Manual Prensa SACMI

D O C U M E N TA Z I O N E
T E C N I C A
USER’S MANUAL
014AZ002A
HYDRAULIC PRESSES
PH 690 - PH 1000 - PH 1500
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇÃO TÉCNICA
LISH
ENG
014AZ002A
TABLE OF CONTENTS
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TABLE OF CONTENTS
USER’S MANUAL
HYDRAULIC PRESSES
PH 690 - PH 1000 - PH 1500
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
DATE OF PUBLICATION
28.10.2003 - 20.05.2004
VERSIONS
PH690A - 1000A - 1500A
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TABLE OF CONTENTS
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TABLE OF CONTENTS
Page
1 GENERAL INFORMATION ........................................................................................................................1 - 1
1.1 INTRODUCTION ........................................................................................................................ 1 - 1
1.2 WHERE TO KEEP THE MANUAL ............................................................................................. 1 - 1
1.3 HOW TO USE THE MANUAL .................................................................................................... 1 - 1
1.4 USERS OF THE MANUAL ......................................................................................................... 1 - 1
1.5 WARRANTY ............................................................................................................................... 1 - 2
1.6 SUPPLEMENTS ......................................................................................................................... 1 - 2
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR
IN THE MANUAL ........................................................................................................................ 1 - 2
1.8 MACHINE IDENTIFICATION PLATE ..........................................................................................1 - 5
2 MAIN FEATURES ......................................................................................................................................2 - 1

2.1 MACHINE DESCRIPTION ......................................................................................................... 2 - 1
2.1.1 MAIN DEVICES ...........................................................................................................................2 - 1
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ................................................. 2 - 7
2.2 OVERALL DIMENSIONS ........................................................................................................... 2 - 8
2.2.1 PH 690 OVERALL DIMENSIONS ...............................................................................................2 - 8
2.2.2 PH 1000 - 1500 OVERALL DIMENSIONS .................................................................................2 - 9
2.3 TECHNICAL DATA .................................................................................................................. 2 - 10
2.3.1 SPECIFICATIONS ................................................................................................................... 2 - 10
2.3.2 AIRBORNE NOISE LEVELS .................................................................................................... 2 - 12
2.3.3 DUST SUCTION HOODS ........................................................................................................ 2 - 13
2.3.4 RATING PLATE ....................................................................................................................... 2 - 16
2.4 DIAGRAMS .............................................................................................................................. 2 - 17
2.4.1 HYDRAULIC/PNEUMATIC SYSTEM DIAGRAM .................................................................... 2 - 17
2.5 MACHINE OPERATION ........................................................................................................... 2 - 27
2.5.1 COMPRESSED AIR SUPPLY ................................................................................................. 2 - 27
2.5.2 FAST HEATING ....................................................................................................................... 2 - 28
2.5.3 HEAT EXCHANGER AND FILTRATION SYSTEM ................................................................. 2 - 28
2.5.4 MAIN PUMP RUNNING - SAFETY BAR INTERLOCKS ACTIVATED (HIGH POSITION) ..... 2 - 29
2.5.5 PRESSURE TRANSDUCER - SETTINGS .............................................................................. 2 - 31
2.5.6 SAFETY BAR INTERLOCKS INACTIVATED (DOWN) ........................................................... 2 - 32
2.5.7 ENCODER RESETTING .......................................................................................................... 2 - 32
2.5.8 DIE-SET CONTROL CIRCUIT ................................................................................................. 2 - 33
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TABLE OF CONTENTS
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3 SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1
3.1 SAFETY DEVICES ......................................................................................................................3 - 1
3.1.1 SAFETY GUIDELINES ............................................................................................................... 3 - 1
3.1.2 SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE ............................................. 3 - 1
3.2 SAFETY RULES FOR HANDLING .............................................................................................3 - 3
3.2.1 LIFTING PROCEDURES ........................................................................................................... 3 - 3
3.2.2 HANDLING PROCEDURES ...................................................................................................... 3 - 3
3.2.3 PLACING THE LOAD ................................................................................................................. 3 - 3
3.3 INSTALLATION ...........................................................................................................................3 - 4
3.3.1 GUIDELINES ...............................................................................................................................3 - 4
3.4 OPERATOR TRAINING ............................................................................................................. 3 - 5
3.4.1 END-USER ..................................................................................................................................3 - 5
3.4.2 OPERATORS ............................................................................................................................. 3 - 5
3.4.3 MAINTENANCE STAFF ............................................................................................................. 3 - 5
3.5 OPERATING INSTRUCTIONS .................................................................................................. 3 - 6
3.5.1 SAFETY GUIDELINES ............................................................................................................... 3 - 6
3.5.2 AUTOMATIC OPERATION ........................................................................................................ 3 - 6
3.5.3 MANUAL OPERATION ...............................................................................................................3 - 6
3.5.4 SET-UP MODE ...........................................................................................................................3 - 6
3.5.5 INSTALLATION MODE ...............................................................................................................3 - 7
3.5.6 CLEANING ..................................................................................................................................3 - 8
3.6 MAINTENANCE ......................................................................................................................... 3 - 9
3.6.1 GENERAL SAFETY RULES ...................................................................................................... 3 - 9
3.7 MACHINE NOT IN USE ........................................................................................................... 3 - 12
3.7.1 GENERAL RULES ................................................................................................................... 3 - 12
3.7.2 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED .............................................. 3 - 12
3.8 DISMANTLING ......................................................................................................................... 3 - 13
4 INSTALLATION ........................................................................................................................................ 4 - 1
4.1 HOW TO LIFT AND PLACE THE PRESS IN POSITION .......................................................... 4 - 1
4.2 HOOKING UP AND CONNECTING THE MACHINE .................................................................4 - 1
4.2.1 EARTHING THE MACHINE ........................................................................................................4 - 2
4.2.2 INSTALLING AND REMOVING THE DIE-SET ..........................................................................4 - 3
4.2.3 CONNECTING THE DIE-SET HEATER .................................................................................... 4 - 4
4.2.4 MAGNETIC LOCK CONNECTIONS .......................................................................................... 4 - 5
4.2.5 DUST EXTRACTION SYSTEM ................................................................................................. 4 - 5
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Page
5 START-UP PROCEDURE ........................................................................................................................ 5 - 1
5.1 GENERAL .................................................................................................................................. 5 - 1
5.2 PRELIMINARY CHECKS ........................................................................................................... 5 - 1
5.2.1 CHECKS TO BE MADE ............................................................................................................. 5 - 1
5.2.2 MOTOR M11 ...............................................................................................................................5 - 1
5.2.3 MOTOR M1 ................................................................................................................................ 5 - 1
5.2.4 SETTING THE PUMP PRESSURE ........................................................................................... 5 - 2
5.2.5 TOP DEAD CENTER POSITION ............................................................................................... 5 - 2
5.2.6 SAFETY DEVICES ......................................................................................................................5 - 2
5.2.7 AUXILIARY CIRCUIT PRESSURE .............................................................................................5 - 2
5.2.8 FILLER BOX ............................................................................................................................... 5 - 3
5.3 MACHINE ADJUSTMENTS ........................................................................................................5 - 4
5.3.1 ADJUSTING THE KNOCKOUT ................................................................................................. 5 - 4
5.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM ............................................5 - 5
5.3.3 ADJUSTING THE SPEED OF THE FILLER-BOX ......................................................................5 - 6
5.3.4 PLUNGER BRAKING ADJUSTMENT ........................................................................................5 - 8
5.3.5 PLUNGER MOTION SETTING .................................................................................................. 5 - 8
5.3.6 SETTING THE PRESS-CYCLE ................................................................................................. 5 - 8
5.3.7 ADJUSTING THE DIE-SET PROTECTION DEVICE (FOR LACK OF POWDER) ................... 5 - 8
5.3.8 ADJUSTING THE PLUNGER SHOCK ABSORBERS ............................................................... 5 - 9
5.3.9 AUTOMATIC WORK CYCLE ......................................................................................................5 - 9
5.3.10 SWITCHING ON THE CONTROLLER TO MAINTAIN THE PRE-SET SPEEDS ................... 5 - 10
6 OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1

6.1 CONTROLS................................................................................................................................ 6 - 1
6.1.1 CONTROLLER ........................................................................................................................... 6 - 2
6.1.2 ELECTRICAL CABINET ............................................................................................................. 6 - 9
6.2 START UP AND SHUT DOWN PROCEDURES ..................................................................... 6 - 10
6.2.1 DAILY START UP .................................................................................................................... 6 - 10
6.2.2 STOPPING THE MACHINE ..................................................................................................... 6 - 10
6.2.3 EMERGENCY STOP ............................................................................................................... 6 - 10
6.3 DIAGRAMS ILLUSTRATING PRESS OPERATION ................................................................ 6 - 11
6.4 AUTOMATIC CYCLE ............................................................................................................... 6 - 14
6.4.1 FILLER-BOX START ................................................................................................................ 6 - 14
6.4.2 POWDER INFEED ................................................................................................................... 6 - 17
6.4.3 FIRST DIE-SET DOWNSTROKE ............................................................................................ 6 - 17
6.4.4 FILLER-BOX OPERATION ...................................................................................................... 6 - 19
6.4.5 SECOND DIE-SET DOWNSTROKE ....................................................................................... 6 - 20
6.4.6 ADDITIONAL DIE-SET DOWNSTROKE (OPTIONAL) ........................................................... 6 - 21
6.4.7 FAST DOWNSTROKE ............................................................................................................. 6 - 21
6.4.8 DOWNSTROKE WITH BRAKE APPLIED ............................................................................... 6 - 21
6.4.9 DELAY TIME FOR THE 1ST PRESS STROKE ...................................................................... 6 - 21
6.4.10 FIRST PRESS-STROKE .......................................................................................................... 6 - 22
6.4.11 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT
ACCUMULATORS) .................................................................................................................. 6 - 22
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6.4.12 1ST SEPARATE PRESS-STROKE ......................................................................................... 6 - 22
6.4.13 DEAERATION .......................................................................................................................... 6 - 23
6.4.14 SECOND PRESS-STROKE (LAST PRESS-STROKE) ........................................................... 6 - 23
6.4.15 SECOND DIRECT PRESS-STROKE ...................................................................................... 6 - 23
6.4.16 PRESS-STROKE WITH PRESSURE BOOSTER ................................................................... 6 - 23
6.4.17 SECOND SEPARATE PRESS-STROKE ................................................................................ 6 - 24
6.4.18 DIE-SET UPSTROKE .............................................................................................................. 6 - 24
6.4.19 CYLINDER PRESSURE RECOVERY (ONLY FOR PH 1500) ................................................ 6 - 24
6.4.20 UPSTROKE WITH BRAKE APPLIED ...................................................................................... 6 - 25
6.4.21 FAST UPSTROKE ................................................................................................................... 6 - 25
6.4.22 EJECTION ................................................................................................................................ 6 - 25
6.4.23 SFS CYCLE: UPPER FORMING DIE (OPTIONAL) ................................................................ 6 - 25
6.4.24 MOBILE DIE (OPTIONAL) ....................................................................................................... 6 - 26
6.4.25 DIE OVER-TRAVEL ................................................................................................................. 6 - 26
6.4.26 BRUSH OPERATION ............................................................................................................... 6 - 27
6.4.27 MOVEMENTS IN MANUAL MODE .......................................................................................... 6 - 28
6.4.28 RESETTING THE ENCODERS ............................................................................................... 6 - 29
7 ADJUSTMENTS ........................................................................................................................................ 7 - 1
7.1 SETTING THE PH 690 - PH 1000 VARIABLE DELIVERY PUMP ............................................ 7 - 1
7.2 SETTING THE PH 1500 VARIABLE DELIVERY PUMP ............................................................7 - 5
7.3 SETTING AND RESETTING THE POSITION ENCODER ........................................................ 7 - 8
7.3.1 PLUNGER TRANSDUCERS ...................................................................................................... 7 - 8
7.3.2 FILLER-BOX ENCODER (DCL) ................................................................................................. 7 - 8
7.3.3 ALM ENCODER (DCL) ...............................................................................................................7 - 8
7.3.4 FILLER-BOX ENCODER (DCP) .................................................................................................7 - 9
8 MACHINE MAINTENANCE ...................................................................................................................... 8 - 1

8.1 SCHEDULED MAINTENANCE .................................................................................................. 8 - 1
8.2 SPECIAL MAINTENANCE ......................................................................................................... 8 - 4
8.2.1 SERVICING THE PLUNGER BUSHES ......................................................................................8 - 4
8.2.2 FILLING THE RESERVOIR ........................................................................................................8 - 4
8.2.3 DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND LINES ..................................... 8 - 6
8.2.4 CHECKING ACCUMULATOR PRECHARGE ............................................................................ 8 - 8
8.3 TORQUES (NUTS AND BOLTS) ............................................................................................... 8 - 9
8.4 SERVICING THE HEAT EXCHANGER ................................................................................... 8 - 10
8.4.1 REPLACING THE GASKETS .................................................................................................. 8 - 10
8.4.2 SECURING THE TIE RODS .................................................................................................... 8 - 11
8.5 SERVICING THE FIXED DELIVERY PUMPS ......................................................................... 8 - 12
8.6 VACUUM .................................................................................................................................. 8 - 14
9 DECOMMISSIONING ................................................................................................................................ 9 - 1
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GENERAL INFORMATION 1
1 GENERAL INFORMATION
1.1 INTRODUCTION
WARNING!
E0004P
Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts.
This manual contains important information for safeguarding the operators, maintenance staff as well as the machine
itself.
SACMI reserves the right to modify the machine and manual without giving prior notice.
Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
1.2 WHERE TO KEEP THE MANUAL
WARNING!
E0004P
This manual is to be considered an essential part of the machine and must be kept along with it even if the machine is
sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be at hand
so that the operator and maintenance staff is able to rapidly consult it at all times.
1.3 HOW TO USE THE MANUAL
The lay out of this manual allows it to be easily consulted as all the information and instructions provided are grouped
together and divided into chapters and paragraphs. The user has to simply refer to the table of contents.
The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the
operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and
are written in italics, as shown below.
WARNING!
E0004P
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety as it contains
important information and warnings regarding safety.
1.4 USERS OF THE MANUAL
In this manual the machine operators are categorized as follows:

- Operator: this is the person responsible for supervising and operating the machine.
- Routine maintenance men.
For a more detailed description, see the paragraph dealing with OPERATOR TRAINING in chapter 3 - SAFETY
EQUIPMENT AND PRECAUTIONS.
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1.5 WARRANTY
SACMI shall be held responsible only for the machine as it was configured at the time of delivery.
Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnel
or duly authorized by SACMI’S Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
E0004P
ATTENTION!
The machine operators and maintenance staff are not responsible for carrying out operations under warranty, special
maintenance and repairs. These operations are to be performed only by the manufacturers specially trained
technicians. For this reason, these types of operations are not dealt with in this manual.
1.6 SUPPLEMENTS
Information regarding the electric and electronic components is given in three handbooks provided separately. These
handbooks are entitled:
- USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM (Instructions B Manual)
- ELECTRONIC CARDS
- LIST OF DEVICES
The above mentioned handbooks supplement this manual.
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL
DANGER SYMBOLS
General danger
E0004P
Hot surfaces - danger of being burnt

E0002P
Danger - hands can be crushed

E0003P
High tension - danger of being electrocuted

E0007P
Danger of entanglement in moving parts

E0010P
Risk of explosion
E0035P
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WARNING SYMBOLS
O2
It is forbidden to use oxygen to recharge the accumulators

E0034D
ALERT SYMBOLS
Heavy duty gloves must be worn

E0005O
The indicated point must be effectively grounded

E0006O
ADDITIONAL SYMBOLS
A list of tools required to carry out maintenance is provided.

E0009C
SYMBOLS
This symbol indicates the machine version with SMU system.

C1819
Available for the PH 690 - PH 1000 - PH 1500.

Any description or illustration in the User’s Manual which has this symbol next to it refers to this
machine version only.
This symbol indicates the machine version with conventional knockout with rods (TRADITIONAL LIFT SYSTEM).
C2086

Any description or illustration in the User’s Manual which has this sy`rol next to it íefers to this
machine version only.
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This symbol indicates the machine version with linear loading device (DCL)
C1821
Available for the PH 1500.

The descriptions and/or figures accompanied by this symbol refer only to this machine version.
This symbol indicates the machine version with connecting rod/crank mechanism loading device (DCP)

The descriptions and/or figures accompanied by this symbol refer only to this machine version.
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1.8 MACHINE IDENTIFICATION PLATE
PH690 PH1000
PH1500
TIPO
TYPE
MATRICOLA No.
SE R I A L N U M B E R
ANNO
YE A R
VIA SELICE PROVINCIALE 17/A IMOLA - I TA L I A
E0021
E0004P
WARNING!
The machine described in this User’s Manual is designed to operate independently and is therefore equipped with
all the safety devices called for by the 98/37/EEC directive solely in the configuration determined by SACMI,
consisting of:
- hydraulic press PH
- fixed part of filler-box CAL
- mobile part of filler-box CAF - CAS
- powder feeder ALM - ACP - FIXED HOPPER
- tile collector
The installation and lay out of the parts mentioned above are described in paragraph 3.5 RULES FOR
OPERATION in this manual.
The safety requirements are not considered satisfied if parts other than those mentioned above are installed or
if the parts are installed in a way that differs from that described in paragraph 3.5 RULES FOR OPERATION in
this manual (if not expressly approved by SACMI).
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MAIN FEATURES 2
2 MAIN FEATURES
2.1 MACHINE DESCRIPTION
The press is a fully automatic machine especially designed to press ceramic powder to produce floor and wall tiles or
other similar products. Either mechanical or isostatic compacting can be employed depending on the type of die-set
installed. In addition, the machine can produce tiles with powders that have different characteristics (double layer).
The distinctive feature of the machine is that it uses hydraulic power to perform the whole work-cycle: from loading the
die set and performing the press-stroke, to the removal and ejection of the work-pieces. The most important machine
assemblies are described below (the references are given in figure 2.1.1 - OVERALL VIEW).
2.1.1 MAIN DEVICES
MAIN DEVICES MACHINE FRAMEWORK (PH 690)

The self-supporting frame 1 includes the machine base, two columns and the crosshead 3. The latter houses a hydraulic
cylinder within which a double-acting piston 4 slides . The cylinder is attached to the plunger so that it can be effectively
driven. The upper part of the crosshead is designed to contain the hydraulic oil required for machine operation. The
plunger 2 slides on the columns through bronze wear-resistant bushes. The main cylinder operates the plunger. Two
spring shock absorbers 17 move the plunger up during de-aeration.
MACHINE FRAMEWORK (PH 1000 - PH 1500)

The self-supporting frame 1 includes the machine base, four columns and the crosshead 3. The latter houses a hydraulic
cylinder within which a double-acting piston 4 slides . The cylinder is attached to the plunger so that it can be effectively
driven. The upper part of the crosshead is designed to contain the hydraulic oil required for machine operation. The
plunger 2 slides on the columns through bronze wear-resistant bushes. The main cylinder operates the plunger. Two
spring shock absorbers 17 move the plunger up during de-aeration.
HYDRAULIC SYSTEM
Pressure boosters 7, located inside the upper part of the crosshead, generate the pressure directly within the cylinder
so that the programmed press-strokes can be carried out. Several plates (located on the machine body, near the points
of use) hold the valves required to control the operating pressures as well as the logic elements used to operate the
working parts of the press. The following control plates are provided:
- Logic element plate 20 used to control and monitor the pressure required to perform the press cycle.
- Accumulator plate 21 used to control the upward and downward strokes of the machine. It is also provided with a brake
unit which limits the speed of the plunger when the die set is being closed.
- The service plate 22 used to operate the ejector and filler-box.
The hydraulic power unit 27 provides the oil required to operate the actuators, filters the oil and controls the oil
temperature. A fixed or variable-displacement axial-piston pump draws the oil from the reservoir and delivers it to the
hydraulic circuit at the required pressure and flow rate. The hydraulic lines are pressurized to keep out ceramic particles
and extraneous matter. The oil-water heat exchanger is located in the hydraulic power unit and maintains the oil
temperature within the correct operating range. The circuit is provided with a motor-and-pump unit 28 which filters and
cools down the oil. The hydraulic lines 18 are provided with the fittings, pipes and hoses required to join the hydraulic
parts to one another.
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2 MAIN FEATURES
DCP
POWDER FILLER-BOX (PH 690 - PH 1000 - PH1500)
The box feeder is used to fill the die-set and eject the finished tiles. The unit features an assembly (mount 9 and geared
motor 14) which can be removed from the press so that the die-set can be quickly replaced from the rear. While the
latter is being performed the speed of the moving parts is lower than that allowed for by current regulations (16 mm/s)
in order to safeguard the operator. The structure sustains and guides a mobile part which consists of the filler-box body
10. The hopper 11 is mounted over the mobile part. This hopper can be fed directly from the main hopper or a mixer.
The hydraulic motor and gear-box unit mounted on the unit operates the mobile assembly with the aid of a crank
mechanism. With this arrangement, the linear motion is turned into a reciprocating one. The stroke of the mobile part,
the speed and stop time of the hydraulic motor are adjustable. All of the devices which join the filler box to the press
come with quick couplings (electrical, hydraulic, pneumatic and mechanical).
DCL
C1821
POWDER FILLER-BOX (DCL TYPE FOR PH 1500)

The filler box is used to load the powder and eject the formed tiles.
It includes a support frame which can be removed from the press so as to rapidly replace the die-set from the back of
the press. During this stage the mechanical parts move at a speed which is lower than that set by current safety
standards (16 mm/sec) - this avoids hazardous situations for the operator from arising.
The support frame holds up and guides the mobile part of the filler box which includes the actual body and a powder
feed hopper. The latter is mounted over the mobile part of the filler box and may be fed with powder delivered directly
from the main hopper or through a mixer.
The electric motor mounted on the support frame drives the mobile part of the filler box through the use of cogged belts.
The speed and stroke of the filler box as well as the point at which the motor stops can all be set.
All the parts which link the filler box to the press are provided with quick couplings for connection to electrical, hydraulic,
pneumatic or mechanical parts.
TRADITIONAL LIFT SYSTEM

C2086
TRADITIONAL HYDRAULIC EJECTOR (as an alternative to the SMU hydraulic ejector)

PH 690
The device comes with hydraulic cylinders which raise the mobile part of the die at the end of each press-stroke. Its
function is to remove the finished workpiece from the die set. The tiles are ejected from the filler-box as soon as they
have been brought to the same level as the die. The lower punches in the die set then move down creating a cavity which
will then be filled with the material to be compacted. The depth of the cavity can be adjusted manually or automatically
after the thickness of the tiles has been set. The two single acting hydraulic cylinders are operated by separate solenoid
valves. A mechanical device is used to re-position the cylinders.
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MAIN FEATURES 2
PH 1000 - 1500
The device comes with hydraulic cylinders which raise the mobile part of the die at the end of each press-stroke. Its
function is to remove the finished workpiece from the die set. The tiles are ejected from the filler-box as soon as they
have been brought to the same level as the die. The lower punches in the die set then move down creating a cavity which
will then be filled with the material to be compacted. The depth of the cavity can be adjusted manually or automatically
after the thickness of the tiles has been set. The two single acting hydraulic cylinders are operated by separate solenoid
valves. A hydraulic device is used to re-position the cylinders.
C1819
SMU
SMU HYDRAULIC EJECTOR (as an alternative to the traditional hydraulic ejector)
The SMU system features a base plate and a punch holder which incorporates the tile ejector. The system is basically
used to remove the finished tiles from the die set. The tile is brought to the same level as the die and is then ejected
from the filler box. The lower punches in the die set move down, creating a cavity for the material to be pressed. The
depth of the cavity can be set in manual mode from the controller. This operation can also be done automatically after
the desired tile thickness has been set. The two cylinders for the 1st downstroke and the four cylinders for the 2nd
downstroke are controlled by two separate solenoid valves. The over-travel control is used to position the die below the
lower punch level. Operated by a solenoid valve, the control is used to clean and facilitate the removal of the lower
punches.
INTAKE, FILTER AND EXHAUST OPENING FOR THE AIR IN THE DIE SET (only with SMU)
The air which flows in and out of the lower part of the die set passes though a filtration unit 5.
GUARDS AND SUCTION HOODS

The mechanical lock 15 prevents the plunger from accidentally moving down while the die set is being cleaned and
maintenance operations are carried out. Covers 29 are provided to protect the working parts. The suction hoods 16 draw
the dust out of the process zone.
MICROPROCESSOR-BASED CONTROLLER
The microprocessor-based controller 31 is used to program the work-cycle that the press will perform automatically.
The controller consists of the following parts:

