PH383.85.050 00.GB

D O C U M E N TA Z I O N E
T E C N I C A
PH 383.85.050
INSTRUCTIONS B
USE OF THE SMC 085

MICROPROCESSOR-BASED CONTROL SYSTEM
FOR PH PRESSES WITH HP PC
PH 383.85.050 Rev. 00 Date 27.02.2006
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACIÓN TÉCNICA
DOCUMENTAÇÃO TÉCNICA
LISH
ENG
PH 383.85.050 Rev. 00 Date 27.02.2006
Written by : Sig. Monduzzi Matteo Written on : 27.02.2006
Last revised :
Revised by : Ing. Tassoni Alberto Revision No. : PH 02.08.01

PH 04.03.01
Title : Number of pages : 213
USE OF THE SMC 085 MICROPROCESSOR-BASED Service code : 9512

FOR PH PRESSES WITH HP PC
Identification no. : PH 383.85.050
SACMI SHALL NOT BE HELD RESPONSIBLE FOR MACHINE FAILURE DUE TO UNAUTHORIZED MODIFICATIONS.
ANY CHANGES THAT ALTER THE CONSTRUCTION OR THE WORKING CYCLE OF THE MACHINE MUST BE
CARRIED OUT OR AUTHORIZED BY SACMI’S AFTER-SALES DEPT.
SACMI RESERVES THE RIGHT TO MAKE ANY CHANGES TO THE MACHINE DESCRIBED HEREIN AT ANY TIME
WITHOUT NOTICE.
IF THERE ARE ANY PRINTING OR OTHER ERRORS, CORRECTIONS WILL APPEAR IN THE SUBSEQUENT
VERSION OF THE MANUAL.
SACMI SHALL BE HELD RESPONSIBLE ONLY FOR THE TEXT IN THE ORIGINAL ITALIAN VERSION.
THIS MANUAL IS PROPERTY OF SACMI. ONLY THE PURCHASER OF THE MACHINE IS AUTHORIZED TO USE
IT.
IT IS NOT TO BE COPIED OR REPRODUCED IN ANY FORM WITHOUT PRIOR CONSENT FROM SACMI. FAILURE
TO DO SO WILL ENTITLE SACMI TO TAKE LEGAL ACTION.
COPIES OF THIS MANUAL ARE AVAILABLE FROM THE AFTER-SALES SERVICE DEPT.
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PH 383.85.050 Rev. 00 Date 27.02.2006
SAFETY PRECAUTIONS TO BE OBSERVED

WHEN OPERATING THE MACHINE
Copies of this manual should be given to all personnel in charge of machine maintenance and
operation. It is essential that the manual is read carefully in its entirety and fully understood, as it
provides important instructions on how to operate the machine properly and safely.
The machine must be used only for the tasks it was expressly designed for. Performing jobs other than
those recommended is hazardous.
SACMI shall not be held responsible for damage to the machine or injuries to personnel resulting from
mishandling, improper use or unauthorized modifications.
Any modifications made to the machine’s structure and/or work-cycle must be performed or authorized
by SACMI’s Service Dept.
The persons in charge of supervising and servicing the machine must read and fully understand the
operating instructions contained in the documentation provided.
Maintenance can be performed and the electrical parts and devices accessed only by competent well-
trained personnel.
The machine’s work-cycle can be set and controlled only by the persons in charge, or those who are
duly authorized.
Only well-trained personnel can operate, set-up and service the machine.
The machine can be started up only after all the safety devices have been activated.
Periodically inspect all the safety devices installed in the machine (stop pushbuttons, interlocks,
proximity switches, limit switches, safety guards, etc..) for proper functioning. Occasionally check to
see whether the machine is still efficiently grounded.
If any faults are found while the machine is being run, they must be reported to the person in charge
without delay.
If the personnel in charge find faults which could endanger the operators, the machine must be shut
off immediately and restarted only after it has been repaired.
Always unplug the machines from the electricity supply before setting up or servicing them if operations
which may endanger personnel are to be performed. Failure to do so may result in severe injury to
personnel. Whenever carrying out maintenance of any type, always shut off the machine and block all
parts before starting. This must be done even when minor jobs are performed.
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PH 383.85.050 Rev. 00 Date 27.02.2006
1 INTRODUCTION
Device Connection State LED indication
Pushbutton N.O. Pressed Led on

Released Led off
N.C. Pressed Led off
Released Led on
Selector switch Closed in pos. x Led on

Open in pos. x Led off
Miniature switch N.O. Energized Led on

De-energized Led off
N.C. Energized Led off
De-energized Led on
Proximity sensor N.O. Energized Led on

Scanner
Photocell N.O. Triggered Led on
Untriggered Led off
Reflector/ Triggered Led off
Detector unit Untriggered Led on
Contactors-relays N.O. Energized Led on

N.C. Energized Led off
De-energized Led on
Level control
Pressure switch
Flow meter
Thermostat N.O. Above threshold Led on
Below threshold Led off
N.C. Above threshold Led off
Below threshold Led on
Vacuum switch N.O. Above set pressure Led off

Below set pressure Led on
N.C. Above set pressure Led on
Below set pressure Led off
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PH 383.85.050 Rev. 00 Date 27.02.2006
2 WARNINGS
MAINTENANCE OPERATIONS
- To replace the microprocessor system cards:

see INSTRUCTIONS C -
- To replace the EPROMs which store the machine program:

see INSTRUCTIONS C -
- Before welding, disconnect the machine from the electrical cabinets by unplugging the cables.
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PH 383.85.050 Rev. 00 Date 27.02.2006
3 MAIN FEATURES OF THE ELECTRIC SYSTEM
The electric system basically consists of three parts:

1) The microprocessor system that controls and monitors machine operation
2) The switchboard that supplies power to the main points of use
3) Machine wiring
1) Microprocessor system for controlling and monitoring machine operation

This system controls and monitors plant operation.
Its function is to control and monitor all the parts that make up the machine.
The microprocessor system consists of a number of cards, each of which is provided to carry out a specific task.
Power Supply Card (AL or SAL):

This card supplies power to the various parts inside the system as well as outside to the sensors. In program PH 14.01.01
and later versions it also contains the configuration data, permanently stored production data and settings to dialogue
with the controller.
CPU Card:
This card stores the main microprocessor and the machine program to be run.
Miscellaneous Card (VA)

This is the CPU card support; it is used to dialog with the operator keyboards. It stores the set work-cycle programs.
Encoder/Analog Input Card (EIA)

It serves for the dual task of reading the encoders located along the axes as well as the pressures and temperatures
present.
Analog Input Card (IA):

It is used to read the pressures and temperatures.
Encoder Input Card (IE):

It is used to read the encoders located along the axes.
Digital Input Cards (IDM):

The function of these cards is to acquire the state of the limit switches and proximity sensors.
Digital Output and Relay Output cards (OD, OR):

These cards are used to pilot the machine actuators.
Digital and Analog Output Cards (ODA)

The function of these cards is to pilot the proportional valves that control the positions and speeds of the axes along
with certain machine actuators.
Analog output card (OA):

This card pilots a number of proportional valves and/or some inverters.
Axes card (AX):

This card may contain up to 4 DSP each of which governs an axis.
All the electronic cards are tested at 60 C for not less than 48 hours.
An emergency circuit is also provided in the control system. This circuit controls all the safety devices independently,
i.e. safety bar, shutdown button located on the machine control keyboard, external shutdown buttons, etc..
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2) Switchboard that supplies power to the main points of use

This part houses all the devices that control the electric motors.
The controls for the motors are protected with magnetic thermal cut-outs (for power outputs less than 11 kW) with mixed
coordination (Ir, type 2, Iq type 1).
Y-D starters are used with power outputs greater than 15 kW.
All the power components are mounted on a bus bar.
3) Electric wiring of the machine

The electric wiring of the machine has been studied in depth and is designed to satisfy installation and maintenance
requirements. Connectors are used for each individual part so that they can be easily unplugged/plugged in when the
machine is installed at the customer’s factory and when maintenance needs to be carried out.
All the materials employed for machine wiring have been carefully examined and selected taking into account the
aggressive agents found in the work area (oil, dust, etc..).
The entire electric system is tested according to current safety regulations.

The entire electric system has been designed and developed in compliance with current international electrical codes
and regulations regarding safety of machinery.
MAIN LAWS AND SAFETY STANDARDS USED AS REFERENCES
European Standard CENELEC HD 420

Auxiliary control equipment for voltages that do not exceed 1000 V - General prescriptions
Italian Standard CEI EN 60204-1 (CEI 44-5)

European Standard CENELEC EN 60204
International Standard IEC 204-1
Safety of machinery- Electrical equipment of machinery
Italian Standard CEI 64-8

European Standard CENELEC HD 384
International Standard IEC 364
Electrical systems that use a rated voltage that does not exceed 1000 Vac and 1500 Vdc.
European Standard EN 954-1

Safety of machinery - Safety-related parts of control systems - Part 1: General principles
for design (under approval)

Safety of machinery - Basic concepts, general principles for design.
Part 1: Basic terminology, methodology.

Safety of machinery - Basic concepts, general principles for design.
Part 2: Technical principles and specification.
European Directive 98/37/EEC

Machinery directive
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PH 383.85.050 Rev. 00 Date 27.02.2006
4 MACHINE CONTROL KEYBOARD
29
26
31
28
25
30
27
19-23
18
22
17
21
16
20
11
15
10
14
13
9
12
8
3
7
2
6
1
5
0
4
24
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4.1 DESCRIPTION OF THE KEYS
FUNCTION 1ST KEY 2ND KEY + KEY SWITCH PUMP
Pump start Ø
Alarm reset 1
Automatic cycle start 28* 2 AUT ON
Start of semi-automatic loading 28* 2 AUT ON
Start of semi-automatic press-cycle 28* 2 AUT ON
Start of semi-automatic press-cycle in manual (20) 28* 2 AUT ON
Plunger upstroke 25 3 MAN/AUT ON
Plunger downstroke 30 3 MAN ON
Plunger upstroke at low speed 25 3 SET-UP ON
Plunger downstroke at low speed 30 3 SET-UP ON
Manual column lubrication cycle start 28 3
Pump stop 4
Reset 28 5 AUT ON
Automatic cycle stop 6
Braking force increase 26 7 MAN/AUT
Braking force decrease 31 7 MAN/AUT
Braking force decrease beyond the limit 28 and 31 7 SET-UP
switch (3) (4)
Braking force increase beyond the limit 26 and 28 7 SET-UP
switch (3) (4)
Assign analog braking input offset (3) (4) 25 and 26 7 SET-UP
Assign analog braking input gain (3) (4) 30 and 31 7 SET-UP
Request to set maximum pressure (13) 28 7 SET-UP ON
YV309 self-learning procedure (14) 28 7 SET-UP ON
YV309 pressure check (15) 28 7 SET-UP ON
YV32/YV318/YV70D self-learning procedure (18) 28 7 MAN ON
YV100 self-learning procedure (19) 28 7 MAN ON
Booster drainage (12) 28 7 MAN ON
Booster encoder reset (5) 28 7 SET-UP ON
YV21P self-learning procedure (22) 28 7 MAN ON
YV21P offset reset (23) 28 7 SET-UP OFF
Proportional valve cleaning (26) 28 7 MAN ON
SPE proportional valve cleaning with oil (27) 28 7 SET-UP ON
SPE proportional valve cleaning without oil (28) 28 7 SET-UP ON
Filler-box forward 29 8 MAN ON
Filler-box reverse 27 8 MAN ON
Filler-box with crank-connecting rod
encoder zero setting, (11) 26+31 8 SET-UP ON
In-line filler-box forward stroke beyond limit
switch (21) 26+29 8 MAN ON
In-line filler-box return stroke beyond limit
switch (21) 27+31 8 MAN ON
Punches in 25 9 MAN/SET-UP ON
Punches out 30 9 MAN/SET-UP ON
Diff. stroke booster forward 29 10 MAN ON
Diff. stroke booster back 27 10 MAN ON
Lower die up 25 10 SET-UP ON
Lower die down 30 10 SET-UP ON
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Upper die-set released 31 11 SET-UP

Upper die-set locked 26 11 SET-UP
Thickness increase (1) 26 12 MAN/AUT
Thickness decrease (1) 31 12 MAN/AUT
Die-sets up (16) 25 13 MAN/SET-UP ON
YV21 de-energized, Last dieset downstroke (2) 27 13 SET-UP ON
YV21 energized, Last dieset downstroke (2) 29 13 SET-UP ON
Die-sets down (17) 30 13 MAN/SET-UP ON
SPE die-set lift 2+2 (6) 25 13 SET-UP ON
SPE emergency upstroke 2+2 (7) 25 13 SET-UP ON
Downstroke after SPE lifting 2+2 (8) 30 13 SET-UP ON
SPE emergency downstroke 2+2 (9) 30 13 SET-UP ON
SPE self-learning procedure 2+2 (10) 28 13 SET-UP ON
Lower punch holder released 31 14 SET-UP
Lower punch holder locked 26 14 SET-UP
Lower die-set locked 31 15 SET-UP
Lower die-set released 26 15 SET-UP
Proportional ejector locked 28 16 SET-UP ON
Proportional ejector release 28 16 SET-UP ON
ALM semiautomatic mode 28 17 AUT ON
ACP semiautomatic mode 28 18 AUT ON
Powered suction hood up (24) 25 20
Powered suction hood down (24) 30 20
Oil leak recovery pump Start/Stop (25) 20
ALM forward 29 21 MAN ON
ALM reverse 27 21 MAN ON
ALM forward stroke beyond limit switch (21) 26+29 21 MAN ON
ALM return stroke beyond limit switch (21) 27+31 21 MAN ON
ACP in manual mode 27 or 29 22 MAN
Left ACP beyond limit switch (21) 26+29 22 MAN
Right ACP beyond limit switch (21) 27+31 22 MAN
Shutdown 24
Note:
* Use key F12 on the computer terminal to select the type of work-cycle.
+
Two keys need to be used for most operations. However, some of them can be performed by pressing only one key.
In these cases, the number of the key which has to be pressed appears in the column marked “2ND KEY”.
(1) Operation possible only with 2-cylinder S.E. or SMU/LIFT
(2) Operation possible only with 2-cylinder S.E.
(3) Operation possible only in presses with ON/OFF hydraulics
(4) Available only as of version PH 13.01.01
(5) SET-UP OPERATION NO. = 12 must be set (go to page O on the PC).
(6) The following data items must be set as indicated: DIE-SET LOCKED = NO and DIE-SET DISASSEMBLY = 2. The
following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered (input
SQ59 off) die-set encoders blocked and the self learning procedure for SPE 2 + 2 carried out.
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(7) The following data items must be set as indicated: DIE-SET SECURED = NO and DIE-SET DISASSEMBLY = 3.
The following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered
(input SQ59 off) die-set encoders blocked and the “DIESET ENCODER NOT RESET MESSAGE” displayed.
(input SQ59 off) die-set encoders blocked and the self learning procedure for SPE 2 + 2 carried out.
(input SQ59 off) die-set encoders blocked and the “DIESET ENCODER NOT RESET MESSAGE” displayed.
(10)The following data items must be set as indicated: DIE-SET LOCKED = NO and DIE-SET DISASSEMBLY = 1. The
following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered (input
SQ59 off) die-set encoders not blocked, “DIESET ENCODER NOT RESET MESSAGE” displayed and die-set down.
(11)Only with DCP type filler box and program version PH 13.xx.yy:
The “FILLER-BOX ENCODER NOT RESET” should not be displayed when the filler-box is in the reset position.
From version PH13.08.01 onwards, the user can reset the encoder zero-point offset for the filler box by performing
the procedure below:
Press keys 25, 30 and 8 with the mode selector turned to SET-UP and the PUMP OFF. Once this operation has been
completed, the filler box will stop exactly when the encoder emits the zero-set pulse.
(12)SET-UP OPERATION NO. = 19 must be set (go to page O on the PC).

