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SAS Stampex 6+ Instruction Manual

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INSTRUCTIONS MANUAL
FOR USE AND MAINTENANCE
OF THE MACHINE
SOAP PRESS TYPE:
STAMPEX 6 +
SERIAL NUMBER: 133/07.
CONSTRUCTION YEAR: 2007.
CUSTOMER: UNILEVER
CUSTOMER:
Bangladesh.
ORDER N.: our proforma invoice n. 001/07
ORDER N.:
and offer n. 6556/06 – B.
1

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Summary of Contents for SAS Stampex 6+

  • Page 1 INSTRUCTIONS MANUAL FOR USE AND MAINTENANCE OF THE MACHINE SOAP PRESS TYPE: STAMPEX 6 + SERIAL NUMBER: 133/07. CONSTRUCTION YEAR: 2007. CUSTOMER: UNILEVER CUSTOMER: Bangladesh. ORDER N.: our proforma invoice n. 001/07 ORDER N.: and offer n. 6556/06 – B.
  • Page 2 INDEX 1. PARTICULARS AND SAFE USE OF THE PRESS............4 1.1. PREAMBLE. 1.2. INTRODUCTION. 1.3. GENERAL SAFETY RULES. 1.4. SAFE USE OF THE MACHINE. 1.5. DANGER CONDITIONS FOR THE OPERATOR. 1.6. EMERGENCY SITUATIONS. 1.7. GUARANTEE. 1.8. NOTES FOR THE EMPLOYER. 2.

  • Page 3: Recommended Spare Parts

    5. PUSH-BUTTON PANEL AND USE OF THE PRESS ..........43 5.1. CONTROL PANEL. 5.2. START-UP. 5.3. MECHANICAL ADJUSTMENTS. 6. PNEUMATIC CIRCUIT ..................60 6.1. PRESSURE REDUCERS. 7. COOLING SYSTEM ....................63 7.1. CHILLER FOR COOLING. 7.2. CLEANING OF THE COOLING CIRCUIT. 8.
  • Page 4 - has to be consigned with the machine in case the same is sold to another customer. 1.2. INTRODUCTION. This document has been prepared for the SAS press’s operators and for the maintenance men, it has been drown up in accordance to CEE 89/392 directive and EN 292-2 p5 rule.
  • Page 5 In case of breakdown or fault, or for any need: SAS MARIANI TOMMASO – ASSISTANCE SERVICE di Mariani Pietro e Carlo s.n.c. via Toscanini, 46 p.o. box 17 20038 SEREGNO (MI) ITALY TEL. ++39 0362 - 239 988 FAX ++39 0362 - 328 413 V.A.T.

  • Page 6: General Safety Rules

    1.3. GENERAL SAFETY RULES. The use of this machine is demanding, so it requests a good instruction of the operators, moreover the machine is manufactured with high technology components that require assistance operators with specific preparation. So, the use and maintenance of the press, request a certain attention for the interventions in the following zones: - working zone - infeed zone...
  • Page 7 The operator must know in detail the functioning modes, the charge and discharge procedures, the risks connected to the processing, damages to persons and goods in case of improper use, abuse and tampering of the SAS press and foreseen safety devices.
  • Page 8 1.4.2. PROTECTION COVER OF THE DANGEROUS ZONE. The stamping area is the dangerous working zone. The access at this zone is prevented by a protection device that doesn’t allow the operator to insert parts of the body in the dangerous zone. The protection device is composed by a front door in lexan or poli-carbonate (photo 1.3) fixed by hinges and positioned in front of the press, so to close completely the slide movement area.
  • Page 9 OF PARTS OF THE BODY IN THE DANGEROUS WORKING ZONE, WHILE THE PRESS IS WORKING, AND ALSO CAUSED BY IMPROPER USE OR ABUSE OF THE SAS PRESS OR TAMPERING OF PROTECTIONS AND SAFETY DEVICES OF WHICH THE PRESS IS SUPPLIED.
  • Page 10 1.5. DANGER CONDITIONS FOR THE OPERATOR. The press is fed by an electric charge conveyor belt, so the feeding is automatic. Please note that when the machine stops because there isn’t any soap billet on the infeed conveyor (when the function “INFEED PHOTOSWITCH” on the touch screen is set as “ON”), it will automatically restart when a soap billet is detected by the photoelectric switch on the infeed conveyor.
  • Page 11 The operator has not the authorization to insert parts of the body in the stopped press during adjustment or start up, or keep scraps away. SAS press is supplied with safety devices and so the machine must and has to run only with closed protection covers, but it would be opportune that the operator has adapted tools (nippers etc.) to eliminate eventual processing scraps.

