Safety Precautions

Before the installation, operation, maintenance and inspection, please read this manual carefully to use correctly. Do not use and operate this machine unless fully understand the principles, all the safety conditions and all precautions of the machine.

Sign description:

Warning!

Indicate that it may cause electric shock in case of misuse.

Warning!

Before the operation of the machine, it must be grounded, and the grounding way should be in line with national standards or the corresponding national standards, otherwise you may get an electric shock.

Note!

Do not put your hand or other articles into the danger area to avoid accidents

1.1  Removal and acceptance

1.1.1      Acceptance

Each press of our company has prepared a good pre-carriage protection before running to ensure it is still complete and safe after arriving at the destination, and please check whether the machine appearance is damaged after receiving the press, and if damaged, please notify the company and the person in charge of transportation to require the inspection. If not damaged, please check whether the fittings are complete, and if missing, please notify the company and the person in charge of transportation to require the inspection as well.

1.1.2      Handling

Due to the large volume and weight of the press itself, ordinary mechanical lifting method cannot be used, so the load bearing range of crane and steel cable must be considered when lifting by crane, and always pay attention to the safety of the machine bulge.

1.1.3      Lifting precautions

(1)  Whether steel cable surface is damaged.

(2)  It is prohibited for steel cable to use 90° lifting method.

(3)  At the lifting bend corner use waste cotton cloth, etc. for binding steel cable surface.

(4)  Do not use chain to lift.

(5)  When the machine is to be moved by manpower, it must not be pushed forward but pulled.

(6)  Keep safe distance during lifting.

1.1.4      Lifting steps

(1)  Insert light round rod (depending on its aperture size) through the left and right sides of the frame.

(2)  Use the steel cable (20mm) in the cross shaped way to pass through the bottom hole of fixed frame and light round rod.

(3)  The crane hook is placed in the appropriate position, slowly leaving the ground and adjust the appropriate load evenly, so that the machine maintains a balanced state.

(4)  Be careful to lift and move it after confirming its safety.

吊取孔 Lifting hole

1.1.5      Unloading notice

The front of the machine is uneven, and both sides of it have electric appliance box and air pipes, etc., so it cannot be inverted forward and transversally, which can only land on the back as marked in the diagram, and of course, it is best to underlay it with the wood block, so as not to hurt the outer of the machine.

The length of the selected wood block must be greater than the width of both sides of the press.

If the height of the door of the plant is lower than that of the press, or when the crane is inconvenient to lift, the press can be inverted to carry out the short distance displacement with the round stick, but you must be careful to prevent accidents. The selected board must be able to withstand the press load.

1.1.6      Basic construction steps

1)    Pre-construction preparation items

(1)  According to the foundation drawing, length, width and height of the foundation, dig in the installation position.

(2)  Soil bearing capacity shall meet the requirements specified in the schedule, and in case of the shortage, it is required to pile to reinforce it.

(3)  Pebbles are rowed on the bottom layer, about 150mm to 300mm high.

(4)  The reserved pit in the foundation should take the board as a spare in advance according to size indicated in the map, which shall be placed to the predetermined position when concrete is being poured.

(5)  If the rebar is used, it must be placed in advance appropriately.

2)    When the above items are prepared fully, pour the concrete at the ratio of 1:2:4.

3)    When the concrete is dry, take off the board, and make an appropriate recondition except for the foundation screw pit. If it has oil-accumulating groove facility, the bottom surface should be reconditioned to be the slope surface, so that the oil can flow smoothly into the oil-accumulating groove.

4)    When installing the machine, the machine and the foundation screw, the horizontal adjustment plate and so on are installed in this position in advance, and after adjusting the level of the frame, the concrete is poured into the foundation screw pit for the second time.

5)    After drying, the recondition is completed.

Note: 1. The pedal on the outside of the machine should be made up with suitable materials by the customer automatically.

2.    If it needs a shockproof device, a layer of fine sand layer should be added on the periphery of the foundation (about 150mm wide groove).

1.2  Installation

1.2.1      Installation of frame working table

(1)  Install the shockproof foot at the bottom of the frame.

(2)  The machine is applied with anti-rust oil in the delivery, and please clean it before installation and then install it.

(3)  When installing, please use the precision leveler to measure its level, to make it fix the machine foundation.

(4)  When measuring the level of the working table, please check whether the working table is locked.

(5)  If the working table top is installed on your own, you should pay attention to the contact surface of the worktable and the frame plate which should be kept clean, and do not put foreign objects, such as paper, metal pieces, plugs, washers, dirt and others left between the frame working table fitting surface and working table.

1.    Please prepare electricity, gas and oil well before installation and commissioning of the press:

Electricity: 380V, 50HZ

Gas: With the pressure of above 5kg, it is better to be dried.

Gear oil: (Add it from the oil tank cover, add the glass cement in the vicinity of it after adding gear oil, in order to prevent oil in the tank from splashing out. Oil cannot be added too much, please do not exceed the 2/3 height of the oil mark)

Grease: 18L (0# grease)

Excess load oil: 3.6L (oil at the 1/2 oil tank scale)

Counter balance oil: 68# (a cup of counter balance oil)

2.    Horizontal adjustment of press

3.    Electrical wiring: As shown in the diagram

C   Frame Single Crank Press Machine（ST series） installation precautions:

1.    Please install the shockproof foot well before the press landing! As shown in the diagram!

2.    If the motor is not installed, please put the motor in the corresponding position after the press landing, as shown in the diagram.

1.2.2      Installation of drive motor

The main drive motor can be combined with the press as far as possible, and in case of the limit in the delivery, motor must be removed and its reinstallation method is shown as follows:

(1)  Open the package of part and check for damage of it.

(2)  Clean motor, motor groove wheel, flywheel groove, bracket, and do not drop the solution in motor, and use a cloth to clean the V-belt, and do not use the solution to clean the belt.

(3)  Install the motor to the joint position, but do not lock it completely, and use the sling to support the weight of the motor before the screw is locked

(4)  Use gauge to measure standard line of motor groove wheel and the flywheel, and move the motor until the standard line is correct. If the standard line of groove wheel and the pulley is not in a good alignment, the belt tunnel and the motor bearing will wear, and when the standard line is aligned, tighten the screws on the motor seat.

(5)  Move the motor slightly towards the flywheel so that the V-belt can slide in the pulley without strain. Caution: Do not force the belt to be installed on the groove wheel tunnel. Belt tightness is best to be about 1/2 under the thumb pressure after the installation.

1.2.3      Horizontal correction

Horizontal adjustment steps:

(1)  Clean the working table thoroughly to increase the accuracy of the horizontal reading.

(2)  Put a precision level gauge in the front edge of the working table, and make measurements in the front, middle and rear.

(3)  If the front and rear sides are tested to be lower, use the tin master slice to pad the frame bottom and make the left and right of it complete level.

Caution: The gasket is at least as large as the foot of the press, which makes the foot contact surface bear the weight averagely. In case of the error, the foundation screw can be slightly adjusted to the level, and others should be checked half a year, to confirm the mechanical level, so the performance of the machine can be maintained to a significant extent.

