Draw Line - Reference Manual

DRAW LINE – ¼ CLUB

REFERENCE MANUAL

1. INDEX

1. INDEX.................................................................................................................................... 1

2. INTRODUCTION................................................................................................................... 3

3. GENERAL INFORMATION...................................................................................................4MACHINE................................................................................................................................ 4MANUFACTURER...................................................................................................................6

4. PRESS INSTALLATION.......................................................................................................7UNLOADING AND LIFTING....................................................................................................7FOUNDATION......................................................................................................................... 8

5. GENERAL SECURITY RECOMMENDATIONS..................................................................11

6. SECURITY........................................................................................................................... 12EMERGENCY OPERATIONS...............................................................................................12EMERGENCY STOP.............................................................................................................12EMERGENCY SWITCHING OFF..........................................................................................12MONITORING OF COMMAND ACTIONS.............................................................................13ENABLING DEVICE..............................................................................................................14CONTROL LIMITATION........................................................................................................15START FUNCTIONS.............................................................................................................15STOP FUNCTIONS...............................................................................................................16INTERLOCKING PRINCIPLES.............................................................................................17PROTECTION OF EQUIPMENT...........................................................................................18HAZARDS............................................................................................................................. 21

7. TECHNICAL CHARACTERISTICS.....................................................................................23AUTOMATIC PRESS MODEL PAE 63/250..........................................................................23AUTOMATIC PRESS MODEL PAP 200 E............................................................................24

8. ELECTRICAL SYSTEM.......................................................................................................25DRAW PRESS PAE 63/250..................................................................................................25TRIMMER PRESS PAP 200 E...............................................................................................25ELECTRICAL CABINET.......................................................................................................25

9. AUTOMATIC LUBRICATION SYSTEM..............................................................................26

10. PNEUMATIC SYSTEM........................................................................................................27GENERAL INFORMATION OF PNEUMATIC SYSTEM.......................................................31DRAW PRESS PAE 63/250..................................................................................................31TRIMMER PRESS PAP 200 E...............................................................................................31

11. SPUR GEARS..................................................................................................................... 32

12. BUTTON PANELS..............................................................................................................33

2002 ® ALL RIGHTS RESERVED – THE UNAUTHORISED COPY OF THIS MANUAL IS STRICTLY FORBIDDEN 1


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13. TOUCH SCREEN ADJUSTMENTS....................................................................................39UPPER DEAD CENTER (PAE 63, PAP 200)........................................................................39LOWER DEAD CENTER (PAE 63).......................................................................................39CAN EXIT CHECK – LEFT / RIGHT (PAE 63)......................................................................40EXIT BLOWER LEFT / RIGHT (PAE 63, PAP 200)..............................................................40CAN BRAKE LEFT /RIGHT (PAP 200).................................................................................40LUBRICATION (PAE 63, PAP 200)......................................................................................42SPEED ADJUSTMENT (PAE 63, PAP 200).........................................................................42

14. TOUCH SCREEN MENU STRUCTURE..............................................................................43B1 MAIN MENU...............................................................................................................43B2 PRESENTATION.......................................................................................................44B10 MACHINE MONITOR.................................................................................................45B11 ELECTROVALVES TEST..........................................................................................47B12 MANUAL AND REVERSE MODE.............................................................................48B20 ADJUSTMENTS MENU.............................................................................................50B21 SPEED SELECTION 1...............................................................................................51B22 SPEED SELECTION 2...............................................................................................52B23 ENCODER ADJUSTMENTS 1...................................................................................53B24 ENCODER ADJUSTMENTS 2...................................................................................55B25 ENCODER ADJUSTMENTS 3...................................................................................57B26 ENCODER ADJUSTMENTS......................................................................................58B27 LINE LEVEL TIMERS................................................................................................60B28 LUBRICATION TIMERS 1.........................................................................................61B29 LUBRICATION TIMERS 2.........................................................................................62B30 DRAW PRESS PRODUCTION COUNTER...............................................................63B40 RESET ALARMS.......................................................................................................64B41 ALARMS HISTORY...................................................................................................65B42 ALARMS FREQUENCY............................................................................................66

15. FREQUENCY CONVERTERS PARAMETERS...................................................................67DRAW PRESS MOTOR FREQUENCY CONVERTER..........................................................67TRIMMER PRESS MOTOR FREQUENCY CONVERTER....................................................69DRAW PRESS EXIT CONVEYOR FREQUENCY CONVERTER..........................................71

16. TROUBLESHOOTING........................................................................................................73



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2. INTRODUCTION

This manual has been prepared to furnish the press user with sufficient informa-

tion to set up, lubricate, connect air and electrical services, and stroke the press

without outside assistance. Maintenance instructions, press inspection check

lists and other operational data are included so that efficient, continued use of

the press may be realized.

Separate part list are included as a portion of the composite press services

manual.

Throughout the manual, warnings are included as a part of service and operat -

ing procedures. It should be noted that some warnings pertain to functions other

than those required for direct operation of the press.

Should additional maintenance assistance be required, please contact the CER-

LEI service and repair parts department. Personnel in this department are pre-

pared to aid press users in retaining the dependable performance expected

from their CERLEI equipment. Your inquiry will receive prompt and courteous

attention. Field service personal are available.

DESIGN CHANGES

Design changes between the press you received and the equipment illustrated

in this manual are the result of design improvement or special arrangement

agreed on, contractually, at the time of purchase. Installation, operation and ser-

vice instructions are for standard CERLEI presses.



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3. GENERAL INFORMATION

MACHINE

DRAW PRESS – PAE 63 / 250


LEGEND1TOOL LOWER TABLE2TOOL UPPER TABLE3SLIDE

4CRANKSHAFT5MOTOR6FLYWHEEL


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TRIMMER PRESS – PAP 200 E


LEGEND1MOTOR2MOTOR PULLEY3CRANKSHAFT4FLYWHEEL5SLIDE6TOOL

UPPER BASE7TOOL LOWER BASE8SCRAP EXIT


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MANUFACTURER

CERLEI, S.A., a well-known machine manufacturer specialized in machinery for

sardine cans – type decollage – lines for draw cans, lines for round and rectan-

gular shaped ends, seamers for filled round and irregular shaped cans, was

founded in 1944 – its traditional markets being Portugal, Spain, North Africa and

Latin America.

Due to constant research and investment DE CEPEDA has been able to further

enlarge its manufacturing program of quality products and is proud to count the

major international canmakers amongst its valued customers and business part-

ners.

LOCALIZATION:

CERLEI – MÁQUINAS INDUSTRIAIS, S.A.

S/ Dr. Afonso Cordeiro, 6744450 – 007 Matosinhos | PortugalTel.: +351 22 939 83 20 – Fax: +351 22 937 51 47E-mail: [email protected]

DE CEPEDA, S.A.

S/ Orense, 68 – Planta 1128020 Madrid | EspañaTel.: +34 91 570 50 56 – Fax: +34 91 571 42 82E- mail: [email protected]: / / www.decepeda.com



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4. PRESS INSTALLATION

Each CERLEI press is carefully prepared for shipment to protect the press dur-

ing transit and to enable the user to install the press with a minimum of reas-

sembly when it arrives at its destination.

When the press is received, it should be inspected externally for visual signs of

damage. This inspection should be performed immediately upon receipt of the

shipment if any damage has occurred notify CERLEI and the carrier for claims

inspections.

UNLOADING AND LIFTING

Remove all accessories and boxes attached to the skids so these parts will not

be damaged in handling the press. The press should remain on the skids until it

is placed under the handling equipment.

WARNING – Be sure the crane or hoist is capable of lifting, safely, the weight

involved. Check condition of ropes, cables, chains, hooks and other lifting

equipment.



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FOUNDATION

The CERLEI presses should be located on a reinforced concrete slab or pit type

foundation. The foundation should be placed on undisturbed soil and must be

strong enough to provide rigid support for the machine. Since mechanical

presses are subjected to shock loading, load bearing characteristics of soil in

the area of selected press location should be known. Area and thickness of the

foundation should be determined after considering soil properties, machine

weight and speed.

It should be pointed out that the draw illustrated here are for reference only.

The methods shown are quite common and have been successfully in many in-

stallations. However, their application should be tempered with good judgement.

Particular attention should be given to press weight, impact loads and load

bearing properties of the soil.