  • Page 12: Motor Brake

    MOTOR BRAKE. The motor of the machine contains an electromagnetic-spring brake. When the machine is supplied with electrical power you can start the machine by pressing the push-button “START”: the brake is disengaged and so the machine can run but only if the door in lexan of the stamping area and the door of the hand-wheel are closed.
  • Page 13 2. Manufacturer and Supplier have no responsibility of breakdown or defects of conformity, and of materials, software, semi finished products, components and any other product incorporated or not in the SAS press, supplied, indicated or requested by the Buyer or by Third persons.

  • Page 14: Manufacturer's Responsibility

    1.7.3. MANUFACTURER’S RESPONSIBILITY. After the installation of the machine in the working site, any damage happened to persons or things (also when they are parts or particulars of the SAS Press) is at charge of the Buyer. The Buyer has to insure any eventual residual risk added after the installation of the machine (L.D.
  • Page 15 2. WORK SITE LAYOUT. 2.1. DANGER ZONE LAYOUT. The dangerous zone is the dashed one (figure 2.1): none can stay in this zone when the press is working in automatic mode. FIGURE 2.1...
  • Page 16 2.2. OPERATOR AND MAINTENANCE MAN ZONE LAYOUT. The operator and maintenance man zone is the dashed one (figure 2.2). It is an area of about 1,5 meter in front of the machine, and 1 meter from the other sides. Only the operator and the maintenance man are permitted to stay in this zone when the press is working or during the maintenance interventions.
  • Page 17 3. TRANSPORT, INSTALLATION AND SETTING UP. 3.1. PACKING AND STORING. Before packing, all the parts not painted are covered with antirust and antioxidant products, while the breakable parts are protected by plastic packing material. The packed and well preserved material, can be stored for a period of two years approximately in a covered area where the temperature ranges between –15°C and +45°C with a relative moisture of 80%.
  • Page 18 3.2. ACCEPTANCE. It is necessary to plan an adequate area with a flat surface for unload and assembling operations. If the cases or the materials, delivered by the Carrier, present signs of damages, the Consignee must notify to the Carrier the objections with due reservations. Before to accept the goods, the Consignee must put down in writing the objections on delivery note, with date and signature of the representative, and send a copy by fax to the Manufacturer.
  • Page 19 3.3. HANDLING. 3.3.1. CRANE HANDLING. In its upper part, the press is provided with lifting hooks (see drawing). USE SUPPLIED HOOKS. USE FLEXIBLE ROPES HOMOLOGATED AND CONTROLLED, WITH SUITABLE MINIMUM CAPACITY FOR THE WEIGHT TO LIFT DO NOT USE CHAINS PRESS WEIGHT: ABOUT 6000 KG 3.3.2.
  • Page 20 3.3.3. HANDLING BY ROLLS. It is an emergency handling. It is possible only if the machine is bolted on the wooden frame or on the bottom of the case and if the displacement happens on a flat surface (not on inclined floor).
  • Page 21 3.6. PREARRANGEMENT OPERATIONS. 3.6.1. INTRODUCTION OF LUBRICANT OIL. ATTENTION: THE OIL TANK OF THE LUBRICATING CIRCUIT AND THE GEAR- REDUCER ARE WITHOUT OIL ! OIL TANK OF THE LUBRICATING CIRCUIT: Open the protection covers PC1 and PC2 (photo 3.1) and fill the oil-tank (photo 3.2) with oil till the level indicator OLM (photo 3.1).
  • Page 22 MAIN GEAR-REDUCER: Open the protection covers PC1 and PC2 (photo 3.1), unscrew the filler plug FPR (photo 3.3) of the gear-reducer and insert oil till the level indicator OLR. Insert oil like the specified in the instruction manual “ROSSI MOTORIDUTTORI” enclosed in the chapter “12.

  • Page 23: Ball Bearings

    BALL BEARINGS. All the ball bearings are already lubricated with grease and so it isn’t necessary further lubrication. 3.6.2. MECHANICAL PREARRANGEMENT. Take away, with cleaning liquids, impurities and antioxidant grease eventually spread on the machine parts not covered. Assemble the charge belt conveyor on the machine by connecting the fixing plate FP (photo 3.6) to the connecting area CA with bolts (photo 3.7).
  • Page 24 Assemble the discharge belt conveyor (photo 3.9) on the proper supports DS (photo 3.8) with bolts. PHOTO 3.8 PHOTO 3.9...
  • Page 25 3.6.3. ELECTRIC CONNECTION FINISHING. Connect the plug XS.1 (photo 3.9) of the charge conveyor belt to the socket XS.1 on the machine. Connect the plug X3.2 (photo 3.8) of the discharge conveyor belt to the socket X3.2 on the machine. Connect the plug XS.3 (photo 3.10) of the electro-mechanical vacuum pump to the socket XS.3 on the machine.