2.    Preparation before operation

2.1  Use of lubricating oil

2.2  Installation of air pressure

The air pressure pipe must be connected to the pipeline from the back of the press (the pipe diameter is 1/2B), and the plant pipe is shown in the following table, and the required air pressure is 5Kg/cm². But the distance from the air source to the assembly position must be within 5m. First of all, try out the air output and check if there is dust or discharged water retained in any part of the pipe. And then, the main valve is switched on and off, and the air connecting hole is provided with an air inlet.

Note: Air consumption per minute refers to the air consumption required by the clutch during intermittent running.

2.3  Connection of power supply.

First of all, the air switch is shifted to “OFF” position, and then power supply shifting switch on the operating panel is shifted to “OFF” position, to isolate the control panel with the power supply, and after checking that the fuse is not blown out, connect the power supply to the connector according to the power supply specifications of this press and main motor power, in light of the provisions of the following table and electrical equipment criterion.

2.4  Special precautions before installing the power supply for the correct power supply wiring methods:

火线 Live wire

控制回路 Control loop

控制回路共同点 Common points on control loop

(1)  Instructions: In case of the failure of controlling the electrical fittings, PE line is grounded, and the fuse is burnt, which can cause the protective effect.

(2)  Wiring methods: (a) Use a test pencil or avometer to measure the no-voltage line (N line) connected to S end of the power supply terminal of press control box, and the other two lines can be arbitrarily connected to two ends of RT. (b) If the motor is running in the opposite direction, the lines of two RT phases are exchanged, which cannot be exchanged with the A.B.C lines.

(3)  The wrong power supply will lead to the wrong action of the solenoid valve (SV), causing the risk of personnel injury and equipment damage, and the customer should pay special attention to inspecting it.

The machine has taken strict quality control, detailed inspection and emergency measures before the shipment, but considering the unusual circumstances, we have listed all inspection items for the operator to refer to and memorize.

3.    Relevant schematic diagrams of operating press

3.1  Schematic diagram of operating panel

3.2  Schematic diagram of cam control box adjustment

(1)  RS-1 is stop for positioning

(2)  RS-2 is stop for positioning

(3)  RS-3 is safety – stroke

(4)  RS-4 is counter

(5)  RS-5 is air jetting device

(6)  RS-6 is photoelectric device

(7)  RS-7 is misfeed detection device

(8)  RS-8 is backup

(9)  RS-9 is backup

(10) RS-10 is backup

3.3  Schematic diagram of pneumatic device adjustment

(1)  Overload device

(2)  Counter balance

(3)  Clutch, brake

(4)  Air jetting device

4.    Operation procedure

Delivering current: 1. Close the main control box door.

2.    Pull the air switch (NFB1) in the main control box to “ON” position and verify whether the machine is abnormal.

Warning: For the sake of safety, the main control box door must not be opened in the operation of press.

4.1  Operation preparation

1).   The operating power supply switch of operating panel will turn to “in” position, and the power supply indicator light (110V loop) is on at that time.

2).   Make sure whether the “emergency stop” button is in the release state.

3).   Operate after confirming all indicator lights are working properly.

4.2  Main motor start and stop

1).   Start of main motor

Press the main motor running button, and the main motor will run and the main motor running light will be on.

Attention should be paid when starting the main motor:

a.    When the selector switch of running mode is in [OFF] position, the main motor can start other positions besides [OFF] position, otherwise it cannot start.

b.    If the reversion shifting switch is in the [reversion] position, only inching operation can be carried out. The formal punching work cannot be carried out, otherwise the press parts will be damaged.

2).   For the stop of main motor, press the stop button of the main motor, and then the main motor will stop, and the main motor running indicator light will be off at this time, but in case of the following actions, the main motor will automatically stop.

a.    When the air switch of main motor loop is tripping.

b.    When the protective device of solenoid shutter [overload relay] is actuated due to overload.

4.3  Confirmation before operation

a.    Please read all indicator lights in the main operating panel, shifting switch and operation button before the operation of press carefully.

b.    Check whether the inching, safety- stroke, continuity and other running operation are normal.

Press operation instruction:

1.    Start-up: Set the shifting switch to the “cut” position, and then press the “main motor start”, otherwise the motor cannot start, as shown in diagram.

2.    Then adjust the motor to the appropriate speed, as shown in diagram.

3.    Set the shifting switch position to “safety-stroke”, “continuity” and “inching” position, which can make the press have different motions.

4.    In case of the press linkage, you can press the red “emergency stop” button if you need to make the emergency stop immediately (which is not recommended as a normal use). Please press “continuous stop” for the normal stop.

4.4  Selection of operation mode

a.    In accordance with the provisions of the safe operation of press, the operation of this press can only be operated with two hands, and if the customer specially adds the pedal operation in the need of processing, the operator should not put their hands in the range of mold.

b.    The two-hand operating panel in the front of the press has the following buttons

(1)  One emergency stop button (red)

(2)  Two running operation buttons (green)

(3)  Slider adjusting button (electrodynamic type slider adjustment)

(4)  Slider adjusting shifting switch (electrodynamic type slider adjustment)

(5)  Linkage stop button

C.   For two-hand operation, you can operate after pressing the operation buttons at the same time, if it exceeds 0.5 second, the operation motion is invalid.

Warning: a. In the press operation, in any case, do not put hand or any part of the body into the mold, so as not to cause accidental injury.

b.    After the operation mode is selected, the multi-section selector switch is required to be locked, and the key should be taken out and kept by a special person.

4.5  Selection of running mode

For the running mode of the press, you can select the [inching], [safety-stroke], [cut], [continuity] and other running modes by multi-section selector shifting switch.

a.    Inching: In the hand operation or pedal operation, if you press operation button, the slider will move, and when the hand or foot is released, the slider will stop immediately. Caution: Inching operation is set for mold trial, adjustment, test run and so on. When the normal punching is running, avoid to use it.

b.    Safety – stroke: In the operation, the start position of the slider shall be in the upper dead center (0°), with the inching at 0°-180°, and the slider stops at the upper dead center (UDC) when pressing the operation button at 180°-360°.

c.    Continuity: In event pressing the operation button or foot switch, the slider shall be continuously pressed and released after 5s; or otherwise, re-operation is to be done in case the continuous action fails to be achieved. If it is to end up, the slider will stop at the UDC after you have pressed the continuous stop button on the operating panel of hands.

Warning: a. For safety purposes, the start position of the slider starts from the UDC all the time. In case the stop position of the slider is not at the UDC (0°) ± 30°, and it still fails to move after pressing the operation button, inching shall be used to lift the slider to the UDC for resuming.

b.    After the running mode is selected, the multi-section selection switch is required to be locked, and the key should be taken out and kept by a special person.

c.    Before running the press, the mode in place shall be confirmed, and it shall check for inching position if running in “inching” as an example.

4.6  Emergency stop button

In running the press, the slider will promptly stop, extraneous with its position, if the emergency stop button is pressed; for reset, it shall slightly rotate back as the arrow on button, and press the reset button for resuming.