- a control keyboard;
- a computer terminal to display the set parameters, operating data and fault messages;
- a number of electronic cards.
The following are connected to the controller:
- a plunger positioner 33: equipment that incorporates a linear encoder which records the position of the plunger and
transmits data to the computer system.
- electrical wiring 30: the latter is based on the same principle as the hydraulic system. It includes all of the electrical
and electromechanical parts found on the press: miniature switches, proximity sensors and related cams, connecting
cables, terminals, etc…
The machine can be equipped with a personal computer (optional) that processes and displays data retrieved by the
microprocessor-based controller along with historical data in real time.
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2 MAIN FEATURES
ELECTRICAL CABINET
The electrical cabinet 32 contains the equipment needed to start and stop all of the motors on the press, the transformers
for the die-set heaters, contactors, thermal relays, fuses, etc....
DIE SET
The forming die 34, which is used to give the pressed powder the required shape, consists of two distinct parts. The
lower part (attached to the base of the machine) incorporates the die, which rests on a number of supports, and the lower
forming punches that are joined to the hydraulic knockout. The upper part, which is attached to the plunger, is provided
with the mounting plate for the upper punches. The die as well as the upper and lower punches is warmed up by electric
heating elements to prevent the powder from sticking.
Three temperature probes continuously measure the temperature of the punches and die. Three separate instruments
can thus control and monitor this important variable.
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MAIN FEATURES 2
FIGURE 2.1.1/A - PH 690 OVERALL VIEW
1 Framework
2 Plunger
3 Crosshead and hydraulic cylinder
4 Hydraulic cylinder
5 Die-set air filtration 16
6 Conventional hydraulic ejector
(as an alternative to the SMU ejector)
7 Pressure booster
8 SMU proportional knockout (as an
alternative to the traditional ejector)
9 Filler-box mount
10 Filler box
11 Hopper
14 Filler-box geared motor
15 Mechanical lock and safety guards
16 Suction hoods
17 Spring shock-absorber
18 Hydraulic lines
20 Logic element plate
21 Accumulator and brake control assembly
22 Knockout and filler-box control assembly
27 Hydraulic power unit
28 Cooling unit (motor-driven pump)
29 Covers
30 Electrical wiring
31 Microprocessor-based control system
32 Electrical cabinet
33 Plunger position control
34 Die-set
35 Control keyboard
2-5
014AZ002A
2 MAIN FEATURES
FIGURE 2.1.1/B - OVERALL VIEW OF PH1000 - PH1500
1 Framework
2 Plunger
3 Crosshead and hydraulic • 20
cylinder 7 •
4 Hydraulic cylinder
5 Die-set air filtration
4
2
3 •
32 • • • 31
•
17 • 35
•
• •
28
34 •
27
1 •
8
6 • 15
30
6 Conventional hydraulic ejector (as an
alternative to the SMU ejector)
7 Pressure booster
8 SMU hydraulic ejector (as an
alternative to the traditional ejector)
9 Filler-box mount
• 10 Filler box
21
11 Hopper
18 33 14 Filler-box geared motor
16 15 Mechanical lock and safety guards
16 Suction hoods
• 14 17 Spring shock-absorber
29 18 Hydraulic lines
10
• 20 Logic element plate
• • • 21 Accumulator and brake control
• assembly
22 Ejector and filler-box control
11 27 Hydraulic power unit
• 5 28 Cooling unit (motor-driven pump
22 • 29 Covers
• 9 30 Electrical wiring
31 Microprocessor-based control system
32 Electrical cabinet
33 Plunger position control
34 Die-set
35 Control keyboard
2-6
014AZ002A
MAIN FEATURES 2
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE
INTENDED USE OF THE MACHINE

The machine is specially designed to compact ceramic powder for the production of tiles.
The emergency stop devices installed have priority over any command to start the machine. As a result, if the machine
is remote controlled it can always be stopped from the machine. In addition, the shut-down signals transmitted from the
machines and equipment located before and after the area where the press-cycle is carried out is always read. The
machine can be restarted only from the push-button panel installed on the machine. However, the run command will
not be executed if the trigger from the machines connected to it is not provided.
WARNING!
E0004
If the machine is remote controlled the operators must be properly instructed regarding its use.
The machine can operate in two modes: manual or automatic. These modes of operation can be selected by using the
selector switch located on the control panels.
UNINTENDED AND PROHIBITED OPERATIONS

The machine must be used only for the tasks it was expressly designed for unless otherwise authorized by the
Manufacturer. The Manufacturer will not be held responsible for any injury to persons or damage to the machine caused
by failure to observe this safety precaution.
MISUSE OR ERRONEOUS USE

The manufacturer shall not be held responsible for any injury to persons or damage to the machine deriving from
incorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use are listed
below:
- personnel not adequately trained to perform the required operations
- fatigue (above all during the night shift) or distraction
- negligence caused by superficiality or wrong habits.
Remember that the machine is to be controlled and run exclusively by expert well trained personnel who are able to:
- correctly operate the machine under normal conditions
- and face any emergencies, this is fundamental!
2-7
014AZ002A
2 MAIN FEATURES
2.2 OVERALL DIMENSIONS
2.2.1 PH 690 OVERALL DIMENSIONS

1000
850
Ø1200
330
MINIMO PER ESTRAZIONE
MINDESTAUSSTOß
WITHDRAWING
MINIMUM FOR
200
530
5400
5000
PH 690
3860
MAX140
3350
3000
550
1300
1920
790
2020 700
1060 1060 TRADITIONAL EJECTOR

1490
AREA DI SERVIZIO
MINIMA
MINIMUM SERVICE AREA
1000
MINIMALES BEDIENFELD
1830
2870
820
1450
1870
1750
500
1020
1200
2060
1100 1390
C1241
2-8
014AZ002A
MAIN FEATURES 2
2.2.2 PH 1000 - 1500 OVERALL DIMENSIONS
MINIMUM FOR WITHDRAWING
MINIMO PARA DESMOLDEO

MINIMO PER ESTRAZIONE
I
MINDESTAUSSTOß
Ø1500
M
200
P
O
PH 1000 D E
R
140
A
600
1920
F
770
00
B1
B
C 900
TRADITIONAL EJECTOR
H 910
2450
1300
B
AREA DI SERVIZIO MINIMA
MINIMUM SERVICE AREA
MINIMALES BEDIENFELD
810
AREA DE SERVICIO MINIMA

1900
450
1600
3900
L
C1240
2905
PH 1000 PH 1500
A (mm) 3170 3850
B (mm) 210 330
1270
B1 (mm) 380 330

C (mm) 2250 2340
D (mm) 3920 4180
E (mm) 4530 4650
F (mm) 1550 1600
G (mm) 1720 1900
H (mm) 1370 1405
I (mm) 1300 1700
L (mm) 1500 1700
M (mm) 525 880
N (mm) 700 500
O (mm) 5000 6000
P (mm) 5700 6500
G 600 R (mm) 3200 4000
2-9
014AZ002A
2 MAIN FEATURES
2.3 TECHNICAL DATA
2.3.1 SPECIFICATIONS
PERFORMANCE PH 690 PH 1000 PH 1500

Max. soft clay filling with traditional lift system mm 40 60 60
with SMU (standard) mm 35 35 35
with SMU (special available on request) mm 50 50 50
Max. plunger stroke mm 140 140 140
Column diameter mm 220 200 240
Distance between columns mm 1300 1550 1600
Distance between press table and plunger mm 550 600 600
Max. withdrawing force kN 96 96 96
Max. pressing force kN 6000 10000 15000
Max. cylinder pressure bar 306 352 340
Cycles per minute up to 34 25 25
Strokes per cycle 1-2-3 1-2-3 1-2-3
ELECTRICAL SYSTEM PH 690 PH 1000 PH 1500

Voltage: Aux. circuitry V ac 110 110 110
Die-set heating V ac 50 50 50
Solenoid valves (regulated) V 24 24 24
Power: Main motor with fixed delivery pump (50 Hz) kW 45 55 75
with variable delivery pump (50 Hz) kW 45 55 55
Heat exchanger pump motor (50 Hz) kW 7.5 7.5 7.5
Die-set heater (standard punches) (50 Hz) kW 10 + 10 10 + 10 10 + 10
Die (50 Hz) kW 4 4 4
Controller (50 Hz) kW 1 1 1
Magnetic lock kW 1.6 1.6 1.6
Sound-proof booth fan kW 0.25 0.25 0.25
Enea cooling (optional) kW 7 7 7
Sacmi exchanger (optional) kW 9 9 9
In-line filler-box control kW 7 7 7
Double loading control kW 2.5 2.5 2.5
Auxiliary circuits kW 1 1 1
2 - 10
014AZ002A
MAIN FEATURES 2
HYDRAULIC SYSTEM PH 690 PH 1000 PH 1500
Hydraulic oil: system capacity l 380 600 800
Cleanliness rating at press inlet in accordance with ISO 4406:1999
Specifications see Lubrication guide for machinery used in the ceramic industry 200.02.A01ª
Max. operating pressure in the hydraulic power unit bar 170 180 180
Accumulators Main circuit: capacity l 20+20 20+20 20+20
precharge pressure bar 110 110 110
Aux. circuit: capacity l 12 12 12
SMU die control: capacity l 2.5 2.5 2.5
precharge pressure bar 110 110 110
Main filter Filtration capacity µ 10 10 10
Filter cartridge in tank Filtration capacity µ 250 250 250
Plate type filter cartridge Filtration capacity µ 10 10 10
Cooling system: Heat to be dissipated with fixed delivery pump kcal/h 30000 45000 52000
with variable delivery pump kcal/h 25000 33000 32000
Water consumption at 20° with fixed delivery pump l/1' 50 65 70
with variable delivery pump l/1' 28 30 30
Water pipe connection diameter 1"1/2-3/8" 1"1/2-3/8" 1"1/2-3/8"
Hoses, Inside diameter mm 40/10 40/10 40/10
Max. pressure bar 4 4 4
Pressurization, Max. pressure (with plunger raised) bar 1.5 1.5 1.5
KNOCKOUT PH 690 PH 1000 PH 1500

Gearbox lubrication: EP oil viscosity ISO VG 320 ISO VG 320 ISO VG 320
WEIGHTS
Weight Press body kg 17000 27000 38500
Hydraulic power unit kg 890 890 890
Aux. equipment (controller, electrical cabinet, filler-box, etc.) kg 2800 2800 2800
ATTENTION!
E0004P
All the specifications of the oil to be used in he hydraulic system are given in Instructions manual 200.02.A01
LUBRICATION GUIDE FOR MACHINERY USED IN THE CERAMIC INDUSTRY.
2 - 11
014AZ002A
2 MAIN FEATURES
2.3.2 AIRBORNE NOISE LEVELS
Test conditions
- Operating conditions :( in compliance with ISO/DIS 11202 standard, point 9.5):
- Simulation: pressing on wooden element.
- Sound-proof booth provided
- Type of operation:
Pressing of ceramic material.
- Operating cycle:
Die-set loading, one or more press-strokes with air vent, press-cycle for final product formation.
- Test conditions:
PH 690 PH 1000 PH 1500
Cycles/minute 15.4 14 17.2
Hydraulic power unit pressure (bar) 170 180 180
Operating pressure (bar) 280 300 300
- Test environment:
Press testing division, SACMI Imola.
Instruments employed
Class 1 instruments (IEC 804)
Sound pressure level (ISO/DIS 11202)

Sound power level (ISO 3746)
Values measured:
PH 690 PH 1000 PH 1500

LpA P1 72.5 72 73.5
(dBA) P2 74.5 76 75.5
LwA 92 95 94
(dBA)
LpA Continuous A-weighted sound pressure level.

LwA Acoustic power level in dB weighted A.
P1 = Occasional control post

P2 = Noisiest position of the ideal machine perimeter measured at floor level.
Figure 2.3.2 - POINTS WHERE NOISE LEVEL IS MEASURED
P2
PH690 C1071
C1071 P1
PH1000 P1 PH1500 P2
2 - 12
014AZ002A
MAIN FEATURES 2
2.3.3 DUST SUCTION HOODS
PH 690 DUST SUCTION HOODS

Dust is let into the atmosphere during normal machine operation. The press is equipped with suction hoods designed
to capture the dust particles. These hoods are to be connected to a suitable suction system. A drawing illustrating the
points where the hoods are installed along with the air delivery rates required for proper operation is given below.
Suction outlet ID NO. of Outlet diameter Total delivery Height from floor
symbol outlets (mm) qt (m3/h) (m)
Front hood S250 1 120 814 +2.0

Rear hood S260 1 120 814 +2.0
Brushes (1) S270 4 100 2260 +1.4
Hopper (19) S150 1 100 565 +6.4
Rear powder level limit P004 1 80 543 +1.0
Front powder level limit P002 1 70 416 +0.2
Powder level limit, Brushes (1) P003 2 60 610 +0.2
Powder level limit, Cleaning P010 1 50 212 +0.8
NOTES: (1) Outlets present on the RPR tile roller conveyor

(19) Point of use not shown in the drawing
NOTE: Suction system vacuum before

reaching the press must fall within
“130 and 150” mm of H2O
P004
(= “0.0126 and 0.0145” bar).
NOTE: Use anti-static tubes to connect S260

the hoods to the suction system.
P010
S250
P002
P003
S270
S270
S270 S270
P003
C2103
2 - 13
014AZ002A
2 MAIN FEATURES
PH 1000 DUST SUCTION HOODS
Front hood S250 2 90 916 +2.0

Rear hood S260 1 120 814 +1.7
Brushes (1) S270 4 100 2260 +1.4
Hopper (19) S150 1 100 565 +6.7(2)

(2) +6.2 m for service floor H = 5000
P004
NOTE: Suction system vacuum before reaching
the press must fall within “130 and 150”
mm of H2O
(= “0.0126 and 0.0145” bar).
NOTE: Use anti-static tubes to connect the

hoods to the suction system.
S260
P010
S250 S250
P002
S270 S270
S270 S270
C2104
2 - 14
014AZ002A
MAIN FEATURES 2
PH 1500 SUCTION HOODS
Front hood S250 2 90 916 +2.0

Rear hood S260 1 120 814 +2.0
Brushes (1) S270 4 100 2260 +1.4
Hopper (19) S150 1 100 565 +6.7(2)

(2) +6.2 m for service floor H = 5000
Left
version
P004
NOTE: Suction system vacuum before

reaching the press must fall within
“130 and 150” mm of H2O
(= “0.0126 and 0.0145” bar).
S260
NOTE: Use anti-static tubes to connect
the hoods to the suction system.
S250 P010
P002 S250
S270 S270
S270 S270
C2102
2 - 15
014AZ002A
2 MAIN FEATURES
2.3.4 RATING PLATE
Figure 2.3.4 - RATING PLATE
PH 690
V Hz In A V Hz In A
Cod. Cod.
N° Com. N° Com.
E0012 E0012
PH 1000 - 1500
V Hz In A V Hz In A
Cod. Cod.
N° Com. N° Com.
E0012
E0012
2 - 16
014AZ002A
MAIN FEATURES 2
2.4 DIAGRAMS
2.4.1 HYDRAULIC/PNEUMATIC SYSTEM DIAGRAM
A block diagram is provided in order to highlight the different separate areas in the machine. The hydraulic and
pneumatic parts are listed according to the identification numbers they have been assigned with so that their functions
can be easily and properly found.
Block diagram
A - Prefilling tank
B - Press-stroke control
C - Upstroke, downstroke and braking control
D - Services control
E - Knockout control
F - SMU die control (optional)
G - Filler-box proportional control (optional)
H - 3rd die-set downstroke (optional)
I - SFS control (optional)
L - Mirror-finished die-set control (optional)
M - Automatic rod lock control (optional for PH 690)
N - Hydraulic power unit with fixed delivery pump
O - Hydraulic power unit with variable delivery pump (optional)
P - Hopper gate control
Q - Blower circuit (optional)
R - Mobile brush pneumatic control (optional)
S - Mobile brush pneumatic system (optional)
T - Filler-box motor
U - Filler-box double speed control (optional)
2 - 17
2
2 - 18
75 271 73 72
74
P P P
71 YV290
A
B 272 R 264
P
275 273 265 266
YV173
125 120 119 118 117 116 131
277 267
126
223 222 YV192
SP2 YV221
YV38 YV70 YV19 YV40 YV41 194
BP1 T T T T 224
13
SQ60
36
SQ61
Q
014AZ002A
M2 M 269
269
124
MAIN FEATURES
28 YV47a C 27 18 270
123 269
174 109 108 S 269
115
247 M15 132 92 270
M
90 114
YV31d YV31s YV32d YV32s YV53
122
BQ1 BQ3
OPT YV47
SFS 184 184
258
82
144
179 SMU SQ3 154
179 180 181 189 189 181 180 179 SQ50a
101 101 179 R
STAMPO
DIE-SET SQ6
STAMPO 48
H2O
112
YV279
H2O
Figure 2.4/A - PH 690 HYDRAULIC AND PNEUMATIC SYSTEM
ESTRATTORE
KNOCKOUT M11
SP1
130 55 58
146 1a
M
P
SQ59a
2a 136
T 49 78
YV129s 42 79 248
56 M BT4
M1
57 SP3 O
T A
M11
H2O
58 N
145 23 P M 48
250 249 145
155 24 24 12
10 H2O
141 142 67
62 49 78
YV172 YV193 141 M
142 M1 BT4 79
YV20a 57
337 43
YV11r
YV11b
YV11a
143 SP3 SP1 248 YV279

338
SQ20s 112a
183 YV20b
339 169 242 61 140
183 5
143 YV20s
T
111
140 336 YV170 YV21 YV22 6
YV135 T T YV20a 188
YV129
251 252
SP4
248
M L I H E F U G D C2204
75 271 73 72
74
P P P
71 YV290
A
B 272 R 264
P
275 273 265 266
YV173
125 120 119 118 117 116 131
277 267
126
223 222 YV192
SP2 YV221
YV38 YV70 YV19 YV40 YV41 194
BP1 T T T T 224
13
SQ60
36
SQ61
Q
M2 M 269
269
124
C 27 18 270
123 269
174 109 108 S 269
115
247 M15 132 92 270
M
90 114
YV31d YV31s YV32d YV32s YV53
122
BQ1 BQ3
OPT YV47
SFS 184 184
258
82
144
179 SMU SQ3 154
179 180 181 189 189 181 180 179 SQ50a
101 101 179 R
STAMPO
SQ6 48
STAMPO
H2O
112
YV279
H2O
ESTRATTORE M11
SP1
130 55 58
146 1a
M
P
SQ59a
2a 136 78
YV129s T 42 49 79 248
56 M BT4
M1
57 SP3 O
Figure 2.4/B - PH 1000 HYDRAULIC AND PNEUMATIC SYSTEM DIAGRAM
T A
M11
H2O
58 N
145 23 P M 48
250 249 145
155 24 24 12
10 H2O
142 67
141 62 49 78
YV172 YV193 141 M
142 M1 BT4 79
YV20a 57
337 43
YV11r
YV11b
YV11a
T P SP3 SP1 248 YV279

338 143
SQ20s 112a
183 YV20b
339 169 242 61 140 5
183 143
T YV20s
111
140 336 YV170 YV21 YV22 6
YV135 T T YV20a 188
YV129
251 252
SP4
MAIN FEATURES
248
2
014AZ002A
2 - 19
2
2 - 20
75 271 73 72
74
A 71
YV290
B P 272 R 264
275 273 265 266

125 YV173
120 118 117 116 131
119
126 277 267
223 222 YV192

Y
SP2 YV221
YV38 YV70 YV19 YV40 YV41 194
V
BP1 P
224
13
PC
SQ60
36 SQ61
014AZ002A
Q
PEL
SM PEL
M2 M 269
269
MAIN FEATURES
124
C 27 18
270
123 269
Y 174 109 108 115 269
M15
S
247 132 92
PS PS 270
Y M R
90
114
YV31d YV31s YV32d YV32s YV53 A
B
122 P
BQ3 A R
BQ1 YV47
OPT A R
T
184 184 144 SQ50a BT4 U
SFS
82
T
258 154 YV99
HO
2
T P1
112
48
179 YV279
179 SMU
SQ3
HO
180 181 189 189 181 180 2
101 101 179 179
STAMPO
SQ6 SP1
STAMPO
79
M11
M
49 78
Figure 2.4/C - PH 1500 HYDRAULIC AND PNEUMATIC SYSTEM
ESTRATTORE
130 58
55 SP3
146 1a
P
P
SQ59a
2a 136 M1
YV129s T 42 M
O
56
A R
A R
T
144 SQ50a U BT4
82
154
T P1
HO
2
145 SP1 48
23 145 M11 YV279
250 249 24 24 12
155 49 HO
10 78 2
141 67
YV172 YV193 142
62 141 79
58
142 YV20a M
P SP3
337 43 P
YV11r
YV11b
143
338
M1
183 SQ20s 112a
YV20b
339 169 242 61 5 M N
183 140
143 YV20s
111
YV135 140 336 YV170 YV21 YV22 YV20a 6
188
YV129
251 252
P P P P
SP4 P
P
T T T T
248
014AZ002A
MAIN FEATURES 2
Figure 2.4/D - LOGIC ELEMENT ASSEMBLY
120
131
YV38
YV41 119
116
118
YV40
117
SP2
YV19 YV70
BP1 C0531
2 - 21
014AZ002A
2 MAIN FEATURES
Figure 2.4/E - PH 690 BRAKE UNIT CONTROL
Figure 2.4/F - PH 1000 - PH 1500 BRAKE UNIT CONTROL
2 - 22
014AZ002A
MAIN FEATURES 2
Figure 2.4/G -FILLER-BOX AND LIFT CONTROL ASSEMBLY
Figure 2.4/H - SERVICE CONTROL Figure 2.4/I - SMU CONTROL ASSEMBLY

ASSEMBLY YV21
YV22
YV11r - YV11b
YV11a
10 C2207
112a 242
61
111
62 23
C2082
188
C2096
Figure 2.4/L
FILLER-BOX DOUBLE FILLER-BOX PROPORTIONAL
SPEED CONTROL CONTROL
YV20s - SQ20s
YV20a Figure 2.4/M - SMU CONTROL

ASSEMBLY
YV20b SP4 YV129 141

252
140
12
YV20a
183
251
43
145
C2084
142
C2085
2 - 23
014AZ002A
2 MAIN FEATURES
Figure 2.4/N - SFS CONTROL ASSEMBLY Figure 2.4/O - MIRROR FINISHED DIE-SET
CONTROL ASSEMBLY
141
337 140
YV172
C2089
155
339
YV193
C2088
183
142
338 250 143 145

249
C2096
Figure 2.4/Q - AUTOMATIC ROD

Figure 2.4/P - 3 DIE-SET DOWNSTROKE
RD LOCK CONTROL ASSEMBLY
CYLINDER CONTROL ASSEMBLY
YV135
YV170
169
C2208
C2087
2 - 24
014AZ002A
MAIN FEATURES 2
LIST OF THE HYDRAULIC/PNEUMATIC COMPONENTS
005 Check valve, Services 154 Service cock, Suction system
006 Check valve, Service control assembly discharge 155 Shut off cock, Mirror-finished die set circuit with
010 Valve (pilot-operated), Low pressure check valve
012 Accumulator, Filler-box and lift control 169 Twin restrictor, 3rd downstroke control
013 Pressure gauge, Pump and cock 174 Logic element, Braking
018 Accumulator, Press-stroke and upstroke 179 Cylinder, Die over-travel
023 Flow control 180 SMU knockout cylinder
024 Flow control, Filler-box at fast speed 181 Cylinder, Loading adjustment, 2nd SMU downstroke
027 Accumulator, Press-stroke and upstroke 183 Check valve, Die hydraulic release
028 Accumulator, Stabilized braking 184 SFS cylinder
036 Pressure gauge, Cylinder and cock 188 Pressure reducer, Filler-box lift unit
042 Hydraulic motor, Filler-box 189 Cylinder, Additional downstroke control
043 Check valve, Filler-box braking 194 Pressure relief valve, Brush drive
048 Heat exchanger 222 Flow control and silencer, Gate cylinder
049 Suction filter, Main pump 223 Flow control and silencer, Gate cylinder
055 Cylinder, 1st die-set downstroke and ejection 224 Gate cylinder
056 Cylinder, 2nd knockout stroke 242 Twin throttle valve, 2nd downstroke
057 Flexible coupling 247 Check valve, Cylinder downstroke
058 Main pump 248 Cock, System drain
061 Restrictor, Non return valve 249 Restrictor, SFS delivery line
062 Restrictor and pilot-operated check valve 250 Restrictor, SFS accumulator
067 Pressure gauge, Service pressure and cock 251 Check valve, Hydraulic die release
071 Safety valve, Pressurization 252 Proportional filter (10 um)
072 Air filter, Pressurization circuit 258 Change-over valve
073 Pressure reducer, Air in the pressurization circuit 264 Air filter, Brush unit
074 Check valve, Air in the pressurization circuit 265 Pressure gauge, Brush unit
075 Pressure gauge, Air in the pressurization circuit 266 Pressure reducer, Brush unit
078 Filtration unit pump 267 Oiler, Brush unit
079 Filter 269 Flow control, Brush drive cylinder
082 Check valve, Delivery line filtration 270 Brush drive cylinder
090 Flow rate control, Slow upstroke 271 Coalescence filter for pressurization
092 Pressure relief valve, Brake system 272 Air filter, Hopper assembly
101 Plunger shock absorber 273 Pressure reducer, Hopper assembly
108 Logic element, Upstroke 275 Pressure gauge, Hopper assembly
109 Logic element, Downstroke 277 Oiler, Hopper assembly
111 Pressure relief valve 336 Pressure relief valve
112 Pilot-operated valve, Line pressure 337 Accumulator, SFS circuit
112a Safety valve, Hydraulic circuit 338 Pressure gauge, SFS circuit
114 Logic element, Check valve, Accumulator control 339 Drain cock, SFS circuit
assembly BP1 Transducer, Cylinder pressure
115 Logic element, Accumulator shut-off during press-cycle BQ1 Position transducer, Plunger
116 Logic element, Flow booster (1st press-stroke) BQ3 Transducer, Brake setting
117 Logic element, Cylinder pressure BT4 Thermocouple, Hydraulic power unit reservoir
118 Logic element, Cylinder drain M1 Motor, Main pump
119 Logic element, Booster drain M11 Motor, Recirculating pump
120 Logic element, Pressure booster M15 Motor, Brake system
122 Plunger M2 Brush motor
123 Rod SP1 Pressure switch, Main filter service
124 Cylinder SP2 Pressure switch, Cylinder (safety)
125 Booster assembly SP3 Pressure switch, Air pressurization
126 Prefilling tank SP4 Pressure switch, Filler-box valve filter service
130 Cylinder, Rack drive SQ3 Sensor, Die-sets up
131 Logic element, Booster supply, 2nd press-stroke SQ20s Proximity switch, YV20s monitoring (optional)
132 Flow control, Plunger braking SQ50a Miniature switch, Suction line cock
136 Cylinder, Knockout rod clamping SQ59a Limit switch, Filler-box backwards
140 Pressure reducer, Mirror finished die-set SQ6 Sensor, Die-sets down
141 Accumulator, Mirror finished die-set SQ60 Sensor, Hopper gate open
142 Pressure gauge, Mirror finished die-set SQ61 Sensor, Hopper gate closed
143 Drain cock, Mirror finished die-set YV11a Solenoid valve (pilot-operated), Pressure off
144 Cock, Main pump suction line YV11b/R Solenoid valve (pilot-operated), Low pressure
145 Restrictor, Non return valve, Mirror-finished die set YV19 Solenoid valve, 2nd press-stroke (direct)
146 Cylinder, Knockout return stroke YV20a Solenoid valve, Filler-box
YV20s Solenoid valve, Filler box interlock
2 - 25
014AZ002A
2 MAIN FEATURES
YV21 Solenoid valve, 2nd die-set downstroke
YV22 Solenoid valve, 1st die-set downstroke
YV31d Solenoid valve, Slow downstroke
YV31s Solenoid valve, Slow upstroke
YV32d Solenoid valve, Plunger downstroke
YV32s Solenoid valve, Plunger upstroke
YV38 Solenoid valve (pilot-operated), Pressure booster
YV40 Solenoid valve (pilot-operated), Flow booster
(1st press-stroke)
YV41 Solenoid valve, Flow booster (2nd press-stroke)
YV47 Solenoid valve, Brake system
YV47a Solenoid valve, Brake system
YV53 Solenoid valve, Accumulator shut-off
YV70 Solenoid valve, Main cylinder drain
YV99 Solenoid valve, Pump control drainage
YV129 Solenoid valve, Die over-travel control
YV129s Pneumatic solenoid valve, Rack rotation
YV135 Solenoid valve, Knockout rod lock
YV170 Solenoid valve, 3rd die-set downstroke (optional)
YV172 Solenoid valve, SFS die-set cylinder drain
YV173 Solenoid valve, Air blower
YV192 Solenoid valve, Brush operation
YV193 Solenoid valve, SFS punch return
YV221 Solenoid valve, Hopper gate control
YV279 Solenoid valve, Cooling water
YV290 Solenoid valve, Pressurization control
2 - 26
014AZ002A
MAIN FEATURES 2
2.5 MACHINE OPERATION
The numbers and symbols used to identify the hydraulic, pneumatic and electric components in the descriptions below
refer to figures 2.4/A and 2.4/B - HYDRAULIC/PNEUMATIC DIAGRAM.
2.5.1 COMPRESSED AIR SUPPLY
FIXED DELIVERY PUMP

