 greaterthan 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!

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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 performtoo many cycles in order to reach the thickness set for the TILE THICKNESS data item, increasethe setting, e.g. to 300.If the thickness of the tiles produced is not always the same, decrease the value, for example to100.

- 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 thethickness 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 upwardmovement during the automatic cycle. The plunger reaches its mechanical end-stop during thesemi-automatic cycle or when the machine is stopped.

IMPACT POSITION: when this plunger setting is reached, braking finishes.

FINAL PRESSURE: enter the pressure of the last press-stroke.

- The PLUNGER PARALLELISM data item may appear in some machines. This value, expressedin 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)

b) The following are shown in the “braking” block:- plunger braking during the first press-stroke;- braking space during the last part of the plunger downstroke- speed control during plunger downstroke and related speed to the IMPACT POSITION;- braking during upstroke; if this function is enabled, braking will start when the plunger rests on

the tile and stops when the value set for END OF BRAKING UPWARDS is reached.

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 atthe 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 notethe following:with the WRITE key switch turned to OFF, the following data items can be modified using methodb) described in point 2) above:1ST PRESS-STROKEDEAERATION LENGTH

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5.9.15 “DIE-SET SET UP” PAGE

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 numberof tiles produced.PRODUCTION BATCH: as soon as the press has produced the tiles which correspond to theset 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 firedtiles 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 thelower 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 tomove them in when the filler-box is at the end of its forward-stroke and 3 to move them in whenthe 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 mobiledie remains locked in its low position at the end of the press-cycle. After the plunger has movedback up again - performing a movement equal to PLUNGER TRAVEL, DIE-SETS UP - the lowerpunch 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 energisingthe 2 sensors SQ63A/B.

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d) Two data items regarding maintenance of the die-sets are given in this block along with the typeof 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. OFCYCLES DIE-SET LIFE” data item.Each time the die-set is changed as the production cycle is modified jot down the value givenfor the “CYCLES PERFORMED WITH DIE-SET” data item shown on the “ACTUAL LOADINGDATA” page regarding the die-set being removed. Once the die-set has been installed, enterthe value for “NO. OF CYCLES PERFORMED”. As soon as the die-set reaches the number ofcycles 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 areprovided for demagnetizing the die-sets: enter YES before demagnetizing the die-set (thesesettings 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 thecurrent control device of the magnetism (AJ1 and AJ2) (see INSTRUCTIONS FOR ADJUSTINGTHE ELECTRICAL EQUIPMENT); turn the key switch to MAN.Demagnetising procedure: with the key switch turned to SET UP set DEMAGNETISATIONUPP. = YES AND LOW. = YES, press the related keys (see DESCRIPTION OF KEYS) andmake 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 solenoidvalve (YV173) for die-set blowing is activated. Set DURING PRESS. = YES to operate theblower during the press-0cycle.Enter the plunger encoder value at which blowing is terminated during the upstroke for the OFFPOS. 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-energizedat 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 oncethe filler-box has exceeded the set value.Two additional data items, NO. CYCLES and LENGTH have been added to the DIE-SETBLOWING 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 andperiodically every n cycles, where n = NO. CYCLES. The length is the value entered for theLENGTH data item.

g) Setting the proportional ejector (2-cylinder S.E. optional):The setting the die-set has to reach during its upstroke along with the speed (expressed inpercentage) at which the die-set carries out the upstrokes and downstrokes are to be enteredhere.DIESET SELF-LEARNING is a procedure to be carried out whenever the die-set is changed sothat the punches and die are aligned during knockout. Proceed as follows:1 - Reset the machine and then reset the encoders. Next, enter the desired values for UPPER

LIMIT A and B.2 - With the safety bar raised, enter DIESET SELF-LEARNING = YES.3 - Carry out DIE-SET UPSTROKE and wait until the led of key 13 flashes.4 - Make sure the punches are at exactly the same level as the die (they must be perfectly aligned);

if they are not, move the cursor to the UPPER LIMIT A data item and use the “-” and “+” keys onthe terminal keyboard to adjust the height of cylinder A. Do the same for cylinder B.

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5 - To end the procedure, enter DIESET SELF-LEARNING = NOTo remove the tiles between the punches enter KNOC. = YES.Finally, set how far the punch should move up during overtravel in relation to the die.

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 SPSWAIT LOWER DIEUPP. MAGNETIC LOCKLOW. MAGNETIC LOCKUPP. DEMAGNETIZATIONLOW. DEMAGNETIZATIONDIESET SELF-LEARNINGEND STOP (UP) AEND STOP (UP) BKNOC.These data items can be modified only if the mode selector is turned to SET-UP.

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5.9.16 “S.P.E. DIE-SET SET-UP” PAGE

die-set setting

upper end stop

die-setupstroke

first die-setdownstroke

soft filling height

last die-setdownstroke

time

The “S.P.E. DIE-SET SET-UP” page can be accessed from the “DIE-SET SET-UP” page bypressing 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 modeand with the die-set down)- 2-downstroke cycle

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- 3-downstroke cycle

b) Set the speed for the various movements of the die-set.

c) Set the following:If the knockout between the punches is required, set KNOCKOUT BTW PUNCHES = numberother than Ø (only with SPE). With the AX card activated, go to data item KNOCKOUT BTWPUNCHES to set the required knockout force (in bar), 0 = upstroke btw punches off.With the 4-cylinder SPE, the following settings need to be entered for KNOCKOUT BTWPUNCHES:- 1 for standard knockout force

1 for a lower knockout force2 for a higher knockout force0 knockout btw punches off

Set DIE-SET ENGAGED = YES only if the die-set has actually been engaged.With the 2+2 cylinder SPE, data item DIE-SET DISASSEMBLY is provided. Enter Ø unless thedie-set is to be operated for the disassembly procedures as described in paragraph 4.1.For the punch overtravel, set PUNCH EXTRA-RUN = YES and raise the die-set (seeDESCRIPTION OF THE KEYS). A setting beyond the upper end-stop can be entered so thatthe die-set can perform its overtravel.With the SPE, if the die-set, when fully up, is not level with the die on either side, the user canenter the difference between the settings for cylinder A and cylinder B on the SPE. If, forexample, cylinder A is flush with the die but cylinder B is below the edge of the die, set MAX.MISALIGNMENT (B-A) = 0.20 mmWith an electronically controlled rod-type lift (optional), enter the data required for the DEADSTROKE. First reset the encoder of the die-set with mechanical end-stops (key in 4 on the samevideo-page as that used to reset the plunger encoder), attach the die-set, then enter the settingto be read with the die-set down during the DEAD STROKE + 1 mm (for example, if the readingis 12.00 mm, enter 13.00 mm). To set the UPPER END-STOP, enter the dead stroke + therequired stroke (e.g. to travel 30 mm, enter 30 + 13 = 43 mm).

die-set setting

upper endstop

die-setupstroke

first die-setdownstroke

base material thickness

second die-setdownstroke

timelast die-setdownstroke

glaze thickness

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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 fromthe 1st downstroke position. For each movement set the following: the filler box setting when itstarts moving, the extent the die-set moves, the filler box return stroke setting at the point where1st downstroke takes place, the die-set travel speed.An explanatory diagram is given below:

With a 4-cylinder S.P.E. the speed of each movement can be calculated automatically so as tosmooth the powder in such a way as to give it a “wedge” shape instead of a “step” shape (AUT =YES).

die-set setting

RETURN

die-set stroke

Filler boxsetting

lastdownstroke

REAR ENDSTOP

END

SPEED

START FRONT ENDSTOP

filler boxreturn

Die-set setting

RETURN

Filler boxsetting

REAR ENDSTOP

END START END STOPFORWARDS

From this page it is possible to go back to the PROGRAMS page by pressing F2 (PROGRAM.)

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As far as data set-up is concerned, refer to the paragraph regarding the LOADING SETUP page.The following data items:NO. OF DOWNSTROKESEND STOPFILLING HEIGHTBASE THICKNESSGLAZE THICKNESSKNOC.DIE-SET SECUREDDIESET DISASSEMBLYPUNCH EXTRARUNMAX. MISALIGNMENT (B - A)NO. CORRECTIONSAUTcan 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

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5.9.17 “FITTINGS SET UP” PAGE

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 (expressedin CYCLES PER MINUTE). The second CYCLES PER MINUTE data item allows the strokes ofthe press to be “halved” with synchronized operation. For example, the press is synchronized andcarries out 12 cycles per minute, if the input that pilots inside synchronization (KA301) is activatedthe 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 eachwork cycle. The numbers range from 1 to 49, with 0 = Off, 50 = ACP operating continuously. Inaddition, a delay time can be set between one movement and anotherThe following is to be set if the loading operations are to be performed through an ALM mobilehopper:

ALM with encoder1) TYPE OF ALM CYCLE = 0

The gate opens and the ALM loading stroke starts after a length of time equal to LOAD DELAYhas elapsed. The gate moves at the speed (%) entered for the loading stroke . The gate closeswhen the required position has been reached. The ALM reaches the end of its forward stroke,reverses and then moves back to the end of its backward stroke at the speed entered duringthe repositioning stage. With two-row loading operations, the gate opens in position 2 duringloading and finally closes in position 2.

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2) ALM CYCLE FIXED/MOBILE = 12.1) APPROACH SETTING = 0

The hopper pauses when it reaches the loading position. When the filler-box arrives backthe gate opens (after a delay time set for gate opening delay). The gate closes when thefiller-box reaches the position for closing during the forward stroke.

2.2) APPROACH SETTING > 0The grid is loaded during the filler-box’s approach stroke. The ALM remains stationaryin its loading position. First of all the gate opens and then the filler-box approach strokebegins once the loading delay time has elapsed. The gate closes when the filler-boxreaches the closing position.

3) ALM CYCLE FIXED/MOBILE = 2Mixed ALM cycle; this is only possible if APPROACH SETTING > 0. Combined fixed ALM /mobile ALM loading is to be used when the CAF stroke is not sufficient to load the entire gridwith the ALM stopped. The cycle is as follows:A) When die-set loading is completed, the CAF brings the front part of the grid under the ALM.B) the ALM gate is opened and stays openC) with the ALM stopped, the CAF moves forward as far as the die-set dimensions will allow

(approach setting) and then stops.D) the ALM moves back while keeping its inlet open until the grid loading operation is

completed with the CAF stopped.

Only set OPEN W/ MCH. STOPPED = YES if the gate is to be opened at the end of the automaticcycle.

ALM with sensorsALM CYCLE FIXED/MOBILE = 0 (mobile), 1 (fixed), 2 (mixed only with approach)DELAYED LOADING (from when the gate opens to when the ALM starts its loading cycle).GATE CLOSING DELAY (from when sensor SQ25 is activated to when the gate closes).If a 2 line die-set is used, enter 2-ROW LOADING = YES. In addition, 2 cams have to be placedunder SQ25 instead of 1. As a result, during the ALM loading stroke the gate will close once thefirst cam is reached. The gate will reopen after the time set for OPENING DELAY has elapsed.As soon as the second cam is reached the time set for the GATE CLOSING DELAY data itemwill start to elapse. Once this time has expired the gate will close definitively.

c) The following settings can be entered for the brush:- whether the brush is present or not- whether the brush is fixed or mobile- if the brush is mobile the following can be set:

1) whether the brush has to clean the lower or the upper die-set2) the point of the filler-box stroke at which the brush moves down3) the point of the filler-box stroke at which the brush moves up

- brush rotation: if this function is enabled, the following modes of operation can be selected:Always CLOCKWISE rotation (REVERSE ROTATION = NO, C.WISE ROTATION = YES);Always COUNTER-CLOCKWISE rotation

(REVERSE ROTATION = NO, C.WISE ROTATION = NO)Reverse rotation every h cycles

(REVERSE ROTATION = YES, CYCLES BTW REVERSALS = h).The ROTATION ENABLING data item allows the following to be selected:NO = rotation off1 = rotation on only during filler-box forward stroke2 = rotation on only during filler-box return stroke3 = rotation constantly on

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- If a linear filler-box is used:The points at which brushing starts and stops in relation to the filler-box stroke (expressed inmm) can be set in the BRUSH block if a linear filler-box is used.

WEAR and MAX (only for proportional presses)If WEAR is set > 0, the upper end-stop for the plunger is lowered in order to automaticallycompensate for brush wear and obtain optimum cleaning. The operator should set a specificvalue for brush wear i.e. the number of cycles during which the brush’s radius is reduced by 1/100th of a mm. The maximum allowable wear (MAX) should also be set: when this value isreached, the machine stops and the message “REPLACE BRUSH” appears. If a reset operationis performed, the procedure begins again.NOTE: The use of this function may gradually reduce the opening of the die-set until the filler boxcan no longer go in.

d) If the Enea Cooling system is provided (optional), the user can select whether to enable or disablethe 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 theACP.

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.

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5.9.18 “PRINT ROUTINE”

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 canbe 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 theoutput on the back of the card rack (marked ST). It is advisable to use the printer installation kit (notsupplied). A4 continuous form paper should be used.

NOTE:A BMOS v. 1.8 operating system or later version is required (see INFO page).

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5.10 FAULT MESSAGES

The fault messages are displayed in the area of the display illustrated in the figure.Each message is identified by a four digit number (the first digit indicates the category the messagebelongs to). The messages are divided into five different categories:

1) SHUTDOWN MESSAGESThese messages are displayed when the machine immediately shuts down. Once the troublehas been remedied, clear them by pressing the Reset key.

2) PARTIAL SHUTDOWN MESSAGESThese messages are displayed when the machine immediately shuts down. Once the troublehas been remedied, clear them by pressing the Reset key.