Warning: a. In the interruption of work or inspection of machine, the emergency stop button must be pressed, to prevent an error operation, and it shall shifted to “cut”, and the key is removed to keep safe.

b.    If a customer assembles the electric circuit or parts by itself, he/she shall get a written approval from the Company when it is necessary to lap with the electric circuit system of this equipment for safety purposes.

4.7  Inspection and preparation before start

a.    To understand the operating instructions of the press, it shall first read the control data and slider cycle process in the Manual; of course, the significances of control switches are equally important.

b.    To check all operation adjustments, it must understand the adjustment instructions for slider and air pressure, and shall not change the adjustment arbitrarily, such as the setting of press plate, the tightness of V-belt and the lubrication device.

c.    The checking auxiliary device for auxiliary device is used to assist the press for special functions, which shall be checked in detail for whether assembled as required before start.

d.    Inspection of lubrication system

Do not forget to first check whether the oil adding parts are fully lubricated as required before start.

e.    Air compressor parts: Automatic spraying oiler is refueled, and attention shall be paid to maintaining a certain amount of oil.

f.     It shall note to tighten screws, such as fixing or adjusting screw of flywheel, brake, guide passage, and wire connector screw of control box as well as other screws in parts.

g.    After adjustment and before operation, it shall be noted that small parts and tools shall not be placed on working table or under slider for the avoidance of block, and especially that screws, nuts, wrenches or screwdrivers, pinchers and other daily tools shall be put into toolkit or in place.

h.    If the air pressure for air source reaches 4-5.5kg/cm², attention shall be paid to leakage of air connections in parts or not.

I.     The power supply indicator will light up when the power supply is turned on. (Make sure that O.L.P indicator does not light)

j.     The inching button is used to test whether the clutch and brake actuate normally.

k.    Inspection and preparation are in completion before braking.

4.8  Operation method:

(1)  The air switch is set to “ON”.

(2)  The lock switch is set to “ON”. If the air pressure reaches the set point, the load indicator light will be on.  If the slider stops at the UDC, the overload indicator light goes out after seconds; or otherwise, the slider is reset to the UDC in the overload reset mode.

(3)  Set the selector switch of operation mode into “OFF” and press the “main motor running” button for running the motor. If the motor is in the mode of direct start, its running light will be on promptly. If it is in one △ start mode, the motor running indicator light will be on after it gets to △ running from running after seconds. If it is to stop the motor, press the “main motor stop” button.

(4)  If the emergency stop loop is tested for normal, the emergency stop indicator light will be on after the large red emergency stop button on the operation box is pressed. The emergency stop light will be off after the rotation is conducted as the “RESET” direction on large red button for reset.

(5)  In the operation, the two large green buttons on the operating panel must be pressed at the same time (within 0.5s for time difference), and then the machinery can move.

(6)  After setting the selector switch of operation mode into “inching” and pressing the operation button, then the press starts to run and promptly stops if released.

(7)  After setting the selector switch of operation mode into “safety – stroke” and pressing the operation button, the down running of the slider is similar to inching running; after 180°, however, the press will continuously run to the UDC and then stops after the button is released. (For manual feeding, please use the operation mode for safe operation).

(8) After setting the selector switch of operation mode into “— stroke”, press and then release the operation button, the slider completes – stroke up and down and then stops at the UDC.

(9)  After setting the selector switch of operation mode into “continuous running”, press and then release the operation button, the slider will continuously move up and down (For automatic feeding).

(10) If it is to stop the continuous running, the slider will stop at the UDC after the “linkage stop” button is pressed.

(11) The slider will promptly stop after the large red “emergency stop” button is pressed in the press running.

(12) Operation method for overload device: Please refer to the running of O.L.P for preparation of implementation.

(13) Over-run: In case of the failure of transmission mechanism of rotary cam control switch, micro switch, and the abrasion of pneumatic system or brake lining shoe, they may cause the stop malfunction and endanger the personnel and machine & mold when running at – stroke or safety – stroke.  In case of the emergency stop of press due to “over-run” in running, the yellow reset button is pressed and indication disappears for continuous operation after the problem solved referring to the following electrical troubleshooting method.

Caution: 1.  To confirm whether “over-run” device is normal, it must be checked before starting up for safety.

2.    In the “safety – stroke”, re-pressing the operation button within 0.2s after the press stops at the UDC, if the press – stroke runs over, which will make the “red” light of over-run on, which is normal, and the reset button is pressed for reset.

Note: A press over 200SPM has no such device

(14) Special fittings: ①    Air ejector – When the press is running, the selector switch is put into “ON” and air can be ejected from some angle thereon for the discharge of finished product or waste. The ejection angle can be adjusted through setting on touch screen.

②   Photoelectric device– If there is a photoelectric safety switch, the switch of touch screen is put into “ON” for photoelectric safety protection. It can choose manual/automatic reset and full/half-way protection.

③   Misfeed detector – It often has two sockets, and one is for the detection of the mold guide pin depending on the mold design. If there is a feeding touching error when the touch screen is put into “ON” normally closed, the misfeed device displays the failure, the press stops and then resumes upon the misfeeding troubleshot. If there is no feeding touching error when the touch screen is put into “ON” normally open, the misfeed device displays the failure, the press stops and then resumes upon the misfeeding troubleshot.

④   Electric slider adjustment – Emergency stop occurs if the selector switch for slider adjustment is put into “ON”, and there is a failure displayed on the touch screen. The slider will adjust up and down in the range of setting if the slider up or down button is pressed. (Note: Attention must be paid to the height of knockout when adjusting.)

⑤   Operation method of “VS motor” is: To adjust the speed, put the speed power switch into “ON” and adjust the variable speed knob switch after the main motor starts.

⑥   Setting method of “counter” is:

Precut: Set the desired number of times, till the machine stops, in the precut setting screen of touch screen.

Preset: Set the desired number of times, till PLC outputs and solenoid valve acts, in the precut setting screen of touch screen.

4.9  Operation selection

a.    Linkage operation: It is applicable for automatic feeding or continuous operation.

b.    Inching operation: It is applicable for trial and mold test.

c.    One-stroke operation: It is applicable for general intermittent operation.

d.    Safety – stroke operation: It applies that in the first punching test (after mold test), the slider can be promptly stopped in any position before the bottom dead center (BDC) if an accident is found when the slider continuously goes down in inching; and upon the exclusion, hands are separated from the button when the slider exceeds the BDC, and then it will automatically lift and stop at the UDC.

e.    Before starting motor each time, it shall first test the clutch and the brake for normal function, check whether the tools, bottom of slider and upper of platform are clean; if OK, the normal operation starts.

f.     Special attention shall be paid to the tests for pre-start and daily maintenance; if OK, the normal operation starts.

Note: A press over 200SPM has no “safety – stroke” device

4.10       Stopping and braking sequence

a.    The slider stops at the UDC.

b.    The switches stop in normal positions and are shifted into “OFF”.

c.    Shift the motor switch.

d.    Shift the power supply switch.

e.    Shift the main power supply switch.

f.     Upon the shutdown, the upper of the working table, the slider bottom and mold shall be cleaned and added a little oil.

g.    The power supply of air compressor (if independently used) is closed.

f.     The gas receiver is discharged.