The unit consists of filter 72, coalescence filter 271, pressure reducer 73, check valve 74, pressure gauge 75 and valve
YV290.
The compressed air is used to pressurize the tank and to put the hydraulic oil contained in it under constant pressure.
The pressure reducer must be set so that a pressure of 1 to 1.2 bar is provided inside tank 126.
Safety valve 71 is used to prevent any over-pressure within the tank from occurring.
The safety valve is set and sealed during machine testing.
A unit (which consists of filter 272, pressure reducer 273, pressure gauge 275, oiler 277 and solenoid valve YV221)
controls cylinder 224 to operate the feed hopper gate, provided that this optional device is installed.
Another unit (which consists of filter 264, pressure reducer 266, pressure gauge 265, oiler 267, solenoid valve YV192,
pressure reducer 194 and flow controls 269) controls cylinder 270 to operate the movable brush, provided that this
optional device is installed.
VARIABLE DELIVERY PUMP

The unit consists of filter 72, coalescence filter 271, pressure reducer 73, check valve 74, pressure gauge 75 and valve
YV290.
The compressed air is used to pressurize the tank and to put the hydraulic oil contained in it under constant pressure.
The pressure reducer must be set so that a pressure of 1 to 1.2 bar is provided inside tank 126.
Safety valve 71 is used to prevent any over-pressure within the tank from occurring.
The safety valve is set and sealed during machine testing.
Pressure switch SP3, which keeps pressurization under control, is mounted on the suction line of pump 58. It prevents
the main pump from being started up if the pressure in the air lines is insufficient.
If this happens, a fault message will be displayed.
A unit (which consists of filter 272, pressure reducer 273, pressure gauge 275, oiler 277 and solenoid valve YV221)
controls cylinder 224 to operate the feed hopper gate, provided that this optional device is installed.
Another unit (which consists of filter 264, pressure reducer 266, pressure gauge 265, oiler 267, solenoid valve YV192,
pressure reducer 194 and flow controls 269) controls cylinder 270 to operate the movable brush, provided that this
optional device is installed.
2 - 27
014AZ002A
2 MAIN FEATURES
2.5.2 FAST HEATING
In order for the press to run efficiently, the oil temperature must be kept at around 40°C. When the machine begins to
run, the oil is normally at ambient temperature; therefore it is necessary to heat it up to at least 30°C before starting an
automatic work-cycle. However, the machine can be started up.
NOTE: With temperatures lower than 5°C, use an external heater.
To heat up the oil, start up the pump with the safety bar raised. If the temperature is below 30°, YV11b/r will be energized
and the oil heating circuit will begin to operate.

The pump will circulate the oil at a pressure of 150 bar (set for valve 10). The electrical power dissipated is then turned
into heat.
FIXED DELIVERY PUMP

The pump will circulate the oil at a pressure of 60 bar (set for valve 10). The electrical power dissipated is then turned
into heat.
The power dissipated in pressure relief valve 10 will cause the oil to be warmed up in a short time (10 to 15 minutes
approximately). If the oil temperature is found to be <2°C, the controller will not allow main motor M1 to start running.
2.5.3 HEAT EXCHANGER AND FILTRATION SYSTEM
FIXED DELIVERY PUMP

The system consists of a pump-and-motor unit M11-78, a plate-type heat exchanger 48 and a filter 79. Pump 78 draws
oil from the reservoir of the hydraulic power unit and delivers it to filter 79 and then heat exchanger 48. The oil is then
cooled down and returned to the reservoir.
Filter 79 is equipped with pressure switch SP1 which signals when the filter is clogged.
Check valve 82 prevents the oil from flowing back to the filter when the filter elements are being replaced.
Drive motor M1 will stop if motor M11 shuts off. As a result, the automatic cycle will be interrupted.
The heat exchanger has to be started up first before main motor M1 can be started.

The system consists of a pump-and-motor unit M11-78, a plate-type heat exchanger 48 and a filter 79. Pump 78 draws
oil from the reservoir of the hydraulic power unit and delivers it to filter 79 and then heat exchanger 48. The oil is then
cooled down and returned to the reservoir.
Filter 79 is equipped with pressure switch SP1 which signals when the filter is clogged.
Check valve 82 prevents the oil from flowing back to the filter when the filter elements are being replaced.
Valve YV279 controls the flow rate of the cooling water.
The microprocessor based control system measures the oil temperature through thermocouple BT4. The latter is
installed on the hydraulic power unit reservoir. When the temperature increases and reaches 41 °C, YV279 is energized.
When the temperature decreases and drops down to 39 °C, YV279 is de-energized.
Drive motor M1 will stop if motor M11 shuts off. As a result, the automatic cycle will be interrupted.
The heat exchanger has to be started up first before main motor M1 can be started.
2 - 28
014AZ002A
MAIN FEATURES 2
2.5.4 MAIN PUMP RUNNING - SAFETY BAR INTERLOCKS ACTIVATED (HIGH POSITION)
FIXED DELIVERY PUMP

The microprocessor-based control system is energized along with the motor control board when the main switch is
turned to its “on” position.
a) The following units start running when key “0” is pressed:

- Fan motor in the sound-proof housing (if installed);
- Motor-and-pump unit for the heat exchanger and filtration unit (M11-78).
b) When key “0” is pressed again (at least 5 seconds have to go by between operations a and b) the following starts
running:
- Main pump and motor (M1-58).
Unit M1-58 is started up under no-load conditions in a pre-determined sequence as solenoid valve YV11a is
energized.

C2086
WITH PH 690 TRADITIONAL LIFT SYSTEM

Solenoid valve YV22 is de-energized draining cylinders 55. As a result the lower punches move downwards.
PH 1000 - PH 1500
Solenoid valve YV22 is de-energized sending oil to the upper chamber of cylinders 55. As a result the lower punches
move downwards.
C1819
SMU
WITH SMU LIFT SYSTEM
move downwards.

The microprocessor-based control system is energized along with the motor control board when the main switch is
turned to its “on” position.
a) The following units start running when key “0” is pressed:

- Fan motor in the sound-proof housing (if installed);
- Motor-and-pump unit for the heat exchanger and filtration unit (M11-78).
b) When key “0” is pressed again (at least 5 seconds have to go by between operations a and b) the following starts
running:
- Main pump and motor (M1-58).
Unit M1-58 is started up under no-load conditions in a pre-determined sequence as solenoid valve YV11a is
energized.
2 - 29
014AZ002A
2 MAIN FEATURES

C2086
WITH PH 690 TRADITIONAL LIFT SYSTEM

Solenoid valve YV22 is de-energized draining cylinders 55. As a result the lower punches move downwards.
PH 1000 - PH 1500
move downwards.
C1819
SMU
move downwards.
Filter 49 and pressure switch SP3 are installed on the suction line of pump 58. The pressure switch indicates when filter
49 is clogged. In fact, if the pressure in the suction line falls below the allowable levels, pressure switch SP3 will detect
it and transmit a signal to the microprocessor system which, in turn, will cause the main pump-motor unit to stop running.
A fault message will appear on the screen of the microprocessor system.
2 - 30
014AZ002A
MAIN FEATURES 2
2.5.5 PRESSURE TRANSDUCER - SETTINGS
The encoders are digital position transducers which continuously detect the position of the plunger and filler-box. The
data entered into the microprocessor based control system provides the machine with information. Consequently, the
machine will perform the programmed operations when the positions of the plunger and filler-box (detected by the
transducers) coincide with the settings.
Encoders 1 and 2 (plunger position) “BQ6” and “BQ7”
The following settings can be entered for the plunger (see Instructions B manual):
- Plunger stoppage due to lack of powder
- Plunger down position (trigger pulse to start the press-stroke)
- Braking space
- Plunger raised position (automatic mode)
- End of braking during plunger upstroke
- Plunger parallelism error: this value, expressed in mm, represents maximum plunger inclination during the
press-cycle.
Encoder 3 (filler-box position) “BQ2”
The following settings can be entered for the filler-box (see Instructions B manual):
- Filler-box back position
- Filler-box forward position
- Approach value
- Filler-box speed during the forward stroke
- Filler-box speed during the return stroke
- Approach speed
- First die-set downstroke position
- Filler-box speed in manual mode
When sensor SQ2 is triggered by the cam integral with the mobile part of the filler-box it provides the zero point for the
encoder.
DCL
C1821
Encoder 6 (ALM position) “BQ10” (only with DCL)
The following settings can be entered for the filler-box (see Instructions B manual):
- Position of ALM when back
- Position of ALM when forward
- ALM speed during forward stroke
- ALM speed during return stroke
- ALM position when hopper gate is opened
- ALM position when hopper gate is closed
When sensor SQ10 is triggered by the cam integral with the mobile part of the filler-box it provides the zero point for
the encoder.
Sensors SQ3 and SQ6 detect when the die-set is in its highest and lowest positions. Indicator lights on the rack of the
microprocessor based control system indicate the state of the inputs and outputs, solenoid valves, miniature switches,
sensors, contactors, etc. during machine operation.
2 - 31
014AZ002A
2 MAIN FEATURES
2.5.6 SAFETY BAR INTERLOCKS INACTIVATED (DOWN)
FIXED DELIVERY PUMP

When the safety bar is lowered, limit switch SQ51 is inactivated while limit switch SQ52 is triggered, transmitting a signal
to the microprocessor system. The latter will de-energize solenoid valve YV11a and energize YV11b/r.
The pressure in the circuit will be adjusted to the pressure in relief valve 10 which is set to 60 bar. The pressure can
then be read on gauge 13.

When the safety bar is lowered, limit switch SQ51 is inactivated while limit switch SQ52 is triggered, transmitting a signal
to the microprocessor system. The latter will de-energize solenoid valve YV11a. At this point, the pressure in the circuit
will be brought to the operating pressure of relief valve 112. This pressure is given on gauge 13.
Valve 111 is set according to the value of valve 112a. The latter acts as a protection device for the hydraulic circuit. (The
operating pressure and safety values are given in chapter 7 - ADJUSTMENTS).
Once the pressures for the relief and safety valves have been set, it is good practice to tighten the adjusters (by using
the locknuts) on the two valves. By doing this, vibrations will be prevented and the adjusters will not come loose, as a
result, the pressure settings can be maintained over long periods.
The pressure level of valve 112 is referred to as line pressure.
2.5.7 ENCODER RESETTING
To perform this operation, press keys 28 & 5 at the same time. This is to be done whenever the microprocessor based
system is disconnected. The encoders must be reset in order to start the machine cycling in automatic mode. The display
of the microprocessor control system will inform the operator when this operation must be done. The message
“ENCODER… NOT RESET” will appear.
As an absolute encoder is used for the plunger it does not have to be zero set whenever the controller is shut off. This
needs to be done only if the encoders are physically moved, if the IE card is replaced or is the encoder’s 0 point has
to be changed (see the procedure given in the Instructions B manual).
2 - 32
014AZ002A
MAIN FEATURES 2
2.5.8 DIE-SET CONTROL CIRCUIT
C1819
SMU
Press pushbuttons 13 & 25 to energise solenoid valves YV22 and YV21.
Solenoid valve YV22 delivers oil to the bottom part of cylinders 180 used to raise the lower punches. Simultaneously,
the upper part of cylinders 180 is joined to the drain through YV22. Adjust flow control 61, located under solenoid valve
YV22 to adjust the speed at which the upward movement takes place. To adjust the downstroke speed, work on throttle
23. Solenoid valve YV21 delivers oil to die-set upstroke cylinders 181 through flow control 242. The latter is used to
adjust the speed for the last downstroke. As a result the lower punches reach the same level as the die.
The upstroke speed is determined by a fixed gigler.

C2086
WITH TRADITIONAL LIFT SYSTEM
PH 690
Solenoid valve YV22 delivers oil to cylinder 55 used to raise the lower punches. Adjust flow control 61, located under
solenoid valve YV22 to adjust the speed at which the upward movement takes place. To adjust the downstroke speed,
work on the throttle located on the line in the point where the pipe used to connect the cylinder for the first downstroke
starts. Solenoid valve YV21 delivers oil to die-set upstroke cylinders 56 through flow control 242. The latter is used to
adjust the speed for the last downstroke. As a result the lower punches
reach the same level as the die.
The upstroke speed is determined by a fixed gigler.
PH 1000 - PH 1500
Solenoid valve YV22 delivers oil to the bottom part of cylinder 55 used to raise the lower punches. Simultaneously, the
upper part of cylinder 55 is joined to the drain through YV22. Adjust flow control 61, located under solenoid valve YV22
to adjust the speed at which the upward movement takes place. To adjust the downstroke speed, work on throttle 23.
Solenoid valve YV21 delivers oil to the die-set upstroke cylinder through flow control 242. The latter is used to adjust
the speed for the last downstroke. As a result the lower punches reach the same level as the die. The upstroke speed
is determined by a fixed gigler.
2 - 33
014AZ002A
2 MAIN FEATURES
2 - 34
014AZ002A
SAFETY EQUIPMENT AND PRECAUTIONS 3
3 SAFETY EQUIPMENT AND PRECAUTIONS

3.1 SAFETY DEVICES
E0004P
WARNING!
3.1.1 SAFETY GUIDELINES
The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard the operators
and the machine itself.
These devices must never be removed, disabled or altered in any way.
Some illustrations provided in the manual show the machine, or parts of it, with the guards removed. This is simply for
added clarity. Never actually use the machine with the guards removed or safety devices disabled.
Warning signs are provided on the machine to indicate any hazards in the zone where the sign is attached.
Always take all necessary safety precautions before working on the machine.
SACMI shall not be held responsible for any personal injury or property damage resulting from failure to observe these
precautions or use the safety devices provided.
3.1.2 SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE
The operator may be injured, cut or get caught in moving machine parts while working in the area where the powder
is loaded or in the area around the die set. A number of barrier guards have been provided to prevent the operator from
gaining access to these hazardous areas:
- Fixed guards on the powder infeed system
- Fixed side guards mounted near the press columns
- Fixed guards mounted on the front of the press
- Fixed guards on the working parts of the filler box infeed system
- Front safety bar with mobile guard
None of the fixed guards can be removed without using special tools. Furthermore, they will not stay in position unless
suitable fasteners are used. The mobile guard is basically a grid which moves when the safety bar is operated. In any
case, the size of the steel mesh is such as to prevent access to the hazardous area.
When the safety bar is raised, limit switches SQ51 and SQ52, located at the front of the machine, prevent any powered
movements from being performed. Moreover, two mechanical locks are engaged to prevent the plunger from abruptly
moving down.
Two interlocking devices SQ66 and SQ66a, which are triggered by the powder infeed system, are found at the rear of
the machine. If the powder infeed system is not present (i.e., when the area where the die-set operates can be accessed
from the rear), the plunger can only carry out a slow downstroke (less than 16 mm/s). This movement is controlled by
self-maintaining buttons.
The front of the press must be safeguarded by installing the tile collector equipped with fixed safety guards that prevent
access to the area where the die-set is found and limit switches SQ53a and SQ53b that signal it is present in its work
position.
The press is also provided with two red emergency stop buttons (on a yellow background). One button is located on
the control panel while the other is to be found at the rear of the press. These buttons are to be pressed whenever an
emergency situation arises, causing the machine to stop and the oil in the largest accumulators as well as the main pump
to be drained.
The machine is to be reset whenever an emergency stop button has been pressed.
The hydraulic system is provided with a pressure relief valve 112a set to the maximum allowable value. This ensures
trouble-free operation and prevents the pressure in the hydraulic system from exceeding the permitted levels in the
presence of malfunctioning.
In addition, a safety valve 71 is on the hydraulic reservoir so as to prevent the pressure from exceeding 2.25 bar. The
pressure setting cannot be changed as the valve is sealed.
3-1
014AZ002A
Reference standards
EN 292-1 Safety of machinery - Basic concepts, general principles for design.

Part 1: Basic terminology, methodology.
EN 292-2 Safety of machinery - Basic concepts, general principles for design.
Part 2: Technical principles and specification.
EN 294 Safety of machinery - Safe distances to prevent danger zones being reached by the upper limbs.
EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
EN 418 Safety of machinery - Emergency stop equipment, functional aspects. Principles for design.
EN 953 Safety of machinery - Guards. General requirements for the design and construction of fixed and movable
guards.
EN 982 Safety of machinery - Safety requirements for fluid power systems and their components. Hydraulics.
EN 983 Safety of machinery - Safety requirements for fluid power systems and their components. Pneumatics.
EN 1088 Safety of machinery - Interlocking devices associated with guards. Principles for design and selection.
PrEN 12692: 1999 Machines for ceramic industry
Safety of presses
3-2
014AZ002A
3.2 SAFETY RULES FOR HANDLING
E0004P
WARNING!
3.2.1 LIFTING PROCEDURES
To safely and correctly lift and handle the machine always:

- use the most suitable lifting equipment with an adequate lift capacity;
- cover all sharp edges;
- make sure the safety device for the lift hook works properly;
- do not shift the load from its initial position while lifting.
Before lifting:
- make sure all personnel is safely away and that no one can enter the area where the machine is being moved
- make sure the load is stable
- make sure there is no material which may fall when the parts are lifted
- gradually lift in a vertical manner in order to avoid swaying and irregular movements.
3.2.2 HANDLING PROCEDURES
During handling operations, the load must remain on a perfectly horizontal plane regardless of the type of equipment
being used.
To facilitate the lifting and handling operations use bars, levers and ramps from a safe distance. Never use your hands.
The person in charge must:
- have a clear view of where the machine is to be moved
- give instructions to the crane operator from a position where he/she can be clearly seen
- stop the operation immediately if dangerous conditions arise (for example people passing by).
3.2.3 PLACING THE LOAD
Before placing the machine make sure the floor is perfectly level and is able to support the weight of the machine.
Do not place the loads in areas where they could create a hazard, prevent the use of equipment or obstruct emergency
exits:
- factory exits,
- fire fighting equipment,
- passage areas,
- control panels
- power lines.
The machine must be placed on suitable bars to make it stable so that the slings can be easily removed.
Do not place worn containers or those with protruding parts on top of each other.
Do not stack material at a dangerous height.
3-3
014AZ002A
3.3 INSTALLATION
3.3.1 GUIDELINES
E0004P
WARNING!
Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations in
force in your country.
The machine is to be installed on adequate concrete foundations as specified by SACMI. In particular, these concrete
foundations should be able to withstand the static and dynamic loads applied by the press during operation. Cover the
electrical conduit and raceways for the hydraulic lines and electrical wiring with non-slip cover plates made in compliance
with current safety regulations. If the press comes equipped with a conventional knockout, the point of access to the
pit where the knockout is installed must be covered up with fixed cover plates, i.e. that can be removed with the aid of
suitable tools.
Make sure there is enough space around the machine so that it can be operated and serviced easily.
The area surrounding the machine must always be kept free of obstacles, clean, dry and well-lit.
The lighting in the areas around the machine and, in particular, in the work zone should be efficient and have a level
of illumination not less than 300 lux.
The customer must make sure that fire-fighting equipment is provided in the area where the machine is installed and
that there is a system for protection against voltage fluctuation in the electricity supply line. These must conform to laws
currently in force in the country where the machine is installed.
The manufacturer or authorized people is to install and commission the machine, therefore the respective instructions
are not given in this user's manual.
WARNING!
E0007
Connect the machine to an effective earth-ground.
WARNING!
E0007
The electrical wiring does not come with a differential protective device unless expressly requested.
WARNING!
E0007
If electronic converters are present in the electrical control cabinet, the differential protective devices installed on the
cabinet’s power supply line must be “B” type as specified by current safety standards.
E0004P
ATTENTION!
SACMI shall not be held responsible for any property damage or personal injury resulting from improper installation.
3-4
014AZ002A
3.4 OPERATOR TRAINING
E0004P
WARNING!
3.4.1 END-USER
The company using this equipment must see that their personnel:
- match the requirements listed below
- read and understand the manual in its entirety
- are adequately instructed and trained on how to safely carry out their tasks
- receive specific training on how to operate this machine correctly.
3.4.2 OPERATORS
The machine operator must:

- understand the technology employed and have specific experience in operating this type of machine
- be well educated enough to read and fully understand the contents of this manual as well as properly interpret the
drawings provided
- know all the safety rules and standards
- general (hygiene and on-the-job safety, accident prevention)
- specific (for the type of product handled by the machine)
in force in the country where the machine is installed.
Operator tasks
The operator is only authorised use the controls and instruments provided on the machine’s control panel.
3.4.3 MAINTENANCE STAFF
The maintenance staff must be selected according to the same criteria as that indicated for the operators.
In addition, they must be trained in specific technological areas (mechanical, electric, hydraulic and pneumatic) so that
they can carry out the operations they are responsible for (as specified in the manual) in complete safety using suitable
tools and equipment.
Tasks for the maintenance staff