3) MACHINE STOPPAGE MESSAGESThese messages appear when the machine stops at the end of the work cycle in progress.Manual operations are still enabled. Once the trouble has been remedied, clear them bypressing the Reset key.

4) INFORMATION MESSAGESThese messages do not affect the work-cycle or manual operations. Press the Reset key to clearthem.

5) MAINTENANCE MESSAGESThese messages do not affect the work-cycle or manual operations. Press the Reset key to clearthem.

NOTE: In some cases, messages are displayed by the operating system. When this happens, thevideo is completely cleared and the machine shuts down. A detailed description of thesemessages 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, inparticular the TROUBLESHOOTING chapter.

- For further information regarding the sensors/actuators consult the LIST OF DEVICEShandbook.

- The location of the sensors/actuators indicated in the fault messages is given in theSPARE PARTS Manual.

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WHAT TO DO WHEN THE MACHINE STOPS DUE TO MALFUNCTIONING

The machine stops immediately when a “shutdown” message is displayed.When a “stoppage” message appears the machine stops after completing the cycle in progress.

Read the message shown on the first line at the top of the display and then refer to the FAULTMESSAGES chapter for information regarding what caused the shutdown or stoppage. In somecases 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 theelectric connections regarding the input in question.

Other information regarding the machine is provided on the following pages:

Outputs (I/O page)State of all the machine outputs.Information that is useful if an axis or accessory fails to work is given on this page. The state of theoutputs is given so that the ones which should have been activated can be easily located.

Inputs (I/O page)State of all the machine inputs. The state of all the inputs is given on this page.The operator can verify whether the physical inputs match those read by the controller (bymeasuring the input voltage of the card: 0V input not activated, 24V input activated). If the actualstate does not coincide with the one read, replace the input card.

Machine status (STATE)The state of the machine axes is given on this page.The state is given in numeric form for each axis (refer to the chapter that deals with this page for themeaning of the code given).In the event of machine shutdown, the state is decoded and described in the relevant block.

Additional information is given on the DATA page.The pressures and settings of the axes are shown on this page.

ALWAYS TAKE DOWN ALL THE INFORMATION MENTIONED ABOVE SO THAT IT CAN BEREADILY QUOTED WHEN CONTACTING SACMI’s SERVICE DEPARTMENT.MACHINE MALFUNCTIONING CANNOT BE PROPERLY DIAGNOSED IF THIS INFORMATIONIS NOT AVAILABLE.

A detailed description of the messages is given below, in numeric order.

1001 SHUTDOWN PUSH-BUTTON (shutdown)

The shutdown push-button on the keyboard has been pressed.If the push-button has not been pressed, check the keyboard power leads.If the power lead is properly connected and is not broken, try replacing the controlKEYBOARD.If the keyboard works properly, try replacing the MISCELLANEOUS card.

1002 EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E) (shutdown)

One of the external shutdown pushbuttons has been pressed.If this is not the case, check the connector blocks of the external shutdown buttons andrelated wiring connections. Also check the input card (Led SB1E must be on when themachine has not shutdown) and the leads/connectors.

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1003 ANALOG/ENCODER CARD NOT WORKING (1) (shutdown)

The encoder/analog card (EIA) is malfunctioning. If a proportional knockout is provided thefault is to be found in the EIA card in location 6/7. Shut off the controller and replace the card.If the trouble persists, replace the CPU card.Note: This message only appears if a program version earlier than PH12.01.01 is beingused.

1004 PUNCHES NOT FIXED (AJ1/AJ2) (shutdown)

If AJ1 or AJ2 does not appear to the right of the fault message the magnetic lock is enabledbut 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 aremagnetized.Check the setting of current control device AJ1 and check the wiring/operation of the uppermagnetic 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 aremagnetized.Check the setting of current control device AJ2 and check the wiring/operation of the lowermagnetic 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 onefeedback 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 checkwhether the fault is in the upper or lower magnetic lock. Then make the required checks.

1005 CHECK PRESET DATA (shutdown)

If this message appears when the machine is started up or after the CPU card has beenreplaced, check all of the set data.If the message appears at any other time, check the battery for proper functioning (locatedon 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 turnedto SET UP) by pressing the Reset button.

1006 CHECK 24 VEV (shutdown)

No 24 VEV voltage is being supplied.Press the Reset key. If the message is not cleared, check safety module AJ100: if poweris not being supplied (“NETZ” Led off or “POWER” off), check the CPU card, the AL cardand the leads/connectors. If power is being delivered but the two signals (S1 and S2) aredifferent or both of them are off, check the internal and external shutdown buttons, inputSB1E and the leads/connectors.Check three phase rectifier bridge VC 101 located in the power switchboard.Also check the upper BUS, Section 1.

1007 MODE SELECTOR (shutdown)

The key on the machine control keyboard was turned during RESETTING, CYCLE or SEMI-AUTOMATIC operation.If the key was not turned, check selector SA9, its connection to the machine keyboard andthe 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.

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1008 ANALOG/ENCODER CARD NOT WORKING (2) (shutdown)

The second encoder/analog card (EIA) in location 10 is malfunctioning. Shut off thecontroller 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 theENCODER data item).NOTE: this message only appears when a program version earlier than PH12.01.01 is beingused.

1009 MAIN SWITCH TRIPPING (BTn) (shutdown)

This fault message is displayed just before the power to the electrical cabinet is cut off. Thishappens because a fault has been detected in one of the die-set heaters (“n” indicates theheater 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 punchesare 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 electricalcabinet is cut off.With program versions earlier than PH12.01.01: check thermocouple BTn, its inputmodule, the EIA card in location 6/7 and the related leads/connectors. If the problem is thefirst possibility mentioned, check the output card, contactor KMn, feedback relay KAn in theelectrical cabinet and the input card.With program version PH12.01.01 or later: check thermocouple BTn, its conversion cardin box 38, the IA card and the related leads/connectors. If the problem is the first possibilitymentioned, check the output card, contactor KMn, feedback relay KAn in the electricalcabinet and the input card.

1010 SHORT CIRCUIT YVn (shutdown)

The OD and ODA cards have a control device which checks that the current supplied fromeach 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 circuitsin 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 Vsupply for the solenoid valves. To do this, check the respective Led on the power supply (seeINSTRUCTIONS C - paragraph 3.1) and the AL Led on the card which has the short circuitedoutput.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 checkcircuit breaker FS101.If the problem persists replace the output card.

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1011 PRESSURE SWITCH/TRANSDUCER ... bar (shutdown)

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 bypressure switch SP2: check the pressure switch and the ID card (if the pressure is withinthe 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 beendetected by pressure transducer BP1. In this case the message appears when thetransducer detects pressure which is 20 bar above the maximum allowable. Checktransducer BP1, the leads/connectors andWith 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.

1012 IE CARD (shutdown)

The IE card does not work. Turn off the controller and replace the card. If the problempersists replace the CPU card.

1013 CONFIG. (shutdown)

This message is for SACMI personnel only.The press cannot perform any movement.If this message appears when no SACMI engineer is working on the press, contact the After-sales Service Dept. - SACMI, IMOLA

1014 ANALOG CARD DOES NOT WORK (shutdown)

The IA card does not work. Turn off the controller and replace the card. If the problempersists, replace the CPU card.

2001 FAN/FILTERING UNIT (KM11) (shutdown)

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 andKM11).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 theleads/connectors.If KM11A, KM13 or KM14 are indicated in the fault message, check the additional heatexchanger.

2002 HYDR. UNIT PUMP (KM1D) (shutdown)

Input KM1D has stayed off for 30 seconds with the main pump running or the input signalhas remained on for 2 seconds while the main pump is being turned off. The main pump isstopped.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.

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2003 LOW PRESSURIZATION (SP3) (shutdown)

Input SP3 has stayed off for 6 seconds. The main pump is stopped.Check the main pump suction filter for efficiency.Check pressure switch SP3, the input card (Led SP3 must be on when the operatingpressure is within the allowable range) and the leads/connectors.

2004 OIL LEVEL (SL1) (shutdown)

Input SL1 has stayed off for 6 seconds. The pumps are stopped.Check the oil level in the reservoir.Check level sensor SL1, the input card (Led SL1 must come on when the oil exceeds themaximum level mark) and the leads/connectors.

2005 CONNECT THERMOC. (BT4) (shutdown)

The machine will shutdown when this message appears and the main pump will stoprunning.Make sure the thermocouple for the oil is properly connected.With program versions earlier than PH12.01.01:check the input module of thermocoupleBT4 (AP304) and the EIA card in location 6/7.With program version PH12.01.01 or later: check conversion card APBT4 (control unitbox) and the IA card.

2006 TEMP. TOO LOW (BT4) (shutdown)

The oil temperature has remained at a temperature which is too low (less than 2° C) for 30seconds. 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 thermocoupleBT4 (AP304) and the EIA card in location 6/7.With program version PH12.01.01 or later: check conversion card APBT4 (control unitbox) and the IA card.

2007 TEMP. TOO HIGH (BT4) (shutdown)

The oil has remained at a temperature which is too high (over 55° C) for 30 seconds. Themain 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 thermocoupleBT4 (AP304) and the EIA card in location 6/7.With program version PH12.01.01 or later: check conversion card APBT4 (control unitbox) and the IA card.The temperature level reached appears to the right of the fault message.

2008 CHECK (SP11) (shutdown)

The input of pressure switch SP11 has stayed off for 6 sec. while motor control KM11 wason. The pumps are stopped. Check the input card (Led SP11 must be on when motor M11is running) and the leads/connectors.

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2009 REPLACE FILTER (SP1) (shutdown)

Input SP1 has remained inactivated and the oil temperature is above 30°C. The main pumpis 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 pressureswitch SP1, the input card (Led SP1 must be on when the filter is not clogged) and the leads/connectors.

2010 OIL LEAK LEVEL (SL4) (shutdown)

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 thelow level mark) and the leads/connectors.

2011 OIL COCK CLOSED (SQ50) (shutdown)

The pumps are stopped.If this message appears when the oil cock is open, check limit switch SQ50 (which opensthe oil passage), the leads/connectors and the input card (Led SQ50 must be on when thecock is open).

2012 HIGH PRESSURE IN THE CYLINDER (shutdown)

With the safety bar raised, the pressure in the cylinder exceeds 6 bar. The main pump isstopped.Check all the logic elements and solenoid valves of the pressing unit and make sure no faultsare present.If there is no pressure in the cylinder, set the pressure transducer of the cylinder (seeNOTE).If the problem persists, replace pressure transducer BP1.With program version earlier than PH12.01.01:check the input module of transducerBP1 (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 whenthe machine is turned on if digital input SP3 is on (air pressurization approx. 1.5 bar) andthe 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 andthen turn it on again. At this point the pressure displayed is that read by the transducer andthe operator can therefore proceed with the setting procedure: see the INSTRUCTIONSFOR SETTING THE TRANSDUCERS Manual.

2013 REPLACE FILTER (SP6) (shutdown)

Input SP6 has stayed off for 60 seconds and the oil temperature is higher than 30°C.The ENEA COOLING filter needs to be replaced as it is clogged.If the message continues to be shown after the filter has been replaced, check pressureswitch SP6 and the input card (with the filter not clogged led SP6 should be on) and therelated leads/connectors.

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2014 TEMPERATURE TOO HIGH (ST1) (shutdown)

Input ST1 has stayed off for 6 sec. The main pump is stopped. Check the flywheel bearingsto see if they are properly lubricated. Make sure the bearings work properly.

2021 PUNCHES INSIDE (SQ62) (shutdown)

During the automatic cycle, SQ62 has not been energised within 0.5 seconds of the momentwhen 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 solenoidvalve YV193, the leads/connectors and related output card.

2022 HOPPER CLOSING (SQ61) (shutdown)

SQ61 has not been energized within one second of YV221 being de-energized during gateclosing.Check solenoid valve YV221 for proper operation.Check proximity switch SQ61, the input card (with the hopper closed, switch SQ61 must beenergized) and the leads/connectors.Check the output card (Led YV221 must go off when the gate has to close) and the leads/connectors.

2023 LAST DIE-SET D.STROKE (SQ6) (shutdown)

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 SQ6must be on) and the leads/connectors.Check the OD card in location 16 (during the last die-set downstroke, Led YV21 must goout) and the leads/connectors.NOTE: SQ6 must be activated once the die-set has completed the first downstroke andmust 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 than2 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 ODAcard, 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 reada value less than 0.5 mm during the press-strokes. Shut off the controller and then turn itback on and reset the encoders.With 4-cylinder proportional knockout: if the value of encoder A or B is not lower than0.8 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 interfacecard AP207, the serial interface card AP208, the OD card in location 14, the ID card inlocation 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 reada value less than 0.5 mm during the press-strokes. Shut off the controller and then turn itback on and reset the encoders.

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2024 PLUNGER DOWN DUR. DIE-SET UPSTR. (shutdown)

The plunger is below the value set for its upper-most position when the die-sets begin tomove up.

2025 F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59) (shutdown)

The filler box is not completely back when the die-set starts moving upIf “(SQ59)” appears to the right of the fault message, this means the fault has beendiagnosed by upper input SQ59. In this case, check filler box safety switch SQ59 and theIDM card in location 11.If nothing appears to the right of the message, this means that the fault has been detectedby the filler box encoder. In this case, check the filler-box encoder setting. If the latter doesnot 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.

2026 2ND FILLER-BOX FORWARD (KA302) (shutdown)

The position of the second filler-box or LB type filler-box is not correct when the die-sets starttheir upstroke. Check the trigger pulse for the plunger downstroke (KA302) and the relatedinput card.