I.     OK.

4.11 Precautions

To smoothly provide the continuous production of the machine for your plant, please pay special attention to the followings:

a.    At the time of start-up daily, it shall note check thereof.

b.    Please note whether the lubrication system is smooth.

c.    Air pressure shall be kept in 4-5.5kg/cm².

d.    After each adjustment (relief and block valves), special attention shall be paid to fastening.

e.    No unusual action will be for connection of electric wiring, and unauthorized dismounting shall not occur if abnormal, which shall be checked based on electrical wiring diagram.

f.     Pneumatic device oiler shall be kept the amount for the avoidance of solenoid valve or other failure.

g.    Brake and clutch are checked for normal actuation.

h.    Screws and nuts in parts are checked for fixing.

I.     For the very fast and fierce acting force of press as one of metal forging machineries, the operator shall not be impetuous or operate in tiredness. If you have worked in a boring and simple operation for some time, and it is liable to act habitually but difficult in concentrating mind, so you shall pause, take a deep breath and then resume.

j.     In the course of slider adjustment, it shall specially note that the knockout rod is adjusted to the zenith to avoid damage to the machine caused by the slider’s knock to the knockout.

5.    Selected fittings adjustment operation

●     When the press of air ejector is running and the setting switch is put into “ON”, air can be ejected from some angle thereon as the arrangement of finished product. In addition, the ejection angle can be used to adjust the setting of cam parameters.

●     For the photoelectric device, a photoelectric safety switch (if any) is put into “ON” for photoelectric safety protection.

●     Misfeed detector – It often has two sockets, and one is for the detection of the mold guide pin depending on the mold design. If there is a feeding error in “ON”, the red light of misfeed detector will be on, the press stops and then reset completes after the selector switch is put into “OFF” then “ON” upon the mold misfeeding cause eliminated.

●     For the electric slider adjustment, the slider adjustment will display after the selector switch is put into “ON”. The slider will adjust up and down in the range of setting if the slider up or down button is pressed. (Note: Attention must be paid to the height of knockout when adjusting.)

●     Setting method of “counter” is to press the white handle 1 with one hand, open the protective cap with the other, toggle switch with fingers to the set figure and then close the cap.

滑块调整 Slider adjustment (15-60)

5.1  Manual procedure

1.    Mold height indicator     2.    Gear axis     3.    Fixed seat    4.       Adjusting screw 5.    Pressure plate screw      6.    Knockout rod 7.    Knockout plate

A.   Loosen the fixed screw first

B.   Take up and cover the ratchet wrench at the slider adjusting rod to clockwise and counterclockwise rotate if slider up and down, respectively

C.   The correct height of slider can be seen from the mold height indicator (0.1MM as a minimum)

D.   Adjustment procedures complete as per the above steps

5.2  Electrodynamic type slider adjustment

(1)  Steps to electrodynamic slider adjustment

a.    The shifting switch of operating panel is shifted into “ON”.

b.    Up/down button can be pressed for operating panel up and down, respectively; and the adjustment will promptly stop if the button is released.

c.    In the slider adjustment, its height can be seen from the mold height indicator (in 0.1mm).

d.    The micro switch in indicator actuates when the slider adjusts to upper/lower limit, and the adjustment automatically stops promptly.

e.    Upon the completion of adjustment, the shifting switch is shifted into the initial position.

(2)  Precautions

a.    Before the slider height is adjusted, the knockout rod shall be adjusted to the zenith to avoid knocking it when the mold height is adjusted.

b.    To reduce the adjusting force of slider, the air pressure in balancer shall be moderately adjusted and reduced before adjustment.

c.    In the adjustment, the emergency adjustment button is pressed to put the shifting switch into “cut” for the avoidance of accident.

5.3  Precautions of rotary cam

Precautions: 1.   For safety, the “operation selection” switch shall be put into “cut”, and then the “emergency stop” button is pressed before adjustment.

2.    When the adjustment is completed, operation is done in “inching” for slow movement to keep the encoder in place.

3.    The parts related to the rotary encoder driving are often checked for the looseness of drive shaft and chain, as well as the looseness and break of coupling; and the abnormity (if any) shall be corrected or replaced immediately.

5.4  Pressure adjustment of balanced cylinder

After the upper mold is assembled a slider, it shall compare with the air pressure in the “Balancer Capability List” on the left of the frame. The proper air pressure is adjusted as per the relations among upper molds. Pressure adjustment methods:

(1)  The locking knob on the pressure regulating valve is loosened.

(2)  The pressure obtained from the “Balancer Capability List” is compared to the value indicating on the pressure gauge to determine the corresponding increase or decrease in the pressure value.

a.    In the increase, it can slowly rotate the valve cover clockwise.

b.    In the decrease, it can slowly rotate the valve cover counterclockwise. When the pressure drops below the required, the balancer’s pressure is adjusted to the required as per Method a after the empty barrel of balancer has been relieved.

(3)  If the pressure observed from the “Balancer Capability List” is consistent with that of the pressure gauge, the locking knob pressure regulating valve is loosened. If not, the pressure is adjusted to the correct as per the above methods.

5.5  Maintenance inspection records

Maintenance inspection records

Inspection date: MM/DD/YY

Maintenance inspection records

Inspection date: MM/DD/YY

Maintenance inspection records

Inspection date: MM/DD/YY

6.    Safety

6.1  To keep operators safe and machine running, the following items shall be followed: For this machine and power machinery structure and line control, please refer to the press safety laws and specifications of the advanced countries, such as Europe, America, Japan, which are elaborated to keep simple and safe for operators who shall not change the operation loop on machinery arbitrarily. Or otherwise, the Company assumes no responsibility. For safe, the protection and test are carried out to the following devices and lines:

(1)  Emergency stop device.

(2)  Motor overload device.

(3)  Loop configuration for linkage prohibition.

(4)  Safety loop configuration with hands.

(5)  Low speed protector.

(6)  Detection for cam failure.

(7)  Interlock protection for over-run system.

(8)  Overload detector.

(9)  Misfeeding detector. (selected fittings)

(10) Photoelectric safety device. (selected fittings)

Daily inspection, start and regular inspections mentioned below are sure to follow.

The operation principal has to carry out the commencement inspections below.

(1)  It runs in inching and tests the clutch and brake for normal.

(2)  It tests the bolts of crankshaft, flywheel, slider, crank connecting rod and other parts for loose.

(3)  The slider will stop in the specified position or not after pressing the operation button (RUN) in case of running in stroke. In running, the slider can promptly stop or not once after the emergency interlock device acts or the emergency stop button is pressed.

After completing the work, when leaving the workplace or checking, adjusting or maintaining the parts, you must turn the power off and pull out the key to power supply switch; meanwhile, the keys to shifting switches shall be submitted to the head of the unit or its designated person for safekeeping.

Only the qualified professionals can carry out the independent inspection of press and properly keep the records as a reference for next inspection.

When the pneumatic device is checked or dismantled, you shall first turn the power supply and air source off, and the remaining pressure is fully released before operation. It is required to close the air valve before connecting the air supply.

