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OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL
CUSTOMER ......................................................
MACHINE MODEL ............................................
SERIAL NUMBER .............................................
OMERA S.r.l.
Via Ponte dei Granatieri, 8
36010 Chiuppano (VI) Italy
Tel +39-0445-805444 - Fax +39-0445-805404
e-mail
ucomm@omera.com
http://www.omera.com
I003203EN.DOC
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Table of Contents
Summary of Contents for OMERA OPI M-400
- Page 1 OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS OPERATION AND MAINTENANCE MANUAL CUSTOMER ............MACHINE MODEL ..........SERIAL NUMBER ..........OMERA S.r.l. Via Ponte dei Granatieri, 8 36010 Chiuppano (VI) Italy Tel +39-0445-805444 - Fax +39-0445-805404 e-mail ucomm@omera.com http://www.omera.com I003203EN.DOC...
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Page 2: Table Of Contents
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS INDEX OF TOPICS: MACHINE ASSEMBLY DRAWING..................... 4 TEST CERTIFICATE.......................... 5 TEST AND INSPECTION DATA (ACCORDING TO SCHLESINGER STANDARDS)......6 EXPECTED USE CONDITIONS ......................7 BEFORE OPERATING THE MACHINE ..................7 DESCRIPTION OF THE MACHINE....................8 3.2.1 ACCESSORIES ........................ - Page 3 OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS MAINTENANCE ..........................32 OIL LEAKS..........................33 OIL FILTER..........................33 TANK AIR FILTER........................34 OIL FILLER CAP ........................34 OIL CHANGE........................... 34 P.L.C. CENTRAL UNIT......................35 MAIN CYLINDER........................36 BLANK HOLDER CUSHION CYLINDER..................37 TAKE-UP OF SLIDE PLAY ....................... 38 7.10 UNIT FOR HOLDING SLIDE AT T.D.C.
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Page 4: Machine Assembly Drawing
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS MACHINE ASSEMBLY DRAWING OPERATION AND MAINTENANCE MANUAL... -
Page 5: Test Certificate
Amount of water required................. m / h _____ 3,7 (water at 20 °C) Amount of oil....................litres __________________ 1800 Overall dimensions and foundations .......... Omera Draw. no. ______________ 17003675 Table drilling................Omera Draw. no. ____________ 4P1AG1MF Slide drilling ................Omera Draw. no. ______________4X1A9B00 Oil-hydraulic system diagram........... -
Page 6: Test And Inspection Data (According To Schlesinger Standards)
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS TEST AND INSPECTION DATA (ACCORDING TO SCHLESINGER STANDARDS) Maximum Measured data Drawing Subject of measurement tolerance mm Flatness of lower face of slide with respect to the table on the plane of symmetry of the machine. (The slide can only lean forward) For machines with up to a maximum pressure of: 0,03/300... -
Page 7: Expected Use Conditions
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS EXPECTED USE CONDITIONS BEFORE OPERATING THE MACHINE Before carrying out any installation operation and/or using the machine, the instructions in this manual should be read thoroughly and adhered to. Current regulations relating to accident prevention and safety in the workplace should also be observed. -
Page 8: Description Of The Machine
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS DESCRIPTION OF THE MACHINE The "OPI" oil-hydraulic presses with two uprights are composed of the following parts: Structure: made of welded sheet metal, in thickness required for maximum rigidity. Before being machined, the structure undergoes heat treatment and sand- blasting in order to eliminate residual internal stress. -
Page 9: Accessories
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 3.2.1 ACCESSORIES Illumination of the work area: the press can be equipped with a lighting system in the work area connected to the electrical system of the machine. Die locking and lifting: the machine can be equipped with an oil-hydraulic unit complete with check and control elements to automatically lock and release the die. -
Page 10: Machine Use
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS MACHINE USE The "OPI" oil-hydraulic presses with two uprights are usually double-effect machines with slide and cushion control; they are used to blank, coin and draw steel plates into shapes and sizes which should be in line with the technical specifications of the relevant model. -
Page 11: Recommended Fluids
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS RECOMMENDED FLUIDS The "OPI" OIL-HYDRAULIC presses have been designed to operate with ESSO NUTO H 46 oil. If other lubricants are used, check that they have the same characteristics as those described in the comparative oil tables given below. Oil type ESSO NUTO H46 Degree of viscosity... -
Page 12: Transportation Conditions
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS TRANSPORTATION CONDITIONS The “OPI-N” oil-hydraulic presses with two uprights are already completely assembled on delivery and for the handling of these, special lifting attachments have been fitted to the upper part of the machine. The tables below contain the weights of the parts of machine; the user should consult these tables for the type of lifting means to use and the correct lifting capacity. -
Page 13: Procedure For Unloading From The Means Of Transport
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS PROCEDURE FOR UNLOADING FROM THE MEANS OF TRANSPORT The machine is transported lying on its side, therefore, proceed as follows to unload the machine: ? fasten the two eye-bolts to the feet “1” (front and back), using the 40mm diameter bolts. ? attach the lifting chains to these eye-bolts and to the lifting points “2”... -
