1000 TON ECCENTRIC PRESS

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 1000 TON ECCENTRIC PRESS USER GUIDE

Table of Contents
1) COMPANY INFORMATION ....................................................................................................................... - 2 -
2) ABOUT THE SYSTEM ................................................................................................................................ - 2 -
2.1 USED PROGRAMS ............................................................................................................................ - 2 -
2.2 SYSTEM REQUİREMENTS ................................................................................................................. - 2 -
3) TEMPLATE SCREEN .................................................................................................................................. - 3 -
4) MAIN SCRREN .......................................................................................................................................... - 5 -
5) MENU SCREEN ......................................................................................................................................... - 6 -
5.1 MAIN MOTOR .................................................................................................................................. - 7 -
5.2 COUNTER BALANCE ......................................................................................................................... - 8 -
5.3 SLIDE (REGLAJ) ................................................................................................................................. - 9 -
5.4 OVERLOAD ..................................................................................................................................... - 10 -
5.5 HYDRAULIC PUMP & EJECTOR ....................................................................................................... - 11 -
5.6 LUBRICATION SYSTEM ................................................................................................................... - 12 -
5.7 CAM BOX ....................................................................................................................................... - 13 -
5.8 DYNAMIC CAMS............................................................................................................................. - 14 -
5.9 PRESS START CONDITIONS ............................................................................................................ - 15 -
5.10 PIECE COUNTER ............................................................................................................................. - 16 -
6) MAINTAIN&MONITORING MENU ......................................................................................................... - 17 -
6.1 MAIN MOTOR & DRIVE.................................................................................................................. - 18 -
6.2 PRESS ANGLE ENCODER................................................................................................................. - 19 -
6.3 SLIDE (REGLAJ) ENCODER .............................................................................................................. - 20 -
6.4 INPUT LIST...................................................................................................................................... - 21 -
6.4.1 Digital Inputs.......................................................................................................................... - 21 -
6.4.2 Analog Inputs ......................................................................................................................... - 21 -
6.5 OUTPUT LIST .................................................................................................................................. - 22 -
6.6 PILZ  SIEMENS COMMUNICATION........................................................................................... - 23 -
6.6.1 PilzSiemens ......................................................................................................................... - 23 -
6.6.2 SiemensPilz ......................................................................................................................... - 24 -
6.7 DATE & TIME.................................................................................................................................. - 25 -
7) ALARM MENU ........................................................................................................................................ - 26 -
7.1 CURRENT ALARM LIST ................................................................................................................... - 26 -
7.2 ALARM HISTORY ............................................................................................................................ - 27 -

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 1000 TON ECCENTRIC PRESS USER GUIDE

1) COMPANY INFORMATION

CONTACT
Preston Makina İmalatı Tasarım Araştırma Geliştirme San. ve Tic. Ltd. Şti.
ADDRESS: Çalı Mah. Alaaddinbey Caddesi, Deli Gönül Sokak 5/B
16120 Nilüfer, Bursa, Türkiye
MAIL: preston@preston.com.tr
TEL: +90 (224) 441 66 96

2) ABOUT THE SYSTEM

2.1 USED PROGRAMS

SIEMENS PLC SIMATIC STEP 7 Professional / Basic V16

SAFETY PLC PNOZmulti Configurator

2.2 SYSTEM REQUİREMENTS

HARDWARE
GEREKSİNİMLER
/SOFTWARE
PROCESSOR Intel® Core™ i5-6440EQ (up to 3.4 GHz)
RAM 16 GB (min. 8 GB, 32 GB for large projects)
HARDDISK SSD with 50 GB free storage space
NETWORK 1 Gbit (for multi-user)
DISPLAY 15.6" Full HD Display (1920 x 1080 or more)
OS Windows 7 (64-bit) Windows 10 (64-bit) Windows Server (64-bit)
Windows 7 Home Premium Windows 10 Home Version 1709, 1803 Windows Server 2012
SP1 Windows 10 Professional Version 1709, R2 StdE (full
Windows 7 Professional SP1 1803 installation)
Windows 7 Enterprise SP1 Windows 10 Enterprise Version 1709, 1803 Windows Server 2016
Windows 7 Ultimate SP1 Windows 10 Enterprise 2016 LTSB Standard (full
installation)
Windows 10 IoT Enterprise 2015 LTSB
Windows 10 IoT Enterprise 2016 LTSB

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 1000 TON ECCENTRIC PRESS USER GUIDE

3) TEMPLATE SCREEN

Template screen appears as the background on every page.