In the maintenance of electric, the qualified professionals shall carry out inspection, adjustment, maintenance and other work as specified.

Before operating the machine, please refer to the main specifications and working capacity limit of the machine, and do not exceed the capacity curve.

●     Before the operation of the press, the operators shall carefully read the operation procedure in detail and confirm the positions of related switches and buttons.

●     If the press fails to properly run due to the failure of control circuit for its driving mechanism and safety device, please refer to (8 Failure Causes and Removal) for solution; or otherwise, please inform the Company of appointing a personnel for maintenance, and do not rebuild it privately.

6.1.1      Emergency stop device

Stroke and linkage have the emergency stop routes (excluding inching), which is an important protection measure for operation. The emergency stop button is red with a RESET knob, which can be pressed in an emergency or maintenance, and then the press slider will promptly stop. For reset, you can be out of the emergency after pressing the emergency button and rotating it to the RESET direction.

6.1.2      Motor overload device.

Before using the machine, the workload shall be not limited below the nominal capacity of the machine to keep the press normal. For overload, the overload protection relay will act to promptly stop the running motor, which can be a device protecting motor. An overload relay shall be used in 1.25 to 1.5 times of rated current of load than full load generally. Meanwhile, its range can be adjusted by an adjustment knob which is aligned with the white angular point if adjusting in 80% to 120% of rated current of overload relay.

6.1.3      Loop configuration for linkage stop

If the slider is continuously running, the press will promptly stop in the UDC as a specified position to protect the machine life and personnel at the time of pressing the linkage stop or changing the linkage selector switch or the speed being too low suddenly.

6.1.4      Safety loop configuration with hands

For the operator’s safety, both hands (if selected) must press simultaneously within 0.2s and then the press will act; or otherwise, they must release and re-operate; while there is no such limit for left, right hand operation and foot operation.

6.1.5      Low speed protector.

When the slider is in running, low speed protection is increased in line to avoid the slider sticking to the mold when the press is at low speed due to the improper adjustment or overload of speed regulator. If the speed is below 600rpm, the linkage stops and the indicator light flickers in IS pulse wave. When the speed is at 600-450rpm and below 450rpm, the stroke can actuate and be in emergency stop, respectively; for the later, all actions stop.

6.1.6      Encoder failure detection

When the press is in the fixed-point stop, the trigger signal generated based on the encoder is transferred to PLC to stop the slider at the UDC upon its judgment. If signal is not generated from the leading edge of cam but from the trailing edge of proximity switch, the encoder is in failure, and the touch screen is out of the screen. After the press runs for a cycle, the slider stops at the upper dead center (UDC), and the reason of causing the encoder failure may be damage of the coupling or looseness of the synchronous belt, and this line is set for protecting the safety of the operators.

6.1.7      Interlock protection for over-run system.

Proximity switches are used to detect overrun action signal. If the proximity switch is damaged but the operation fails to know that, so that the overrun action cannot be detected, for the safety of the operators, this circuit can estimate whether the proximity switches are damaged or not by cross detection of encoder and proximity switches, which is the chain reaction on the line, and is elaborately designed for the safety of operators.

6.1.8      Overload detector

The device is multi-functional oil pressure overload device that can have emergency stop instantly in the overload state (1/100 second), and the slider will automatically go back to the upper dead center (UDC) when resetting. The protection device can ensure safety of mold and press.

6.1.9      Misfeed detector (selected fittings)

Misfeed detector generally has two sockets, one of which is used for mold guide pin, and the other of which is used for chamfer, depending on the design of the mold. This safety device is to protect the press operation. When the press combines with the feeder, if the feed is delivered mistakenly, then the misfeed detection indicator is on, and the press will have the emergency stop. After the mold misfeed reason is ruled out, then the selector switch is turned to “OFF”, and then is turned to “ON”, and then the red light is off, and resetting is finished.

6.1.10    The photoelectric safety device (selected fittings) shall refer to the instruction of photoelectric safety device.

6.2  Safety distance (D)

●     The position of safety device by means of both hands

When the press slider moves downward, the switch will release by both hands. When both hands are still under the slider or the dangerous area of the mold, the press has not stopped yet, which easily triggers danger, so the installation position of the operation switch is shown as follows:

Precautions:

模高 Die Height

1.    The unit is operated in both hands and its mounting position must meet A + B + C> D and shall not change its installation position.

2.    The value of TS shall be measured every year, and the value of D and A + B + C shall be compared to ensure its installation position.

●     Position of the photoelectric safety device is installed as follows:

Precautions:

(1)  The installation position of the photoelectric safety device must be correct and the conditions of A> D must be met, and the installation position shall not be changed arbitrarily.

(2) (TL + TS) values shall be measured per year, and the values of A and D shall be compared to ensure the installation position of the photoelectric device.

7.    Maintenance

7.1  Maintenance item introduction

7.1.1      Air pressure:

a.    Air piping: Check whether there is a leak in each pipeline.

b.    Air valve and solenoid valve: Under proper operation, check whether the control of the air valve and the solenoid valve is normal.

c.    Balanced cylinder: Check whether the air leaks and check whether proper lubrication exists.

d.    Die cushion: Check whether the air leaks and check whether proper lubrication exists. Check if the fixed screws of the die cushion are loose.

e.    Pressure gauge: Check if the axis of the pressure gauge is normal.

7.1.2      Electrical:

a.    Electrical control Check the controller and the situation of operation reaction, replace the problematic controller, and tighten the loose parts. Check the fuse for proper size, check the insulation of the wire for damage, replace the bad wire.

b.    Motor: Check whether the fixed screws of the motor and the bracket are tightened.

c.    Button and foot switch: Be careful to check these switches and replace them if they are abnormal.

d.    Relay: Check the wear of the contacts, and please carefully implement maintenance for looseness or broken lines of tie lines, etc.

7.1.3      Lubrication:

a.    Clutch air lubrication assembly: Eliminate all the water, check the status of the unit, fill the lubricating oil to the correct location.

b.    Lubrication system: Refer to the lubrication section described in this section to perform maintenance of the lubrication system. Check whether the lubrication line is broken, worn, check the fittings are with loopholes, rupture or damage, check whether the oil surface inspection of the oil level is in line with the standard. Under normal operating conditions, the oil immersion gear tank is changed every three months and the tank is cleaned once every six months (about 1500 hours).

7.1.4      Mechanical section

a.    Working table: Make sure that no foreign matter is placed between the working table and the frame, make sure that the table fixed screws do not have any loosening phenomenon, and confirm that the flatness of the working table is within the tolerance range.

b.    Clutch: Check if there is leakage, check the friction plate wear and tear.

c.    Drive gear: Check if the gears and keys are tight and check if the gears are properly lubricated.

d.    Slider adjustment parts (electrodynamic type): Check if the slider adjustment motor is locked, to confirm the automatic brake is of no problem. Check if the worm and the worm gear are adjusted for proper lubrication. Check if the mold height indicator is accurate.

e.    Slider adjustment parts (manual type): Check if the slider adjustment gears are properly lubricated. Check if the holder has a failure condition. Check if the mold height indicator is accurate.

f.     Motor transmission: Check if the motor shaft and pulley are loose. Whether the belt and pulley are cracked and deformed.

g.    Cleaning: Clean the inside and outside of the press and remove any accumulated foreign matter.