2027 DIE-SET UPSTROKE (SQ3) (shutdown)

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 mustcome 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 reachthe upper end-stop setting less 2 mm within 8 seconds from when the signal for the die-setupstroke 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 AP206installed 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 reachthe upper end-stop setting less 0.8 mm within 8 seconds of the signal for the die-set upstrokebeing 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 location14, 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 amax. time of 8 seconds. SQ6 should be de-energised within this time and should beenergized when the die-set performs its first downstroke.

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2028 1ST DIE-SET D.STROKE (SQ3/SQ6) (shutdown)

Proximity switch SQ3 is not de-energized or proximity switch SQ6 is not energized within1 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) andthe 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 = Upperend-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 beenreached 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 ODAcard, 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 mmtolerance) has not been reached within 8 seconds from when the signal for the firstdownstroke was sent:Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface cardAP207, 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 andshould remain energized for the rest of the downstrokes and during the press-cycle. SQ3should be energized as soon as the die-set starts to move down.

2029 HOPPER OPEN (SQ60) (shutdown)

SQ60 has not been energized within 1 second of YV221 being energized during gateopening.Check solenoid valve YV221 for proper functioning.Check proximity switch SQ60, the input card (with the hopper open, proximity switch SQ60must 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.

2030 2ND F-BOX TRIGGER P. (KA304) (shutdown)

Digital input KA304 has not come on within 15 seconds from when the signal for starting the2nd 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 inputcard (Led KA304 must be on when the trigger pulse is provided) and the leads/connectors.

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2031 2ND DIE-SET D.STROKE (SQ6) (shutdown)

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 theleads/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 within8 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 ODAcard, 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 mmtolerance) has not been reached within 8 seconds of the signal for the second downstrokebeing sent:Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface cardAP207, 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.

2032 2ND F-BOX TRIGGER P. (KA302) (shutdown)

Digital input KA302 has not come on within 15 seconds of the second die-set downstroke.Check that the second filler box functions and moves properly.Check the trigger pulse contact for the last die-set downstroke (KA302), the input card (LedKA302 must be on when the last die-set downstroke is triggered) and the leads/connectors.

2033 DIE DOWN (SQ63) (shutdown)

SQ63 has not been energized within 0.5 seconds from when = the plunger reached itsuppermost 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.

2034 REPLACE FILTER (SP5) (shutdown)

Digital input SP5 is off and the oil temperature is higher than 30°C.The knockout filter must be replaced as it is clogged.If the message is still displayed after the filter has been replaced, check pressure switchSP5, the ID card in location 12 (when the filter is not clogged, Led SP5 should be on) andthe leads/connectors.

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2035 DIE-SET DEVIATION > 2 mm (shutdown)

With a 2-cylinder proportional knockout: during their upstroke, both proportionalknockout cylinders have exceeded the setting for UPPER END-STOP (DIE-SET SET-UPpage) by more than 3 mm.Try reducing the UPSTROKE SPEED. Check proportional solenoid valves YV22A/22B,axis cards AP204/205 and related ODA card, synchronization card AP203, encoderinterface 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: during their upstroke one or two of the proportionalknockout cylinders have exceeded the setting for UPPER END-STOP (DIE-SET SET-UPpage) by more than 2 mm.Try reducing the UPSTROKE SPEED. Check solenoid valve YV22S, proportional solenoidvalves YV22A/22B, axis card AP210, encoder interface card AP207, serial interface cardAP208, 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.

2036 DIE-SET PARALLELISM ERROR (shutdown)

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 (settingB > 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.

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2037 DIE-SET UP. ERROR (A=..., B=...) (shutdown)

At the filler-box start, the difference between the value measured by one of the two encodersand the upper end-stop is > 0.4 mm. The values measured for cylinders A and B of theproportional knockout are indicated in brackets.Try reducing the setting for UPSTROKE SPEED.With 2-cylinder proportional knockout: Check solenoid valve YV22S, proportionalsolenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronizationcard 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, proportionalsolenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serialinterface 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.

2038 DIE-SET ENCODER RESET (shutdown)

The die-set encoder reset procedure has failed.Check the proportional solenoid valves of the die-set (YV22A, YV22B) for proper operation.Make sure the aux. equipment circuit is under pressure.Make sure the SPE is under pressure (solenoid valves YV22S, YV25).With proportional 2+2 or 4-cylinder knockout:0) No zero-set pulse is emitted from one or both encoders.1) During the first 1 mm upward travel, the encoder on side A has not recorded an adequate

movement2) During the first 1 mm upward travel, the encoder on side B has not recorded an adequate

movement3) During the first 1 mm upward travel, a parallelism error has been found.4) During the upward travel, the encoder on side A has not recorded an adequate

movement.5) During the upward travel, the encoder on side B has not recorded an adequate

movement6) During the upward travel, a parallelism error has been found.7) During the upward travel, the die-set has moved up too quickly.8) At the end of the reset procedure, the value recorded by one or both encoders is not

within +0.5 and -0.5 mm.9) The zero-point signal of one encoder is not recorded. To locate the fault, refer to item

“Zero Position” on the Die-Set display12) With the SPE encoders not reset, when solenoid valve YV 25 (YV22S in the 4-cylinder

SPE) is energised to deliver oil to the SPE, the die-set has moved up more than 2.5 mm.Solenoid valve YV25 or YV22S is de-energised.The proportional solenoid valve has got stuck during upstroke. Check card AX.

With proportional 2-cylinder knockout:Check the “ANALOG” value on the ACTUAL DIE SETTINGS video-page. If the setting ofencoder is less than 0.5 mm or higher than 1.5 mm at the end of a reset procedure theENCODER MUST BE SET UP. (See SETUP PROCEDURES FOR THE PROPORTIONALKNOCKOUT ENCODER).1) At the end of the reset procedure, the analog value read by one or both encoders is not

between 0.5 mm and 1.5 mm.Check the point of contact between the encoder sensor and the mobile part of the die-set. Check the encoder setting on the relevant card installed on the die-set. Make surethere are no blockages which could prevent the knockout from moving down (e.g.

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powder built up under the die-set).3) While the cylinders were moving during the second downstroke (YV21), the value read

by one or both encoders has not exceeded the 0.2 mm setting (digital value).Check for any jammed parts and for hydraulic pressure in the auxiliary equipmentcontrol assembly. Encoder blocked, not working or not connected to electricity supply.Make sure the thickness gauge is adjusted correctly to a setting greater than 0.2 mm.

4) The values read by each of the two encoders for the second downstroke cylinders withYV21 energized differs by more than 0.5 mm (digital value).Check for any jammed parts. The operator has released the encoder but the lockingsystem has remained engaged.An encoder has blocked during operations.

5) The value read by one or both encoders has reached 12 mm (digital value).Encoder not reset (the reset pulse for one or both encoders is not read).

6) A misalignment between the two cylinders of more than 3.5 mm has been detected.Proportional valves connected the wrong way round or malfunctioning. Make sure thehydraulic lines have been completely drained.Make sure the die-set can move freely on both sides without obstructions or excessivefriction.

7) A misalignment between the two cylinders of more than 4.5 mm has been detected.YV22S is de-energized.A proportional valve is malfunctioning (blocked during upstroke); check the Moog andODA cards.

8) Both encoders have read a value of more than 14 mm (YV22S is de-energized).Both proportional valves are malfunctioning (both blocked during upstroke); check theMoog and ODA cards.

9) The electrical signal sent by one of the proportional valves has exceeded 16 mm.Valve malfunctioning (blocked during downstroke) or not connected; check the Moogand ODA cards.Check for any jammed parts.

10) After an electrical signal equal to zero has been sent by a proportional valve, the die-set does not move down.Check for any jammed parts. Proportional valve blocked.

11) During the last stage of the die-set resetting procedure and after a 12 mm electricalsignal has been sent by the proportional valves, one or neither of the cylinders havereached a setting equal to half the signal sent (6 mm).Check for any jammed parts.

12) With the die-set not yet reset and following a reset signal, the die-set is found to moveup more than 2.5 mm (digital value) as soon as YV22S is energised. YV22S is then de-energised.Proportional valve blocked during upstroke; check the Moog and EIA cards.

2039 PERFORM DIE-SET LEARNING (shutdown)

Perform the die-set self-learning procedure. See the DIE-SET SET UP page.

2040 CHECK DIE-SET ENCODER (shutdown)

A fault has been detected in one of the die-set encoders (the difference between the analogvalue and the digital one is > 1 mm). Check the encoder interface card AP206 installed onthe SMU, encoders BQ4 and BQ5 andWith program version earlier than PH12.01.01: input modules AP327/328 and the EIAcard in location 10.With program version PH12.01.01or later: the IA card and the IE card in location 9.

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2041 DIE SETTING NOT REACHED (shutdown)

During the die-set learning procedure one of the two encoders has reached the value setfor 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.

2042 CONTROL UP: PERFORM DIE-SET SELF-LEARNING (shutdown)

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.

2043 AXES CARD ERROR (shutdown)

The card which controls the proportional knockout has emitted a fault signal. Make surethere 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 proportionalsolenoid 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 theSPE, the AX card indicates that there are problems with the feedback of proportionalsolenoid 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.

2044 DIE-SET ENCODER BLOCKED (SQ4) (shutdown)

The proportional knockout cannot be moved because the encoders are blocked.Release them.If the message continues to appear, check the two sensors SQ4 and SQ5, the wiring andIDM card in location 13.

2045 RESET PRESSURE (shutdown)

While the proportional knockout pressure was being reset, one of the two encoders read avalue greater than 0.6 mm (the die-set was not fully down and therefore the reset procedurewas 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.

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2046 KNOCKOUT BETWEEN PUNCHES (shutdown)

The die-set moves up more slowly than the plunger.Try reducing the plunger speed. If the problem persists, try disabling the “knockout betweenpunches” function to see whether a different fault message appears.

2047 ENCODER FAULTY (BQ4A) (shutdown)

Check BQ4A = position of rod-type knockout (linear absolute encoder) and the relatedelectrical wiring.Check card IE, location 9.

2048 TIME-OUT, KNOCKOUT UP (shutdown)

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-typeknockout.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, location9.

2049 TIME-OUT, KNOCKOUT DOWN (shutdown)

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= knockoutinterlock solenoid valve, YV21P= proportional solenoid valve to control the rod-typeknockout.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.

2050 WRONG KNOCKOUT MOTION (BQ4A) (shutdown)

The rod-type knockout has moved in the wrong direction.Proportional valve YV21P may be blocked.Check YV21P= proportional solenoid valve to control the rod-type knockout and card ODA,location 17.Check BQ4A= position of the rod-type knockout (linear absolute encoder) and card IE,location 9.

2053 SAFETY BAR UP (shutdown)

The safety bar has been raised.If the message appears when the safety bar is down, press the Reset key. If the messageremains on the screen, check limit switches SQ51and SQ52 for secure mounting and properoperation. Also check the ID card in location 11 and the leads/connectors. This messageonly appears if LEDS SQ51 and SQ52 (on the ID card in location 11) are on with modeselector SA9 turned to MANUAL or AUTOMATIC.

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2054 ENCODER FAULTY (BQ6) (shutdown)

A fault has been detected in the system which monitors the setting of a plunger encoder (thename of the encoder is specified in brackets).Check the encoder, connecting lead and the encoder card (IE) in location 9 for properfunctioning. Try turning off the control system, removing the IE card and putting it back inand then turning the system on again.

2055 PUNCHES OVERTRAVEL/LIFT RODS (shutdown)

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 (LedSA1 must be on if no contacts are energized) and the leads/connectors.With 4-cylinder proportional knockout: data item PUNCH OVERTRAVEL = YES hasbeen set on the S.P.E. die-set set-up page. Enter NO for this setting.

2056 CHECK (SQ68/SQ67) (shutdown)

The device for changing the die-set is activated (it is out). If this is not the case, checksensors SQ68A, SQ68B, SQ67A, SQ67B (when the hook is in, sensors SQ67 areenergized 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.

2057 REPLACE FILTER (SP4) (shutdown)

Input SP4 has stayed off for 0.5 seconds with the oil temperature higher than 30°C.Replace the filter located on the proportional solenoid valve in the filler-box as it is clogged.If the message is still displayed even after the filter has been replaced, check pressureswitch SP4, the ID card in location 11 (Led SP4 must be on when the filter is not clogged)and the leads/connectors.

2058 PLUNGER ENCODER/ACTUATOR (shutdown)

Approx. 300 msecs. have elapsed since the plunger downstroke began and the plungerspeed is still lower than 4mm/sec.In “proportional” PHs, this fault message may be displayed during the first few plungerdownstrokes just before reaching the impact position. In this case, try restarting the machinebecause 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 thecard 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 andWith program version earlier than PH12.01.01: check the EIA card in location 6/7 if anincremental encoder is installed or the IE card in location 9 if an absolute encoder isinstalled.With program version PH12.01.01 or later: check the IE card in location 8.

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2059 F-BOX ENCODER/ACTUATOR (shutdown)

200 msecs. have elapsed since the filler-box forward stroke signal was sent but the filler-box encoder value has not changed.Check encoder BQ2, its mount and the leads/connectors.With rod-crank mechanism filler-box: check proportional solenoid valve YV20 (seeNOTE), the related electrical wiring and hydraulic lines for proper functioning. Check thepressure in the service circuit.Check solenoid valve YV20S and related electrical wiring. Also inspect YV20 control cardAP201 and the OD card in location 16.If solenoid valve YV20S does not work, also check circuit breaker FS101, mode selectorSA9 and contactors KA102/102A, KA103/103A.NOTE: if proportional valve YV20 is not installed, check solenoid valve YV20A and therelated 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-boxmoving) and the related electrical wiring. Check relays KA20E/20I, inverter U20 and motorM20.- 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.

