USER S AND MAINTENANCE MANUAL AUTOMATIC MOUNTING PRESS

Transcription

1 USER S AND MAINTENANCE MANUAL AUTOMATIC MOUNTING PRESS THIS MANUAL AND THE CONFORMITY DECLARATION MUST BE PRESERVED FOR THE ENTIRE LIFE OF THE MOUNTING PRESS AND MUST BE HANDED OVER TO ANY OTHER USER OR TO THE NEW OWNER OF THE MOUNTING PRESS CONTAINS EEC CONFORMITY DECLARATIONS EDITION 2015 CODE 1/2015

2 GENERAL INDEX 1. TECHNICAL INFORMATION & DATA INTRODUCTION IDENTIFICATION DATA MACHINE DESCRIPTION LIST OF COMPONENTS EXPECTED OPERATING CONDITIONS OPERATIONS NOT ALLOWED LIGHTING LIST OF APPLIED PROTECTIONS SAFETY DEVICES ACCESSORIES ELECTRIC SYSTEM PNEUMATIC SYSTEM NOISE TRANSPORTATION PACKING CONDITIONS FOR STORING THE MACHINE MACHINE LOADING, TRANSPORTATION AND UNLOADING INSTRUCTIONS OPERATION WORKING POSITION ELECTRICAL CONNECTIONS WATER CONNECTION PNEUMATIC CONNECTION MOUNTING OPERATION MAINTENANCE ROUTINE MAINTENANCE MOUNTING PRESS DISMANTLING RESIDUAL RISKS INSPECTION CERTIFICATE REPAIRING AND SPARE PARTS MANUFACTURER S CERTIFICATE

3 1. TECHNICAL INFORMATION & DATA 1.1 INTRODUCTION This user s and maintenance manual supplies the most important information for setting at work safely the mounting press. The information and the illustrations herewith contained are updated to the moment of distribution of the manual itself. The manufacturing company reserves itself the right to make modifications without prior notice. CAUTION!!!! This symbol is used to point operations and points which are dangerous for the operator s safety. When this symbol is present, read carefully the message that follows and be aware of the potential risk of accident. The technical information contained in this manual is owned by Remet and must be treated as confidential. Any distribution or reproduction, also partial, is forbidden unless previously approved in writing by Remet. Moreover, this manual must not be used for different purposes than the ones strictly connected to the maintenance of the mounting press. CAUTION!!!! The mounting press or any of its parts must not be modified or tampered by the user for any reason. Any attempt to modify or tamper any part of the machine will render null the guarantee freeing the company Remet from all responsibility for eventual damages to persons or things resulting from this tampering. This manual must be well preserved as to be available for consultation for the entire productive life of the mounting press. This manual and the EEC conformity declaration are an integral part of the mounting press. Before using the cutter consult the user s and maintenance manual. 2

4 1.2 IDENTIFICATION DATA - Mounting diameter: from10 to 60 mm - Manufactured in the year: Weight of the mounting press; up to 40 mm 40 kg. over 40 mm 50 kg. - Dimensions: L = 400 mm P = 400 mm H = 510mm - Max. mounting temperature: 200 C - Max. mounting time: 99 min. - Voltage (single phase): V - Power; up to 30 mm 600W from 30 to 40 mm 650W over 40 mm 700W - Max. working pressure: 6 bar - Sound intensity level: < 70 db(a) 3

5 1) TIPO: machine model. 2) MATR. N : serial number. 3) ANNO DI COSTRUZIONE: manufacturing year. 4) MASSA: total weight of the machine. 5) PRESSIONE MASSIMA: max. working pressure. 6) TEMPERATURA MASSIMA: max. mounting temperature. 7) TENS. ALIMENTAZ. MONOFASE: power supply. 8) POTENZA COMPLESSIVA: max. total power absorbed by the mounting press. 4

6 1.3 MACHINE DESCRIPTION The automatic mounting press is composed of: Body in compact oven varnished sheet with pressure regulator, pressure gauge and device for maintaining constant the pressure during the mounting cycle. Moulding unit for 10 to 60 mm diameter mounts with moulding cylinder, piston and counter piston complete with screw-locking device. Electric immersion heater with a regulator to adjust temperature to the desired level and a digital temperature indicator. Time with alarm audio signal at the end of the programmed heating and cooling cycles. Water circulating cooling device with entrance and exit on moulding unit. Electric input V single-phase. 5

