Use and Maintenance Vitruvit

USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 1

U S E & M A I N T E N A N C E M A N U A L

CONSTRUCTOR

GAROLL SRL


HPC 201T Date: 25/03/2009


1 INTRODUCTION Through this manual GAROLL s.r.l. provides its customers with all the information necessary to ensure correct maintenance and use of the high pressure casting module for the HPC Series. Any instructions, drawings, tables, and anything else contained in this handbook, are confidential technical information and cannot be reproduced in whole or in part without written approval by GAROLL s.r.l., which is the exclusive proprietor of the same and which reserves the right to make all the modifications it considers necessary. Technicians and machine control and maintenance operators are forbidden from divulging the information contained herein and from using the manuals for purposes other than those strictly linked to correct use of the machine. We advise you to keep this book in good condition in an easy-to-access place to allow rapid consultation, if necessary. For any additional information, please contact GAROLL s.r.l. - the service department technicians will be glad to help you. WORK ORDER: XX/XXXX DATE OF MANUFACTURE: 2008 CUSTOMER: Vitruvit, Thessaloniki These user instructions were written to broaden knowledge of the system in order to exploit its intended use to the full. GAROLL cannot foresee all the circumstances that could cause a potential hazard while the machine is being used and maintained. Consequently, the safety messages in this manual and those shown on machine plates may not include all possible safety precautions. This manual provides important instructions on safe, professional and economic use of the system. If you observe these instructions, you will avoid needless risks, while reducing repair and down-time costs, and, at the same time, increasing the system’s reliability and life. This manual must be integrated with the instructions in the national legal regulations on accident prevention and environmental protection. This manual must always be available in the place where the system is installed. This manual must be read and applied by anyone charged to carry out work with and on the system, for example:

- use including preparation, troubleshooting during the operating cycle, removal of production waste, care, disposal of consumables and auxiliary materials

- Maintenance In addition to this manual and to the current regulations in the country of destination and in the place of use concerning prevention of accidents, the laws on safety and professional use must also be observed.


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2 GENERAL WARNINGS 2.1 INTRODUCTION Before attempting any job on the system and/or on the packing of parts, carefully read the instruction manual to the letter. This manual contains information which is important for the safety of both machine control operators and routine maintenance operators, and the machine itself. GAROLL reserves the right to make any technical modifications to the machines and manuals without notice. Property rights reserved, reproduction forbidden. GAROLL protects its rights under law regarding drawings and technical documentation. For any further copies of this manual, contact GAROLL’s Customer Servicing department. Storing the manual This manual is an essential part of the machine and must always accompany it even if the machine is sold. The manual must always be kept near the machine, in a place known to and easily accessible by the personnel. The operator and maintenance person must be able to obtain and consult the manual at all times. How to search and consult the manual Information and instructions are contained and arranged in chapters and sections and are easy to trace by consulting the index. Any information preceded by a warning, obligation or prohibition sign must be carefully read. The essential notes for the health and safety of operators are contained in a box, highlighting warning, obligation and/or prohibition signs in italics as illustrated below. We particularly urge you to read the section “general safety regulations” several times, as it contains important information and warnings on safety. Addressees of this manual For the purpose of this manual, machine personnel are split into the following categories: Machine control operator: He/she is responsible for surveying, using and controlling the machine. Machine routine maintenance operators. For a precise definition of these operators, see section QUALIFICATIONS AND SKILLS OF USERS. Guarantees GAROLL considers itself responsible for the system in its original configuration. Any intervention that changes the machine’s configuration or operating cycle must be executed or approved by GAROLL’s technical department.


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GAROLL does not consider itself responsible for the consequences of using non-original spare parts. All servicing jobs under guarantee, extraordinary maintenance and repair jobs are not to be performed either by the operator or maintenance persons but must be carried out strictly by the machine manufacturer’s technical specialists. Therefore, these operations are not described in this manual. Reference standards The system was designed and built by GAROLL S.R.L. to conform to the technical prescriptions contained in DPR 459/96, Machine Directives 89/392/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC and in the following harmonized standards: EN 292-1 Machine safety. Fundamental concepts, general design principles. Part 1: basic terminology and methods. EN 292-2 Machine safety. Fundamental concepts, general design principles. Part 2: specifications and technical principles. EN 349 Machine safety. Minimum distances to avoid crushing parts of the body. EN 418 Machine safety. Emergency stop equipment, functional aspects. Design principles. EN 60204-1 Safe use of the machine. Machine electrical equipment. EN 746 The machine conforms to the standards concerning Safety and Health in the Work Place in observance of D.P.R. 547/55 and of Decree Law 626/94.


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Key to safety signs on the machine and/or in the instructions manual In this instructions manual, the following names and symbols are used for particularly important signs. The symbols are always located on the left side of the page so that they can be seen immediately. N.B. Notes on economic use of the system. WARNING! Sign or prohibition aimed at preventing damage.

DANGER! Sign or prohibition aimed at preventing damage to objects or persons.


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3 GENERAL SAFETY INSTRUCTIONS 3.1 INSTALLATION

Before beginning work, put the machine in a safe condition. Carry out the jobs observing safety regulations and measures, and following the machine manufacturer’s instructions. When you have finished the jobs, make sure the machine is able to work safely and, in particular, make sure that the protective and safety devices are fully efficient. Incorrect installation can cause damage to persons or things, and GAROLL cannot be held liable for such damage. 3.2 SAFETY DEVICES

The system is provided with electrical and/or mechanical safety devices which protect both operators and the machine. We therefore warn the user not to remove these devices or tamper with them. GAROLL declines all liability due to tampering or incorrect use. 3.3 CHECKS, REPAIRS AND MAINTENANCE

Any check, repair or maintenance jobs must not be carried out on moving parts. Operators must be warned of this prohibition by means of clearly visible notices. Before attempting any operation, turn off power to the machine. To ensure the machine is efficient and operates correctly, you must observe GAROLL’s instructions and carry out scheduled maintenance of the machine. In particular, we recommend you periodically to check the efficiency of all safety devices and insulation of electrical cables, which must be replaced if damaged.


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3.4 LIVE PARTS

Performing jobs on live parts or in their immediate vicinity is forbidden. 3.5 EXPERT PERSONNEL

Jobs concerning assembly, dismantling and maintenance in general must be entrusted to expert, technical qualified personnel, and provided that suitable tools or devices are used and that the relevant instructions are observed. 3.6 PUTTING THE MACHINE OUT OF SERVICE

When no longer in use, the machine must be electrically isolated. The electrical panels must not be powered and restoring power with normal commands must be disabled. The machine is now ready for a general in-depth overhaul followed by dismantling and disposal of all the system’s parts. All current legal regulations and the immediate environment must be observed and respected during all dismantling operations and all operations involving disposal of exhausted substances.


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4 HANDLING INSTRUCTIONS 4.1 SLINGING HANDLES

To ensure lifting and suspension operations are correctly performed: -use equipment of the most suitable type and carrying capacity cover sharp edges check the hook safety device Before beginning to lift:

- allow all operators to reach the safe area and prevent people accessing the handling area

- make sure the load is stable - check if there is any material that could fall when being lifted - lift vertically and gradually to prevent swinging and dynamic stress

4.2 TRANSFER

As lifting and load transfer aids, use rods, levers, and grapnels placed at a safe distance: -never use hands only. The operator must:

- have a general view of the path to be followed - give instructions to the crane driver while staying in a visible position - interrupt the manoeuvre in the event of dangerous situations.


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4.3 LAYING DOWN THE LOAD

Before laying down the load, makes sure the floor is flat and of sufficient capacity to support the load in question. Do not lay down loads near to shed exits, fire protection systems, passages, control panels or electrical lines. The load must be laid down on appropriate cross-pieces to make it stable and facilitate removing the slinging. Do not superimpose containers in poor condition or containing projecting materials. Do not stack materials to a height whereby stability is at risk.


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5 QUALIFICATION AND SKILLS OF USERS 5.1 THE USER COMPANY

It is the responsibility of the user Company to ensure that operators:

- conform to the requirements listed below - read and understand the manual - receive training suitable for their duties and to carry them out safely - receive training specifically aimed at using the machine correctly

5.2 THE OPERATOR

The operator must have at least: -a knowledge of the machine’s technology and specific experience of running the machine -basic general culture and basic technical culture of a sufficient level to enable him/her to read and understand the contents of the manual including correct interpretation of the drawings. Mechanical knowledge (in the electrical, mechanical and pneumatic fields) sufficient to enable him/her to carry out the jobs entrusted to him/ her as specified in this manual

- knowledge of accident prevention regulations: - general regulations (hygiene and safety in work place, preventing accidents in

work place) - specific regulations (for the type of machine) - current regulations in the country where the machine is installed


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5.3 THE MAINTENANCE OPERATOR

Maintenance persons must be selected according to the criteria listed for operators. Moreover, they must have the specific, specialised technical knowledge (mechanical, electrical and pneumatic) to safely perform the duties allotted to them as specified in this manual. Duties and limits of operator and maintenance persons. The use and maintenance operations, split according to purpose (use, routine maintenance, extraordinary maintenance) are indicated in various parts of the manual. Each worker must limit his/her work to his/her specific duties (mechanical, electrical and pneumatic duties). Operator’s duties The operator must not access the electrical equipment installed inside the electrical panel and must not remove protective devices for live parts of components installed on the machine, such as:

- motor terminal boards - terminal board for solenoid-valves and servo-controlled adjustment valves - terminal boards for electrical connector blocks pressure-switches - the operator may only use the controls and instruments on the machine control

panel The operator or machine controller must not carry out any work on the electrical equipment. Routine maintenance persons must not modify cables and electrical connections.


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6 MAINTENANCE INSTRUCTIONS

Running the machine while removing, modifying or tampering with guards, protective devices and safety devices is always forbidden. Before doing any job on the machine, always consult the manual which indicates the correct procedures and contains important information on safety. In case of doubt, consult GAROLL’s Customer Servicing Department. Before attempting any maintenance operation, put the machine in a safe condition and, when you have finished, make sure that the machine is able to work safely and, in particular, that the safety devices are fully efficient. Precautions for handling acid or basic solutions (scale removers or disinfectants). 6.1 SAFETY DURING THE MANIPULATION OF ACID OR BASIC SUBSTANCES Strictly observe the instructions on the safety and toxicology chart of the product being handled Operator: Equip the operator handling solutions with the following equipment:

- Gas mask with filters for acid vapours - Anti-spray goggles - Rubber gloves - Body protection clothes that can be slipped off when necessary

Machine:

- immediately wash with water the parts of the machine that came into contact with the chemical solutions.

Environment:

- immediately wash with water the areas of the work place affected by any leaks of chemical solutions.


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Avoid direct contact between basic and acid solutions – this may cause toxic gasses. 7 RANGES OF APPLICATIONS The system is capable of casting various types of ceramic sanitary-ware, which are agreed together with Garoll during the project and realization phases:

- Shower trays - Console washbasins - Wall-mount washbasins - Pedestals

7.1 INTENDED USES The system was designed and built for making products with the characteristics indicated in the technical specifications agreed with GAROLL s.r.l. 7.2.1 NON-INTENDED AND NON-PERMITTED USES

No other uses are allowed unless specifically approved by the Manufacturer. Consequently, the Manufacturer is relieved of all liability due to failure to observe these prescriptions. 7.2.2 INCORRECT OR IMPROPER USES

The Manufacturer is not liable for any consequences due to incorrect or improper use of the system. The most frequent cases of such use are normally due to:

- inadequate training of personnel - tiredness (especially during night shifts) or distraction - neglect due to an overly casual approach or incorrect habits.

N.B.: Supervision and operation control must be entrusted to expert, well-trained personnel able to correctly use the system under normal operating conditions and (very important) to handle any emergencies.


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7.2.3 OPERATING AND ENVIRONMENTAL LIMITS The casting system was developed for casting ceramic sanitary-ware. The following conditions must be observed to ensure this is performed correctly and in a way not endangering things and/or people and the immediate environment:

Safety devices must be fitted and be perfectly efficient;

Electrical panels must be powered at the correct tension and all earth connections must conform to safety regulations;

Conveyors and/or manipulators must be efficient in common with all accessories assisting operation.

The pneumatic system must be fed at correct pressure and flow-rate at the delivery point (see technical specifications)

Use only trolleys and setting plates for pieces of correct shape and mass to avoid any subsequent damage to equipment during robot manipulation of said setting plates.


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7.3 OPERATOR’S AREA AND DANGEROUS ZONES

GAROLL considers itself responsible for the system in its original configuration. Any intervention that changes the machine’s configuration or operating cycle must be executed or approved by GAROLL’s technical department. GAROLL does not consider itself responsible for the consequences of using non-original spare parts.

All servicing jobs under guarantee, extraordinary maintenance and repair jobs are not to be performed either by the operator or maintenance persons but must be carried out strictly by the machine manufacturer’s technical specialists. Therefore, these operations are not described in this manual.

In view of this, the operator must stay in the appropriate areas indicated on the floor and avoid hazardous areas indicated with suitable signs and safety prescriptions. It is the sole responsibility of the client to demarcate walkways, safe and non-safe areas and to display appropriate danger signs in accordance with local legislation.

Access to the more dangerous areas is prevented by fixed guards and guards that can only be removed intentionally (with appropriate tools and subject to authorisation).


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During the maintenance operations all risks and safety hazards must be avoided in a normal professional way. 7.4 SAFETY DEVICES AND SIGNALS

Protective panels: the areas considered as high risk are protected by protective panels designed to prevent any action by the operator that might cause damage to things and/or persons and to the immediate environment. Panels must remain locked at all times and should only be accessed by suitably qualified technicians.

Motor protection: all motors are provided with overload protection to prevent damage during overloading or malfunctioning.

Emergency: All control panels and portable pendants are equipped with red emergency buttons. In the event of an emergency, this device makes it possible to manually disable the system. Pressing any emergency button disables all equipment in the casting cell.


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Safety signs: make sure all safety symbols are legible. Clean or replace them if text and/or figures are difficult to read. To clean the signs, use a cloth, water and soap. Do not use solvents, petrol etc. Replace damaged, missing and/or difficult to read signs. If necessary, ask GAROLL’s Customer Servicing department for new signs or for information regarding their correct use. Safety signs in and around the casting cell must conform to local safety legislation and it’s the sole responsibility of the client to display this signs in appropriate places. If sings are worn and/or deteriorated, the client must replace them under his/her own responsibility. GAROLL is not liable for damage to things and/or people due to non replacement of faulty signs. 7.5 HAZARDS AND RESIDUAL RISKS

There is a special category of incident that the system manufacturer is unable to analyse and thus foresee. The repeatability through time and the cause is almost always accidental but arises through poor maintenance. Here is an example to better explain the above concept: faulty pipe leaks water without the user or maintenance person noticing the problem – this leak could reach a motor and trip its protective device. This type of incident may seem small or negligible, but, in common with other similar accidents it occurs very frequently. The operator must wear adherent clothes, so to avoid entanglements with moving parts. See next section about personal protective equipment. The system produce quite a high level of noise and personnel should wear hearing protection. It is also forbidden to insert body parts or any object during handling. Water is an integral part of the process and may cause dangerous situations if in contact with electrical equipment, All safety fences and safety barriers must be kept in a good condition at all times. Safety barriers and emergency buttons must be tested regularly.


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8 PERSONAL PROTECTIVE EQUIPMENT It is not the duty of the system manufacturer to indicate the clothes and protection devices most suitable to ensure safety and freedom from harm of the personnel.

However, personnel must be equipped to face all the risks and unforeseen events that the person responsible for safety has noted. If, due to special production needs, unknown products have to be used, ask for all the necessary information to make sure they are handled safely in order to avoid damage to things and/or people, and to the immediate environment.

Garoll would be very glad to help, explain and suggest any personal protective equipment which may be considered necessary to avoid damage to things and/or persons, and to the immediate environment.


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1. THE TECHNOLOGY The HPC machine is a unit for forming ceramic articles by high pressure casting. The machine was designed to allow use of micro-porous resin moulds. Main work phases: 1. Closing and fixing of mould. All parts of the mould are brought together and closed by high pressure in order to deform the closing surfaces to the degree set on the hydraulic closing cylinders or hammers. Closing surfaces has to connect parallel to each other and at the same amount of compression to prevent any leakage of slip during the casting process. Leakages of slip during the casting cycle can damage a mould very seriously. 2. Mould filling. After closing the press and compressing the mould closing surface in high pressure slip is injected into the model forming cavity of the porous resin mould. 3. Forming of thickness. During filling of the mould with slip, thickness formation on the casting surface immediately starts even before pressure is applied. Water from the slip is absorbed into the porous resin and leaves a skin on the casting surface which is the external face of the piece being cast. Due to casting pressure inside the casting cavity, water in the slip passes through the skin or formed thickness into the porous mould. Thickness dimension is in proportion to the time the mould is under pressure and to the pressure value used. During the whole thickness formation process the mould acts as a filter to keep the residual particles on the mould surface and only allowing the water to exit from the forming cavity. During the later part of thickness formation the water has to pass first through the already formed skin before arriving to the resin. Slip rheology and particle size distribution of the slip plays a very important role in the filtering or transport of water through the skin of the piece itself towards the mould. 4. Draining. After the thickness formation process, excess slip is discharged from the mould by injecting compressed air into the newly formed piece. 5. Hardening. After draining all residual liquid slip from the piece, air is slowly injected into the piece and maintained at medium pressure for a few minutes. This pressure on the inside walls of the piece will force the last water towards the outside into the resin mould and will ensure mechanical strength of the piece. 6. Piece opening and demoulding. This phase consists of two similar but independent steps. First the mould has to be opened and for this the first detachment happens from the “non-demoulding side” of the press. The piece is now only suspended on the remaining half of the mould. The second step is to demould the now suspended piece from the other part or “demoulding side”. The piece is made to detach from the mould by injecting compressed air in the mould rear circuit in order to create a counter pressure flow of air from the resin surface. This air pressure forces out the water that


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resides in the mould pores which, in turn, produces a water curtain between mould surface and piece thus enabling the piece to detach. Demoulding robots or automatic manipulators are installed to mechanically demould the piece. 7. Washing. This is the final phase of the cycle and cleans the mould in counter current direction to clear out any slip particles that may have entered the pores near the casting surface of the mould. The washing cycle prepares the mould for casting of the next cycle. Correct washing parameters ensures the correct “dryness” of the mould surface to enhance proper thickness formation.