2060 PWD FEED SHUTOFF AT... c.mm (shutdown)

There is no powder in the die-set.The plunger has reached a value higher than the one set for the STOP DUE TO LACK OFPWD data item. Alternatively, the plunger has reached a value higher than that set for theSTOP DUE TO LACK OF PWD - 1ST data item during the first press-stroke.The setting of the plunger encoder which caused the alarm is indicated in the message.

2061 FILLER-BOX RETURN (shutdown)

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 solenoidvalve 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 fillerbox itself (when the filler box is fully back, led KA302 on the ID card should come on andled SQ59 should go out). Also check the ID card and the KA59 relay.

2062 FILLER-BOX FORWARD (shutdown)

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 solenoidvalve 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 fillerbox itself (when the filler box starts moving, led KA302 on the ID card should go out and ledSQ59 should come on). Also check the ID card and the KA59 relay.

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2063 F-BOX ENCODER RESET (shutdown)

The filler-box encoder reset procedure has failed.With connecting rod/crank filler-box: the encoder zero-point has not been found within8 seconds of the signal to reset the filler-box.Check the encoder for proper functioning. Check proportional solenoid valveYV20 (seeNOTE), its electrical wiring and related hydraulic lines, the service circuit pressure, solenoidvalve YV20S and related wiring, YV20 control card AP201 and the OD card in location 16.If solenoid valve YV20S is not energized check circuit breaker FS101, mode selector SA9and contactors KA102/102A, KA103/103A.NOTE: if proportional solenoid valve YV20 is not installed, check solenoid valve YV20A andrelated electrical wiring;If the proportional valve is installed, YV20A will be identified as 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: with the reset sensor energised the encoder zero point has not beenfound.Check that the encoder is working properly. Check digital outputs KA20E (led on = filler-boxmoving) and KA201 (filler-box forwards/backwards) on the ODA card. Also inspect therelated wiring, 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.

2064 PLUNGER DOWN AT F-BOX START (shutdown)

The plunger is below the value set for its upper-most position when the filler-box begins itsforward/return strokes.If an absolute encoder is installed, check that the value read by the encoder when theplunger is against the end-stop is 0. If this is not the case, repeat the plunger encoder resetprocedure (see AXES RESET page). If the fault persists, try replacing the IE card in location8.

2065 FILLER-BOX BACKWARD (KA302 - SQ59) (shutdown)

When the automatic or semi-automatic cycle is started, the filler-box for double loading isnot fully back. When the filler-box is fully back, input SQ59 should be off and input KA302should come on. Check cards ID in locations 11 and 13.

2066 1ST DOWNSTROKE SIGNAL (KA305) (shutdown)

The signal for the first die-set downstroke sent from the PLC controlled filler-box was notreceived within 15 seconds of the filler-box start.Check the connection for the first die-set downstroke signal and the input card in location13 (when the request is provided Led KA305 must come on).

2067 3RD DOWNSTROKE SIGNAL (KA306) (shutdown)

The signal for the third die-set downstroke was not received from the filler-box for doubleloading.Check the connection for the third die-set downstroke signal and the input card (when therequest is provided Led KA306 must come on).

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2068 WAIT FOR F-BOX TO GO BACK (KA302) (shutdown)

Digital inputs SQ59 and KA302 have not changed over within 15 seconds of the lastdownstroke (when the filler-box arrives at the rear end-stop, led SQ59 should go out andled 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 contactorKA59 and the related press/filler-box leads/connectors.

2069 CHECK (SQ51/SQ52) (shutdown)

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.

2070 CHECK (YV20S) (shutdown)

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 offwhereas when the filler-box is stopped (YV20S de-energized) input SQ20S must be on.Check the ID input card in location 12.

2071 CHECK (SQ58) (shutdown)

The ejector cylinder is malfunctioning. Check the sensor indicated in the fault message andthe ID input card in location 13 (when the sensor is activated the corresponding Led of thecard must be on) and the leads/connectors.

2072 FAULT, FILLER-BOX DRIVE (U20) (shutdown)

Digital input U20 on the ID card in location 13 is not energized.The converter that drives the linear filler-box is malfunctioning or is not energized.Check the two miniature switches SQ20A and SQ20I which, when triggered, shut off thepower supply to the converter.Check the converter and consult the Instruction Manual to locate what is causing the fault.If the converter is not faulty, check the input card (when the converter is running, Led U20must be on) and the leads/connectors.

2073 CHECK (AJ101) (shutdown)

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 cutoutFS100. If power is being delivered but the two signals (S1 and S2) are different or they areboth 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 properoperation. If Leds S1 and S2 stay on and the message remains on the screen, check theinput card (Led AJ101 must be on when the safety bar is down) and the leads/connectors.

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2074 WRONG DIE-SET OP. (A=..., B=...) (shutdown)

The value of one or both die-set encoders has exceeded the Upper End Stop (FCA) settingby more than 0.5 mm or has fallen below it by more than 1 mm during the filler-box forwardstroke (up until the first downstroke).Refer to fault message 2037 for trouble-shooting instructions.

2075 CHECK (SQ53/SQ54) (shutdown)

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 rollerdeck is connected Leds SQ53 and SQ54 on the ID card must be off). After checking, movethe roller deck back and press the Reset key.

2076 FILLER-BOX DID NOT START (KA302 - SQ59) (shutdown)

Digital inputs SQ59 and KA302 failed to change-over within 30 sec. from the moment inwhich the start signal was sent to the PLC controlled filler-box from contact KA20A (whenthe 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 cardOD 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/backsignals from SQ59 and the signals for the plunger downstroke from KA302. In addition,check contactor KA59 and the leads/connectors for the relative press/filler-box.

2077 F.BOX/PLUNGER COLLISION (shutdown)

The linear filler-box has exceeded the safety position (set for the FILLER-BOX SAFETYSETTING data item on the LOADING SET- UP page) and the plunger is lower than the valueset for PLUNGER UP (PRESS CYCLE SET-UP page). Decrease the value set for F.BOXSTART ADVANCE.If this is not enough to solve the problem, try reducing the value set for PLUNGER UP oradjust the UPPER END-STOP PRECISION data item.

2081 MIXER (KM22A) (shutdown)

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

2082 HOMOGENIZER (KM21A) (shutdown)

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) andthe related input card.Check the output card (when the motor has to run, Led KM21A must be on) and the leads/connectors.

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2083 MIXER (KM22B) (shutdown)

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.

2084 HOMOGENIZER (KM21B) (shutdown)

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.

2085 MOBILE HOPPER (KM23I) (shutdown)

The ALM failed to complete its loading stroke correctly.ALM with encoder:- If the ALM does not reach the setting for the end of the forward stroke within 15 secs.,- If the ALM accidentally performs an overtravel beyond the setting for end of backstroke

and does not return to the end of backstroke setting within 15 seconds,check ALM encoder BQ10, the IE card in location 10 and the leads/connectors.ALM with sensors: If limit switch SQ24 is not energised within 15 seconds (the ALM mustbe at the maximum distance from the press)check sensor SQ24 and the input card (with the ALM at the maximum distance from thepress, led SQ24 should be on).Check contactor KM231 and the OR output card (when the ALM moves away from thepress, led KM231 should be on) and the leads/connectors.

2086 MOBILE HOPPER (KM23A) (shutdown)

ALM with encoder: if the ALM does not reach the setting for the end of the backstroke within15 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 ALMshould be near the press).Check sensor SQ23 and the input card (with the ALM near the press, led SQ23 should beon).Check contactor KM23A and the OR output card (when the ALM moves near the press, ledKM23A should be on) and the leads/connectors.

2087 MOBILE HOPPER (SQ23/SQ24) (shutdown)

- With the fixed ALM, limit switch SQ23 is not energized at the filler-box start (the ALMshould 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 operationor ALM reset procedure.Try increasing the ALM speed.

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2088 MOBILE HOPPER (U23) (shutdown)

Digital input U23 on the ID card in location 11 is not energized.The inverter which drives the ALM is malfunctioning.Check inverter U23, the input card (Led U23 must be on when the inverter is running) andthe leads/connectors.

2089 MOBILE HOPPER (SQ25) (shutdown)

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.

2090 REDUCE ALM OPENING DELAY TIME (shutdown)

This fault message is provided with 2-LINE LOADING of the ALM when the second cam forSQ25 or limit switch SQ24 is activated before the time set for OPENING DELAY for the gatehas elapsed.Decrease the value set for the OPENING DELAY data item found on the FITTINGS SETUP page.

2091 MOBILE HOPPER (SQ24S) (shutdown)

Sensor SQ24S was activated while the ALM was being moved back in manual mode orbeing reset. Check sensor SQ24S and the input card (when the ALM is at the end of itsbackwards 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 theend of its backwards overtravel position with the manual control for the back stroke beforecarrying out the operation. If a semi-automatic loading cycle is required, move the ALMforwards before carrying out the operation.

2092 FILLER-BOX FORWARD (shutdown)

If the ALM has to be moved back in manual mode or be reset, move the filler-box fully backbefore carrying out the operation.

2093 MOBILE HOPPER (shutdown)

- With the fixed ALM, the value read by the ALM encoder BQ10 differs from the rear end-stop value by more than 20 mm.Check encoder BQ10, 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 manualoperation or while being reset.Try increasing the ALM speed.

- With an ALM with sensors, make certain limit switches SQ23 and SQ24 are not activatedat the same time. Check the ID card in location 12.

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2096 MOBILE HOPPER (SQ10) (shutdown)

- The position of the ALM during the filler-box return stroke, with the filler-box nearly at theend 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 beingoperated in manual mode or was being reset.Try increasing the ALM speed, check reset sensor SQ10, the IE card in location 9 andthe leads/connectors.

- The ALM encoder zero-point was not found with reset sensor SQ10 energized.Check the ALM encoder BQ10 and the leads/connectors.

2097 ALM ACTUATOR/ENCODER (shutdown)

The ALM encoder value has not changed after 0.75 secs. following the signal for the ALMto move.Check the encoder for proper functioning, check the ODA card in location 18, the OR cardin location 20 (when the ALM needs to move, one of outputs KM23A/KM23I should beenergized), relays KA23A/KA23I, the IE card in location 10, inverter U23, motor M23 andthe leads/connectors.

2098 CHECK (U24) (shutdown)

With the pump running, mode selector SA9 in the manual or automatic position and safetymodules 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 (withinverter U24 in operating mode, digital input U24/KM22AB should be on) and the leads/connectors.

2101 CARRY OUT LOADING (shutdown)

A press-cycle has been attempted before carrying out a loading cycle.

2102 CYLINDER PRESSURE TRANSDUCER (BP1) (shutdown)

The pressure measured by transducer BP1 before the plunger begins its downstroke ismore than 20 bar.Check pressure transducer BP1, the leads/connectors andWith program versions earlier than PH12.01.01: check the input module of transducerBP1 (AP201) and the EIA card in locations 6/7.With program version PH12.01.01 or later: check the IA card in location 7.

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2103 PLUNGER DOWNSTROKE (shutdown)

- If the plunger encoder value does not reach the IMPACT POSITION setting within 8seconds during a downstroke in manual mode;

- if the plunger encoder value does not reach the IMPACT POSITION - BRAKING SPACEsetting (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 valveYV32D and related hydraulic lines for proper operation, inspect the plunger encoder andmake sure it is securely mounted, check the leads/connectors, the ODA card (whensolenoid valve YV32D is energised, the corresponding green LED should be on) andWith program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if theincremental encoder is installed or the IE card in location 9 if the absolute encoder isinstalled.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 upafter receiving a downstroke signal. In this case, replace YV32 and/or card ODA - location17 (YV32D or YV32S with non-proportional presses).

2104 EXCESSIVE BRAKING (shutdown)

- The plunger encoder value does not reach the setting for IMPACT POSITION while theplunger is moving down.

- The plunger encoder value does not reach the setting for PLUNGER UP while the plungeris moving up.

Make sure that the setting for IMPACT POSITION can be reached. Check solenoid valvesYV32D and YV32S and related hydraulic lines for proper operation. Also check the plungerencoder 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) andWith program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if theincremental encoder is installed or the IE card in location 9 if the absolute encoder isinstalled.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 setfor UPPER END-STOP PRECISION.

2105 BRAKING (shutdown)

Make sure that the braking space set is sufficient so that the solenoid valve can workproperly.Check solenoid valve YV47 and the related hydraulic lines for proper functioning. Inspectthe 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.

2106 DIE-SETS UP (SQ3/SQ6) (shutdown)

The die-set is not down when the plunger begins its downstroke. Proximity switch SQ6 isinactivated or SQ3 is activated.Check proximity switch SQ6, the input card (Led SQ6 must be on when the die-sets aredown) and the leads/connectors. Do the same for SQ3.The same fault message will appear on the display when the filler box is moved manuallyand the PROPORTIONAL KNOCKOUT is 0.4mm higher than the set value. In this casemove the die-set manually so as to bring it into the correct position.

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2107 F-BOX FORW. DUR. PLUNGER DOWNSTROKE (shutdown)

The filler-box is not all the way back when the plunger begins to move down. Check the fillerbox encoder setting which should be lower than the REAR END STOP. Try increasing theREAR END STOP setting. If the problem persists check YV20 and card VT 11023.

2108 F.BOX SAFETY SW. (SQ59) (shutdown)

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.