The maintenance staff are responsible for carrying out the routine maintenance operations described in this manual.
It is important that the members of staff carry out only the tasks in the areas they are specifically responsible for
(mechanical, electric, pneumatic, etc.).
3-5
014AZ002A
3.5 OPERATING INSTRUCTIONS
3.5.1 SAFETY GUIDELINES
E0004P
WARNING!
The machine is equipped with electric and/or mechanical safety devices that safeguard the operating personnel as well
as the machine. The press can be run within the limits determined by the manufacturer as long as these devices are
operative and efficient. These limits are specified in the following chapters. In addition, these devices must not be
removed or tampered with under any circumstances whatsoever. The control systems and safety devices installed can
ensure operator safety only if a powder loading system approved by SACMI is used. In addition, only die-sets that
employ one of the following systems for locking the upper punches can be used: mechanical, with permanent magnets
and electromagnets, in the latter case a mechanical emergency system that prevents falling must be provided. The
manufacturer of the pressing tool shall be held responsible for any damage or injury resulting from the pressing tool.
The press can operate in three different modes by setting the mode selector to the desired position: automatic, manual
and set-up.
3.5.2 AUTOMATIC OPERATION
When the press is running in automatic no operations need to be carried out by the operator. Hazardous areas (die-
set area) are fully protected by fixed and mobile guards which make these areas totally inaccessible. In particular, the
following are provided:
- Fixed guards are mounted on the powder infeed system
- Fixed guards at the sides of the press near the columns. The guards include an access door which can be opened
with special tools, thus allowing the operator to visually check machine functioning without gaining access to
hazardous areas of the machine.
- Fixed guards are on the working parts of the filler box infeed system. The strokes of the filler box should be set when
the machine is stopped.
- Front safety bar with mobile guard. This bar is wired up to the microprocessor-based control system. When the bar
is completely down, it prevents the operator from gaining access to the work areas during the production run.
All the guards have been placed at a safe distance as recommended by current safety standards (EN 294).
The front of the press must be safeguarded by installing the tile collector equipped with fixed safety guards that prevent
access to the area where the die-set is found (figure 3.5.5) and limit switches that signal it is present in its work position.
If the front safety bar is raised, two mechanical locks are engaged to prevent the plunger from abruptly moving down.
This arrangement prevents the press from performing any hazardous powered movements which may harm the
operating personnel. Moreover, the plunger can be raised so as to disengage the mechanical locks and allow single
parts of the die-set to be moved so as to perform routine cleaning.
3.5.3 MANUAL OPERATION
When set to manual mode, the operator can control some movements of the press directly, for example to carry out
semiautomatic cycles, test runs, etc... All the safety devices used during the automatic cycle must be on and operating.
3.5.4 SET-UP MODE
This mode of operation can be used only by the maintenance staff. When the machine is in set-up mode, the plunger
can move up and down only at a low speed (less than 16 mm/s) so that the die-set can be replaced. In this case, the
rear box feeder or the front tile transfer system can be moved to access the machine. However, no operations can be
performed while the machine is running under any circumstances. Instructions on how to install the die-set are given
in chapter 4, INSTALLATION.
The press is equipped with two emergency stop buttons. One is located on the control panel while the other is placed
at the back of the machine. Pressing one of these buttons immediately stops the machine and discharges the pump.
In the event of an emergency always press one of these two buttons.
3-6
014AZ002A
WARNING!
E0004P
The operator who sets the press to set-up mode must keep the key to the selector switch in his/her pocket until
special machine servicing has been completed. It is therefore important that just one copy of the key is available
in the workshop to prevent more than one person from working on the machine at the same time. As most of the
safety devices are inactivated, machine and personnel safety are at the hands of the operator who must be
informed and clearly understand what he/she is responsible for.
3.5.5 INSTALLATION MODE
The diagram below shows the layout foreseen by the manufacturer for correct operation. The tile collector and handling
device, is not an integral part of the machine however, safety is compromised if it is not present. The signal transmitted
by the sensor must be in series with the other limit switches installed on the press. This collector should be equipped
with an arm that activates the right and left safety guards of the press and be placed near the die-set, with less than 25
mm play on each side, to prevent access to the danger zone from the bottom. In addition it must be fitted with two limit
switches SQ53a and SQ53b, hooked up as shown in the wiring diagram, that detect when the device is in place in its
work condition. When the arm of the tile collector is not in place, therefore not in its work condition, the press can run
only in SET-UP mode. The signal from these limit switches should be in series with the other limit switches installed in
the press.
Figure 3.5.5 - RULES FOR OPERATION
POWDER FEED SYSTEM TILE COLLECTOR
SQ53a
SQ53b
C1327
3-7
014AZ002A
3.5.6 CLEANING
Stop the machine to clean the die set area. Follow the procedure below:
- Stop the moving parts of the tile collector and back up the mobile arm so that the front of the die-set can be accessed.
- Fully raise the plunger by pressing buttons 25 & 3 located on the control panel.
- Raise the safety bar.
E0004P
WARNING!
When cleaning the die-set, the personnel must wear adequate clothing for protection against heat. For more
thorough cleaning, perform the same procedures as recommended for maintenance.
3-8
014AZ002A
3.6 MAINTENANCE
3.6.1 GENERAL SAFETY RULES
WARNING!
E0001
Never inspect, repair or service moving parts. Clear warning signs should be attached near the parts in question to warn
operators of the danger.
E0004P
WARNING!
Before attempting to carry out any operations on the machine, discharge the accumulators and wait until they are empty.
O2
E0004P
WARNING!
E0034D
The accumulators are to be precharged using only dry nitrogen in tanks with reducer. Use of compressed air and/or
oxygen is severely forbidden.
WARNING!
E0007 E0010
Before performing any operations on the machine, including the replacement of components of the control panel or
electrical cabinet, the maintenance staff must shut off the electricity supply by using the main switch located on the
control panel. This switch should then be locked out with a padlock so that the machine cannot be accidentally started
up.
WARNING!
E0007
The electrical cabinets and junction boxes installed on-board the machine contain live parts.
As laid down by the EN 60204-1 directive, access to the electrical cabinet should only be possible with a special tool.
This tool should be kept by one member of staff qualified and trained to work on live parts.
When the electrical cabinet is energised, the only task that this member of staff should perform is to reset the circuit
breakers.
WARNING!
E0007
Wherever “plug-outlet” connections are present, whether they are in the electrical control cabinets or junction boxes on-
board the machine, they are to be disconnected only with the machine stopped and after shutting off power from the
supply mains.
3-9
014AZ002A
WARNING!
E0007
Specific tools are to be used to connect and disconnect the conductors inserted in “spring” terminals.
WARNING!
E0017
When working on the machine never climb up on any part other than the service floor or ladders. The machine guards
and enclosing barriers are not designed to bear the weight of a person. If climbed on, they may collapse causing personal
injury and equipment damage.
E0004P
WARNING!
It may be necessary to temporarily remove or disable certain safety devices when making adjustments or servicing the
machine. Once these operations have been completed, it is highly important that the safety devices are put back in place
and reactivated before the machine is started up.
WARNING!
E0002 E0005
During operations, the electric motors can reach extremely high temperatures which would cause burning if touched.
Always take the necessary safety precautions when working on the motors.
WARNING!
E0007 E0009
In order to ensure that the machine operates efficiently, safely and in a trouble-free manner always follow SACMI’s
instructions carefully. Carry out the scheduled maintenance operations exactly as described and at the time intervals
recommended.
In particular, regularly check all the safety devices for proper functioning. Also check the insulation of the electrical cables
and replace if necessary.
E0004P
WARNING!
The user must restore the markings (conductors, terminals, devices, etc..), monitor signals and nameplates when no
longer legible or if removed for any reason.
3 - 10
014AZ002A
3.6.2 NOTES REGARDING MAINTENANCE
In order to guarantee top machine performance and efficiency, the scheduled maintenance operations indicated by
SACMI must be carried out, as stated in chapter 8, MAINTENANCE. In particular, the following should be periodically
performed: make sure all the safety devices and emergency stop buttons are in the right position and operate properly,
check the insulation of the cables, replacing them if damaged and make sure the machine is effectively grounded. The
maintenance staff is to be qualified as dictated in the OPERATOR TRAINING paragraph in this chapter. Before carrying
out any operations, proceed as follows:
1) Move the plunger fully up by using buttons 25 and 3 located on the control keyboard.
2) Raise the safety bar by activating the lever on the side at the same time.
3) Press key 4 to shut off the main pump.
4) Press the emergency stop button.
5) Disconnect the machine from the mains electricity supply by turning the main switch to OFF. The main switch can
be locked with a pad lock and key (not supplied with the machine) in the “power off” position to prevent it from
being accidentally started.
6) Discharge service accumulator 12 by changing over die-set solenoid valves YV22 manually until the knockout
no longer moves.
7) Discharge the upper accumulators by changing over “cylinder pressure” solenoid valve YV19 and/or “downstroke
and upstroke” solenoid valves YV32s and YV32d simultaneously.
8) If accumulators 141 and 337 are present they must be discharged through valves 143 and 339.
E0004P
WARNING!
Before attempting to carry out any operations wait until the accumulators have been completely discharged.
3 - 11
014AZ002A
3.7 MACHINE NOT IN USE
E0004P
ATTENTION!
3.7.1 GENERAL RULES
When the machine is no longer to be used, make it inoperative by shutting off the electricity and air supplies etc.
Use suitable safety devices.
Thoroughly clean the entire machine, especially the working parts, and if necessary apply a protective lubricant.
Close the electrical control cabinet doors and any machine access doors to prevent any parts being tampered with or
dust getting in.
3.7.2 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED
If the machine is no longer going to be used, it should be made inoperative by performing the following operations:
1) Move the plunger fully up by using buttons 25 and 3 located on the control keyboard.
2) Raise the safety bar by activating the lever on the side at the same time.
3) Press key 4 to shut off the main pump.
4) Discharge service accumulator 12 by changing over die-set solenoid valves YV22 manually until the knockout
no longer moves.
5) Discharge the upper accumulators by changing over “cylinder pressure” solenoid valve YV19 and/or “downstroke
and upstroke” solenoid valves YV32s and YV32d simultaneously.
6) If accumulators 141 and 337 are present they must be discharged through valves 143 and 339.
E0004P
WARNING!
Before attempting to carry out any operations wait until the accumulators have been completely discharged.
7) Disconnect the machine from the mains by unplugging the power cable.
3 - 12
014AZ002A
3.8 DISMANTLING
If the press is to be dismantled, follow the instructions given in chapter 9 - DECOMMISSIONING THE MACHINE.
3 - 13
014AZ002A
3 - 14
014AZ002A
INSTALLATION 4
4 INSTALLATION Figure 4.1 - LIFTING AND POSITIONING

THE MACHINE
The machine is to be installed and started up only by
persons authorized by SACMI.
4.1 HOW TO LIFT AND PLACE THE

PRESS IN POSITION
Use sling ropes and other suitable equipment when hoisting

the press. Always follow the safety regulations in force in
your country.
To properly place the press, refer to the foundation plan
provided before hand.
E0004P
WARNING!
Follow the instructions for hoisting the machine
given in chapter 3 - SAFETY EQUIPMENT AND
PRECAUTIONS.
The load must always remain perfectly horizontal,
regardless of the type of equipment used for hoisting,
while it is being moved.
C0535
EQUIPMENT PH 690 kg 18.000

E0009C
PH 1000 kg 27.000
- Pair of slings
- Pair of safety clamps PH 1500 kg 39.000
4.2 HOOKING UP AND CONNECTING THE MACHINE
The machine must be hooked up and connected only by specially trained personnel. Carefully follow the instructions
provided by the manufacturer.
E0004P
WARNING!
As there are several electronic converters inside the electrical cabinet, make sure the ground fault circuit
interrupters on the power supply are of the B type (as called for by CEI 64-8 standard article 532.2.1.4), thereby
ensuring adequate protection against leakage currents.
4-1
014AZ002A
4 INSTALLATION
4.2.1 EARTHING THE MACHINE
E0004P
WARNING!
The machine (electrical control cabinet - press body - power unit - filler-box) has to be effectively earthed. Hook
the machine up to the external protective circuit. The connection point marked PE (EN60445) is found beside the
main shut off switch (see figure 4.2/B). The cross-section of the cable must be at least half that of the cabinet’s
power cable.
In addition, hook up the connection points on the machine frame marked with symbol (417-IEC-5019)
to the earth bar at the bottom of the electrical control cabinet (see figure 4.2/A).
The cross-section of the cables must be at least half that of the largest heater cable.
Connect the copper bar in the electrical control cabinet to the machine C and the cross-head to the plunger A-B.
Join earth wires D and E as shown in the DIE-SET WIRING DIAGRAM figure.
The points where the earth connections are to be made should be free of paint. Any paint present should be removed
before the relative screws are tightened in order to ensure perfect electrical continuity.
E0004P
WARNING!
Failure to earth the machine may cause serious personal injury as well as equipment damage.
Figure 4.2/A - EARTH BAR IN ELECTRICAL Figure 4.2/C - EARTH CONNECTION

CONTROL CABINET
B
Figure 4.2/B - EARTH CONNECTION
C
C2783
F
EARTH BAR IN
ELECTRICAL
CONTROL CABINET
4-2
014AZ002A
INSTALLATION 4
4.2.2 INSTALLING AND REMOVING THE DIE-SET
The die-set can be installed on the press only by expert personnel as indicated in chapter 3 - SAFETY EQUIPMENT
AND PRECAUTIONS. Only die-sets which incorporate the punch locking systems listed below can be used:
1) mechanical lock
2) locking by means of permanent magnets
3) locking by means of electromagnets with a mechanical safety system
The die-set can be installed either from the front or back of the machine. In both cases, enough space must be left free
to move around so that the die-set can be manoeuvred conveniently. This can be done, for example, by removing the
box feeder or the tile transfer system.
Preliminary operations:
a) move the plunger to its top dead center position
b) raise the front safety bar
c) select set-up mode
d) thoroughly clean the mating surfaces of the press and die-set and lubricate them with oil.
Two systems can be employed to bring the die-set inside the press:
- by using a fork lift truck
- with special equipment for example, carts fitted with lift systems and a roller surface.
E0004P
WARNING!
Whenever moving the die-set always observe the safety precautions for handling hanging loads.
Perform the following operations regardless of the means used to move the die-set.
1) Remove the die-set from the packaging using adequate lift systems. Place the die-set on 2 shims so that it is
raised approximately 10 cm from the floor.
2) Protect the forks of the truck to prevent damaging the die-set.
3) Place the forks under the die-set Slightly raise it, making sure the forks lift it symmetrically in relation to the center
of gravity.
4) Make sure the press and die-set are thoroughly clean.
5) Bring the die-set under the plunger, making sure the it is perfectly centered in relation to the press’ elements: press
columns and plunger for centering lengthwise and crosswise).
6) Remove the forks of the truck from the press or the roller surface from the lower part of the die-set. To do this,
raise the die-set in one of the following ways:
a) if the die-set is mounted on SMU, it is provided with four rests so that it can be easily raised
b) if the press is fitted with quick change devices, the die-set can be hooked to the plunger and then moved up
c) if the press or die-set are not provided with autonomous lift devices, hydraulic cylinders can be used as
long as they conform with current safety regulations.
E0004P
WARNING!
Devices that are not suitable for lifting the die-set for example, levers, shims, etc.. must never be used.
4-3
014AZ002A
4 INSTALLATION
7) Secure the base plate of the die-set to the press’ bed.
8) Move the front bar down.
NOTE: the machine is in set-up mode therefore it can run at a maximum speed of 16 mm/s.
E0004P
WARNING!
Never carry out any type of operation while the machine is running.
9) Move the plunger until it rests on the die-set.

10) Secure the upper part of the die-set to the plunger.
11) Hook up the die-set and connect it to the pneumatic system so that it can operate (see the CONNECTING THE
DIE-SET HEATER and the MAGNETIC LOCK CONNECTIONS paragraphs).
12) Bring the die-set to the required temperature within the limits determined by the die-set manufacturers.
13) Center the punches.
14) Secure the punches in place with permanent magnets or electromagnets, in the latter case a mechanical
emergency locking device must be installed.
15) Loosen and then retighten the fixing screws of the die and/or dies.
16) Move the punches a number of times to make sure they move freely.
17) Make sure any magnetic locks installed are properly set.
4.2.3 CONNECTING THE DIE-SET HEATER
E0004P
WARNING!
Make the connections as illustrated in figure 4.2.4 - DIE-SET WIRING DIAGRAM
The connections must be properly performed. Failure to do so may result in severe damage to the columns and cylinder.
- Do not reverse the wires between the upper and lower heating element.
- Connect both wires of the upper heating elements to the die set. Do not connect one wire to the die set and the other
to the plunger.
- Do not ground the secondary winding of the die-set heater transformers.
- Make sure connection of the grounding cables is efficient.
4-4
014AZ002A
INSTALLATION 4
4.2.4 MAGNETIC LOCK CONNECTIONS
- Join the cables and connector XJ6 as shown in figure 4.2.4 - DIE-SET WIRING DIAGRAM.
E0004P
WARNING!
Reversing one or more wires may severely damage the machine.
Figure 4.2.4 - DIE SET WIRING DIAGRAM
HEATER MAGNETIC LOCK

510-511 Upper punch cables 911-912 Lower plate cable
514-515 Lower die cables 921-922 Connector XJ6 (upper plate cables)
516-517 Lower punch cables
D Lower punch holder-die ground cable

E Machine base-die ground cable
VERSION WITH TRADITIONAL LIFT SYSTEM 922
921 XJ6
510
511
D
514
515
912
516 911
517
C0523
VERSION WITH SMU LIFT SYSTEM 922
921 XJ6
510
D
511
514 E
515 912
516
911
517
C0524
4.2.5 DUST EXTRACTION SYSTEM
Join the various suction outlets to an efficient suction system sized according to the data provided by SACMI.
4-5
014AZ002A
4 INSTALLATION
4-6
014AZ002A
START-UP PROCEDURE 5
5 START-UP PROCEDURE
5.1 GENERAL
After the press, filler-box and die set have been properly installed, the following conditions will be present: the plunger
will be raised and the safety bar will be up (limit switch SQ51 is activated while limit switch SQ52 is inactivated).
5.2 PRELIMINARY CHECKS
The numbers which identify the hydraulic, pneumatic and electric components in the descriptions below refer to figure
2.4.1/A HYDRAULIC/PNEUMATIC DIAGRAM. The functions of the pushbuttons and selector switches are illustrated
in the figures in paragraph 6.1 - CONTROL DEVICES paragraph given in chapter 6 - OPERATING INSTRUCTIONS.
5.2.1 CHECKS TO BE MADE
PERFORM THE FOLLOWING:

- Make sure the die-set heating elements are grounded and properly connected.
- Make sure the upper and lower magnetic lock are properly set (the leds in buttons 11 and 15 must be on).
- Make sure the press’ body is effectively grounded. Check the braid that connects the plunger to the crosshead for
condition.
- Make sure the oil level in the reservoir (on the top of the press) is correct.
- Make sure the pressure in the hydraulic system is within the correct operating range indicated in paragraph 2.3.1 -
SPECIFICATIONS.
- Make sure the tile thickness gauge is properly connected.
- Make sure the filler-box limit switches and interlocks on the safety bar are properly wired and work as required.
- Make sure the device that indicates “filter clogged” is properly wired.
- Check the powder detector (located on the filler box feed hopper) for efficiency.
- Make sure the controller and the tile transfer (placed immediately before the press) are properly connected (these
conditions are to be fully satisfied when the machine is started or stopped).
5.2.2 MOTOR M11
Start motor-driven pump M11 to cool down the oil by pressing push-button 0 located on the control keyboard. Check
the direction of rotation.
5.2.3 MOTOR M1
After pump M11 has run for at least three minutes, completely loosen the knob on safety valve 112a. Start main motor
M1 by pressing pushbutton 0 located on the control keyboard. Turn off the motor after it has run for approximately two
seconds by pressing pushbutton 4. While the motor is running check the direction in which it runs.
Wait for it to stop and then restart motors M11 and M1. Allow the motor to run for a few seconds and then stop it. Repeat
this operation several times and let the motor run if there are no troubles. Idle the motor for a few minutes, so that the
air in the ducts and control assemblies can be let out. Keep key 28, on the control keyboard, pressed and gradually
tighten the knob on valve 112a to increase the pressure in the circuit to approximately 100 bar. Make sure no oil leaks
from the hose fittings.
5-1
014AZ002A
5.2.4 SETTING THE PUMP PRESSURE
FIXED DELIVERY PUMP

Proceed as follows:
- Disconnect solenoid valve YV11b/r (oil heating).
- Start the main pump with the safety bar raised.
- Completely loosen pressure control valve 112a.
- Gradually tighten valve 112a while keeping button 28 pressed until the desired pressure is read on the gauge. Once
the value has been reached, fully tighten the adjustment screw.
Operating
pressure (bar)
PH 690 170
PH 1000 - PH 1500 180
- Connect solenoid valve YV11b/r. As the oil has not reached the required temperature yet, the heating cycle will start.
- Loosen pressure relief valve 10 completely, relieve the pressure in the upper accumulators and tighten valve 10 until
the desired oil pressure (60 bar) is read on gauge 13. Once the value has been reached, fully tighten the adjustment
screw.

Set the safety pressure - operating pressure by following the instructions given in ADJUSTING THE VARIABLE
DELIVERY PUMP in chapter 7 - ADJUSTMENTS.
5.2.5 TOP DEAD CENTER POSITION
Bring the plunger into its top dead center position by using the keys 3 and 25 on the control keyboard. The main cylinder
should reach its top dead center position while the pressure in the hydraulic power unit, shown on pressure gauge 13,
increases until the value set during testing, which is equal to the operating pressure, is reached.
5.2.6 SAFETY DEVICES
Lower the safety bar. The filler box can now perform its movements. Before starting operation, make sure the emergency
stop buttons 24 work efficiently.
5.2.7 AUXILIARY CIRCUIT PRESSURE
Completely loosen the adjustment screw of pressure reducer valve 188. Make sure the pressure read in the auxiliary
circuit (pressure gauge 67) does not exceed 50 bar. If it does, manually discharge accumulator 12 by activating solenoid
valves YV21 and YV22.
Press the button 28 used to apply pressure and tighten the screw of valve 188 until the pressure required in the auxiliary
circuit (140 bar) is read on gauge 67.
5-2
014AZ002A
5.2.8 FILLER BOX
DCL
C1821
FILLER-BOX (DCL)
Make sure:
- The filler-box is correctly positioned and secured in place.
- The slide plate is perfectly level with the die surface.
- The filler-box guides are aligned and centered.
- The mobile part of the filler-box is properly adjusted.
- The brush is properly adjusted (if present).
- The powder feeder (ALM) is properly adjusted.
- All electrical connections have been properly made.
- The safety guards are in place.
Set the values for the end of the forward and return strokes (they represent the distance in millimeters in relation to the
home position of the guides).
Press keys 28 and 5 to zero set the filler-box encoder.
Move the filler-box in manual mode to verify that the values entered for the end of the forward and return stroke are
correct.
Make sure limit switch SQ59 has been properly set. Limit switch SQ59 that provides the signal for the plunger to move
down should be triggered only when the mobile part of the filler-box is out of the danger zone.
DCP
FILLER-BOX (DCP)
FILLER-BOX ACTUATED BY A NON-PROPORTIONAL VALVE
Set filler box control = NO.
Set the speeds of the 10 filler box steps (from the 1st forward step to the fifth return step) to 100%. Start up the filler box
by pressing keys 8, 27 and 29 at the same time. Block the flow regulator in this position. Operate the filler-box so that
any air bubbles present can be eliminated from the hydraulic circuit. Carry out a few cycles in semi-automatic mode
(press key F8 to select a semi-automatic loading cycle and then press buttons 28 and 2) making sure that the filler box
always reaches the end of its stroke safely, i.e. the limit switch should be effectively triggered. Make sure that the filler
box encoder setting shown on the display is lower than the value set for the end of the return stroke (usually a few mm).
FILLER-BOX ACTUATED BY A PROPORTIONAL VALVE

Set filler box control = NO.
Set the GAIN item (RP2) to its max. value and set the speeds of the 10 filler box steps (from the 1st forward step to the
fifth return step) to 100%. Start up the filler box by pressing keys 8, 27 and 29 at the same time. In any case, it must
be greater than the presumed working speed. Block the flow regulator in this position. Set the GAIN item (RP2) to 50%
and then operate the filler box so that any air bubbles can be removed from the hydraulic circuit. Carry out a few cycles
in semi-automatic mode (press key F8 to select a semi-automatic loading cycle and then press buttons 28 and 2) making
sure that the filler box always reaches the end of its stroke safely, i.e. the limit switch should be effectively triggered.
Make sure that the filler box encoder setting shown on the display is lower than the value set for the end of the backward
stroke (usually a few mm). Under the conditions described above (speed 100% and RP2 = 50%), the speed of the filler
box must be at least equal to the max. operating speed required to produce tiles of the correct size. If it is not, increase
RP2 until the desired speed is reached (Maximum acceptable value RP2 = 70%).
5-3
014AZ002A
5.3 MACHINE ADJUSTMENTS
5.3.1 ADJUSTING THE KNOCKOUT
C1819
SMU
ADJUSTING THE SMU KNOCKOUT
Set the pressure for the cylinder (which holds the die) to approx. 80 bar when a die-set with through-punches is used
(50 bar with a mirror-finished die set). To set the pressure, work on relief valve 253 and observe the reading given on
pressure gauge 142.
Set the speed at which the tiles are ejected by adjusting restrictor 61. To adjust the speed for the first die-set downstroke
work on restrictor 23 until a suitable speed is obtained.
To set the speed for the second die-set downstroke, adjust restrictor 242 until the die set rests on the base plate without
banging on it.
Check the first die-set downstroke by pressing buttons 13 and 30 once or twice so that the lower punch is ready to
perform the second downstroke. Measure the distance between the lower punch and the upper surface of the die. If the
distance is not correct, allow the die-set to rest on the base plate again by pressing push buttons 13 and 30. Push buttons
26 or 31, while keeping button 12 pressed, to increase or decrease the soft filling setting until the desired value is
reached.

C2086
ADJUSTING THE TRADITIONAL ROD-TYPE KNOCKOUT

Set the speed at which the tiles are ejected by adjusting restrictor 61. To adjust the speed for the first die-set downstroke,
work on restrictor 23 until the movements are performed at the required speed.
Set the speed for the second downstroke by adjusting restrictor 242 until the die-set gently rests on the lower plate
without banging it.
Check the first die-set downstroke by pressing buttons 13 & 30 once or twice so that the lower punch is set for the second
downstroke. Measure the distance between the lower punch and the top surface of the die. If the distance is incorrect,
allow the die-set to rest again on the base plate by pressing buttons 13 & 30 and buttons 26 or 31 (keeping button 12
pressed) in order to increase or decrease the soft filling setting until the desired value is reached.
5-4
014AZ002A
5.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM
The press is factory set before shipment. However, the information below is supplied to ensure that the original settings
have not been accidentally altered.
LOGIC ELEMENT CONTROL ASSEMBLY

Preliminary adjustment Preliminary adjustment Preliminary adjustment
Component Operated by PH 690 PH 1000 PH 1500
120 YV38 Fully open Open by 6 turns Open by 6 turns

119 YV70 Open by 2 turns aperto 2 turns Open by 2 turns
118 YV70 Fully open Fully open Open by 10 turns
117 YV19 Fully open Open by 3.5 turns Open by 3.25 turns
116 YV40 Open by 2.5 turns Open by2.5 turns Open by 2.25 turns
131 YV41 Open by 4 turns Open by 5 turns Open by 5 turns
ACCUMULATOR CONTROL ASSEMBLY

Preliminary adjustment Preliminary adjustment Preliminary adjustment
Component Operated by PH 690 PH 1000 PH 1500
115 YV53 Fully open Open by 6 turns Open by 6 turns

108 YV32s Open by 5.5 turns Open by 5 turns Open by 7.5 turns
109 YV32d Open by 8 turns Open by 6 turns Open by 8.5 turns
174 YV47 Open by 5 turns Open by 8.5 turns Open by 8.5 turns
114 - Fully open Open by 6 turns Open by 6 turns
90 - Open by 5.5 giri Open by 5.5 turns Open by 6.5 turns
92 - Open by 1 and 2/3 turns Open by 1 and 2/3 turns /
5-5
014AZ002A
5.3.3 ADJUSTING THE SPEED OF THE FILLER-BOX
DCL
C1821
FILLER-BOX SPEED SETTING (DCL)

SETTING (DCL)
Once the filler-box has been inspected for proper operation, set the speeds for each of the 5+5 steps which form the
total stroke of the filler box (expressed in % from 0 to 100). This indicates the actual aperture of the control valve. An
optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder,
determine the position in which the filler-box must be when the die-set performs its first downstroke. Simulate a number
of filler-box cycles in semi-automatic mode. Press pushbuttons 8 & 27 to check the filler-box for proper operation before
loading the working material.
If the value entered for the FILL.-BOX APPROACH POS. data item during the filler-box return stroke is greater than
zero, plunger downstroke will be triggered once the FILL.-BOX APPROACH POS. setting has been passed. As soon
as the filler-box reaches the end of its return stroke, the ALM cycle will start. The filler-box will reach the value set for
the FILL.-BOX APPROACH POS. data item after the grid has been loaded. The filler-box will run at the set APPROACH
SPEED.
When set to manual mode, the filler-box runs at a constant speed equal to that set for SPEED IN MANUAL MODE. When
set to automatic and semi-automatic modes, the filler-box runs at the set speeds. If the setting for FILL.-BOX
APPROACH POS. is greater than zero, the 8 + 8 steps go from the FILL.-BOX APPROACH POS. to END OF FORW
STROKE settings. The last step of the return stroke is performed at the speed used for the eighth step of the return stroke.
The cycle can be set while the ALM is not working. Loading takes place while the ALM is stationary. In this case, the
grid is loaded through filler-box operation. In this case, the FILLING STROKE will equal the APPROACH STROKE.
POWDER INFEED (DCL)