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2. ADJUSTMENT BEFORE STARTING THE SYSTEM 2.1 SAFETY PROCEDURE FOR CELL ACCESS DURING ANY WORK PERFORMED BY TECHNICIANS INSIDE THE SAFETY FENCE

Any unauthorised access to the casting cell causes the hardware security intervention of the separate equipment (Robot and presses). This is to prevent any injury or damage to people and equipment. To restore the cell it is necessary to identify and reset the emergency cause and to re-enable on each press the motors button. For the robot it is necessary to resume the program from the interrupted point. Procedure for SAFE ACCESS into the cell: Safe access is required for mould changes, mould washing with hypochlorite, scheduled maintenance and breakdown repairs.

- Turn off the auto start to all presses. - Wait for all presses to complete casting cycles. . - Wait for the robot to complete any manipulation that may still be in progress. - Stop the robot at the end of its working sequence. - Turn the safety key on the press panel to the safety position to prevent the

possibility to start any equipment. This safety key allows the operator to manipulate the press movement in manual mode but any auto start is disabled. Robot movement is also inhibited by the safety key.

- Open the cell entrance gate (All the equipment go in safety). - Take care that all equipment has stopped. - Install moulds from the front part of the machine with proper tools and in safe

condition. There is a safety access gate next to every press to allow safe entry. - Perform any other maintenance work that necessitated the stoppage. SAFE RESTARTING OF EQUIPMENT - Remove all tools from the cell. - Direct all personnel out of the cell and close the gate - Enable the robot and the press motors of the equipment. - Enable the auto start to the presses. - The cell is back in automatic mode. - It is not recommended to “bridge” the safety switches on the fence gates to

perform mould changes on a single press while the rest of the cell is functional. Robot movement is unpredictable and can cause serious injury to personnel.


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2.2 VERTICAL SETTING AND CLOSURE PRE-LOADING REGULATION 2.2.1 VERTICAL SETTING

It is of the utmost importance to first regulate the verical setting of the press before attempting the set the pre-load. The vertical adjustment is very much part of the eventual setting of mould closure and compression. After installation of EVERY new mould on the press, the vertical adjustment has to be controlled.

A: Main nut for adjustment of Horizontal position.

B: Locking nut for locking Horizontal position

C: Locking nut for locking Vertical position

D: Locking bolts for locking piston end of hydraulic cylinder.

E: Left cylinder

F: Right cylinder

- Enter MANUAL mode. - Start only the hydraulic pump as described in the manual operation of the press

on the SERVICES manual page of the touch pendant. This is to ensure that the hydraulic cylinders can be pushed to the set vertical position during lateral movement of the press. This will further ensure that the press is in the locked vertical position when you make the control measurement.

- Drive the press to an open position of approximately 200mm between mould closing surfaces.

- Measure the distance between the mobile and fixed part in the four corners of the mould holding frame of the press.

- Compare the 4 readings and determine if the mould frames are parelel or if the mobile part needs any adjustment.


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- If the measures in the lower part of the press is bigger than the readings in the higher part, the two cylinders E and F needs to be extended until the measures in lower and higher parts are equal (to a tolerance of 0,5mm).

- If the contrary is true and the lower part measures are smaller than the higher part measures, the two cylinders E and F needs to be shortened.

- Move the mobile part of the press untill the rotating position and rotate slightly towards horizontal. This will allow the piston to be free from hydraulic pressure that will allow it to be turned. If the press is left in the vertical position, the piston is locked at the end of the cylinder stroke.

- Unscrew the locking bolts D to release the screw thread on the end of the piston. - Ensure that the main nut A and Locking nut B are tightly locked together. - Unlock the locking nut C by turning it anti-clockwise. - To extend the cylinder stroke, turn the piston anti-clockwise using the correct key

on the big nut A (because A and B are locked it can be used to turn the piston). - To shorten the cylinder stroke, turn the piston clockwise using the correct key on

the big nut A. - Rotate back to vertical and control the measures again. Repeat this adjustment

untill the mobile and fixed sides of the press is paralel. - When the setting is done, lock the locking bolts D tight. - Lock the big locking nut C by turning it clockwise until it locks onto the metal

frame. 2.2.2 CLOSURE PRE-LOADING REGULATION

Always perform this task only after proper regeneration of the mould for approximately 10 minutes. This ensures the mould is at the correct flexibility and temperature. Also first set the correct vertical adjustment of the mould carrier before adjusting the pre-load on the hdraulic hammers. The closure pre-loading is the deformation dimension of the closing surface of every single mould part. It allows the sealing of the mould by means of hydraulic tightness when the slip is under pressure inside the mould during the casting cycle. The adjustment of the pre-load setting on the hammers is on the one hand to ensure some compression of the resin on the closing surface of the mould but on the second hand to prevent permanent deformation of the mould if the hammers could not be locked at a certain point. It guarantees the tightness of the mould closing but at the same time deforms the closing surfaces to the minimum. The correct pre-load setting for each mould has to be found in order to prevent leaking and consequent damage to moulds. On presses where several different moulds are


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used it is useful to install and work with moulds that are of more or less the same casting life or age. This means that when a mould is new it has a specific pack thickness (the thickness of the complete mould measured from back to back of the aluminium plates). As the mould age the pack thickness will reduce due to the constant compression and decompression of the mould during closing and opening the press in the normal casting cycles. The pre-loading values should be in the range of 1 to 2,5mm but ideally for a new mould it should be around 1,5mm.

A: Hydraulic hammer locking nut

B: Hydraulic hammer setting nut

C: Hydraulic cylinder closing face

D: Lock the locking nut A in clockwise direction

E: Lock the setting nut B in the anti clockwise direction

F: Hydraulic hammer cylinder body.

Pre-loading regulation sequence. - Unlock all the locking nuts (A) and open them 3 to 4 turns. - Open all setting nuts to near the locking nut position. - Close the press mobile part until the two halves of the resin mould are in contact. - Read the position of the mobile part on the display screen and verify that it is the

same as in setup configuration. - Close the hydraulic hammers in low pressure as described in 4.2.1.4 Manual

Movement of press. - Control that none of the setting nuts are in contact with the hydraulic cylinder

body (F). - Systematically adjust all setting nuts to touch the hydraulic hammer body and

then carefully unscrew it to the desired free space between setting nut and cylinder body.

- Lock the setting nut and locking nuts together as in the second figure. - A thin plate thickness gauge can be used to determine the space between the

nut and the cylinder body. An easy rule of thumb is 1 rotation of the nut = 1,5mm.


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.

On all mould parts the cylinders must be set at exactly the same deformation values. Different values can cause mould carrier non alignment with consequential damage to the mobile part carrier guides as well as for the moulds.


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3. AUTOMATIC CYCLE SET-UP After mould installation it is necessary to carefully change the setup parameters for the casting cycle of the press in order to achieve the optimum results for the particular shape that is to be cast. This includes the casting cycle parameters in the setup pages as well as the configuration parameters in the configuration setup pages.

Push the SETUP button for the press you wish to select. A password entry screen will appear.


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1. Touch the blue rectangle once. 1. A flashing rectangular box will appear in the blue rectangle. 2. Touch <CLR> once to delete any incorrect typing. 3. Touch the corresponding numbers of the password on the keypad. 4. Confirm the password by pressing <ENTER> for approximately 2 seconds. 5. If the password is correct, you will obtain access to the parameter setting pages. 6. If the password is not accepted, repeat from point 1.

The <MAIN> key at the top of the page returns you to the main selection screen.

Knowing the password will give you access to the machine set-up and manual movement pages. This access must be reserved only for machine maintenance and


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adjustment personnel. If this confidentiality is lost, we advise you to contact us so we can reprogram a new code. 3.1 HOW TO INTRODUCE OR MODIFY DATA ON THE SETUP PAGES All setup screens contain data relevant to some part of the process. The setup pages are located in sequence and can be found by touching the <FOLLOW> key or the <PREC> key to return to previous pages. To change any parameter, touch the block containing the value for that parameter. A numerical keypad similar to the password input pad will appear. The parameter value that you touched will be highlighted.

1. Touch the <CLR> key. 2. The original value in the parameter box will return to 0. 3. Touch the corresponding numbers of the new value you wish to enter on the

keypad. 4. Touch the <DEL> key to move one character backwards to delete any incorrect

input. 5. Confirm the new value by pressing <ENTER>. 6. The keypad will disappear and you will only see the setup screen. 7. Control if the parameter is now of the correct value.

Pay attention when entering or changing parameter values. Incorrect values can cause unpredicted behaviour of the equipment!


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3.2 PRESSURE CASTING SYSTEM TECHNOLOGICAL PARAMETERS NOTE: There are several columns on each of the setup screens. The heading for each column is described below: 3.2.1 TIME or DURATION The cycle phase is time controlled and finishes only when the time set for each parameter in this column elapses. There are some conditional parameters that are not controlled by time and thus without the possibility to set any time value. All time values are set in seconds. 3.2.2 DELAY With the complex layout and design of the press, it may be necessary to delay some functions on one circuit while the process continues on the other circuit. Delays are set to equalise the conditions in two moulds which may be of variable shape and size. All delay values are set in seconds. 3.2.3 RAMP The ramp setting is the time over which the pressure can change from Low to High or on the other hand from High to Low. This setting ensures that no sudden pressure changes can occur inside the mould or cast piece which may damage the mould and/or cause the cast piece to have defects after the process. Ramp is set in time (seconds) and initial and final pressures (bar). 3.2.4 INITIAL PRESSURE This is the first or starting pressure of any phase and measured in bar. 3.2.5 FINAL PRESSURE This is the pressure achieved after the time of any parameter has elapsed. Ramp settings are normally included inside the total setting of any parameter and are therefore part of the total time of the specific parameter.


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3.3 IDENTIFICATION OF THE MOULD ON THE MACHINE

The presses are set up to allow for various configuration of installation. In the above diagram the layout means:

- Mould 1/1 and Mould 2/1 are the two moulds on the <Left/Down> configuration in setup. All pages referring to <Left/Down> will change configuration for the mould/moulds installed in the lower part of the press.

- Mould 2/1 and Mould 2/2 are the two moulds on the <Right/Up> configuration in setup. All pages referring to <Right/Up> will change configuration for the mould/moulds installed in the upper part of the press.

- Always take care to open the correct manual valves on the Air/Water and Draining circuits on the top manifolds that feed the Demoulding and Non Demoulding sides of the press. From setup it is important to address the correct part of the mould in each phase of demoulding.

In the following pages the setup of the press parameters will be described in detail.


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3.3.1 TECHNOLOGICAL CYCLE PHASE PAGE C1

3.3.1.1 Initial Draining After the mould is closed it is possible to blow air into the casting cavity of each mould to disperse any water that may still be on the mould surface. The air enters through the draining air inlet pipes into the cavity. All discharge valves on the resin parts of the moulds are open at this stage and water is forced to the back of the mould and drained to the floor. This leaves the mould casting surface more dry for casting and avoid any possibility to have drops of water on the casting surface. For the final 5 seconds of this setting the slip draining valve to the floor is also opened to force any accumulated water in the filling circuit to the floor. PARAMETERS: 1. Time or Duration Total duration of this phase in seconds. 2. Pressure Pressure into the circuit is regulated by the proportional valve in the control panel at the end of the press.


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3.3.1.2 Slip Recirculation Slip is recirculated in the feeding circuit prior to the filling of the moulds. The main purpose of this is to transport fresh and hot slip to the manifold next to the press. Slip is pumped from the slip pump to the main manifold and returns to the return tank. It also removes the slip in the circuit that has already been under pressure during the previous cycle. Time duration and Pressure in bar can be set for this parameter PARAMETERS: 1. Time or Duration Total duration of this phase in seconds. 2. Pressure Pressure to the pneumatic slip pump is regulated by the proportional valve in the control panel at the end of the press. 3.3.1.3 Slip Filling with Pump After mould composition, initial draining and recirculation, the moulds can now be filled with slip to start the casting cycle. The slip pump transfers slip from the heated slip tank into the moulds. Ensure that the mould is completely filled during the filling phase. PARAMETERS: 1. Time or Duration Total duration of this phase in seconds. 2. Ramp This is the gradual change from initial pressure to final pressure of filling. Ramp is set in seconds and must be shorter or equal to the filling time of the mould. 3. Initial Pressure The pressure to the pneumatic slip pump is regulated by the proportional valve in the control panel at the end of the press. This is the pressure at the start of the filling phase. 4. Final Pressure Pressure of compressed air supply of the filling pump at end of ramp time – this value will be maintained until end of filling phase. 3.3.1.4 Proportional Air Slip Valve Norgren Ramp This is a secondary proportional valve that controls the volume flow of air to the slip pump. This is to maintain constant pressure at low pressure from the pneumatic slip pump. PARAMETERS: 1. Ramp This is the time of gradual change from initial pressure setting to final pressure of this flow control valve. Ramp is set in seconds and must be shorter or equal to the filling time set in the Slip Filling With Pump parameter.


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2. Initial Pressure The initial setting of the valve on a scale of 0 to 100%. The settings can be 1, 2, 3 and 4 and each increment represents 25% of flow. 3. Final Pressure The final setting of the valve on a scale of 0 to 100%. The settings can be 1, 2, 3 and 4 and each increment represents 25% of flow. The use of this valve in conjunction with the inline proportional valve is to ensure control over the flow of air at lower pressure from the proportional valve. 3.3.1.5 Delay Filling Mould with Valves 450 & 451 If the two moulds installed on the press are of diverse nature, it is possible to delay the filling to any one at the beginning of filling. This may be necessary if for example there is a larger mould installed in one position that requires longer time for filling. It is then possible to delay the start of filling for the smaller piece to ensure the filling in both pieces are completed at almost the same moment. PARAMETERS: 1. Time This is the time set for the active delay on the mould you require to have a delay. If the moulds are almost equal in size the delay setting for both moulds should be 0. 3.3.1.6 Offset of filling Filling offset is the threshold pressure value (in bar) used to allow the cycle to continue to the next phase. It is like a second security to ensure the moulds are completely filled. Offset pressure is set slightly lower than the Final Pressure of filling and the filling phase will continue until this parameter is met before stepping to the next phase. Even if filling time have elapsed, the cycle will remain in Filling until this condition is met. PARAMETERS: 1. Final Pressure This setting is a conditional interlock value that must be met to ensure the Slip Filling With Pump is completed successfully.


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3.3.2 TECHNOLOGICAL CYCLE PHASE PAGE C2

3.3.2.1 Thickness Formation with Slip Pump Directly after the moulds are filled, the cycle switch over to thickness formation with slip pump. This is a phase where thickness formation on the mould surface takes place but the pressure in the circuit is still relatively low. It adds the further benefit that water that is forced out of the slip into the resin mould can be replaced by fresh slip into the circuit without forfeiting any volume on the stroke of the injector. PARAMETERS: 1. Time This is the total time in seconds for the phase. 1. Ramp This is the time of gradual change from initial pressure setting to final pressure of this phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time parameter. 2. Initial Pressure The initial pressure setting at the start of the phase. 3. Final Pressure The final pressure setting for the end of the phase (the end of Ramp Pressure).


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3.3.2.2 Thickness Formation with Injector N1 The real thickness formation under pressure starts from this phase. Where the slip pump effectively works until 5bar, the injector can increase the pressure to the desired top limit. The injector is hydraulically operated and forces slip through the filling circuit towards the mould to maintain high pressure as water is filtered to the resin mould. The injector takes over from the thickness with slip pump. Take care to set the initial pressure equal to the final pressure of N1 to avoid sudden pressure changes in the mould. Any sudden changes may lead to damage of the mould and/or defects to the piece being cast. PARAMETERS: 1. Time This is the total time in seconds for the phase. 1. Ramp This is the time of gradual change from initial pressure setting to final pressure of this phase. As the pressure during this phase is high, it is important to set a ramp time that does not apply sudden pressure changes inside the mould. 120 seconds should be the minimum ever used to reach final pressure. Take care to set the initial pressure equal to the final pressure of thickness with slip pump to avoid sudden pressure changes in the mould. Any sudden changes may lead to damage of the mould and/or defects to the piece being cast. Ramp is set in seconds and must be shorter or equal to the time set in the Time parameter. Ramp is included in total time of this phase. 2. Initial Pressure The initial pressure setting at the start of the phase. 3. Final Pressure The final pressure setting for the end of the phase. 3.3.2.3 Thickness Formation with Injector N2 Sometimes it may be necessary to set also a second thickness formation time after N1. Some pieces are sensitive and need a reduction in pressure towards the end of thickness formation. On the other hand some pieces may require a more gentle first thickness formation and higher pressure on the second phase. N2 takes over immediately from N1. Take care to set the initial pressure equal to the final pressure of N1 to avoid sudden pressure changes in the mould. Any sudden changes may lead to damage of the mould and/or defects to the piece being cast. PARAMETERS: 1. Time This is the total time in seconds for the phase. This time setting can be varied to make less or more thickness formation depending on the piece requirements. 2][ Ramp This is the time of gradual change from initial pressure setting to final pressure of this phase. As the pressure during this phase is high, it is important to set a ramp time that does not apply sudden pressure changes inside the mould. 120 seconds should be the


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minimum ever used to reach final pressure. Ramp is set in seconds and must be shorter or equal to the time set in the Time parameter. Ramp is included in total time of this phase. 2. Initial Pressure The initial pressure setting at the start of the phase. 3. Final Pressure The final pressure setting for the end of the phase. 3.3.2.4 Offset of Draining Pressure Draining offset is the threshold pressure value (in bar) used to enable start of mould draining. At the end of the thickness formation phase (at high pressure), the cycle must change over to the next phase which is draining of the remaining slip from the mould cavity. To effect the draining, compressed air has to be pushed into the cavity to force out the slip. To safely introduce the compressed air into the piece, the high pressure of thickness formation first has to be released. Draining offset is the pressure threshold below which the draining phase can safely begin. PARAMETERS: 1. Final Pressure This is only a control parameter or interlock to allow the next phase to begin if it becomes true. 3.3.2.5 Delay Start Draining N1 It is possible to place a delay on the start of draining. It is to effect some natural decompression inside the piece after thickness formation and before draining. PARAMETERS: 1. Time Time is set in seconds.