2109 2ND F.BOX SAFETY SW. (KA302) (shutdown)

When the plunger begins its downstroke the trigger pulse from the 2nd filler-box or the LBtype filler-box is not provided. Check limit switch KA302, its mount, the input card (LedKA302 must be on when the 2nd filler-box or LB type filler-box is fully back) and the leads/connectors.

2110 PLUNGER UPSTROKE (shutdown)

In manual mode: the manual upstroke keys have been kept pressed for more than 8seconds.In automatic mode: if upstroke with braking has been selected and plunger encoder has notreached the “end of braking during upstroke” setting;check that the setting for END OF BRAKING DURING UPSTROKE can be reached, checksolenoid 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 cardin location 16 (when solenoid valve YV32S is energised, the related green LED should beon) andWith program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if theincremental encoder is installed or the IE card in location 9 if the absolute encoder isinstalled.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 downafter receiving an upstroke signal. In this case, replace YV32 and/or card ODA - location 17(YV32D or YV32S with non-proportional presses).

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2111 PLUNGER ENCODER RESET (shutdown)

The plunger encoder reset procedure has failed.With incremental encoder: the encoder zero-point has not been found with reset sensorSQ1 energised.With absolute encoders:- If only one encoder is installed: the encoder value is > 5 mm with the safety bar raised- if both encoders are installed: the difference between the values of the two encoders is

> 5 mm.Check solenoid valves YV31D and YV31S for proper functioning.Inspect the plunger encoder, its mount, the plunger reset sensor, the EIA card and the leads/connectors.Check the reset signal for the plunger encoder (see the USER’S MANUAL).If the machine has a double plunger encoder or just one absolute encoder they are to bereset (see AXES RESET).If the message continues to appear, try replacing the IE card. If led HL7 on the IE card doesnot come on when the encoder is reset, try replacing the CPU card.

2112 1ST PRESS STROKE (shutdown)

The set pressure has not been reached within 4 seconds.Check solenoid valve YV40 and the related hydraulic lines for proper functioning.Check pressure transducer BP1, the ODA card (when the solenoid valve is energized,green LED YV40 should be on) and the leads/connectors.With program versions earlier than PH12.01.01: check the input module of transducerBP1 (AP301) and the EIA card in locations 6/7. With program version PH12.01.01 orlater: check the IA card in location 7 and, if the proportional press-stroke is delivered, alsocheck solenoid valve YV318, related hydraulic lines and the ODA card in location 17.

2113 EJECTOR FORWARD (SQ58) (shutdown)

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, LedSQ58 must be on) and the leads/connectors.

2114 DIRECT PRESS STROKE (shutdown)

The set pressure was not reached within 4 seconds.Check solenoid valve YV19 and the related hydraulic lines for proper functioning.Check pressure transducer BP1, the ODA card (when the solenoid valve is energized,green LED YV19 should be on) and the leads/connectors.With program versions earlier than PH12.01.01: check the input module of transducerBP1 (AP301) and the EIA card in locations 6/7.With program version PH12.01.01 or later: check the IA card in location 7 and, if theproportional press-stroke is delivered, also check solenoid valve YV318, related hydrauliclines and the ODA card in location 17.

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2115 BOOSTED PRESS STROKE (shutdown)

The set pressure was not reached within 4 seconds.Check solenoid valves YV38/41 and the related hydraulic lines for proper functioning.Check pressure transducer BP1, the ODA card (when the solenoid valves are energized,green LEDs YV38/41 should be on) and the leads/connectors.With program versions earlier than PH12.01.01: check the input module of transducerBP1 (AP301) and the EIA card in locations 6/7. With program version PH12.01.01 orlater: check the IA card in location 7 and, if the proportional press-stroke is delivered, alsocheck solenoid valve YV318, related hydraulic lines and the ODA card in location 17.

2116 PRESSURE NOT RECUPERATED (shutdown)

The press was not able to restore the correct pressure.PH400 - PH3590: If the cylinder pressure is not lower than the pump pressure + 30 bar (theset pump pressure is approx. 200 bar) within 2 seconds after the end of the press-stroke;PH4200: if the cylinder pressure is not lower than the pressure in the accumulators asdetected by transducer BP3 + 4 bar within 2 seconds after the end of the press-stroke;Check solenoid valves YV19 and YV19A and the related hydraulic lines for properfunctioning.Check pressure transducers BP1 and BP3 (BP3 only with PH4200), the ODA card (whenthe solenoid valves are energised, green LEDs YV19 and YV19A should be on), the leads/connectors andWith program versions earlier than PH12.01.01: check the input module of transducerBP1 (AP301) and the EIA card in locations 6/7. With program version PH12.01.01 orlater: check the IA card in location 7 and, if the proportional press-stroke is delivered, alsocheck solenoid valve YV318, related hydraulic lines and the ODA card in location 17.

2117 CHECK (SQ67/SQ68) (shutdown)

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 usedonly sensors SQ67A/B have to be activated.Check the input card and the leads/connectors.

2118 CHECK (BQ1) (shutdown)

The plunger has carried out a stroke which is longer than the allowable one.Reset the plunger encoder (see the USER’S MANUAL).

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2119 POWDER IN DIE-SET BELLOWS (shutdown)

With 2-cylinder proportional knockout: the difference between the analog and digitalvalues 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 checkencoders 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 mmduring 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.

2120 INCORRECT PLUNGER PARALLELISM (shutdown)

The max. difference (value to be entered in INCORRECT PLUNGER PARALLELISM on thePRESS CYCLE SET-UP page) on the diagonal of the plunger has been exceeded. Thedetected value is the difference between encoders BQ6 and BQ7.

2121 REPLACE FILTER (SP7) (shutdown)

With the oil temperature higher than 30°C, digital input SP7 has stayed off for more than 2.5seconds.Replace the filter of the control line of proportional solenoid valves YV32 and YV318 as itis 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 notclogged) and the leads/connectors.

2122 ACCUMULATOR CHARGE (shutdown)

While the accumulators were being re-charged, the line pressure is less than the pressureof the accumulators or the pressure of the accumulators has not reached the required valuewithin 5 sec. Make sure there is no pressure loss in the main hydraulic circuit line or line forthe accumulators. Check pressure transducers BP2 and BP4, the cables and IA card. Carryout the self-learning procedure for YV309 again (see message 2124).

2123 PERFORM PLUNGER LEARNING (YV32) (shutdown)

For program version PH 13.03.01.7TR and laterThe self-learning cycle for calculating the offset values for proportional valves (YV32,YV318) has been stopped in an incorrect manner.The various cases are examined below. The number that appears on the right side of themessage is given.1. The mode selector switch has been turned from the MAN position or the plunger has

not moved down 1 mm with YV31D energized. Check the solenoid valve for the slowdownstroke, the relative cables and OD card in location 16. If the plunger moves downbut the encoder does not count, check plunger encoder BQ6 and the IE card in location8.

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2. The mode selector switch has been turned from the MAN position or the plunger hasnot moved down 15 mm (19 mm for P1-14200) with YV318 open 35%. Checkproportional solenoid valve YV318, the relative cables and OD card in location 17.Check the solenoid valve for the booster downstroke: solenoid valve YV32M (it shouldbe energized during this stage), solenoid valve YV40 (it should be energized during thisstage) 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 hasnot reached the IMPACT POSITION - 40 mm with YV31D energized.Check the value set for the IMPACT POSITION data item on the press-cycle set-uppage. Check the solenoid valve for the slow downstroke, the relative cables and OD cardin location 16.

4. During the stage in which the offset value for YV32 is determined, the cylinder pressurehas exceeded 10 bar to keep the plunger stationary. Check proportional solenoid valveYV318 (it should be closed during this stage), the relative cables and ODA card inlocation 17. Check the solenoid valve used to put the cylinder under pressure: solenoidvalve YV19 (it should be de-energized during this stage), logic element 117 (it shouldbe closed during this stage), solenoid valve YV40 (it should be de-energized during thisstage), 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 closedduring 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 shouldbe de-energized during this stage) and logic element 118 (it should be opened duringthis stage).

5. During the stage in which the offset value for YV32 is determined, the mode selectorswitch was turned from the MAN position to keep the plunger stationary or the plungerdid not move down with YV31D energized. Decrease the value set for the IMPACTPOSITION data item on the press-cycle set-up page. Check the solenoid valve for theslow 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 selectorswitch was turned from the MAN position to keep the plunger stationary or the plungerdid not move up with YV31S energized.Check the solenoid valve for the slow upstroke, the relative cables and OD card inlocation 16.

7. The mode selector switch was turned from the MAN position or the plunger did not moveup 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 inlocation 16.

8. The mode selector switch was turned from the MAN position or the plunger did not move1 mm down with YV31D energized. The plunger should move up to 26 mm (30 mm forP1-14200). Check the solenoid valve for the slow downstroke, the relative cables andOD card in location 16.

9. During the stage in which the offset value for YV318 is determined, the command to thesolenoid valve has exceeded the maximum allowable value (4095 valve points, givenon page 110). Check proportional solenoid valve YV318, the relative cables and ODAcard in location 17. Check pressure transducer BP5 for the upstroke chamber, therelative cables and IA card in location 7. Check the solenoid valves used to charge theupstroke chamber during this stage: solenoid valve YV19 (it should be energized duringthis 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 thecylinder has exceeded 10 bar or the plunger has reached the IMPACT POSITION - 10mm. In the latter case increase the value entered for the IMPACT POSITION data itemon 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 theupstroke chamber, the relative cables and IA card in location 7. Check the solenoidvalves used to charge the upstroke chamber during this stage: solenoid valve YV19 (itshould be energized during this stage), solenoid valve YV70 (it should be energizedduring this stage). If the pressure in the cylinder has exceeded 10 bar and the plunger

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has reached the material, decrease the value entered for the IMPACT POSITION dataitem on the press-cycle set-up page. Check logic element YV303 which should be openduring 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 solenoidvalve YV318, the relative cables and ODA card in location 17. Check pressuretransducer 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 (itshould be energized during this stage).

12. During the stage in which the offset value for YV32 (downstroke) is determined, theplunger has reached the IMPACT POSITION - 10 mm. Increase the value entered forthe IMPACT POSITION data item on the press-cycle set-up page. Otherwise checkproportional solenoid valve YV32, the relative cables and ODA card in location 17.Check solenoid valve YV303 used for plunger movement (it should be energized duringthis stage) and ODA card in location 17.

13. During the stage in which the offset value for YV32 (downstroke) is determined, thepressure 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 closedduring 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 shouldbe de-energized during this stage), logic element 131 (it should be closed during thisstage), solenoid valve YV38 (it should be de-energized during this stage), logic element120 (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 thisstage).

14. The mode selector switch was turned from the MAN position or the plunger did not reachthe IMPACT POSITION - 20 mm with YV31D energized. Check the value entered forthe IMPACT POSITION data item on the press-cycle set-up page. Check the solenoidvalve 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 plungerhas 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 forplunger movement (it should be energized during this stage) and ODA card in location17.

16. During the stage in which the offset value for YV32 (upstroke) is determined, thepressure 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 closedduring 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 shouldbe de-energized during this stage), logic element 131 (it should be closed during thisstage), solenoid valve YV38 (it should be de-energized during this stage), logic element120 (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 thisstage).

17. The mode selector switch was turned from the MAN position or the plunger did not reachthe mechanical end-stop at the end of the self-learning cycle. The booster may not havemoved up. Make sure the solenoid valves allow upward movement: solenoid valveYV32M (it should be de-energized during this stage) and solenoid valve YV71 (it shouldbe de-energized during this stage).

18. The self-learning procedure has been interrupted because solenoid valve YV32 has gotstuck during the upstroke or downstroke (with solenoid valve YV303 energised and asignal sent to YV32 so that the valve over-center is closed, the plunger travels at a speed> 40 mm/s).

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For program versions PH 12.xx.01.7TRThe self-learning cycle for calculating the offset values for proportional valve YV32 has beenstopped in an incorrect manner.The various cases are examined below. The number that appears on the right side of themessage is given.1. Not used.2. Not used.3. The mode selector switch has been turned from the MAN position or the plunger has

not reached the IMPACT POSITION - 40 mm with YV31D energized.Check the value set for the IMPACT POSITION data item on the press-cycle set-uppage. Check the solenoid valve for the slow downstroke, the relative cables and OD cardin location 16.

4. During the stage in which the offset value for YV32 is determined, the cylinder pressurehas exceeded 10 bar to keep the plunger stationary. Check the solenoid valve used toput the cylinder under pressure: solenoid valve YV19 (it should be de-energized duringthis stage), logic element 117 (it should be closed during this stage), solenoid valveYV307 (it should be de-energized during this stage), solenoid valve YV70 (it should bede-energized during this stage) and logic element 118 (it should be opened during thisstage).

5. During the stage in which the offset value for YV32 is determined, the mode selectorswitch was turned from the MAN position to keep the plunger stationary or the plungerdid not move down with YV31D energized. Decrease the value set for the IMPACTPOSITION data item on the press-cycle set-up page. Check the solenoid valve for theslow 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 selectorswitch was turned from the MAN position to keep the plunger stationary or the plungerdid not move up with YV31S energized.Check the solenoid valve for the slow upstroke, the relative cables and OD card inlocation 16.

7. The mode selector switch was turned from the MAN position or the plunger did not moveup with YV31S energized. The plunger should move up to 30 mm.Check the solenoid valve for the slow upstroke, the relative cables and OD card inlocation 16.

8. Not used.9. Not used.10. Not used.11. Not used.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 forthe IMPACT POSITION data item on the press-cycle set-up page. Otherwise checkproportional solenoid valve YV32, the relative cables and ODA card in location 17.Check solenoid valve YV303 used for plunger movement (it should be energized duringthis stage) and ODA card in location 17.