7 1.4 LIST OF COMPONENTS 6

8 7

9 1) Head cover 2) Mainframe cover 3) Mainframe 4) Warning lights heating / cooling 5) Warning lights SET POINT 1 / SET POINT 2 6) Visual display unit (set parameters while programming and real temperature during mounting process) 7) PROG Key for setting the mounting parameters 8) Mounting parameters display 9) Microprocessor ITM control unit 10) Ram valve control 11) Key to modify mounting parameters while programming 12) Key to modify mounting parameters while programming 13) Mounting process start switch 14) Pressure gauge 15) Pressure regulator 16) Shock absorber foot 17) Lower panel screws 18) Lower panel 19) Upper panel screws 20) Upper panel 21) Pneumatic cylinder 22) Flange 23) Mounting unit (mounting cylinder, electric heater, water cooling circuit, thermocouple) 24) Mounting cylinder 25) Closing screw with counter piston 26) Closing shaft 27) Closing spring 28) Closing knob 29) Closing screw pivot 30) Cooling water mounting unit inlet 31) Cooling water tube 32) Cooling water connection 33) Cooling water connecting tube 34) Compressed air connection ( 8 mm tube) 35) Air exhaust 36) Cooling water outlet tube 37) Power supply cord (220V-single phase) 38) Mounting unit power supply cord CONSUMABLES AND ACCESSORIES: - N 1 Kg red phenolic resin - N 1 Kg black phenolic resin - N 1 dosing beaker 8

10 1.5 EXPECTED OPERATING CONDITIONS The mounting press has been designed for hot mounting of metallographic samples. Every material can be embedded (metals, plastics, glass, ceramic, etc ) but not materials sensible to the pressure and the temperature required for resin polymerisation. Every resin can be used, up to 200 C of polymerisation temperature, that doesn t bond to the molding unit. 1.6 OPERATIONS NOT ALLOWED The mounting press can t be used with materials that could burn or produce toxic gases if heated. 1.7 LIGHTING The mounting press is supposed to be used in a working environment with enough light. 1.8 LIST OF APPLIED PROTECTIONS The mounting press is manufactured with safety components (air cylinder, valve, pressure flange, etc ) The electric heater is fully insulated. The cooling water outlet tube is heat proof. 1.9 SAFETY DEVICES The mounting press is not equipped with a main switch, so it is suggested to connect it to a wall panel with a main switch. All the components of the machine are connected to the ground ACCESSORIES If the compressed air is not filtered the mounting press be equipped with a dehumidifying lubricating unit. 9

11 1.11 ELECTRIC SYSTEM WIRING DIAGRAM LEGEND L-N - Line V F1-F2 - Fuses 5A/ V P.E. - Ground I.G. - Switch R - Electric heater B - Electro valve TC - Thermo couple MPS - Microprocessor WHAT TO DO IN CASE OF FIRE In case of fire don t use water, but powder fire extinguisher. 10

12 1.12 PNEUMATIC SYSTEM PNEUMATIC DIAGRAM LEGEND E M R C V S - air inlet - pressure gauge - pressure regulator - air cylinder - valve - air exhaust 1.13 NOISE The max sound intensity level is < 70 db (A). 11

13 2. TRANSPORTATION 2.1 PACKING The machines are usually packed in a cardboard box. Inside the cardboard box there is another box containing the consumables delivered with the mounting press. 2.2 CONDITIONS FOR STORING THE MACHINE The packed mounting press must be stored in an environment protected from bad weather. Do not stack packed mounting press. Do not pile up other objects on packed machines. 2.3 MACHINE LOADING, TRANSPORTATION AND UNLOADING INSTRUCTIONS The mounting press can be moved, during the loading and unloading operations, by hand. The mounting press must be fixed adequately on the transport vehicle as to avoid dangerous movements. Do not stack packed machines on the transport vehicle. 3. OPERATION 3.1 WORKING POSITION Unpack the mounting press. Deposit the machine in its place paying attention that all four feet lay on a flat surface. The machine can be placed against a wall since the working area is in front of the mounting press. Special fasteners or anchoring are not necessary since the machine is mounted on vibration-damping feet. For disassembling the mounting press it is necessary to carry out backwards the instructions supplied for its assembly. 3.2 ELECTRICAL CONNECTIONS Before setting at work check the integrity of the safety protections which could have been damaged during transportation. Check that the network voltage is the same as the voltage indicated on the plate. The mounting press is not equipped with a main switch so we highly recommend a wall panel with a main switch having a overload cut-out proportional to the installed power. All the parts of the mounting press are grounded, so a proper ground connection must be prepared on the wall panel. 12