  • Page 26: Compressed Air Connection

    3.6.4. COMPRESSED AIR CONNECTION. Connect your compressed air source with the pneumatic circuit of the machine by the connection AIR IN (photo 3.10). The required air pressure is between 5 and 6 bar. The diameter of the connection pipe has not to be smaller then the diameter of the connection filter. Air has to be dry, clean and lubricated with oil before being sent to the press.
  • Page 27 3.6.5. DIES ASSEMBLING. 3.6.5.1. INSERT OF THE DIES.
  • Page 28 3.6.5.2. HOW TO ASSEMBLE THE DIES ON THE MACHINE. The assembling operations cannot be made if the machine is not supplied with electrical power because, on the other case, the brake cannot be disengaged and so you cannot put the machine in the different positions for the die assembling.
  • Page 29 To prepare the machine at the dies assembling operations, please follow the next instructions: - close all the protection covers; - turn the “MAIN SWITCH” switch (positioned on the main electric panel) into “1- ON” position; the light “POWER ON” will be activated to show that the machine is supplied with electrical power;...
  • Page 30 NOTE ABOUT THE DISPLACEMENT OF THE LOWER DIE. Please note that to help the displacement of the lower die you can screw threaded tools (for example a simple screw as shown in the photo A) into the threaded holes TH (photo A, one at left-side and one at right-side) on the die support plate.
  • Page 31 3.6.5.2.A. SEMI-AUTOMATIC MODE. Use the button “JOG RW” (JOG BACKWARD) or “JOG FW” (JOG FORWARD) to reach the position “open dies” (with the upper die in the highest position). WHEN YOU USE THESE ELECTRIC COMMANDS, YOU HAVE TO CLOSE THE PROTECTION COVERS.
  • Page 32 Lock the bolts to fix the upper die and the rotating die at their supports when they are in the lowest position and the centring pins are assembled. WARNING: ABSOLUTELY DO NOT TURN THE PRESS IN FORWARD DIRECTION WITH THE CENTRING PINS ASSEMBLED IN THE DIES ! THE DIES CAN BE DAMAGED BECAUSE THE LOWER DIE STARTS TO ROTATE BEFORE THE UPPER ONE HAS REACHED A POSITION THAT LET THE CENTRING PINS GO COMPLETELY OUT FROM THEIR...
  • Page 33 PHOTO 3.10 _ AS PHOTO 3.10 _ REAR VIEW PHOTO 3.11...
  • Page 34 3.6.5.2.B. AUTOMATIC MODE. This mode is similar at the “SEMI-AUTOMATIC” mode but it is simpler because it allows the automatic positioning of the machine in the positions for the different dies assembling steps. Please push the MECHANICAL TOOL BUTTON on the “MAIN SCREEN” screen, then insert the code “12345”...
  • Page 35 When the machine has reached the “OPEN DIES” position, you have to open the lexan protection cover and do the action described in the “Operation” field of the “STEP 1” paragraph (see next page). Now the button “2” will be in evidence to show you that you have to press this button to reach the next position.
  • Page 36 3.6.6. COOLING CONNECTION FINISHING. After had assembled the dies, connect them to the cooling circuit by the proper pipes. Connect the chiller (or your other cooling source) with the cooling circuit of the press: _ connect pipes from the liquid outlet (delivery) of your cooling source (chiller) to the connection “C.IN”...
  • Page 37 3.7. ACCEPTANCE TEST AND DELIVERY. If foreseen in the contract, make functioning tests on-load and full load; make training to the operators; draw up the acceptance report that transfers responsibility for the machine and its direction to the Buyer, and define the date of the guarantee period beginning.
  • Page 38 TECHNICAL SPECIFICATIONS. 4.1. PURPOSE AND USE OF THE MACHINE. The SAS press must exclusively be used to stamp soap bars and similar products. It must be placed into an automatic soap line from which receives cut soap bars and to which gives stamped soap tablets.

  • Page 40: General Features

    4.3. GENERAL FEATURES. "STAMPEX" is an all-purpose fully automatic soap press designed to stamp: rectangular, oval and round banded soaps rectangular, oval and round bandless soaps irregular specialty shapes like animals, flowers and alike hotel size soaps of every shape The press is supplied complete with: ♦...
  • Page 41 4.4. OPTIONALS. MOVABLE CASTORS It is easy to move the press in or out the line when movable castors are provided. SLUG EJECTOR CONVEYOR For fully continuous and automatic finishing line operation a "slug ejector conveyor" is advisable between the Cutter and the Press. This independently driven conveyor has two control photocells and a pneumatic deflection flap.

  • Page 42: Machine Components

    A die set consists of 1 top die and 1 lower rotating die and accessories. We can supply a wide range of die sets: • Engraved dies for regular shapes • Engraved dies for Irregular shapes • Special banded dies with possibility to change weight varying the thickness •...