The following information can be monitored here;

 Main Motor Actual Speed in “rpm” and “stroke/minute”

 Counter Balance Actual Pressure in “bar”
 Overload Actual Pressure in “bar”
 Press Angle in “degree”
 Slide(Reglaj) Position in “mm”
 TDC Cam (Top Death Center Cam From Cam Box)
 in the range of approximately 350 to 15 degrees of press angle
 Run Up Cam From Cam Box
 in the range of approximately 180 to 10 degrees of press angle
 BDC Cam (Bottom Death Center Cam From Cam Box)
 in the range of approximately 160 to 190 degrees of press angle
 STATIC ENABLE
 Must be present for the press start-up. If Statik enable = 0, the press immediately stops.

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 1000 TON ECCENTRIC PRESS USER GUIDE

 START ENABLE
 Must be present for the press start-up. During the press stroke, start enable can change
to zero.

 SAFET ENABLE
 The safety enable must be present during the hazardous downward movement of the
press. In the upward movement, safety enable can be overridden by the run-up cam if
no other hazards exist.

 COUNTER BALANCE
 OVERLOAD Must be ready to start the press
 LUBRICATION

 PRESS READY
 All conditions are ready for start to press.
 Press Mode according to mod key switch;
 Close Mode (in 1 key position)
 Setup Mode (in 2 key position)
 Single Stroke Mode (in 3 key position)
 Automatic Mode (in 4 key position)

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 1000 TON ECCENTRIC PRESS USER GUIDE

4) MAIN SCRREN

 Tap anywhere to switch screen.

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 1000 TON ECCENTRIC PRESS USER GUIDE

5) MENU SCREEN

The following screens can be reached on menu screen;

 MAIN MOTOR
 COUNTER BALANCE
 SLIDE (REGLAJ)
 OVERLOAD
 HYDRAULIC PUMP & EJECTORS
 LUBRICATION SYSTEM
 CAM BOX & DYNAMIC CAMS
 PRESS START CONDITIONS
 MAINTENANCE & MONITORING
 PIECE COUNTER
 ALARMS
 LANGUAGE (TURKISHENGLISH)
 EXIT RUNTIME

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.1 MAIN MOTOR

On the main motor menu;

 Motor speeds, ramp time up and ramp time down can be adjusted.
 5 – 12 spm speed limit in setup mode
 12 – 20 spm speed limit in single stroke&automatic mode
 30 – 60 second ramp time limit
 If there are error or alarm on the motor driver; can be observed. Fault & alarm description
appears when click on the “alarm id” or “fault id”.

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.2 COUNTER BALANCE

On the counter balance menu;

 Mould weight must be entered correctly.
 With the main motor start, the counter balances start to fill up to pressure value calculated
according to mould weight.
 Pressure in no-load and in 1 ton load are constant values and must not be changed unless
necessary.
 Dynamic cam is the soft cam to fill counter balance. Between in this two degree counter
balances start to fill.
 Filling & discharge valves, actual pressure values in tank, right&left cylinder can be observed.

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.3 SLIDE (REGLAJ)

 Slide (Reglaj) can be operated with buttons on the operator panel.

These buttons;
 Slide Mode according to mod key switch;
 Close Mode (in 0 key position)
 Manuel Mode (in 1 key position)
 Manual Up Button
 Manual Down Button
 Automatic Mode (in 2 key position)
 Automatic Start Button
 Automatic Stop Button
 Setpoint Values;
 Setpoint value must be between upper & lower soft limit values.
 If press will work in setup mode; slide value must be at the setup setpoint value.
 If press will work in single stroke or automatic mode; slide value must be one of the
setup or production setpoint value.
 Limit Switch;
 There are two limit switch, upper and lower.
 If these switches present while in the slide movement , slide movement stop
immediately.
 Slide (reglaj) contactors and actual position of slide can be observed.

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.4 OVERLOAD

 With the main motor start, the overload starts to fill up to set pressure value.

 Overload max pressure

 This shows the max pressure that overload reaches at every stroke.
 Overload Pressure Switch
 If the overload value is above 60 bar this switch present.
 Filling & discharge valves, actual pressure value of overload, overload level and pressure
switch can be observed.
 OVERLOAD SHUNT
 Used when the press is stopped due to overload. This button can be used if press setup
mode.
 When the press is stopped due to overload and if press angle is lower than 180 degree,
main motor must be run opposite direction.
 After the press reaches TDC cam, overload shunt drops and the overload starts to fill.