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3.3.3 TECHNOLOGICAL CYCLE PHASE PAGE C3 – RAMPS FOR LOWER MOULD

3.3.3.1 Ramp Draining N1 Mould 1 This is the ramp setting for the start of the Draining phase. The duration of the Draining phase is set on another page of the setup parameters. This sets the variable pressure from start to end of draining. PARAMETERS: 1. Ramp Time This is the time in seconds for the ramp during the 1st draining phase. 2. Initial Pressure This is the starting pressure applied inside the piece when Draining N1 starts. 3. Final Pressure The final pressure setting at the end of the ramp and will be maintained until the end of the draining phase. 4. Water Off/On Normally draining is effected by pushing compressed air into the cavity to force out the slip at the draining (filling) point in the mould. In some cases but very rare it may be possible to pump water into the cavity during draining to enable better draining of the residual slip. 3.3.3.2 Internal Washing with Water Mould 1


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It is possible to pump water also after the first draining into the mould to rinse out any slip that have not drained during the 1st draining phase. This can be used if slip viscosity is not suitable to drain fast and some slip remains on the internal walls of the piece. If used at all, it should be very briefly as too much water will damage the internal of the piece. Ensure that the selector switch for Internal Washing with Air is set to the Off position to prevent water to end up in return slip. PARAMETERS: 1. Time This is the total time in seconds for the phase. 3.3.3.3 Internal Washing with Air Mould 1 If the piece is washed internally with water as described in the previous point, it is necessary to blow some air through the piece once more before the hardening phase. This is important to remove any liquid residue (slip/water) that may remain in the bottom part of the piece. This setting can also be used as a secondary draining after Draining N1. In some cases where slip is slow to drain you may need a secondary draining curve at different pressures to clean the piece internally before hardening. PARAMETERS: 1. Ramp Time This is the time in seconds for the ramp during the 1st draining phase. 2. Initial Pressure This is the starting pressure applied inside the piece when Internal Washing with Air starts. 3. Final Pressure The final pressure setting at the end of the ramp and will be maintained until the end of the Washing with Air phase. 4. To Return Circuit Off/On This switch is toward the bottom of the page. This is the selector switch to send slip to the return tank (ON) or directly to the floor (OFF). 3.3.3.4 Ramp for Hardening Mould 1 When the piece is completely drained of residual slip, air pressure is applied inside the internal room of the piece with compressed air. This is to force some moisture out of the piece into the resin mould and to give the piece some mechanical strength. This phase describes the change from end of draining pressure to hardening pressure inside the piece. The duration of hardening is set on Setup page C5. PARAMETERS: 1. Ramp Time This is the total time in seconds for the ramp at the start of hardening phase.


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2. Initial Pressure This is the starting pressure applied inside the piece when Hardening starts. 3. Final Pressure The final pressure setting at the end of the ramp and will be maintained until the end of the Hardening phase. 3.3.3.5 Ramp for Decompression Hardening Mould 1 At the end of Hardening the pressure inside the piece has to be released gently to avoid any structural damage to the piece. By decompression you gently change from hardening pressure to normal atmospheric pressure to avoid any damage or deformation to the piece during opening of the press. PARAMETERS: 1. Ramp Time This is the total time in seconds for the Decompression phase. 2. Initial Pressure This is the starting air pressure applied inside the piece when Decompression starts. 3. Final Pressure This is the final pressure inside the piece at the end of Decompression. 3.3.3.6 Ramp Draining N3 Mould 1 After hardening there may again be some slip in the bottom of the piece that has run down from the internal walls of the piece. This needs to be drained before the piece is demoulded from the press. PARAMETERS: 1. Ramp Time This is the time of gradual change from initial pressure setting to final pressure of this phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time parameter on Setup page C7 – Draining N3. 2. Initial Pressure This is the starting air pressure applied inside the piece when Draining N3 starts. 3. Final Pressure The final air pressure setting at the end of the ramp and will be maintained until the end of the Draining N3 phase. 4. Water Off/On It is possible in this phase to wash again the piece internally with water. With the switch ON the piece will have water and with the switch OFF the piece will be drained with air. When water is selected, the Initial and Final pressures do not apply as only air pressure is controlled by a proportional valve. 5. To Return Circuit Off/On This switch is toward the bottom of the page. This is the selector switch to send slip to the return tank (ON) or directly to the floor (OFF) when water is selected.


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3.3.3.7 Ramp Draining N4 Mould 1 This is similar to Draining N3 as well as to the Internal Washing with Air. A secondary gentle flushing of air through the internal room of the piece may be necessary to remove the last of any residual slip (or water if Draining N3 was set to flush with water). PARAMETERS: 1. Ramp Time This is the time of gradual change from initial pressure setting to final pressure of this phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time parameter on Setup page C7 – Draining N4. 2. Initial Pressure This is the starting air pressure applied inside the piece when Draining N4 starts. 3. Final Pressure The final air pressure setting at the end of the ramp and will be maintained until the end of the Draining N4 phase. 4. Water Off/On It is possible in this phase to wash again the piece internally with water. With the switch ON the piece will have water and with the switch OFF the piece will be drained with air. When water is selected, the Initial and Final pressures do not apply as only air pressure is controlled by a proportional valve. 5. To Return Circuit Off/On This switch is toward the bottom of the page. This is the selector switch to send slip to the return tank (ON) or directly to the floor (OFF) when water is selected.


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3.3.4 TECHNOLOGICAL CYCLE PHASE PAGE C4 – RAMPS FOR UPPER MOULD

3.3.4.1 Ramp Draining N1 Mould 2 This is the ramp setting for the start of the Draining phase. The duration of the Draining phase is set on another page of the setup parameters. This sets the variable pressure from start to end of draining. PARAMETERS: 1. Ramp Time This is the time in seconds for the ramp during the 1st draining phase. 2. Initial Pressure This is the starting pressure applied inside the piece when Draining N1 starts. 3. Final Pressure The final pressure setting at the end of the ramp and will be maintained until the end of the draining phase. 4. Water Off/On Normally draining is effected by pushing compressed air into the cavity to force out the slip at the draining (filling) point in the mould. In some cases but very rare it may be possible to pump water into the cavity during draining to enable better draining of the residual slip.


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3.3.4.2 Internal Washing with Water Mould 2 It is possible to pump water also after the first draining into the mould to rinse out any slip that have not drained during the 1st draining phase. This can be used if slip viscosity is not suitable to drain fast and some slip remains on the internal walls of the piece. If used at all, it should be very briefly as too much water will damage the internal of the piece. Ensure that the selector switch for Internal Washing with Air is set to the Off position to prevent water to end up in return slip. PARAMETERS: 1. Time This is the total time in seconds for the phase. 3.3.4.3 Internal Washing with Air Mould 2 If the piece is washed internally with water as described in the previous point, it is necessary to blow some air through the piece once more before the hardening phase. This is important to remove any liquid residue (slip/water) that may remain in the bottom part of the piece. This setting can also be used as a secondary draining after Draining N1. In some cases where slip is slow to drain you may need a secondary draining curve at different pressures to clean the piece internally before hardening. PARAMETERS: 1. Ramp Time This is the time in seconds for the ramp during the 1st draining phase. 2. Initial Pressure This is the starting pressure applied inside the piece when Internal Washing with Air starts. 3. Final Pressure The final pressure setting at the end of the ramp and will be maintained until the end of the Washing with Air phase. 4. To Return Circuit Off/On This switch is toward the bottom of the page. This is the selector switch to send slip to the return tank (ON) or directly to the floor (OFF). 3.3.4.4 Ramp for Hardening Mould 2 When the piece is completely drained of residual slip, air pressure is applied inside the internal room of the piece with compressed air. This is to force some moisture out of the piece into the resin mould and to give the piece some mechanical strength. This phase describes the change from end of draining pressure to hardening pressure inside the piece. The duration of hardening is set on Setup page C6.


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PARAMETERS: 1. Ramp Time This is the total time in seconds for the ramp at the start of hardening phase. 2. Initial Pressure This is the starting pressure applied inside the piece when Hardening starts. 3. Final Pressure The final pressure setting at the end of the ramp and will be maintained until the end of the Hardening phase. 3.3.4.5 Ramp for Decompression Hardening Mould 2 At the end of Hardening the pressure inside the piece has to be released gently to avoid any structural damage to the piece. By decompression you gently change from hardening pressure to normal atmospheric pressure to avoid any damage or deformation to the piece during opening of the press. PARAMETERS: 1. Ramp Time This is the total time in seconds for the Decompression phase. 2. Initial Pressure This is the starting air pressure applied inside the piece when Decompression starts. 3. Final Pressure This is the final pressure inside the piece at the end of Decompression. 3.3.4.6 Ramp Draining N3 Mould 2 After hardening there may again be some slip in the bottom of the piece that has run down from the internal walls of the piece. This needs to be drained before the piece is demoulded from the press. PARAMETERS: 1. Ramp Time This is the time of gradual change from initial pressure setting to final pressure of this phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time parameter on Setup page C8 – Draining N3. 2. Initial Pressure This is the starting air pressure applied inside the piece when Draining N3 starts. 3. Final Pressure The final air pressure setting at the end of the ramp and will be maintained until the end of the Draining N3 phase. 4. Water Off/On It is possible in this phase to wash again the piece internally with water. With the switch ON the piece will have water and with the switch OFF the piece will be drained with air. When water is selected, the Initial and Final pressures do not apply as only air pressure is controlled by a proportional valve.


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5. To Return Circuit Off/On This switch is toward the bottom of the page. This is the selector switch to send slip to the return tank (ON) or directly to the floor (OFF) when water is selected. 3.3.4.7 Ramp Draining N4 Mould 2 This is similar to Draining N3 as well as to the Internal Washing with Air. A secondary gentle flushing of air through the internal room of the piece may be necessary to remove the last of any residual slip (or water if Draining N3 was set to flush with water). PARAMETERS: 1. Ramp Time This is the time of gradual change from initial pressure setting to final pressure of this phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time parameter on Setup page C8 – Draining N4. 2. Initial Pressure This is the starting air pressure applied inside the piece when Draining N4 starts. 3. Final Pressure The final air pressure setting at the end of the ramp and will be maintained until the end of the Draining N4 phase. 4. Water Off/On It is possible in this phase to wash again the piece internally with water. With the switch ON the piece will have water and with the switch OFF the piece will be drained with air. When water is selected, the Initial and Final pressures do not apply as only air pressure is controlled by a proportional valve. 5. To Return Circuit Off/On This switch is toward the bottom of the page. This is the selector switch to send slip to the return tank (ON) or directly to the floor (OFF) when water is selected.


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3.3.5 TECHNOLOGICAL CYCLE PHASE PAGE C5 – DRAINING & HARDENING LOWER MOULD

3.3.5.1 Draining 1 - Mould 1 through YV230 and YV231 During the 1st draining phase after thickness formation, air is injected into the mould to force out the remaining liquid slip inside the piece. The filling valve to the mould, YV450, and return valves YV420 and YV470 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV230 and/or YV231 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. PARAMETERS: 1. Delay It is possible to delay the opening of YV230 while air is injected through YV231 or delay the opening of YV231 while air is injected through YV230. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of draining air through each of YV230 and YV231. Delay is set in seconds. 2. Time The total time in seconds these valves will be opened during the Draining 1 phase. Any delays set may lengthen the total time of Draining 1. 3.3.5.2 Internal Washing with Air - Mould 1 through YV230 and YV231


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This is also referred to as 2nd draining. During the Internal Washing with Air phase after 1st draining, air is injected into the mould to force out the remaining liquid slip (or water if water on time was selected on page C3) inside the piece. The filling valve to the mould, YV450, and return valves YV420 and YV470 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV230 and/or YV231 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. NOTE: If Internal Washing with Water time was selected on page C3, only the discharge valve YV460 at the bottom of the press will open when air is injected into the mould (YV450, YV420 and YV470 closed). This is to avoid water to be drained to the slip return tank. Please take care that the selector switch toward the bottom of page C3 is in the OFF position to ensure that water drains to the floor and not to the slip return tank. PARAMETERS: 1. Delay It is possible to delay the opening of YV230 while air is injected through YV231. Delay is set in seconds. 2. Time The total time in seconds this valve will be opened during the Internal Washing with Air phase. 3.3.5.3 Hardening - Mould 1 through YV230 and YV231 During the hardening phase after draining and internal washing with air, air is injected into the mould to pressurise the piece internally. This is done to force some water out of the walls of the newly cast piece into the resin mould. It ensures mechanical strength of the piece. The filling valve to the mould, YV450, is opened during this phase but the return valves YV420 and YV470 are closed. Compressed air is injected via YV230 and/or YV231 to pressurise the piece internally. The total hardening or consolidation time for different pieces may vary due to their shape and size. PARAMETERS: 1. Delay It is possible to delay the opening of YV230 while air is injected through YV231 or delay the opening of YV231 while air is injected through YV230. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of hardening air through each of YV230 and YV231. 2. Time The total time in seconds these valves will be opened during the Hardening phase. Any delays set may lengthen the total time of Hardening. 3.3.5.4 Detachment in Hardening - Mould 1 through YV280


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It is possible to initiate some detachment on the non-demoulding side of the mould during the hardening phase. Take in consideration that the pressure applied through YV280 can only be the same of the current pressure during the hardening phase. This means that the pressure internally and on the mould surface will be exactly the same. PARAMETERS: 1. Delay It is possible to delay the opening of YV280 during the hardening phase until only the last few seconds of hardening. For example, if hardening is 200 seconds and you wish to set this parameter for the last 15 seconds during hardening, you have to set a 185 second delay. 2. Time The total time in seconds YV280 will be opened during the Hardening phase.


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3.3.6 TECHNOLOGICAL CYCLE PHASE PAGE C6 – DRAINING & HARDENING UPPER MOULD

3.3.6.1 Draining 1 - Mould 2 through YV232 and YV233 During the 1st draining phase after thickness formation, air is injected into the mould to force out the remaining liquid slip inside the piece. The filling valve to the mould, YV451, and return valves YV421 and YV471 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV232 and/or YV233 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. PARAMETERS: 1. Delay It is possible to delay the opening of YV232 while air is injected through YV233 or delay the opening of YV233 while air is injected through YV232. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of draining air through each of YV232 and YV233. Delay is set in seconds. 2. Time The total time in seconds these valves will be opened during the Draining 1 phase. Any delays set may lengthen the total time of Draining 1. 3.3.6.2 Internal Washing with Air - Mould 2 through YV232 and YV233


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This is also referred to as 2nd draining. During the Internal Washing with Air phase after 1st draining, air is injected into the mould to force out the remaining liquid slip (or water if water on time was selected on page C4) inside the piece. The filling valve to the mould, YV451, and return valves YV421 and YV471 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV232 and/or YV233 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. NOTE: If Internal Washing with Water time was selected on page C4, only the discharge valve YV461 at the bottom of the press will open when air is injected into the mould (YV451, YV421 and YV471 closed). This is to avoid water to be drained to the slip return tank. Please take care that the selector switch toward the bottom of page C4 is in the OFF position to ensure that water drains to the floor and not to the slip return tank. PARAMETERS: 1. Delay It is possible to delay the opening of YV232 while air is injected through YV233. Delay is set in seconds. 2. Time The total time in seconds this valve will be opened during the Internal Washing with Air phase. 3.3.6.3 Hardening - Mould 2 through YV232 and YV233 During the hardening phase after draining and internal washing with air, air is injected into the mould to pressurise the piece internally. This is done to force some water out of the walls of the newly cast piece into the resin mould. It ensures mechanical strength of the piece. The filling valve to the mould, YV451, is opened during this phase but the return valves YV421 and YV471 are closed. Compressed air is injected via YV232 and/or YV233 to pressurise the piece internally. The total hardening or consolidation time for different pieces may vary due to their shape and size. PARAMETERS: 1. Delay It is possible to delay the opening of YV232 while air is injected through YV233 or delay the opening of YV233 while air is injected through YV233. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of hardening air through each of YV232 and YV233. 2. Time The total time in seconds these valves will be opened during the Hardening phase. Any delays set may lengthen the total time of Hardening. 3.3.6.4 Detachment in Hardening - Mould 2 through YV290


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It is possible to initiate some detachment on the non-demoulding side of the mould during the hardening phase. Take in consideration that the pressure applied through YV290 can only be the same of the current pressure during the hardening phase. This means that the pressure internally and on the mould surface will be exactly the same. PARAMETERS: 1. Delay It is possible to delay the opening of YV290 during the hardening phase until only the last few seconds of hardening. For example, if hardening is 200 seconds and you wish to set this parameter for the last 15 seconds during hardening, you have to set a 185 second delay. 2. Time The total time in seconds YV290 will be opened during the Hardening phase.