Properly set the ALM feeder (see relevant manual).
Select the desired type of loading: grid loaded while the ALM is stationary or grid loaded with ALM running.
Set the time for the “DELAYED LOADING” data item. This is the length of time the hopper gate stays open.
Set the “GATE CLOSING DELAY” time. This is the amount of time which elapses from when the hopper reaches the
position in which the gate closes and the gate actually closes.
A special cycle can be selected if double rows of tiles have to be pressed. This is done by setting 2-ROW FILLING =
YES. In this case, two values have to be entered in the PLC. The first refers to the point at which the gate closes during
the stroke for loading the ALM.
This gate opens again after the time set for OPENING DELAY has elapsed. Once the second value is reached, the time
set for GATE CLOSING DELAY starts elapsing after which the gate closes definitively.
Move the filler-box completely backward and let powder into the feed hopper.
Set the number of strokes to be performed (from right to left) during each cycle (set 1 or 2 strokes. If 3 strokes are set
the ACP will move non-stop).
Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found
to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder.
The ALM can carry out an overtravel during its return stroke to zero set the filler-box encoder. This may also be useful
when installing and removing the grid.
Timed filler-box and knockout operations can also be carried out during loading. In particular, the knockout can perform
up to 5 movements during the filler-box return stroke, starting from the 1st downstroke position. The following are set
for each movement:
filler-box setting at the start of the movement, degree to which the die-set moves, filler-box return stroke setting up to
setting for 1st downstroke and die-set speed during the movement.
5-6
014AZ002A
DCP
FILLER-BOX SPEED SETTING
SETTING (DCP)
Two different systems can be used:
FILLER-BOX ACTUATED BY A NON-PROPORTIONAL VALVE

Once the filler box has been inspected for proper operation, set the speed levels for the 5 + 5 steps which form the total
stroke of the filler box. These are expressed in %:
- the filler-box will run at the min. speed if a value between 0 and 75% is set
- the filler-box will run at the max. speed if a value between 75% and 100% is set
An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder,
determine the position in which the filler box should be when the die-set performs its first downstroke. Press keys 8 and
27 at the same time to simulate various filler box cycles in semi-automatic mode to check the filler box for proper
functioning before loading the powder.
FILLER-BOX ACTUATED BY A PROPORTIONAL VALVE (OPTIONAL)

Once the filler box has been inspected for proper operation, set the speed levels for the 5 + 5 steps which form the total
stroke of the filler box. These are expressed in % from 0 to 100 which represent the degree to which the control valve
is open in relation to its maximum opening. An optimal speed range is thus determined in order to suit the product to
be obtained. To properly load the powder, determine the position in which the filler box should be when the die-set
performs its first downstroke. Press keys 8 and 27 at the same time to simulate various filler box cycles in semi-automatic
mode to check the filler box for proper functioning before loading the powder.
POWDER INFEED (DCP)

Two different systems can be used:
FILLER-BOX WITH HOPPER AND ACP

After the ACP device has been properly set up (see relevant manual), put powder into the filler box infeed hopper. Set
the number of strokes to be carried out (from right to left) per cycle (1 or 2 strokes). If 3 is entered, the ACP will operate
non-stop.
FILLER-BOX WITH ALM MOBILE HOPPER

Properly set the ALM device (see relevant manual).
Set the “delayed loading”. This is the amount of time the hopper stays open before moving backwards. Set the “gate
closing delay”.
This is the amount of time which elapses from when the hopper reaches the position in which the gate closes (on the
sensor) and the actual closure of the gate.
Move the filler-box completely backward and place powder in the feed hopper. Set the number of strokes to be carried
out (from right to left) per cycle (1 or 2 strokes). If 3 is entered, the ACP will operate non-stop.
Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found
to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder.
5-7
014AZ002A
5.3.4 PLUNGER BRAKING ADJUSTMENT
To check the value entered for plunger braking, observe the braking logic element value, which should be approx. 80.
If it is not, allow the plunger to rest on the powder, press buttons 7 and 26 at the same time to increase the braking force
or buttons 7 and 31 to decrease it until approximately 80 is read. At the beginning, inactivate the brake control (speed
control on = NO) and set an adequate braking action (e.g.. braking space = 90.00) in order to have safe braking during
the first stage. After filling the die-set with powder, perform some downstrokes, adjust the braking action and change
the braking logic element setting until the desired braking force is obtained.
Once the machine has been started up, the automatic brake control can be activated. To do this, check that the braking
space is ≥ 70.00 (if it is less than 70.00, the automatic brake control cannot be switched on). After the die-set has been
filled with powder, read the speed at which the punches come into contact with the powder. If it is suitable for the press-
cycle, type in “YES” for speed control on and enter the impact speed setting previously read. From this time on, the
controller will correct the brake settings until the impact speed remains constant throughout the cycle.
5.3.5 PLUNGER MOTION SETTING
Read the setting for start of pressing (punches on the powder). Slowly lower the plunger until the punches come into
contact with the powder, read the plunger encoder setting (expressed in mm and referred to the end of its upward stroke)
and enter the setting given for start of pressing. Turn the key switch to WRITE to enter a high temporary safety value
for indicating lack of powder (stoppage due to lack of powder = 140.00). In this case, the control will no longer be
activated. Enter a setting for the end of the upward stroke (plunger up). Remember that the last setting should allow the
filler box to move freely. Enter YES to brake during upstroke as well as the value for end of braking while the plunger
moves up again. Allow the plunger to move up and down in manual mode with the die cavity full of powder.
5.3.6 SETTING THE PRESS-CYCLE
Enter the data related to the press-cycle. Enter the number of press-strokes per cycle, the pressure settings (expressed
in bar) for the first, second and (if necessary) third press-strokes, the delay time (expressed in milliseconds) for the first
press-stroke as well as the first and (if necessary) second de-aeration. These settings must be compatible with the size
of the tiles to be obtained. Fill the die-set with new powder in semi-automatic mode (with selector 23 set to automatic,
select semi-automatic loading by pressing key F8; then press pushbuttons 28 and 2 respectively). After making sure
that the powder is evenly distributed in the die cavities, perform a press-cycle in semi-automatic mode with selector
switch 23 set to automatic (to select the semi-automatic mode, press key F8 and push buttons 28 and 2 respectively).
Fill the die-set ten times approx. and perform the same number of press-cycles in semi-automatic mode in order to
eliminate the air in the hydraulic system and allow the automatic pressure regulators to make the required corrections.
Once the tile has been properly formed, measure its thickness and adjust the height of the soft filling by pressing push
buttons 26 (+) or 31 (-) with the die-set down and push-button 12 pressed to obtain tiles of the desired thickness. Once
the desired thickness has been reached (thickness control on = NO, enter the measured tile thickness for the thickness
displayed). Perform other press-cycles in semiautomatic mode and make sure that the measured thickness corresponds
to that actually read. If it does, the automatic thickness gauge can be switched on (thickness control on = YES, tile
thickness = desired thickness).
5.3.7 ADJUSTING THE DIE-SET PROTECTION DEVICE (FOR LACK OF POWDER)
Inspect the automatic thickness gauge for proper functioning. The tile must not be too thin as this may severely damage
the die-set. Enter the setting for plunger stoppage because of lack of working material. This should be equal to the max.
allowable stroke for the plunger during the press-cycle. Make sure that the plunger can move down an additional 0.5
mm in relation to a tile of the desired thickness. Once this setting has been entered, make sure that a fault message
is actually displayed when the plunger moves below the preset level.
5-8
014AZ002A
5.3.8 ADJUSTING THE PLUNGER SHOCK ABSORBERS
With the plunger in its uppermost position and the safety bar raised, loosen the locknut and lower spring shock absorber
pads 101.
Fill the die-set with fresh powder, allow the punches to rest on it and raise the pads until they come into contact with
the plunger. Bring the cylinder into its uppermost position, raise the safety bar and the pads by approx. half a turn and
then secure the pads in place by using the locknuts provided.
NOTE: Adjust the height of the shock absorbers whenever the punches or die-set are replaced.
5.3.9 AUTOMATIC WORK CYCLE
With the plunger completely down, check the oil level and make sure that the die-set has reached the desired
temperature. Observe the displayed die-set temperature. With the temperature properly set, make sure that the die-set
moves freely. Thoroughly clean the die and start the automatic work-cycle by pressing push buttons 28 and 2. During
the initial work stages, keep the process zone under control so that emergency stop button 24 can be readily pressed
in case of malfunctioning. If there are no problems, allow the machine to run for a few minutes. Stop the work cycle by
pressing push-button 6 then check the finished product and make the required corrections. If tiles are to be ejected
during the last cycle, enter ejection when stopping = “YES”, if not, ejection when stopping = “NO”.
NOTE: the corrections which require adjustments to the press body and the filler box must be carried out with the
machine turned off. Corrections to the data entered into the controller or any adjustments to the hydraulic
components must be performed with the machine running.
When good quality products are obtained, duplicate the program (see par. 4.9.5, Instructions B manual) and perform
further adjustments to increase productivity.
5-9
014AZ002A
5.3.10 SWITCHING ON THE CONTROLLER TO MAINTAIN THE PRE-SET SPEEDS
DCL
C1821
SWITCHING ON THE FILLER-BOX SPEED CONTROLLER (DCL)

Once the press has been started up and the tiles have been properly formed (i.e. the die-set has been loaded correctly),
the speed controller is switched on (FILLER-BOX CONTROL ON = YES). At this point, set the filler-box forward and
filler-box return times (this should correspond to the time previously measured to perform the
forward and return strokes).
The control system sees whether the time error is 5% greater than the set time. If this is the case, a fault message will
appear.
DCP
SWITCHING ON THE SPEED CONTROLLER FOR FILLER-BOXES ACTUATED BY PROPORTIONAL
VALVES(OPTIONAL) (DCP)
The press comes with an electronic device which energizes solenoid valves YV20a to correct any interferences which
may affect the speeds set for the powder feeder. When starting up the machine, switch off this control device (filler box
control on = NO).
When the press has been started up and the tiles are found to be properly formed (the die-set has been properly filled),
the control is switched on (filler-box control = YES). Set the times for the filler box forward and return strokes (the times
set should be the same as those previously read for the forward and return strokes). Check that the gain for the forward
and return strokes falls within 145-155. If they are not, work on RP2 (in the controller) until the desired values are
displayed (max. allowable value, RP2 = 70%).
5 - 10
014AZ002A
OPERATING INSTRUCTIONS 6
6 OPERATING INSTRUCTIONS
6.1 CONTROLS
The following are used to control and monitor press operations:
- CONTROLLER
All the controls necessary to operate the press along with the keys used to program the work-cycle are found here.
- ELECTRICAL CABINET
All the switches used to turn on the motors are located here.
Figure 6.1/A - PH 690 CONTROLS
CONTROLLER
ELECTRICAL CABINET
Figure 6.1/B- PH 1000 - PH1500 CONTROLS
ELECTRICAL CABINET
CONTROLLER
IMPORTANT!
E0004P
All information about how to program and use the controller are given in Instructions B manual - Use of the
microprocessor control system.
The illustrations of the control keyboard and auxiliary control panel are not binding.
The background colors and colors and shapes of the keys may vary according to the electric codes in force in the
country of installation and color of the machine.
However, the number and functions of the keys do not vary even if the colors are different.
6-1
014AZ002A
IMPORTANT
- “CYCLE PROGRAMMING” refers to setting all the data required to perform an automatic work-cycle.
- To access the programming mode, put the key into the switch found on the controller keyboard.
- Only authorized personnel can gain access to the programming mode as altering the programmed data may
cause severe damage to the machine.
- It is advisable to keep a library of the programs loaded by using the sheets provided.
6.1.1 CONTROLLER
The microprocessor-based programmable logic controller is used to:
- set up a work cycle and make modifications to the programmed work stages even when the machine is cycling. These
operations are performed from the control keyboard.
- display messages and typical process variables;
- store and retrieve the data related to each pre-selected press cycle;
- self-diagnosis;
- automatically regulate the operating pressures;
- automatically gauge the tile thickness;
- automatically control the machine even in the event of system failure.
Figure 6.1.1/A - CONTROLLER
SYSTEM CARDS
COMPUTER TERMINAL
MACHINE CONTROL KEYBOARD
INDICATOR LIGHTS AND SELECTORS
NOTE: A detailed description of each section is given on the following pages.
6-2
014AZ002A
Figure 6.1.1/B - (CONTROLLER)

SYSTEM CARDS
SYSTEM CONFIGURATION
Card location
1-4 AL POWER SUPPLY (rectified supply voltage)

5 CPU Central processing unit
6 VA MISCELLANEOUS
7 IA ANALOG INPUT
8 IE ENCODER INPUT
9 IE ENCODER INPUT
10 (not used)
11-12-13 ID DIGITAL INPUT (reads 24 Vdc external signals)
14-15-16 OD DIGITAL OUTPUTS (energize the 24Vdc outputs)
17-18 ODA ANALOG & DIGITAL OUTPUTS
19 (not used)
20-21 OR RELAY OUTPUT
C1463 RACK - PLC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
AL CPU VA IA IE IE
ID ID ID OD OD OD ODA ODA OR OR
DATA
POWER SUPPLY PROCESSING INPUTS OUTPUTS
ALIMENTAZIONE ELABORAZIONE INGRESSI USCITE
The configuration given above is for reference purposes only. For more detailed information, refer to the
INSTRUCTIONS B manual, chapter 2 “LIST OF THE DEVICES”.
6-3
6
6-4
+5
WRITE
R
OFF ON
WD
SL
SC
B
COMPUTER TERMINAL
A1
- D
014AZ002A
7 8 9 A2
A
4 5 6 E SCREEN HOME PAG
+
Figure 6.1.1/C1 - (CONTROLLER)
C
DEL
1 2 3 E F QUIT
CHAR
N
T
. E DEL
0 - R G LINE END PAG
H
OPERATING INSTRUCTIONS
B F1 F2 F3 F4 F5 F6 F7 F8
SMC 085-11-409
17 18 25 26
+5
I R I R
MAN +
SET UP AUT
WD
0 1 2 3 8 9 10 11 16 SL
SC
27 I 29
28
P
A1
I A2 19-23 –
24 4 5 6 7 12 13 14 15 20 21 22 30 31
Figure 6.1.1/D1 - (CONTROLLER)
SMC 085-11-442
014AZ002A
Figure 6.1.1/C2 - (CONTROLLER)

COMPUTER TERMINAL
A 25 line x 80 column electro luminescent display

B Function keys
C Numeric keypad
D Write enable key switch
E Not used
F Deletes last character typed in
G Deletes last line typed in
H Cursor keys
ELECTROLUMINESCENT DISPLAY
The press comes with an electro luminescent display on which the following
are displayed:
- fault messages
- machine configuration data
- production data
- actual settings
- list of the programs
- set points and any modifications made to them
NOTE: To display data, consult MANUAL - B
Figure 6.1.1/D2 - (CONTROLLER)

OPERATION 1ST KEY 2ND KEY+ KEY SWITCH PUMP
Pump start Ø
Alarm reset 1
Automatic cycle start 28* 2 AUT ON
Semi-automatic loading start 28* 2 AUT ON
Semi-automatic press cycle start 28* 2 AUT ON
Plunger up 25 3 MAN/AUT ON
Plunger down 30 3 MAN ON
Slow plunger upstroke 25 3 SET-UP ON
Slow plunger downstroke 30 3 SET-UP ON
Pump stop 4
Repositioning 28 5 AUT ON
Automatic cycle stop 6
Braking force increase 26 7 MAN/AUT
Braking force decrease 31 7 MAN/AUT
Braking force decrease beyond end-stop 28 and 31 7 SET-UP
Braking force increase beyond end-stop 26 and 28 7 SET-UP
Assigns braking analog input offset 25 and 26 7 SET-UP
Assigns braking analog input gain 30 and 31 7 SET-UP
Filler-box forward 29 8 MAN ON
Filer-box return 27 8 MAN ON
Zero point of filler-box with connecting rod
and crank mechanism encoder 26+31 8 SET-UP ON
Punches in 25 9 MAN/SET-UP ON
Punches out 30 9 MAN/SET-UP ON
Upper die-set de-magnetization 31 11 SET-UP
Upper die-set magnetization 26 11 SET-UP
Thickness increase 26 12 MAN/AUT Note: * Press the F8 terminal key to
Thickness decrease 31 12 MAN/AUT set-up the cycle. + Two
Die-sets up 25 13 MAN/SET-UP ON
Die-sets down 30 13 MAN/SET-UP ON
keys need to be pressed
Lower die-set de-magnetization 31 15 SET-UP for almost all of the
Lower die-set magnetization 26 15 SET-UP operations. However, only
Proportional knockout hook up 28 16 SET-UP ON
End of proportional knockout hook up 28 16 SET-UP ON one key has to be pressed
ALM semi-automatic mode 28 17 AUT ON for some operations. In
C.P. semi-automatic mode 28 18 AUT ON
Oil leak recovery pump start/stop 20 these cases, the number of
ALM forward 29 21 MAN ON the key to be pressed is
ALM reverse 27 21 MAN ON
C.P. manual mode 27 or 29 22 MAN
given in the “2ND KEY”
Emergency stop 24 column.
6-5
6
6-6
B
Q W E R T Y U I O
A S D F G H J K L
Z X C V B N M P :
;
+ & * (
SPACE
014AZ002A
" = 7 8 9 +
A
CAPS PAGE 5 % ^
ESC TAB 4 5 6 _
LOCK UP
1 @ #
SHIFT ALT INS 1 2 3 E
N
T
PAGE ) > < E
CTRL BKSP DEL 0 " " R
DOWN
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 C
Figure 6.1.1/E1 - (PERSONAL COMPUTER) (OPTIONAL)
SMC 085-11-449
C1421
17 18 25 26
+5
I R I R
MAN +
SET UP AUT
WD
0 1 2 3 8 9 10 11 16 SL
SC
27 I 29
28
P
A1
I A2 19-23 –
24 4 5 6 7 12 13 14 15 20 21 22 30 31
SMC 085-11-442
TER) MACHINE CONTROL KEYBOARD
Figure 6.1.1/F1 - (PERSONAL COMPU-
014AZ002A
Figure 6.1.1/E2 - (PERSONAL COMPUTER) (OPTIONAL)
A Color monitor
B Function keys
C Mouse
COLOR MONITOR
The press comes with an electro luminescent display on which the
following are displayed:
- fault messages
- machine configuration data
- production data
- actual settings
- list of the programs
- set points and any modifications made to them
NOTE: To display data, consult MANUAL - B
Figure 6.1.1/F2 - (PERSONAL COMPUTER)

OPERATION 1ST KEY 2ND KEY+ KEY SWITCH PUMP
Pump start Ø
Alarm reset 1
Automatic cycle start 28* 2 AUT ON
Semi-automatic loading start 28* 2 AUT ON
Semi-automatic press cycle start 28* 2 AUT ON
Plunger up 25 3 MAN/AUT ON
Plunger down 30 3 MAN ON
Slow plunger upstroke 25 3 SET-UP ON
Slow plunger downstroke 30 3 SET-UP ON
Pump stop 4
Repositioning 28 5 AUT ON
Automatic cycle stop 6
Braking force increase 26 7 MAN/AUT
Braking force decrease 31 7 MAN/AUT
Braking force decrease beyond end-stop 28 and 31 7 SET-UP
Braking force increase beyond end-stop 26 and 28 7 SET-UP
Assigns braking analog input offset 25 and 26 7 SET-UP
Assigns braking analog input gain 30 and 31 7 SET-UP
Filler-box forward 29 8 MAN ON
Filer-box return 27 8 MAN ON
Zero point of filler-box with connecting rod
and crank mechanism encoder 26+31 8 SET-UP ON
Punches in 25 9 MAN/SET-UP ON
Punches out 30 9 MAN/SET-UP ON
Upper die-set de-magnetization 31 11 SET-UP
Upper die-set magnetization 26 11 SET-UP
Thickness increase 26 12 MAN/AUT Note: * Press the F11 terminal key
Thickness decrease 31 12 MAN/AUT to set-up the cycle. + Two
Die-sets up 25 13 MAN/SET-UP ON
Die-sets down 30 13 MAN/SET-UP ON keys need to be pressed
Lower die-set de-magnetization 31 15 SET-UP for almost all of the
Lower die-set magnetization 26 15 SET-UP
Proportional knockout hook up 28 16 SET-UP ON
operations. However, only
End of proportional knockout hook up 28 16 SET-UP ON one key has to be pressed
ALM semi-automatic mode 28 17 AUT ON for some operations. In
C.P. semi-automatic mode 28 18 AUT ON
Oil leak recovery pump start/stop 20 these cases, the number
ALM forward 29 21 MAN ON of the key to be pressed is
ALM reverse 27 21 MAN ON
C.P. manual mode 27 or 29 22 MAN given in the “2ND KEY”
Emergency stop 24 column.
6-7
014AZ002A
Figure 6.1.1/G - (CONTROLLER)

SELECTORS AND INDICATOR LIGHTS
HL300 Indicator light, Stand-by and automatic start up on (optional)

SA1 Selector switch, Punch overtravel
SA2 Selector switch, Rod release
SA300 Selector switch, Automatic start-up (optional)
HL300
SA1 SA2 SA300
C1136
6-8
014AZ002A
6.1.2 ELECTRICAL CABINET
The electrical cabinet supplies electricity to the motors installed in the hydraulic power unit and press as well as to the
die-set heater.
Figure 6.1.2 - ELECTRICAL CABINET
A Ammeter
QS1 Main switch
V Voltmeter
(*) Optional
V A
(*)
QS1
C1235
6-9
014AZ002A
6.2 START UP AND SHUT DOWN PROCEDURES
6.2.1 DAILY START UP
The machine is started up by pressing key 0 on the keyboard which first starts the recirculation pump and then the main
motor.
WARNING!
E0004P
Never press push-button 28 on the controller during start up.
Consult the Instructions B Manual when starting the machine in automatic mode.
6.2.2 STOPPING THE MACHINE
The machine can be stopped in two ways:

- from the controller, by pressing key 6;
- from the outer shut down circuit (KA300).
6.2.3 EMERGENCY STOP
The machine is provided with two emergency stop buttons. One is located on the machine control keyboard while the
other is found on the back of the machine. When pressed, these red mushroom-head buttons stop the machine as well
as all of the equipment placed before it. The following takes place when these buttons are pressed:
- the hardware of the solenoid valves that control the plunger is disabled;
- the hardware of the motors that drive the powder loading system is disabled;
- the hardware of the hydraulic power unit motors is disabled.
Consequently, the machine immediately shuts down and accumulator 12 of the service control assembly. Accumulators
18 and 27 of the brake control assembly have to be manually discharged with cock 153 and accumulators 141 and 337,
if present, through valves 143 and 339.
Once the machine has stopped, it can be restarted as follows:
- bring the emergency stop button back into its original position;
- reset the machine;
- carry out the operations given in paragraph 6.2.1.
6 - 10
014AZ002A
6.3 DIAGRAMS ILLUSTRATING PRESS OPERATION
PH 690 PRESSURE-LOADS GRAPH

The total pressure applied by the press results from the pressure exerted by the central cylinder F. The pressure setting
for the central cylinder is marked in the “P” column. The corresponding thrust F can be read in the left-hand column by
drawing a horizontal line. Once the total thrust has been found F, the value must be marked at the ordinates in the graph.
When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed
S can be found. The value expressed in sq.cm is recorded at the abscissa. The line which passes through the point
(whose co-ordinates are the two values previously found) indicates the specific pressure applied to the tiles.
Figure 6.3/A - PH 690 PRESSURE-LOAD GRAPH
5-200 x 200
6-150 x 200
2-330 x 330
2-300 x 300
F (kN) 6-150 x 150 9-100 x 200 4-250 x 250 P (bar)
6000 306
00
00
00
00
30
60
40
50
5000 254
00
20
4000 203
2
cm
N/
3000 153
0
100
2000 102
1000 51
S (cm2)
200
600
1000
1400
1800
2200
2600
400
800
1200
1600
2000
2400
2800
C0528
Cylinder cross-section = 1963.5 sq.cm
6 - 11
014AZ002A
PH 1000 PRESSURE-LOAD GRAPH
Figure 6.3/B - PH 1000 PRESSURE-LOAD GRAPH
2-330 x 330 4-270 x 270
8-150 x 150 5-215 x 215 5-250 x 250

F (kN) 2-300 x 300
6-200 x 200 5-2105x 330 6-200 x 300
7-160 x 160 P (bar)
10.000 352
9000 318
8000 282
7000 248
6000 212
00
00
00
00
30
60
40
50
5000 176
0
2 00
4000 142
2
cm
N/
3000 106
1 000
2000 70
1000 35
S (cm2)
200
600
1000
1400
1800
2200
2600
3000
3400
3800
400
800
1200
1600
2000
2400
2800
3200
3600
4000
Cylinder cross-section = 2827 sq.cm C0772
6 - 12
014AZ002A
PH 1500 PRESSURE-LOAD GRAPH
Figure 6.3/C - PH 1500 PRESSURE-LOAD GRAPH
4-275 x 275 9-110 x 220
7-150 x 300 5-220 x 330
4-275 x 275 3-330 x 330 4-275 x 275
5-210 x 315 2-440 x 440

4-220 x 440
7-150 x 150 5-220 x 220 3-360 x 360
F (kN) 1-650 x 650 P (bar)
15000 340
14000 317
00
00 00 00 00 30
50 45 40 35
q
cm
12000 N/ 271
2500
10000 228
2000
8000 179
1500
6000 133
4000 91
S (cm2)
1000
1500
2000
2500
3000
3500
4000
4500
5000
C1250
Cylinder cross-section = 4417 sq.cm
6 - 13
014AZ002A
6.4 AUTOMATIC CYCLE
In the descriptions below, the numbers and symbols used to identify the hydraulic, pneumatic and electric components
refer to figure 2.4 - HYDRAULIC DIAGRAMS.
6.4.1 FILLER-BOX START
DCP
START OF FILLER-BOX OPERATED BY A TWO-SPEED VALVE
Solenoid valves YV20a and YV20b are energized when the two cycle start keys (28 & 2) are pressed. The oil provided
by pump 58 and service accumulator 12 passes through valves YV20a and YV20b and starts hydraulic motor 42. The
motor combined with the gears drive the filler-box. The microprocessor control system allows eight different speeds for
the forward and return strokes to be set. Limit switch SQ59, mounted on the filler-box frame, and must be de-energized
after the latter has traveled a few millimeters forward. This will prevent the plunger from moving down until the switch
is triggered by the filler-box during its return stroke. This will happen a few millimeters before the filler-box stops in its
initial start position, i.e. when the encoder reaches the set value. It is important that the position at which solenoid valves
YV20a and YV20b are de-energized and the point where the crank stops are within the operating range of limit switch
SQ59 (see figure 6.4.1/A).
START OF FILLER-BOX OPERATED BY A PROPORTIONAL VALVE (OPTIONAL)