Encoder BQ12 for the booster must be reset. It takes approximately 10 minutes to drain the booster. This procedure
can be interrupted at any time with the mode selector.
The circuit pressure reaches a value equal to the pressure set for the FINAL PRESSURE data item on the Press
cycle set-up page.
(16) When a proportional rod lift system is used, the upstroke in SET-UP mode is interrupted as soon as one of the two
keys is released.
The die-set upstroke can be carried out only with die-sets with the AX axes card.
(17) When a proportional rod lift system is used, the downstroke in SET-UP mode is interrupted as soon as one of the
two keys is released.
Downstroke with the mode selector turned to MAN:
- with a 2-downstroke cycle:
the first die-set downstroke is executed by pressing keys 30 and 13;
the last die-set downstroke is executed by pressing keys 31 and 13.
- with a 3-downstroke cycle:
the first die-set downstroke is executed by pressing keys 26 and 13;
the second die-set downstroke is executed by pressing keys 30 and 13;
the last die-set downstroke is executed by pressing keys 31 and 13.

The filler-box must be hooked up, the safety bar down, the limit switch for end of filler-box’s return stroke triggered
(input SQ59 off), the die-set down and the plunger raised with the encoders zero set.

The filler-box must be hooked up and encoder BQ11 for the differentiated booster zero set.
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(20)If SEMI-AUTOMATIC PRESS-CYCLE IN MANUAL has been selected and two encoders are mounted for the
plunger, once a semi-automatic loading cycle has been completed with the bar down, the bar can be raised and
lowered and a semi-automatic press-cycle can be carried.
(21)Operation possible with in-line filler-box, ALM or ACP with absolute encoders (even if they are not zero set yet).

The following conditions must be satisfied: safety bar down, limit switch for end of filler-box’s return stroke triggered
(input SQ59 off), die-set encoder reset, plunger raised with encoders reset.
If problems arise during the YV21P self-learning procedure which prevent the correct offset values from being
determined or the values found do not allow for proper upward movement, the values can be assigned manually.
This is accomplished by setting the value in valve points of the downstroke and upstroke for the DOWNSTROKE
and UPSTROKE items.
(24) Available starting from version PH 15.01.01.
(25) Available only with versions PH 12.xx.yy, PH 13.xx.yy and PH 14.xx.yy.
(26)Operation possible only in presses with proportional hydraulics. SET-UP OPERATION NO. = 21 must be set (go
to page O on the PC). The plunger should be raised. The bar should be lowered. The filler box should be connected
and back. If the SPE is used, the die set should be down.
(27)Only for presses with 2 + 2 SPE with Sacmi axes card (AX). SET-UP OPERATION NO. = 22 must be set (go to page
O on the PC). The plunger should be raised. The bar should be lowered. The filler box should be connected and back.
The die set should be down.
(28)Only for presses with SPE with Sacmi axes card (AX). SET-UP OPERATION NO. = 23 must be set (go to page O
on the PC). The plunger should be raised. The bar should be lowered. The filler box should be connected and back.
The die set should be down.
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4.2 DESCRIPTION OF THE LEDS
+5 Keyboard supply (+5V)
R Reset
WD Watch-dog
SL Serial line (comes on if the keyboard is not hooked up to the PLC)
SC Scan control (comes on to indicate that a key is malfunctioning)
B Comes on when a key is pressed
A1
A2
} Keyboard address (both of them on → first keyboard)
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5 PROGRAMMING KEYBOARD
A Display
B Function keys (F1, F2 – F12)
C CTRL key
D Number keys (1, 2 – 0)
E: Mouse
F: Leds signaling the following:
Power: Turns on power to PC
B: Buttons depressed
Caps: Used to type capital letters
Scroll: Used to scroll
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6 PAGE LAY-OUT AND GENERAL INFORMATION
Photograph 1
Information regarding machine operation is given on various video-pages.

Each page has a status bar at the top and a button bar on the bottom.
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PH 383.85.050 Rev. 00 Date 27.02.2006
6.1 STATUS BAR
The information below is given on two lines that appear at the top of the page:
First line
1 - Fault messages
2 - Machine status icon
3 - Date
4 - Time
5 - Authorized username
6 - Symbol indicating mode selector position (key selector)
Second line
7 - Description of the type of automatic cycle (present only if the mode selector is turned to AUT)
8 - Operating program number
6.2 MACHINE STATUS
Symbols are used to indicate the operational state of the machine. A list of the symbols and their meanings is given
below:
MACHINE IN AUTOMATIC MODE (key turned to AUT)
MACHINE BEING STOPPED (key turned to AUT)
MACHINE SHUT DOWN (key turned to AUT)
MACHINE BEING AUTOMATICALLY RESET (key turned to AUT)
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6.3 STATE OF THE KEY SWITCH
Three symbols are used to indicate the state of the key switch:
AUT Key switch on keyboard turned to AUTOMATIC
MAN Key switch on keyboard turned to MANUAL
SET UP Key switch on keyboard turned to SETUP
NOTE:
If the key switch on the machine control keyboard during operation, the press will shutdown.
6.4 USERNAME
The username actually authorized is shown in the status bar.
6.5 OPERATING PROGRAM NUMBER
Operating program refers to the data entered in the computer system used to carry out an entire automatic work-cycle.
The programs are permanently memorized in a data base on the Hard Disk.
The program number shown on the screen (in section 8) represents the operating program which is either actually
being run or can be run.
The operating program (that is being run or can be run) is memorized in a RAM located on the CPU card. A buffered
battery is employed to protect this memory. However, data may be lost in the event of malfunctioning. If this should occur,
read the source program. In any case, only the modifications made to the program which were not saved in the
permanent memory will be lost.
If a red LED ( ) appears to the right of the program number, it means modifications have been made to the program
which have not been saved yet.
When the operating program is 0 (zero), it means that the program has not been saved in the permanent memory.
If the CANCEL function is employed to delete an operating program from the permanent memory, while it is either being
run or can be run, 0 (zero) will automatically be assigned to the program being used.
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7 ADDITIONAL FUNCTIONS
7.1 BUTTON BAR
The button bar, which changes from page to page, appears on the bottom of the page. In any case, the seven buttons
described below are provided:
First four buttons to the left
F1 : calls up help for the page displayed
F2 : accesses the “Stops” page. The user can specify the reason why the machine stops running
on this page.
F3 : opens the “Menu” page
F4 : goes back to the video page previously displayed
Last two buttons to the right
F11 : allows the user to login and logout
F12 : configures the type of cycle executed when the cycle is started. The button is enabled only if
the mode selector is turned to AUT and the press is not cycling in automatic mode or being reset.
7.2 LOGGING IN AND LOGGING OUT
The operator has to press F11 and enter the username and password for the relative items in the window
displayed in order to log into the system. Once this has been done, press ENTER.
Once the user has logged in, he/she can carry out the authorized operations, according to his/her category (e.g.: input
data, reset partial data, etc..).
The user can logout once the operations protected by a password have been completed by pressing key F11. Once
the user has logged out, only operations not protected by a password can be executed.
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7.3 SETTING THE ORDER OF THE CYCLE STAGES
The automatic cycle is the standard one; in this case, the following appear at the beginning of the second line:
0. CYCLE = AUTOMATIC (LOADING + PRESSING)
Automatic cycle. The machine carries out a complete cycle a number of times until the operator stops the
machine or a fault occurs.
The following appears 1 second after the F12 key is pressed.
1. CYCLE = SEMI-AUTOMATIC LOADING
Semi-automatic loading cycle. The machine performs a loading cycle and then stops.
The following appears 1 second after the F12 key is pressed.
2. CYCLE = SEMI-AUTOMATIC PRESSING
Semi-automatic press-cycle. The machine performs a press- cycle and then stops.
The following appears 1 second after the F12 key is pressed (only if the machine works with two plunger
encoders, after a semi-automatic loading cycle has been completed with the safety bar down and a level
4 password has been entered)
3. CYCLE = SEMI-AUTOMATIC MANUAL PRESS-CYCLE
Semi-automatic press-cycle in manual mode. The safety bar can be raised and lowered and a press-cycle
carried out. The cycle goes back to CYCLE = AUTOMATIC.
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7.4 MEMO FUNCTION
This function is accessed by pressing the F9 key on the main navigation page.
When the memo function is used, a text box is opened and the user can write a message inside it. The message will
be saved in the system along with the date and time it was written. Press the button to save the
message. The button on the main navigation page will flash to signal a message is present.
Press the button to cancel the message.
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7.5 STOPS PAGE
Photograph 2
The Stops page allows the user to specify the reasons the machine stops running. As a result, the operator knows the
downtime resulting from one of the causes listed. A detailed report with a chart illustrating the causes of machine
stoppage can be drawn up. Press the F2 key from any page to go to this page. Select the cause by moving the flashing
cursor to it (use the arrow keys) and then press ENTER.
Once the cause has been selected, the Stops page is automatically quit and the system goes back to the previously
selected page.
NOTE
The data elements that stop the press can be set only if there are no faults present.
If a stop, information or maintenance message is shown, the new causes that stop the machine can be set by performing
the steps given above.
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8 HOW TO MOVE AMONG THE PAGES
8.1 SCROLLING THE PAGES
The page assigned to a button can be called up in four different ways:
A) typing the letter or digit given next to the button;

B) moving the cursor (flashing yellow rectangle) on the button and pressing ENTER;
C) moving the mouse arrow on the button in question and clicking with the left mouse key;
D) move among the columns with F5, move among the buttons in a column with F6 select the
indicated button with F7.
8.2 CURSOR
“Cursor” refers to the yellow rectangle that appears in all the program windows, except for the dialog boxes.
The cursor can be moved with the ← ↑ → ↓ keys or the upper keyboard mouse.
8.3 USE OF THE BUTTONS
The function assigned to a button can be called up by either placing the yellow cursor on the button (with the ← ↑ →
↓ keys) and pressing ENTER or moving the mouse arrow on the button and clicking the left mouse key. This goes for
any button.
The functions associated to the buttons in the button bar (bottom of page) can be activated by pressing the function key
(F1, F2, F3 - F12) given below.
The two buttons described below are special as they are always associated with the same keys.
PAGE DOWN F8
PAGE UP F9
These buttons are used to scroll the pages that are part of the subset of the displayed page (for example, if a data input
page is displayed, these buttons are used to scroll all the data input pages).
Some buttons are opaque grey; this means they are disabled and the associated function cannot be activated.
They can be disabled for two reasons:

A) the user level does not authorize him/her to perform the associated operation;
B) the machine status is not as required for the associated operation to be performed.
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8.4 MOVING THE CURSOR IN THE DIALOG WINDOWS
Use the TAB key to move the cursor within the dialog boxes.
When this key is depressed repeatedly, the cursor moves among all the boxes and accessible buttons. The mouse can
be used as an alternative.
When the cursor is on a button, it becomes a dashed rectangle. On the other hand, when it is inside a text box, it appears
as a vertical bar.
To use a key within the dialog windows, move the cursor to it (with the TAB key) and then press ENTER.
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9 MENU PAGE
Photograph 3
This page can be accessed from any page by pressing F3.
The page to be displayed is selected from this page. Five groups of buttons are provided. A page (or a series of similar
pages) is assigned to each button.
The groups are described below.
9.1 OPERATING DATA READ-OUT
0) Display page
1) Data page
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PH 383.85.050 Rev. 00 Date 27.02.2006
2) Loading page
3) Press-cycle page
4) Die-set page
5) Page with data acquisition chart (oscilloscope)
6) Page for inputting data for manual operation
9.2 OPERATING PROGRAM DATA INPUT
A) Programs page
B) Page for setting data regarding plunger braking
C) Page for setting loading cycle data
D) Page for setting press-cycle data
E) Page for setting die-set data
F) Page for setting proportional ejector data
G) Page for setting data for accessories and timing
H) Page for setting data for differentiated press-cycle
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9.3 TROUBLESHOOTING
J) Fault messages page
K) Fault statistics
L) Maintenance page
M) Input/output page
N) Work-cycle status page
O) Submenu for resetting and setting data
9.4 PRODUCTION DATA AND QUALITY ASSURANCE
Q) Production counters and meters
R) Production histograms
S) Consumptions page
T) Statistics and trends submenus
U) Events page
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9.5 SYSTEM SET-UP
V) Set-up page
W) Info page
X) Config page
Allows the PC to be shut down if the UPS battery is run down.
9.6 PRINTING FUNCTIONS
A button (top right-hand side) is associated to each column that allows the most important pages in the column
to be printed out (a printer has to be installed and hooked up).
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10 OPERATING DATA DISPLAY
The contents of the pages, except for the first and second lines, are given below.
10.1 DISPLAY (0) 0
DISPLAY is the first data display page shown.
Photograph 4
Tile thickness and maximum cylinder pressure are shown in extremely large characters on this page so that they can
be easily read even when far away. The data are updated each cycle.
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10.2 DATA DISPLAY (1) 1
Photograph 5
10.2.1 PAGE LAYOUT
This page appears as soon as the system is turned on. The main operating data is shown here.
This page is divided into five distinct sections:
• The data recorded by the position transducers installed on the machine appear in the bottom block on the left side
of the page. The data are updated in real time.
• The pressures and temperatures measured by the transducers installed on the machine are given in the top block
on the right side of the page. As regards the pressure of the cylinder, the maximum pressure reached during each
press-stroke of the last cycle is shown.
• Data concerning the actual production batch are given in the middle block on the right side of the page.
• A chart is given in the bottom block to the right showing the trends of two sample variables in real time. This chart
is set on the data acquisition page (curves to be shown selected, time bases, etc…).
• A model of the press installed is given in the large square on the top left-hand side of the page.
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10.2.2 ENCODER SETTINGS
The encoders values are shown in real time
PLUNGER (mm)
The position of the plunger recorded by 1 or more absolute encoders (BQ6, BQ7 and BQ8) is given in real time.
BOOSTER (mm)
The position of the booster recorded by an absolute encoder (BQ12) is given in real time. This data item is present
only in “Power” series presses with external booster.
FILLER BOX (%) / (°) / (mm)