Page 14: Installation Conditions
This drawing should have already been supplied to the customer but is also included at the beginning of this manual. Installation and commissioning are usually carried out by Omera technicians. As far as possible, the machine should be installed away from possible sources of electromagnetic interference (such as welding equipment) and a sufficient amount of space should be left around the machine for routine and extraordinary maintenance. -
Page 15: Filling Of Oil Tank
OMERA does not normally supply the general protection device against short-circuits and overloading; this device should be installed by the user in proximity to the machine and should be capable of sustaining the maximum current required by the load. -
Page 16: Illumination Of The Work Area
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS ILLUMINATION OF THE WORK AREA When the lighting has to be installed for the work area of the machine and the same electricity line as the line which supplies the press is to be used, then cabling needs to be carried out inside and outside the electric panel, in compliance with the relevant technical and work safety standards. -
Page 17: Operation Conditions
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS OPERATION CONDITIONS The "OPI" oil-hydraulic presses with two uprights are prepared for normal functioning by using the following three separate control units: Electric controls. Oil-hydraulic controls. Cycle cams. ELECTRIC CONTROLS The machines are equipped with a hanging push-button board and a control console located in the manual loading and unloading area. - Page 18 OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS "ALARM" (111HL5) red warning light: it indicates that the machine cycle is blocked; the cause of such a failure is shown in the display of the service panel. "STOP" (56SB30) mushroom red push button with mechanical lock: when pressed, it stops the movements of the slide and blank holder.
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Page 19: Control Console
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS CONTROLS ON REAR UP-RIGHT "REAR BARRIER RESET” (54SB8) luminous blue button: it is used to reset the operation of the mobile rear mechanical barrier after the operator has entered the danger zone of the press. The "BARRIER RESET"... - Page 20 OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS "KNOCKOUT DOWN” (57SB20) green button: when pressed this activates the downstroke of the knockout cylinder as far as the end-of-stroke position; the function switch should be in adjustment position. To command ejector downstroke, it is necessary that the slide is at TDC and ejector operation is enabled (see “EJECTOR PROGRAMMING”...
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Page 21: Oil-Hydraulic Controls
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS OIL-HYDRAULIC CONTROLS The machine is not provided with panel-mounted oil-hydraulic devices for normal adjustment and reading of the pressures set during the operation cycle. The INDUSTRIAL PC is used to set the working pressure of the various oil-hydraulic devices. Based on the values entered in the memory, the electronic equipment connected to the INDUSTRIAL PC controls four oil- hydraulic proportional-control valves, and detects the feedback signal from the three analogic pressure switches. -
Page 22: Electronic Cycle Cams
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS ELECTRONIC CYCLE CAMS The machine is equipped with a programmable electronic system capable of controlling, during the work cycle, the position of the slide and the blank-holder and activating the intervention sequence of the solenoid valves as required. -
Page 23: Control Of The Blank Holder Cushion
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 6.3.2 CONTROL OF THE BLANK HOLDER CUSHION The blank holder cushion position along its stroke is CUSHION displayed on the INDUSTRIAL PC. This electronic instrument allows to set all the cycle parameters (T.D.C.; T.D.C. extra-stroke microswitch B.D.C.;... -
Page 24: Industrial Pc Switching On Procedure
“ START / STOP UPS ” selector positioned on the electric panel door. use the mouse to click on the “Password” field in the window displayed; use the alphanumeric keys to enter: OMERA; use the mouse to click on the “OK” key to confirm entry. PASSWORD... -
Page 25: Device For Holding The Slide At T.d.c
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS DEVICE FOR HOLDING THE SLIDE AT T.D.C. The oil-hydraulic presses with two uprights are equipped with an automatic slide holding device, capable of physically blocking the downstroke of the slide by means of its own weight when the machine is not activated; moreover a limit switch de-activates the control of the downstroke if the slide is locked at T.D.C. -
Page 26: Functioning Modes
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS FUNCTIONING MODES NOTICE: The “SLIDE UP”control, positioned on the main control pulpit is always operative! By any mushroom-shaped pressed “CYCLE STOP” push-button or with movable mechanical barriers open it is possible to let the slide go up with low speed. 6.9.1 INITIAL CYCLES Once installation of the machine has been carried out, as described above, the slide and the blank holder can... -
Page 27: Block Reset For Slide And Cushion Overstroke
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 6.9.6 BLOCK RESET FOR SLIDE AND CUSHION OVERSTROKE In the event of the over-stroke limit switch of the slide or blank-holder being triggered, the auxiliary circuits of the machine are de-activated; these can be restored by following procedure given below: 1. -
Page 28: Die Loading