Solenoid valves YV20a and YV20s are energized when the two cycle start keys (28 & 2) are pressed. The oil provided
by pump 58 and service accumulator 12 passes through proportional flow control valves YV20a and YV20s and starts
hydraulic motor 42. The motor combined with the gears drive the filler-box. The microprocessor control system allows
eight different speeds for the forward and return strokes to be set. Limit switch SQ59, mounted on the filler-box frame,
and must be de-energized after the latter has traveled a few millimeters forward. This will prevent the plunger from
moving down until the switch is triggered by the filler-box during its return stroke. This will happen a few millimeters before
the filler-box stops in its initial start position, i.e. when the encoder reaches the set value. It is important that the position
at which solenoid valves YV20a and YV20s are de-energized and the point where the crank stops are within the
operating range of limit switch SQ59 (see figure 6.4.1/A).
DCL
C1821
FILLER-BOX START-UP (DCL TYPE)

Press the two cycle start keys 28 and 2 to start the filler-box’s electric motor (M20). This motor drives the mobile part
of the filler-box through the belts provided.
Eight different speeds can be set for the forward and return strokes from the microprocessor control system. Limit switch
SQ59, located on the fixed filler-box mount, should be released after the box feeder has moved a few millimeters forward,
thereby preventing the plunger from moving down until it is triggered by the filler-box while carrying out its return stroke
a few millimeters before stopping in the initial start position, i.e. when the encoder reaches the value set for the end of
the return stroke.
6 - 14
014AZ002A
Figure 6.4.1/A - FILLER-BOX START-UP
ASYNCHRONOUS OPERATION
C Crank’s range of action
T Tolerance to be observed when repositioning the filler-box back
0 Theoretical position of the filler-box when back
FC Allowable position when the filler-box is back
T
SQ59
PREMUTO
TRIGGERED
0%
FC
C
SQ59
NOT
NON TRIGGERED
PREMUTO
100%
C0351
6 - 15
6
6 - 16
SQ3
SQ6
YV99
YV38
YV40
YV41
YV70
YV53
YV19
YV47
YV21
YV22
SQ61
SQ60
SQ59
YV32s
YV20s
YV32d
YV221
YV20a
YV47a
(PH690
(PH1500
(solo PH690)
(solo PH1500)
only)
only)
START CARRELLO
FILLER-BOX START
solenoid
solenoid
elettrovalvola
elettrovalvola
INIZIO
STARTPRIMA CADUTA
OF FIRST STAMPO
DIE-SET E2 = C15
DOWNSTROKE
FINE CADUTA
valveeccitata
valveeccitata
END PRIMA
OF FIRST DOWNSTROKE
014AZ002A
energized
energized
se sono
if the
selezionate
END OF FILLER-BOX TRAVEL - START OF DOWNSTROKE/HOPPER
GATE
FINE OPENING
CARRELLO - INIZIO DISCESA / APERTURA SERRANDA TRAMOGGINO
FINE STAMPO
related options
END 2„OFCADUTA
SECOND DIE-SET DOWNSTROKE
le relative
have
INIZIO
STARTFRENATURA
OF BRAKING
opzioni
Figure 6.4.1/B - PH 690 - PH 1000 - PH 1500 BAR CHART
ARRIVO
PUNCHESSULLA
ON POLVERE
POWDER
INIZIO
STARTPRIMA PRESSATA
OF FIRST PRESS-STROKE
been selected
FINE
END PRIMA PRESSATA
OF FIRST PRESS-STROKE
DECOMPRESSIONE-DEAERAZIONE
DECOMPRESSION - DE-AERATION
FINE
END DEAERAZIONE
OF DE-AERATION
INIZIO
STARTPRESSATA DIRETTA
OF DIRECT PRESS-STROKE
FINE
END RITARDO SALITA
OF DELAY TIMESTAMPI
FOR DIE-SET UPSTROKE
INIZIO PRESSATA
START MOLTIPLICATORE
OF PRESS-STROKE (WITH PRESSURE BOOSTER)
END
FINE 2„ SECOND PRESS-STROKE
OFPRESSATA
FINE
END RITARDO SALITA
OF DELAY TIMESTAMPI
FOR DIE-SET UPSTROKE
INIZIO
STARTSALITA
OF UPSTROKE
FINE
END SALITA STAMPI
OF DIE-SET UPSTROKE
FINE SALITA FRENATA
END OF UPSTROKE WITH BRAKE APPLIED
C2211
FINE OF UPSTROKE
END SALITA
HOPPER GATE
CHIUSURA CLOSURE
SERRANDA TRAMOGGINO
014AZ002A
6.4.2 POWDER INFEED
DCP
POWDER INFEED (DCP)
The powder can be fed in the following ways:
- a feed hopper with a fixed opening; the powder is fed by gravity and no parts are brought into operation during the
cycle.
- a feed hopper with fully controlled opening; the hopper gate is controlled by sensors located on the filler-box and
solenoid valve YV221.
The operator can thus adjust the amount of powder loaded onto the mobile grid of the box feeder during its travel by
changing the position of the sensors and setting different times for “LOADING DELAY TIME” and GATE CLOSING
DELAY TIME”.
DCL
C1821
POWDER INFEED (DCL)

The powder can be fed by a hopper. Hopper opening is controlled and can be adjusted: the hopper gate is controlled
by the sensors located on the filler-box and solenoid valve YV221.
The operator can therefore adjust the amount of powder let into the filler-box’s grid while carrying out its stroke by varying
the position of the sensors and adequately setting the times for the “LOADING DELAY TIME” and “GATE CLOSING
DELAY TIME” data items.
6.4.3 FIRST DIE-SET DOWNSTROKE
C1819
SMU
While the filler-box moves forward, the encoder records the loading
position (the relevant setting can be entered into the microprocessor
control system) according to the setting for the first downstroke. At this point, solenoid valve YV22 is de-energized,
causing the oil to flow from pump 58 and accumulator 12 to the upper part of cylinders 180. Meanwhile, the oil coming
from the lower part of cylinders 180 is drained through solenoid valve YV22. Pilot operated check valve 62 allows the
fast downstroke to be performed.
The speed for the downstroke can be adjusted with flow regulator 23 (directly mounted on the line). The lower punches
stop moving when they reach a limit stop formed by cylinders 181. Solenoid valve YV21 stays on throughout the whole
stage. In this way, the die-set performs its 1st downstroke, i.e. the cavity which will be filled with powder (on the grid of
the filler box) is created by gravity. It is important that the 1st
downstroke setting is correct as it determines when the powder is to be dropped and consequently the lower cavity
filled.
In addition, this operation depends on a number of other factors, e.g. the speed of the filler-box which is governed by
proportional flow control valve YV20a. During this phase, sensor SQ3 must be de-energized (lower punches raised)
and the cam brought opposite SQ6. If this does not happen, the machine stops and a fault message will appear on the
display.
6 - 17
014AZ002A

C2086
PH 690 WITH TRADITIONAL LIFT SYSTEM

While the filler-box moves forward, the encoder records the loading position (the relevant setting can be entered into
the microprocessor control system) according to the setting for the first downstroke. At this point, solenoid valve YV22
is de-energized draining cylinder 55. Pilot operated check valve 62 allows the fast downstroke to be performed. The
speed for the downstroke can be adjusted with flow regulator 23 (directly mounted on the line). The lower punches stop
moving when they reach a limit stop formed by cylinders 56. Solenoid valve YV21 stays on throughout the whole stage.
In this way, the die-set performs its 1st downstroke, i.e. the cavity which will be filled with powder (on the grid of the filler
box) is created by gravity. It is important that the 1st downstroke setting is correct as it determines when the powder
is to be dropped and consequently the lower cavity filled. In addition, this operation depends on a number of other factors,
e.g. the speed of the filler-box which is governed by proportional flow control valve YV20a. During this phase, sensor
SQ3 must be de-energized (lower punches raised) and the cam brought opposite SQ6. If this does not happen, the
machine stops and a fault message will appear on the display.
PH 1000 - PH 1500
While the filler-box moves forward, the encoder records the loading position (the relevant setting can be entered into
the microprocessor control system) according to the setting for the first downstroke. At this point, solenoid valve YV22
is de-energized so that oil flows from pump 58 and accumulator 12 to the top part of cylinders 55. Meanwhile, the oil
coming from the lower part of cylinders 55 is drained through solenoid valve YV22. Pilot operated check valve 62 allows
the fast downstroke to be performed. The speed for the downstroke can be adjusted with flow regulator 23 (directly
mounted on the line). The lower punches stop moving when they reach a limit stop formed by cylinders 56. Solenoid
valve YV21 stays on throughout the whole stage. In this way, the die-set performs its 1st downstroke, i.e. the cavity
which will be filled with powder (on the grid of the filler box) is created by gravity. It is important that the 1st downstroke
setting is correct as it determines when the powder is to be dropped and consequently the lower cavity filled. In addition,
this operation depends on a number of other factors, e.g. the speed of the filler-box which is governed by proportional
flow control valve YV20a. During this phase, sensor SQ3 must be de-energized (lower punches raised) and the cam
brought opposite SQ6. If this does not happen, the machine stops and a fault message will appear on the display.
6 - 18
014AZ002A
6.4.4 FILLER-BOX OPERATION
DCP
FILLER-BOX OPERATION WITH A TWO-SPEED VALVE
The encoder detects the position of the filler-box while it is moving. The speed range for the filler-box can be set by
entering values for the 5+5 steps of the forward and return strokes in the microprocessor-based control system.
A low and high speed can be set:
- If a value between 0 and 75% is entered, YV20a is energized and the filler-box runs at low speed. Use the restrictor
valve mounted on YV20b to adjust.
- if a value between 76% and 100% is entered, YV20a and YV20b are energized. As a result, the highest speed for
the filler-box is obtained which can be adjusted through flow control 24.
Valves YV20a and YV20b provide a link between accumulator 12 and motor 42 changing the speed according to the
values entered and position of the potentiometer.
FILLER-BOX OPERATION WITH A PROPORTIONAL VALVE (OPTIONAL)

The encoder detects the position of the filler-box while it is moving. It is possible to decide the speed profile for the filler
box by entering the set points for the 5+5 steps of the forward and return strokes (1) into the microprocessor-based
control system. To vary all the speeds proportionally, set the GAIN (RP2) (2) data item accordingly. Proportional valve
YV20a will control the oil flow from accumulator 12 to motor 42 according to the set points entered.
NOTE:
(1) The set points are values which range from 0 to 100% and provide a speed range for each individual step.
(2) The set point works on the voltage output in the microprocessor control system, making the signal which
reaches the valve stronger or weaker.
DCL
C1821
FILLER-BOX OPERATION (DCL)

The encoder detects the position of the filler-box while it is moving. The speed range for the filler-box is determined by
entering the set points for the 5+5 steps of the forward and return strokes (1) in the microprocessor-based control
system.
NOTE:
(1) The set points are values which range from 0 to 100% and provide a speed range for each individual step.
6 - 19
014AZ002A
6.4.5 SECOND DIE-SET DOWNSTROKE
C1819
SMU
The filler-box continues to move until it reaches the end of its pre-determined stroke. At this point, solenoid valves YV21
and YV20s are de-energized whereas solenoid valve YV20a is assigned the OFF SET value. While solenoid valve YV21
is de-energized, cylinders 181 for the 2nd downstroke are drained. With solenoid valve YV22 de-energized, the oil
delivered increases the pressure in the die-set return cylinder 180. As a result, the pressure generated within the cylinder
181 causes the oil to flow out though flow regulator 242 and solenoid valve YV21 so that the die-set can perform its
downward movement. Work on plate-mounted flow regulator 242 to govern the movement.
During this phase, it is essential that sensor SQ6 continues to be energized by the respective cam. If it is not, the press
automatically stops working and a fault message will appear on the display (refer to the Instructions B Manual). The
setting entered for the end of the return stroke will cause the filler box to stop in its rest position. Before the filler box
stops moving, safety switch SQ59 must be triggered. The respective Led, located on the front panel of the
microprocessor control system (KA59) should go out.

C2086
PH 690 WITH TRADITIONAL LIFT SYSTEM

is de-energized, cylinders 56 for the 2nd downstroke are drained. Thanks to the springs pressure is exerted on cylinder
56 causing the oil to flow through flow control 242 and YV21. As a result, the die-set carries out its second downstroke.
Adjustments are made by working on plate-type flow control 242.
microprocessor control system (KA59) should go out.
PH 1000 - PH 1500
is de-energized, cylinders 56 for the 2nd downstroke are drained. The oil pressure delivered by solenoid valve YV22
when de-energized is in cylinder 55 used for the die-set return stroke. As a result, pressure is exerted on cylinder 56
causing the oil to flow through flow control 242 and YV21. As a result, the die-set carries out its second downstroke.
Adjustments are made by working on plate-type flow control 242.
microprocessor control system (KA59), should go out.
6 - 20
014AZ002A
6.4.6 ADDITIONAL DIE-SET DOWNSTROKE (OPTIONAL)
An intermediate rest for the lower punches allows the powder to be loaded so that two layers can be formed. The punches
first rest on cylinders 189, allowing the die-set to perform its downward stroke.
At this point, solenoid valve YV170 is de-energized while solenoid valve YV21 stays on. The powder is then loaded so
that a second layer can be formed.
The punches rest on the press table after solenoid valve YV21 has been de-energized. The speed at which the additional
downstroke is performed is governed by plate-mounted flow regulator 169.
The cavity can be filled twice when a second filler box triggers a press-cycle at the end of its stroke.
6.4.7 FAST DOWNSTROKE
The following conditions must be satisfied in order for the plunger to start its downward movement:
- Sensor SQ6 activated (lower punches down)
- Limit switch SQ59 triggered by the box feeder when fully backward.
Under these conditions, the microprocessor control system must receive an electric pulse from solenoid valve YV32d.
This will relieve the pressure in the rear part of the cone on logic element 109. At this point, the combined weight of the
plunger-and-cylinder assembly and the pressure that the air contained in pre-filling tank 126 exerts generates a
pressure in the annular chamber of the cylinder. This pressure will overcome the push of the spring, thus opening logic
elements 174 and 109.
The oil can thus be drained through the annular chamber. The oil will encounter little resistance along its passage. As
a result, the main cylinder will begin its downstroke as the air pushes the oil in the pre-filling tank through the ports in
the pressure booster located in the main cylinder. The speed, during this part of the downstroke can be adjusted by
opening the cone of logic element 109. To do this, work on the adjuster provided. In any case, as this adjustment is used
to bring the upper punches close to the powder to be pressed, it is advisable to select the highest possible speed which
can be used.
6.4.8 DOWNSTROKE WITH BRAKE APPLIED
As soon as the plunger exceeds the setting entered for start of braking solenoid valve YV47 will be energized. As a result,
the oil under pressure will flow from accumulators 27 and 18 to the back part of the cone of logic element 174. This will
cause the nozzle (found beneath the pressure line of solenoid valve YV47) to shut the logic element in a pre-determined
time. The oil will have to pass through flow control 132 (which is motor-operated) and because of its small size, slows
down the downward movement of the plunger, thus creating a back-pressure for braking. Pressure relief valve 92 is a
protective device which reduces the peak pressures; therefore it must not be used to adjust the brake system. To adjust
the speed at which the upper punches come into contact with the powder contained in the cavity, it is necessary to set
“speed control on” = YES in the Microprocessor control system. After this has been done, set the impact speed to
the desired setting in mm/sec. The automatic speed control can be used only if there is a braking space of ≥ 70 mm.
The program comes with a corrective function which, when activated, detects the impact speed and compares it to the
set one, thus altering the settings of flow control 132 by means of motor M15.
The speed control during braking can be turned off by entering “speed control on” = NO.
The braking length can be varied by setting the following data items:
- BRAKING IN PRESSING = YES. Braking is shut off by de-energized YV47 when the 2ND PRESS-STROKE WITH
BOOSTER is started.
- BRAKING IN PRESSING = NO. Braking is shut off by de-energized YV47 when the 1ST PRESS-STROKE is started.
6.4.9 DELAY TIME FOR THE 1ST PRESS STROKE
The plunger will continue to move down at the braking speed until the upper punches come into contact with the powder
contained in the die cavities.
While the upper punches are being brought near the powder, the encoder will reach the setting entered to start the press-
stroke a second before the upper punches come into contact with the powder contained in the die cavities. This time
corresponds to the start of the delay time for the 1st press-stroke. The length of the delay time is entered in the
microprocessor control system. Throughout this period, the weight of the cylinder and plunger as well as the pressure
exerted by the compressed air is applied on the powder contained in the die cavities. In this way, the powder is
compacted for the first time and a certain amount of air is let out. This operation is very important to obtain good de-
aeration in the next process stages.
6 - 21
014AZ002A
6.4.10 FIRST PRESS-STROKE
Once the delay time (for the 1st press stroke) has elapsed, the 1st press stroke will begin. The required pressure is set
and measured by pressure transducer BP1.
The program which runs the microprocessor-based control system monitors the operating pressure, compares it with
the set one and, if there are any deviations, corrects them.
The hydraulic circuit will now be examined.
The microprocessor-based control system transmits a signal to solenoid valve YV40 (1st press-stroke) which is then
energized, allowing logic element 116 to open. The logic element permits the oil which comes from pump 58 and
accumulators 18 & 27 to flow to pressure booster assembly 125. The flow rate of the oil can be regulated along with
the working speed of the press by turning the adjuster on logic element 116. Accumulators 18 & 27 are brought into action
by logic element 115 that is operated by solenoid valve YV53, which is energized.
The cylinder chamber filled with oil receives the pressure produced by the piston of the oil flow booster while the plunger
moves down. The latter provides pressure through the main cylinder to the plunger.
The pressure is shown on the display of the microprocessor-based control system. Remember that the exact pressure
value shown on the display does not include any delay time and is therefore more accurate than mechanical pressure
gauges. Pressure gauge 36 must always be turned off during normal operation and used only to check or set the
displayed value.
6.4.11 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT ACCUMULATORS)
To allow the machine to perform the 1st press-stroke without pressure booster, set “1st p.stroke w/out f. boost.”
to YES.
The first press-stroke is different from the previous one from a hydraulic standpoint. The program allows for a fixed time
during which solenoid valve YV40 is energized, as described in the paragraph above. Once this time has elapsed,
solenoid valve YV40 is de-energized and solenoid valve YV19 is energized, thus allowing logic element 117 to open.
As the line pressure is higher than that in the section which joins logic element 117 to the cylinder, the oil will flow into
the latter. This will allow the press stroke to be completed without having to use the booster, thus saving on oil. Obviously,
this type of 1st press-stroke should be performed only when a large amount of oil is needed for the 1st press-stroke (with
SFS die-set or any other optional equipment for very thick tiles made from a dry ground mix).
Setting “1ST P. STROKE W/OUT P. BOOST.” = YES and “1ST SEPARATE PRESS-STROKE” = YES, the press-stroke
will be performed without the accumulators and pressure booster (see FIRST SEPARATE PRESS-STROKE).
6.4.12 1ST SEPARATE PRESS-STROKE
The function of the 1st press-stroke is to remove the air from the powder to be compacted. If the first press-stroke is
too fast or too violent, the air may not be completely released, resulting in defective tiles (grooves in the tiles). It is
therefore sometimes necessary to perform the 1st press stroke at a slower speed and with a more steady pressure.
This phase is known as “1st separate press-stroke”.
To perform this stage, set “1ST SEPARATE PRESS-STROKE” = YES. The type of 1st press-stroke to be performed
depends on the powder to be pressed.
Once the delay time for the 1st press-stroke has elapsed, the solenoid of valve YV40, which pilots logic element 116
when opening, is energized. At the same time, the solenoid of valve 53, which pilots logic element 115 when closing,
is energized. As a result, accumulators 18 and 27 are shut off.
The press-stroke ends when the cylinder reaches the set pressure, without using the accumulators. The action of the
main cylinder will be slower and steadier, thus allowing the air to be let out from the powder being pressed. This type
of press-stroke requires less energy as the pressure in the pump is proportional with that of the cylinder starting from
“0” up to the max. value, whereas the accumulators would have caused the pump to work at the highest pressure.
6 - 22
014AZ002A
6.4.13 DEAERATION
During deaeration, the upper punches move away from the powder just pressed so that the air compressed in the cavity
can be released. Once the 1st press stroke has been completed, the time set for deaeration (set from the microprocessor
system) starts elapsing.
Meanwhile, solenoid valve YV40, which pilots logic element 116 while closing, is de-energized. Solenoid valve YV70
(drain) is also de-energized, allowing logic elements 118 and 119 to open. The first logic element eliminates the pressure
applied for the first press-stroke which built up in the main cylinder, thus opening a passage to tank 126.
On the other hand, logic element 119 allows the oil contained in tank 126 to be drained into the flow booster.
At this point, two spring shock absorbers 101 (located beneath the plunger), which were compressed during the 1st
press-stroke, push the plunger upwards, allowing the upper punches to move away from the powder and the air to
escape from the cavity through suitably sized openings in the die-set.
Note that de-aeration is strictly related to the time set and space left free (upward movement of the plunger, expressed
in mm, in relation to the shock absorbers). Obviously, the correct adjustment must be performed in the least amount
of time, remembering that the finished tiles must not have any defects in the finish.
6.4.14 SECOND PRESS-STROKE (LAST PRESS-STROKE)
The last press-stroke is performed in two separate stages, which are:
- SECOND DIRECT PRESS-STROKE

- PRESS-STROKE WITH PRESSURE BOOSTER
A pressure of up to 150 bar can be reached during the first stage. If higher pressures are required the second stage
must be used.
6.4.15 SECOND DIRECT PRESS-STROKE
Once the de-aeration time has elapsed, the solenoid of valve YV70 is energized, piloting logic elements 118 and 119
while closing. Solenoid valve YV19 is then energized allowing logic element 117 to be opened by the line pressure. As
a result, the accumulators will be directly connected to the main cylinder. If the set pressure is < 150 bar, the second
press-stroke will end as soon as the set point has been reached. If the set pressure is > 150 bar (once the optimal setting
determined by the controller has been reached with the aid of pressure transducer BP1), solenoid valve YV19 will be
de-energized thus shutting off the accumulators. The press-stroke with the pressure booster will then begin.
6.4.16 PRESS-STROKE WITH PRESSURE BOOSTER
The first stage of the press-stroke must be performed as described in the “SECOND DIRECT PRESS-STROKE”
paragraph.
When the pressure in the main cylinder reaches the optimal value (determined by the control system), solenoid valve
YV19 is de-energized, piloting logic element 117 while closing. Solenoid valves YV38 and YV41 are energized thus
allowing logic elements 120 and 131 to open. The oil put under pressure in the pump and accumulators 18 and 27 flows
to pressure and flow booster 125.
MAXIMUM SETTABLE PRESSURE

FOR MAIN CYLINDER
(bar)
PH690 306
PH1000 352
PH1500 340
If the max. allowable pressure in the main cylinder is exceeded for any reason, pressure switch SP2 (set and sealed
during machine inspection at the factory) will come into action to stop the work-cycle. A fault message will appear on
the display of the microprocessor control system.
6 - 23
014AZ002A
6.4.17 SECOND SEPARATE PRESS-STROKE
If the second press-stroke has to be carried out at a slower and steadier speed, accumulators 18 and 27 can be shut
off by entering “2” for the “2ND SEPARATE PRESS-STROKE = YES” data item in the microprocessor based control
system. As soon as solenoid valve YV19 is energized, the solenoid of valve YV53 (accumulator shut off) which pilots
logic element 115 while closing, will be inactivated.
The logic element will prevent the oil (contained in accumulators 18 & 27) from flowing into the pressure lines. As a result,
only the oil which comes from main pump 58 will fill the cylinder of the main piston.
Solenoid valve YV53 will be energized as soon as the operating time of solenoid valve YV19 has elapsed. During the
second half of the press-stroke, where the pressure booster is used, the accumulators are also employed. This kind
of press-stroke allows the user to save on energy as the pressure in the pump is proportional with the pressure in the
cylinder. The pressure will not remain at its highest level when the accumulators are used.
6.4.18 DIE-SET UPSTROKE
C1819
SMU
At the beginning of the 2nd press-stroke, the delay time for the die-set upstroke will begin to elapse (the time is set from
the micro-processor control system).
As soon as the delay time has elapsed, the solenoids of valves YV21 and YV22 will be energized at the same time. The
pressurized oil in accumulator 12 will flow into the lower part of cylinders 181 and 180 thus allowing the lower punches
to move up after the plunger has begun its upstroke. If the delay time is properly regulated, the punches and plunger
will move up at the same time (the tile is taken out between the punches). The longer the delay time, the greater the
time required to energize solenoid valves YV22 and YV21. As a result, the lower punches will move up with a certain
delay in relation to the plunger upstroke.