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.5 HYDRAULIC PUMP & EJECTOR

 Ejector pins are controlled with buttons on the operator panel

 Manual Ejector Up Button
 When the up button is pressed, the Ejector pins move up to the work position
 Manual Ejector Down Button
 When the down button is pressed, the Ejector pins move up to the home position
 The stroke lenght is 300 mm
 Hydraulic Pump contactor&feedbacks, hydraulic unit oil level switch, hydraulic valves for
ejector pin can be observed

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.6 LUBRICATION SYSTEM

 With the main motor start, the lubrication system starts to oiling.
 Valves
 Q4.1 Gear Lubrication Valve works always.
 Q4.2&Q4.3 Right&Left counter balance lubrication valves work according to
work&stop time.
 Oil Temperature
 If the actual oil temperature reaches the alarm temperature, lubrication stops.
 Lubrication System Pump contactor&feedbacks, actual value of oil temperature, oil level
switch, lubrication valves can be observed.

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.7 CAM BOX

On the cam box menu;

 Shows that actual press angle
 TDC Cam (Top Death Center Cam From Cam Box)
 in the range of approximately 350 to 15 degrees of press angle
 Run Up Cam From Cam Box
 in the range of approximately 180 to 10 degrees of press angle
 BDC Cam (Bottom Death Center Cam From Cam Box)
 in the range of approximately 160 to 190 degrees of press angle

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 1000 TON ECCENTRIC PRESS USER GUIDE

5.8 DYNAMIC CAMS

 These values were found by testing according to the main motor speed.
 Do not change unless necessary.

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5.9 PRESS START CONDITIONS

 All conditions for the press to work can be observed on this menu.

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5.10 PIECE COUNTER

 Total & actual piece counter of pressed.

 Can be reseted with “Totak Piece Reset” and “Actual Piece Reset” buttons.

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 1000 TON ECCENTRIC PRESS USER GUIDE

6) MAINTAIN&MONITORING MENU

The following screens can be reached on maintain&monitoring screen;

 MAIN MOTOR DRIVE
 PRESS ANGLE ENCODER
 SLIDE (REGLAJ) ENCODER
 INPUT LIST MONITORING
 OUTPUT LIST MONITORING
 PILZSIEMENS MONITORING
 SIEMENSPILZ MONITORING
 SYSTEM SCREEN
 DATE & TIME

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 1000 TON ECCENTRIC PRESS USER GUIDE

6.1 MAIN MOTOR & DRIVE

 Control and status bits used in profinet connection between plc and driver can be monitored.
 Actual speed (rpm), current (A), torque (Nm), alarm and fault id of the drive can be observed.

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 1000 TON ECCENTRIC PRESS USER GUIDE

6.2 PRESS ANGLE ENCODER

 Press angle encoder maintain menu is used to observe the communication bits used between
the encoder and the plc, to read the actual values of encoder and to reset the encoders.
 Time to start control
 At the end of the entered time, the encoder rotation direction and position are checked.
 When the press angle is exactly 180 degrees, reset must be done.

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 1000 TON ECCENTRIC PRESS USER GUIDE

6.3 SLIDE (REGLAJ) ENCODER

 Slide encoder maintain menu is used to observe the communication bits used between the
encoder and the plc, to read the actual values of encoder and to reset the encoders.
 Time to start control
 At the end of the entered time, the encoder rotation direction and position are checked.
 When the slide is lower position, reset must be done.

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 1000 TON ECCENTRIC PRESS USER GUIDE

6.4 INPUT LIST

6.4.1 Digital Inputs

 The status of all inputs used in the system can be observed.

6.4.2 Analog Inputs

 The status of all analog inputs used in the system can be observed.

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 1000 TON ECCENTRIC PRESS USER GUIDE

6.5 OUTPUT LIST

 The status of all outputs used in the system can be observed.

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6.6 PILZ  SIEMENS COMMUNICATION

6.6.1 PilzSiemens

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6.6.2 SiemensPilz

 These menus is used to observe the communication bits used between the pilz safety and the
siemens plc.

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6.7 DATE & TIME

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7) ALARM MENU
7.1 CURRENT ALARM LIST

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 1000 TON ECCENTRIC PRESS USER GUIDE

7.2 ALARM HISTORY

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