The filler-box position is given in real time.
If the machine is equipped with a filler-box with a connecting rod-and-crank mechanism, the encoder value (BQ2)
is expressed as both a percentage (%) and in degrees (°). On the other hand, if a linear filler-box is used, the
encoder (BQ2) value is expressed in millimeters (mm).
ALM (mm)
The position of the ALM (mobile hopper) is given in real time.
This corresponds to the value of encoder BQ10.
ACP (mm)
The position of the ACP (powder feeder) recorded by an absolute encoder (BQ21) is given in real time.
This data item is present only in presses with filler boxes that have a base ACP with encoder and inverter.
DIE-SET (mm)
The position of ejector cylinders A and B recorded by 2 incremental encoders (BQ4 and BQ5) is given in real time.
If the machine works with a proportional rod lift system, only the value read by encoder BQ4A is shown.
A green 0 ( ) appears in front of the plunger, filler-box and ALM encoder values to indicate the device is being reset
(after an automatic repositioning cycle) in machines with INCREMENTAL ENCODERS.
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10.2.3 HISTOGRAMS
Four types of histograms are provided that deal with different variables.
CYLINDER PRESS. (bar)

Maximum cylinder pressure read by pressure transducer BP1 reached during each individual press-stroke
included in a complete cycle. Up to five histograms can be shown depending on the number of press-strokes set
for a cycle. The value displayed always refers to the previous cycle.
PRESSURE ACCUMULATORS (bar)

Pressure read in accumulators.
The chart is shown in “power” series presses without booster (BP2) while in presses with booster it is provided
only if pressure transducer BP3 is installed.
PUMP PRESSURE (bar)

Pressure measured by pressure transducer BP4 in the pump line. The data item is shown only in “power” series
presses without booster.
TEMPERATURE OIL (°C or °F)

Temperature of oil circulating (BT4).
The bar values are given in numeric form in all the histograms.
10.2.4 ACTUAL PRODUCTION BATCH
The main data items that affect the final product produced during the current production batch are given here.
MAX. FORCE (KN)

Maximum force applied on the powder at the end of the previous press-cycle.
SPECIF. PRESS. ON POWDER (bar)

Maximum pressure applied on the powder at the end of the previous press-cycle.
NO. OF OUTPUTS
Number of tiles produced each cycle.
DEVIATION THICKNESS (mm)

Tile thickness error compared to set value.
The degree to which the thickness deviates from the set value is shown in a different color in the histogram so
that the error can be clearly seen.
CYCLES PER MINUTE

Estimated number of cycles the machine completes in one minute.
NUMBER OF CYCLES
Absolute counter that shows the number of cycles the machine has completed from when it was first started up.
MATERIAL PRODUCED (m2)

Counter that shows the total amount of material the machine has produced from when it was first put into
operation.
TILE THICKNESS (mm)

Tile thickness produced at the end of the press-cycle.
TILE WIDTH (mm)

Tile width after firing set for the actual production batch.
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TILE LENGTH (mm)

Tile length after firing set for the actual production batch.
TILE CODE
Code and description of tiles produced during a production batch.
This data item is present only if the machine is hooked up to the division’s controller that automatically governs
the production batches.
10.2.5 CHART
The first two curves selected on the data acquisition page (oscilloscope) are displayed. Refer to paragraph 10.6 for more
detailed information.
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10.3 LOADING DATA DISPLAY (2) 2
Photograph 6
10.3.1 PAGE LAYOUT
The data display page regarding the powder loading cycle is divided into seven sections:
• Three histograms that identify where the filler-box and ALM are located while traveling are given in the top box on
the right side of the page. The first two regard the filler-box’s forward and return stroke while the third one refers to
the ALM stroke.
• The gains for opening the filler box valve during the forward and return strokes are given in the left box (only with
filler box with crank and connecting rod mechanism). The offset values regarding the forward and returns strokes
are also indicated.
• The length of the first die-set downstroke is given in the middle block. It is divided into two parts, depending on the
type of die set used.
• Actual brush status is shown in the box on the right side of the page.
• The times used during the five steps that make up the filler-box stroke are indicated in the bottom box. These times
refer to the previous cycle.
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• The last box at the bottom (only with external filler box for double loading or DIP controlled by its own PLC), shows
the times between downstrokes that the filler box’s stroke is divided into. These times were recorded during the
previous cycle.
10.3.2 HISTOGRAMS
Three histograms that identify the position of the filler-box during its forward and return strokes as well as the position
of the ALM during its stroke (back and forth) are provided.
Symbols are provided on each histogram that indicate the most significant settings.
A red arrow indicates the value set for the end of the return stroke.
A light blue arrow indicates the set approach value.
A blue arrow indicates the value set for the end of the forward stroke.
The values that limit the filler box’s forward steps are indicated by several green numbers
The values that limit the filler box’s return steps are indicated by several purple numbers
FILLER-BOX POS. (%) / (mm)

The position of the filler-box recorded by the encoder (BQ2) is given in real time.
FILL.-BOX AFTER 1ST DWNSTR. (%) / (°) / (mm)

The position of the filler-box recorded at the end of the first die-set downstroke is given.
ALM position (mm)

The position of the ALM recorded by the encoder (BQ10) is given in real time.
10.3.3 FILLER BOX MOTION
FORWARD GAIN
Gain to open filler box valve (YV20A) during the forward stroke.
FORWARD OFFSET
Minimum signal required for the filler box to move during the forward stroke.
RETURN GAIN
Gain to open filler box valve (YV20A) during the return stroke.
RETURN OFFSET
Minimum signal required for the filler box to move during the return stroke.
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10.3.4 FIRST DIE-SET DOWNSTROKE
LGTH OF 1ST DWNSTR. (ms)

Length of the first die-set downstroke divided into two parts. The first half is the time from when solenoid valve
YV22 is de-energized and sensor SQ3 is deactivated. The second half ranges from when SQ3 is deactivated and
sensor SQ6 is activated; only one time appears when a proportional ejector is used
10.3.5 BRUSH
CYCLES BTW REVERSES

Number of cycles remaining before the brush reverses.
An icon showing the direction in which the brush operates is shown in the block
Brush stationary Brush running clockwise
Brush running counter-clockwise
10.3.6 FILLER-BOX TIMES
FILL.-BOX FWD. (ms)

Time taken to carry out each of the 5 steps that make up the forward stroke of the linear filler-box.
The values are measured at the end of each cycle (these times are calculated only during an automatic or semi-
automatic loading cycle).
FILL.-BOX RTN (ms)

Time taken to carry out each of the 5 steps that make up the return stroke of the linear filler-box.
The values are measured at the end of each cycle (these times are calculated only during an automatic or semi-
automatic loading cycle).
TOTAL FILL.-BOX FWD. (ms)

Time taken for the filler-box to complete its forward stroke (excluding first and last 20 mm of stroke).
TOTAL FILL.-BOX RTN (ms)

Time taken for the filler-box to complete its return stroke (excluding first and last 20 mm of stroke).
TOTAL FILL BOX TIME (s)

Total time taken to perform the filler box loading cycle (including first and last 20 mm of stroke).
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10.3.7 EXTERNAL DOUBLE LOADING FILLER BOX OR EXTERNAL TILE FEEDER TIMES
If a double loading filler box or external D.I.P. is employed to load the powder, the press’ program delegates an external
controller to govern loading. This system consists of a piloting electronic control and its own controls. Under these
conditions, the press does not acquire any data about the position of the filler box each and every second nor information
about the operating times of the accessory.
FILLER BOX OPERATING TIME START UP -> 1ST DOWNSTROKE (s)

Time taken by the filler box to travel from its start up position to the position in which the die sets perform the first
downstroke.
FILLER BOX OPERATING TIME 1ST DOWNSTROKE -> 2ND DOWNSTROKE (s)
Time taken by the filler box to travel from the position in which the die sets perform the first downstroke to the
second die set downstroke position.
FILLER BOX OPERATING TIME 2ND DOWNSTROKE -> 3RD DOWNSTROKE (s)
Time taken by the filler box to travel from the position in which the die sets perform the second downstroke to the
third die set downstroke position.
FILLER BOX OPERATING TIME 3rd DOWNSTROKE -> ARRIVAL (s)

Time taken by the filler box to travel from the position in which the die sets perform the third downstroke to the
arrival position.
TOTAL FILLER BOX OPERATING TIME (s)

Total taken by the filler box to travel from the position in which it starts to its arrival position.
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10.4 PRESS-CYCLE DATA DISPLAY (3) 3
Photograph 7
10.4.1 PAGE LAYOUT
The press-cycle data display is divided into four sections:
• The pressures measured by the transducers installed in the hydraulic circuit to control the press-cycle are shown
in the top section on the left side of the page. The offset values of the proportional valves measured during the self-
learning procedure that regard the press-cycle are indicated at the side (only in proportional machines).
• The length, pressure and thickness values regarding the press-cycle are given in the bottom box on the left side of
the page. Values (stroke and length) regarding de-aeration during the individual press-strokes that make up a
complete cycle, measured at the end of the previous cycle, are also given.
• The length of the plunger upstroke and downstroke is given in the first top box on the right side of the page. The total
press-cycle time, referring to the last cycle performed, is given underneath.
• A number of parameters used for plunger operation during the press-cycle are shown in the bottom box on the right
side of the page.
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10.4.2 OFFSET VALUES OF THE PROPORTIONAL VALVES AND HYDRAULIC CIRCUIT

PRESSURES
CYLINDER PRESS. (bar)

Cylinder pressure measured by pressure transducer BP1.
PLUNG. UPSTR. CHAMB PRESS. (bar)

Pressure in the plunger upstroke chamber measured by pressure transducer BP5 (only for proportional presses).
TYPE OF JOLLY TRANSDUCER BP99 (bar)

Select the type of jolly transducer BP99.
JOLLY TRANSDUCER BP99 END SCALE VALUE (bar)

Set the end scale value for jolly transducer BP99.
JOLLY TRANSDUCER BP99 PRESSURE (bar)

Pressure measured by jolly transducer BP99 provided.
BOOSTER STROKE BEING RESET (mm)

Stroke performed by external booster while encoder BQ12 is being reset (only for “Power” series presses with
external booster).
MOTOR POWER ON M1 (KW)

Motor M1 power transmitted to the drive shaft measured by power meter PJ3.
This data item is displayed only if the machine has the accessory for measuring the current absorbed in the
cabinet.
MIN PLUNG. UPSTR. CHAMB PRESS. (bar)

Minimum pressure value in the upstroke chamber to move the plunger up (only for “Power” series presses).
BOOSTER SPEED (mm/s)

Actual speed of the external booster (only for “Power” series presses with external booster).
BOOSTER REPOSITIONING (mm)

Repositioning value the external booster has to reach at the end of each cycle (repositioning starts from when
the plunger completes the upstroke). The value is calculated by comparing the maximum stroke performed with
the flow booster and the pressure value in order to determine a starting position that allows the booster to remain
within the top and bottom end stops.
BP203 OFFSET
Offset value of pressure transducer BP203 measured when YV210 (solenoid valve for transducer BP203) is not
activated (transducer connected with atmospheric pressure).
BP204 OFFSET
Offset value of pressure transducer BP204 measured when the booster is fully forward.
OFFSET YV32 DOWNSTROKE

Proportional valve YV32 offset value for the plunger downstroke.
OFFSET YV32 CENTERED

Proportional valve YV32 offset value to keep the plunger stationary.
PREVIOUS OFFSET YV32 CENTERED

Proportional valve YV32 offset value to keep the plunger stationary during the last self-learning procedure
performed. In fact, in presses that have YV104 (oil leak compensation valve), the YV32 centered offset value may
vary from cycle to cycle to compensate for any oil leaks that may be present during operation.
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OFFSET YV32 UPSTROKE

Proportional valve YV32 offset value for the plunger upstroke.
YV318 DECOMPRESSION OFFSET

Proportional valve YV318 offset value for decompression (only for “Power” series presses with external booster).
YV318 CENTERED OFFSET

Proportional valve YV318 offset value to keep the cylinder under pressure (only for “Power” series presses with
external booster).
YV318 PRESSING OFFSET

Proportional valve YV318 offset value for pressing (only for “Power” series presses with external booster).
YV100 FORWARD OFFSET

Proportional valve YV100 offset value for booster forward stroke at 6 mm/s.
YV100 CENTERED OFFSET

Proportional valve YV100 offset value to keep the booster stationary.
YV100 RETURN OFFSET

Proportional valve YV100 offset value for booster return stroke at 6 mm/s.
YV70D OFFSET
Proportional valve YV70D offset value for decompression (only for “2000” series presses set up for differentiated
press cycles and PH3800).
OFFSET YV318
Proportional valve YV318 offset value to compensate for the structural differences of the valve (only for “2000”
series presses and PH3800).
While the self-learning procedure is in progress, the background becomes blue to signal which offset value is
in question.
10.4.3 TYPICAL PRESS-CYCLE PARAMETERS
The parameters typical of each individual press-stroke are displayed on each line. These data are based on a minimum
of one (1) press-stroke to a maximum of three (3) press-strokes per cycle when conventional presses are used and five
(5) for “Power” series machines.
The values regarding the pressing stage are given on each line (left side) while the de-aeration values are given on the
lines that deal with the various press-strokes (right side).
All the values are measured at the end of the previous cycle.
PRESSURE (bar)
Maximum pressure reached during the press-stroke.
1ST STAGE LENGTH (ms)

Time taken to reach half of the set pressure value (if mode = 1 or mode = 2) or time taken to reach the thickness
set (if mode = 0) during the individual cycle stages (only for proportional presses with booster).
LENGTH (ms)
Length of the press-stroke.
DECOMPRESSION (ms)
Decompression time.
THICKNESS (mm)
Tile thickness measured at the end of the various press-strokes.
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DEAERATION STROKE (mm)

Stroke plunger executed during de-aeration (only for proportional presses).
This value is obtained by adding the set value to the detected error.
DEAERATION LENGTH (ms)

Length of the de-aeration stage.
10.4.4 BRAKING
PLUNGER D.STROKE (ms)

Time taken for the plunger to move down.
MAX. DOWNSTROKE SPEED (mm/s)

Maximum speed reached by the plunger during the previous downstroke (in manual or automatic mode).
IMPACT SPEED (mm/s)

Plunger speed at the end of the downstroke measured when it comes into contact with the powder.
PLUNGER U.STROKE (ms)

Time taken for the plunger to move up.
MAX. UPSTROKE SPEED (mm/s)

Maximum speed reached by the plunger during the previous upstroke (in manual or automatic mode).
UPSTR. SPEED W/BRAK. (mm/s)

Plunger speed at the end of the section where the brake is applied during the upstroke (only if braking during the
upstroke has been enabled).
TOTAL (ms)
Time taken to complete the press-cycle.
BRAKE POS. (mm) (not present in proportional presses)

Position of the needle of the logic element used for braking. 40 corresponds to maximum braking, 470 to minimum.
10.4.5 PLUNGER POSITION
A number of parameters regarding plunger braking and the maximum stroke it carried out during the last press-cycle
are given in this box.
MAXIMUM PLUNGER STROKE (mm)

Maximum plunger stroke reached during the previous cycle recorded by BQ6. In machines that have 2 or more
absolute encoders mounted on the plunger, the stroke measured by the other encoders (BQ7, BQ8) is also
displayed.
DISTANCE BETWEEN PUNCHES (mm)