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FOUNDATION OF DRAW PRESS



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FOUNDATION OF TRIMMER PRESS



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5. GENERAL SECURITY RECOMMENDATIONS

NEVER operate , service or adjust the press, or install dies, without

proper instructions and without first reading and understanding instruc-

tions in the press service and operating manual.

Give special attention to all WARNING signs.

Despite the security systems installed on the machines, it doesn’t pre-

vent the operator to:

Know the location of the emergency buttons

Proceed to a visual daily check before working with the equipment

Check Oil / Grease level

Check if the working area is free of strange objects

Avoid the use of watches, bracelets, rings, etc.

Avoid the use of large clothes.

Use protection equipment.

NEVER dismount or put out of service protective covers and security

locks.

NEVER detach the remarks on the machines.

NEVER start the machine with the protections taken off or out of service.

NEVER lubricate or replace oil / grease with the machine running.

NEVER leave keys on the machine before running.

NEVER proceed to service work before switching off the main switch on

the electrical cabinet.



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6. SECURITY

EMERGENCY OPERATIONS

EMERGENCY STOP

In addition to the requirements for stop, the emergency stop function has the

following requirements:

It shall override all other functions and operations in all modes;

Power to the machine actuators that can cause a hazardous condition(s)

shall be removed as quickly as possible without creating other hazards;

Reset shall not initiate a restart.

The emergency stop shall function as a category stop or as a category 1 stop.

The choice of the category of the emergency stop shall by the risk assessment

of the machine.

Where a category 0 stop is used for the emergency stop function, it shall have

only hard-wired electromechanical components. In addition, its operation shall

not depend on electronic logic (hardware or software or on the transmission of

commands over a communications network or link.

Where a category 1 stop is used for the emergency stop function, final removal

of power to the machine actuators shall be ensured and carried out by means of

electromechanical components.

EMERGENCY SWITCHING OFF

Emergency switching off should be provided where:

Protection against direct contact is achieved only by placing out of reach

or obstacles; or

There is the possibility of other hazards or damage caused by electricity.



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Emergency switching off is accomplished by disconnecting the incoming supply

of the machine effecting a category 0 stop. When a machine cannot tolerate the

category 0 stop, it may be necessary to provide other protection, for example

against direct contact, so that emergency switching off is not necessary.

MONITORING OF COMMAND ACTIONS

Movement or action of a machine or part of a machine that can result in a haz-

ardous condition shall be monitored. On manually controlled machines, operat-

ors can provide some of this monitoring. Conditions that cannot reasonably be

expected to be monitored by the operator will require means which may include

over travel limiters, motor over speed detection, mechanical overload detection

or anti-collision.

HOLD – TO – RUN CONTROLS

Hold-to-run controls shall require continuous actuation of the control device(s)

to achieve operation.

TWO – HAND CONTROL

Three types of two-hand control are available, the selection of which is determ-

ined by the risk assessment. These shall have following features:

TYPE I: this type requires:

The provision of two control devices and their concurrent actuation by

both hands;

Continuous concurrent actuation during the hazardous condition;

Machine operation shall cease upon the release of either one or both of

the control devices when hazardous conditions are still present.

TYPE II: a type I control requiring the release of both control devices before ma-

chine operation may be reinitiated.



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TYPE III: a type II control requiring concurrent actuation of the control devices

as follows:

It shall be necessary to actuate the control devices within a certain time

limit of each other, not exceeding 0,5 sec.;

Where this time limit is exceeded, both control devices shall be released

before operation may be reinitiated.

ENABLING DEVICE

An enabling device is an additional manually operated control device used in

conjunction with a start control which, when continuously actuated, allows a ma-

chine to function.

When an enabling device is provided as a part of a system, it shall be designed

to allow motion when actuated in one position only. In any other position motion

shall be stopped.

It shall have be the following features:

Be connected to category 0 stop or to a category 1 stop (see stop func-

tions);

Be designed in consideration of ergonomic principles;

For a two-position type:

Position1: off-function of the switch (actuator is not operated,

Position 2: enabling function (actuator is operated);

For a three-position type:

Position 1:off-function of the switch (actuator is not operated,

Position 2: enabling function (actuator is operated in its mid position),

Position 3: off-function (actuator is operator past its mid position).

When returning from position 3 to position 2, the function shall not be enabled.

CABLE LESS CONTROL

This part deals with the functional requirements of control systems employing

cable less techniques for transmitting commands and signals between a ma-

chine control system and operator control station(s).



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Means shall be provided to readily remove or disconnect the power supply of

the operator control station.

Means (e.g. key operated switch, access code) shall be provided, as necessary,

to prevent unauthorized use of the operator control station.

Each operator control station shall carry an unambiguous indication of which

machine(s) is intended to be controlled by the operator control station.

CONTROL LIMITATION

Measures shall be taken to ensure that control commands:

Affect only the intended machine;

Affect only the intended functions.

Measures shall be taken to prevent the machine from responding to signals

other than those from the intended operator control station(s).

Where necessary, means shall be provided so that the machine can only be

controlled from operator stations in one or more predetermined zones or loca-

tions.

START FUNCTIONS

The start of an operation shall be possible only when all of the safeguards are in

place and are functional except.

On those machines where safeguards cannot be applied for certain operations,

manual control of such operations shall be by hold-to-run controls, together en-

abling devices, as appropriate.

Suitable interlocks shall be provided to secure correct sequential starting.

On machines requiring the use of more than one control station to initiate a

start:

Each control station shall have a separate manually actuated start con-

trol device;

All required conditions for machine operation shall be met;



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All start control devices shall be in the released (off) position before a

start may be permitted;

All start control devices shall be actuated concurrently.

STOP FUNCTIONS

There are three categories of stops as follows:

CATEGORY 0: stopping by immediate removal of power to the machine

actuators;

CATEGORY 1: a controlled stop with power available to the machine ac-

tuators to achieve the stop and then removal of power when the stop is

achieved

CATEGORY 2: a controlled stop with power left available to the machine

actuators.

Category 0, category 1 and/or category 2 stops shall be provided where indic-

ated by the risk assessment and the functional requirements of the machine.

Category 0 and category 1 stops shall be operational regardless of operational

regardless of operating modes and category 0 shall take priority. Stop functions

shall override related start functions.

Where required, facilities to connect protective devices and interlocks shall be

provided. If such a protective device or interlock causes a stop of the machine,

it may be necessary for that condition to be signalled to the logic of the control

system. The reset of the stop function shall not initiate any hazardous condition.

EQUIPOTENTIAL BONDING

The protective bonding circuit consists of:

PE terminal(s);

The conductive structural parts of the electrical equipment and the ma-

chine;



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The protective conductors in the equipment of the machine including slid-

ing contacts where they are part of the circuit

On mobile machines with on-board power supplies, the protective circuits, the

exposed conductive parts shall all be connected to a protective bonding ter-

minal to provide protection against electric shock. When a mobile machine is

also capable of being connected to an external incoming supply, the protective

bonding terminal shall be the connection point for the external protective con-

ductor.

All parts of the protective bonding circuit shall be so designed that they are cap-

able of withstanding the highest thermal and mechanical stresses that can be

caused by earth-fault currents that could flow in that part of the protective bond-

ing circuit.

Any structural part of the electrical equipment or of the machine may be used as

part of the protective bonding circuit provided that it satisfies the requirements.

If an IT distribution system is used, the machine structure shall be used as part

of the protective bonding circuit in conjunction with an earth supervision system.

The structural bonding is not required where all the equipment provided is.

Interlocking devices associated with guards

INTERLOCKING PRINCIPLES

CONTROL INTERLOCKING The control command from the interlocking device is introduced into the control

system so that interruption of the energy supply to the machine actuators-or

mechanical disconnection of moving parts from the machine actuators- is

triggered by the control system.



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POWER INTERLOCKING

The stop command from the interlocking device interrupts the energy supply to

the machine actuators or disconnects moving parts from the machine actuators.

"Directly" means that, unlike control interlocking, the control system does not

play any intermediate role in the interlocking function.

TYPICAL FORMS OF INTERLOCKING DEVICES

INTERLOCKING DEVICE (WITHOUT GUARD LOCKING)

It is always possible to open the guard. As soon as the guard is no longer

closed, the interlocking device generates a stop command. As it is possible to

start opening the guard during operation of the machine, the function is that of

an interlocking device.