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 6.9.8 DIE LOADING If the press is not equipped with an automatic die insertion and locking device, to load the die, proceed as follows: NOTE: Check that the geometrical characteristics of the die are suited to the model of machine used. ? Select the adjustment cycle ? Lock the slide to T.D.C. -
Page 29: Die Unloading
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 6.9.9 DIE UNLOADING If the press is not equipped with an automatic die release and knockout device, to unload the die, proceed as follows: ? Select the adjustment cycle ? With the slide at T.D.C. activate the downstroke of the blank holder using the “CUSHION DOWNSTROKE” button located on the control console (bring the pressure pins just under the work table of the press). -
Page 30: Operation With Automatic Feeder
“X60A” on the press electric board and insert the interface plug attached to the automation. If not clearly stated in the supply agreement, Omera S.r.l. will not be held responsible for the installation of the automatic feeder at customer’s factory. -
Page 31: Automatic Cycle Stop
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 6.9.12 AUTOMATIC CYCLE STOP While operating the press with the feeder, it is possible to stop the automatic cycle in a controlled manner. To do this, it is necessary to recall the “LINE GENERAL PAGE” on the screen of the INDUSTRIAL PC located on the hanging push-button board of the OPI 315 press and use the “AUTOMATIC CYCLE STOP”... -
Page 32: Maintenance
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS MAINTENANCE DANGER: Any operations carried out on the oil-hydraulic equipment (safety blocks, single components, cylinders, etc.) must be carried out only by specialised personnel with particular knowledge and experience of oil-hydraulic plants ! Before beginning the above maintenance bring the slide and cushion to B.D.C. -
Page 33: Oil Leaks
The filter used is made by M.P. and is the following type: MPS 350 R G1 P10 A FX (Omera code 76801060) The cartridge used is made by M.P. and is the following type: CS 150 – P10A (Omera Code 76801120) -
Page 34: Tank Air Filter
The filter used is made by M.P. and is the following type: SA 185 G1 L10 A (Omera Code 76807017) The cartridge used is made by M.P. and is the following type: A 10 L10... -
Page 35: Central Unit
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS P.L.C. CENTRAL UNIT Key: 1. “memory card” housing 2. CPU condition signalling LED’s 3. “memory card” ejector 4. Removable key selector for CPU operation selection 5. 9-pole connector for connection to INDUSTRIAL PC 6. Optional 7. -
Page 36: Main Cylinder
Down position: SHAMBAN EXCLUDER 2 - S 56202 1000 A46 NOTE: Omera S.r.l. does not supply individual gaskets but complete replacement sets; when placing an order remember to indicate the type and serial number of the machine. OPERATION AND MAINTENANCE MANUAL... -
Page 37: Blank Holder Cushion Cylinder
SHAMBAN - STEPSEAL - S 55013 2400 A 46 GACO - OR - 81000 NOTE: Omera S.r.l. does not supply individual gaskets but complete replacement sets; when placing an order remember to indicate the type and serial number of the machine. OPERATION AND MAINTENANCE MANUAL... -
Page 38: Take-Up Of Slide Play
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS TAKE-UP OF SLIDE PLAY The slide is equipped with self-lubricating sliding shoes which allow take up of play in two directions: lengthways (face A) and crossways (face B). Side A adjustment : To carry out this operation, observe the following procedure: Bring the slide to B.D.C. -
Page 39: Unit For Holding Slide At T.d.c
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.10 UNIT FOR HOLDING SLIDE AT T.D.C. The slide holding device is positioned inside the left upright of the press. It is made up of the following parts: 1. Hydraulic cylinder EMMEBI COP5025 20x1.5 J 65 01 S 2. -
Page 40: Encoder
The following table contains the description of parts which may have to be replaced. Pos. Function Make Type Omera’s Code Actuator for encoder STEGMANN Slide position STEGMANN AG 626 XSR SL 3002 8832010L... - Page 41 OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.13 TABLE SUMMARIZING MAINTENANCE INTERVENTIONS The INDUSTRIAL PC displays, after a predefined time, the main maintenance operations to be carried out on the machine, The following table specifies the recommended maintenance intervals and their frequency expressed in terms of machine working hours.
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Page 42: Comparative Oil Tables
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.14 COMPARATIVE OIL TABLES OPERATION AND MAINTENANCE MANUAL... -
Page 43: Wiring Diagram
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.15 WIRING DIAGRAM OPERATION AND MAINTENANCE MANUAL... -
Page 44: Oil-Hydraulic Diagram
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.16 OIL-HYDRAULIC DIAGRAM OPERATION AND MAINTENANCE MANUAL... -
Page 45: Pneumatic Diagram
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.17 PNEUMATIC DIAGRAM OPERATION AND MAINTENANCE MANUAL... -
Page 46: Lubrication System Diagram
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.18 LUBRICATION SYSTEM DIAGRAM OPERATION AND MAINTENANCE MANUAL... - Page 47 OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.19 TABLE DRAWING OPERATION AND MAINTENANCE MANUAL...
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Page 48: Slide Drawing
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.20 SLIDE DRAWING OPERATION AND MAINTENANCE MANUAL... -
Page 49: Knockout Drawing
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.21 KNOCKOUT DRAWING OPERATION AND MAINTENANCE MANUAL... -
Page 50: Other Drawings
OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS 7.22 OTHER DRAWINGS OPERATION AND MAINTENANCE MANUAL...
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