C2086
WITH TRADITIONAL LIFT SYSTEM

At the beginning of the 2nd press-stroke, the delay time for the die-set upstroke will begin to elapse (the time is set from
the micro-processor control system).
As soon as the delay time has elapsed, the solenoids of valves YV21 and YV22 will be energized at the same time. The
pressurized oil in accumulator 12 will flow into the lower part of cylinders 55 and 56, thus allowing the lower punches
to move up after the plunger has begun its upstroke. If the delay time is properly regulated, the punches and plunger
will move up at the same time (the tile is taken out between the punches). The longer the delay time, the greater the
time required to energize solenoid valves YV22 and YV21. As a result, the lower punches will move up with a certain
delay in relation to the plunger upstroke.
6.4.19 CYLINDER PRESSURE RECOVERY (ONLY FOR PH 1500)
This option can be turned on from the controller. It is active only if the pressure in the cylinder exceeds the line pressure.
Once the last press-stroke has been completed, the oil under pressure in the cylinder flows to the accumulators 18 and
27 which are at a lower pressure. YV19 will be energized so that logic element 117 can open. Oil will be transferred until
the pressure in the cylinder drops to a value equal to the line pressure + 30 bar. At this point, YV19 is de-energized
closing logic element 117. YV70 is de-energized so that the cylinder chamber can be decompressed, reaching zero.
This is done through logic elements 118 and 119.
6 - 24
014AZ002A
6.4.20 UPSTROKE WITH BRAKE APPLIED
To move the plunger up, the pressure in the main cylinder which was used for the last press-stroke has to be eliminated.
This is done by de-energizing solenoid valve YV70 which, in turn, opens logic elements 118 and 119. Logic element
118 will open an oil passage from the main cylinder to tank 126. Meanwhile, the solenoid of valve YV32s, which pilots
logic element 108 while opening, will be energized, thus allowing the oil which comes from pump 58 and accumulators
18 and 27 to flow into the chamber of the main cylinder. Some of this oil will enter the chamber of the booster, thus
allowing the shutter to open. This takes place because solenoid valve YV38 has remained energized. Logic element
120 is still piloted when opening and, as a result, the pressure built up in the chamber of the pressure booster can be
relieved in tank 126.
At this point, the pilot system pressure (applied to the shutter) will cause the piston in the pressure booster to move up.
The oil contained in the pressure booster chamber can flow through the opening in the shutter up to the tank. The oil
contained in the flow booster reaches the tank through logic element 119, which is piloted by drain solenoid valve YV70,
when de-energized. While the piston of the booster is moving up, the oil passages between the main cylinder and the
tank are opened. In this way, the pressure exerted in the upstroke chamber of logic element 108 (piloted by solenoid
valve YV32s when opening) can operate the main cylinder and the oil is thus allowed to enter the tank.
Solenoid valves YV32s and YV47 are energized at the same time. The latter stays on until the plunger encoder reaches
the setting entered for the end of braking during upstroke (only if upstroke braking on = YES is entered). Solenoid valve
YV47 pilots logic element 174 while closing and the oil from main pump 58 and accumulators 18 and 27 (through logic
element 108) is forced to pass through restrictor 90 before reaching the chamber for main cylinder upstroke. The oil
flowing through the restrictor will allow the braking force to be properly adjusted.
6.4.21 FAST UPSTROKE
When the plunger (whose position is recorded by the encoder) is no longer within the predetermined braking range
during upstroke, the oil which comes from logic element 108 can enter the chamber for plunger upstroke (because
solenoid valve YV47 is de-energized). The plunger will continue to move up at a high speed until the encoder detects
the settings for the plunger raised. Solenoid valve YV32s is de-energized and pilots logic element 108 while closing.
Meanwhile, solenoid valve YV38 is de-energized and pilots logic element 120 when closing. The plunger will now stop
moving.
6.4.22 EJECTION
To remove the finished tiles from the cavity, it is necessary to energize solenoid valves YV21 and YV22. This will cause
the lower punches to move up as described in the DIE-SET UPSTROKE paragraph. It is possible to decide when the
solenoid valve is to be energized by setting a delay time for the die-set upstroke. The
operator can also select whether to take out “tiles from between the punches” or to freely remove the tiles. As soon as
sensor SQ3 has been activated (i.e. the pressed tiles have been removed), the box feeder will start moving to eject the
tiles and a new cycle can now begin.
6.4.23 SFS CYCLE: UPPER FORMING DIE (OPTIONAL)
Control cylinders of the SFS system 184 are found in the upper part of the die-set. The system features a three-position
solenoid valve YV193, YV172, accumulator 337 and pressure relief valve 336.
The tiles are removed when solenoid valve YV193 has been energized (after the delay time for punch removal, set from
the microprocessor system and determined before plunger upstroke, has elapsed) thus allowing the oil to flow from
accumulator 337 to the upper part of cylinders 184.
The speed is adjusted by means of flow control 250. The punches’ return stroke can be set by setting that solenoid valve
YV172 is energized either as soon as the filler-box starts or when the filler-box is forward or when it is at the end of its
return stroke. Energizing solenoid valve YV172 will allow the oil to flow from the accumulator to the lower part of cylinders
184. To adjust the speed work on flow control 249.
6 - 25
014AZ002A
6.4.24 MOBILE DIE (OPTIONAL)

C2086

If a mirror finished die-set is installed, the lower die has to be moved in order to bring the upper punches into contact
with the powder. To move the die, a special system - consisting of accumulator 141 and relief valve 140 (which controls
the max. pressure immediately after it) - has been adopted. During the press-cycle, the upper punch (rigidly mounted
on the plunger) moves the lower die downward. The oil which comes from the lower part of cylinders 179 flows back,
partially charging accumulator 141; part of the oil is drained through relief valve 140. Once the press-cycle has been
completed, accumulator 141 will provide the thrusting force and the oil required to place the die in its highest position.
The upstroke speed is adjusted through flow control 145. Check valve 183 is used to prevent the die from moving down
because of leakage if the machine remains inoperative for a long period of time.
C1819
SMU
SMU LIFT SYSTEM
If a mirror finished die-set is installed, the lower die has to be moved in order to bring the upper punches into contact
with the powder. To move the die, a special system - consisting of accumulator 141 and relief valve 253 (which controls
the max. pressure immediately after it) - has been adopted. During the press-cycle, the upper punch (rigidly mounted
on the plunger) moves the lower die downward. The oil which comes from the lower part of cylinders 179 flows back,
partially charging accumulator 141; part of the oil is drained through relief valve 253. Once the press-cycle has been
completed, accumulator 141 will provide the thrusting force and the oil required to place the die in its highest position.
The upstroke speed is adjusted through flow control 145. Check valve 183 is used to prevent the die from moving down
because of leakage if the machine remains inoperative for a long period of time.
6.4.25 DIE OVER-TRAVEL
C1819
SMU
CON ESTRATTORE TIPO SMU
This function is used when the lower punches are to be cleaned. Use the selector switch located on the microprocessor
system. Turning the selector switch to the “on” position will energize solenoid valve YV129 which, in turn, will deliver
oil to the upper part of cylinders 179 and open check valve 251 thus allowing the die to move down.
Under these conditions, the lower punches can be raised so that the user can reach their sides to clean or disassemble
them.

C2086
WITH TRADITIONAL KNOCKOUT

This function is used when the lower punches are to be cleaned. Use the selector switch located on the microprocessor
system. Turning the selector switch to the “on” position will energize solenoid valve YV129s which, in turn, will trigger
rack cylinder 130 thereby increasing the stroke of cylinders 55 and 56.
Under these conditions, the user can reach the side of the punches so that they can be cleaned or disassembled. To
do this, raise the lower punches.
6 - 26
014AZ002A
6.4.26 BRUSH OPERATION
DCP
BRUSH OPERATION (OPTIONAL) (DCP)
The brush is used to keep the punches and die thoroughly clean. An electric motor combined with a belt drive rotates
the brush and advances the filler-box. The brush can operate only if the press is set for automatic operation or semi-
automatic loading. If the operator has entered “rotation enable” = 3 rotation will always be enabled. If “rotation enable”
= 1 is entered, rotation will be enabled only when the filler box is performing its forward stroke. If “rotation enable” = 2
is entered rotation will be enabled only for filler box return.
The direction in which the brush operates can be set. When NO is entered for “REVERSE ROTATION” the direction
of rotation can be selected: clockwise = YES, counter-clockwise = NO. In addition, it is also possible for the brush to
reverse its direction of rotation from time to time. To do this, enter “REVERSE ROTATION” = YES and then the number
of cycles between one reverse rotation and another. If a mobile brush is used, it can also move up and down. As soon
as the “brush down” value has been reached, solenoid valve YV192 will be energized, causing the brush to lower until
it touches the lower die after pneumatic cylinders 270 have been brought into action. As soon as the filler-box encoder
exceeds the setting entered for brush raised, solenoid valve YV192 will be de-energized, thus allowing the brush to move
up.
DCL
C1821
BRUSH OPERATION (OPTIONAL) (DCL)

The brush is used to keep the punches and die thoroughly clean. An electric motor combined with a belt drive rotates
the brush and advances the filler-box. The brush can operate only if the press is set for automatic operation or semi-
automatic loading. If the operator has entered “ROTATION ENABLE” = 3 rotation will always be enabled. If “ROTATION
ENABLE” = 1 is entered, rotation will be enabled only when the filler box is performing its forward stroke. If “ROTATION
ENABLE” = 2 is entered rotation will be enabled only for filler box return.
The brush may operate constantly in the same direction or reverse after a set number of revolutions. If “REVERSE
ROTATION” = NO is entered the brush always runs in the same direction; CLOCKWISE = YES, COUNTER
CLOCKWISE = NO. If “REVERSE ROTATION” = YES is entered the number of cycles after which the brush reverses
operation has to be entered. If a mobile brush is used, it can also move up and down. . As soon as the “brush down”
value has been reached, solenoid valve YV192 will be energized, causing the brush to lower until it touches the lower
die after pneumatic cylinders 270 have been brought into action. As soon as the filler-box encoder exceeds the setting
entered for brush raised, solenoid valve YV192 will be de-energized, thus allowing the brush to move up.
6 - 27
014AZ002A
6.4.27 MOVEMENTS IN MANUAL MODE
A number of movements in manual mode can be performed by using the relevant keys on the control keyboard.
In any case, the movements allowed will not endanger the operator. These movements can be performed provided
that the mode key switch on the control keyboard is turned to MAN.
Different situations may be encountered:
- Safety bar raised and led built into key 15 on. The magnetic lock for the lower punches has been applied. Only the
die-set (push buttons 25, 30 and 13) can be moved upward and downward.
- Safety bar raised and led built into key 15 off. The magnetic lock for the lower punches has not been applied. The
machine is shut-down and the die-set cannot be moved up or down.
- Safety bar raised and led built into key 15 off. The magnetic lock has not been applied.
The following can be set:
A) Magnetic lock = YES if the magnetic lock is to be applied, the machine will be shut down and the die-set cannot
move up and down.
B) Magnetic lock = NO if the magnetic lock does not have to be used. In this case, only the die-set can move up and
down.
- Safety bar lowered and filler box installed. The plunger can be moved upward and downward (push buttons 25, 30
and 3), the filler-box can move backward and forward (push buttons 27, 29 and 8), the die-set can be moved upward
and downward (push buttons 25, 30 and 13), the ALM can move back and forth (buttons 21, 27 and 29), the ACP can
move from right to left (buttons 22, 27 ad 29) ad the upper punches can move up and down (buttons 9, 25 and 30)
if the SFS is installed.
- Safety bar lowered and filler box mount not attached to the press. The plunger can move up and down (push buttons
25, 30 and 3). In this case, the movements are controlled by solenoid valves YV31s and YV31d. These allow the
movements to be performed at speeds lower than 16 mm/sec. The die-set can move upwards and downwards (push
buttons 25, 30 and 13).
With the key switch is turned to SET UP, only the plunger can move up and down at low speed and the die-set can
perform upward and downward movements.
6 - 28
014AZ002A
6.4.28 RESETTING THE ENCODERS
The encoders are automatically reset in the following order when keys 5 and 28 are pressed:
PLUNGER ENCODER RESET PROCEDURE(ABSOLUTE)

- Move the plunger fully up.
- Raise the safety bar and set the machine to set-up.
- Enter encoder number 1 = PLUNGER on the ENCODER RESET page. Refer to the Instructions B Manual - USE OF
THE MICROPROCESSOR-BASED CONTROL SYSTEM.
DCL
C1821
CAL AND ALM ENCODER RESET PROCEDURE (DCL)

- The ALM moves fully back activating sensor SQ10 (ALM encoder BQ10 reset).
- If encoder reset sensor SQ2 is activated, the filler-box will move forward at low speed until sensor SQ2 is inactivated.
- The filler-box moves back at low speed until reset sensor SQ2 is activated (fully back position) (filler-box encoder BQ2
reset).
- The filler-box moves fully back at low speed (set value).
- The ALM moves completely forward (set value).
DCP
FILLER-BOX ENCODER RESET PROCEDURE (DCP)
- The filler-box reaches the “0” position activating YV20a and YV20s.
- The ALM moves completely forward activating SQ23.
6 - 29
014AZ002A
6 - 30
014AZ002A
ADJUSTMENTS 7
7 ADJUSTMENTS
7.1 SETTING THE PH 690 - PH 1000 VARIABLE DELIVERY PUMP
For the reference items, see figures 7.1/A and 7.1/B.
PUMP START-UP
- Fill the hydraulic system.
- Fill the pump casing by using fitting 2. Be sure that the pump casing is completely full.
- Turn the motor on and off, allowing it to run for a few seconds until all the air is let out.
SETTING THE MAX. PRESSURE LIMIT FOR THE SYSTEM
In order to prevent the system from malfunctioning, a pressure relief valve is provided. This valve (112a+111) is found
on the control assembly of the lift system and filler box. To set the pressure limit, perform the following operations:
- Disconnect valve YV11b/r (oil heating)
- Start up the main pump with the safety bar raised.
- Completely loosen valve 112a.
- Completely tighten valve 112 (found on pump 4).
- Press pressure control button 28, found on the microprocessor control system; the pressure will reach 10-20 bar.
Solenoid valves YV11a and YV11b/r will be de-energized and the pump will reach its max. displacement thus draining
the whole delivery line.
- Slowly tighten relief valve 112a until the gauge on the pump 13 reads the required pressure.
- After the valve has been set, tighten it with the locknut provided.
SAFETY PRESSURE
(bar)
PH690 230
PH1000 230
7-1
014AZ002A
7 ADJUSTMENTS
Figure 7.1/A - VARIABLE DELIVERY PUMP PH 690
1 Adjustment screw, Max. displacement limit

2 Pump casing inlet and drain ports
3 Pressure regulator
4 Screw, Pressure control setting
5 Flow control (the screw has to be fully tightened)
6 Flow regulator
7 Pump casing
4
C0540
5
➞
➞
➞
M M11
➞
➞
➞
➞
112
256 78
7 49
58 BT4
SP1 79
SP3
57
M1
C2092
1 2 6
7-2
014AZ002A
ADJUSTMENTS 7
Figure 7.1/B - VARIABLE DELIVERY PUMP PH 1000
1 Adjustment screw, Max. displacement limit

2 Pump casing inlet and drain ports
4 Screw, Pressure control setting
5 Pump flow
6 Pump casing
M M11
➞
➞
➞
➞
112
6 78
49
58 BT4
SP1 79
SP3
57
M1
C2108
1 2 5
7-3
014AZ002A
7 ADJUSTMENTS
SETTING THE OPERATING PRESSURE
The valve 4 which controls the line pressure 112 is mounted on the pump. To perform this operation, set the pressure
limit as described above.
Proceed as directed below:
- Start up the main pump with the safety bar up.
- Apply pressure by pushing button 28, located on the microprocessor control system. The pump provides the max.
amount of fluid and the pressure reaches the permissible limit.
- Loosen pressure regulating valve 112 and eliminate the pressure from the accumulators.
Tighten pressure regulator 112a with button 28 pressed until the gauge reads the desired pressure. Tighten the
adjustment screw.
Once adjusted, pump displacement will become nearly zero. Under these conditions, the oil will no longer be drained
from pressure relief valve 111.
- Tighten pressure relief valve screw 112 when the desired position has been reached.
PH 690
The max. delivery of the pump must be set to 145 l/min. To set the delivery rate, turn screw 1 which limits the maximum
displacement, making sure the current absorbed does not exceed the rated value given on the main motor plate (set
with maximum displacement present).
PH 1000
The max. delivery of the pump must be set to 181 l/min. To set the delivery rate, turn screw 1 which limits the maximum
displacement, making sure the current absorbed does not exceed the rated value given on the main motor plate (set
with maximum displacement present).
Operating pressure
(bar)
PH 690 170
PH 1000 180
OPERATING CONDITIONS
- Motor On; pump running; safety bar raised; max. pump displacement; line pressure = 20 bar.
- Press in standby mode; motor on; pump running, safety bar lowered; pump displacement drops, the line pressure
will be at the operating pressure previously set.
If pump displacement is not zero, it means there is an oil leak somewhere in the system (make sure pressure relief valve
112a has been properly set).
7-4
014AZ002A
ADJUSTMENTS 7
7.2 SETTING THE PH 1500 VARIABLE DELIVERY PUMP

For the reference items, see figure 7.2.
PUMP START-UP
- Fill the hydraulic system.
- Fill the pump casing by using fitting 4. Be sure that the pump casing is completely full.
- Turn the motor on and off, allowing it to run for a few seconds until all the air is let out.
SETTING THE MAX. POWER OUTPUTS FOR THE SYSTEM

The variable delivery pump comes with a power control which limits the power absorbed to a level less than or equal
to the motor power output (see chart) regardless of the pressure reached.
POWER OUTPUT OF
HYDRAULIC UNIT MAIN MOTOR
(kW at 50 Hz)
PH1500 55
This can be done by adjusting power control 5. Proceed as directed below:

- Loosen screw 6 of power control 5.
- Close valve 112.
- If the “oil heating cycle” has been activated (YV11r energized), disconnect valve YV11r.
- Make sure the operating pressure is present. If it is not, adjust it (see paragraph SETTING THE OPERATING
PRESSURE) with 112a.
- Keep push-button 28, found on the microprocessor control system, pressed (solenoid valve YV99 is energised thus
allowing the oil delivery pump to be drained through relief valve 111; the pressure will reach the press’ operating
pressure).
- Attach a clamp tester to the supply wires of the motor.
- Turn screw 6 on the power control until the value read (in AMPERES) is the same as that given on the motor’s rating
plate divided by 1.732 if a 50 Hz motor is used. On the other hand, if a 60 Hz motor is used, divide by 1.732 and then
again by 1.15. The reading should be taken on each supply wire and the reference current corresponds to the average
of the readings taken on the three wires. If a clamp tester is not available, use the ammeter in the switchboard
remembering that the current reading corresponds to the total value for the three supply wires. As a rule, the max.
output currents should be the same as that given on the motor’s rating plate if a 50 Hz motor is used. On the other
hand, if a 60 Hz motor is used, it should equal the rated value divided by 1.15.
When measuring under these conditions, the other utilities have to be shut off as the ammeter is on the cabinet’s line
and not the control unit’s motor.
NOTE
As a rule, the maximum current should be:

For 50 Hz
- equal to the rated current when the reading is taken on the ammeter in the cabinet;
IReading = IRated value
- equal to the rated current divided by 1.732 if the reading is taken on each supply wire;
IReading = IRated value : 1.732
For 60 Hz
- equal to the rated current divided by 1.15 when the reading is taken on the ammeter in the cabinet;
IReading = IRated value : 1.15
- equal to the rated current divided by 1.732 and then by 1.15 if the reading is taken on each supply wire;
IReading = IRated value : (1.732 x 1.15)
- Lock screw 6 in position.

After this procedure has been performed, reset the valves 112a, 112 and 10 and reconnect valve YV11r (see the
SETTING THE SYSTEM PRESSURE and SETTING THE OPERATING PRESSURE paragraphs).
7-5
014AZ002A
7 ADJUSTMENTS
SETTING THE MAX. PRESSURE LIMIT FOR THE SYSTEM (Oil heating and relief valve)
In order to prevent the system from malfunctioning, a pressure relief valve is provided. This valve (112a + 111) is found
on the control assembly of the lift system and filler-box. To set the pressure limits, perform the following operations:
- Detach connector YV11b/r (oil heating valve).
- Fully loosen valve 112a (to be set).
- Completely tighten valve 112 found on the block secured to the frame of the hydraulic power unit.
- Press pressure control pushbutton 28, found on the microprocessor control system; the pressure will reach 10 – 20
bar. Solenoid valve YV99 will be energized and the pump will reach its max. displacement (indicator 9 in position 11),
thus draining the whole delivery line.
- Slowly tighten relief valve 112a until the gauge on pump 13 reads the desired pressure to be set.
- After the valve has been set, lock it in the correct position.
- Attach connector YV11b/r (oil heating valve). As the oil should not yet be at its correct temperature, YV11b/r will see
that the oil heating cycle is started again.
Completely loosen relief valve 10, relieve the pressure in the upper accumulators, tighten valve 10 until the desired
pressure for oil heating (150 bar) has been obtained and then tighten the adjustment screw.
SAFETY PRESSURE
(bar)
PH1500 230
SETTING THE OPERATING PRESSURE

(See figure 7.2)
The valve which controls the operating pressure in the circuit 112 is mounted on a block which is fixed to the frame of
the hydraulic power unit. To perform this operation, the pressure limit has to be set as described above. Proceed as
directed below:
- Start up the main pump with the safety bar up.
- Loosen pressure relief valve 112 and relieve the pressure in the accumulators.
- Gradually tighten pressure relief valve 112 (with pushbutton 28 pressed) until the desired pressure is read on the
gauge and then tighten the adjustment screw.
Once adjusted, pump displacement will become nearly zero (meter 9 reads 10 which corresponds to 0°). Under these
conditions, oil will no longer be drained from pressure relief valve 112a.
OPERATING PRESSURE
(bar)
PH1500 180
CHECKING THE OPERATING CONDITIONS

(See figure 7.2)
- With the motor off; pump stationary: displacement meter 9 reads 11

- With the motor on; pump running; safety bar raised: displacement meter 9 reads 10. When the pump delivery tends
to drop, the line pressure will be at 20 bar.
- Press in stand-by mode; motor on; pump running; safety bar lowered: displacement meter 9 reads 10. Pump
displacement drops. The line pressure will be the operating pressure previously set.
In these two cases, when pump displacement is not zero, it means that there is oil leakage in the system (make sure
that pressure relief valve 112a has been properly set).
7-6
014AZ002A
ADJUSTMENTS 7
Figure 7.2 - REXROTH VARIABLE DELIVERY PUMP PH 1500

1 Displacement regulator body
2 Adjustment screw, Max. displacement limit 18 7 8
3 Adjustment screw, Min. displacement limit
4 Pump casing inlet and drain 6
5 Power control
6 Adjustment screw, Power control
4
8 Adjustment screw, Min. pressure
9 Displacement meter 5
2 3
10 No displacement
11 Max. displacement
12 Pump casing
13 Suction line
14 Delivery line 1
15 Pressure control valve
17 Driver, Power control 9
18 Connection with external pilot system XD
12
11
10
15° 0 15°
Pos. 11
Pos. 10
C0190
C0197
(Pump as seen from above)
YV99 A B
7 15
10
YV11R 112
18
5
112A 6
111
8
17
3 254
49
12
13 58 2
5 1 4
13
SP3
14
M
M1
7-7
014AZ002A
7 ADJUSTMENTS
7.3 SETTING AND RESETTING THE POSITION ENCODER
The resetting operations must be done each time the encoder or any other related mechanical parts are replaced.
7.3.1 PLUNGER TRANSDUCERS
The encoders mounted on the plunger have a central work zone and two outer non-reading areas (see figure) that are
66 mm and 25.4 mm long respectively.
The field of motion of the axis the encoder is used for must be completely centred in the work area.
Figure 7.3.1 - RESETTING THE PLUNGER ENCODER
* = Position not read *

Dead zone
** *
66.0 mm
Blank space
** = Work zone (2.60 in.)
28 mm
(1.00 in.)
To perform the reset procedure, proceed as directed below:

a) Move the plunger fully up in SET-UP mode.
b) Raise the safety bar.
c) Turn the selector switch to SET-UP.
d) Go to the page used to RESET THE ENCODER on the microprocessor terminal.
e) Enter encoder number 1 = PLUNGER.
DCL
C1821
7.3.2 FILLER-BOX ENCODER (DCL)

If the reset procedure (see par. 6.4.28.2) was not successful, proceed as directed below:
a) Move the mobile part of the filler-box (CAF) fully back activating sensor SQ2 but without triggering limit switch SQ20i
(approximately 10 mm from the end-stop).
b) Loosen the encoder support screws and grub screw that secures the encoder shaft to the flexible coupling.
c) Plug the encoder connector into the encoder reset box provided.
d) Turn the encoder until the red led that indicates the encoder zero mark has come on.
e) Keeping the encoder in place fully tighten the support screws and grub screw.
f) Repeat the reset procedure with keys 28 and 5.
DCL
C1821
7.3.3 ALM ENCODER (DCL)

If the reset procedure (see par. 6.4.28) was not successful, proceed as directed below:
a) Move the ALM fully back activating sensor SQ10.
b) Loosen the encoder support screws and grub screw that secures the encoder shaft to the flexible coupling.
c) Plug the encoder connector into the encoder reset box provided.
d) Turn the encoder until the red led that indicates the encoder zero mark has come on.
e) Keeping the encoder in place fully tighten the support screws and grub screw.
f) Repeat the reset procedure with keys 28 and 5.
7-8
014AZ002A
ADJUSTMENTS 7
Figure 7.3.4 - FILLER-BOX ENCODER

DCP
1 Encoder
7.3.4 FILLER-BOX ENCODER (DCP) 2 7-pin connector
Software reset procedure: 3 Encoder reset box
Software reset procedure: 4 Half flanges and related fixing screws
- Fully raise the plunger. 5 Holes and plugs to access to the coupling
- Press keys 28 and 5 to automatically reposition the fillerbox. 6 Geared motor 1 22 3
The filler-box will stop in any position (the filler-box stops 7 Connecting rod
when the encoder’s 0 pulse is read, almost surely it will not CK1
be when the filler-box is back). 4
- Turn the key selector to MAN and press keys 29 and 8 to CK2
move the filler-box back (the filler-box moves at the speed
set for the 1st forward step). 5
- Turn the key selector to SET-UP and press keys 26, 31 and
8 simultaneously with the filler-box in this position (limit
switch SQ59 should be triggered). The encoder’s offset
value will be stored, i.e. the distance traveled by the
6
fillerbox
from the encoder’s 0 position to the position the fillerbox
reaches when fully back.
From this point on whenever the filler-box is moved it will

return to its back position (encoder’s 0 position + offset
value).
7
The encoder can be zero set in a conventional manner:
- With the pump off and key turned to SET-UP, press keys C0207
25, 30 and 8.
- Fully raise the plunger.
- Raise the safety bar.
- Turn off the controller.
- Disconnect the lead which runs from the connector 2 on the encoder 1.
- Hook up the reset box 3.
Two green LEDS, located on the box 3, are used for signals CK1 and CK2. A red LED which lights up only when
the encoder is being reset is also provided.
- Set the rod 7 perpendicular to the press, as when the filler box is fully backwards.
- Loosen the screws which secure the encoder to the half-flange 4.
- Perform the reset operations by turning the encoder body until the red led comes on.
- Fully tighten the screws 4.
- Plug the controller cable into the connector 2.
- Install the guard, making sure the cable is not in the way.
If the operation cannot be done, perform a different procedure.
- Remove the two plugs 5 from the metal cylinder which is located just beneath the encoder.
- Turn the rod 7 until the screw on the coupling is brought near the hole.
- Loosen the screw in the lower part of the coupling and set the rod 7 perpendicular to the machine. Do not turn the
encoder coupling.
- Tighten the bottom screw.
- Loosen the top screw and the screws 4 which secure the encoder to the two half-flanges.
- Remove the encoder.
- Turn the spindle until the red led comes on.
- Re-install the encoder and tighten all the screws.
7-9
014AZ002A
7 ADJUSTMENTS
7 - 10
014AZ002A
MAINTENANCE 8
8 MACHINE MAINTENANCE
The checks and maintenance operations required to keep the press in top running order are listed below.
The first operations dealt with in the chart below, have to be carried out regularly at the stated intervals. The other
operations are to be performed when required, i.e. at the operator’s discretion.
WARNING!
E0004P
Carefully read the precautions given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS before carrying
out any maintenance operations.
8.1 SCHEDULED MAINTENANCE