7.2  Operation and maintenance precautions:

7.2.1      The key points of daily inspection maintenance:

Mainly carried out before and after the daily operation, with 10 hours a day as the basis, when the period is more than 10 hours, the relevant operation should be suspended and re-checked.

7.2.2      The key points of weekly inspection maintenance:

Implement a maintenance every 60 hours of operation rotation, in addition to the daily inspection and maintenance items, it is necessary to implement the following inspection and maintenance.

7.2.3      The key points of monthly inspection maintenance:

That is, implement an inspection maintenance every 260 hours, in addition to the daily and weekly maintenance items, it is necessary to implement the following inspection and maintenance.

7.2.4      Annual inspection and maintenance requirements

The annual maintenance refers to implementation of inspection and maintenance every 3000 hours. In addition to the previous inspection and maintenance items, the following items shall be carried out, and due to different operating conditions, the various parts shall have the considerable wear and damage, for this reason, there must be skilled personnel or the staff with professional experience to assist in the implementation of careful inspection and maintenance.

7.3  Electrical parts maintenance:

7.3.1      Daily maintenance items

A.   Whether the press operation stop position is normal or not.

B.   Fixed point stop shall use the proximity switch and whether the cam is fixed and the clearance is normal.

C.   Whether the transmission mechanisms of rotary encoders are abrasive or loose.

D.   For the emergency stop button, whether the action is normal.

7.3.2      Monthly maintenance items

Fixed point stop detection of proximity switches and cams.

A.   Whether the fixed screw is loose

B.   Whether the distance between the cam and the proximity switch is appropriate.

C.   For the cam and the proximity switch, whether there is water, oil or dust and other debris attached.

Use push button switch for operation

A.   Whether there is oil, dust attached at the contact.

B.   For sliding part, whether there is dust and oil attached, and whether the action is smooth.

Solenoid valve

A.   Whether there are foreign matters in the coil and exhaust parts.

B.   Whether the coil part is discolored.

C.   Check if the O-ring is broken, and if the action is smooth.

7.3.3      Every six-month maintenance items

A.   Check if the action is true for all safety devices.

B.   Whether solenoid valve switch is normal.

C.   Inspection of important relays.

D.   Inspection of metal socket welding parts.

E.    Whether the pressure switch part is in normal operation.

F.    Check the wiring joints

7.3.4      Annual maintenance items

The general inspection shall be carried out once a year, and at this time, confirm if the following items are normal, and in order to prevent accidents, it is best to make regular replacement.

A.   Important relays (for press operation and prevention of restarting).

B.   Fixed point stop shall use proximity switch (or micro switch).

C.   The micro switch, etc. with high action frequency.

D.   Operation button, emergency stop button (often used).

7.3.5      Other maintenance precautions

A.   In addition to electrical parts inspection points of the above-mentioned general press, if there are selected fittings, they should be regularly checked.

B.   The dust and oil is very bad issue for the electrical parts, the door absolutely shall not be opened or removed.

C.   Replacement of the parts shall pay attention to be fixed, and after the replacement, it is necessary to do trail run, and they shall only work when there is no problem.

D.   If the frequency of mechanical use is high, the above check interval needs to be shortened. In particular, when adjusting the motor’s electromagnetic switch, doing inching running frequently, it is necessary to pay attention to easy wear of the contacts.

E.    The manufacturers of the electrical parts shall have the description on their service life, so in practice, it is necessary to pay attention to the use frequency and the working environment, often check and replace, so as to avoid accidents.

F.    Rotary encoder has been adjusted when it works, and please do not make any adjustment arbitrarily.

7.3.6      V-belt replacement: When V-belt is damaged, it should be replaced according to the following points:

Move the motor to the side of the flywheel, to make the belt loose, remove it, and then replace it with all the new pieces at the same time. If there are several old belts still available to be used, they should be removed for replacement, and kept as spare parts. Because the old and new belts are used in mixed way, the elongation of the two is uneven, which may reduce the durability. In addition, even if the nominal length of the belts is the same, the actual size may also be slightly different. Therefore, it is necessary to be very careful to select the products with the consistent length. The standard specifications of the belt are shown in the table below. This specification applies to the number of strokes “S” and the 50HZ area. (If the number of strokes “S” changes and is used in the 60HZ area, the belt specifications also follow to change).

跨距长度 Span length

飞轮 Flywheel

挠曲量（沉陷量） Amount of deflection (amount of settlement)

荷重 Load

When the belt tension is too strong, the bearing life will be shortened, more serious case is the shaft is also possible to break, so the tension adjustment must make the belt have appropriate looseness. In the center of the belt span, press it by hands, if the amount of settlement is in line with the values in the following table, it can be considered that the belt tension is qualified, the belt takes a few days to fit with the belt groove. It is possible to be checked after a few days, and according to the situation, the necessary tension shall be subject to adjustment. Keeping the belt, should choose places with less sun, heat and moisture, and pay attention to prevent the grease attached to the above.

The correspondence between the load and the amount of deflection of the V-belt is shown in the following table.

8.    Failure causes and troubleshooting

The separation between the upper and lower clamping molds after the closure:

When the upper and lower clamping molds are closed and the slider stops working, follow the procedure below to disengage the clutch.

(1)  The position of the crankshaft shall be confirmed before or after the bottom dead center.

(2)  The air pressure of the clutch is adjusted to 4-5.5 kg/cm².

(3)  After the bottom dead center of the motor is arrived, in accordance with the original forward rotation, the motor edge connection is reversed before the bottom dead center, so that the motor can rotate in reversal.

(4)  Start the motor to drive the pulley idling, then rotate at full speed.

(5)  The operation switch is switched to [inching] and then the buckle switch is pressed and released, and with repeated operations, the slider is lifted up to the upper dead center (UDC).

Method for disengaging the overload safety device (limited to oil pressure overload safety device):

(1)  The shut-off valve in the piping of the overload device is closed so that the pump cannot be operated.

(2)  The bolts of the oil circuit of overload safety protection device in front of the slider are pulled out to make the oil flow away, the inside pressure reduces, then the bolts are fixed in place.

(3)  Start the motor to drive the pulley idling, then rotate at full speed.

(4)  The operation shifting switch is switched to the inching and then press and release the buckle switch, and if the clutch cannot drive the operation, the overload shifting switch is switched to the reset position, and then repeatedly press and release the buckle switch, so that the slider can be lifted to the upper dead center (UDC).

(5)  When the upper and lower molds are disengaged, the shut-off valve in the piping of the overload device is opened and the operation sequence of the overload safety device is the same, and the normal operation can be carried out.

Hydraulic overload resetting:

The unit is equipped with a hydraulic overload safety device inside the slider. Please indicate the shifting switch on the operating panel in the normal position. When the press overload occurs, the overload safety protection state of the oil in hydraulic chamber being squeezed out disappears, while the slider action is also an automatic emergency stop.