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3.3.7 TECHNOLOGICAL CYCLE PHASE PAGE C7 – DRAINING 3&4 LOWER MOULD

3.3.7.1 Draining 3 - Mould 1 through YV230 and YV231 During the 3rd draining phase after hardening, air is injected into the mould to allow the draining of any liquid slip inside the piece. The filling valve to the mould, YV450, and return valves YV420 and YV470 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV230 and/or YV231 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. Normally very low pressure is required for Draining 3. As described in the Ramps page for this mould circuit (C3), it is possible to wash the piece once again internally with water in this phase. If water is selected on page C3 only the discharge valve YV460 at the bottom of the press will open when water is injected into the piece (YV450, YV420 and YV470 closed). This is to avoid water to be drained to the slip return tank. Please take care that the selector switch toward the bottom of page C3 is in the OFF position to ensure that water drains to the floor and not to the slip return tank. When air is selected the pressure setting should always be very low in Draining 3 as it is generally a very small quantity of slip that is drained. If water is selected, a very short time should be chosen as too much water can damage the piece internally.


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PARAMETERS: 1. Delay It is possible to delay the opening of YV230 while air/water is injected through YV231 or delay the opening of YV231 while air/water is injected through YV230. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of draining air/water through each of YV230 and YV231. Delay is set in seconds. 2. Time The total time in seconds these valves will be opened during the Draining 3 phase. Any delays set may lengthen the total time of Draining 3. 3.3.7.2 Draining 4 - Mould 1 through YV230 and YV231 During the 4th draining phase after 3rd draining, air is injected into the mould to allow the draining of any liquid slip inside the piece. The filling valve to the mould, YV450, and return valves YV420 and YV470 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV230 and/or YV231 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. Normally very low pressure is required for Draining 4. As with Draining 3 water can also be used in this phase. It is not recommended and only very low pressure air should be used. If you select water, the same valve conditions apply as in Draining 3. PARAMETERS: 1. Delay It is possible to delay the opening of YV230 while air is injected through YV231 or delay the opening of YV231 while air is injected through YV230. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of draining air through each of YV230 and YV231. Delay is set in seconds. 2. Time The total time in seconds these valves will be opened during the Draining 3 phase. Any delays set may lengthen the total time of Draining 3. 3.3.7.3 Offset Demoulding Pressure - Mould 1 This is the threshold pressure that will allow the press to open. If the internal pressure is too high, the press will stay in waiting position until the condition is met. PARAMETERS: 1. Pressure Pressure setting in bar. The press can only open when internal pressure is lower than the set pressure.


HPC 201T Date: 25/03/2009


3.3.7.4 Vacuum to Demoulding Part in Detachment – Mould 1 For some types of pieces it may be necessary to apply vacuum in the one half of the mould from where the robot must take the piece. The purpose of the vacuum in the mould is to keep the piece supported while the press open and to prevent it to fall down from the mould while the press rotate to the horizontal position. The vacuum is applied to the mould via the valve YV350 on the auxiliary vacuum circuit. This is a direct connection from the vacuum pump to the mould circuit between the mould and valve YV250. During this auxiliary vacuum in detachment the discharge valve YV251 is also closed to ensure the vacuum is applied on the back of the piece from the resin mould. PARAMETERS: 1. Time This is a time setting in seconds. The vacuum to demoulding part starts at the same time as Demoulding 1 to the non demoulding side of the mould before the hydraulic hammers are opened.


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3.3.8 TECHNOLOGICAL CYCLE PHASE PAGE C8 – DRAINING 3&4 UPPER MOULD

3.3.8.1 Draining 3 - Mould 2 through YV232 and YV233 During the 3rd draining phase after hardening, air is injected into the mould to allow the draining of any liquid slip inside the piece. The filling valve to the mould, YV451, and return valves YV421 and YV471 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV232 and/or YV233 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. Normally very low pressure is required for Draining 3. As described in the Ramps page for this mould circuit (C4), it is possible to wash the piece once again internally with water in this phase. If water is selected on page C4 only the discharge valve YV461 at the bottom of the press will open when water is injected into the piece (YV451, YV421 and YV471 closed). This is to avoid water to be drained to the slip return tank. Please take care that the selector switch toward the bottom of page C4 is in the OFF position to ensure that water drains to the floor and not to the slip return tank. When air is selected the pressure setting should always be very low in Draining 3 as it is generally a very small quantity of slip that is drained. If water is selected, a very short time should be chosen as too much water can damage the piece internally.


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PARAMETERS: 1. Delay It is possible to delay the opening of YV232 while air/water is injected through YV233 or delay the opening of YV233 while air/water is injected through YV232. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of draining air/water through each of YV232 and YV233. Delay is set in seconds. 2. Time The total time in seconds these valves will be opened during the Draining 3 phase. Any delays set may lengthen the total time of Draining 3. 3.3.8.2 Draining 4 - Mould 2 through YV232 and YV233 During the 4th draining phase after 3rd draining, air is injected into the mould to allow the draining of any liquid slip inside the piece. The filling valve to the mould, YV451, and return valves YV421 and YV471 are opened during this step. Slip is drained to the return tank through these valves by injecting air via YV232 and/or YV233 to force the slip out of the piece. It is important to drain the piece as quick as possible with the minimum possible air pressure. Normally very low pressure is required for Draining 4. As with Draining 3 water can also be used in this phase. It is not recommended and only very low pressure air should be used. If you select water, the same valve conditions apply as in Draining 3. PARAMETERS: 1. Delay It is possible to delay the opening of YV232 while air is injected through YV233 or delay the opening of YV233 while air is injected through YV232. These two valves work in parallel and can also open simultaneously without any delay setting on either of them. To set a delay depends on the design and geometry of the piece to determine the time of draining air through each of YV232 and YV233. Delay is set in seconds. 2. Time The total time in seconds these valves will be opened during the Draining 3 phase. Any delays set may lengthen the total time of Draining 3. 3.3.8.3 Offset Demoulding Pressure - Mould 2 This is the threshold pressure that will allow the press to open. If the internal pressure is too high, the press will stay in waiting position until the condition is met. PARAMETERS: 1. Pressure Pressure setting in bar. The press can only open when internal pressure is lower than the set pressure.


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3.3.8.4 Vacuum to Demoulding Part in Detachment – Mould 2 For some types of pieces it may be necessary to apply vacuum in the one half of the mould from where the robot must take the piece. The purpose of the vacuum in the mould is to keep the piece supported while the press open and to prevent it to fall down from the mould while the press rotate to the horizontal position. The vacuum is applied to the mould via the valve YV351 on the auxiliary vacuum circuit. This is a direct connection from the vacuum pump to the mould circuit between the mould and valve YV260. During this auxiliary vacuum in detachment the discharge valve YV261 is also closed to ensure the vacuum is applied on the back of the piece from the resin mould. PARAMETERS: 1. Time This is a time setting in seconds. The vacuum to demoulding part starts at the same time as Demoulding 1 to the non demoulding side of the mould before the hydraulic hammers are opened.


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3.3.9 TECHNOLOGICAL CYCLE PHASE PAGE C9 – DETACHMENT LOWER MOULD

3.3.9.1 Detachment 1 Non-demoulding side – Mould 1 This is the 1st phase of detachment of the piece from the non-demoulding side (opposite side from where the robot will take the piece from the press). During this phase the hydraulic hammers are still closed in high pressure. Air (or water) is injected in the resin mould to start to release the piece from the resin surface. The valve YV280 is opened and YV281 is closed. PARAMETERS: 1. Water ON/OFF It is possible to inject water in the back of the mould to have better release of pieces with difficult shapes. Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary.


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3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.2 Detachment 2 Non-demoulding side – Mould 1 This is the 2nd phase of detachment of the piece from the non-demoulding side. During this phase the hydraulic hammers are opened. Air (or water) is injected in the resin mould to continue to release the piece from the resin surface. This phase follows immediately after detachment 1. The valve YV280 is opened and YV281 is closed. When all hammers are completely open, the mobile part of the press will remain in the detachment position as set in the setup configuration page. PARAMETERS: 1. Water ON/OFF Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. Normally water is not used after detachment 1 but it may be required to use. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary. 3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.3 Detachment 3 Non-demoulding side – Mould 1 This is the 3rd phase of detachment of the piece from the non-demoulding side. Before this phase the hydraulic hammers are already open and auxiliary inserts completely detached. Air (or water) is injected in the resin mould to continue to release the piece from the resin surface. This phase follows immediately after detachment 2 of auxiliary inserts. The valve YV280 is opened and YV281 is closed. PARAMETERS: 1. Water ON/OFF Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when


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OFF is selected air will be used. Normally water is not used after detachment 1 but it may be required to use. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary. 3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.4 Detachment 4 Non-demoulding side – Mould 1 This is the 4th phase of detachment of the piece from the non-demoulding side and follows immediately after demoulding 3. The mobile part of the press will start to move towards the rotation position (or open position if the piece does not require horizontal demoulding by the robot). Air (or water) is injected in the resin mould to continue to release the piece from the resin surface. This phase follows immediately after detachment 2. The valve YV280 is opened and YV281 is closed. PARAMETERS: 1. Water ON/OFF Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. Water is hardly ever used in the 4th phase of detachment. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary. 3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.5 Detachment 1 Demoulding side – Mould 1 This is the 1st phase of detachment of the piece from the demoulding side. During this phase the robot will be in position already with the demoulding tool or setter plate almost in contact with the piece. There should always be 2 to 3 mm space between the


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tool and the piece to allow the detachment pressure to push the piece away from the mould. If the tool is pushed against the piece you are almost sure of having deformation on the part that is still in the half mould. Air (or water) is injected in the resin mould to release the piece from the resin surface. This phase starts immediately when the robot is in demoulding position and the signal is received by the press from the robot. The valve YV250 is opened and YV251 is closed. If auxiliary vacuum is used through valve YV350, the vacuum is stopped immediately before this 1st detachment starts. PARAMETERS: 1. Water ON/OFF Sometimes when auxiliary vacuum is used, it is necessary to inject some water into the mould to help with the release of the piece onto the robot tool. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.6 Detachment 2 Demoulding side – Mould 1 This is the 2nd phase of detachment of the piece from the demoulding side. During this phase the robot will start to move away from the mould gently taking the piece from the mould. Air is injected in the resin mould to release the piece from the resin surface. The valve YV250 is opened and YV251 is closed. When the time of this phase have elapsed, the valveYV250 will close and YV251 will open releasing any residual air that may be in the mould after detachment is completed. PARAMETERS: 1. Water ON/OFF If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. Water is hardly ever used in this phase of detachment. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.7 Detachment 1 Auxiliary Inserts – Mould 1 This is the 1st phase of detachment of the auxiliary inserts from the piece (mobile inserts that are used to create fixing holes in the back of washbasins). Air (or water) is injected in the resin insert to release it from the piece. This phase starts immediately after the hammers are opened in detachment 2 from non demoulding side. The valve YV240 is


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opened and YV240A is closed. The inserts can only start to detach when the hammers are released to avoid any pressure from the closed mould on the barrel of the insert. PARAMETERS: 1. Water ON/OFF If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.8 Detachment 2 Auxiliary Inserts – Mould 1 This is the 2nd phase of detachment of the auxiliary inserts from the piece. Air (or water) is injected in the resin insert to release it from the piece. This phase starts immediately after detachment 1 for auxiliary inserts. The valve YV240 is opened and YV240A is closed. The inserts can only start to detach when the hammers are released to avoid any pressure from the closed mould on the barrel of the insert. PARAMETERS: 1. Water ON/OFF If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected.


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3.3.10 TECHNOLOGICAL CYCLE PHASE PAGE C10 – DETACHMENT UPPER MOULD

3.3.10.1 Detachment 1 Non-demoulding side – Mould 2 This is the 1st phase of detachment of the piece from the non-demoulding side (opposite side from where the robot will take the piece from the press). During this phase the hydraulic hammers are still closed in high pressure. Air (or water) is injected in the resin mould to start to release the piece from the resin surface. The valve YV290 is opened and YV291 is closed. PARAMETERS: 1. Water ON/OFF It is possible to inject water in the back of the mould to have better release of pieces with difficult shapes. Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary.


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3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.10.2 Detachment 2 Non-demoulding side – Mould 2 This is the 2nd phase of detachment of the piece from the non-demoulding side. During this phase the hydraulic hammers are opened. Air (or water) is injected in the resin mould to continue to release the piece from the resin surface. This phase follows immediately after detachment 1. The valve YV290 is opened and YV291 is closed. When all hammers are completely open, the mobile part of the press will remain in the detachment position as set in the setup configuration page. PARAMETERS: 1. Water ON/OFF Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. Normally water is not used after detachment 1 but it may be required to use. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary. 3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.10.3 Detachment 3 Non-demoulding side – Mould 2 This is the 3rd phase of detachment of the piece from the non-demoulding side. Before this phase the hydraulic hammers are already open and auxiliary inserts completely detached. Air (or water) is injected in the resin mould to continue to release the piece from the resin surface. This phase follows immediately after detachment 2 of auxiliary inserts. The valve YV290 is opened and YV291 is closed. PARAMETERS: 1. Water ON/OFF Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when


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OFF is selected air will be used. Normally water is not used after detachment 1 but it may be required to use. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary. 3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.10.4 Detachment 4 Non-demoulding side – Mould 2 This is the 4th phase of detachment of the piece from the non-demoulding side. During this phase the hydraulic hammers are already open and the mobile part of the press will start to move towards the rotation position (or open position if the piece does not require horizontal demoulding by the robot). Air (or water) is injected in the resin mould to continue to release the piece from the resin surface. This phase follows immediately after detachment 2. The valve YV290 is opened and YV291 is closed. PARAMETERS: 1. Water ON/OFF Take care when using water as too much water can cause deformation in pieces with hollow casting. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. Water is hardly ever used in the 4th phase of detachment. 2. Delay If more than one mould is installed on the machine, it is possible that different times are required for detachment. Compare the detachment time for every phase and set a delay time equal to the difference between the time parameter for mould 1 and 2 on the mould with the shorter of the two times. If the detachment times are equal, no delay is necessary. 3. Time This is the duration of the phase. Time is set in seconds. 4. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.10.5 Detachment 1 Demoulding side – Mould 2 This is the 1st phase of detachment of the piece from the demoulding side. During this phase the robot will be in position already with the demoulding tool or setter plate almost in contact with the piece. There should always be 2 to 3 mm space between the


HPC 201T Date: 25/03/2009


tool and the piece to allow the detachment pressure to push the piece away from the mould. If the tool is pushed against the piece you are almost sure of having deformation on the part that is still in the half mould. Air (or water) is injected in the resin mould to release the piece from the resin surface. This phase starts immediately when the robot is in demoulding position and the signal is received by the press from the robot. The valve YV260 is opened and YV261 is closed. If auxiliary vacuum is used through valve YV351, the vacuum is stopped immediately before this 1st detachment starts. PARAMETERS: 1. Water ON/OFF Sometimes when auxiliary vacuum is used, it is necessary to inject some water into the mould to help with the release of the piece onto the robot tool. If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.10.6 Detachment 2 Demoulding side – Mould 2 This is the 2nd phase of detachment of the piece from the demoulding side. During this phase the robot will start to move away from the mould gently taking the piece from the mould. Air is injected in the resin mould to release the piece from the resin surface. The valve YV260 is opened and YV261 is closed. When the time of this phase have elapsed, the valveYV260 will close and YV261 will open releasing any residual air that may be in the mould after detachment is completed. PARAMETERS: 1. Water ON/OFF If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. Water is hardly ever used in this phase of detachment. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.7 Detachment 1 Auxiliary Inserts – Mould 1 This is the 1st phase of detachment of the auxiliary inserts from the piece (mobile inserts that are used to create fixing holes in the back of washbasins). Air (or water) is injected in the resin insert to release it from the piece. This phase starts immediately after the hammers are opened in detachment 2 from non demoulding side. The valve YV241 is


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opened and YV241A is closed. The inserts can only start to detach when the hammers are released to avoid any pressure from the closed mould on the barrel of the insert. PARAMETERS: 1. Water ON/OFF If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected. 3.3.9.8 Detachment 2 Auxiliary Inserts – Mould 1 This is the 2nd phase of detachment of the auxiliary inserts from the piece. Air (or water) is injected in the resin insert to release it from the piece. This phase starts immediately after detachment 1 for auxiliary inserts. The valve YV241 is opened and YV241A is closed. The inserts can only start to detach when the hammers are released to avoid any pressure from the closed mould on the barrel of the insert. PARAMETERS: 1. Water ON/OFF If the switch is selected to ON, water will be used in this phase and when OFF is selected air will be used. 2. Time This is the duration of the phase. Time is set in seconds. 3. Final Pressure This is the pressure set in bar that is applied to the mould when air is used in this phase. Pressure cannot be set when water is selected.