Distance between upper and lower punches.
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10.5 DIE-SET DATA DISPLAY (4) 4
Photograph 8
10.5.1 PAGE LAYOUT
The die-set data display page is divided into four sections:
• Histograms are shown at the top of the page. These illustrate the die (upper and lower) and punch (upper and lower)
temperatures, comparing the set value to the value measured in real time.
• The positions of proportional ejector cylinders A and B and main variables (length and speed) regarding the die-set
downstroke are given in the middle block. In addition, the ratio (percentage) between the soft filling height and final
tile thickness is given.
• A histogram that shows how the die-set is wearing down is given in the bottom block. A colored bar is used that
represents the number of cycles performed with the die-set in relation to its expected service life.
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10.5.2 DIE-SET TEMPERATURES
The temperatures of the die-set measured in the areas listed below are provided:
- upper punches
- lower punches
- upper die
- lower die
The following are provided for each item displayed:
TEMPERATURE (actual value) (°C or °F)

Temperature measured by the thermocouple in real time. The thermocouples in question are listed below:
- BT5 = upper punches

- BT6 = upper die
- BT7 = lower die
- BT8 = lower punches
A histogram shows the temperature. The numeric value is given at the base of the bar.
TEMPERATURE (set-point) (°C or °F)

Set temperature the element in question has to reach. The numeric value is shown on the left side of the relative
histogram. A red arrow is used to indicate the value.
START-UP TIME (%)

Time for turning on the heater for each part of the die-set expressed as a percentage of the time it is on in relation
to the time it is enabled.
A colored light comes on to signal the corresponding die-set heater is on is provided under each histogram.
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10.5.3 DIE-SET POSITION
The values of the two proportional ejector encoders are given in the block in real time.
DIE SET VALUE (A, B) (mm)

The values of cylinders A and B are shown.
If the machine is set up to work with a proportional lift system with rods, only the value that determines the position
of the ejector is displayed.
10.5.4 DIE-SET DOWNSTROKE
DIE-SET UPSTR. (ms)

Length of the die-set upstroke (only if the proportional lift system with rods is not installed).
DIE-SET UPSTR. SPEED (mm/s)

Speed at which the die-set carries out the upstroke (only with 4-cylinder or 2 + 2 cylinder proportional ejector).
1ST DIE-SET D.STROKE (ms)

Length of the first die-set downstroke (only with 4-cylinder or 2 + 2 cylinder proportional ejector).
1ST DIE-SET D.STROKE SPEED (mm/s)

Speed at which the die-set carries out the first downstroke (only with 4-cylinder or 2 + 2 cylinder proportional
ejector).
2ND DIE-SET D.STROKE (ms)

Length of the second die-set downstroke (only with 4-cylinder or 2 + 2 cylinder proportional ejector). The value
is displayed only if the machine is configured to perform a cycle with the third die-set downstroke and the glaze
thickness is set.
2ND DIE-SET D.STROKE SPEED (mm/s)

Speed at which the die-set carries out the second downstroke (only with 4-cylinder or 2 + 2 cylinder proportional
ejector). The value is displayed only if the machine is configured to perform a cycle with the third die-set
downstroke and the glaze thickness is set.
LAST DIE-SET DOWNSTR. (ms)

Length of the last die-set downstroke (only with 4-cylinder or 2 + 2 cylinder proportional ejector).
LAST DIE-SET DOWNSTR. SPEED (mm/s)

Speed at which the die-set carries out the last downstroke (only with 4-cylinder or 2 + 2 cylinder proportional
ejector).
SOFT FILLING HGHT (mm)

Measured soft filling height.
TILE THICKNESS / SOFT FILLING HGHT (%)

Ratio between tile thickness and soft filling height. This value indicates the degree to which the filling height is
reduced to obtain the required tile thickness.
AXES CARD STATUS

Axes card status code.
ERROR FROM AXES CARD

Error code from axes card.
CONTROL
Analog reference from axes card to proportional valve side A and B; it ranges from 0 (lowest value) to 4095
(highest value).
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EJECTOR THRUST (bar)

Force expressed in bar measured by the two SPE pressure transducers.
HOME POSITION (mm)

The following data are displayed whenever the die-set encoder is reset:
distance between end-stop and zero pulse for side A, side B and cycle counter. The values measured the next
to last time the reset procedure was performed are shown on the underlying line.
Generally speaking, the home values range from 2 to 3 mm.
If -1.00 mm appears, it signifies the zero pulse for that encoder has not been read.
SIGNAL TO AXIS CARD

Signal to axis card.
AXIS CARD MOVEMENT

Axis card movement.
OFFSET (%)
Offset value measured for the SPE proportional valves expressed in % of the maximum opening; it is measured
during the die-set encoder reset procedure.
FEEDBACK (%)
Position of the spools of the SPE proportional solenoid valves on side A and B; it may range from – 100.0%
(opening to the greatest extent during downstroke) to 100.0% (opening to the greatest extent during upstroke)
(only with AX card).
UPSTROKE CHAMBER PRESSURE (bar)

Pressure transducer (in bar) for SPE lower chambers.
DOWNSTROKE CHAMBER PRESSURE (bar)

Pressure transducer (in bar) for SPE upper chambers.
10.5.5 DIE-SET CYCLES
NO. OF CYCLES PERFORMED W. DIE-SET

Number of cycles performed with the current die-set. This number must be zero set whenever the die-set is
changed.
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10.6 DATA READ BY TRANSPONDER
Photograph 49
A fronte di ogni RFID viene visualizzato un codice di errore.
1 - module not ready: not in Idle State

2 - module does not respond to Send request (module not working?)
3 - module does not respond to 1st segment Send request
4 - module does not respond to 2nd segment Send request
5 - module does not respond to 3rd segment Send request
6 - module does not respond with Job End Acknowledgement
7 - module does not respond to Receive request (rfd not fed? connection between module and RFID?)
8 - response from RFID does not start with STX
9 - module does not respond to Receive 1st segment request
10 - response from RFID is not Ok but is “time out transponder” (tag not in correct position? RFID not fed
sufficiently?)
11 - response from RFID is not Ok but is “transponder error” (RFID not fed sufficiently?)
12 - response from RFID is not Ok but is “command error”
13 - module does not respond to Receive 2nd segment request
14 - module does not respond to Receive 3rd segment request
15 - module does not respond to Receive 4th segment request
16 - response from RFID does not end with ETX
17 - response from RFID does not have correct BCC (checksum)
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PH 383.85.050 Rev. 00 Date 27.02.2006
18 - module does not respond to Receive 5th segment request

19 - response from RFID does not end with CR
21 - module not ready: not in Idle State
22 - module does not respond to Send request (module not working?)
23 - module does not respond to 1st segment Send request
24 - module does not respond to 2nd segment Send request
25 - module does not respond to 3rd segment Send request
26 - module does not respond to 4th segment Send request
27 - module does not respond to 5th segment Send request
29 - module does not respond to Receive request (rfd not fed? connection between module and RFID?)
30 - response from RFID does not start with STX
31 - module does not respond to Receive 1st segment request
32 - response from RFID is not Ok but is “time out transponder” (tag not in correct position? RFID not fed
sufficiently?)
33 - response from RFID is not Ok but is “transponder error” (RFID not fed sufficiently?)
34 - response from RFID is not Ok but is “command error”
35 - response from RFID does not end with ETX
36 - module does not respond to Receive 2nd segment request
37 - response from RFID does not have correct BCC (checksum)
38 - response from RFID does not end with CR
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PH 383.85.050 Rev. 00 Date 27.02.2006
10.7 DATA ACQUISITION CHART (5) 5
Photograph 9
The charts shown on the pages called up from the submenu are “real time charts”. This means the data are acquired
at the moment in which the user accesses the chart. As a result, the values displayed regard the cycle completed just
before the page was opened.
This system (when data is displayed the first time) enters a delay time for displaying the chart. This is done as the
machine must complete a cycle before it can furnish updated data. If the chart page is not quit, the values of the cycle
just completed are displayed non-stop. When changing the chart page, it is necessary to wait for the system to
synchronize itself again with the machine before displaying the requested curve (or curves).
Up to four variables are shown in the charts. The chart curve, scale of the ordinates and name of the first variable are
shown in red. On the other hand, the chart curve, scale of the ordinates and name are displayed in yellow for the second
variable.
Use the ON-OFF button ( ) to decide whether or not to display the data for the variable.
Button is used to select the parameter to be displayed from amongst the ones present.
Use the button to change the minimum and maximum thresholds of the vertical axis.
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To modify one of the two scale values for a variable, select the corresponding button, type the new value in the
designated space next to the two data elements and then press ENTER. Once the minimum or maximum threshold has
been changed, the new scale will be used for the next cycle.
Use button to change the sampling time of the chart. A value ranging from 0.6 to 120 seconds can be entered.
In addition, the minimum or maximum thresholds of the horizontal axis can be changed.
Use button to select the trigger (cycle phase) to time the chart.
Use button to display the track (tracks) regarding the next to last cycle performed to check to see if the cycles
are repeated correctly over time.
A green led ( ), located beside the key, comes on to signal the option has been selected.
Press the button again to eliminate the track/s. The track/s will no longer be present and the green led will go out.
Use button to display the track (tracks) regarding a cycle that was previously performed to check to see if the
cycles are repeated correctly over time. In particular, the curve for the first variable is displayed in light blue while the
curve for the second variable appears in magenta.
A green led , located beside the key, comes on to signal the option has been selected.
Press the button again to eliminate the track (tracks). The track (tracks) will no longer be present and the green led will
go out.
Use button to memorize the current track (tracks).
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10.8 PRODUCTION DATA INPUT PAGE (6) 6
Photograph 10
This page allows the user to enter the values for the data items that cannot be directly monitored by the machine and
therefore statistics regarding them can be drawn up.
Once the data have been entered, press the button shown beside it to save the data entered on the Hard Disk.
Press buttons (F9) and (F10) or the PGDN and PGUP keys on the keyboard to scroll the list.
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The following data elements can be input:
Density (Kg/dm3) = Measured tile density.
Penetration (mm/100) = Measured tile penetration.
Bin = Number of silo powder is provided from.
Moisture, s.d.m. (%) = measured moisture content of powder before being pressed.
Grain size (%) = Measured concentration of granules in the powder before being pressed.
Two data items that can be set are shown on the bottom of the page: hourly consumption rate for water used to cool
down the pump and weight per piece produced. These values are used for the estimated consumption values given on
the relative page. If an energy meter (optional) is not provided, the hourly consumption rate regarding electrical power
can be set.
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11 OPERATING PROGRAM DATA INPUT
11.1 LIST OF OPERATING PROGRAMS (A) A
Photograph 11
The list of programs stored in the system memory is displayed on the programs page. A program contains all the machine
operating data that can be set. Each program is identified by a number and name selected by the operator. The number
and name of the program appears on each line. Use the F9 and F10 keys or the Page Up
and Page Down keys on the keyboard to scroll the list of programs. If the number is displayed without the name it means
the relative program has been cancelled.
Press (4) to enter a filter to search a title.
Press (5) to order the programs according to tile instead of number.
Press (6) to print out a report with all the data set in the various programs saved on the hard disk (it must be
installed and hooked up to a printer).
Press (7) to enter a filter to search a certain size.

The number of programs that can be saved is strictly related to the hard-disk memory. The programs should be saved
in chronological order so that they can be quickly located.
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11.1.1 SAVING A PROGRAM
When the key (1) is selected, a window with two boxes appears. One is for the program number and the
other is for the name.
Program number: this is the number that will be assigned to the program being saved.
Regarding the program number, there are two possibilities:
1) Select the “New program” button in the window; as a result, the system saves the program with the first available
number. The name is automatically assigned to the program but can be changed by writing the new name in the
“program name” box.
2) Type a number from 1 to 9999; if the number is actually being used for an existing program, the program active will
take the place of the previously stored program (the system first asks the user is he/she wants to write over the program).
Program name: this is the name that will be assigned to the program being saved. Any name can be used for the
program. Up to 60 characters can be used. This data item is optional; if this box is left blank, the system automatically
assigns a name to the program (for program number x the name “PROGRAM NO. x” is assigned).
Once the program number and name (optional) have been entered, select the “Write” button and press ENTER.
Press ESC or select the “Cancel” button to cancel the operation.
11.1.2 PROGRAM READ-OUT
The program cannot be read while the machine is cycling.
When key (2) is selected, a window with a box for the program number appears.
Type the program number to be read in this box. Only the numbers used for the stored programs are valid (the number
and name must be shown on the relative line).
Press ESC or select the “Cancel” button to cancel the operation.
11.1.3 CANCELLING A PROGRAM
When key (3) is selected, a window with a box for the program number appears.
Type the program number to be cancelled in this box. Only the numbers used for the stored programs are valid (the
number and name must be shown on the relative line). The system asks the user if he/she is sure he/she wants to cancel
the program before it is actually erased. If the active program is cancelled, the number of the active program will become
0 (zero).
Press ESC or select the “cancel” button to cancel the operation.
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11.1.4 DATA INPUT
When modifying a set data item, first of all open the relative data input page (for example, to set the number of tiles per
batch, open the page for setting the die-set data).
Move the yellow cursor to the data item to be modified and then press ENTER. The same result is achieved by moving
the mouse arrow to the data item and clicking the left mouse key.
If the data item can be set (the user has logged in), a dialog window will open. Two windows are provided, depending
on whether the data item is a number or YES / NO type.
See:
Dialog window for numerical data
Dialog window for YES / NO data items.
Use button from each data input page to highlight the data items that have been modified in relation to the
stored program. The background of the modified data items will turn red.
The operation described above can be executed for all the settable data items on all the data input pages. Use button
provided on all the data input pages when the data items no longer need to be highlighted.
The mode selector switch has to be turned to a particular position on some pages in order for data to be modified.
Data is input on 8 pages:
REQUIRED SET UP/MAN/AUT MODE

LOGIN LEVEL SELECTOR POSITION
PLUNGER BRAKING 1 X
FILLING 1 O
PRESS-CYCLE 1 O
DIE-SET 1 O
PROPORTIONAL EJECTOR (*) 1 O
FITTINGS AND TIMING 1 X
DIFFERENTIATED (*) 1 O
* Optional page
X = Insignificant
O = Key must be turned to set up for some data items
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11.1.5 DIALOG WINDOW FOR NUMERICAL DATA
The following are displayed in the dialog window:

- a text box containing the actual value of the data item;
- “ ” button ;
- “ ” button ;
- “OK” button ;
- maximum and minimum allowable values for the data item to be set;
- one or two important data items (optional) that may help in setting the value; these data items are displayed on the
last lines in the window. They are constantly updated.
The data item can be set in three different ways:
A) By cancelling the actual value displayed in the text box on the top left-hand side (use the BKSP key to cancel it) and
entering the new value with the numeric keys (for values with decimals use a decimal point instead of a comma).
B) By decreasing or increasing the value with the “ ” and “ ” keys given in the dialog window.
C) By decreasing or increasing the value with the “↓” and “↑” keys on the keyboard.
Use the “OK” button to make the entry operative and close the window. This is also achieved by pressing ENTER.
To cancel the modifications made, press ESC.
11.1.6 DIALOG WINDOW FOR YES / NO DATA ITEMS
The following are displayed in the dialog window:

- a text box containing the actual value of the data item;
- “ ” button ;
- “ ” button ;
- “OK” button ;
- one or two important data items (optional) that may help in setting the value; these data items are displayed on the
last lines in the window. They are constantly updated.
The data item can be set in two different ways:
A) By decreasing or increasing the value with the “ ” and “ ” keys given in the dialog window.
B) By decreasing or increasing the value with the “↓” and “↑” keys on the keyboard.
Use the “OK” button to make the entry operative.
To cancel the modifications made, press ESC.
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11.2 PLUNGER BRAKING DATA INPUT (B) B
Photograph 12
Date regarding plunger operation are to be entered on this page. The plunger along with related values are illustrated
in the middle of the page while the data items are being set.
The parameters for plunger braking during the downstroke are given on the left side of the figure.
11.2.1 PLUNGER BRAKING DURING DOWNSTROKE
BRAKING DURING P. CYCLE (YES/NO)

Used to select whether or not the plunger is braked during the first press-stroke.
BRAKING SPACE (mm)

Braking space in the last section of the plunger downstroke (only for non-proportional presses).
IMPACT POS. (mm)

When this plunger setting is reached, braking finishes.
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CHECK SPEED (YES/NO)

Used to select whether or not the speed is monitored during the plunger downstroke (not used in proportional
presses).
IMPACT SPEED (mm/s)

Speed at which the plunger reaches the impact position.
STOPPAGE, NO POWDER 1ST (mm)

Plunger position at which the machine shuts down during the first press-stroke when there is no powder in the
die-set.
STOP, NO POWDER (mm)

Plunger position at which the machine shuts down during the next press-strokes when there is no powder in the
die-set.
PLUNGER PARALLELISM ERROR (mm)

This value, expressed in mm, represents maximum plunger inclination during the press-cycle (only for machines
with 2 or more absolute encoders).
11.2.2 PLUNGER BRAKING DURING UPSTROKE
The parameters for plunger braking during the upstroke are given on the right side of the figure.
PLUNGER UP POS. (mm)

Position the plunger reaches when it completes its upward movement during the automatic cycle. The plunger
reaches its mechanical end-stop during the semi-automatic cycle or when the machine is stopped.
TOP LIMIT SWITCH ACCUR. (%)

Used to more precisely position the plunger at the value set for PLUNGER UP POS. If 0 is entered, minimum
precision is obtained. On the other hand, if 100 is entered, plunger positioning is extremely precise while the
production output is reduced (because the plunger slows down to a greater extent) (only for “proportional”
presses).
UPSTR. BRAKING (YES/NO)

Used to select whether or not the brake is used during the upstroke. Braking starts when the plunger is on the
tile and ends when the value entered for END OF BRAK. UPSTR. has been reached. When “proportional” presses
are used, enter the plunger speed in the section where the brake is applied.
UPSTRK. SPEED W/BRAK (%)

Speed at which the plunger moves up in the section where the brake is applied (only for “proportional” presses).
END OF BRAK. UPSTR. (mm)

Value at which braking ends during the upstroke.
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11.3 LOADING CYCLE SET-UP PAGE (C) C
Photograph 13
The loading cycle data are to be entered on this page.
REAR LIMIT SWITCH (mm)

Position of the encoder that determines the end of the filler-box’s return stroke.
FRONT LIMIT SWITCH (mm)

End of filler-box’s forward stroke in relation to the encoder’s zero position.
APPROACH POS. (mm)

If a value greater than 0 is entered, the filler-box will carry out an approach stroke:
• Without ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box has passed
the value set for APPROACH POS. during its return stroke. Once the filler-box reaches the end of its return
stroke it stops for the amount of time set for the APPROACH DELAY TIME data item. After the APPROACH
DELAY TIME has elapsed the filler-box starts traveling again at the speed set for APPROACH SPEED until
the value set for APPROACH POS. is reached;
• With ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box has passed the
value set for APPROACH POS. during its return stroke. Once the filler-box reaches the end of its return stroke
the ALM cycle will start. After the grid has been loaded, the filler-box starts traveling again at the speed set
for APPROACH SPEED until the value set for APPROACH POS. is reached.
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APPROACH SPEED (%)

Speed (in percentage) at which the filler-box travels to reach the APPROACH POS.
FILLER BOX RETURN DELAY (ms)

Delay time before the filler box performs its return stroke.
1ST D.STROKE POS. (mm)

Point of the filler-box forward stroke at which the 1st die-set downstroke is carried out.
GLAZE APPLICATION POS. (mm)

Position of the filler-box in which the die-sets should perform the 2nd downstroke (intermediate).
A data item used to select the filler-box stroke during which glaze is applied is given on the left side. This parameter
should be set as follows:
- 0 = 2nd downstroke during the filler-box forward stroke.
- 1 = 2nd downstroke during the filler-box return stroke.
If the glaze is to be applied during the forward stroke, the value that can be set ranges from the 1st downstroke
position to the position in which the filler-box ends its forward stroke. On the other hand, if the glaze is to be applied
during the return stroke, the value that can be set ranges from the approach position (if set) and the position in
which the filler-box ends its forward stroke. The position in which the glaze is to be applied can be set only with
cycles with 3 downstrokes and when a filler-box NOT for double loading or D.I.P. is used.
SPEED IN MANUAL (%)

Filler-box speed in manual mode.
Set the step limits (maximum 5 forward steps and 5 return steps) along with the filler-box speed when in these
zones.
FILL.-BOX FWD (1st, 2nd, 3rd, 4th STEP) (mm)

Start and end positions of the various steps that form the forward stroke.
FILL.-BOX FWD (1st, 2nd, 3rd, 4th, 5th STEP) (%)

Speed of the filler-box (percentage) used during the steps that form the forward stroke.
The following are to be set for the forward stroke:

- end of 1st step position
- end of 2nd step position
- end of 3rd step position
- end of 4th step position (the end of the 5th forward step coincides with the end of the forward stroke)
- speed used in the 5 zones that make up the forward stroke
FILL.-BOX RTN. (1st, 2nd, 3rd, 4th STEP) (mm)

Start and end positions of the various steps that form the forward stroke.
FILL.-BOX RTN. (1st, 2nd, 3rd, 4th, 5th STEP) (%)

Speed of the filler-box (percentage) used during the steps that form the return stroke.
The following are to be set for the return stroke:

- end of 1st step position
- end of 2nd step position
- end of 3rd step position
- end of 4th step position (the end of the 5th return step coincides with the end of the return stroke)
- speed used in the 5 zones that make up the return stroke
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Example of linear filler-box:

End of return stroke = 175 mm;
Approach position = 430 mm;
End of forward stroke = 1185 mm;
End of forward steps = 520 - 700 - 700 - 1050

Forward speed = 35 - 55 - 55 - 85 - 70
Meaning:
the filler-box travels at the approach speed from the end of the return stroke to the approach position
zone 1) from the approach position to 520 mm the filler-box travels at 35% of the speed
zone 2) from 520 mm to 700 mm the filler-box travels at 55% of the speed
zone 4) from 1050 mm to the end of the forward stroke the filler-box travels at 70% of the speed
End of return stroke = 1000 - 685 - 520 - 430

Return speed = 70 - 85 - 80 - 70 - 60
Meaning
zone 1) from the end of the forward stroke to 1000 mm the filler-box travels at 70% of the speed
zone 5) from 430 mm to the end of the return stroke the filler-box travels at 60% of the speed
When the mode selector switch is turned to MAN (manual), the filler-box travels at a constant speed equal to the value
set for SPEED IN MANUAL.
FILL.-BOX CONTROL ON (YES/NO)

Use the FILL.-BOX CONTROL ON data item to select whether or not an alarm is to be signaled when an error
that exceeds 5% of the set total time (forward or return) occurs.
TOTAL FILL.-BOX FWD (ms)

Length of the filler-box forward stroke.
TOTAL FILL.BOX RTN (ms)

Length of the filler-box return stroke.
If APPROACH POS. > 0 is entered, the trigger pulse for the plunger downstroke is provided as soon as the filler-box
has passed the value set for APPROACH POS. during its return stroke. Once the filler-box reaches the end of its return
stroke the ALM cycle starts. After the grid has been loaded, the filler-box starts traveling again at the speed set for
APPROACH SPEED until the value set for APPROACH POS. is reached.
When in manual mode, the filler-box travels at the speed set for SPEED IN MANUAL. The filler-box travels at the set
speeds when in automatic and semi-automatic mode. If APPROACH POS. > 0, the steps go from APPROACH POS.
to FRONT LIMIT SWITCH. The last part of the return stroke is carried out at the speed set for the 8th return step.
If APPROACH POS. = 0, the steps go from the values set for the end of the return and forward strokes and are the same
length.
EJEC. WHEN STOPPING (YES/NO)

This data item is used to eject the tiles at the end of a press stop cycle.
TYPE OF LOADING
With the pump shut off and the mode selector turned to SET UP, the type of filler box governed by the controller
can be changed selecting from amongst the ones indicated.
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F-BOX SETTING, PLUNGER START (mm)

During the linear filler-box’s return stroke, the plunger starts moving down at the set value as long as miniature
switch SQ59 is activated otherwise a fault will be signaled. If a mobile die is used, the value should be set so that
the grid is out of the die. Enter 0 to inactivate this function.
FILL-BOX START ADVANCE (mm)

When the value set for PLUNGER UP POS. - FILL-BOX START ADVANCE is exceeded during the plunger
upstroke, the filler-box will start operating.
SAFETY FILL-BOX SETTING (mm)

As soon as the filler-box reaches the value set for SAFETY FILL-BOX SETTING, the system checks that the
plunger has moved fully up to the set value otherwise the filler-box shuts down and the “FILLER-BOX/PLUNGER
COLLISION” message is displayed. Set FILL-BOX START ADVANCE = 0 to inactivate this function.
The data item given below:

• APPROACH POS.
• F-BOX SETTING, PLUNGER START
• SAFETY FILL-BOX SETTING
can be modified only if the mode selector is turned to SET UP.
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11.4 PRESS-CYCLE SET-UP PAGE (D) D
Photograph 14
The press-cycle data are to be entered on this page. “Press-cycle” refers to all the operations carried out by the plunger
during the pressing stage.
11.4.1 GENERAL SETTINGS
The pressure and thickness values used to produce the tiles are given at the top left side of the page.
NO. OF P. STROKES (1-2-3-4-5)

Number of press-strokes the machine performs per cycle.
If the machine is set up to carry out 2 press-cycles, just one press-stroke can be set.
More than 3 press-strokes can be set for “Power” series presses.
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PRESS-STR. START POS. (mm)

When this plunger setting is reached, the first press-stroke delay time (1ST PRESS-STROKE DELAY) starts to
elapse. When the delay time has elapsed, the first press-stroke starts. If the first press-stroke is to stop once the
set thickness has been reached, set the PRESS STROKE START THICKNESS data item, which is the soft filling
height at which the first press-stroke should start (only for “proportional” presses).
1ST/2ND PRESS-STROKE DELAY (ms)

Delay time which goes by before the 1st press-stroke starts (that stops once the set pressure has been reached)
when the plunger reaches the value set for PRESS-STR. START POS.
If the machine is set-up for piloted de-aeration, a delay time can be set for the 2nd press-stroke.
FINAL THICK. (mm)

Tile thickness to be obtained at the end of the last press-stroke.
FINAL PRESS. (bar)

Pressure of the last press-stroke.
Only for “proportional presses”, enter the tolerance for the pressure reached during the last press-stroke to the
right of the ± symbol. If the tolerance has been set to zero the last press-stroke will end once the final pressure
has been reached. On the other hand, if the tolerance has been set to 5 bar or more the last press-stroke will end
as soon as the required tile thickness has been obtained as long as the pressure falls within “final pressure -
tolerance” and “final pressure + tolerance” (see figure 1).
LAST PRESS STROKE ACCURACY (%)

The final precision during the last press stroke can be set in some machines: 0% equals minimum precision, 100%
equals maximum precision with a lower production output as it takes the pressure longer to reach the set point.
CYLIN. PRESS. RECOVERY (YES/NO)

If selected, energy is saved.
DECOMPRESSION W/PRESSURE BOOSTER (YES/NO)

If yes is selected, it allows the cylinder to be decompressed by the booster. This data item can be set only in
“Power” series presses.
FINAL DECOMPRESSION PRESSURE (bar)

Pressure at which decompression controlled by the cylinder is completed.
This data item can be set only if the machine is equipped with a knock out with die.
DECOMPRESSION TIME (ms)

Time cylinder is decompressed at the end of the last press stroke (only for “Power” series machines without
booster).
ACCUMULATORS PRESSURE (bar)

Pressure used to recharge the aux. equipment circuit. This is the value at which the service circuit is charged by
solenoid valve YV306/YV309.
ADDITIONAL ACCUMULATOR RECHARGE PRESSURE

When the de-aeration has been completed, if the pressure is below the set threshold, the pressure is restored
and checked just before the die-sets perform the upstroke.
TYPE OF SET PRESS CYCLE (0-1-2)

Used to select the type of press cycle.
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11.4.2 TYPICAL PRESS-CYCLE PARAMETERS
Various parameters that regard the individual press-strokes included in a complete press-cycle are given in the table
at the bottom of the page.
While the data items are being set, a chart is displayed (only for “proportional” machines) that shows the press-cycle
profile the machine executes during the cycle.
The chart consists of five lines (parameters regarding the single press-strokes are given on each line). A number
indicating the press-stroke index is given at the beginning of each line. The parameters regarding the pressing stage
are given on the left side.
MODE (TH/PR) (0-1-2)

0= stops once the set thickness has been reached (only during the first press-stroke), 1 = stops once the set
pressure has been reached, 2 = stops according to set time (this data item can be set only in SET UP and solely
when “proportional” presses are used)
Mode 0: the press-stroke finishes when the soft filling height set in the TH/PR column is reached.
Mode 1: the press-stroke finishes when the cylinder pressure has reached the setting in the TH/PR column.
Mode 2: the press-stroke finishes after a time controlled by the control system, in order to obtain cylinder pressure
equal to the setting in the TH/PR column, has elapsed.
TH/PR (mm/bar)
If MODE (TH/PR) = 0, enter the soft filling height to be reached to end the press-stroke (only during the first press-
stroke).
If MODE (TH/PR) = 1 enter the cylinder pressure value to be reached to end the press-stroke.
PWF (YES/NO)
Used to select whether or not the booster is to be used during the press-stroke (in this case, it is performed with
the solenoid valve for the direct press-stroke).
1 PUMP (YES/NO)
Used to select whether or not the press-stroke is to be carried out with just one (1) pump. If YES is entered, energy
will be saved as the power unit motors absorb less current (only for presses not supplied with a booster).
SEPARATE (YES/NO)
Used to select whether or not a separate press-stroke, i.e. without the accumulators, is required (only for
“traditional” presses).
P1/PS (mm/bar)
If MODE (TH/PR) = 0 enter the thickness value at the first point of the profile.
If MODE (TH/PR) = 1 enter the pressure value at the first point of the profile (in presses that use a booster, the
data item cannot be changed and equals half the pressure set for TH/PR)(only for “proportional” presses).
T1 (ms)
First pressure profile time during which the value set for S1/P1 is reached (only for “proportional” presses).
T2 (ms)
Pressure profile duration (only for “proportional” presses).
Example no. 1 (see figure 2):