13. During the stage in which the offset value for YV32 (downstroke) is determined, thepressure in the cylinder has exceeded 10 bar. Check the solenoid valves used to putthe cylinder under pressure: solenoid valve YV19 (it should be de-energized during thisstage), 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 thisstage).

14. The mode selector switch was turned from the MAN position or the plunger did not reachthe IMPACT POSITION - 20 mm with YV31D energized. Check the value entered forthe IMPACT POSITION data item on the press-cycle set-up page. Check the solenoidvalve 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 plungerhas reached 4 mm. Check proportional solenoid valve YV32, the relative cables andODA card in location 17. Check solenoid valve YV303 used for plunger movement (itshould be energized during this stage) and ODA card in location 17.

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16. During the stage in which the offset value for YV32 (upstroke) is determined, thepressure in the cylinder has exceeded 10 bar. Check the solenoid valves used to putthe cylinder under pressure: solenoid valve YV19 (it should be de-energized during thisstage), 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 thisstage).

17. The mode selector switch was turned from the MAN position or the plunger (encoderBQ6) did not reach the mechanical end-stop at the end of the self-learning cycle.

2124 PERFORM YV309 LEARNING (shutdown)

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 keys28 and 7. The procedure takes a few minutes. Once completed, press the Reset key to clearthe message.

2125 START OF PRESS-STROKE SETTING NOT REACHED (shutdown)

During its downstroke the plunger had exceeded the IMPACT POSITION setting but hasnot reached the START OF PRESS-STROKE POS. (or START OF PRESS-STROKETHICKNESS) - 5 mm - within 5 seconds.Check that the value set for START OF PRESS-STROKE POS. can be reached (forexample it could be something in the die-set or soft filling that is preventing the downstrokefrom being performed).

2126 PERFORM SELF-LEARNING (YV32) (shutdown)

The proportional solenoid valve self-learning procedure must be performed before switchingthe press over to automatic or semi-automatic mode (refer to the “self-learning for plungerupstroke/downstroke...” item in the DESCRIPTION OF THE KEYS).

3001 UPPER PUNCH HEATING (KM5) (stoppage)

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 punchesas they fail to close.

3002 UPPER DIE HEATING (KM6) (stoppage)

Check the contact on contactor KM6 for heating the upper die as it fails to close.

3003 LOWER DIE HEATING (KM7) (stoppage)

Check the contact on contactor KM7 for heating the lower die as it fails to close.

3004 LOWER PUNCH HEATING (KM8) (stoppage)

Check the contacts on contactors KM8 and KM8B (optional) for heating the lower punchesas they fail to close.

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3005 CONTACTS STUCK IN CONTACTOR (KM5) (stoppage)

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.

3006 CONTACTS STUCK IN CONTACTOR (KM6) (stoppage)

See message no. 3005.

3007 CONTACTS STUCK IN CONTACTOR (KM7) (stoppage)

See message no. 3005.

3008 CONTACTS STUCK IN CONTACTOR (KM8) (stoppage)

See message no. 3005.

3009 TEMP. TOO HIGH (BT5) (stoppage)

The temperature measured by thermocouple BTn is higher than 110°C (80°C if the punchesare 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 theinput module of the thermocouple and then try replacing the analog card.NOTE: n = 5 upper punchesn = 6 upper dien = 7 lower dien = 8 lower punches

3010 TEMP. TOO HIGH (BT6) (stoppage)

See message no. 3009.

3011 TEMP. TOO HIGH (BT7) (stoppage)

See message no. 3009.

3012 TEMP. TOO HIGH (BT8) (stoppage)

See message no. 3009.

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3013 BRUSH NOT WORKING (KM2A/KM2B ) (stoppage)

Feedback digital input KM2 is off after a signal for brush rotation has been sent (KM2A orKM2B = 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 theleads/connectors.

3014 LACK OF POWDER IN HOPPER (AD1K1) (stoppage)

Digital input AD1K1 is off.Check the powder level in the hopper.Check level sensor AD1K1, the input card (Led AD1K1 must come on when the powderexceeds the maximum level) and the leads/connectors.If Led AD1K1 is off when the powder exceeds the maximum level adjust the sensitivity ofthe powder detector amplifier (AD1).

3015 EXTERNAL STOP (KA300) (stoppage)

Digital input KA300 is off.The line after the press has stopped.Check signal KA300.If the line after the press has not stopped, check the input card (when the line is running LedKA300 must be on) and the leads/connectors.

3016 STOP PUSH-BUTTON (stoppage)

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.

3017 STOP. DUE TO EXT. SYNCH. (KA301) (stoppage)

The outer synchronization contact has remained closed (when the filler-box starts its travel)for more than the maximum allowable time (2 minutes).Check contact KA301, the input card (Led KA301 must be off when the press is running)and the leads/connectors.

3018 BATCH COMPLETED (stoppage)

The production batch has been completed as set for the “PRODUCTION BATCH” data item.

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3019 SERVICE-ACCUMULATORS (stoppage)

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 theaccumulators.

3020 DECREASE RP2 (stoppage)

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 DATAvideo-page.If the problem persists check YV20 and card VT 11023.If the problem persists check the EIA card and the leads/connectors.

3021 INCREASE RP2 (stoppage)

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 DATAvideo-page.If the problem persists check YV20 and card VT 11023.If the problem persists check the EIA card and the leads/connectors.

3022 PLUNGER LEAKS (stoppage)

The plunger has moved down more than 5 mm during the loading cycle.

3023 THICKNESS ERROR > 40 c.mm (stoppage)

A tile thickness deviation greater than 0.4 mm has been indicated. The thickness isautomatically adjusted (the 0.4 mm threshold can be entered).If the thickness measured does not correspond to the actual thickness, check the plungerencoder, its mount, the EIA/IE card (EIA if an incremental encoder is installed, IE if anabsolute one is installed) and the leads/connectors.With SMU and 2-cylinder proportional knockout: Check the automatic filling heightcontrol, motor M9 and contactors KKM9A/KM9B, the OR output card (either output KM9Aor 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, encoderinterface 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.

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3024 CHECK THERMOCOUPLE (BTn) (stoppage)

The die-set heater is on (OUT KMn = ON) but the temperature measured by thermocoupleBTn 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.

3025 WRONG DIE-SET OP. (A=..., B=...) (stoppage)

At the filler-box start the value of one or both die-set encoders has exceeded the setting forUpper End Stop (FCA) by more than 0.4 mm or has fallen below the setting by more than0.6 mm.

3026 CONNECT THERMOC. (BT5) (stoppage)

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 thermocoupleBT5 (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.

3027 CONNECT THERMOC. (BT6) (stoppage)

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 thermocoupleBT6 (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.

3028 CONNECT THERMOC. (BT7) (stoppage)

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 thermocoupleBT7 (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.

3029 CONNECT THERMOC. (BT8) (stoppage)

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 thermocoupleBT8 (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.

3030 PUMP STOP PUSH-BUTTON (stoppage)

The pump stop button on the keyboard has been pressed.If it has not, check the keyboard power cord.If the cord is properly plugged in and is not broken, try replacing the control KEYBOARD.If the keyboard works properly, try replacing the MISCELLANEOUS card.

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3031 LOW PRESSURIZATION/FILTER (SP3) (stoppage)

Digital input SP3 is off.Check the suction filter of the main pump.Make sure the pressurization pressure is sufficient.Check the ID card in location 11 and the leads/connectors.

3032 CLEANING (stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page.

3033 DIE-SET CHANGE (stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page.

3034 SCHEDULED MAINTENANCE (stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page.

3035 SPECIAL MAINTENANCE/REPAIRS (stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page.

3036 CHECK TILE/ADJUST MACHINE (stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page.

3037 PAUSE/WORKSHIFT CHANGE (stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page.

3038 OTHER PROBLEMS (stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page.

3039 TURN SELECTOR SA293 TO ON (stoppage)

Open the controller and turn selector SA293 to engage the proportional knockout.

3040 DIE-SET NOT DOWN (stoppage)

One of the die-set cylinders moved more than 2 mm while the proportional knockout wasbeing hooked.Repeat the procedure for hooking the proportional knockout.

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3041 PLUNGER LEAKS (stoppage)

With 2-cylinder proportional knockout: the plunger moved by more than 1 mm while theproportional knockout was being engaged.With 4-cylinder proportional knockout: the plunger moved by more than 2 mm while theproportional knockout was being engaged.

3042 CHECK (KM3) (stoppage)

Output KM3 is energised but feedback digital input KM3 is off.The oil leak recovery motor has failed.Input KM3 must be closed when the motor is running.Check the input card and the leads/connectors.Check the output card (when the motor has to run, output KM3 must be activated) and theleads/connectors.

3043 FILLER-BOX BACKWARD (stoppage)

The filler-box is further back than its END OF BACKSTROKE setting when the plunger startsto move down or the ALM begins its forward stroke. Bring the filler-box into the correctposition.

3044 REPOSITION (stoppage)

Before starting the automatic CYCLE perform an automatic repositioning procedure.

3045 REPLACE BRUSH (stoppage)

The maximum allowable brush wear set on the FITTINGS SET-UP page has been reached.Replace the brush, press Reset and start up again.

3046 CHECK (SQ59) (stoppage)

Miniature switch SQ59 has been energised (input SQ59 off) at the end of the filler-boxforward stroke (after the first downstroke with a double-loading filler-box) in automatic orsemi-automatic mode.Check the filler-box back miniature switch and related ID card (with the filler-box forward theminiature switch should be inactivated an the input should be on).

3049 CHECK (FILLER BOX FORWARD/BACK TIME) (stoppage)

The time the linear filler box requires to complete its forward and backward stroke deviatesmore than 10% from the pre-determined timeSet the correct time for the filler-box forward and return stroke. If the press does not needto stop, set FILLER BOX CONTROL ON = NO

4001 CYCLE TIME GREATER THAN SYNCH. TIME (message)

The time required for the press to perform a complete cycle is greater than the time set fora synchronized cycle. The number of cycles per minute set cannot be carried out.

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4002 WAIT FOR SYNCH. TIME (message)

The press is stationary and is waiting for the internal synchronization time to elapse.

4003 WAIT FOR EXTERNAL SYNCH. (message)

The press is stationary and is waiting for external synchronization contact KA301 to open.

4004 LOADING CORRECTION NOT ALLOWED (message)

Loading cannot be corrected as the die-sets are not down.

4005 TEMP. TOO HIGH (BT5): ... °C (message)

The temperature of the die-set is high.Do not touch the die-set without wearing heavy duty work gloves.

4006 TEMP. TOO HIGH (BT6): ... °C (message)

The temperature of the die-set is high.Do not touch the die-set without wearing heavy duty work gloves.

4007 TEMP. TOO HIGH (BT7): ... °C (message)

The temperature of the die-set is high.Do not touch the die-set without wearing heavy duty work gloves.

4008 TEMP. TOO HIGH (BT8): ... °C (message)

The temperature of the die-set is high.Do not touch the die-set without wearing heavy duty work gloves.

4009 F-BOX FORW. RUN TIME (message)

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%.

4010 FILLER BOX RETURN TIME (message)

The time taken for the filler-box to perform its return stroke differs from the set value (FILLERBOX RETURN TIME) by more than 5%.

4011 OIL TEMPERATURE (message)

The temperature of the oil is less than 30° C. If the safety bar is raised, under theseconditions, 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 theReset key on the control keyboard.

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4012 FILTER CLOGGED (SP5) (message)

Digital input SP5 is off.Make sure that the filter on the die-set proportional solenoid valve is not clogged. Checkpressure switch SP5, the ID card in location 12 (Led SP5 must be on when the filter is notclogged) and the leads/connectors.

4013 FILTER CLOGGED (SP4) (message)

Digital input SP4 is off.Make sure that the filter on the filler-box proportional solenoid valve is not clogged. Checkpressure switch SP4, the input card (Led SP4 must be on when the filter is not clogged) andthe leads/connectors.

4014 WAIT FOR END OF MOBILE HOPPER CYCLE (message)

The press is stationary and is waiting for the ALM to stop moving.

4015 THICKNESS ERROR > 25 c.mm (message)

Tile thickness is wrong. The thickness is automatically adjusted. The deviation falls within0.25 and 0.4 mm; the max. threshold (0.4 mm) can be entered.

4016 POWDER IN DIE-SET BELLOWS (message)

With 2-cylinder proportional knockout: the difference between the analog and digitalvalues during the press-cycle is more than 1 mm and the encoder value is between 0.3 and0.6 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 between0.3 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.

4017 CHECK PLUNGER SETTING (message)

This message is displayed after a program has been read. Go to the PRESS CYCLE SETUP page and check the data in the square that deals with the PLUNGER.

4018 TOO MUCH TIME TAKEN TO SET DIE-SET (message)

The difference between the value of one or both die-set encoders and the Upper End Stopis > 0.2 mm.The upward movement of the proportional knockout is not very precise and it takes it longerto reach the value set for the UPPER LIMIT data item. To avoid slowing down the cycle, setthe upstroke of the proportional knockout.

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4019 1ST DIE-SET D.STROKE (message)

An error greater than 0.4 mm was detected after the proportional knockout completed itsfirst downstroke.

4020 FILLER-BOX FORWARD (message)

A semi-automatic ALM cycle was requested with the filler-box forwards. Move the filler-boxfully back and try again.