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3.3.11 TECHNOLOGICAL CYCLE PHASE PAGE C11 – WASHING TOTAL DURATION

3.3.11.1 Filling Circuit This refers to the slip filling circuit and refers to the part after the valve YV440 to the mould filling point. If this phase is selected the valve YV450 opened and water will be injected in the mould filling circuit from valve YV510. The discharge valve YV460 will also be opened. It is sometimes necessary to clean the filling circuit with water as a hard slip build-up is possible to form inside the circuit. PARAMETERS: 1. Water Time On This is the time in seconds that water will be injected into the filling circuit. 2. Vacuum Time On This is not used on this model of press. 3.3.11.2 Draining Valve YV230 This is one of the 2 draining air valves of mould 1. It can be cleaned using own parameters to suit the need of the particular circuit. Some draining circuits require more cleaning than others. Some circuits with the special plastic sleeved insert only require cleaning with air.


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PARAMETERS: 1. Water This is the time in seconds that water will be injected through this valve YV230. 2. Time This is the time in seconds that air will be injected through this valve YV230. 3. Pressure This is the pressure in bar of the air during the air phase. Water pressure is not controlled. 3.3.11.3 Draining Valve YV231 This is the second of the 2 draining air valves of mould 1. It can be cleaned using own parameters to suit the need of the particular circuit. Some draining circuits require more cleaning than others. Some circuits with the special plastic sleeved insert only require cleaning with air. PARAMETERS: 1. Water This is the time in seconds that water will be injected through this valve YV231. 2. Time This is the time in seconds that air will be injected through this valve YV231. 3. Pressure This is the pressure in bar of the air during the air phase. Pressure was already set for YV230 and also applies to this valve. 3.3.11.4 Draining Valve YV232 This is one of the 2 draining air valves of mould 2. It can be cleaned using own parameters to suit the need of the particular circuit. Some draining circuits require more cleaning than others. Some circuits with the special plastic sleeved insert only require cleaning with air. PARAMETERS: 1. Water This is the time in seconds that water will be injected through this valve YV232. 2. Time This is the time in seconds that air will be injected through this valve YV232. 3. Pressure This is the pressure in bar of the air during the air phase. Water pressure is not controlled. 3.3.11.5 Draining Valve YV233 This is the second of the 2 draining air valves of mould 2. It can be cleaned using own parameters to suit the need of the particular circuit. Some draining circuits require more cleaning than others. Some circuits with the special plastic sleeved insert only require cleaning with air.


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PARAMETERS: 1. Water This is the time in seconds that water will be injected through this valve YV233. 2. Time This is the time in seconds that air will be injected through this valve YV233. 3. Pressure This is the pressure in bar of the air during the air phase. Pressure was already set for YV232 and also applies to this valve. The water for the cleaning of the above four valves will start simultaneously if set and the air will only start when all water cleaning have elapsed. The air again will start simultaneously. 3.3.11.6 2nd Draining Air After washing of the mould sections in the press, the draining air circuit is once again cleaned with air. This is to ensure there is no water remaining in the circuit that could cause damage to the piece internally later on in the cycle. All the valves, YV230, YV231, YV232 and YV233 are cleaned simultaneously in this phase. PARAMETERS: 1. Time This is the time in seconds that air will be injected through these valves. 2. Pressure This is the pressure in bar of the air during the air phase. 3.3.11.7 Mould Circuit All resin parts of the moulds also has to be washed between casting cycles. It is possible to clean every resin part individually by opening and closing the water, air and vacuum to the particular part independently from any other resin part. Between casting cycles it is important to clean out any fine particles of slip that may have penetrated the pores of the resin during casting. It is important to understand that the times and pressures set for mould circuit are the global time. These times are divided and shared by the individual parts depending on the % of each global time you select on the next page for washing. The reasons for using divided times are twofold. Firstly you have to prevent any water from one section of mould to fall onto another mould part that has already been cleaned. Secondly with divided time you have more dedicated pressure and flow resulting in better cleaning. Depending on the slip used, the phases could run in parallel and save some time in washing. The sequence of washing is first water, then air and finally vacuum. The air will force water out of the resin. Vacuum is to dry the mould surface somewhat in preparation for the next casting cycle. The degree of moisture in the resin after washing is very important for the performance and thickness formation of the piece. Controlling the moisture in the resin at this phase also determine the ease of detachment at the end of the cycle.


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PARAMETERS: 1. Water On Time This is the total time in seconds that water will be injected to the distribution manifold and be available for washing of any resin part. Valves YV520 for lower mould and YV521 for upper mould are used. 2. Vacuum On Time This is the total time in seconds that vacuum will be applied to the distribution manifold and be available to any resin part. Valves YV320 for lower mould and YV321 for upper mould are used. 3. Air On Time This is the total time in seconds that air will be injected to the distribution manifold and be available for washing of any resin part. Valves YV220 for lower mould and YV221 for upper mould are used. 4. Air Pressure Lower Mould This is the pressure in bar of the air during the air phase of washing of the lower mould. 5. Air Pressure Upper Mould This is the pressure in bar of the air during the air phase of washing of the upper mould. 3.3.11.8 Vacuum Tank It is possible to clean the vacuum tank after each washing cycle to remove any dirt and residue from it. During aspiration of the pieces some dirty water and slip may reach the tank and this need to be rinsed out. Valves YV520/YV521 and YV320/YV321 will transfer water to the vacuum tank. At the end of this cleaning sequence, water will drain from the bottom of the tank through YV300 PARAMETERS: 1. Water On Time This is the total time in seconds that water will be injected to the distribution manifold and be available for washing of the vacuum tank. 2. Vacuum On Time This is the total time in seconds that vacuum will be applied to the distribution manifold and be available for washing of the vacuum tank. 3.3.11.9 Mould Regeneration It is possible to do some continuous washing of the resin parts of the mould. During regeneration water and air will be injected alternatively. All resin parts receive water and air simultaneously as per the individual settings for water and air. Water and air will never be opened simultaneously as it hold some danger in cracking the mould from behind. PARAMETERS: 1. Water On Time This is the total time in seconds that water will be injected to the distribution manifold and from there to all resin parts simultaneously.


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2. Air On Time This is the total time in seconds that air will be injected to the distribution manifold and from there to all resin parts simultaneously. When the presses are stopped for any extended time more than one day, it is important to set the maintenance time for moulds. The moulds will then be automatically regenerated as per the set points on the maintenance page,


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3.3.12 TECHNOLOGICAL CYCLE PHASE PAGE C12 – WASHING PROPORTIONAL TIME

3.3.12.1 Washing Non Demoulding Mould 1 This is the washing sequence of the non demoulding part of the lower mould. PARAMETERS: 1. Water Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with water through YV520 (water inlet to manifold) and YV280 (valve from manifold to mould). Water is first in washing sequence. 2. Vacuum Start/Stop Time This is the start and stop point in percentage of the global time set for applying vacuum to this section of mould through YV320 (vacuum inlet to manifold) and YV280 (valve from manifold to mould). Vacuum is last in the washing sequence. 3. Air Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with air through YV220 (air inlet to manifold) and YV280 (valve from manifold to mould). Air is second in washing sequence. 3.3.12.2 Washing Non Demoulding Mould 2 This is the washing sequence of the non demoulding part of the upper mould.


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PARAMETERS: 1. Water Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with water through YV521 (water inlet to manifold) and YV290 (valve from manifold to mould). Water is first in washing sequence. 2. Vacuum Start/Stop Time This is the start and stop point in percentage of the global time set for applying vacuum to this section of mould through YV321 (vacuum inlet to manifold) and YV290 (valve from manifold to mould). Vacuum is last in the washing sequence. 3. Air Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with air through YV221 (air inlet to manifold) and YV290 (valve from manifold to mould). Air is second in washing sequence. 3.3.12.3 Washing Demoulding Mould 1 This is the washing sequence of the demoulding part of the lower mould. PARAMETERS: 1. Water Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with water through YV520 (water inlet to manifold) and YV250 (valve from manifold to mould). Water is first in washing sequence. 2. Vacuum Start/Stop Time This is the start and stop point in percentage of the global time set for applying vacuum to this section of mould through YV320 (vacuum inlet to manifold) and YV250 (valve from manifold to mould). Vacuum is last in the washing sequence. 3. Air Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with air through YV220 (air inlet to manifold) and YV250 (valve from manifold to mould). Air is second in washing sequence. 3.3.12.4 Washing Demoulding Mould 2 This is the washing sequence of the demoulding part of the upper mould. PARAMETERS: 1. Water Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with water through YV521 (water inlet to manifold) and YV260 (valve from manifold to mould). Water is first in washing sequence. 2. Vacuum Start/Stop Time This is the start and stop point in percentage of the global time set for applying vacuum to this section of mould through YV321 (vacuum inlet to manifold) and YV260 (valve from manifold to mould). Vacuum is last in the washing sequence.


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3. Air Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with air through YV221 (air inlet to manifold) and YV260 (valve from manifold to mould). Air is second in washing sequence. 3.3.12.5 Washing Auxiliary Circuit Inserts This is the washing sequence of the auxiliary circuit inserts. The inserts for lower and upper moulds are set in the same line of the setup page. PARAMETERS: 1. Water Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with water through YV520 and YV521 (water inlet to manifolds lower and upper moulds) and YV240A and YV241A (valve from manifold to inserts lower and upper moulds). Water is first in washing sequence. 2. Vacuum Start/Stop Time This is the start and stop point in percentage of the global time set for applying vacuum to this section of mould through YV320 and YV321 (vacuum inlet to manifolds lower and upper moulds) and YV240A and YV241A (valve from manifold to inserts lower and upper moulds). Vacuum is last in the washing sequence. 3. Air Start/Stop Time This is the start and stop point in percentage of the global time set for washing of this section of mould with air through YV220 and YV221 (air inlet to manifold) and YV240A and YV241A (valve from manifold to inserts lower and upper moulds). Air is second in washing sequence.


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3.3.13 SETUP PAGE C13 – CONFIGURATION

The configuration setup pages address some physical characteristics of the press and needs to be completed very carefully to avoid damage to the equipment. To arrive in the configuration pages you have to press the Configure button at the bottom of any setup page. Once more you will be required to enter a password as described in Automatic Setup. Some of the parameters on this page is very critical and have to be tested and controlled in manual after the values were updated. 3.3.13.1 Press in Open Position This is the position when the press is in the vertical position and the mobile part is driven fully open. This is normally the demoulding position when pieces are demoulded from the vertical mobile part by the robot. Take care to use the maximum open position and do not change the setting. If a smaller value is set after robot programming is done, you will have a collision by the robot to the mobile part. The press sends a ready signal to the robot when the parameter value in this setting is met. PARAMETER: 1. Distance Value in mm. This value is controlled by means of a linear transducer in the top of the press that accurately reads the travel distance of the press mobile part.


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3.3.13.2 Press in Washing Position This is the position where you set the mobile part to stop for completion of the washing cycle. PARAMETER: 1. Distance Value in mm. This value is controlled by means of a linear transducer in the top of the press that accurately reads the travel distance of the press mobile part. 3.3.13.3 Press in Demoulding Position This is the position of the mobile part immediately after the hydraulic hammers were opened during detachment. It must be tested if it is safe to open the hydraulic hammers in this position. PARAMETER: 1. Distance Value in mm. This value is controlled by means of a linear transducer in the top of the press that accurately reads the travel distance of the press mobile part. 3.3.13.4 Press in Closing Position This is the position of the mobile part when it is safe to close the hydraulic hammers. This position is reached during lateral movement of the mobile part when the two mould parts touch each other and the mould is practically in a closed position by the motor that drive the mobile part. PARAMETER: 1. Distance Value in mm. This value is controlled by means of a linear transducer in the top of the press that accurately reads the travel distance of the press mobile part. 3.3.13.5 Deceleration Space The movement of the mobile part of the press is controlled by a frequency inverter. This gives you the possibility to control variable speed settings on the movement. Deceleration space is the distance required before any open or closed position of the mobile part to safely slow down. PARAMETER: 1. Distance Value in mm. This value is controlled by means of a linear transducer in the top of the press that accurately reads the travel distance of the press mobile part. 3.3.13.6 Slow Demoulding Space When the press opens after casting, the initial movement of the mobile part is called the slow demoulding space. The mobile part carefully extracts the piece from the fixed side of the mould.


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PARAMETER: 1. Distance Value in mm. This value is controlled by means of a linear transducer in the top of the press that accurately reads the travel distance of the press mobile part. 3.3.13.7 Offset Locking Low Pressure This is the threshold level of the hydraulic circuit when the press is in low pressure hydraulic operation. During closing of the press the hammers will turn and lock on the press frame. When all hammers are completely locked in low pressure a certain pressure in the system is reached. Before the system can switch over to high pressure, the PLC will determine if the pressure is over the offset pressure. Over time the limit of low pressure will deteriorate as the internal of the pump wears out, when filters are blocked or when cylinders are leaking oil. PARAMETER: 1. Pressure in bar. This value is controlled by comparing the actual oil pressure with the set point. 3.3.13.8 Offset Locking High Pressure This is the threshold level of the hydraulic circuit when the press is in high pressure hydraulic operation. After closing the hammers in low pressure and the low pressure offset is met, the hydraulic circuit will switch over to high pressure and close all hammers in high pressure. When a static situation is reached, the PLC will control to see if the high pressure is reached. Filling of the moulds will not commence if the offset is not met. PARAMETER: 1. Pressure in bar. This value is controlled by comparing the actual oil pressure with the set point. 3.3.13.9 Presence of Mould 1 This is a selector to set ON if a mould is installed in position 1 (Lower part). If it is set to ON, all functionality for the mould is possible. If it is set to OFF, all functionality on the circuit is disabled. 3.3.13.10 Presence of Mould 2 This is a selector to set ON if a mould is installed in position 2 (Upper part). If it is set to ON, all functionality for the mould is possible. If it is set to OFF, all functionality on the circuit is disabled. 3.3.13.11 Synchronised Start Select ON if you want the press to be synchronised with the other presses (ensuring that presses open one at a time with no robot overlaps). There may be a short waiting time at the end of each cycle to synchronise presses.


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3.3.13.12 Opening Cylinders ON/OFF Some presses are equipped with hydraulic cylinders that assist in opening the press from the closed position during demoulding. Some pieces have more complex geometry that creates excess friction between the mould surface and the piece. This friction makes it difficult to drive the press open with only the electric motor. Not all presses are equipped with this function and is normally used in the casting of water tanks (cisterns). 3.3.13.13 Casting Mould 1 ON/OFF It is possible to prevent casting on a mould that is installed on the press. Sometimes you need to stop casting one mould while the other one is casting. Select the switch to ON to enable casting and OFF to disable casting. When the mould is disabled, all slip circuits will be disabled but the mould circuit will still be washed every cycle during washing phase. 3.3.13.14 Casting Mould 2 ON/OFF It is possible to prevent casting on a mould that is installed on the press. Sometimes you need to stop casting one mould while the other one is casting. Select the switch to ON to enable casting and OFF to disable casting. When the mould is disabled, all slip circuits will be disabled but the mould circuit will still be washed every cycle during washing phase. 3.3.13.15 Demoulding Mould 1 Fixed/Mobile Side Select the position of demoulding. If Fixed is selected, mould 1 will be taken by the robot from the fixed part of the press. The fixed part then becomes the Demoulding side and the mobile side becomes the Non Demoulding side. If Mobile is selected the opposite becomes true and the robot will take the piece from the mobile side of the press. Ensure to test all valves from the manual pages to make sure the correct functionality of the press is active. 3.3.13.16 Demoulding Mould 2 Fixed/Mobile Side Select the position of demoulding. If Fixed is selected, mould 2 will be taken by the robot from the fixed part of the press. The fixed part then becomes the Demoulding side and the mobile side becomes the Non Demoulding side. If Mobile is selected the opposite becomes true and the robot will take the piece from the mobile side of the press. Ensure to test all valves from the manual pages to make sure the correct functionality of the press is active.


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3.3.14 SETUP PAGE C14 – ROTATION

3.3.14.1 Press Rotation Position This is the position at which the press can safely rotate from vertical to horizontal and vice versa. When the mobile part reach this point it will stop and the hydraulic cylinders on the back of the press frame will move the press frame from vertical to horizontal for the demoulding operation. PARAMETER: 1. Distance Value in mm. This value is set and confirmed on the next page that appears when this value is touched for changing. 3.3.14.2 Press Security Position This is the position where the moulds can safely be changed. From the original rotation position it is possible to move the mobile part more open while in the press is in horizontal until the mobile part reaches the safety frame on the top of the press. This operation is done in manual mode and will be described later in the manual. PARAMETER: 1. Distance Value in mm. This value is set and confirmed on the next page that appears when this value is touched for changing.


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3.3.14.3 High Speed Rotation % In the rotation movement path there are 4 sensors to read the physical position of the mobile part in rotation. Between the sensors there is a long area of travel when no sensor is read by the PLC. During this movement it is possible to apply maximum pressure to the cylinders to enable high speed movement. PARAMETER: 1. Percentage setting between 0% and 100%. 3.3.14.4 Medium Speed Rotation % Near the vertical position and near the horizontal position the PLC will read a first signal from the medium speed sensor. Pressure will be adjusted to slow down the rotation to the medium speed as set in the parameters. This is the first deceleration of the rotation movement. PARAMETER: 1. Percentage setting between 0% and 100%. 3.3.14.5 Low Speed Rotation % After the medium speed sensor is read, a second sensor is read to slow down the movement further (both sensors read together). The pressure will be adjusted to slow down the rotation to the slow speed as set in the parameters. This is final deceleration and rotation will continue until the mechanical stop is reached at the end of the cylinder stroke. PARAMETER: 1. Percentage setting between 0% and 100%. 3.3.14.6 Demoulding Combination There are several possible configurations to take the piece from the press by the robot. Depending on the piece geometry it is possible to support the new piece in almost any possible condition on the open mould for demoulding. PARAMETERS: 1. V-V: This is vertical and vertical and both pieces are suspended on one of the

vertical surfaces of the press for taking by the robot. 2. V-H: This is vertical and horizontal. The mould 1 piece will be taken from the vertical

on the fixed side of the press and the mould 2 piece will be taken from the horizontal on the mobile part of the press.