1st press-stroke with MODE (TH/PR) = 0 with PRESS STROKE START THICKNESS = 15.00 mm, TH/PR = 12.00 mm,
S1/P1 = 13.00 mm, T1 = 2000 ms, T2 = 3000 ms. This means that the press-stroke starts when the soft filling height
is 15.00 mm. The press reaches a soft filling height that is 13.00 mm in 2 seconds then reaches a soft filling height that
is 12.00 mm in one second.
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Example no. 2 (see figure 3):

Last press-stroke with MODE (TH/PR) = 1 with FINAL PRESS. = 250 bar, S1/P1 = 125 bar, T1 = 2000 ms, T2 = 3000
ms. This means the cylinder pressure will reach 125 bar in 2 seconds and then 250 bar in 1 second.
SPEED (%)
This is the extent to which YV318 opens during the press-stroke, expressed as a percentage. YV318 controls
the delivery rate to the press-cycle control assembly (only for “proportional” presses that employ a booster).
The de-aeration parameters are given on the right side of the table:
UPSTR. MOT. (%)

The speed for the deaeration upstroke (only for “proportional” presses) should be entered here. Enter 0 to perform
the upstroke at a slow constant speed (through YV31S), enter 100 to perform a fast upstroke (through YV32).
PLUNGER STR. (mm)

The deaeration upstroke is set here (only for “proportional” presses).
LENGTH (ms)
Set the amount of time deaeration should last.
D.STR. SPEED (%)

Set the speed of the downstroke after deaeration (only for “proportional” presses).
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Soft filling
height Fig. 1
Final thickness
Tolerance Tolerance
Final pressure Cylinder pressure
Thickness
Fig. 2
Thickness at
start of press-
stroke
S1/P1
SP/PR
T1 T2 time
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Pressure
Fig. 3
TH/PR or final
pressure (=PR)
PR/2
T1 T2 time
The following data items:

• MODE (TH/PR)
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11.5 DIE-SET SET UP PAGE (E) E
Photograph 15
The data items for the die-set are set on this page.
The page is divided into six blocks that contain the parameters for the various types of die-sets (SMU or traditional lift
system, 2-cylinder S.E., 2 + 2 cylinder S.E., 4-cylinder S.P.E., proportional lift system with rods).
11.5.1 FORMATS
The parameters regarding the tiles being produced are given in the first block at the top left side of the page.
TILE WIDTH (mm)

Width of the tiles being produced during the current production batch.
TILE LENGTH (mm)

Length of the tiles being produced during the current production batch.
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NO. OF OUTPUTS
Number of tiles produced per cycle.
TILE SHRINK (%)

Difference (expressed as a percentage) between the dimensions of the die-set cavity (and therefore the unfired
tile) and the fired tile.
The data item regarding the specific pressure on the tile is calculated using the parameters for the unfired tile
(previously set) while the kiln production (m2 of tiles produced) is calculated using the value set for the “shrink”
data item.
THICKNESS SETTING (mm)

Measured tile thickness.
THICKNESS CONTROL COEFFICIENT (%)

Value used by the system to automatically control the tile thickness.
- With SMU with traditional lift system
The recommended THICKNESS GAUGE IMPULSE value is 200; if the press performs too many cycles to
reach the value set for TILE THICKNESS increase the value, for example to 300.
If the thickness is unstable, decrease the value, for example to 100.
- with 4-cylinder or 2 + 2 cylinder S.P.E.:
The automatic thickness gauge is enabled by entering a number greater than 0 for THICKNESS CONTROL
COEFFICIENT.
The recommended value is 50%; ; if the press performs too many cycles to reach the value set for TILE
THICKNESS increase the value.
If the thickness is unstable, decrease the value.
Perform the procedure given below to correctly set these values:
1. Set IMPACT POSITION to the highest allowable value, for example = 140.00 mm;
2. Set THICKNESS SETTING to the highest allowable value, for example = 40.00 mm;
3. Move the plunger down in manual mode until it comes in contact with the powder in the die-set.
4. Move the cursor to IMPACT POSITION and press ENTER; the window for setting the data item used to read the
actual plunger encoder value opens (to close the window, press ESC);
5. Enter a value lower than the encoder value for IMPACT POSITION.
Example: if PLUNGER ENCODER = 106.80 mm set IMPACT POSITION = 105.00 mm; for “proportional presses”
set PRESS STROKE START POSITION = 105.00 mm;
6. Carry out a press-cycle;
7. Move the cursor to STOP TIME DUE TO POWDER and press ENTER; the window for setting the data item used
to read the MAXIMUM PLUNGER STROKE value opens (to close the window, press ESC) and enter a value
higher than the given one for SHUTDOWN DUE TO POWDER.
8. Proceed in the same way for NO POWDER 1A;
9. Move the cursor to THICKNESS SETTING and press ENTER; the window for setting the data item used to read
the TILE THICKNESS value opens (to close the window, press ESC);
10. Measure the actual tile thickness;
11. Enter a value equal to the measured one for TILE THICKNESS.
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12. Set THICKNESS CONTROL COEFFICIENT to a value greater than 0 to enable the automatic thickness gauge
function.
13. Enter the desired thickness for TILE THICKNESS.
NOTE: This procedure should be executed whenever the die-set is changed.
NOTE: If a program is retrieved from the memory after the die-set has been replaced, use this procedure after reading
the program.
THICKNESS DEVIATION LIMIT (mm)

Threshold (positive or negative) for the final tile thickness. When this value is exceeded, fault messages are
displayed. Two types of fault messages are provided: one that stops the cycle when the set threshold is exceeded
and a message to the operator when an error that is 63% of the set threshold is reached (the press does not stop
running when this message is displayed).
The data item can be set only if the automatic thickness gauge function is enabled.
M2 PRODUCTION BATCH (m2/n°)

As soon as the press has produced the tiles which correspond to the set value, the press will stop and BATCH
COMPLETED will appear on the display.
It is possible to express the production batch in square meters of material or in number of tiles to be produced.
To switch over from one mode to another, press the button beside the data item.
11.5.2 DIE-SET TEMPERATURES
The temperatures of the various parts that make up the die-set are given in the underlying block.
UPPER PUNCH TEMPERATURE (°C/°F)

Set temperature of the die-set upper punches.
Enter 0 for the relevant data item to make the heater inoperative.
LOWER PUNCH TEMPERATURE (°C/°F)

Temperature of the die-set lower punches.
UPPER DIE TEMPERATURE (°C/°F)

Set temperature of the die-set upper die (only with SFS enabled).
LOWER DIE TEMPERATURE (°C/°F)

Set temperature of the die-set lower die.
RUBBER PUNCHES UPPER (YES/NO)

Enter the type of material used to construct the die-set upper punches.
RUBBER PUNCHES LOWER (YES/NO)

Enter the type of material used to construct the die-set lower punches.
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11.5.3 DIE SET MAINTENANCE
NO. OF CYCLES DONE

Number of cycles completed with the actual die set. The value can be set by the operator that determines the initial
number of cycles. After which the value is automatically increased one unit each cycle.
NO. OF CYCLES, DIE SET LIFE

Number of cycles set by the operator after which the die set has to be replaced.
First of all, set the expected service life of the die set for “ NO. OF CYCLES, DIE SET LIFE”. Whenever production is
changed and therefore the die set is changed, write down the value given for “ NO. OF CYCLES DONE” on the “DIE
SET PAGE” for the die set being changed.
Once the die set has been installed, set “NO. OF CYCLES DONE”. When the die set has performed the number of cycles
set for “NO. OF CYCLES, DIE SET LIFE”, message CHANGE DIE SET is displayed.
11.5.4 DIE-SET BLOWER
The parameters for the die-set blower are given in the last block on the bottom of the page (left side).
PRESS. BLOW. (YES/NO)

Set the stages in which solenoid valve YV173 for die-set blowing is activated. Enter YES to operate the blower
during the press-strokes.
DUR. UP. (mm)

Plunger encoder setting at which blowing ends (YV173) during the upstroke.
MOB. DIE CLEANING: START (mm)

Setting for blowing the SFS pusher to clean the mobile die (YV178). It is activated at the set value during the
plunger downstroke.
MOB. DIE CLEANING: END (mm)

Setting for blowing the SFS pusher to clean the mobile die (YV178). It is inactivated at the set value during the
plunger downstroke.
DOUBLE-ROW BLOWER (mm)

If a value greater than 0 is entered, YV175 is energized when the filler-box starts running and is de-energized
once the filler-box has exceeded the set value during the forward stroke (only with machines equipped with a
linear filler-box).
BASE BLOWER: N. OF CYCL.

YV174 (base blowing) is energized for two seconds whenever the automatic cycle is started and periodically
every set number of cycles (only for the PH 4200).
BASE BLOWER: LENGTH (ms)

YV174 (base blowing) is energized for two seconds whenever the automatic cycle is started and periodically
every set number of cycles (only for the PH 4600).
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11.5.5 SFS MANAGEMENT
The parameters for controlling the SFS are given in the first block in the right-hand column at the top of the page.
MOULD TYPE (-1-0-1)

Enter (only if the mode selector is turned to SET UP):
- 1 = SFS upper die;
0 = fixed lower die;
1 = mobile lower die.
DOUBLE EFFECT (YES/NO)

Enter YES if there is a double-acting die-set or NO if it is single-acting.
PUNCH EJEC. DELAY (ms)

Delay time for removing the punches from the end of the last press-stroke (this data item can be set only if the
SFS is enabled).
- with WAIT LOWER DIE-SET = NO; the time starts from the end of the last press-stroke.
- with WAIT LOWER DIE-SET = YES; the time starts from the beginning of the last press-stroke.
PUNCHES IN (1-2-3)
Enter 1 to move the upper punches back in when the filler-box starts, 2 to move them in when the filler-box is at
the end of its forward-stroke and 3 to move them in when the filler-box is at the end of its return stroke.
DIE-SET UP DELAY (ms)

Time at which upward movement of the die-sets is delayed from the end of the last press-stroke.
- with LOWER DIE-SET WAIT = NO; if a SMU or traditional ejector is used, the time starts from the beginning
of the last press-stroke; if a proportional knockout is used, the time starts from the end of the last press-stroke.
- LOWER DIE-SET WAIT = YES; the data item becomes DIE UP DELAY and starts once the plunger has
reached the PLUNGER STR., DIE-SET UPSTR. value.
DIE STOPPED (1st, 2nd, 3rd, 4th) (YES/NO)

Enter YES if the lower die is to stay in place during each de-aeration stage. To obtain the same result during the
last press-stroke, enter YES for the WAIT LOWER DIE-SET data item.
WAIT LOWER DIE-SET (YES/NO)

Used to enable the “lock/unlock die” operation when the lower mobile die remains locked in its low position at
the end of the press-cycle. After the plunger has moved back up again - performing a movement equal to
PLUNGER STR., DIE-SET UPSTR. - the lower punch upstroke is performed. After the DIE UPSTROKE DELAY
time has elapsed the lower die is unlocked and moves up to the upper end-stop thus energizing the 2 sensors
SQ63A/B.
PLUNGER STR., DIE-SET UPSTR. (mm)

Plunger stroke after which the lower punches move up.
11.5.6 LOWER DIE
KNOCKOUT WITH DIE (YES/NO)

This data item is used to perform the tile ejection cycle using the lower mobile die.
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MOBILE DIE ENABLE (YES/NO)

This data item is used to enable the lower mobile die during the press-cycle as per the following criteria:
NO = the lower die stays in place (it does not follow the plunger) during all the set de-aeration stages;
YES = the lower die is able to move (to follow the plunger) during the de-aeration stage; it is possible to select
whether or not the die is to track the plunger for each de-aeration stage by setting the DIE BLOCKED data item
accordingly
DIE DOWNSTROKE DELAY (ms)

Time at which the lower die downstroke is delayed at the end of the last press-stroke before controlled cylinder
decompression starts.
DIE UPSTR. DELAY (ms)

Time at which upward movement of the lower die is delayed during tile ejection.
11.5.7 MAGNETIC LOCK
The data items for locking and unlocking the upper and lower punches to secure the pads are given in the underlying
block.
UPPER LOCK (YES/NO)

Used to lock the upper die-set pads.
Enter YES if the press is equipped with a magnetic lock.
LOWER LOCK (YES/NO)

Used to lock the lower die-set pads.
LOWER LOCK NR. 1 (YES/NO)

Used to lock the die-s lower punch holder.
UPPER LOCK RELEASED (YES/NO)

Used to unlock the upper die-set pads.
Enter YES before unlocking the die-set.
LOWER LOCK RELEASED (YES/NO)

Used to unlock the lower die-set pads.
LOWER LOCK RELEASED NR. 1 (YES/NO)

Used to unlock the lower die-set punch holders.
If the press is equipped with a magnetic lock, set UPPER LOCK = YES, LOWER LOCK = YES and, if the third magnetic
lock is present, enter LOWER LOCK NR.1 = YES.
Locking procedure:
- with the key switch turned to SET UP press the “magnetisation” keys (see DESCRIPTION OF KEYS paragraph) and
make sure the related leds come on. Adjust the current control device of the magnetism (AJ1, AJ2 and AJ3) and turn
the key switch to MAN.
Release procedure:
- with the key switch turned to SET UP set UPPER LOCK RELEASED = YES, LOWER LOCK RELEASED = YES and,
if the third magnetic lock is present, enter LOWER LOCK RELEASED NR. 1 = YES. Press the related keys (see
DESCRIPTION OF KEYS paragraph) and make sure the related leds go out (they flash for more than a minute).
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To release a magnetic lock, first demagnetise it and then set UPPER = NO (or LOWER = NO and, if the third magnetic
lock is present, enter LOWER LOCK NR. 1 = NO).