INTERLOCKING DEVICE WITH GUARD LOCKING The guard is held closed by a guard locking device. There are 2 types of devices:

Those where unlocking the guard can be initiated at any time by the op-

erator (unconditional locking)

Those where unlocking the guard is possible only if a condition is fulfilled,

thus ensuring that the hazard has disappeared (conditional unlocking)

PROTECTION OF EQUIPMENT

OVER CURRENT PROTECTION

Over current protection shall be provided where the current in a machine circuit

can exceed either rating of any component or the current carrying capacity of

the conductors, whichever is the lesser value.



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OVERLOAD PROTECTION OF MOTORS

Overload protection of motors shall be provided for each motor rated at more

than 0.5 kW. In applications where an automatic interruption of the motor opera-

tion is unacceptable, the overload detection shall give a warning signal to which

the operator can respond. For motors that cannot be overloaded (e.g. torque

motors, motion drivers that either are protected by mechanical overload protec-

tion devices or are adequately dimensioned) the overload protective devices

may be omitted. Overload protection of motors can be achieved by the use of

devices such as overload protective devices, temperature sensing devices, or

current-limiting devices.

ABNORMAL TEMPERATURE PROTECTION

Resistance heating or other circuits that are capable of attaining or causing ab-

normal temperatures and therefore can cause a hazardous condition shall be

provided with suitable detection to initiate an appropriate control response.

PROTECTION AGAINST SUPPLY INTERRUPTION OR VOLTAGE

REDUCTION AND SUBSEQUENT RESTORATION

Where a supply interruption or a voltage reduction can cause a hazardous con-

dition, damage to the machine, or the work in progress, under voltage protection

shall be provided (e.g. to switch off the machine) at a predetermined voltage

level.

Where the operation of the machine can allow for an interruption or a reduction

of the voltage for a short time period, delayed under voltage protection may be

provided. The operation of the under voltage device shall not impair the opera-

tion of any stopping control of the machine.

Upon restoration of the voltage or upon switching on the incoming supply, auto-

matic or unexpected restarting of the machine shall be prevented when such a

restart can cause a hazardous condition.



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Where only a part of the machine or of the group machines working together in

a co-ordinated manner is affected by the voltage reduction or supply interrup-

tion, the under voltage protection shall initiate appropriate control responses to

ensure co-ordination.

MOTOR OVERSPEED PROTECTION

Overspeed protection shall be provided where overspeeding can occur and

could possibly cause a hazardous condition taking into account measures.

Overspeed protection shall initiate appropriate control responses and shall pre-

vent automatic restarting.

EARTH FAULT/RESIDUAL CURRENT PROTECTION

This protection can be used to reduce damage to equipment due to earth fault

currents less than the detection level of the over current protection.

PHASE SEQUENCE PROTECTION

Where an incorrect phase sequence of the supply voltage can cause a hazard-

ous condition or damage to the machine, protection shall be provided.

PROTECTION AGAINST OVER VOLTAGES DUE TO LIGHTING AND TO

SWITCHING SURGES

Protective devices can be provided to protect against the effects of the over

voltages due to lighting or switching surges.

Devices for the suppression of over voltages due to lighting shall be connected

to the incoming terminals of the supply disconnecting device.

Devices for the suppression of over voltages due to switching surges shall be

connected across the terminals of all equipment requiring such protection.



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HAZARDS

SIGNIFICANT HAZARDS AND DANGER ZONE

HAZARDS DANGER ZONE

MECHANICAL HAZARDS

CRUSHING HAZARDSHEARING HAZARDCUTTING OR SEVERING HAZARDENTANGLEMENT HAZARDDRAWING-IN OR TRAPPING HAZARDIMPACT HAZARD

TOLLS AREA: BETWEEN MOVING TOOLS MOVING SLIDE MOVING DIE CUSHIONS WORK PIECE EJECTORS GUARDSMOVING PARTS OF ELECTRICAL, HY-DRAULIC AND PNEUMATIC EQUIPMENTMOTOR AND DRIVE MACHINERYMECHANICAL HANDLING DEVICE

EJECTION HAZARD MACHINE COMPONENTSWORK PIECE AND TOOLS

HIGH PRESSURE FLUID EJECTION HAZ-ARD

HYDRAULIC SYSTEMS

SLIP, TRIP AND FALL HAZARDS ALL WORKS AT HEIGHTSFLOOR AREA AROUND THE PRESS

ELECTRICAL HAZARDS

DIRECT CONTACT HAZARD ELECTRICAL EQUIPMENTINDIRECT CONTACT HAZARDTHERMAL RADIATION HAZARD (BURNS)

ELECTRICAL EQUIPMENTPARTS MADE LIVE BY ELECTRICAL EQUIPMENT UNDER FAULTS CONDI-TIONS

THERMAL HAZARDS

THERMAL HAZARDS RESULTING IN BURNS AND SCALDS, BY A POSSIBLE CONTACT OF PERSONS

BRAKES, CLUTCHES, PARTS OF THE HYDRAULIC SYSTEM

NOISE HAZARDS

HAZARDS GENERATED BY NOISE RE-SULTING IN HEARING LOSSES (DEAF-NESS)

ANY AREA AT THE PRESS WHERE THERE IS A RISK TO HEARING



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SIGNIFICANT HAZARDS AND DANGER ZONE

HAZARDS DANGER ZONE

VIBRATION HAZARDS

HAZARDS GENERATED BY VIBRATION PARTS OF THE PRESS WHERE THE RISK OCCURS, E.G. THE WORKSTA-TION(S)

USED AND EXHAUSTED MATERIAL HAZARD

HAZARDS GENERATED BY MATERIALS AND SUBSTANCES PROCESSED, USED OR EXHAUSTED BY MACHINERY

HYDRAULIC SYSTEMS, PNEUMATIC SYSTEMS AND THEIR CONTROLS, TOXIC WORK MATERIALS

FIRE OR EXPLOSION HAZARD

FIRE OR EXPLOSION HAZARD EXHAUST VENTILATION AND DUST COLLECTION EQUIPMENT



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7. TECHNICAL CHARACTERISTICS

AUTOMATIC PRESS MODEL PAE 63/250

Power 630 kN

Distance table center – body 270 mm

Tool table length 740 mm

Tool table width 510 mm

Tool table thickness 90 mm

Slide base 500 x 300 mm

Throat gap 350 mm

Maximum distance between slide and tool table 395 mm

Fixed crankshaft stroke 140 mm

Strip width 110 – 320 mm

Maximum strip feeding 240 mm

Strokes per strip 4 - 16

Maximum strip length 1050 mm

Maximum draw depth 60 mm

Slide adjustment 60 mm

Feeder adjustment (from center of the press to gap) 60 mm

Minimum distance between tool table and feeder table 90 mm

Maximum distance between tool table and feeder table 150 mm

Maximum cutting area (double die with scroll cut) 163 mm

Motor power 11 kW / 1500 rpm

Electrical tension 380 V / 50-60Hz

Strokes per minute (variable by frequency converter) 100 % = 100 str/min



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TECHNICAL CHARACTERISTICS

AUTOMATIC PRESS MODEL PAP 200 E

Power 200 kN

Distance table center – body 220 mm

Tool table length 620 mm

Tool table width 430 mm

Tool table thickness 65 mm

Base of slide 355 x 220 mm

Throat gap 300 mm

Maximum distance between slide and tool table 335 mm

Slide adjustment 50 mm

Opening on tool table 375 x 150 mm

Motor power 5 kW / 900 rpm

Electrical tension 380 V / 50-60Hz

Strokes per minute (variable by frequency converter) 30 % = 100 str/min



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8. ELECTRICAL SYSTEM

The redraw line electrical system is composed by:

DRAW PRESS PAE 63/250

- Button panel with touch screen- Emergency buttons- Security switches on the protections- Alarm sensors on feeder- Double sheet sensor- Sheet detectors on the tool table- Optical sensors for the can exit control- Temperature sensor on the slide- Press speed controlled by frequency converter- Encoder connected to the crankshaft

TRIMMER PRESS PAP 200 E

- Button panel- Emergency button- Security switches on the protections- Connection for line signal after press (see electrical manual under line signal)- Press speed controlled by frequency converter- Encoder connected to the crankshaft

ELECTRICAL CABINET

- Touch screen- Programmable logical controller- Frequency converters- Solid-state relays for output signals- Communication system

The constructor warns you that, changes in the electrical and electronic system can only be made by qualified technicians

Read the electrical manual



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9. AUTOMATIC LUBRICATION SYSTEM

The presses are equipped with an automatic lubrication system.