3. H-H: This is horizontal and horizontal. Both pieces are taken from the horizontal on the mobile part of the press.


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3.3.15 SETUP PAGE C15 – ROTATION

3.3.15.1 Press Rotation Position If the value is touched on the previous screen to change this parameter, the page changes automatically to this page to give you a second chance to select and change the position of rotation. This is only a security measure to prevent the value to be changed by mistake on the previous page. Ensure that the press can rotate safely in the position that you select. Slowly rotate the press and look to see if the mobile part is not touching the hammers or that the two mould halves does not interfere during rotation. 3.3.15.2 Press Security Position If the value is touched on the previous screen to change this parameter, the page changes automatically to this page to give you a second chance to select and change the security position. This is only a security measure to prevent the value to be changed by mistake on the previous page. Ensure that the press can safely move to the security position after you have changed this parameter. Rotate the press horizontal and select mould change. Move the press to the security position and look if it is correct.


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3.3.16 FIRST DISPLAY DURING AUTOMATIC OPERATION OF THE CELL

After entering all the setup parameters carefully, it is possible to run the presses in automatic and to test the cycle introduced in the previous pages. Select the AUTO START button on the MAIN display page. The press will start in automatic if there are no alarms present and if the synchronisation conditions with the other presses in the cell are met. From the MAIN screen select NEXT and the above active display page will appear, continuously showing the progress of the casting cycle. 3.3.16.1 Main Graphic Window The progress and shape of the cycle curve is displayed in the main rectangular window in real time. The X axis is time in minutes and the Y axis is pressure in Bar. The scale of the X axis is 30 seconds for every longer line on the axis line. The scale of the Y axis is 2 Bar for every line on the axis line. 3.3.16.2 Phase C1 The description of the current phase in progress of Press C Mould 1 is displayed in the long rectangle.


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3.3.16.3 Phase C2 The description of the current phase in progress of Press C Mould 2 is displayed in the long rectangle. 3.3.16.4 Time Set Point The set duration for the phase in Press C is displayed here. 3.3.16.5 Time Display The expired time of the phase in Press C is displayed here. 3.3.16.6 Average Pressure Display The average pressure between Mould 1 and Mould 2 of Press C is displayed in the small rectangle to the right of the Time Display. 3.3.16.7 Pressure Display Mould 1 The actual pressure in Mould 1 circuit of Press C is displayed in the green rectangle. 3.3.16.8 Pressure Display Mould 2 The actual pressure in Mould 2 circuit of Press C is displayed in the red rectangle. 3.3.16.9 Phase B1 The description of the current phase in progress of Press B Mould 1 is displayed in the long rectangle. 3.3.16.10 Phase B2 The description of the current phase in progress of Press B Mould 2 is displayed in the long rectangle. 3.3.16.11 Time Set Point The set duration for the phase in Press B is displayed here. 3.3.16.12 Time Display The expired time of the phase in Press B is displayed here. 3.3.16.13 Average Pressure Display The average pressure between Mould 1 and Mould 2 of Press B is displayed in the small rectangle to the right of the Time Display. 3.3.16.14 Pressure Display Mould 1 The actual pressure in Mould 1 circuit of Press B is displayed in the yellow rectangle. 3.3.16.15 Pressure Display Mould 2 The actual pressure in Mould 2 circuit of Press B is displayed in the blue rectangle.


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3.3.16.16 Events The event window will display some communication regarding the process for example the status of the robot, the status of the press during opening etc. 3.3.16.17 History Columns There are two columns in the bottom right of the page with the green column containing data for Press C and the yellow column containing data for Press B.

- Total Cycles – this is the total number of cycles cast from installation of the press. - Partial Cycles – this is an intermediate counter and can be reset by touching the

number. You can choose when to reset, daily, weekly or monthly to count production or reset when a new mould is fitted to keep track of mould life.

- Time Last Cycle – shows the total cycle time of the previously completed cycle. - Time Cycle – shows the cumulative time of the current cycle. This value resets to 0

at the end of washing. - Temperature of water – shows the temperature of the heated water entering the

manifold of each press. 3.3.16.18 Top Line Buttons There are several selection buttons on the top line of the page.

- Main – takes you back to the MAIN selection page. - Press C Vacuum – enables you to do aspiration of a piece from Press C vacuum

pump. - Press B Vacuum – enables you to do aspiration of a piece from Press B vacuum

pump. - Alarms – takes you to the alarm page for view of current alarms and to reset

alarms. - Next – takes you to the second visual display page of automatic operation of the

presses.


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3.3.17 SECOND DISPLAY DURING AUTOMATIC OPERATION OF THE CELL

The second page of automatic operation monitoring is very important. Some specific conditions regarding the hydraulic system and position of the mobile part is displayed on this page. The page is divided in two sections, left in green for Press C and right in yellow for Press B. 3.3.17.1 Washing Whenever the press is not in cycle, the washing button can be selected to perform a single washing operation as set in the Setup of Washing on pages C11 and C12 of technological setup. 3.3.17.2 Simulate Robot When the press opens after an automatic cycle and for some reason the robot is not available, it is possible to select this button to do a step by step detachment of the pieces (first selection = Mould , second selection = Mould 2 and third selection = robot out of press and press can continue with washing and return to vertical position).


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3.3.17.3 Jump Cycle If during any casting cycle a leakage of slip occurs on any mould, it is recommended to jump the cycle. This means the pressure from the injector is immediately released and the mould will drain and go directly to opening after draining without hardening. This is to prevent any damage to the closing surface of the mould. 3.3.17.4 Regeneration of Moulds To regenerate the mould is to continuously pass water and air through the resin mould parts to remove dirt from the pores. When the mould is still cold before starting it is recommended to use regeneration to bring the mould to working temperature via the hot water that is passing through the resin. Mould regeneration is set on pages C11 and C12 of technological setup. 3.3.17.5 Top Line Buttons There are several selection buttons on the top line of the page.

- Main – takes you back to the MAIN selection page. - Alarms – takes you to the alarm page for view of current alarms and to reset

alarms. - Previous – takes you to the first visual display page of automatic operation of the

presses. 3.3.17.6 Active Displays There are several active displays that indicate the current status of the press.

- Hammers - in the top part of the page is a series of green lights for Press C hammers and yellow lights for Press B hammers. If the light is clear the hammer is open and when there is a small black dot in the light, the hammer is closed.

- Water Temperature – displays the water temperature where it enters the manifold of each press. The left display is Press C and the right display is Press B.

- Locking Bar – displays the active hydraulic pressure of each press. - Position Press – displays the actual position of the mobile part of the press.


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3.3.18 SEMI-AUTOMATIC OPERATION OF THE CELL

It is possible to perform several functions in semi-automatic mode. Semi-automatic movement is using all parameters from automatic movement and performs the singular selected operation. Semi-automatic movement is useful to test movement before running a full automatic cycle. Semi-automatic should be used to determine if the open and closed positions of the press as well as the rotation position of the mobile part are correct as set and tested in manual mode. 3.3.18.1 Rotation of Press By selecting Vertical Rotation the press will rotate to the absolute vertical position. By selecting the Horizontal Rotation the press will rotate to the absolute horizontal position. The mobile part has to be in the rotation position in order for these buttons to work. 3.3.18.2 Translation of Press By selecting Closing Machine the mobile part will move to the closed position and when reaching the closed position, the hydraulic hammers will close. When selecting Opening Machine, the hammers will open (if closed at the moment) and the mobile part will move to the open position.


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3.3.18.3 Main Selecting the button in the top left corner returns you to the Main selection page. 3.3.18.4 Active Displays There are several active displays to note:

- Translation of Mobile – the blue rectangle above the figure of the press shows the actual position of the mobile part.

- FC Forward - this indicator is to the left of the upper corner of the picture of the press on the screen. It always appears grey and when the press reach the completely open position the indicator will light up.

- NC Limit – The completely closed position of the mobile part. It will have a black dot when the press reaches the closed position.

- Rotation Position – this is the position set to rotate the press for demoulding or mould changes.

- Press in Vertical Position – the mobile is in perfect vertical and it is safe to open or close the press. If the press is not in vertical position, the hammer heads can touch the female flanges on the mobile frame.

- Press in Horizontal Position – the mobile part is in perfect horizontal position and ready to demould.

It is not desirable to close the press in semi-automatic before long stoppages. In semi-automatic the hammers will close and therefore leave the moulds compressed if the press is left in this condition for a long time.


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4 MANUAL MOVEMENTS AND MANIPULATION OF THE PRESS It is possible to simulate all functions and movements of the press in manual mode. It is very important to test and prove that all connections of circuits are indeed correct and that the parameters chosen for movement positions are correct. As in the setup sequence, it is necessary to press the Manual button on the touch panel to enter the manual screens. A password selector screen will appear. Enter the Manual password and Enter. On all manual screens there are the same series of buttons on the right of the screen. This buttons are to navigate to the different functions as described in the next section. Carefully test all functionality of the installation.

IMPORTANT: Actions by the operator in this mode can cause hazardous or unsafe situations. When entering the manual mode please ensure that no personnel are inside the island and all staff present being made aware that the machine is not in safety mode. Therefore, one must be wholly familiar with the machine and have full knowledge of all operations being carried out. Consequently, we recommend that all such operations be carried out STRICTLY by trained personnel. To this end, access to the MANUAL operating mode is protected by an ACCESS CODE (password) which must be known by trained personnel only. Active Menu Buttons on all pages

PRINC. – Takes you back to the MAIN selection screen SETUP – Takes you to the SETUP screens (via password entry) ROTATION – This screen MOVEMENT – Takes you to the manual movement of mobile part screen FILLING – Left button takes you to filling of mould 1 and right button to filling of

mould 2 DRAINING – Left button takes you to draining of mould 1 and right button to

draining of mould 2 MOULD NON DEMOULDING – Left takes you to the mould circuit of mould 1 non

demoulding side and right button takes you to mould circuit mould 2 non demoulding side.


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MOULD DEMOULDING – Left takes you to the mould circuit of mould 1 demoulding side and right button takes you to mould circuit mould 2 demoulding side.

SERVICE – Takes you to the services page TOOLS – Takes you to the robot tool management page ALARMS – Takes you to an overview of current alarms

All the above active buttons appear on all the manual pages to enable navigation to any point of the equipment from anywhere. When some function is activated in manual it will automatically terminate if you exit the manual pages. For the purposes of this manual copies are included from Press C setup and manual pages. The diagrammatic colour on the ProFace panel is yellow and for that reason reference is made to yellow sensor indicators on the screen pages. In some presses the yellow indicators may be represented by green indicators.


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4.1 MANUAL OPERATION – ROTATION PAGE C1

4.1.1 Active Buttons on this page 4.1.1.1 Right Arrow When pressed, the mobile part of the press will start to rotate towards the horizontal position. For ability of this switch, the mobile part has to be in the rotation position, the hydraulic pump has to be on (SERVICES) and the hydraulic high pressure must be selected (SERVICES). When only the button is pressed continuously, the rotation movement will be at low speed. A secondary hidden button can be pressed simultaneously to make the rotation movement in high speed (this point is located at the top right hand corner of the picture of the press frame). Slow speed rotation is possible over the complete rotation curve. High speed is only available between the vertical and horizontal slowdown sensors. 4.1.1.2 Up Arrow When pressed, the mobile part of the press will start to rotate towards the vertical position. Exactly the same conditions as in 4.1.1.1 apply for this button regarding position and speed. Take care that the rotation position selected and set in configuration is safe and that no parts of the press will collide with any other part during rotation.


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4.1.2 Active Displays on this page 4.1.2.1 Press in Rotation Position This the yellow indicator at the top left of the picture. When it is only yellow, the mobile part is in the rotation position (as set in the configuration setup as well as by the position sensor on the horizontal beam of the press). When there is a black dot in the yellow indicator, the press is out of the rotation position. 4.1.2.2 Vertical Position This indicator is located just below the Rotation Position indicator. When it is only yellow, the mobile part is in the vertical position (as read by the vertical position sensor on the rotation axis of the press). When there is a black dot in the yellow indicator, the press is out of the vertical position. 4.1.2.3 Horizontal Position This indicator is located at the bottom right hand corner of the picture. When it is only yellow, the mobile part is in the horizontal position (as read by the horizontal position sensor on the rotation axis of the press). When there is a black dot in the yellow indicator, the press is out of the horizontal position. 4.1.2.4 Slowdown Indicators These indicators are located at the right hand back of the diagonal part of the picture. The upper one is the slowdown indicator towards the vertical position and the lower one is the slowdown indicator towards horizontal position of the press. When both indicators have black dots in the yellow indicators, the press is somewhere between vertical and horizontal. In this condition it is possible to rotate in high speed. When rotating towards vertical and the vertical slowdown sensor is read, the press will change over to medium speed mode until also the vertical sensor is read. The press will then change to low speed mode and while you continue to press the button will continue to rotate until the mechanical stop is reached at the end of the cylinder stroke. The same condition applies in the horizontal direction. 4.1.2.5 Linear Position of Carriage This is the blue rectangular display at the centre bottom of the page. This window displays the physical position of the carriage as read by the linear transducer in the top of the press.


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4.2 MANUAL OPERATION – MOVEMENTS PAGE C2

4.2.1 Active Buttons on this page 4.2.1.1 Change Mould When you want to do a mould change, it is possible to drive the mobile part (when in the horizontal position) approximately another 120mm more open. At this position the mould frame enters a security position preventing accidental rotation of the mobile part. The mobile part is prevented by a mechanical stop to rotate. Personnel can now safely work under the mould carrier frame to detach the previous mould and attach a new mould. Extreme care must be taken during mould change operations to prevent injury to people or damage to equipment and moulds. Forklifts used must be of the correct capacity and forklift operators must be well trained and qualified. Before detaching the previous mould from the press, ensure that the forklift is supporting the mould well before starting to unscrew the mould holding bolts. 4.2.1.2 Left Arrow (Press Closing) Before attempting to move the mobile part in any direction, select the SERVICES page and enable the hydraulic pump. This is necessary to enable hydraulic pressure to the rotating cylinders during lateral movement. Lateral movement cannot take place without the mould frame being in the vertical position. At any time when the lateral movement button is pressed, the PLC will activate the hydraulic unit in high pressure to


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resume pressure on the rotating cylinder to ensure the mould frame is vertical when it moves. This is to prevent that the hammer heads touch the female slots on the closing frame as well as to ensure that mould halves always touch only when they are perfectly parallel. To close the press, continuously push the Left Arrow until the mobile part is against the fixed part. There is a hidden button in the top right corner of the press frame picture on the screen that can be pressed simultaneously with the closing button to enable high speed movement. The lateral movement is by means of an overhead electric motor and gearbox that drive the carriage by two chains and sprockets. The motor is controlled by a frequency inverter that control high and low speed as well as acceleration and deceleration. The deceleration space as set in configuration setup will apply also in manual movement. 4.2.1.3 Right Arrow (Press Opening) As described in the closing operation, all the same conditions apply with regard to the control of this function. To open the press, you have to continuously press the right arrow. 4.2.1.4 Hammers Closing Button The hydraulic hammers are closed by pressing the top button on the left once. An arrow will appear showing that the hammers are closing. For the hammers to be closed the following conditions must be true:

- The press must be in the closed position as set in configuration setup. Since the hammers also make a rotation movement, it is not allowed to activate movement when the press is not completely in the closed position. The hammers can however also be activated when the press is open more than 700mm.

- The hydraulic pump must be activated on SERVICES page - The low pressure switch must be activated on SERVICES page

4.2.1.5 Hammers Opening Button The hydraulic hammers are opened by pressing the lower button on the left once. An arrow will appear showing that the hammers are opening. For the hammers to be opened, the same conditions as in closing must be true. 4.2.2 Active Displays on this page 4.2.2.1 Press in Rotation Position This the yellow indicator at the top left of the picture. When it is only yellow, the mobile part is in the rotation position (as read on the linear transducer and as set in the configuration setup). When there is a black dot in the yellow indicator, the press is out of the rotation position. 4.2.2.2 Vertical Position This indicator is located just to the right of the press mould frame in the picture. When it is only yellow, the mobile part is in the vertical position (as read by the vertical position


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sensor on the rotation axis of the press). When there is a black dot in the yellow indicator, the press is out of the vertical position. 4.2.2.3 Rotation Position Sensor This indicator is located above the press picture on the screen and is the left of the two sensors in the centre. It displays yellow when the press is in this position and have a black dot on the yellow when the press is out of this position. 4.2.2.4 Mould Changing Position Sensor This indicator is located above the press picture on the screen and is the right of the two sensors in the centre. It displays yellow when the press is in this position and have a black dot on the yellow when the press is out of this position. 4.2.2.5 Press Completely Open (fc forw) This indicator is to the left of the upper corner of the picture of the press on the screen. It always appears grey and when the press reach the completely open position the indicator will display yellow. 4.2.2.6 Hammers Open or Closed Sensors The press is equipped with 14 closing hammers for locking the fixed and mobile parts together. There is a sensor indicator for every one of the hammers. 7 are located above the hammer closing button and 7 are located below the hammer opening button. When the hammers are open, the sensor indicators will be yellow and when the hammers are in the closed position the yellow indicator will have a black dot in it.