4021 LAST DIE-SET D.STROKE (message)

With the proportional knockout carrying out three downstrokes, an incorrect self-learningvalue for the encoder of the die-set on the cylinders for the last downstroke (YV21) wasdetected. Shut the controller off, turn it back on and then carry out an automatic resettingcycle.If the message is not cleared, check the die-set for the last downstroke.

4022 FILLER-BOX ENCODER NOT RESET (message)

Carry out an automatic resetting cycle to zero set the filler-box encoder.

4023 DIE-SET ENCODER NOT RESET (message)

Carry out an automatic resetting cycle to zero set the die-set encoder.

4024 PLUNGER ENCODER NOT RESET (message)

Carry out an automatic resetting cycle to zero set the plunger encoder.

4025 FILLER-BOX SAFETY GUARD (SQ66) (message)

The filler-box has been moved from its seat. Make sure limit switches SQ66/SQ66A arecorrectly 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.

4026 CONTROL UP PERFORM DIE-SET LEARNING (message)

Carry out the self-learning procedure for the die-set. See the DIE SET SET UP chapter.

4027 WAIT FOR AUTO. RESTART (KA300) (message)

The press is in standby ready to start automatically. No trigger pulse has been sent from thenext machine in line (KA300). When the trigger pulse is emitted the machine will restart.

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4028 CONTROL UP DURING 1ST DOWNSTROKE (message)

It is advisable to perform a die-set self-learning procedure.See DIE-SET SET-UP chapter.

4029 CARD NOT ENERGIZED (ODA 17) (message)

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 switchesSQ66, SQ66A, SQ51, SQ52, SQ53A and SQ53B (optional), contactors KA102, KA103,circuit breaker FS101, mode selector SA9 and safety module AJ101.

4030 INCORRECT PRESSING (message)

The pressure reached during the last press stroke deviates more than 15 bar in relation tothe set value. If the message continues to appear check the solenoid valves (YV19, YV41,YV38), pressure transducer BP1, the leads/connectors andWith program versions earlier than PH12.01.01: the input module of transducer BP1(AP301) and the EIA card in locations 6/7With program version PH12.01.01or later: check the IA card in location 7 and, if theproportional press-stroke is delivered, solenoid valve YV318, the related hydraulic lines andthe ODA card in location 17.

4031 CHECK HEAT EXCHANGER (message)

HEAT EXCHANGER = NO has been set on the FITTINGS SET-UP page but the feedbackdigital input KM11A of the heat exchanger is on.

4032 PLUNGER LEAKS (message)

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.

4033 WAIT (message)

Wait before performing any machine operation.

4034 DIE-SET NOT LOCKED (message)

The proportional knockout is not locked.Lock the die-set.

4035 HYDRAULIC JOINT OIL TEMP. (message)

To ensure top performance of the hydraulic joint in the power unit, wait 10 minutes beforestarting the pump.

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4036 ALM ENCODER NOT RESET (message)

Perform an automatic reset procedure to set the ALM encoder back to zero.

4037 ROLLER CONVEYOR LIMIT SWITCHES (SQ53) (message)

The roller conveyor has been moved away from the press.Check miniature switches SQ53A/SQ53B, the ID card in location 13 (with the rollerconveyor in the work position, digital input SQ53A should be off) and the leads/connectors.

4038 SELF-LEARNING IN PROGRESS (message)

The press is carrying out the self-learning cycle to calculate the offset values for theproportional valves (YV32, YV318). Turn the mode selector switch to stop the cycle.

4039 YV32 OFFSET VALUE TOO HIGH ·[O/D/S] (message)

The offset values for YV32, determined during the self-learning procedure, are too high. If(S) appears on the right side of the message it means the upstroke offset value is too high.(D) appears to signal the downstroke offset value is too high.(O) appears to signal the zero offset value is too high.Carry out the self-learning cycle again with hot oil. If the message is still displayed, replaceYV32 (plunger proportional solenoid valve).

4040 CHECK (BP5) (message)

While the plunger is moving up, the value in the upstroke chamber read by the pressuretransducer is < 10 bar. Check pressure transducer BP5, its cables and the IA card in location7.

4044 ALLOW DIE-SET TO PERFORM LAST DOWNSTROKE (message)

Turn the mode selector to MAN or SETUP and allow the die-set to perform the downstrokein 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.

4048 WAIT FOR TRIGGER PULSE FROM D.I.P. (KA311) (message)

The press is waiting for a trigger pulse from the D.I.P to indicate that the KA311 is ready tooperate.As soon as the trigger pulse has been emitted (input KA311 signal high) the press restartscycling. 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.

4900 MEMORY READ (message)

This message appears for a few seconds when the machine is turned on.

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4901 INVALID DATA IN SERIAL EEPROM (message)

If this message appears when the machine is turned on, contact the CUSTOMER SERVICEDEPT - SACMI IMOLA.

4902 INVALID DATA AFTER SERIAL EEPROM READ (message)

If this message appears when the machine is turned on, contact the CUSTOMER SERVICEDEPT - SACMI IMOLA.

4903 SACMI BMOS V.1.X - MINIMUM BMOS V.1.Y (message)

A CPU card with at least a BMOS v. 1.Y operating system has to be installed in order to runthe program.Check the version. If it is earlier than 1.Y, replace the CPU card. If this is not the case, shutoff the system and then turn it back on.

4904 CHECK CONFIGURATION (message)

If this message appears when the machine is turned on, contact the CUSTOMER SERVICEDEPT - SACMI IMOLA.

4905 ID 13 CARD (message)

The ID card is not present in location 13.Program execution is interrupted.

4910 ERROR DURING PRINTING (message)

Make sure the printer is properly hooked up to the machine controller, power is supplied andthat it is ON-LINE.Remember that the CPU card must have an operating system that is at least BMOS 1.8.

4911 EEPROM FAILURE (message)

If this message appears, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA.

4912 PROGRAM NOT AVAILABLE (message)

The user tried to store a back-up copy of the operating program in an area (in the computer’smemory) which is already occupied by another program. Enter a different program number.

4913 WRONG PROGRAMMED DATA (message)

An error was found while a program was being read. Try to read the program again. If thefault message is not cleared, erase the program.

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4916 OPERATION NOT ALLOWED (message)

A program cannot be read if the machine is set to RESETTING or CYCLE

5001 REPLACE FILTER (SP1) WITHIN ...h (message)

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 theRESET key.The number to the right of the message indicates the number of hours the pump can operatewith the filter clogged.

5002 SCHEDULED MAINTENANCE (80 hrs) (message)

This message appears after the main pump has operated for 80 hours.The maintenance operations which are described in the INSTRUCTIONS MANUAL needto be performed.NOTE: To clear the message, turn the key switch on the machine control keyboard to “SETUP” and press the Reset key.

5003 SCHEDULED MAINTENANCE (200 h)(message)

See message no. 5002.

5004 SCHEDULED MAINTENANCE (500 h)(message)

See message no. 5002.

5005 SCHEDULED MAINTENANCE (2000 h)(message)

See message no. 5002.

5006 SCHEDULED MAINTENANCE (4000 h)(message)

See message no. 5002.

5007 REPLACE DIE-SET (message)

The die-set has already carried out the number of cycles set for the “DIE-SET LIFE INCYCLES” data item on the DIE SET SET-UP page. It needs to be replaced. NOTE: Themessage is cleared by turning the key on the machine control keyboard to SET UP andpressing the Reset key.

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5008 SCHEDULED MAINTENANCE (6,000,000 CYCLES) (message)

See message no. 5002.

5009 CLOGGED FILTER (SP6) (message)

Check to see whether the ENEA COOLING filter is clogged.Check pressure switch SP6, the input card (if the filters are not clogged, led SP6 shouldcome on) as well as the leads/connectors.Note: the message can be cancelled by turning the selector key on the keyboard to SET-UP and pressing the RESET key.

5010 AT END OF BATCH LOAD PROGRAM NO. (message)

Perform the operation requested by the controller.

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5.11 OPERATING SYSTEM MESSAGES

The machine shuts down and the screen is cleared when these messages are displayed. The listof messages is given below:

KEYBOARD ERROR [PE\OE\FE]

Improper communication with the machine control keyboard.Shut off the electrical power and then turn it on again.If the trouble does not re-occur it can be ignored, otherwise check the power cord that hooks thekeyboard up to the miscellaneous card or replace the keyboard and/or “Miscellaneous” (VA) card.Parameter: PE (parity error), OE (overrun error), FE (framing error).

INVALID MEMORY

The program is not valid. Shut off the power supply, make sure the card located on the CPU isproperly plugged in and then turn the power supply back on. If the trouble persists, contact SACMIquoting the alpha-numeric code stamped on the card.

POWER SUPPLY/FUSES nnV

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.

OVERFLOW PROG n LINE nn

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.

DIVIDE ERROR PROG n LINE nn

A division by 0 has been performed.The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears.

PROG n PC nnnn:nnnn CODnn

An instruction not acknowledged was executed. The version of the operating system is probablyprior to the one required by the program.The problem cannot be solved by the customer. Contact SACMI quoting the message as it appearsand the version of the operating system.

OVERFLOW STACK PROG n LINE nn

The pointer stack is outside the allowable limits.The problem cannot be solved by the customer.Contact SACMI quoting the message as it appears.

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TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................. 5

2 WARNINGS ......................................................................................................................... 6

3 MAIN FEATURES OF THE ELECTRIC SYSTEM ............................................................... 7

4 MACHINE CONTROL KEYBOARD .................................................................................. 124.1 DESCRIPTION OF THE KEYS ............................................................................... 134.2 DESCRIPTION OF THE LEDs ................................................................................ 16

5 COMPUTER TERMINAL ................................................................................................... 175.1 DESCRIPTION ........................................................................................................ 175.2 DESCRIPTION OF THE LEDs ................................................................................ 185.3 PAGE LAY-OUT ....................................................................................................... 195.4 NO. OF THE OPERATING PROGRAM ................................................................... 215.5 DATE AND TIME ..................................................................................................... 225.6 DESCRIPTION OF THE WORK-CYCLE ................................................................. 235.7 MACHINE STATUS.................................................................................................. 245.8 LIST OF PAGES ...................................................................................................... 255.9 DATA INPUT & READ-OUT ..................................................................................... 27

5.9.1 “DATA” ......................................................................................................... 275.9.2 “INFORMATION AND LANGUAGE SELECTION” PAGE............................ 295.9.3 AXES CONFIGURATION RESET .............................................................. 315.9.4 “ACTUAL LOADING DATA” PAGE .............................................................. 325.9.5 “ACTUAL PRESS CYCLE DATA” PAGE ..................................................... 335.9.6 “ACTUAL DIE-SET DATA” PAGE ................................................................ 355.9.7 “I/O” PAGE .................................................................................................. 375.9.8 “FAULTS” PAGE .......................................................................................... 395.9.9 “STATISTICS” PAGES................................................................................. 405.9.11 “STATE OF EXECUTION” PAGE ................................................................ 475.9.11 “PRODUCTION DATA” PAGE ..................................................................... 515.9.12 “PROGRAMS” PAGE .................................................................................. 525.9.13 “LOADING SET UP” PAGE ......................................................................... 555.9.14 “PRESS-CYCLE SET UP” PAGE................................................................ 625.9.15 “DIE-SET SET UP” PAGE ........................................................................... 695.9.16 “S.P.E. DIE-SET SET-UP” PAGE ................................................................. 725.9.17 “FITTINGS SET UP” PAGE......................................................................... 765.9.18 “PRINT ROUTINE” ...................................................................................... 79

5.10 FAULT MESSAGES ................................................................................................. 805.11 OPERATING SSTEM MESSAGES ....................................................................... 127

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FAULT MESSAGES LIST

1ST DIE-SET D.STROKE ....................................................................................................................... 1211ST DIE-SET D.STROKE (SQ3/SQ6) ...................................................................................................... 891ST DOWNSTROKE SIGNAL (KA305) .................................................................................................... 981ST PRESS STROKE............................................................................................................................. 1062ND DIE-SET D.STROKE (SQ6) .............................................................................................................. 902ND F-BOX TRIGGER P. (KA302) ............................................................................................................ 902ND F-BOX TRIGGER P. (KA304) ............................................................................................................ 892ND F.BOX SAFETY SW. (KA302) ......................................................................................................... 1052ND FILLER-BOX FORWARD (KA302) .................................................................................................... 883RD DOWNSTROKE SIGNAL (KA306) .................................................................................................... 98

A

ACCUMULATOR CHARGE..................................................................................................................... 108ALLOW DIE-SET TO PERFORM LAST DOWNSTROKE ....................................................................... 123ALM ACTUATOR/ENCODER .................................................................................................................. 103ALM ENCODER NOT RESET ................................................................................................................ 123ANALOG CARD DOES NOT WORK ........................................................................................................ 84ANALOG/ENCODER CARD NOT WORKING (1) ..................................................................................... 82ANALOG/ENCODER CARD NOT WORKING (2) ..................................................................................... 83AT END OF BATCH LOAD PROGRAM NO. ........................................................................................... 127AXES CARD ERROR ............................................................................................................................... 94

B

BATCH COMPLETED ............................................................................................................................. 115BOOSTED PRESS STROKE.................................................................................................................. 107BRAKING ................................................................................................................................................ 104BRUSH NOT WORKING ......................................................................................................................... 114