14 The user is responsible for ascertaining that the installation conforms to the local provisions on the matter. The machine must be installed only by qualified personnel who must have read beforehand the information indicated on this manual. 3.3 WATER CONNECTION The lower tube on the mounting press is the filling one, which must be connected to the water system by means of a faucet set up outside the machine: if the pressure is too high, install also a pressure regulator. The upper tube in the mounting head is the drainage one which can be simply placed inside a sink. 3.4 PNEUMATIC CONNECTION The pressure must be at least 6 Atmospheres. Compressed air, if not already treated, must first go through a small group with the dehumidifier and the lubricator with which the machine can be equipped. Such a device can be fixed, also for accessible inspection, on the wall behind the machine. The lubricator s container will be filled, approx halfway with appropriate oil and its flow must be adjusted with a drop every seconds. The mounting press is equipped in the back with special air escape with their own silencers. 3.5 MOUNTING OPERATION The mounting process is fully automatic and must be preset: heating temperature, time of permanence and cooling temperature can be adjusted by the microprocessor. SETTING WORKING PARAMETERS a) switch on the machine b) wait until the end of the resetting operation c) push the PROG key d) the heating temperature ( C) is displayed in the upper display PV (S.P.1) e) adjust the temperature pushing the and keys (for phenolic resins the temperature is C). f) push the PROG key g) the time of permanence (min.) is displayed in the upper display PV (t.i.) h) adjust the time pushing the and keys (this time for a 30 mm machine for the first mounts with cold mounting unit is min., then can be reduced to 8 10 min.) i) push the PROG key l) the cooling temperature ( C) is displayed in the upper display PV (S.P.2) m) adjust the temperature pushing the and keys (usually C) n) push the PROG key o) the machine is ready; the upper display (PV) shows the real temperature, the lower display (SV) shows the set temperature. 13

15 PREPARING FOR MOUNTING a) Adjust the pressure with the regulator until the pressure gauge reaches 3,5 4 atmospheres (it must be adjusted depending on mounting diameter) b) Lift the ram to the upper dead center, working on the pressure control valve; c) Place the sample with the surface to be analized turned downwards; d) Take the ram to the lower dead center e) Fill the molding cylinder with the resin, an everage load for 30mm samples is of approx. 30 ml, however, this depends on the size of the samples. The samples should not be too thick or too wide and preferably it should not have sharp edges; f) Screw the counter piston leaving it half a turn free; g) Lift the ram; h) Turn on the on-off switch to start-up the preset cycle. MOUNTING PROCESS a) Switch on the machine, the microprocessor reset them shows in the upper display (PV) the real mounting temperature and in the lower display (SV) the set temperature. The heater red LED and the S.P.1 red LED (heating temperature) are ON. b) Once the heating temperature has been reached, the heater red LED is off and in the lower display (SV) the time LED start flashing. The heater red LED is alternatively on and off to indicate when the heater works c) At the end of the preset time, the cooling starts; the heater is off and the electro-valve opens allowing the water to flow inside the mounting unit. The lower display (SV) shows the preset cooling temperature; the green cooling LED and the green LED S.P.2 (cooling temperature) are on. The red LEDs (time, S.P.1. and heater) are definitively off. Once the cooling temperature has been reached, a working sound advice that the sample is ready; the green LEDs (S.P.2. and cooling) are off and the upper display (PV) shows the final mounting unit temperature EXTRACTION OF THE SAMPLE a) Lower the ram and unscrew the counter piston WARNING: to avoid burnings don t touch the counter piston. Don t try to unscrew the counter piston before the ram is in the lower position b) Rotate the counter piston clockwise c) Lift the ram WARNING: don t stay over the molding unit while extracting the sample. d) Take the sample e) To start a new mounting process switch off and then switch on the machine. 14

16 4. MAINTENANCE 4.1 ROUTINE MAINTENANCE The machine doesn t need a programmed maintenance. If the cooling water is very calcareous it is suggested to use a filter. If the cooling circuit will be obstructed by calcareous deposits, it should be cleaned with normal cleaning liquid. If the compressed air is not filtered it is suggested to use a lubricating dehumidifier filter (1 drop of oil every seconds). The mounting unit is in special hardened steel and it sometime needs to be cleaned from residual resin with a soft cloth; with our resin it is not necessary to lubricate the mounting unit. WARNING: in order to avoid mounting unit damages, do not use metallic tools to clean it. 5. MOUNTING PRESS DISMANTLING Mounting press dismantling must be done in respect of the local regulations and laws. 6. RESIDUAL RISKS - To avoid burnings do not touch the mounting unit during mounting operations. - To avoid burnings do not touch the water that gets out from the machine during cooling - To avoid the danger of samples thrown from the machine during the expulsion phase, do not stand over the mounting press. 7. INSPECTION CERTIFICATE The automatic mounting press, has successfully passed all the partial, final and functional inspection tests. The inspector 8. REPAIRING AND SPARE PARTS Please enquire directly at the local dealer. 9. MANUFACTURER S CERTIFICATE The warranty is valid for twelve months from the delivery date. Any repairing during the warranty period will be carried out ex-works and include labour and any replaced parts. Any inspection requested at the user s factory will be carried out by charging the transfer expenses and travelling hours. The warranty does not include wear out parts (especially, fuses, leds, etc.) and is null if the mounting press is used for operations which are not apt for the purposes it was manufactured. 15