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4.3 MANUAL OPERATION – FILLING CIRCUIT LOWER MOULD PAGE C3

4.3.1 Active Buttons on this page 4.3.1.1 Injector Forward Select the black box next to the FORWARD by pressing it once. To enable any movement of the injector the hydraulic circuit has to be switched on and low pressure activated on the SERVICES page. Under no circumstances may the injector be pushed forward if the slip feeding valve YV410 is open. This is to protect the pneumatic pump. 4.3.1.2 Injector Backward It is not suggested to select the BACKWARD movement of the injector. Normally the injector will move backward during the filling of the press. If BACKWARD is selected without any valves on the circuit open it will cause suction inside the injector that may suck air into the circuit during the next start. 4.3.1.3 Slip Pump To start the slip pump by touching the pump figure once. Always ensure that slip feed pipes to the pump is in a good order without any perforation (caused by the movement of the pipe during any pump action). Check that the manual valve at the tank is open to feed slip to the pump.


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4.3.1.4 Slip Feed Valve YV410 This is the main slip feeding valve to the slip distribution manifold. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.3.1.5 Slip Feed Valve YV440 This is the main slip feeding valve to the lower mould circuit. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.3.1.6 Slip Feed Valve YV450 This is the main slip feeding valve to the lower mould. When opened, the mould can be filled with slip. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.3.1.7 Slip Discharge Valve YV460 This is the slip discharge valve from the lower mould circuit. When opened, slip will drain to the floor. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.3.1.8 Slip Draining Valve YV420 This is the main slip returns valve from the lower mould circuit. When this valve is opened, slip will pass to the returns line.. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.3.1.2 Slip Draining Valve YV470 This is the decompression control valve. When it is closed while YV420 is opened, slip will bypass through the manual decompression valve. If YV470 is opened together with YV420, slip will pass directly to the slip returns tank. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.3.1.9 Water Feed Valve YV510 This is water inlet valve into the slip circuit for cleaning purposes only. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.3.2 Active Displays on this page 4.3.2.1 Injector Forward When the FORWARD button is touched, a black downward arrow in the button will indicate that the injector is in forward pressure. 4.3.2.2 Injector Forward When the BACKWARD button is touched, a black upward arrow in the button will indicate that the injector is in backward pressure. 4.3.2.3 Slip Pump The + in the pump figure will change to X showing that the pump is activated.


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4.3.2.4 Pressure Indicator The pressure indicator on the upper part of the screen will display the active pressure in the slip circuit at any given moment. 4.3.2.5 Valve Indicators All valves turns light blue when activated or open and grey when deactivated or closed. NOTE: Take care of the following:

- Avoid opening water and return valves at the same time. This may cause water to enter your slip tanks at the back and seriously affecting slip rheology.

- Never activate the injector FORWARD while the slip valve YV410 is open. The pneumatic pump can be damaged seriously.

- Always leave the injector in the FORWARD position after cleaning the circuit with water. This will prevent that you have an injector full of water at the start of a cycle.

- Always clean the complete slip circuit with water when the plant is to be stopped for an extended period. This will prevent that slip becomes solid inside the lines.

- It is suggested to clean the slip circuit weekly at least to prevent build-up inside the lines.


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4.4 MANUAL OPERATION – FILLING CIRCUIT UPPER MOULD PAGE C4

4.4.1 Active Buttons on this page 4.4.1.1 Injector Forward Select the black box next to the FORWARD by pressing it once. To enable any movement of the injector the hydraulic circuit has to be switched on and low pressure activated on the SERVICES page. Under no circumstances may the injector be pushed forward if the slip feeding valve YV410 is open. This is to protect the pneumatic pump. 4.4.1.2 Injector Backward It is not suggested to select the BACKWARD movement of the injector. Normally the injector will move backward during the filling of the press. If BACKWARD is selected without any valves on the circuit open it will cause suction inside the injector that may suck air into the circuit during the next start. 4.4.1.3 Slip Pump To start the slip pump by touching the pump figure once. Always ensure that slip feed pipes to the pump is in a good order without any perforation (caused by the movement of the pipe during any pump action). Check that the manual valve at the tank is open to feed slip to the pump.


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4.4.1.4 Slip Feed Valve YV410 This is the main slip feeding valve to the slip distribution manifold. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.4.1.5 Slip Feed Valve YV441 This is the main slip feeding valve to the lower mould circuit. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.4.1.6 Slip Feed Valve YV451 This is the main slip feeding valve to the lower mould. When opened, the mould can be filled with slip. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.4.1.7 Slip Discharge Valve YV461 This is the slip discharge valve from the lower mould circuit. When opened, slip will drain to the floor. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.4.1.8 Slip Draining Valve YV421 This is the main slip returns valve from the lower mould circuit. When this valve is opened, slip will pass to the returns line.. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.4.1.2 Slip Draining Valve YV471 This is the decompression control valve. When it is closed while YV421 is opened, slip will bypass through the manual decompression valve. If YV471 is opened together with YV421, slip will pass directly to the slip returns tank. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.4.1.9 Water Feed Valve YV511 This is water inlet valve into the slip circuit for cleaning purposes only. When the valve on the screen is touched it will turn light blue from grey indicating that it is open. 4.4.2 Active Displays on this page 4.4.2.1 Injector Forward When the FORWARD button is touched, a black downward arrow in the button will indicate that the injector is in forward pressure. 4.4.2.2 Injector Forward When the BACKWARD button is touched, a black upward arrow in the button will indicate that the injector is in backward pressure. 4.4.2.3 Slip Pump The + in the pump figure will change to X showing that the pump is activated.


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4.4.2.4 Pressure Indicator The pressure indicator on the upper part of the screen will display the active pressure in the slip circuit at any given moment. 4.4.2.5 Valve Indicators All valves turns light blue when activated or open and grey when deactivated or closed. NOTE: Take care of the following:

- Avoid opening water and return valves at the same time. This may cause water to enter your slip tanks at the back and seriously affecting slip rheology.

- Never activate the injector FORWARD while the slip valve YV410 is open. The pneumatic pump can be damaged seriously.

- Always leave the injector in the FORWARD position after cleaning the circuit with water. This will prevent that you have an injector full of water at the start of a cycle.

- Always clean the complete slip circuit with water when the plant is to be stopped for an extended period. This will prevent that slip becomes solid inside the lines.

- It is suggested to clean the slip circuit weekly at least to prevent build-up inside the lines.


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4.5 MANUAL OPERATION – DRAINING CIRCUIT LOWER MOULD PAGE C5

4.5.1 Active Buttons on this page 4.5.1.1 Controlled Air Valve YV220 Air through this valve is controlled by the proportional valve as set in C11. 4.5.1.2 Non Controlled Air Valve YV202 Air through this valve is not controlled by the proportional valve but is coming directly from the compressed air circuit and controlled by a pressure regulating valve. 4.5.1.3 Water Valve YV520 Through this valve water is pumped through the draining circuit. 4.5.1.4 Draining Valves YV230 and YV231 Air will enter the hollow part of the cast piece through these two valves. 4.5.2 Active Displays on this page All valves change from grey to light blue when opened and from light blue to grey when closed.


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4.6 MANUAL OPERATION – DRAINING CIRCUIT UPPER MOULD PAGE C6

4.6.1 Active Buttons on this page 4.6.1.1 Controlled Air Valve YV221 Air through this valve is controlled by the proportional valve as set in C11. 4.6.1.2 Non Controlled Air Valve YV203 Air through this valve is not controlled by the proportional valve but is coming directly from the compressed air circuit and controlled by a pressure regulating valve. 4.6.1.3 Water Valve YV521 Through this valve water is pumped through the draining circuit. 4.6.1.4 Draining Valves YV232 and YV233 Air will enter the hollow part of the cast piece through these two valves. 4.6.2 Active Displays on this page All valves change from grey to light blue when opened and from light blue to grey when closed.


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4.7 MANUAL OPERATION – MOULD CIRCUIT NON DEMOULDING LOWER MOULD PAGE C7

4.7.1 Active Buttons on this page 4.7.1.1 Controlled Air Valve YV220 Air through this valve is controlled by the proportional valve as set in C11. 4.7.1.2 Non Controlled Air Valve YV202 Air through this valve is not controlled by the proportional valve but is coming directly from the compressed air circuit and controlled by a pressure regulating valve. It is not recommended to send high pressure air to the mould circuit if only one mould section is selected. This option should be used only if more than 2 mould halves are selected and opened through YV250, YV260, YV280 or YV290. 4.7.1.3 Water Valve YV520 Through this valve water is pumped into the back of the selected mould circuit. 4.7.1.4 Vacuum Supply Valve YV320 It is possible to apply vacuum to the back of the mould circuit to allow cleaning with chemicals on the mould casting surface. To have the most efficient use of this application, ensure that only one mould section is open at any given time during the cleaning with chemicals.


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4.7.1.5 Vacuum Tank Discharge Valve YV300 During vacuum application to any mould circuit some water will accumulate in the vacuum tank. This water can be drained afterwards by stopping the vacuum pump and by opening the discharge valve YV300. 4.7.1.6 Vacuum Pump Stop and start the vacuum pump by touching the figure of the pump on the screen. 4.7.1.7 Air/Water Supply to Resin Inserts YV240A The resin inserts are mini mould parts and need the same air, water and vacuum circuit connected as all the normal mould parts. 4.7.1.8 Discharge Valve from Resin Inserts YV240B Pressure discharge from the resin inserts. The YV240A and YV240B are working in the opposite and when YV240A is open, YV240B will be closed and vice versa. 4.7.1.9 Air/Water Supply to Non Demoulding Lower Mould YV280 Air, water and vacuum are applied to the back of the mould via this valve. When YV280 is open, the discharge valve YV281 will close automatically. 4.7.1.10 Discharge Valve from Non Demoulding Lower Mould YV281 Air Pressure discharge from the back of the resin mould. The YV280 and YV281 are working in the opposite and when YV280 is open, YV281 will be closed and vice versa. 4.7.1.11 Auxiliary Vacuum Supply to Non Demoulding Lower Mould YV350 It is possible to apply vacuum directly to the mould circuit when this side of the press is used as DEMOULDING side. In that case the manual selector valve on the auxiliary vacuum circuit must be selected towards this section of the mould. 4.7.2 Active Displays on this page 4.7.2.1 All Valves All valves change from grey to light blue when opened and from light blue to grey when closed. 4.7.2.2 Vacuum Pump The + in the pump figure will change to X showing that the pump is activated.


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4.8 MANUAL OPERATION – MOULD CIRCUIT NON DEMOULDING UPPER MOULD PAGE C8

4.8.1 Active Buttons on this page 4.8.1.1 Controlled Air Valve YV221 Air through this valve is controlled by the proportional valve as set in C11. 4.8.1.2 Non Controlled Air Valve YV203 Air through this valve is not controlled by the proportional valve but is coming directly from the compressed air circuit and controlled by a pressure regulating valve. It is not recommended to send high pressure air to the mould circuit if only one mould section is selected. This option should be used only if more than 2 mould halves are selected and opened through YV250, YV260, YV280 or YV290. 4.8.1.3 Water Valve YV521 Through this valve water is pumped into the back of the selected mould circuit. 4.8.1.4 Vacuum Supply Valve YV321 It is possible to apply vacuum to the back of the mould circuit to allow cleaning with chemicals on the mould casting surface. To have the most efficient use of this application, ensure that only one mould section is open at any given time during the cleaning with chemicals.


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4.8.1.5 Vacuum Tank Discharge Valve YV300 During vacuum application to any mould circuit some water will accumulate in the vacuum tank. This water can be drained afterwards by stopping the vacuum pump and by opening the discharge valve YV300. 4.8.1.6 Vacuum Pump Stop and start the vacuum pump by touching the figure of the pump on the screen. 4.8.1.7 Air/Water Supply to Resin Inserts YV241A The resin inserts are mini mould parts and need the same air, water and vacuum circuit connected as all the normal mould parts. 4.8.1.8 Discharge Valve from Resin Inserts YV241B Pressure discharge from the resin inserts. The YV241A and YV241B are working in the opposite and when YV241A is open, YV241B will be closed and vice versa. 4.8.1.9 Air/Water Supply to Non Demoulding Upper Mould YV290 Air, water and vacuum are applied to the back of the mould via this valve. When YV290 is open, the discharge valve YV291 will close automatically. 4.8.1.10 Discharge Valve from Non Demoulding Upper Mould YV291 Air Pressure discharge from the back of the resin mould. The YV290 and YV291 are working in the opposite and when YV290 is open, YV291 will be closed and vice versa. 4.8.1.11 Auxiliary Vacuum Supply to Non Demoulding Upper Mould YV360 It is possible to apply vacuum directly to the mould circuit when this side of the press is used as DEMOULDING side. In that case the manual selector valve on the auxiliary vacuum circuit must be selected towards this section of the mould. 4.8.2 Active Displays on this page 4.8.2.1 All Valves All valves change from grey to light blue when opened and from light blue to grey when closed. 4.8.2.2 Vacuum Pump The + in the pump figure will change to X showing that the pump is activated.


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4.9 MANUAL OPERATION – MOULD CIRCUIT DEMOULDING LOWER MOULD PAGE C9

4.9.1 Active Buttons on this page 4.9.1.1 Controlled Air Valve YV220 Air through this valve is controlled by the proportional valve as set in C11. 4.9.1.2 Water Valve YV520 Through this valve water is pumped into the back of the selected mould circuit. 4.9.1.3 Vacuum Supply Valve YV320 It is possible to apply vacuum to the back of the mould circuit to allow cleaning with chemicals on the mould casting surface. To have the most efficient use of this application, ensure that only one mould section is open at any given time during the cleaning with chemicals. 4.9.1.4 Vacuum Tank Discharge Valve YV300 During vacuum application to any mould circuit some water will accumulate in the vacuum tank. This water can be drained afterwards by stopping the vacuum pump and by opening the discharge valve YV300.


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4.9.1.5 Vacuum Pump Stop and start the vacuum pump by touching the figure of the pump on the screen. 4.9.1.6 Air/Water Supply to Demoulding Lower Mould YV250 Air, water and vacuum are applied to the back of the mould via this valve. When YV250 is open, the discharge valve YV251 will close automatically. 4.9.1.7 Discharge Valve from Demoulding Lower Mould YV251 Air Pressure discharge from the back of the resin mould. The YV250 and YV251 are working in the opposite and when YV250 is open, YV251 will be closed and vice versa. 4.9.1.8 Auxiliary Vacuum Supply to Demoulding Lower Mould YV351 It is possible to apply vacuum directly to the mould circuit when this side of the press is used as DEMOULDING side. In that case the manual selector valve on the auxiliary vacuum circuit must be selected towards this section of the mould. 4.9.2 Active Displays on this page 4.9.2.1 All Valves All valves change from grey to light blue when opened and from light blue to grey when closed. 4.9.2.2 Vacuum Pump The + in the pump figure will change to X showing that the pump is activated.


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4.10 MANUAL OPERATION – MOULD CIRCUIT DEMOULDING UPPER MOULD PAGE C10

4.10.1 Active Buttons on this page 4.10.1.1 Controlled Air Valve YV221 Air through this valve is controlled by the proportional valve as set in C11. 4.10.1.2 Water Valve YV521 Through this valve water is pumped into the back of the selected mould circuit. 4.10.1.3 Vacuum Supply Valve YV321 It is possible to apply vacuum to the back of the mould circuit to allow cleaning with chemicals on the mould casting surface. To have the most efficient use of this application, ensure that only one mould section is open at any given time during the cleaning with chemicals. 4.10.1.4 Vacuum Tank Discharge Valve YV300 During vacuum application to any mould circuit some water will accumulate in the vacuum tank. This water can be drained afterwards by stopping the vacuum pump and by opening the discharge valve YV300.


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4.10.1.5 Vacuum Pump Stop and start the vacuum pump by touching the figure of the pump on the screen. 4.10.1.6 Air/Water Supply to Demoulding Lower Mould YV260 Air, water and vacuum are applied to the back of the mould via this valve. When YV260 is open, the discharge valve YV261 will close automatically. 4.10.1.7 Discharge Valve from Demoulding Lower Mould YV261 Air Pressure discharge from the back of the resin mould. The YV260 and YV261 are working in the opposite and when YV260 is open, YV261 will be closed and vice versa. 4.10.1.8 Auxiliary Vacuum Supply to Demoulding Lower Mould YV361 It is possible to apply vacuum directly to the mould circuit when this side of the press is used as DEMOULDING side. In that case the manual selector valve on the auxiliary vacuum circuit must be selected towards this section of the mould. 4.10.2 Active Displays on this page 4.10.2.1 All Valves All valves change from grey to light blue when opened and from light blue to grey when closed. 4.10.2.2 Vacuum Pump The + in the pump figure will change to X showing that the pump is activated.


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4.11 MANUAL OPERATION – SERVICES PAGE C11

4.11.1 Active Buttons on this page 4.11.1.1 Oil Pump The hydraulic oil pump is started and stopped with this switch. To the left the switch is off and to the right the switch is on. By starting the pump, the circuit will have only the pump pressure active which is less than 20Bar. 4.11.1.2 Low Pressure Enable With the pump started the low pressure can be enabled (to do hammer adjustment for example). Low pressure ends at approximately 50Bar. When the switch is enabled the figure will change colour to light blue ad when it is disabled it will be grey. 4.11.1.3 High Pressure Enable This switch enables high pressure. If activated it is possible to test the hydraulic functions in high pressure. High pressure ends at approximately 160Bar. When the switch is enabled the figure will change colour to light blue ad when it is disabled it will be grey.