• MOULD TYPE
• WAIT LOWER DIE-SET
• DIE BLOCKED (1st, 2nd, 3rd, 4th)
• KNOCKOUT WITH DIE
• MOBILE DIE ENABLE
• UPPER LOCK
• LOWER LOCK
• LOWER LOCK NR. 1
• UPPER LOCK RELEASED
• LOWER LOCK RELEASED
• LOWER LOCK RELEASED NR. 1
can be changed only if the mode selector is turned to SET UP.
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11.6 PROPORTIONAL EJECTOR SET-UP PAGE (F) F
Photograph 16
The data for the proportional ejector (4-cylinder S.P.E. and 2 + 2 cylinder S.E. and proportional rod lift system) are to
be set on this page (optional, only with machines equipped with a proportional ejector).
11.6.1 EJECTOR SETTINGS
The values to be reached by the ejector encoder during the various die-set downstrokes (cycle with 2 or 3 downstrokes)
are given in the first block on the top left side of the page.
NO. OF APPL. (2-3)

Number of proportional ejector downstrokes.
- When a 2 downstroke cycle is carried out, enter the value of the filler-box’s forward stroke at which the first
downstroke is performed along with the soft filling height.
- When a 3 downstroke cycle is carried out, enter the value of the filler-box’s forward stroke at which the first
downstroke is performed, the value of the filler-box’s forward stroke at which the second downstroke is
performed (they can be set either during the forward or return strokes) and the thickness of the base and glaze.
This parameter is used to select the number of downstrokes independently from the type of loading system the
press works with.
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TOP LIMIT SWITCH (mm)

Values for cylinders A and B of the 4-cylinder S.P.E. or 2 + 2 cylinder S.E. the die-set has to reach during the
upstroke.
BASE THICKNESS (mm)

Soft filling height (for presses that perform the loading cycle with 2 downstrokes). If 3 downstrokes are used during
the loading cycle, set BASE THICKNESS.
GLAZE THICKNESS (mm)

Glaze loading thickness (for presses that perform the loading cycle with 3 downstrokes).
KNOCKOUT IDLE STROKE (mm)

Proportional rod lift system idle stroke.
Procedure for setting the values for the electronic rod lift system:
• zero set the absolute encoder for the die-set at the end of its stroke;
• lock the die-set;
• enter the value read with the die-set down at the value set for KNOCKOUT IDLE STROKE + 1 mm (for
example, if 12.00 mm is displayed, enter 13.00 mm); the value entered for TOP LIMIT SWITCH should be
equal to the idle stroke + the required stroke (for example to obtain 30 mm, enter 30 + 13 = 43 mm).
A graph illustrating the ejector’s loading cycle is given next to the block.
• 2-downstroke cycle
die-set setting
soft filling
end of height
upstroke
time
die-set first die-set last die-set
upstroke downstroke downstroke
• 3-downstroke cycle
die-set setting
base thickness
end of
upstroke glaze thickness
time
die-set first die-set second die-set last die-set
upstroke downstroke downstroke downstroke
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11.6.2 SPEED
The die-set speeds are set in the underlying block.
DIE-SET UPSTR. (%)

Die-set speed (percentage) during the upstroke.
1ST DIE-SET D.STROKE (%)

Die-set speed (percentage) during the first downstroke.
2ND DIE-SET DOWNSTR. (%)

Die-set speed (percentage) during the second downstroke (only for machines that carry out a loading cycle with
3 downstrokes).
LAST DIE-SET DOWNSTR. (%)

Die-set speed (percentage) during the last downstroke.
11.6.3 LOADING CORRECTIONS
The parameters used to synchronize the proportional ejector with the FILLER-BOX are given in the block on the bottom
left side of the page.
NO. OF CORRECS. (0-1-2-3-4-5)

Number of corrections made to the proportional ejector during the filler-box return stroke starting from the position
in which the 1st downstroke is performed.
LOADING WIDTH (mm)

Loading width.
The settable ejector parameters for each correction are given in the table below.
STROKE DIE-SET (mm)

Extent of the die-set stroke while the individual loading corrections are made.
FILLER-BOX START (mm)

Position in which the filler-box starts while the individual loading corrections are made.
END (mm)
Value at which the filler-box returns to the 1st downstroke position while the individual loading corrections are
made.
SPEED (%)
Die-set speed (percentage) while the individual loading corrections are made.
AUT (YES/NO)
The speed can be automatically calculated to even out the powder in such a way as to give it a “wedge” shape
instead of a “step” shape (AUT = YES).
RETURN SPEED (%)

Speed of the loading corrections while the die-set is carrying out its return stroke.
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A graph illustrating the die-set corrections are given beside the block.
• Step shape
filler-box
return
Die-set setting
die-set stroke
END OF END START END OF Filler-

RETURN FORWARD box
STROKE STROKE setting
last downstroke RETURN SPEED
• Wedge shape
Die-set
setting
END OF END START END OF Filler-

RETURN FORWARD box
STROKE STROKE setting
RETURN
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11.6.4 ADDITIONAL FUNCTIONS
A number of operations to be performed with the die-set can be set. They are given in the last block in the right-hand
column between the two graphs.
KNOCKOUT BTW PUNCHES (bar)

If knockout between the punches is desired then set KNOCK. to a value other than 0 (only with S.P.E.).
The “knock” setting refers to the knockout force. Enter a value expressed in bar (when 0 is entered “knockout”
is made inoperative).
DIE SET REMOVAL (0-1-2-3)

When a 2 + 2 cylinder S.E. is used, the way in which the die-set is disassembled can be set. Enter 0 unless the
operations for installing the die-set given in the DESCRIPTION OF THE KEYS paragraph are required.
0 = No operations for installing the die-set;

1 = Self-learning procedure required for the 2 + 2 cylinder S.E.;
2 = 2 + 2 cylinder S.E. die-set lift - Downward movement after the 2 + 2 cylinder S.E. die-set has been lifted;
3 = Emergency upstroke for the 2 + 2 cylinder S.E. - Emergency downstroke for the 2 + 2 cylinder S.E.
PUNCH OVERTRAVEL LENGTH (mm)

Extent to which the die-set goes beyond the end of its upstroke during its overtravel.
MAX. MISALIGN. (B - A) (mm)

If the die-set is not level with the die on both sides when fully up, a different setting for cylinder A and cylinder B
of the S.P.E. may be set. For example if cylinder A is level with the die but cylinder B is beneath it set MAX.
MISALIGN. (B - A) = 0.20 mm.
DIE-SET FASTENED (YES/NO)

Enter YES if the die-set has actually been locked.
Instructions for locking 2 + 2 cylinder S.E. die-sets:
1. Adjust the reducer’s pressure so that it is discharged.
2. Lock the die-set fasteners making sure that at least 4.5 turns are made in the closing direction and 0.25 in
the opening direction.
3. Set the reducer to the pressure value read before the die-set was locked.
4. Press the relative keys to end die-set locking.
5. Remove the spacers and finish installing the die-set.
6. With the die-set down set DIE-SET FASTENED = YES.
7. Turn the PLC off and then back on.
8. Set the pressure reducer as required:

a. Read the pressure given on gauge 198 with the die-set up and oil hot.
b. Move the die-set down and read the pressure given on gauge 196. Work on reducer 166 to set the value
given in pressure chart 198/196. Repeat the procedure until the pressure when the die-set is up and down
is as required.
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Instructions for locking 4-cylinder S.P.E. die-sets:
1. Adjust the reducer’s pressure so that it is discharged.
2. Lock the front l.h. and rear r.h die-set fasteners making sure that at least 4.5 turns are made in the closing
direction and 0.25 in the opening direction.
3. Set the reducer to 180 bar.
4. Lock the front r.h. and rear l.h die-set fasteners making sure that at least 4.5 turns are made in the closing
direction and 0.25 in the opening direction.
5. Set the reducer to the pressure value read before the die-set was locked.
6. Press the relative keys to end die-set locking.
7. Remove the spacers and finish installing the die-set.
8. With the die-set down set DIE-SET FASTENED = YES.
9. Turn the PLC off and then back on.
10. Set the pressure reducer as required:

a. Read the pressure given on gauge 196 with the die-set up and oil hot.
b. Move the die-set down and read the pressure given on the gauge. Work on valve YV304A manually to
set reducer 166. The pressure should equal the value read when the die-set is up.
c. Release YV304A and move the die-set up.
d. Repeat the procedure until the pressure with the die-set up and down differs by no more than ± 3 bar.
PUNCH OVERTRAVEL (YES/NO)

Enter YES for the punches to go beyond their end stop and move the die-sets up (see the DESCRIPTION OF
THE KEYS paragraph).
BALANCING DOWNSTROKE (mm)

Balancing downstroke.

• TOP LIMIT SWITCH
• SOFT FILLING THICK.
• BASE THICKNESS
• GLAZE THICKNESS
• KNOCKOUT IDLE STROKE
• NO. OF APPL.
• KNOCK.
• DIE-SET FASTENED
• DIE-SET REMOVAL
• PUNCH OVERTRAVEL LENGTH
• MAX. MISALIGN. (B - A)
• NO. OF CORRECS.
• AUT
can only be changed if the Mode selector is turned to SET-UP.
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11.7 FITTINGS AND TIMING SET-UP PAGE (G) G
Photograph 17
The data for the accessories the machine is equipped with are set on this page (optional, only with “proportional”
machines).
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11.7.1 ALM
The box to the left contains all the data that can be set for loading performed with the ALM mobile hopper.
NO. OF ACP STROKES

Number of movements performed by the ACP during each cycle. If 0 is entered, the ACP stays still. If 50 is
entered, the ACP moves continuously.
DELAY FOR ACP STROKES (ms)

Time that goes by between each ACP stroke.
ACP SPEED (%)

Base ACP speed percentage during stroke.
This data item is present only when an ACP with inverter and encoder is provided.
LH END STOP (mm)

Position of left hand end stop for the base ACP.
RH END STOP (mm)

Position of right hand end stop for the base ACP.
CYCLE TYPE ALM (0-1-2)

ALM mobile hopper operating mode.
ALM CYCLE = 0 (mobile cycle)

The gate opens and, after a time set for DELAYED LOADING, the ALM loading cycle begins. The ALM moves
at the set SPEED. The gate closes at the CLOSURE SETTING, the ALM arrives at the value set for FWD.
END-STOP and then reverses to bring itself back to the REAR END-STOP (travelling at the set SPEED). With
2-row loading (2-ROW LOADING = YES), the gate reopens at the OPENING SETTING during the loading
stroke and then closes at the 2ND CLOSURE SETTING.
ALM CYCLE = 1(fixed cycle)

Two cases may be used for the fixed ALM loading cycle:
1. APPROACH POS. = 0
The hopper pauses when it reaches the LOADING POSITION. When the filler-box is fully back the gate opens
(after a delay time set for GATE OPENING DELAY). The gate closes when the filler-box reaches the
CLOSURE SETTING during the forward stroke.
2. APPROACH POS. > 0
The grid is loaded during the filler-box’s approach stroke. The ALM remains stationary in its LOADING
POSITION. First of all the gate opens and then the filler-box approach stroke begins once the DELAYED
LOADING has elapsed. The gate closes when the filler-box reaches the CLOSURE SETTING (during the
approach stroke).
ALM CYCLE = 2 (mixed cycle)

The mixed ALM cycle can be carried out only if APPROACH POS. > 0. Combined fixed ALM/mobile ALM
loading should be used when the CAF stroke is not long enough to fill the entire grid whole the ALM is at a
standstill. Cycle description:
A) Once the die-set has been loaded the CAF brings the front of the grid beneath the ALM.
B) The ALM gate opens and stays open.
C) The CAF advances as far as possible according to the overall dimensions of the die-set (approach value)
with the ALM at a standstill and then stops.
D) The ALM moves back keeping the outlet open until the grid has been filled with the CAF stationary.
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DELAYED LOADING (ms)

Time that goes by from when the gate is opened and the ALM loading cycle begins.
FIRST CLOSURE POSITION (mm)

Position in which the ALM gate closes. If 2-row loading is used, the data item represents the position in which
the gate closes the first time.
CARRIAGE CLOSING POS. (mm)

Position in which the ALM gate closes during the filler-box’s forward stroke.
REAR LIMIT SWITCH (mm)

End of the ALM return stroke .
FWD. LIMIT SWITCH (mm)

End of the ALM forward stroke .
ALM SPEED (%)

Speed of the ALM (percentage) depending on the type of cycle set:
• If a mobile or mixed ALM is used, enter the repositioning speed.
• if a fixed ALM is used, enter the speed used for operations in manual mode and when the encoder is reset.
ALM SPEED (LOADING) (%)

ALM speed (percentage) during the powder loading stroke (entered only with a mobile ALM or mixed ALM cycle).
GATE OPENING DURING SHUTDOWN (YES/NO)

Gate opening at the end of press shutdown (gate is opened at the end of the cycle).
2-ROW LOADING (YES/NO)

If a two-row die set is used, type in YES for this data item.
SECOND OPENING POSITION (mm)

Position in which the ALM gate opens the second time (for 2-row loading cycle).
SECOND CLOSURE SETTING (mm)

Position in which the ALM gate closes the second and last time (for 2-row loading cycle).
11.7.2 MDR
The MDR parameters are given in the block at the top of the page on the right side.
MDR CYCLE TYPE (0-1-2-3)

Type of MDR base mixer (with rotary diaphragm) cycle:
0 = MDR off;
1 = revolved to the right;
2 = revolves to the left;
3 = right/left rotation.
MDR SPEED (%)

Speed (percentage) of the mixer with rotary diaphragm installed on the ACP (only in machines equipped with the
MDR accessory).
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11.7.3 BRUSH
The block at the foot of the page contains all the data concerning the brush assembly installed on the filler-box.
BRUSH (YES/NO)
Enter YES if the filler-box is equipped with an hydraulic brush.
FIXED BRUSH (YES/NO)

Used to select the operating mode of the brush (fixed or mobile).
BOTTOM CLEANING (YES/NO)

Used to select whether the brush has to clean the lower or upper die-set.
ROTATION ON (0-1-2-3)
Used to select how the brush rotates:
0 = no rotation;
1 = rotation only during the filler-box forward stroke;
2 = rotation only during the filler-box return stroke;
3 = rotation constantly on;
If this has been enabled, the following modes can be selected:

• Constant clockwise rotation (REVERSE ROT. = NO, CLOCKWISE ROTATION = YES)
• Constant counter-clockwise rotation (REVERSE ROT. = NO, CLOCKWISE ROTATION = NO)
• Rotation reversed every n. cycles (REVERSE ROT. = YES, CYCLES BTW REVERSES = n)
REVERSE ROT. (YES/NO)

Used to enable brush reversal after the set number of cycles.
CYCLES BTW REVERSES

Number of cycles after which the brush reverses.
CLOCKWISE ROTATION (YES/NO)

Used to enable brush clockwise rotation. If NO is entered, the brush rotates counter-clockwise.
CONSUMP. (cycle/c.mm)
If the parameter has been set, the position for the end of the plunger’s upstroke is lowered to automatically
compensate for brush wear and perfect cleaning. The operator has to enter brush consumption, i.e. the number
of cycles in which the radius of the brush decreases 1 1/100 of mm (only for “proportional” presses).
MAX (mm)
Maximum allowable brush consumption (MAX): when this value is reached, the machine shuts down and
“REPLACE BRUSH” is displayed. The procedure starts again if the reset procedure is performed.
NOTE: when this function is used, the degree to which the die-set opens may be reduced gradually until the filler-
box is no longer able to pass!
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A figure illustrating the cycle the brush executes according to the data entered is given at the bottom of the block.
• Fixed brush that does not rotate:
• Fixed brush that rotates counter-clockwise during the forward stroke:
• Fixed brush that rotates clockwise during the forward stroke:
• Fixed brush that rotates counter-clockwise during the return stroke:
• Fixed brush that rotates clockwise during the return stroke:
• Fixed brush that rotates counter-clockwise during the forward and return strokes:
• Fixed brush that rotates clockwise during the forward and return strokes:
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• Mobile brush for bottom cleaning without rotating:
• Mobile brush for bottom cleaning that rotates counter-clockwise during the forward stroke:
• Mobile brush for bottom cleaning that rotates clockwise during the forward stroke:
• Mobile brush for bottom cleaning that rotates counter-clockwise during the return stroke:
• Mobile brush for bottom cleaning that rotates clockwise during the return stroke:
• Mobile brush for bottom cleaning that rotates counter-clockwise during the forward and return strokes:
• Mobile brush for bottom cleaning that rotates clockwise during the forward and return strokes:
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• Mobile brush for top cleaning without rotating:
• Mobile brush for top cleaning that rotates counter-clockwise during the forward stroke:
• Mobile brush for top cleaning that rotates clockwise during the forward stroke:
• Mobile brush for top cleaning that rotates counter-clockwise during the return stroke:
• Mobile brush for top cleaning that rotates clockwise during the return stroke:
• Mobile brush for top cleaning that rotates counter-clockwise during the forward and return strokes:
• Mobile brush for top cleaning that rotates clockwise during the forward and return strokes:
The following parameters, found near the figures, can be set:
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• Point (mm) of the filler-box stroke at which the brush moves down;
• Point (mm) of the filler-box stroke at which the brush moves up;
• Point (mm) of the filler-box stroke at which the brush starts brushing (only for machines equipped with linear filler-
boxes);
• Point (mm) of the filler-box stroke at which the brush finishes brushing (only for machines equipped with linear filler-
boxes).
11.7.4 SYNCHRONIZATION
The block on the left side of the page contains the parameters for machine synchronization.
INSIDE (YES/NO)
Enter YES to run the press at the set speed (number of cycles).
CYCLES PER MIN.