A pressostate controls the pressure level during each lubrication cycle.

A pressure lack during a lubrication cycle stops the machine. The fault is sig -nalised by a flashing red light on the control panel and it can be visualised at the touch screen.

All distributors control pistons should move during one lubrication cycle.


The draw press feeder has one mechanical oil pump. The lubrication here is al-ways made when the machine is running.

LINCOLN lubrication system and feeder: BP CS 150 or equivalent

Lubrication cycle: 10 min – time of clutch connected(Adjusted on touch screen adjustments – lubrication adjustments)

Lubrication time: 2,5 seconds


LINCOLN lubrication system and feeder: BP ENERGREASE LS-3 or equivalent

Lubrication cycle: 30 min – time of clutch connected(Adjusted on touch screen adjustments – lubrication adjustments)

Lubrication time: 2,5 seconds

CAUSES OF A LUBRICATION PROBLEM

- Lubricant lack in the tank- Rupture of a pipe or union- Pressostate problem- Lack of compressed air

Make attention to have lubricant without dirt



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10. PNEUMATIC SYSTEM

INTRODUCTION / GENERALITY’S

Fault diagnosis involves a methodical and logical approach towards solving a

problem. Faults within fluid power systems may occur due to:

External failure, i.e. within the machine or process itself,

Failure of the fluid power system.

FAULT DIAGNOSIS – CAUSES AND EFFECTS OF MALFUNCTIONS

In general, malfunctions of a system fall into the following categories:

1. Wear and tear on components and lines, which can be accelerated by envi -

ronmental influences:

Quality of compressed air,

Relative motion of components,

Incorrect load of components,

Incorrect maintenance or more usually the lack of maintenance,

Incorrect mounting and connection (i.e. signal lines are too long).

2. These conditions can lead to the following malfunctions or failures of the sys-

tem:

Seizure of units,

Breakages,

Leakages,



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Pressure drop,

Incorrect switching.

SAFETY RULES

Before working on any circuit lower off or chock up any cylinder which could

allow a load to fall,

Ensure that no unauthorized person can switch air on or off the system,

In no circumstances block an air line by hand as air can penetrate the skin.

Use a stop valve to switch air on or off,

Loose air lines can fly about under air pressure. It is sufficient just to crack a

joint to determine if a line is pressurized,

If an electrical fault suspected, a qualified electrician should check the elec-

trical systems,

In no circumstances must mechanical trip valves be operated by hand. A screwdriver blade, spanner, etc, may be used.

MALFUNCTIONS CAUSED BY UNDERSIZED AIR SUPPLY PNEUMATIC SYSTEMS

Frequently, sections of pneumatic systems are extended without enlarging the

necessary air supply. Depending on the sequence and design of the plant sec-

tion, malfunctions then occur not continuously; with the result that faultfinding is

made increasingly difficult.

Two possible effects that can arise are:

The piston rod speed is not always correct, since the actuation of additional

components can cause sodden pressure drops,



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The force at the power cylinder drops for a short time during a pressure

drop.

The same symptoms may occur as a result of the changes in orifice cross-sec-

tions caused by contamination or by leaks at connectors which have worked

loose (for example, a reduction in diameter of 20 per cent means a doubling of

pressure drop).

MALFUNCTIONS CAUSED BY CONDENSATE WITHIN PNEUMATIC SYSTEMS

It is essential to ensure that the compressed air fed into the network is free of

condensate. Apart from the corrosive damage to surfaces by condensate, which

is, in many cases, extremely aggressive, there is the considerable danger of

seizure of valve components if they need to be reset by spring force after being

held in one switching position for a considerable time. Lubricants without addi-

tives have a tendency to emulsify and create resin or gumming. All close-toler-

ance sliding fits in valves are particularly susceptible to these resistances to

movement.

MAINTENANCE OF PNEUMATIC SYSTEMS

For pneumatic systems, the following regular maintenance routines are recom-mended:

Check the filter and service units – drain water regularly from traps and

replenish and adjust lubricators,

Discuss with operators of the system any noted difference in perfor-

mance or unusual events,

Check for air leaks, crimped air-lines or physical damage,

Check signal generators for wear or dirt,



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Check cylinder bearings and mountings.

EVERY DAY

Drain condensate from the filters if the air as a High water content, if no auto-

matic condensate drainage has been provided. Check the oil level in the com-

pressed air lubricator and check the setting of oil metering.

EVERY WEEK

Check signal generators for possible deposits of dirt or swarf. Check the pres-

sure gauge of the pressure regulators. Check that the lubricator is functioning

correctly.

EVERY TREE MONTHS

Check the seals of the connectors for leaks. If necessary, re-tighten the connec-

tors. Replace lines connected to moving parts. Checks exhaust ports of the

valves for leaks. Clean filter cartridges with soapy water (do not use solvents)

and blow them out with compressed air in the reverse of the normal flow direc-

tion.

EVERY SIX MONTHS

Check the rod bearings in the cylinders for wear and replace if necessary.

Also replace the scraper and sealing rings.



REFERENCE MANUAL

GENERAL INFORMATION OF PNEUMATIC SYSTEM

The presses are equipped with a centralised pneumatic system, type CPV mini,

from FESTO, with exception to the clutch command.

C type valves are for blow valves

M type valves are for cylinder operation

The electrical tension is 24 V DC (direct current)

Clutches: HERION valves, electrical tension 220 V AC (alternated current)


General network pressure: 5,5 bar

Vacuum Venturi valve: 4 bar

Exit blowers: 3-3,5 bar

Pressostate adjustment: 4,5 bar

Pneumatic connection: ½ “ – 13 mm pipe

Air preparation filter: 40 micron


General network pressure: 5,5 bar

Exit blowers: 2-2,5 bar

Pressostate adjustment: 4,5 bar

Pneumatic connection: ½ “ – 13 mm pipe

Air preparation filter: 40 micron

Never replace the FESTO modules by another individual valve of another

brand, because they can damage the PLC. The FESTO valves are dir-

ectly connected to the PLC inputs without any relay to obtain a higher re-

sponse speed.



REFERENCE MANUAL

11. SPUR GEARSFor the adjustment of the number of strokes per sheet we need to change the spur gears.The spur gears have two relations. One is fixed (Z1 and Z2) the other is variable (Z3 and Z4). Only the variable relation is changed by changing one or two wheels.In the following table we can see the relation between Z3 and Z4 for the differ-ent number of strokes per sheet.

SPUR GEARSZ3 AND Z4

NUMBERSTROKES / STRIP Z3 Z4

4 60 605 40 506 40 607 40 708 40 809 40 9010 40 10011 28 7712 28 8413 28 9114 24 8415 24 9016 24 96


Z2

Z3 = PAR 175Z1

Z4 = PAR 181

FIXED GEAR TRANSMITION: Z1Z2

14

25100

= =


REFERENCE MANUAL



REFERENCE MANUAL

12. BUTTON PANELS

In this point we have a small description of the three button panels.

DRAW PRESS - BUTTON PANELS

B4 / B5 – This two buttons must be pressed at the

same time to activate the clutch. How the machine

works depends on the selected work mode.

B3 – This emergency button stops the trimmer press.

SH15 – Stop or start the trimmer press flywheel.

B6 – This button stops the machine in the upper dead center.



REFERENCE MANUAL

TRIMMER PRESS - BUTTON PANELS

B4 / B5 – This two buttons must be pressed at the

same time to activate the clutch. How the machine

works depends on the selected work mode.

B3 – This emergency button stops the trimmer press.

SH15 – Stop or start the trimmer press flywheel.

B6 – This button stops the machine in the upper dead center.

B13 – Activating manually the lubrication.



REFERENCE MANUAL


B8 – Starting the draw press flywheel

B9 – Stopping the draw press flywheel

H1 - This lamp indicates if we have minimum level at the trimmer press input.

H2 – When this lamp is flashing we have maximum level at the trimmer press output.

S24 – This makes the reset to all existing alarms. When we have one alarm only resetting it allows us to put the machine again to work.