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4.11.1.4 Multiplier Enable This switch will multiply the current high pressure of the system by 2. Multiplied pressure is the pressure necessary for closing the hammers during the casting cycle. Multiplied pressure ends at approximately 320Bar. When the switch is enabled the figure will change colour to light blue ad when it is disabled it will be grey. 4.11.1.5 Grease Pump Conveyor Robot This switch enables the lubrication pump on the robot track movement. When the switch is enabled the figure will change colour to light blue ad when it is disabled it will be grey. 4.11.1.6 Hydraulic Inserts Outside the Mould For moulds equipped with the hydraulic type piston insert to make the water overflow hole in the piece, this switch will push the piston out of the resin to the ready for cast position. Button activated will show a green light and deactivated will show a red light. 4.11.1.7 Hydraulic Inserts Inside the Mould This switch will draw the insert back into the mould as in the demoulding position for the cast piece. Button activated will show a green light and deactivated will show a red light. 4.11.1.8 Pneumatic Inserts Lower Mould This switch will push the insert out of the mould to the normal casting position when activated and withdraw back inside the mould to demoulding position when deactivated. Button activated will show a green light and deactivated will show a red light. 4.11.1.9 Pneumatic Inserts Upper Mould This switch will push the insert out of the mould to the normal casting position when activated and withdraw back inside the mould to demoulding position when deactivated. Button activated will show a green light and deactivated will show a red light. 4.11.1.10 Vacuum Pump It is possible to start the vacuum pump from this page to enable manual aspiration of pieces at the aspiration pipe on the tool supports. Stop and start the vacuum pump by touching the figure of the pump on the screen. 4.11.1.11 Aspiration Piece This valve should be opened to enable aspiration of a piece while in the same time the vacuum pump is enabled.


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4.11.1.12 Slip Pressure Set point Enter a value in the rectangular box to control the set point of slip movement during any manual operation of the slip injector or pump. Touch the box, a small input screen will appear, clear the old value and type the new value. Press ENTER when the new value is typed. 4.11.1.13 Air Pressure Set point Mould 1 Enter a value in the rectangular box to control the set point of air movement during any manual operation of the draining or mould circuit of MOULD 1. This set point also determines the maximum level of air available to the slip pump. Touch the box, a small input screen will appear, clear the old value and type the new value. Press ENTER when the new value is typed. 4.11.1.14 Air Pressure Set point Mould 2 Enter a value in the rectangular box to control the set point of air movement during any manual operation of the draining or mould circuit of MOULD 2. This set point also determines the maximum level of air available to the slip pump. Touch the box, a small input screen will appear, clear the old value and type the new value. Press ENTER when the new value is typed. 4.11.2 Active Displays on this page 4.11.2.1 All Valves All valves change from grey to light blue when opened and from light blue to grey when closed. 4.11.2.2 Vacuum Pump The + in the pump figure will change to X showing that the pump is activated. 4.11.2.3 Temperature of Water The current temperature of water entering the manifold is displayed in °C.


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4.12 MANUAL OPERATION – TOOLS PAGE C12

The casting cell is equipped with 4 overhead tool storage areas from where the robot can automatically pick up and deposit tools during manipulation of pieces from the press. If different model moulds are installed on the presses it becomes necessary to place the correct manipulating tools in these storage spaces to enable automatic operation.

IMPORTANT: The only time this mode should be entered is when tools are changed on the storage supports. This is a potentially dangerous situation and if care is not taken, damage to equipment or injury to persons can occur. Only competent persons should be in control of the panel during this operation. It is important to realise that the lock must be closed on the tool before the robot release the tool on the storage position.


HPC 201T Date: 25/03/2009


4.12.1 Active Buttons on this page 4.12.1.1 Tool 1&2 Lock and Unlock Drive the robot to the tool to be changed and lock the tool changer head of the robot on the tool. Press the unlock button on the press panel. It is now possible to drive the tool with the robot to a safe position near the floor to take down the old tool from the robot and to place a new tool on the robot. When a new tool is attached to the robot, drive the robot back to the storage position and stop the movement of the robot when the tool rests safely on the rack. Press the locking button on the press panel. When the locking arm is safely in position on the tool, release the tool changer head from the tool and drive the robot back to Home Position. 4.12.2 Active Displays on this page 4.12.2.1 Lock sensor When the locking arms above the tools are locked onto the tool the indicator will have a black dot in the centre. 4.12.2.2 Unlock sensor When the locking arms above the tools are unlocked (tool should be held up by the robot) the indicator will have a black dot in the centre.


HPC 201T Date: 25/03/2009


5. SLIP TANK OPERATION AND SETUP

From the MAIN page, select SLIP Tank button. A selection page with two options will appear. From here you can select to monitor the slip tank where it is possible to see the actual status of the circuit. It is also possible to select the Setup page to change the process parameters relating to the slip circuit. If Setup is selected, a password keypad will appear and only after entering the correct password, will you be able to edit the setup parameters.


HPC 201T Date: 25/03/2009


5.1 Slip Tank Monitoring

5.1 Active Buttons on this page 5.1.1 Heating Enable When ON is selected, the temperature of the slip in the tank will be controlled as per the set point in Slip Tank Setup. When OFF, the heating will be disabled but the motorised valve will remain in the last position of operation. If you need to disable the heating it is preferred that you first reduce the set point to near ambient temperature. After about 5 minutes you can then turn off the heating. 5.1.2 Agitator in Automatic When ON is selected, the agitator of the slip tank will rotate as per the time and direction set points in Slip Tank Setup. When OFF is selected, the agitator will remain in the stationary position. 5.1.3 Vitreous China This is the speed as set in the frequency inverter parameter A0069 (slow speed). Select this switch ON when vitreous china slip is used.


HPC 201T Date: 25/03/2009


5.1.4 Fireclay This is the speed as set in the frequency inverter parameter A0070 (high speed). Select this switch ON when fireclay slip is used. Fireclay requires higher speed due to the density and coarser particles. 5.1.5 Automatic Filling Select On to enable automatic filling of the tank. Between casting cycles the tank level will be controlled by the level sensor and the filling valve will open and close to maintain the slip level as per the set point in Slip Tank Setup. 5.1.6 Manual Filling It is possible to manually fill the tank after it was cleaned. The slip feed valve will open when ON is selected. Pease observe the tank level as automatic control is OFF. 5.2 Active Displays on this page 5.2.1 Maximum Level This is the maximum level of slip allowed in the tank. Above this level an alarm will sound and you have to inspect if the tank is not overflowing. 5.2.2 Set Point Level This is the level set for the desired level to have in the tank. Optimally it should be in the region of 90cm. 5.2.3 Alarm Level This is the low level set for the tank. Below this level the volume of slip in the tank is too little and you must urgently follow up why the tank is not filling. 5.2.4 Temperature Set Point Slip This is the set point for heating the slip to a workable temperature. The maximum is 49°C to prevent mould damage with too hot slip. 5.2.5 Tank Actual Level The actual level of slip in the tank will be indicated in the upper part of the tank diagram in a numerical value. A schematically live graph is also showing the level of material in the tank diagram. 5.2.6 Temperature The real temperature is displayed in the small rectangle right from the tank diagram.


HPC 201T Date: 25/03/2009


6. MOULD MAINTENANCE

This section about mould maintenance is only about keeping moulds wet and workable. Refer to the separate manual on mould treatment and cleaning for clear views on cleaning the moulds in a safe and efficient way. It is important to keep the moulds wet during times of extended stoppage. It is furthermore very important to clean the moulds very well with Sodium Hypochlorite prior to an extended stoppage as mould maintenance is intended to keep moulds wet and not to necessarily clean them. When Mould Maintenance is selected, the press will not be able to start until mould maintenance is deactivated. The page is divided in two halves and for the purpose of this manual will address the functions only once as they are identical for the two presses. 6.1 Water Set Time This is the set point in seconds for feeding water to the mould circuit. Depending on your water pressure this value may vary between 10 seconds and 30 seconds. 6.2 Air Set Time This is the set point in seconds to feed air to the mould circuit.


HPC 201T Date: 25/03/2009


6.3 Air Pressure This is the pressure set point for the duration of the air in mould maintenance. 6.4 Number of Regeneration Cycles Mould maintenance is regeneration of the moulds at a time different than set in the washing setup. At this setting you can select the number of regeneration cycles. 6.5 Waiting Time in Hours This is the time delay in hours between mould maintenance cycles. 6.6 Waiting Time in Minutes This is the additional waiting time in minutes added to the hours in 6.5. 6.7 Opening Machine This is a button for semi-automatic opening of the press. 6.8 Closing Machine This is a button for semi-automatic closing of the press. When the press is left unattended for an extended time it is recommended to close the press (by drive motor only but without the hydraulic hammers closing). 6.9 Start Mould Maintenance By pressing the big black button at the bottom of the screen, the automatic times regeneration of the moulds will be activated. The button will flash green when activated. When this function is activated, it is not possible to start the press or perform semi-automatic functions until it is deactivated again.


HPC 201T Date: 25/03/2009


7. FIRST START PROCEDURE

Before the press is started in the morning (after overnight or extended stoppage), it is recommended to perform the FIRST START PROCEDURE. This procedure automatically prepares the casting circuits for casting. Water from previous circuit cleaning is displaced from the slip circuits, the injector is filled with fresh slip and moulds are regenerated and washed several times to bring them to casting condition and temperature. By selecting the correct parameters you can prepare the press in a proper manner before starting to cast. 7.1 Air Set Point This is the set point of air pressure in the air circuit from proportional valve during this operation. 7.2 Slip Pressure Set Point This is the set point of slip pressure during this operation. 7.3 First Recirculation YV470/471 The procedure flush the slip circuit properly with fresh slip prior to filling the injector. This is to remove the residual water that was left in the slip circuit when the FINAL WASHING


HPC 201T Date: 25/03/2009


procedure was executed previously. Slip is pumped from the slip tank via the slip feed line through to the return lines and into the return tank. The duration of this step is set in seconds. The small light on the right will indicate if the phase is active and have a small black dot when it is not active. 7.4 Cycle Number For Injector Movement and Draining With YV420/421 After the first circulation of slip through the slip circuit, the injector needs to be filled and emptied several times to ensure it is free from any residual water and also to guarantee it is filled with fresh slip prior to starting. Set here the number of filling and emptying of the injector. During the last filling the injector will remain full and ready for casting. This is effected by opening and closing only the valves YV420/421 while the rest of the circuit remains open all the time (excluding the valves to the moulds). The small light on the right will indicate if the phase is active and have a small black dot when it is not active. The two lights at the bottom of this block indicates the injector position (UP and DOWN). 7.5 Recirculate with YV450/451 After the circuit is properly flushed and prepared the last step in the slip line cleaning is to flush the line until the mould filling points. Slip is now pumped towards the mould through valves YV450/451 and discharged on the floor through YV460/461. The duration of this step is set in seconds. The small light on the right will indicate if the phase is active and have a small black dot when it is not active. 7.6 Regeneration Cycles Number After all slip lines have been flushed, the moulds can be prepared for casting. Several cycles of regeneration can be selected. Regeneration times and pressure will be as per the setup in the WASHING page of SETUP. Ideally 6 to 10 regeneration cycles should be selected to heat up the moulds properly. 7.7 Washing Cycles Number After regeneration some washing cycles are selected to ensure the correct moisture content inside the resin as well as the proper cleaning of the draining circuits. Ideally 2 to 4 washing cycles should be selected. 7.8 Second Circulation with YV470/471 After regeneration and washing the slip circuit is once again flushed with fresh slip. The press should now be ready to start casting. 7.9 Start Procedure At the top of the two columns there are a green and yellow button FIRST START. When the button is pressed it will change colour to violet for the duration of the procedure. 7.10 MAIN and FOLLOW The MAIN button returns to the main page and FOLLOW takes you to FINAL WASHING.


HPC 201T Date: 25/03/2009


8. FINAL WASHING PROCEDURE

Before the press is left unattended for an extended period it is very important to clear all the slip circuits of slip and to leave the circuit completely empty as old slip can cause blockages and problems when the press is restarted. 8.1 Air Set Point This is the set point of air pressure in the air circuit from proportional valve during this operation. 8.2 Slip Pressure Set Point This is the set point of slip pressure during this operation. 8.3 Cycle Number For Injector Movement and Draining With YV470/471 To clear the circuit of slip, it has to be flushed with water. To ensure the injector is completely clear of slip it has to be flushed several times with water. At the end of the last filling the injector will push the water out of the circuit and remain in the down position during the stoppage. The small light on the right will indicate if the phase is active and have a small black dot when it is not active. The two lights at the bottom of this block indicates the injector position (UP and DOWN).


HPC 201T Date: 25/03/2009


8.4 Regeneration Cycles Number After all slip lines are cleaned, the moulds must be cleaned with water to avoid any residual slip to harden on the mould surface. Ideally 6 to 10 regeneration cycles should be selected to clean the moulds properly. 8.5 Washing Cycles Number After regeneration some washing cycles are selected to ensure the proper cleaning of the draining circuits. Ideally 2 to 4 washing cycles should be selected. 8.6 Start Procedure At the top of the two columns there are a green and yellow button FINAL WASHING. When the button is pressed it will change colour to violet for the duration of the procedure. 8.7 MAIN and PREVIOUS The MAIN button returns to the main page and PREVIOUS takes you to FIRST START.


HPC 201T Date: 25/03/2009


9. ROUTINE CLEANING AND MAINTENANCE For the equipment to function well and to ensure the maximum life from resin moulds, it is extremely important to follow a proper inspection and maintenance plan on the equipment. Attached are typical lists of daily, weekly and monthly inspection and maintenance. It is very important to note that this is merely a guide and additional points from your own experience should be added to the list. The following list is typically an operators list that should be controlled daily. It can be part of his day to day work and could be done during the first start or mould cleaning in the morning.

DAILY INSPECT

1 Inspect water circuit temperature 2 Inspect water circuit filters for accumulation of sediment 3 Inspect moulds surfaces for cleanliness 4 Inspect air/water pipe connections on moulds for leakages

5 Inspect and correct water pressure on slip casting tank heating jacket

6 Inspect vacuum tank filter for presence of water and drain if necessary 7 Inspect moulds for any leaking or surface damage 8 Control and record slip rheology (Density, Viscosity, Thixotropy 1 and 5 minutes) 9 Cast plaster test mould and record the thickness formation during 1 hour

10 Control and record the thickness formation of pieces 11 Inspect finishing tools and replace if worn

12 Clean all slip circuits and draining circuits if press is stopped overnight (Final Washing)

13 Flush all slip circuits and fill injector with fresh slip every morning before first casting (First start)

14 Clean moulds every 3rd day with Hypochlorite if working 24 hour shifts

15 Clean moulds every 2nd day with Hypochlorite if not working continuous shifts.

16 Set presses on auto mould regeneration maintenance if press is stopped over night or weekend

17 Inspect plaster setter surfaces for damage or deformation. Repair if possible or change.

18 Remove all draining circuit inserts and replace the heat shrink black tube. Replace inserts and test for leaks


HPC 201T Date: 25/03/2009


The following list is typically a maintenance technician’s list and could partially be shared by the operator. The company can decide the responsibilities and roles of operators and technicians. WEEKLY INSPECT

1 Lubrication of mobile part of Press 201. 2 Inspect hydraulic circuit for leakages in high and low pressure 3 Check hydraulic tank level

4 Inspect compressed air line filters for presence of oil as it can damage moulds from behind

5 Test compressed air proportional valve setting to actual pressure on manifold with portable manometer

6 Clean machine and robot exterior and apply wax for protection 7 Test one by one every control valve on filling circuit of press 8 Test one by one every control valve on draining circuit of press 9 Test one by one every control valve on mould circuit of press

10 Check black plastic tubes on draining circuit inserts for any perforations. Change if required.

11 Perform chemical washing on all moulds as per the prescribed recipe 12 Test Hydraulic pressure on injector and clean the transducers for slip. 13 Confirm actual vs. set positions of all linear transducers on mobile parts of the Press

14 Measure plaster setter level and replace if 3mm consumption reached. Adjust Robot level accordingly

15 Inspect and clean all robot tool changers with dry cloth. Wipe after cleaning with oiled cloth

16 Inspect and clean filters on vacuum circuit on robot

17 Inspect all slip feeding hoses for correct inclination during washing position to prevent water in slip

18 Clean slip casting tank, agitator and circuits to eliminate any build-up of dry material The following list is typically a maintenance technicians. MONTHLY INSPECT

1 Regulate all hydraulic hammers for uniform mould compression 2 Inspect electric cables in the island and look for any damage on housings

3 Inspect Fast in screws and apply grease in the centre screw for protection against corrosion

4 Inspect oil level in gearboxes of Press mobile parts 5 Inspect chain tension on mobile part Press 201T 6 Confirm the sensor connections on hydraulic circuit for clean filter monitoring 7 Test all security gates and optical beams on the Island 8 Clean insides of electrical panels with blower or vacuum cleaner 9 Clean robot panel and heat exchanger elements on the back of panel

10 Check paintwork and repair if necessary to avoid rust 11 Check robot as per robot standard maintenance instructions in robot manual 12 Open and clean venturi for piece demoulding and remove all slip dust

Documents

Use and Maintenance Vitruvit