INITIAL MAINTENANCE TO BE CARRIED OUT EVERY
OPERATIONS THEREAFTER EVERY (HOURS)
(***)
8 40 80 200 500 2000 4000
1 - GENERAL CLEANING OF DIE-SET AND PRESS 8 hours
2 - INSPECT CONDITION OF THE FELTS 80 hours
3 - LUBRICATE PLUNGER BUSHES 80 hours
4 - CHECK OIL LEVEL IN FILLER-BOX GEARED MOTOR 80 hours
5 - INSPECT EJECTOR 80 hours
6 - CHECK NUTS & BOLTS TO SEE IF TIGHT 2000 hours
7 - CHANGE OIL IN HYDRAULIC POWER UNIT 4000 hours
8 - CHANGE OIL IN FILLER-BOX GEARBOX 4000 hours
9 - CLEAN ELECTRICAL CABINET INSIDE 2000 hours
10 - REPLACE FILTER ELEMENTS (*)
11 - CHECK FOR LEAKS 200 hours
12 - INSPECT VARIABLE DELIVERY PUMP 200 hours
13 - CHECK EARTH CONNECTIONS FOR CONDITION (**) 80 hours
14 - CLEAN DIE-SET AIR FILTERS 80 hours
15 - CHECK SAFETY DEVICES 80 hours
16 - REPLACE PRESSURIZATION AIR FILTER ELEMENT 4000 hours
17 - CHECK EFFICIENCY OF SUCTION SYSTEM 500 hours

18 - CHECK EFFICIENCY OF OIL/WATER HEAT EXCHANGER 200 hours
19 - REPLACE THE PLUNGER UPSTROKE LINE Every 6,000,000 cycles or within 5 years
20 - REPLACE THE BOOSTER UPSTROKE LINE Every 6,000,000 cycles or within 5 years
(*) Operation to be carried out only when specified. C2200

(**) Inspect after the die-set has been changed.
(***) Intervals at which these operations are to be carried out are automatically indicated on
Approximate value
1 - GENERAL CLEANING OF THE PRESS. The filler-box, grid, slide plate and the part of the die set which rests on
the table need special attention.
2 - INSPECT THE CONDITION OF THE FELTS which protect the plunger bushes.
8-1
014AZ002A
8 MAINTENANCE
3 - LUBRICATE THE PLUNGER BUSHES (this operation must be done by hand with the grease gun provided. Inject
the grease through the fittings provided).
4 - CHECK THE OIL LEVEL IN THE FILLER-BOX GEARED MOTOR.
5 - INSPECT THE EJECTOR. Make sure there are no oil leaks and that the screws are tight.
6 - INSPECT BOLTS AND NUTS TO SEE IF TIGHT. Refer to chart 8.3.

7 - CHANGE THE OIL IN THE HYDRAULIC POWER UNIT. Change the oil, taking care to remove any deposits which
may have accumulated in the reservoirs. Only oils which have the characteristics indicated in the “Specifications”
paragraph must be used. The intervals indicated in the chart at which the oil should be changed is given for reference
purposes only. Follow the intervals established by the manufacturer of the oil used.
8 - CHANGE THE OIL IN THE FILLER-BOX GEARBOX.
9 - CLEAN THE ELECTRICAL CABINET INSIDE. Clean the electronic and electrical equipment by removing any
extraneous matter with a suitable suction device; do not blow in air! Clean the contacts with ether.
10 - REPLACE THE FILTER ELEMENTS Indicators SP1 (filter on main filtration circuit located in hydraulic power unit)
and SP4 (filler box filter) will cause fault messages to appear on the controller display screen when the filter elements
are clogged. When the message “Filter clogged (SP1)” is displayed a counter that signals “Change filter within XX” also
appears. The press can continue the production cycle until the time after which the filter has to be changed is reached.
Once this time is over, the press will shut down, completing the press-cycle in progress. Operation can be re-started
only after the filter has been changed.
As a result, the operator can change the filters from the time that spans from the message signaling the filter is clogged
is displayed and the press actually shuts down thereby allowing the job to be planned in advance.
Each time a filter element is replaced, thoroughly clean the filter housing.
Check the condition of the filter gaskets each time the filter housing is opened.
The filters monitored by indicator SP1 should be changed only when signaled by the press’ PLC or whenever the oil
is changed.
The filters monitored by indicators SP2 and SP4 should be changed when signaled by the press’ PLC or yearly (when
scheduled maintenance is performed).
Use only genuine SACMI filters to prevent malfunctions from arising.
11 - CHECK FOR OIL LEAKS. Check the logic elements and valve seats for oil leaks. Check the level in the oil leak
collector.
12 - INSPECT THE VARIABLE DELIVERY PUMP. Check the seals for wear. The following conditions should be
satisfied for proper operation.
Keep the pressure control button pressed and make sure the displacement meter, located on the pump casing, reads
zero and that the motor which drives the pump does not consume more power than that set for maximum power
absorption.
If this is not the case, contact our Customer Service Dept.
8-2
014AZ002A
MAINTENANCE 8
13 - EARTH CONNECTIONS
Inspect the earth electrodes of the machine and the earth connections between the crosshead and the plunger. Make
the connections, if required.
Earth terminals:
A - Crosshead
B - Plunger
A
C - Machine base
F - Earth bar in electrical cabinet
B
C
F C2783
Make sure the die-set has been properly earthed (See figure 4.2.4 - DIE SET WIRING DIAGRAM, cables D and E in
chapter 4 - INSTALLATION).
E0004P
WARNING!
Remove the paint from the points where the machine’s earth conductors are attached before tightening the screws
provided in order to guarantee adequate electrical continuity.
Failure to properly earth the machine parts shown may result in damage to the machine and injury to the operator.
14 - CLEAN THE DIE-SET AIR FILTERS

Remove the filters and clean them using compressed air. Check their condition and replace them if necessary (special
attention should be given to the filter gaskets while the covers are being closed.
15 - CHECK THE SAFETY DEVICES

Check all the safety devices for proper operation: emergency stop buttons, limit switches and barrier guards.
16 - REPLACE THE PRESSURIZATION AIR FILTER ELEMENT

Replace the coalescence filter element 271 at least once a year.
17 - CHECK EFFICIENCY OF THE SUCTION SYSTEM

Make sure the suction outlets are hooked up and that the systems run according to SACMI specifications.
18 - CHECK EFFICIENCY OF OIL/WATER HEAT EXCHANGER

Make sure the oil temperature remains within the allowable range and that it does not increase rapidly. If the exchanger
needs to be adjusted, follow the instructions given in paragraph 8.4 - HEAT EXCHANGER MAINTENANCE.
19 - REPLACE THE PLUNGER UPSTROKE LINE

Drain the oil from the machine and replace the tube.
20 - REPLACE THE BOOSTER UPSTROKE LINE

Drain the oil from the machine, remove the cover of the cross-head and replace the tube.
8-3
014AZ002A
8 MAINTENANCE
8.2 SPECIAL MAINTENANCE
8.2.1 SERVICING THE PLUNGER BUSHES
The bushes do not need to be adjusted. The seals, which stop dust from entering, and the high quality materials used
ensure a long service life. When installing, make sure that the oval section marked O and stamped on the bush, is turned
towards the center of the press.
PH690 PH1000 - PH1500
C0542 C0306
8.2.2 FILLING THE RESERVOIR
The reservoir is filled with the aid of a portable charge pump.

- Loosen the level plug Q (pre-filling tank).
- Open the ball valve A (suction line).
- Put one end of the suction hose B into the oil can C.
- Attach the end of the delivery hose D to point N (suction hose).
- Open the ball valve P.
- Turn the switch F to start the charge pump.
- Make sure that the oil filter G is not clogged (indicator H red).
Replace the filter element if necessary (3 absolute µm).

- The presence of oil in the tube L indicates that the system has been filled to the required level.
Once the correct amount of oil has been put in (with the plunger down):
- Turn the switch F to stop the pump.
- Close the ball valve P.
- Remove the hose D from N.
E0004P
ATTENTION!
If the optional filling pump has not been purchased, the customer must see that the oil drawn from the cans is
filtered. The filters used should have a 3 µ absolute degree of filtration to assure the cleanliness rating at the press
inlet conforms to ISO 4406:1999 of 19/17/13.
8-4
014AZ002A
MAINTENANCE 8
Figure 8.2.2 - FILLING THE RESERVOIR
A - Ball valve found on the suction line

B - Pump suction hose
C - Oil can
D - Delivery or drain hose
F - Switch to start the charge pump.
G - Oil filter
H - Indicator (filter clogged)
L - Tube (leaks)
N - Fitting
P - Ball valve
Q - Level plug
8-5
014AZ002A
8 MAINTENANCE
8.2.3 DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND LINES
Draining the reservoir

- Make sure that the ball valve A is open (suction line).
- Put the delivery hose D into the oil can C.
- Connect the drain hose D to point N on the suction line.
- Open the ball valve P.
- This operation can be made faster by pressurizing the circuit (1 bar) using compressed air.
- Close the ball valve P.
Draining the hoses and hydraulic control assemblies

- Attach the hose D to the fitting I)and then put the opposite end into an empty can C.
- Pressurize the circuit (1 bar).
- Open the needle valve E to drain the hoses and the hydraulic control assemblies.
Draining the heat exchanger ad control unit

- Attach the hose D to the fitting R and then put the opposite end into an empty can C.
- Open the ball valve O.
- Drain the exchanger.
8-6
014AZ002A
MAINTENANCE 8
Figure 8.2.3 - DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND LINES
A - Ball valve found on the suction line

C - Oil can
D - Delivery or drain hose
E - Needle valve
I - Fitting
N - Fitting
O - Ball valve
P - Ball valve
Q - Level plug
R - Fitting
8-7
014AZ002A
8 MAINTENANCE
8.2.4 CHECKING ACCUMULATOR PRECHARGE
Gas precharge pressure of the accumulators is set to the standard value indicated in paragraph SPECIFICATIONS at
the time of machine installation.
To check precharge, follow the steps given below:
- Drain the oil from all the accumulators installed in the machine with the cocks provided.
- Make sure the hydraulic circuit is not under pressure.
- Unscrew the cap on the side of inflation valve 38.
- Unscrew the control 39.
- Open the release 40.
- Screw the tester on the inflation valve by hand.
- Secure the fitting directing the gauge block by hand.
- Tighten the control 39 observing the hand of the gauge. When the hand moves away from 0, continue tightening (1/
2 a turn is sufficient; there is no need to tighten completely).
- Read the inflation pressure given on the gauge (check the values obtained with those foreseen for the various
accumulators in paragraph SPECIFICATIONS).
• To reduce the pressure
- Slowly open the release until the desired pressure is reached.
• To increase the pressure
- Take off the knurled cap 41.
- Connect the end of the hose (1/4” BSO at 60°) to fitting 42.
- Connect the other end of the hose to the nitrogen source and put under pressure (it is fundamental to wait for heat
exchange caused by movement of the pressures, to become stable before testing or precharging).
E0004P
ATTENTION!
The accumulators are to be precharged using only dry nitrogen in tanks with reducer. Use of compressed air and/
or oxygen is severely forbidden.
- To disassemble, perform the steps in the reverse order.

- Make certain the inflation valve on the accumulator is tight.
- Tighten the cap on the inflation valve side.
Figure 8.2.4 - CHECKING ACCUMULATOR PRECHARGE
39
41
42
T2543
40
38
8-8
014AZ002A
MAINTENANCE 8
8.3 TORQUES (NUTS AND BOLTS)
S.R = Resisting cross section (sq.mm)

MS = Tightening torque (kgm)
V = Pre-load (corresponding to the tightening torque, kg)
NOTE: 12-K class screws must be tightened with a torque wrench. The operation must be done as if they were
of the 10K class.
Example: A 12-mm dia. screw with a 1.75 pitch (class 12K) must be tightened to 12.28 kgm instead of 14.74 kg.
STANDARD THREAD SCREWS
DIAMETER mm. 4 5 6 8 9 10 12 14 16 18 20 22 24
PITCH mm. 0.70 0.80 1.00 1.25 1.25 1.50 1.75 2.00 2.00 2.50 2.50 2.50 3
S.R. mm2 8.11 13.31 18.68 34.57 45.77 55.28 79.92 110.16 150.49 185.16 236.52 294.16 338
5S MS = kgm 0.22 0.43 0.73 1.81 2.33 3.23 5.46 8.33 12.72 16.02 24.88 33.10 44.00
V = kg 227 373 523 978 1282 1548 2238 3084 4214 5184 6823 8436 9880
8G MS 0.34 0.69 1.16 2.90 3.73 5.18 8.74 13.32 20.36 25.63 35.81 43.36 60.5
V 363 596 837 1549 2050 2477 3580 4935 6742 8295 10596 13178 15800
10K MS 0.49 0.96 1.64 4.07 5.25 7.28 12.28 18.74 28.63 36.04 50.36 60.97 85.3
V 511 839 1177 2178 2884 3483 5035 6940 9481 11665 14900 18532 21740
12K MS 0.58 1.16 1.96 4.89 6.30 8.73 14.74 22.49 34.36 43.25 60.43 73.16 100.9
V 613 1006 1412 2613 3460 4179 6042 8328 11377 13998 17830 22238 26000
FINE THREAD SCREWS
DIAMETER mm. - - - 8 - 10 12 14 16 18 20 22 24
PITCH mm. - - - 1.00 - 1.00 1.50 1.50 1.50 1.50 1.50 1.50 2
S.R. mm2 - - - 37.14 - 61.87 83.83 119.42 161.29 209.44 263.86 324.58 374.5
5S MS = kgm - - - 1.92 - 3.52 5.68 8.83 13.37 17.48 27.16 35.81 45.7
V = kg - - - 1040 - 1732 2347 3344 4516 5864 7688 9388 10800
8G MS - - - 3.08 - 5.63 9.09 14.12 21.39 27.96 38.65 52.10 66.00
V - - - 1664 - 2772 3756 5350 7226 9383 11821 11541 17200
10K MS - - - 4.33 - 7.91 12.78 19.86 30.08 39.32 54.36 73.82 91.00
V - - - 2340 - 3898 5281 7523 10161 13195 16623 21249 24300
12K MS - - - 5.19 - 9.50 15.34 23.83 36.09 47.18 65.23 88.79 110.0
V - - - 2808 - 4677 6338 9005 12194 15834 19948 21538 29200
8-9
014AZ002A
8 MAINTENANCE
8.4 SERVICING THE HEAT EXCHANGER
CLEANING THE EXCHANGER

- Loosen the nuts on the tie rods and move the plate away.
- Check the width of the gaskets and replace them if necessary.
- Remove the plates from the frame.
- If the plates are dirty or covered with calcium deposits, proceed as follows:
Type of deposits Cleaning
Solid deposits not stuck to the plates or grilles Remove them with running water at low pressure
Soft sludge Proceed as above
Hard sludge Soak the plates, and then proceed as above.
Hard calcium deposits Fully immerse the plates (without removing the gaskets and
grilles) in a solution containing water and 10% of hydrochloric
and nitric acid for about 5 minutes. Thoroughly rinse under
running water. Repeat the operation if necessary.
NOTE: Never remove the grilles and the gaskets from their seats unless the gaskets are worn and need to be replaced.
E0004
WARNING:
DO NOT use solvents under any circumstances.
8.4.1 REPLACING THE GASKETS
Check the width of the gaskets measuring it along with the plate. The gasket along with the relative plate should not
be less than 4.1 mm. If worn down and less than this value, replace the heat exchanger gaskets and close it taking into
consideration a precharge value for the plates for the new heat exchanger.
- Remove the square mesh grille from the plate.

- Remove the gasket and thoroughly clean the edges of the plate.
If the gaskets are difficult to install, slightly raise the curled edge of the plate with the aid of a spatula.
- Re-install the grille, making sure that it fits into the inside groove of the gasket.
8 - 10
014AZ002A
MAINTENANCE 8
8.4.2 SECURING THE TIE RODS
No special tools are required to perform this operation (e.g... torque wrenches).
The value n x A, indicated in the diagram, can be exceeded (the plate cluster must be more compact) without causing
the heat exchanger to malfunction (see the chart below). Tighten the tie rods in the following order:
• Secure tie rods 1, 6, 10 and 5.

• Secure tie rods 2, 7, 9 and 4.
• Secure tie rods 3 and 8.
Repeat this operation until the correct dimension is reached.
Figure 8.4.2 - SECURING THE TIE RODS

nxA
1 6
2 7
3 8
4 9
5 10
C0315
n = number of plates that make up the exchanger
TIGHTENING THE TIE ROD (1 PLATE)

New gaskets Minimum
A 3.75 3.5
NOTE:
- The first value was used when the heat exchanger was constructed and for exchangers overhauled with new gaskets.
- The min. tightness is the min. allowable value. To compensate for a plate that has worn down in relation to another,
do not exceed this value as when the space between plates is reduced the section for oil and water flow is also
decreased causing greater loses and reducing efficiency of the exchanger.
8 - 11
014AZ002A
8 MAINTENANCE
8.5 SERVICING THE FIXED DELIVERY PUMPS
These operations must be carried out by well trained personnel, especially when the most important parts of the pump
are to be replaced.
Disassembling:
Thoroughly clean the pump outside and wash it with diesel fuel if necessary.
Do not disassemble the pump in dusty environments or near grinding wheels. Secure the pump to a work bench with
the drain port A turned downwards. Mark the body B and head assembly C for future reference purposes. Remove the
mounting bolts D and pull off the head assembly C.
The head assembly is provided with a reference pin which is used to determine when the perforated plate is to be
reinstalled.
Remove the gasket E.
Take out the perforated plate F.
Fit a rubber ring on the shaft G in order to protect the cylinder block surface.
Secure the block P by applying a shim and a screw.
Remove the tab I, snap ring L, part M and shims V. Be careful not to damage the gaskets N and O.
Remove all equipment from the casing with the aid of a puller. Attach the puller to the threaded section at the end of
the shaft.
Remove the cylinder block P. It is not necessary to mark the pistons and related cylinders.
Remove the Belleville washers Q observing their position.
Remove the pistons R from their housing. Use an electric screwdriver to loosen all the screws S. It is advisable not to
remove the bearings T and U, as the whole unit will have to be set-up if a single bearing is replaced.
Replace the piston rings:
- Remove worn or damaged rings.
- Fit the upper and lower piston rings. When observing the pistons from the top, make sure the marks can be clearly
seen on both faces.
Assembling:
Fit the pistons R back into place and tighten the screws S after applying “Loctite” on their surfaces to prevent them from
loosening. Replace the Belleville washers and the shim Q making sure they are correctly positioned. Grease the
central bore in the block P (do not use standard Belleville washers). Make sure that all the parts are assembled as shown
in the diagram.
Put the pistons R in place in the cylinder block P and insert the pin G in the central hole in the block. Fit the rubber ring.
Use a screw and washer to secure the cylinder block P.
Heat the casing B up to approx. 80°C. Prepare all the tools required to install the front part of the pump so that it can
be installed before the casing cools down. Place the impeller in the pre-heated casing so that the bearings can be fully
pushed home. A heat shield should be used to protect the operator.
Finish assembling the lower part of the pump by installing the gasket O, the shims required and the part M. The last part
to be fitted is the snap ring L.
Remove the rubber ring, the screw and the washer. Install the perforated plate F and the gasket E. Install the head
assembly C and insert the dowel W in the hole provided by referring to the marks made during the disassembly
procedure. Fully tighten the bolts D on the head assembly.
8 - 12
014AZ002A
MAINTENANCE 8
Figure 8.5 - FIXED DELIVERY PUMP
C0500
8 - 13
014AZ002A
8 MAINTENANCE
8.6 VACUUM
If hydraulic components need to be replaced without draining the oil from the press, put the hydraulic circuit under
vacuum with the equipment supplied with the machine. Proceed as follows:
- drain the hydraulic accumulators.
E0004P
WARNING!
Before attempting any operations, wait for the hydraulic accumulators to be completely drained.
- disconnect the pressurization circuit from the air line and wait until air no longer flows out of the circuit;
- connect tube A to fitting B for the vacuum device and tube C to fitting D of the vacuum device;
- wait a few minutes.
To avoid damaging the hydraulic circuit the time the press is kept under vacuum should be as short as possible, in any
case less than 60 minutes. In addition, cover any openings in the hydraulic circuit to prevent pollutants from entering.
NOTE: drain the oil from the press when replacing valves with large diameters directly connected to the reservoir.
Figure 8.1.2 - VACUUM
0 12
C2138
8 - 14
014AZ002A
DECOMMISSIONING 9
9 DECOMMISSIONING
When the machine is to be dismantled, follow the directions given below:
1) rest the plunger on the mechanical stop and secure it in this position so that it can not move in any way
2) disconnect the machine from the supply mains with the main switch and then unplug the power cable
3) if present, discharge accumulators 141 and 337 through valves 143 and 339
WARNING!
E0004P
Wait until the accumulators have been completely discharged before working on the press.
4) drain the hydraulic fluid in the press as instructed for scheduled maintenance
5) disconnect all the machine parts from the power supply
6) disconnect the water lines for cooling down the oil
7) disconnect the hydraulic lines
8) remove the filler-box
9) remove the control unit for the electrical connections
10) discharge all the accumulators of the gas under pressure that is present in them by using the tool for checking
gassing, available on request
11) remove all the accumulators
12) remove all the hydraulic control units
13) the press can be moved as directed for installing it. Refer to the relevant chapter.
When dismantling, parts of the machine (hydraulic control units, accumulators, etc.) have to be moved with suitable lift
devices. These operations are to be carried out only by expert personnel observing the safety regulations currently in
force. In addition, whenever the upper part of the machine has to be reached, all the safety devices and gear called for
by current safety regulation are to be used.
9-1
014AZ002A
9 DECOMMISSIONING
9-2

Manual Prensa SACMI

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Manual Prensa SACMI

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

PH 690 - PH 1000 - PH 1500

PH 690 - PH 1000 - PH 1500

PH690A - 1000A - 1500A

2 MAIN FEATURES ......................................................................................................................................2 - 1

6 OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1

8 MACHINE MAINTENANCE ...................................................................................................................... 8 - 1

1.2 WHERE TO KEEP THE MANUAL

1.3 HOW TO USE THE MANUAL

1.4 USERS OF THE MANUAL

In this manual the machine operators are categorized as follows:

The above mentioned handbooks supplement this manual.

Hot surfaces - danger of being burnt

Danger - hands can be crushed

High tension - danger of being electrocuted

Danger of entanglement in moving parts

It is forbidden to use oxygen to recharge the accumulators

Heavy duty gloves must be worn

The indicated point must be effectively grounded

A list of tools required to carry out maintenance is provided.

This symbol indicates the machine version with SMU system.

Available for the PH 690 - PH 1000 - PH 1500.

Available for the PH 690 - PH 1000 - PH 1500.

Available for the PH 1500.

Available for the PH 690 - PH 1000 - PH 1500.

1.8 MACHINE IDENTIFICATION PLATE

VIA SELICE PROVINCIALE 17/A IMOLA - I TA L I A

2.1 MACHINE DESCRIPTION

2.1.1 MAIN DEVICES

MAIN DEVICES MACHINE FRAMEWORK (PH 690)

MACHINE FRAMEWORK (PH 1000 - PH 1500)

POWDER FILLER-BOX (DCL TYPE FOR PH 1500)

TRADITIONAL LIFT SYSTEM

TRADITIONAL HYDRAULIC EJECTOR (as an alternative to the SMU hydraulic ejector)

GUARDS AND SUCTION HOODS

The controller consists of the following parts:

FIGURE 2.1.1/A - PH 690 OVERALL VIEW

FIGURE 2.1.1/B - OVERALL VIEW OF PH1000 - PH1500

INTENDED USE OF THE MACHINE

UNINTENDED AND PROHIBITED OPERATIONS

MISUSE OR ERRONEOUS USE

2.2.1 PH 690 OVERALL DIMENSIONS

MINIMO PER ESTRAZIONE

1060 1060 TRADITIONAL EJECTOR

MINIMUM FOR WITHDRAWING

MINIMO PARA DESMOLDEO

AREA DE SERVICIO MINIMA

B1 (mm) 380 330

PERFORMANCE PH 690 PH 1000 PH 1500

ELECTRICAL SYSTEM PH 690 PH 1000 PH 1500

KNOCKOUT PH 690 PH 1000 PH 1500

Sound pressure level (ISO/DIS 11202)

PH 690 PH 1000 PH 1500

LpA Continuous A-weighted sound pressure level.

P1 = Occasional control post

Figure 2.3.2 - POINTS WHERE NOISE LEVEL IS MEASURED

PH 690 DUST SUCTION HOODS

Front hood S250 1 120 814 +2.0

NOTES: (1) Outlets present on the RPR tile roller conveyor

NOTE: Suction system vacuum before

NOTE: Use anti-static tubes to connect S260

Front hood S250 2 90 916 +2.0

NOTES: (1) Outlets present on the RPR tile roller conveyor

NOTE: Use anti-static tubes to connect the