REFERENCE MANUAL


S36 – With this selector we choose the work mode. The available modes are:1 – MANUAL MODE: here we can only activate the clutch without flywheel and then move the machine by hand2 – IMPULSE MODE: moving the machine by impulse (S33 and S34)3 – 1 CYCLE: the machine makes one work cycle stopping in the upper dead center4 – AUTOMATIC: this puts the machine in automatic mode (continuous work mode)



REFERENCE MANUAL


DRAW PRESS BUTTON PANEL


REFERENCE MANUAL


TRIMMER PRESS BUTTON PANEL


REFERENCE MANUAL

13. TOUCH SCREEN ADJUSTMENTS

The next point informs you about the possible adjustments of the press. All val-

ues in the touch screen are in angles or time. The angle value is transmitted to

the PLC by the encoder that gives us the position of the crankshaft and so of

the position of the tool.

ONE TURN OF THE CRANKSHAFT CORRESPONDS TO:

360 degrees encoder version 360 degrees


The maximum opening position are 0 degrees – upper dead center

The maximum closed position are = Lower dead center



UPPER DEAD CENTER (PAE 63, PAP 200)

Access: MENU ENCODER ADJUSTMENTS

This value is adjusted before the upper dead center so that the machine never

stops on the real upper dead center but with the inertia a little after.

LOWER DEAD CENTER (PAE 63)


This value is adjusted before the lower dead center.

The passage trough the lower dead center when we have at the same time the

presence of sheet in the tool starts the can exit control



REFERENCE MANUAL

CAN EXIT CHECK – LEFT / RIGHT (PAE 63)


THE CAN EXIT CHECK STARTS WHEN:

PAE 63

1. The sensor on the tool table detects sheet on the tool

2. And there is a passage trough the lower dead center

The drawn can must be detected by the optical barrier before the maximum

angle value (OFF). When at this value the can didn’t came out the machine

stops with the can exit control error. This machine should stop before it

smashes the next can.

EXIT BLOWER LEFT / RIGHT (PAE 63, PAP 200)


This value is adjusted slightly after the lower dead center until the complete exit

of the can.

If we don’t need this function we can use same values for the angle. For ex-

ample 000 – 000.

CAN BRAKE LEFT /RIGHT (PAP 200)


In this point we define the range of operation of the cylinders in the can feeding

system.



REFERENCE MANUAL

DRAW PRESS PAE 63 Encoder 360Degrees

START STOPUpper dead center 300 340Lower dead center 175 185Cup exit check 15 25Left exit blower 230 330Right exit blower 230 330

These adjustments are for 100 str/min. For a different speed it’s possible to

have some adjustments to some values.

TRIMMER PRESS PAP 200 Encoder 360Degrees

START STOPUpper dead center 300 345Left can feeder 180 240Right can feeder 180 240Left can exit blower 145 220Right can exit blower 145 220

DRAW PRESS PAE 63 Encoder 1000Degrees

START STOPUpper dead center 830 945Lower dead center 485 505Cup exit check 80 150Left exit blower 665 830Right exit blower 665 830

These adjustments are for 100 str/min. For a different speed it’s possible to

have some adjustments to some values.



REFERENCE MANUAL

TRIMMER PRESS PAP 200 Encoder 1000Degrees

START STOPUpper dead center 915 950Left can feeder 500 665Right can feeder 500 665Left can exit blower 500 720Right can exit blower 500 720

LUBRICATION (PAE 63, PAP 200)

Access: MENU LUBRICATION ADJUSTMENTS

In this part we adjust the lubrication of the machine. This value must be adjus-

ted considering the local temperature of the machine work place. The lubrica-

tion time is adjusted at 2,5 seconds. When we have a lack of pressure during

the lubrication the machine will give a warning.

SPEED ADJUSTMENT (PAE 63, PAP 200)

Access: MENU LINE SPEED

Here we can change the work speed of the presses and of the air conveyors. Al

changes made here are immediately written in the frequency converter. The

typical value is about 100 str/min for the presses. A little more on the trimming

press than in the redraw press and here a little more than in the draw press. So

it is more difficult to have accumulation at the input of one machine.



REFERENCE MANUAL

14. TOUCH SCREEN MENU STRUCTURE

In this point we will explain some features of each screen and how to make

changes to the values.

B1 MAIN MENU

This is the main screen. It is always with base on this screen that we access all

other screens.

From this screen we have access to the following screens and menus:

MACHINE MONITOR (B10) ADJUSTMENTS (B20) PRODUCTION COUNTERS (B30) ALARMS (B40)

Pressing DE CEPEDA logo we change to the presentation screen (B2).

We have also some information about the time and date.


MACHINE MONITOR

ADJUSTMENTS

PRODUCTION COUNTERS

ALARMS

MAIN MENUHH:MM DD/MM/YY

COPYRIGHT © 2001 – 2002 CERLEI


REFERENCE MANUAL

B2 PRESENTATION

This is the presentation screen, pressing any point we go back to the main

menu (B1).

Here we have information about contacting with CERLEI.


CERLEI – MÁQUINAS INDUSTRIAIS, S.A.RUA DR. AFONSO CORDEIRO, 674P- 4450-007 MATOSINHOS PORTUGALTEL: +351 22 9398320FAX: +351 22 [email protected]

COPYRIGHT © 2001 – 2002 CERLEI

DRAWLINE


REFERENCE MANUAL

B10 MACHINE MONITOR

In this screen we monitor some values related to the machine work. The values we can see in this screen are:

LINE SPEED Information about the selected line speed

DRAW PRESS SPEED Let us know the draw press speed

TRIMMER PRESS SPEED Let us know the trimmer press speed

UPPER SLIDE Temperature value of the draw press upper slide

LOWER SLIDE Temperature value of the draw press lower slide

Here we can see in which operation mode the machine is.

CONVEYORS ON / OFFFLYWHEEL ON / OFFVACUUM ON / OFFLUBRICATION ON / OFF

With this buttons we can switch on/off the conveyor, the draw press flywheel motor and the feeding.


MACHINE MONITOR

DRAW PRESS0.0 Hz

0 str / minUPPER SLIDE 0.0 ºCLOWER SLIDE 0.0 ºC

TRIMMER PRESS0.0 Hz

0 str / min

MACHINE SPEEDS AND TEMPERATURES

MENU ALARMS EXITEV. TESTMANUAL

ON

OFF

ON

OFF

CO

NVE

YOR

S

ON

OFF

WORKMODE

CERLEIMÁQUINAS INDUSRIAIS

FLYW

HEE

L

VAC

UU

M

ON

OFF

LUB

RIC

ATIO

N


REFERENCE MANUAL

From this screen we can change to the following screens:

MANUAL: Change to the manual and reverse mode screen (B12)

ELECTROVALVES TEST: Change to the elect. test screen (B11)

MENU: Return to the main menu (B1)

ALARMS: See the existing alarms on the machine (B40)

EXIT: Pressing this button we go back to the previous screen



REFERENCE MANUAL

B11 ELECTROVALVES TEST

In this screen we can actuate manually all electro valves of the draw press. With exception of the lubrication electro valve it is necessary to have one emergency button pressed to activate manually the electro valves. The lubrication electro valve only works when there is no emergency pressed.






ELECTROVALVES TEST

MENU ALARMS EXIT

LEFT INPUT BLOWER

LEFT CAN BRAKE

LEFT CAN HOLDER

LEFT CAN POSITIONER

LEFT CAN EXTRACTOR

LEFT EXIT BLOWER

COUNTER BALANCE LUB.

RIGHT INPUT BLOWER

RIGHT CAN BRAKE

RIGHT CAN HOLDER

RIGHT CAN POSITIONER

RIGHT CAN EXTRACTOR

RIGHT EXIT BLOWER

GENERAL LUBRICATION

1 /2


REFERENCE MANUAL

B12 MANUAL AND REVERSE MODE

In this screen we can select the manual mode or we can select de reverse mode. It is only possible to have one of these modes selected.






MANUAL MODEON

OFF

ON

OFF

REVERSE MODEMENU

ALARMS

EXIT


REFERENCE MANUAL

B13 ELECTROVALVES TEST

In this screen we can actuate manually all electro valves of the draw press. With exception of the lubrication electro valve it is necessary to have one emergency button pressed to activate manually the electro valves. The lubrication electro valve only works when there is no emergency pressed.