In this case, please reset it according to the following points

(1)  Run the shifting switch to the [inching] position, and operate the buckle switch to move the slider to the upper dead center (UDC).

(2)  When the slider gets up to the upper dead center position, the overload safety protection device restores after about a minute, and the oil pump stops automatically.

(3)  After trail run in inching, the normal operation can be carried out.

Press operation instruction:

Remove the snap gauge, release from the media, and hit the slider to the upper dead center, and hear the sound of the oil and then lock it

Causes and Countermeasures of Overload Safety Protection

Lubrication system diagram (manual lubrication system)

Lubrication system diagram (manual lubrication system)

9.    Lubrication

9.1  Lubrication instruction

a.    Please pay attention to the operation of the oil feed state, when using, hand pump shall be closed at any time, do not cut off the oil bearing bush causing slide guide plate heating to burn out. The heat is allowed to run at room temperature below +30° C and must be stopped when overheating. The motor case is heated to a temperature of 60° C or less as the limit.

b.    Maintenance of oil-immersed gear grooves: Oil change every three months, and clean up the tank every six months (about 1500 hours). c. Flywheels and gear shaft bearings are usually greased once every two months and checked once every six months. d. Balanced cylinder system shall use manual oiling device, and inspection shall be done at interval of one week. And inspection shall be carried out every six months. e. To ensure the lubrication between adjustment screw and ball cup, the machine must be installed before the first test, adding 100CC of special grade circulating oil R115 (R69) on the slider.

9.2  Oiling and oil change cycle

The unit shall consider the grease and oil as the lubricating oil.

a     Replacement of lubricating oil in gear box: When the machine starts to use for three months to change the oil once, after every six months to change once.

b     Counter balance oil feed: Inspection and injection shall be carried out once every week.

c     Flywheel and bearing: This is closed, before the assembly, the grease shall be injected, and grease shall be put every two months, and inspection shall be carried out once every six months.

d     Manual centralized oil feed device (grease or oil): The oil collection tank of the system is set with a window from which the oil quantity can be seen, when the amount of oil is not enough that is to fill with oil into the tank.

9.3  Precautions:

Lubrication and oil change method, should refer to the previous “lubrication list” for the lubrication system.

(1)  Lubrication during start-up:

a     The lubrication operation is carried out by manual pump before it can be put into operation.

b     When restarting after rest for 24 hours, use a manual pump to perform the operation twice as the usual lubrication operation and then put it into production.

(2)  Lubricating oil tank: The amount of oil should be checked daily and supplemented as needed. Especially in the early installation, due to the need to meet the oil storage requirements of the machine so the fuel may be greatly reduced, should be noted.

(3)  Manual oiling:

a     When manually supplementing oil or applying grease, be sure to turn off the power supply first.

b     When the chain is coated with grease, it is necessary to check the tightness of chain at the same time, and if necessary, re-adjust properly through the chain wheel.

(4)  Replacement of lubricating oil in gear box after mechanical acceptance, the lubricating oil in the gear box is changed three months after operation of the new car (750 hours) and is replaced every six months (1500 hours) and clean the tank. Amount of oil and oil type, please refer to the list of lubricating oil in [installation].

10.  Function descriptions of press components

10.1       Standard configuration

10.1.1    Frame:

The structure of the machine uses computer-aided design, the strength of the frame and the distribution of the load stress are the most reasonable design.

10.1.2    Slider section:

a.    Manual adjustment device: With manual adjustment device (ST25-60)

b.    Electric adjustment device: Use disc brake motor and operate with the buttons, with stable mechanism, positioning accuracy, the adjustment work can be quickly completed. (ST80-315)

c     Mold height indicator: Fitted with the electric adjustment device action, the reading is up to 0.1mm.

d     Equipped with balanced cylinder: Bear the weight of the slider and molds, so that the press runs smoothly to ensure the accuracy of products.

e     Overload device (and snap gauge release device): The device is multi-functional hydraulic overload device that can have emergency stop instantly in the overload state (1/1000 second), and the slider will automatically go back to the upper dead center (UDC) when resetting. And ensure safety of molds and press.

10.1.3    Transmission part:

a     Compound pneumatic friction clutch and clutch brake: Use the compound pneumatic friction clutch and clutch brake, to reduce the passive inertia loss, easy for adjustment and inspection.

b     Brake friction plate: Use super-molded brake friction plate with good wear resistance to be stopped in any position instantaneously, with high security.

c     Built-in transmission mechanism: Transmission part completely built in the body can improve safety, transmission gear immersed in the tank, extend the life of the machine to eliminate noise.

10.1.4    Rotary cam control box:

It is placed on the right side of the press to adjust easily and securely for automatic control of the components

10.1.5    Air piping control box:

Placed under the left side of the frame with pressure adjustment switch, lubricator, air filter, safety pressure gauge and other air compressor parts.

10.1.6    Electrical control box:

It is placed on the right side of the frame, with stroke confirmation, emergency stop, air pressure confirmation and various safety loops.

10.1.7    Operating control panel:

It is located in front of the frame, equipped with a variety of indicators, and control buttons to provide control signals at any time.

10.2       Selected fittings:

10.2.1    Photoelectric safety device: If necessary, photoelectric safety device can be installed to ensure the safety of the operator.

10.2.2    Quick mold changeover device: This model can be equipped with quick mold lifting, mold changeover device to reduce time to lift and change molds, improving production efficiency.

10.2.3    Automatic feed shaft end: The left frame is equipped with the automatic operation gear shaft at the request of customers to be convenient for customers to install automatic feed devices.

10.2.4    Die cushion: If necessary, a die cushion can be installed, which applies to extension processing and can improve the efficiency of press operations.

10.3       Slider structure/slider assembly structure diagram

10.31     Slider assembly structure diagram (ST15-60)

10.3.2    Slider assembly structure diagram (ST80-315)

10.4       Special units

10.4.1    Type: Mechanical knockout

Specification Knockout capacity is based on 5% of press capacity.

Structure: (1)       It consists of a knockout rod, a fixed seat and knockout plate.

(2)  Knockout plate is mounted on the slider centerline.

(3)  When the slider is raised, the knockout plate contacts with the knockout rod to eject the product.

The dimensions in the above list are the values that the slider at the BDC is adjusted at the upper limit.

I.     Operation and adjustment

1.    The fixed screw of knockout rod is loosened, knockout rod is put in desired place, and it is noted that the knockout rods on both ends are adjusted to the same size.

2.    Upon the adjustment, the fixed screw must be tightened.

3.    When the knockout is in operation, there will be of some noise due to the contact of the knockout plate and the slider.

II.   Precautions:

When the mold is changed, special attention shall be paid to that the knockout rod is adjusted to the vertex before the adjustment of slider height, to avoid knocking it when adjusting the mold height.

Counter – It can calculate and display the cumulative number of slider strokes. An automatic calculation occurs when the slider lifts up and down a cycle, it will automatically calculate once; there is a reset button with a total of six figures. The counter can be used to calculate production when pressing products.

Structure:

Operating method::Selector switch

(1)  The counter will keep still when it is put into “OFF”.

(2)  The counter will be in working state when it is put into “ON”.