C

CARD NOT ENERGIZED (ODA 17) ....................................................................................................... 122CARRY OUT LOADING .......................................................................................................................... 103CHECK (AJ101) ........................................................................................................................................ 99CHECK (BP5) ......................................................................................................................................... 124CHECK (BQ1) ......................................................................................................................................... 108CHECK (FILLER BOX FORWARD/BACK TIME) .................................................................................... 118CHECK (KM3) ......................................................................................................................................... 119CHECK (SP11) ......................................................................................................................................... 85CHECK (SQ51/SQ52) ............................................................................................................................... 99CHECK (SQ53/SQ54) ............................................................................................................................. 100CHECK (SQ58) ......................................................................................................................................... 99CHECK (SQ59) ....................................................................................................................................... 118CHECK (SQ67/SQ68) ............................................................................................................................. 107CHECK (SQ68/SQ67) ............................................................................................................................... 96CHECK (U24) .......................................................................................................................................... 103CHECK (YV20S) ....................................................................................................................................... 99CHECK 24 VEV......................................................................................................................................... 82CHECK CONFIGURATION ..................................................................................................................... 124CHECK DIE-SET ENCODER ................................................................................................................... 93CHECK HEAT EXCHANGER.................................................................................................................. 123CHECK PLUNGER SETTING................................................................................................................. 121CHECK PRESET DATA............................................................................................................................. 82CHECK THERMOCOUPLE (BTn) .......................................................................................................... 116CHECK TILE/ADJUST MACHINE ........................................................................................................... 118CLEANING .............................................................................................................................................. 117

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CLOGGED FILTER (SP6) ....................................................................................................................... 127CONFIG. ................................................................................................................................................... 84CONNECT THERMOC. (BT4) ................................................................................................................... 85CONNECT THERMOC. (BT5) ................................................................................................................. 116CONNECT THERMOC. (BT6) ................................................................................................................. 116CONNECT THERMOC. (BT7) ................................................................................................................. 116CONNECT THERMOC. (BT8) ................................................................................................................. 117CONTACTS STUCK IN CONTACTOR (KM5) ......................................................................................... 113CONTACTS STUCK IN CONTACTOR (KM6) ......................................................................................... 113CONTACTS STUCK IN CONTACTOR (KM7) ......................................................................................... 114CONTACTS STUCK IN CONTACTOR (KM8) ......................................................................................... 114CONTROL UP DURING 1ST DOWNSTROKE ....................................................................................... 122CONTROL UP PERFORM DIE-SET LEARNING ................................................................................... 122CONTROL UP: PERFORM DIE-SET SELF-LEARNING .......................................................................... 94CYCLE TIME GREATER THAN SYNCH. TIME ...................................................................................... 119CYLINDER PRESSURE TRANSDUCER (BP1) ..................................................................................... 103

D

DIE DOWN (SQ63) ................................................................................................................................... 90DIE SETTING NOT REACHED................................................................................................................. 94DIE-SET CHANGE.................................................................................................................................. 117DIE-SET DEVIATION > 2 mm ................................................................................................................... 91DIE-SET ENCODER BLOCKED (SQ4) .................................................................................................... 94DIE-SET ENCODER NOT RESET.......................................................................................................... 121DIE-SET ENCODER RESET .................................................................................................................... 92DIE-SET NOT DOWN ............................................................................................................................. 118DIE-SET NOT LOCKED .......................................................................................................................... 123DIE-SET PARALLELISM ERROR ............................................................................................................. 91DIE-SET UP. ERROR (A=..., B=...) ........................................................................................................... 92DIE-SET UPSTROKE (SQ3) ..................................................................................................................... 88DIE-SETS UP (SQ3/SQ6) ....................................................................................................................... 104DIRECT PRESS STROKE ...................................................................................................................... 106

E

EJECTOR FORWARD (SQ58) ................................................................................................................ 106ENCODER FAULTY (BQ4A) .................................................................................................................... 95ENCODER FAULTY (BQ6) ........................................................................................................................ 96EXCESSIVE BRAKING........................................................................................................................... 104EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E) .................................................................................. 81EXTERNAL STOP (KA300) .................................................................................................................... 114

F

F-BOX ENCODER RESET ....................................................................................................................... 98F-BOX ENCODER/ACTUATOR ................................................................................................................ 97F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59) ................................................................................. 88F-BOX FORW. DUR. PLUNGER DOWNSTROKE .................................................................................. 105F-BOX FORW. RUN TIME ....................................................................................................................... 120F.BOX SAFETY SW. (SQ59) ................................................................................................................... 105F.BOX/PLUNGER COLLISION ............................................................................................................... 100FAN/FILTERING UNIT (KM11) .................................................................................................................. 84FAULT, FILLER-BOX DRIVE (U20) ........................................................................................................... 99FILLER BOX RETURN TIME .................................................................................................................. 120FILLER-BOX BACKWARD ...................................................................................................................... 119FILLER-BOX BACKWARD (KA302 - SQ59) ............................................................................................. 98FILLER-BOX DID NOT START (KA302 - SQ59) ..................................................................................... 100FILLER-BOX ENCODER NOT RESET ................................................................................................... 121FILLER-BOX FORWARD ......................................................................................................... 97, 102, 121

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FILLER-BOX RETURN ............................................................................................................................. 97FILLER-BOX SAFETY GUARD (SQ66) .................................................................................................. 122FILTER CLOGGED (SP1) ....................................................................................................................... 125FILTER CLOGGED (SP4) ....................................................................................................................... 120FILTER CLOGGED (SP5) ....................................................................................................................... 120

H

HIGH PRESSURE IN THE CYLINDER..................................................................................................... 86HOMOGENIZER (KM21A) ...................................................................................................................... 100HOMOGENIZER (KM21B) ...................................................................................................................... 101HOPPER CLOSING (SQ61) ..................................................................................................................... 87HOPPER OPEN (SQ60) ........................................................................................................................... 89HYDR. UNIT PUMP (KM1D) ..................................................................................................................... 84HYDRAULIC JOINT OIL TEMP. .............................................................................................................. 123

I

ID 13 CARD ............................................................................................................................................ 125IE CARD.................................................................................................................................................... 84INCORRECT PLUNGER PARALLELISM ............................................................................................... 108INCORRECT PRESSING ....................................................................................................................... 122INCREASE RP2 ...................................................................................................................................... 115INVALID DATA AFTER SERIAL EEPROM READ ................................................................................... 124INVALID DATA IN SERIAL EEPROM ...................................................................................................... 124

K

KNOCKOUT BETWEEN PUNCHES......................................................................................................... 95

L

LACK OF POWDER IN HOPPER (AD1K1) ............................................................................................ 114LAST DIE-SET D.STROKE ..................................................................................................................... 121LAST DIE-SET D.STROKE (SQ6) ............................................................................................................ 87LOADING CORRECTION NOT ALLOWED ............................................................................................ 119LOW PRESSURIZATION (SP3) ................................................................................................................ 85LOW PRESSURIZATION/FILTER (SP3) ................................................................................................. 117LOWER DIE HEATING (KM7) ................................................................................................................. 113LOWER PUNCH HEATING (KM8) .......................................................................................................... 113

M

MAIN SWITCH TRIPPING (BTn) .............................................................................................................. 83MEMORY READ ..................................................................................................................................... 124MIXER (KM22A)...................................................................................................................................... 100MIXER (KM22B)...................................................................................................................................... 101MOBILE HOPPER .................................................................................................................................. 102MOBILE HOPPER (KM23A) ................................................................................................................... 101MOBILE HOPPER (KM23I) ..................................................................................................................... 101MOBILE HOPPER (SQ10) ...................................................................................................................... 103MOBILE HOPPER (SQ23/SQ24)............................................................................................................ 101MOBILE HOPPER (SQ24S) ................................................................................................................... 102MOBILE HOPPER (SQ25) ...................................................................................................................... 102MOBILE HOPPER (U23) ........................................................................................................................ 102MODE SELECTOR ................................................................................................................................... 82

O

OIL COCK CLOSED (SQ50) ..................................................................................................................... 86OIL LEAK LEVEL (SL4) ............................................................................................................................ 86OIL LEVEL (SL1) ...................................................................................................................................... 85

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OIL TEMPERATURE ............................................................................................................................... 120OPERATION NOT ALLOWED ................................................................................................................ 125OTHER PROBLEMS ............................................................................................................................... 118

P

PAUSE/WORKSHIFT CHANGE .............................................................................................................. 118PERFORM DIE-SET LEARNING.............................................................................................................. 93PERFORM PLUNGER LEARNING (YV32) ............................................................................................ 109PERFORM SELF-LEARNING (YV32) .................................................................................................... 112PERFORM YV309 LEARNING ............................................................................................................... 112PLUNGER DOWN AT F-BOX START ....................................................................................................... 98PLUNGER DOWN DUR. DIE-SET UPSTR. ............................................................................................. 88PLUNGER DOWNSTROKE .................................................................................................................... 104PLUNGER ENCODER NOT RESET ...................................................................................................... 122PLUNGER ENCODER RESET ............................................................................................................... 106PLUNGER ENCODER/ACTUATOR .......................................................................................................... 96PLUNGER LEAKS ................................................................................................................. 115, 118, 123PLUNGER UPSTROKE .......................................................................................................................... 105POWDER IN DIE-SET BELLOWS .................................................................................................. 108, 120PRESSURE NOT RECUPERATED ........................................................................................................ 107PRESSURE SWITCH/TRANSDUCER ... bar ........................................................................................... 84PROGRAM NOT AVAILABLE ................................................................................................................. 125PUMP STOP PUSH-BUTTON ................................................................................................................ 117PUNCHES INSIDE (SQ62) ....................................................................................................................... 87PUNCHES NOT FIXED (AJ1/AJ2) ............................................................................................................ 82PUNCHES OVERTRAVEL/LIFT RODS .................................................................................................... 96PWD FEED SHUTOFF AT... c.mm ............................................................................................................ 97

R

REDUCE ALM OPENING DELAY TIME ................................................................................................. 102REPLACE BRUSH .................................................................................................................................. 118REPLACE DIE-SET ................................................................................................................................ 127REPLACE FILTER (SP1) .......................................................................................................................... 86REPLACE FILTER (SP1) WITHIN ...h ..................................................................................................... 125REPLACE FILTER (SP4) .......................................................................................................................... 96REPLACE FILTER (SP5) .......................................................................................................................... 90REPLACE FILTER (SP6) .......................................................................................................................... 86REPLACE FILTER (SP7) ........................................................................................................................ 108REPOSITION .......................................................................................................................................... 119RESET PRESSURE ................................................................................................................................. 94ROLLER CONVEYOR LIMIT SWITCHES (SQ53) .................................................................................. 123

S

SACMI BMOS V.1.X - MINIMUM BMOS V.1.Y ........................................................................................ 124SAFETY BAR UP ...................................................................................................................................... 95SCHEDULED MAINTENANCE .............................................................................................. 118, 126, 127SCHEDULED MAINTENANCE (80 hrs) ................................................................................................. 126SELF-LEARNING IN PROGRESS.......................................................................................................... 123SERVICE-ACCUMULATORS .................................................................................................................. 115SHORT CIRCUIT YVn............................................................................................................................... 83SHUTDOWN PUSH-BUTTON .................................................................................................................. 81SPECIAL MAINTENANCE/REPAIRS ..................................................................................................... 118START OF PRESS-STROKE SETTING NOT REACHED ...................................................................... 112STOP PUSH-BUTTON ............................................................................................................................ 115STOP. DUE TO EXT. SYNCH. (KA301) ................................................................................................... 115

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T

TEMP. TOO HIGH (BT4) ............................................................................................................................ 85TEMP. TOO HIGH (BT5) .......................................................................................................................... 114TEMP. TOO HIGH (BT5): ... °C ................................................................................................................ 119TEMP. TOO HIGH (BT6) .......................................................................................................................... 114TEMP. TOO HIGH (BT6): ... °C ................................................................................................................ 119TEMP. TOO HIGH (BT7) .......................................................................................................................... 114TEMP. TOO HIGH (BT7): ... °C ................................................................................................................ 119TEMP. TOO HIGH (BT8) .......................................................................................................................... 114TEMP. TOO HIGH (BT8): ... °C ................................................................................................................ 120TEMP. TOO LOW (BT4) ............................................................................................................................ 85TEMPERATURE TOO HIGH (ST1) ........................................................................................................... 87THICKNESS ERROR > 0.25 mm............................................................................................................ 120THICKNESS ERROR > 0.4 mm.............................................................................................................. 115THICKNESS ERROR > 25 c.mm ............................................................................................................ 120THICKNESS ERROR > 40 c.mm ............................................................................................................ 115TIME-OUT, KNOCKOUT DOWN ............................................................................................................... 95TIME-OUT, KNOCKOUT UP ..................................................................................................................... 95TOO MUCH TIME TAKEN TO SET DIE-SET .......................................................................................... 121TURN SELECTOR SA293 TO ON .......................................................................................................... 118

U

UPPER DIE HEATING (KM6) ................................................................................................................. 113UPPER PUNCH HEATING (KM5) ........................................................................................................... 113

W

WAIT ....................................................................................................................................................... 123WAIT FOR AUTO. RESTART (KA300) .................................................................................................... 122WAIT FOR END OF MOBILE HOPPER CYCLE .................................................................................... 120WAIT FOR EXTERNAL SYNCH. ............................................................................................................ 119WAIT FOR F-BOX TO GO BACK (KA302) ................................................................................................ 99WAIT FOR SYNCH. TIME ....................................................................................................................... 119WAIT FOR TRIGGER PULSE FROM D.I.P. (KA311) .............................................................................. 123WRONG DIE-SET OP. (A=..., B=...) ................................................................................................ 100, 116WRONG KNOCKOUT MOTION (BQ4A) ................................................................................................... 95WRONG PROGRAMMED DATA ............................................................................................................. 125

Y

YV32 OFFSET VALUE TOO HIGH ·[O/D/S] ............................................................................................ 124