ELECTROVALVES TEST

LEFT FEEDER

LEFT EXIT BLOWER

GENERAL LUBRICATION

RIGHT FEEDER

RIGHT EXIT BLOWER

MENU

ALARMS

EXIT2 /2


REFERENCE MANUAL

B20 ADJUSTMENTS MENU

This screen allows us to access all other settings and adjustment screens:

SPEED SELECTION (B21)

ENCODER SETTINGS (B23)

LINE LEVEL TIMERS (B26)

LUBRICATION TIMERS (B27)

To access one of the adjustment screens for the draw press the emergency but-

ton must be pressed. To change the values the emergency button warning must

be recognised (pressing the reset alarm button).


MONITOR: Go to the monitor screen (B10)





SPEED SELECTION

ENCODER SETTINGS

LINE LEVEL TIMERS

LUBRICATION TIMERS

ADJUSTMENTS

MENU ALARMS EXITMONITOR

TRIMMER ENCODER


REFERENCE MANUAL

B21 SPEED SELECTION 1

In this screen we have the graphical presentation of the redraw press and out -put conveyor speeds. The speeds are given in frequency (Hz) and are at the moment the operation frequency in the converters. This menu allows us also to change the speed.We move between the fields with the arrows, to enter a value we press the enter key.We can also see the number of strokes per minute in the redraw press.







SPEED SELECTION

MENU ALARMS EXITMONITOR1 /2

2000

%

0.0 Hz

0.0 %

DRAW PRESS

0 STROKES / min.

2000

%

0.0 Hz

0.0 %

EXIT CONVEYOR


REFERENCE MANUAL

B22 SPEED SELECTION 2

In this screen we have the graphical presentation of the trimmer press. The speeds are given in frequency (Hz) and are at the moment the operation fre-quency in the converters. This menu allows us also to change the speed.We move between the fields with the arrows, to enter a value we press the enter key.We can also see the number of strokes per minute in the trimmer press.







SPEED SELECTION


2000

%

0.0 Hz

0.0 %

TRIMMER PRESS

0 STROKES / min.


REFERENCE MANUAL

B23 ENCODER ADJUSTMENTS 1

This menu gives us the possibility of adjusting the operation range of the valves and can exit check of the draw press. We have always the start point and the end point for each range.

We move between the fields with the arrows, to enter a value we press the enter key.

LEFT OUTPUT BLOWER: Range where we operate the left output blower

RIGHT INPUT BLOWER: Range where we operate the right output blower

LEFT OUTPUT CONTROL: This is the point where we feed the press activating the left output control

RIGHT OUTPUT CONTROL: This is the point where we feed the press activating the right output control

LEFT EXTRACTOR: range where we define the operation range of the left extractor

RIGHT EXTRACTOR: range where we define the operation range of the right extractor


ENCODER ADJUSTMENTS


START STOP

LEFT OUTPUT BLOWER 0 0

RIGHT OUTPUT BLOWER 0 0

LEFT OUTPUT CONTROL 0 0

RIGHT OUTPUT CONTROL 0 0

LEFT EXTRACTOR 0 0

RIGHT EXTRACTOR 0 0

E: 0G: 0


REFERENCE MANUAL








REFERENCE MANUAL


This menu gives us the possibility of adjusting the operation range of the valves

and can exit check of the draw press. We have always the start point and the

end point for each range.


LEFT TOOL BLOWER: In this field we adjust the operating range of the

left tool blower

RIGHT TOOL BLOWER: In this field we adjust the operating range of

the right tool blower

SHEET LUBRICATION: Corresponds to the point where we adjust the

sheet lubrication

SHEET SEPARATOR: Corresponds to the point where the we adjust the

sheet separator


ENCODER ADJUSTMENTS


STARTSTOPLEFT TOOL BLOWER00RIGHT TOOL BLOWER00SHEET

LUBRICATIONE:00G:00SHEET SEPARATOR E:00G:00

E: 0

G: 0OFF

OFF


REFERENCE MANUAL








REFERENCE MANUAL


This menu gives us the possibility of adjusting the operation range of the valves and can exit check of the draw press. We have always the start point and the end point for each range.


VACUUM: corresponds to the point where we adjust the vacuum of the press

VACUUM BAR: corresponds to the point where we adjust the vacuum bar

SCRAPS EXPULSOR: corresponds to the point where we adjust the scraps expulsor.







ENCODER ADJUSTMENTS


START STOP

VACUUME: 0 0

G: 0 0

VACUUM BAR E: 0 0

G: 0 0

SCRAPS EXPULSOR E: 0 0

G: 0 0

E: 0

G: 0

OFF


REFERENCE MANUAL

B26 ENCODER ADJUSTMENTS

This menu gives us the possibility of adjusting the operation range of the valves

and can exit check of the redraw press. We have always the start point and the

end point for each range.


LEFT EXIT BLOWER: corresponds to the point where we adjust the trimmer press left exit blower

RIGHT EXIT BLOWER: corresponds to the point where we adjust the trimmer press right exit blower

LEFT FEEDER: corresponds to the operation range of the pistons that make the can feeding of the left side

RIGHT FEEDER: corresponds to the operation range of the pistons that make the can feeding of the right side

SCRAPS BLOWER: corresponds to the point where we adjust the trim-mer press scrap blower


ENCODER ADJUSTMENTS


TRIMMER PRESS START STOP

LEFT EXIT BLOWER 0 0

RIGHT EXIT BLOWER 0 0

LEFT FEEDER 0 0

RIGHT FEEDER 0 0

SCRAPS BLOWER 0 0

E: 0


REFERENCE MANUAL








REFERENCE MANUAL

B27 LINE LEVEL TIMERS

In this screen we can adjust the timing of the maximum and minimum level.

The maximum level on the trimmer press output is an external signal.







LINE LEVEL TIMERS


ON OFF

TRIMMER PRESS INPUT MAXIMUM 0.0 0.0

TRIMMER PRESS INPUT MINIMUM 0.0 0.0

TRIMMER PRESS OUTPUT MAXIMUM 0.0 0.0


REFERENCE MANUAL

B28 LUBRICATION TIMERS 1

Here we can adjust the time between lubrications on the draw press.We move between the fields with the arrows, to enter a value we press the enter key.







LUBRICATION TIMERS


DRAW PRESS GENERAL LUBRICATION

LUBRICATION TIMING0TIME TO NEXT LUBRICATION0LUBRICATION TIME0.0TIME IS IN MINUTES

TIME IS IN SECONDS

GENERAL LUBRICATION


REFERENCE MANUAL

B29 LUBRICATION TIMERS 2

Here we can adjust the time between lubrications on the trimmer press.We move between the fields with the arrows, to enter a value we press the enter key.







LUBRICATION TIMERS


TRIMMER PRESS GENERAL LUBRICATION

LUBRICATION TIMING0TIME TO NEXT LUBRICATION0LUBRICATION TIME0.0TIME IS IN MINUTES

TIME IS IN SECONDS

GENERAL LUBRICATION


REFERENCE MANUAL

B30 DRAW PRESS PRODUCTION COUNTER

In this screen we can see the production of cans, partial or total, of the redraw press. We see also the number of sheets drawn on the press.







DRAW PRESS PRODUCTION COUNTER


PARTIAL TOTAL

SHEETS 0 0

LEFT OUTPUT 0 0

RIGHT OUTPUT 0 0

TOTAL OUTPUT 0 0


REFERENCE MANUAL

B40 RESET ALARMS

In this screen we can see all the alarms from the machine. With the arrows we can move up and down between the messages. The program changes auto-matically each time a new alarm occurs. To acknowledge an alarm or to reset it we need to press the reset alarm button.

With the arrow button we can exit to the previous screen. The program only al -lows this when all existing alarms are acknowledged or when there are no alarms in the system.






RESET ALARMS

MONITOR MENU EXIT

DRAW PRESS OUTPUT CONVEYOR TRIPSTRIP EJECTOR TERMICAL PROTECTIONSTRIP EJECTOR SECURITYSHEET FEEDER OIL PRESSUREDOUBLE SHEETDRAW PRESS LUBRICATION PRESSUREDRAW PRESS UPPER SLIDE HIGH TEMPERATUREDRAW PRESS LOWER SLIDE HIGH TEMPERATUREDRAW PRESS LEFT OUTPUT JAMDRAW PRESS RIGHT OUTPUT JAM


REFERENCE MANUAL

B41 ALARMS HISTORY

In this screen we can see all the alarms history from the machine. With the ar-rows we can move up and down between the messages. The program changes automatically each time a new alarm occurs.