Precautions: Reset must be carried out when the slider stops at the UDC; or otherwise, it will become the maximum reason for damage to counter if reset occurs when the machine is running.

10.4.2    Foot switch

For safety, it must be used together with the photoelectric safety device or safety guide grid. In unnecessary case, a foot switch is not used as far as possible for safety.

Operation method:

(1)  The switch of operation mode is put into “FOOT”.

(2)  When feet are put on the pedal, the action plate is made to press the micro switch shafted by the shaft tip, the movable button is also pressed; and then the press can act.

(3)  In use, special attention shall be paid to the operation method of foot switch; or otherwise, the poor use will damage it, thus indirectly influencing the pressing operation and the operator’s safety.

10.4.3    Hydraulic overload protection device

If the press is used in overload, it will cause damage to the machinery and mold. To prevent this, a hydraulic overload protection device is installed in the slider for ST series. Only supplying the air pressure of (O.L.P) can make the press used in the required working load.

(1)  Type: Hydraulic

(2)  Specification: Action stroke of (O.L.P) hydraulic load for 1 max

(3) Structure:

1.    Fixed seat

2.    Fixed plate

3.    Ball head gland

4.    Nut

5.    Piston

6.    Oil cylinder

7.    Slider

8.    Crank connecting rod

9.    Adjusting nut

10.  Connecting rod

11.  Worm wheel

12.  Ball cup

13.  Overload pumping

(4)  Running preparation of O.L.P

a.   Check and confirm the amount between H.L, and oil (if insufficient) is added to the filler upon the opening of screw therein.

b.    It shall confirm if the pressure of air manometer is normal.

c.    The power supply of electric operating panel is put into “ON” from “OFF”, and then the overload indicator light will be on.

d.    If the slider stops near the UDC, the hydraulic pump starts to actuate; and the Pump will stop, if the oil pressure of O.L.P hydraulic in 1min reaches the set pressure, while the “overload” indicator light will be off.

e.    Or otherwise, please reset as per the following methods:

●     The shifting switch OFF and ON of overload device is put into “OFF”.

●     The selector switch of operation mode is put into “inching”.

●     The operation button is pressed for inching, and the slider stops at the UDC. (Attention shall be paid to the operation height of the mold (if mounted already) for safety)

●     When the slider reaches near the UDC, the Pump of O.L.P starts to actuate, and it will automatically stop within 1min when the set pressure reaches the Pump.

●     “Overload” means the selector switch of the “Overload device” is put into “ON” after light off, thus operation preparation completed.

(5)  Air removal of O.L.P hydraulic

If there is any air in the hydraulic, O.L.P will fail in function, and even the Pump will continuously run.  Methods of air removal:

a.    Stop the slider near the UDC.

b.    For safety, the screws of oil outlet for O.L.P behind the slider are reversed half a circle with a hexagonal wrench after the main motor and other flywheels are fully static, thus oil flowing.

c.    As observed, the intermittent or bubble-mixed flowing oil refers to the presence of air, and the screws of oil outlet are tightened when the conditions above disappear.

d.    Completion

(6)  Reset for hydraulic overload protection device:

The unit is equipped with a hydraulic overload safety device inside the slider. Please indicate the shifting switch on the operating panel in the normal position. When the press overload occurs, the overload safety protection state of the oil in hydraulic chamber being squeezed out disappears, while the slider actuation is also an automatic emergency stop. In this case, please reset it according to the following points:

●     Run the shifting switch to the [inching] position, and operate the buckle switch to move the slider to the upper dead center (UDC).

●     When the slider gets up to the upper dead center position, the overload safety protection device restores after about a minute, and the oil pump stops automatically.

11.  Use range and life:

The machine only applies to the metal punching, bending, stretching and compression molding, etc. No additional purpose beyond the application of the machine as specified is allowed.

The machine is not suitable for the processing of cast iron, wood, glass, ceramics and other brittle materials or magnesium alloy and other inflammable materials.

For the use of materials beyond the application above, please contact the sales or service unit of the Company.

Estimated service life

8 hrs x 6 Days x 50 Weeks x 10 Y = 24000 hrs

12.  Schematic diagram of press equipment

13.  Press specifications and parameters

●     MODEL: ST25 press

●     MODEL: ST35 press

●     MODEL: ST45 press

●     MODEL: ST60 press

●     MODEL: ST80 press

●     MODEL: ST110 press

●     MODEL: ST160 press

●     MODEL: ST200 press

●     MODEL: ST250 press

●     MODEL: ST315 press

14.  Press precision requirements

The machine is carried out the precision based on the measurement method of JISB6402, and is manufactured with the allowed precision of Grade JIS-1.

15.  Three factors of press capacity

When a press is used, no pressure, torque and power capacities can exceed the specifications. Or otherwise, it may not only cause damage to the press and even human injury, thus special attention shall be paid to.

15.1       Pressure capacity

The “pressure capacity” refers to the maximum allowable pressure capacity below the capacity generation position available for safe load on press structure. Considering the difference in material thickness and tension stress (hardness), as well as the change for the lubricating state or abrasion of press and other factors, however, the pressure capacity must be given a certain degree of extension.

The pressing force of the punching process must be limited below especially if the pressing operation performed includes the punching process, which may result in the penetration-caused pressing load. Limits to the punching capacity

ST (V)   Below 70% of pressure capacity

ST (H)   Below 60% of pressure capacity

If the limit is exceeded, the damage to the connection part of slider and the machine may occur.

In addition, the pressure capacity is calculated based on the uniform load for 60% of mold base center, so no concentrated load for large or eccentric load that the load combination is off-centered occurs in a small area. If it is necessary for operation thereunder, please contact the Technical Dept.

15.2       Torque capacity

The pressure capacity of the press varies with the position of the slider.  “Stroke Pressure Curve” can express this change. In the use of the machine, the working load shall be less than the pressure shown in the curve.

As no safety device for the torque capacity, the overload safety device or the interlock mechanism thereon is the device that corresponds to the load capacity, which has no direct relationship to the “Torque Capacity” described in the Item.

15.3       Power capacity

The said “Power Capacity” is the “Operating Energy”, namely the total work for each pressure. The energy that the flywheel has and that can be used for one operation in the main motor output is limited. If the press is used beyond the power capacity, the speed will reduce, thus making the main motor stop due to heat.

15.4       Snap gauge

The phenomenon will occur generally if operating over the torque capacity and also when load is applied if the clutch is not fully engaged.。This will have an adverse effect on the clutch, so shutdown shall be done if found immediately before or during the operation, and necessary measures shall be taken to prevent the recurrence.

15.5       Allowable eccentricity capacity

Basically, an eccentric load shall be of avoidance, which may cause a lean for the slider and the worktable. Therefore, it shall limit the use of load to keep the machine safe.

15.6       Intermittent stroke number

To use the machine in the best condition and maintain the life of clutch brake, it shall use below the intermittent stroke number (SPM) as specified. Or otherwise, the abnormal abrasion of friction plate of clutch brake may occur, and it is prone to accident.

Schedule 1 ST Series Press Accessory List

16.  Electric

Product Executive Standard JIS

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