ALARMS HISTORY

MONITOR MENU EXIT


REFERENCE MANUAL

B42 ALARMS FREQUENCY

In this screen we can see all alarms frequency from the machine. With the ar-rows we can move up and down between the messages. The program changes automatically each time a new alarm occurs.







ALARMS FREQUENCY

MONITOR MENU EXIT


REFERENCE MANUAL

15. FREQUENCY CONVERTERS PARAMETERS

DRAW PRESS MOTOR FREQUENCY CONVERTERPARAMETER FUNCTION VALUE

0.00 Macro Selection, Configuration, Saving 00.01 Minimum Frequency 0.00.02 Maximum Frequency 100.00.03 Acceleration Rate 0.00.04 Deceleration Rate 0.00.05 Reference Selector 00.06 Current Limit 150.00.07 Voltage Mode Selector Fd0.08 Boost Voltage 3.00.09 Dynamic V/F Select bit 00.10 Estimated Motor Speed —0.11 Pre-Ramp Reference —0.12 Pst-Ramp Reference —0.13 Motor Active-Current —0.14 Jog Reference 50.00.15 Ramp Mode Selector FAST0.16 Stopping Mode Selector rP0.17 Torque Mode Selector 00.18 S-Ramp Enable bit 10.19 S-Ramp Da/Dt Limit 180.00.20 Skip Frequency 1 0.00.21 Skip Band 1 0.50.22 Skip Frequency 2 0.00.23 Skip Band 2 0.50.24 Analog Input 1 Mode Selector VOLT0.25 Analog Input 2 Mode Selector VOLT0.26 Analog Input 2 Destination Selector 1.370.27 Eur> Positive Logic Select Bit 00.28 Eur> Current-Loop Proportional Gain 200.29 Eur> Current-Loop Integral Gain 400.30 Fwd/Rev Key Enable Bit 00.31 Macro Number 00.32 Serial S. Mode ANSI 40.33 Drive Rated Current (Flc) 25.000.34 User Security Code 1490.35 Keypad Reference 0.0



REFERENCE MANUAL

PARAMETER FUNCTION VALUE0.36 Serial Comms, Baud Rate 96000.37 Serial Comms. Address 1.10.38 Initial Parameter Displayed 0.100.39 Synchronize To A Spinning Motor Bit 00.40 Auto tune Bit 00.41 Pwm Switching Frequency Selector 30.42 Motor- Number Of Poles 4 POLE0.43 Motor- Power Factor 0.9200.44 Motor- Rated Voltage 4000.45 Motor- Rated Speed 14400.46 Motor- Rated Current 23.500.47 Motor- Rated Frequency 50.00.48 Drive Software Built Number 50.49 Security Status 10.50 Drive Software Version 3.01



REFERENCE MANUAL

TRIMMER PRESS MOTOR FREQUENCY CONVERTERPARAMETER FUNCTION VALUE

0.00 Macro Selection, Configuration, Saving 00.01 Minimum Frequency 0.00.02 Maximum Frequency 100.00.03 Acceleration Rate 0.00.04 Deceleration Rate 0.00.05 Reference Selector 00.06 Current Limit 1500.07 Voltage Mode Selector Fd0.08 Boost Voltage 3.00.09 Dynamic V/F Select BIT 00.10 Estimated Motor Speed —0.11 Pre-Ramp Reference —0.12 Pst-Ramp Reference —0.13 Motor Active-Current —0.14 Jog Reference 45.00.15 Ramp Mode Selector Stnd.Ct0.16 Stopping Mode Selector rP0.17 Torque Mode Selector 00.18 S-Ramp Enable bit 10.19 S-Ramp Da/Dt Limit 1800.20 Skip Frequency 1 0.00.21 Skip Band 1 0.50.22 Skip Frequency 2 0.00.23 Skip Band 2 0.50.24 Analog Input 1 Mode Selector Volt0.25 Analog Input 2 Mode Selector Volt0.26 Analog Input 2 Destination Selector 1.370.27 Eur> Positive Logic Select bit 00.28 Eur> Current-Loop Proportional Gain 200.29 Eur> Current-Loop Integral Gain 400.30 Fwd/Rev Key Enable bit 00.31 Macro Number 00.32 Serial Comms. Mode ANSI 40.33 Drive Rated Current (Flc) 9.500.34 User Security Code 1490.35 Keypad Reference 0.00.36 Serial Comms, Baud Rate 9600



REFERENCE MANUAL

PARAMETER FUNCTION VALUE0.37 Serial Comms. Address 1.20.38 Initial Parameter Displayed 0.100.39 Synchronize To A Spinning Motor bit 00.40 Auto tune bit 00.41 Pwm Switching Frequency Selector 30.42 Motor- Number Of Poles 8 Pole0.43 Motor- Power Factor 0.8840.44 Motor- Rated Voltage 4000.45 Motor- Rated Speed 7500.46 Motor- Rated Current 9.50.47 Motor- Rated Frequency 50.00.48 Drive Software Build+B22 Number 50.49 Security Status 10.50 Drive Software Version 3.01



REFERENCE MANUAL

DRAW PRESS EXIT CONVEYOR FREQUENCY CONVERTERPARAMETER FUNCTION VALUE

P0 Minimum Frequency 0P1 Maximum Frequency 100P2 Acceleration Time 2.0P3 Deceleration Time 2.0P4 Timed Current Limit 100P5 Maximum Continuous Current 100P6 Torque (Voltage) Boost 5.1P7 Slip Compensation 0P8 Dc Injection Brake Current 150P9 Serial Address 21Pa Fail Log --Pb Security Code 0B0 Speed And Torque Reference Selector 1B1 Automatic Or Manual Start Selector 1B2 Stopping Mode Selector 0B3 Low Speed Torque Boost Selector 0B4 Bipolar Select 1B5 Logic Selector 1B6 Speed Reference Selector 1B7 Stopping Mode Selector 0B8 Display Mode Selector 0B9 Terminal Or Keypad Mode Selector 1

B10 Display Time-Out Mode 0B11 Remote Reference Input Selector 4.20B12 Baud Rate Selector 9.6B13 Parameters Reset 0B14 Switching Frequency And Frequency Range Selector 2.9Pc Maximum Voltage Frequency 50.0Pd Menu Selector (Final Select) 0

P10 Skip Frequency 1 0P11 Skip Frequency 2 0P12 Skip Frequency 3 0P13 Skip Bandwidth 1 0.5P14 Skip Bandwidth 2 0.5P15 Skip Bandwidth 3 0.5P20 Preset Speed 1 50.0P21 Preset Speed 2 0



REFERENCE MANUAL

PARAMETER FUNCTION VALUEP22 Preset Speed 3 0P23 Preset Speed 4 0P24 Preset Speed 5 0P25 Preset Speed 6 0P26 Preset Speed 7 0P27 Jog 1.5B20 Preset Speed Selector 0B21 Preset Ramp Selector 0B22 Preset Speed Reversal Selector 0B23 Preset Ramp Selector 0B24 Analog Output Selector 0B25 Analog Output Selector 0B26 Current Loop Lost 0B27 Normal Running Ramp 0B28 Pi Control 0P30 Preset Acceleration 1 5.0P31 Preset Acceleration 2 5.0P32 Preset Acceleration 3 5.0P33 Preset Acceleration 4 5.0P34 Preset Acceleration 5 5.0P35 Preset Acceleration 6 5.0P36 Preset Acceleration 7 5.0P37 Jog Acceleration 0.2P40 Preset Deceleration 1 10.0P41 Preset Deceleration 2 10.0P42 Preset Deceleration 3 10.0P43 Preset Deceleration 4 10.0P44 Preset Deceleration 5 10.0P45 Preset Deceleration 6 10.0P46 Preset Deceleration 7 10.0P47 Jog Deceleration 0.2P50 Number Of Reset Attempts 0P51 Reset Delay 1.0B50 Status Relay Selector 1B51 Fwd/Rev Key 0B52 Catch A Spinning Motor 0B53 Status Output Selector 0B54 Voltage-Frequency Ratio 0B55 Not Used 0B56 Deceleration Selector For Non-Important Trips 0



REFERENCE MANUAL

16. TROUBLESHOOTING

1 DRAW PRESS FREQUENCY INVERTER DOWN

The draw press frequency converter has a trip error. This can be because of: Bad adjustment of some parameters (Acceleration, Braking) Over tension Over current (Overcharge) To high speed for the motor Read the trip code and see in the frequency converter manual for more

details about the error

3 AIR CONVEYER ON EXIT OF DRAW PRESS DOWN

The air conveyor (exit of draw press) frequency converter has a trip error. This can be because of:

Bad adjustment of some parameters (Acceleration, Braking) Over tension Over current (Overcharge) To high speed for the motor Read the trip code and see in the frequency converter manual for more


4 STRIP FEED ON DRAW PRESS

The protection of the draw press strip feeder is open If the protection is closed verify the correct operation of the security

switch

6 LOW AIR PRESSURE ON DRAW PRESS

Low air pressure alarm on the draw press Check if the compressor is working Check if there are some air leak Check the pressure level on the manometers Check all security valves and taps Check the correct functioning and adjustment of the pressostate



REFERENCE MANUAL

7 GENERAL LUBRICATION ERROR ON DRAW PRESS

Low-pressure alarm during the lubrication of the draw press Check if the compressor is working Check if there are some air leak Check the pressure level on the manometers Check all security valves and taps Check the correct functioning and adjustment of the pressostate Check the correct functioning of the automatic oil pump

8 DOUBLE SHEET DETECTOR

Double sheet detection. Check if there are two sheets on the entrance of the draw press. If there

is only one sheet check the adjustment of the double sheet detector.

9 STRIP FEED COVER OPEN

The strip holder on the draw press is open. If the strip holder is closed verify the correct operation of the security

switch

10 LOW OIL PRESSURE ON STRIP FEED OF DRAW PRESS

Low-pressure alarm on the draw press feeder lubrication system. Check if there are some pressure leaks Check the correct functioning and adjustment of the pressostate Check the correct functioning of the automatic oil pump If the machine works at a low speed it’s possible that the pressure is not

enough to activate the pressostate

11 EMERGENCY ON STRIP FEED OF DRAW PRESS

The emergency button on the body of the draw press was pressed (over the feeder).

If the button is not pressed check the correct functioning of the button



REFERENCE MANUAL

12 EMERGENCY ON DRAW PRESS

The emergency button on the body of the draw press was pressed (near the exit conveyor).

If the button is not pressed check the correct functioning of the button

13 COVER SENSOR ON DRAW PRESS

The protection of the draw press tools is open

If the protection is closed verify the correct operation of the security switch

14 SENSOR ON FEEDER-TRANSPORT DRAW PRESS

The safety sensor on the sheet transporter detected a problem.

Check if there is some problem with the vacuum system of the draw press

Check if the sensor is correctly placed and adjusted Check the correct operation of the sensor

15 CUP EXIT CHECK ON LEFT DIE OF DRAW PRESS

The can exit check on left side of the draw press was not confirmed

See if the can is somewhere in the die or tool This error happens normally when the can doesn’t come out correctly,

maybe it’s necessary to adjust the exit blowers and the position of the ex-tractor

Check if the photocell is clean and if she is correctly positioned When this error occurs lot’s of times without apparent reason then you

must check the range of the encoder where the exit check is done



REFERENCE MANUAL

16 CUP EXIT CHECK ON RIGHT DIE OF DRAW PRESS

The can exit check on right side of the draw press was not confirmed See if the can is somewhere in the die or tool This error happens normally when the can doesn’t come out correctly,

maybe it’s necessary to adjust the exit blowers and the position of the ex-tractor

Check if the photocell is clean, working correctly and if she is correctly positioned

When this error occurs lots of times without apparent reason then you must check the range of the encoder where the exit check is done.

17 CUP EXIT BLOCKED ON LEFT DIE OF DRAW PRESS

We have an accumulation of cans on the draw press left exit Check if you have an accumulation near the photocell Check if the photocell is clean, working correctly and if she is correctly

positioned This error can be also because the can doesn’t exit correctly and stays to

long time in front of the photocell

18 CUP EXIT BLOCKED ON RIGHT DIE OF DRAW PRESS

We have an accumulation of cans on the draw press right exit Check if you have an accumulation near the photocell Check if the photocell is clean, working correctly and if she is correctly

positioned This error can be also because the can doesn’t exit correctly and stays to

long time in front of the photocell

19 VERTICAL FEEDER LEFT ON DRAW PRESS

The safety sensor on the left bar of the vertical sheet transporter detected a problem.





REFERENCE MANUAL

20 VERTICAL FEEDER RIGHT ON DRAW PRESS

The safety sensor on the right bar of the vertical sheet transporter detected a problem.



21 EMERGENCY BUTTON ON DRAW PRESS

The emergency button on the button panel of the draw press was pressed. If the button is not pressed check the correct functioning of the button

22 CTF1 JACK DISCONNECTED ON DRAW PRESS

The connection signal of jack CFT1 is not present Check if the cable is connected on all connectors Check if the cable is in good condition

23 HIGH TEMPERATURE UPPER SLIDE OF DRAW PRESS RAM

The temperature limit for upper slide of the draw press ram was achieved Check the lubrication on the upper slide Check the time between lubrications and if it’s necessary adjust this time Check if there is grease in the deposit Check if the temperature limit is correct

24 HIGH TEMPERATURE LOWER SLIDE OF DRAW PRESS RAM

The temperature limit for lower slide of the draw press ram was achieved Check the lubrication on the lower slide Check the time between lubrications and if it’s necessary adjust this time Check if there is grease in the deposit Check if the temperature limit is correct



REFERENCE MANUAL

25 TRIMMER PRESS FREQUENCY INVERTER DOWN

The trimmer press frequency converter has a trip error. This can be because of: Bad adjustment of some parameters (Acceleration, Braking) Over tension Over current (Overcharge) To high speed for the motor Read the trip code and see in the frequency converter manual for more


26 TRIMMER PRESS LUBRICATION ERROR

Low-pressure alarm during the lubrication of the trimmer press Check if the compressor is working Check if there are some air leak Check the pressure level on the manometers Check all security valves and taps Check the correct functioning and adjustment of the pressostate Check the correct functioning of the automatic oil pump

27 TRIMMER PRESS TOOL PROTECTION OPEN

The protection of the trimmer press tool is open If the protection is closed verify the correct operation of the security

switch

28 TRIMMER PRESS MOTOR PROTECTION OPEN

The protection of the trimmer press flywheel is open If the protection is closed verify the correct operation of the security

switch

29 EMERGENCY BUTTON TRIMMER PRESS

The emergency button on the button panel of the trimmer press was pressed. If the button is not pressed check the correct functioning of the button



REFERENCE MANUAL

30 CTF4 JACK DISCONNECTED ON TRIMMER PRESS


31 EMERGENCY BUTTON (PANEL) DRAW PRESS ON

The emergency button on the button panel of the redraw press was pressed. If the button is not pressed check the correct functioning of the button

32 CTF3 JACK DISCONNECTED ON DRAW PRESS


33 EMERGENCY BUTTON TWIN LINE ON

The emergency button on the twin line was pressed. If the button is not pressed check the correct functioning of the button Check the connection cable between the two lines

34 ELECTRIC PHASE FAULT

This error means that it’s missing one phase or that the phase rotation is not the correct one

Check if the three fazes are present Check the correct faze rotation and if it is necessary change two phases

until you have the correct faze rotation

35 HIGH TEMPERATURE UPPER SLIDE DRAW PRESS

The temperature limit for upper slide of the draw press ram is almost achieved Check the lubrication on the lower slide Check the time between lubrications and if it’s necessary adjust this time Check if there is grease in the deposit Check if the temperature limit is correct



REFERENCE MANUAL

36 HIGH TEMPERATURE LOWER SLIDE DRAW PRESS

The temperature limit for lower slide of the draw press ram is almost achieved Check the lubrication on the lower slide Check the time between lubrications and if it’s necessary adjust this time Check if there is grease in the deposit Check if the temperature limit is correct

"-NO EMERGENCY STOPS ON MACHINE-"

This message tells us that there are no emergency stops on the machine


Documents

Draw Line - Reference Manual