Number of cycles completed by the press per minute.
CYCLES/MINUTE WITH STROKES HALVED

This data item allows the strokes of the press to be “halved” with synchronized operation.
Example: the press operates at 12 cycles/minute in synchronous mode. If the input which controls internal synch.
(KA301) is activated, the press will operate at a rate
of 6 cycles/minute.
OUTSIDE (YES/NO)
Allows the press to be timed with an external device.
TIMED PAUSE (YES/NO)

If YES is entered, a pause can be set for the work-cycle. The length and interval between the pauses can be set.
DELAY 1 (s)
Time between two consecutive timed pauses (optional).
DELAY 2 (min)
Length of the timed pause (optional).
11.7.5 HEAT EXCHANGER
The parameters for the heat exchanger are given in the block on the right side of the page (ENEA cooling).
HEAT EXCHANGER (YES/NO)

Used to enable the additional heat exchanger (controlled by Sacmi or externally).
FAN 1 (YES/NO)
Used to enable cooling fan M13 (Only with ENEA cooling controlled by Sacmi).
FAN 2 (YES/NO)
Used to enable cooling fan M14 (Only with ENEA cooling controlled by Sacmi).
The following data item:

• CYCLE TYPE ALM
can be modified only if the mode selector is turned to SET-UP.
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11.8 DATA INPUT PAGE FOR DIFFERENTIATED PRESS-CYCLE (H) H
Photograph 18
Data regarding differentiated press-cycles are to be entered on this page (optional, only if the machine is set up to carry
out differentiated press-cycles). All the read-out data items given for this particular type of cycle are also shown on this
page.
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11.8.1 DIFFERENTIATED PRESS-CYCLE (READ-OUT)
The values of the data items employed during the differentiated press-cycle are displayed at the top of the page.
DIFFERENTIATED PADS PRESSURE (bar)

Pad pressure measured by transducer BP203. This is a 0 - 50 bar transducer that needs a safety solenoid valve.
If YV210 (safety solenoid valve for transducer BP203) is not energized, a red led (..........) comes on to signal the
measured pressure does not match the actually pad pressure as the pad is not connected to the transducer.
DIFFERENTIATED BOOSTER PRESSURE (bar)

Pressure of the hydraulic circuit booster measured by transducer BP204. If the fasteners are open, this is also
the pad pressure.
DIFFERENTIATED BOOSTER POSITION (mm)

Position of the isostatic circuit booster given in real time.
This corresponds to the value of encoder BQ11.
11.8.2 DIFFERENTIATED PRESS-CYCLE (DATA INPUT)
The data items used during the differentiated press-cycle that have to be set appear at the bottom of the page.
To aid in setting the parameters, all the values are expressed as the stroke of the pistons present inside the pad. The
control system converts these values into the booster stroke to be carried out. This is done as the position transducer
is found on the booster.
DIFF. PRESS CYCLE ENABLE (YES/NO)

This data item is used to enable the differentiated press-cycle (this data item can be set only in SET UP mode).
NO. OF PULSATION CYCLES

Number of pulsation cycles to be repeated during a press-stroke.
CYLINDER PRESS. AT DIFF. CYCLE START (bar)

Cylinder pressure to be reached during the last press-stroke in order for the differentiated press-cycle to start.
MINIMUM PAD PRESSURE (bar)

Minimum pressure needed in the pad when it works as isostatic.
NO. OF PRESS STROKES TO CHANGE OIL

Number of press-strokes after which the oil in the isostatic pad is changed. When this is done, the oil is first drained
and the pads are then filled again.
NO. OF PISTONS IN PAD

Number of pistons found inside the isostatic pad.
PISTON DIAMETER
Select the diameter of the pad pistons.
CYLINDER STROKE INCREASE (mm)

“Virtual” increase (oil compression is not taken into consideration) expressed as the piston stroke to be gradually
subtracted from or added to the piston stroke during the pulsation cycles.
successione dei cicli di pulsazione.
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11.8.3 DIFFERENTIATED PRESS-CYCLE DURING PRECHARGE
These data items, regarding the precharge stage, have to be set.
CYLINDER PRECHARGE STROKE (mm)

Theoretical value of the die-set piston stroke to be carried out during the precharge stage.
PRECHARGE/REPOSITIONING SPEED (%)

Percentage to which YV100 opens (YV100 controls the flow rate in the isostatic circuit) during the booster
precharge and repositioning stage.
PRECHARGE DELAY (ms)

Delay from the end of the first press stroke to pad precharging.
11.8.4 DIFFERENTIATED PRESS-CYCLE UNDER PRESSURE
Data items regarding the differentiated press-cycle when under pressure that need to be set.
CYLINDER STROKE UNDER PRESS. (mm)

“Virtual” increase (oil compression is not taken into consideration) expressed as the die-set piston stroke to be
performed during the differentiated press-cycle.
SPEED UNDER PRESSURE (%)

Percentage to which YV100 opens (YV100 controls the flow rate in the isostatic circuit) during the differentiated
press-cycle.
TIME UNDER PRESSURE (ms)

Time during which the isostatic circuit stays under pressure.
RAMP TIME UNDER PRESSURE (ms)

Time it takes YV100 to reach the value set for SPEED UNDER PRESSURE starting from closed centered during
TIME UNDER PRESSURE.
11.8.5 DIFFERENTIATED PRESS-CYCLE UNDER DECOMPRESSION
Data items regarding decompression to be set for the differentiated press-cycle.
CYLINDER STROKE DUR. DECOMPRESS. (mm)

“Virtual” increase (oil compression is not taken into consideration) expressed as the die-set piston stroke to be
performed during the decompression stage of the differentiated press-cycle.
SPEED DURING DECOMPRESSION (%)

Percentage to which YV100 opens (YV100 controls the flow rate in the isostatic circuit) during the decompression
stage of the differentiated press-cycle.
TOTAL DECOMPRESSION TIME (ms)

Time during which the isostatic circuit is decompressed.
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RAMP TIME DURING DECOMPRESSION (ms)

Time it takes YV100 to reach the value set for SPEED UNDER PRESSURE starting from closed centered during
TIME UNDER PRESSURE.

• DIFF. PRESS CYCLE ENABLE
• NO. OF PISTONS IN PAD
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12 FAULT TRACING
12.1 LIST OF FAULT MESSAGES (J) J
Photograph 19
The list of the last few faults that have arisen are given on this page.
The following information is given for each fault displayed:
- date fault occurred

- time fault occurred
- time fault was cleared
- length in minutes and seconds
- fault code
- fault message
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Use keys F9 and F10 or the PGUP and PGDOWN keys to scroll the list.
Refer to the “FAULT MESSAGES” chapter for a full description of the messages.
If the multimedia version of this manual has been installed, position the cursor on a line with a fault and press ENTER
(or click on the line with the mouse). The help for the fault in question will be opened (optional).
Use F5 to go to the filter functions.
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12.1.1 “FAULT SEARCH” DIALOG WINDOW
The dialog window “fault code selection” is used to filter the faults displayed according to the fault code and time
parameters.
Selecting the fault code
To select only faults with a certain code, pick out the desired code from the list given under the “fault code” data item.
Select searching according to the ‘FAULT CODE”
When a numeric code is selected (e.g.; 2024, 4022, etc..), only the fault messages concerning that particular code will
be displayed.
Each message is identified by a letter followed by three digits (the letter represents the category of the message). The
various categories are dealt with in the FAULT MESSAGES paragraph.
If a NXXX type code (e.g.: 1XXX, 2XXX, etc...) is selected, only the fault messages with a code that starts with the number
of the selected category will be displayed (e.g.: if 1XXX is selected all the total shutdown fault messages are filtered).
If XXX is selected, all the relative fault messages will be displayed (e.g.: if XXXX is selected, all the faults occurred are
filtered).
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Setting the time interval
To select the faults that have arisen during a certain time interval, specify the date and time at which the interval should
start and end.
If the date and time at which the interval starts and ends are not modified, the proposed ones will be used. As a result,
messages for all the recorded faults will be displayed.
To modify the date and time, cancel the proposed ones and enter the new ones being careful to observe the input format:
Date format: dd/mm/yyyy

Time format: hh/mm/ss
If the date/time for starting interval is after the date/time at which the interval ends, the search procedure will not be
performed.
Selecting faults with a certain description
To select solely faults with a certain description, type part of the text that described the fault in the space provided and
select “description” for the type of search procedure.
Results
The three criteria are combined and all the faults whose code and description match the specified data and have
occurred during the set date/time at which the interval starts and ends will be displayed.
The results obtained are displayed on the Filter page.
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12.1.2 FILTER PAGE
Photograph 20
The fault messages selected with the “fault code selection” function are shown on this page.
Use keys F9 and F10 or the PGUP and PGDOWN keys to scroll the list.
Use F5 to go to the filter functions.
Use F6 to print out the displayed fault messages (only if a printer is installed).
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12.2 STATISTICS (K) K
Photograph 21
Two types of statistics can be drawn up:
1) The 15 faults that have stopped or shutdown the machine for the longest time (given in decreasing order according
to the total stop time).
2) The 15 faults that have most frequently caused the machine to stop or shutdown given in decreasing order according
to the number of stops (shown in the figure).
The statistics are illustrated in a histogram with horizontal bars. Information regarding the 15 faults that caused the
machine to stop is provided.
Press F9 to display the faults that caused the machine to stop according to the number of shutdowns. To
display the faults according to the stop times press F9.
Zero setting the statistics
Use F5 to zero set the statistics. The histograms for both types of statistics will be zero set when the reset
procedure is performed from any of the statistics pages.
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12.3 SCHEDULED MAINTENANCE PAGE (L) L
Photograph 22
All the pending alarms regarding maintenance along with their state (number of cycles or hours left before the alarms
are issued) are shown on this page.
The colored bars display the number of hours of operation or cycles that have gone by in relation to the number of
operating hours or cycles that have to go by before an alarm is issued. The number of hours of operation or cycles
remaining before the alarm is issued are shown in numerical form on the right side of the page.
When an alarm is active, the text line becomes red on a black background and flashes. Inactive alarms are shown in
yellow on a black background.
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Settable maintenance messages
The user can set four maintenance messages, two based on the number of cycles and two based on the hours of
operation. These will be treated as preset maintenance alarms. If a preset maintenance alarm is active, the maintenance
alarm set by the user will be issued only after the preset one has been cleared.
Setting the messages
To set the messages displayed for the faults, move the cursor to the fault code shown on the left-hand side, type the
message and then press ENTER. To set the number of cycles/hours after which the alarms are issued, move the cursor
to the box to the right which shows the number of cycles or hours, type the number of cycles or hours after which the
alarm is issued and then press ENTER. If the number of cycles or hours are set to 0 (zero), the alarm will not be issued.
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12.4 INPUT/OUTPUT STATE PAGE (M) M
NOTE
The figure shown below illustrates a page with all the inputs and outputs that can be installed on the press.
If a data item is not provided it means that the relative optional device is not installed on the press.
Photograph 23
The following type of inputs may be used:
Digital input (ON-OFF)
A green circle appears next to the name of the input to indicate it is on while a grey circle appears if it is off.
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Two kinds of outputs may be used:
Digital output (ON-OFF )
A green circle appears next to the name of the output to indicate it is on while a grey circle appears if it is off.
Analog output
A number ranging from 0 to 255 appears next to the name of the output. Zero appears when the set-point is null, numbers
1 to 255 indicate the value of the set-point at that precise moment.
NOTE: Numbers 1 to 255 represent the output current (0-20 mA) that the card supplies to the corresponding channel.
The number varies from 0 to 4095 for some analog outputs.
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12.5 STATE OF WORK-CYCLE EXECUTION (N) N
Photograph 24
The state of the work-cycle is given in numeric form on this page.

The numbers related to each machine axis increase as the cycle progresses.
In the event of machine shut-down, the numbers are decoded in the block and a message is displayed so that the user
can know the operation being performed at the moment the machine stopped running.
NOTE: Decoding of the state is cancelled the first time the Reset key is pressed.
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The meaning of each digit is given on the following pages:
FILLER-BOX 0 X X X X H
{1st 2nd 3rd

1st) Coding of the main stage
01 = RETURN STROKE IN MANUAL
02 = FORWARD STROKE IN MANUAL
0A = RESETTING
1E = START OF AUTOMATIC CYCLE
20 = AUTOMATIC CYCLE IN PROGRESS
2nd) Not used.
3rd) Coding of operation in progress

0 = FORWARD STROKE
F = RETURN STROKE
DIE SETS 0 X X X X H
{
1st 2nd 3rd

01 = UPSTROKE 14 = LOADING IN SEMI-AUTOMATIC
02 = DOWNSTROKE 15 = PRESS-CYCLE IN SEMI-AUTOMATIC
03 = UPPER PUNCHES IN 1E = START OF AUTOMATIC CYCLE
04 = UPPER PUNCHES OUT 1F = END OF RESETTING DURING AUTOMATIC CYCLE
05 = OVERTRAVEL 20 = AUTOMATIC CYCLE IN PROGRESS
0A = RESETTING
2nd) Coding of filler-box operation in progress

1 = FILLER-BOX FORWARD STROKE
2 = FILLER-BOX RETURN STROKE
3 = 2nd FORWARD STROKE (Optional)
4 = 2nd RETURN STROKE (Optional)
3rd) Coding of the secondary stage

1 = START OF LAST PRESS-STROKE
2 = START OF DELAY TIME FOR DIE-SET UPSTROKE
3 = END OF REMOVAL
4 = SYNCHRONIZATION
5 = END OF SYNCHRONIZATION
6 = FILLER-BOX START
7 = FIRST DIE-SET DOWNSTROKE
8 = LAST DIE-SET DOWNSTROKE
9 = THICKNESS CONTROL START
A = SECOND DIE-SET DOWNSTROKE
PLUNGER 0 X X X X H
{
1st 2nd 3rd

01 = SLOW UPSTROKE
02 = SLOW DOWNSTROKE
03 = UPSTROKE
04 = DOWNSTROKE
0A = RESETTING
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14 = SEMI-AUTOMATIC PRESS-CYCLE
1E = START OF AUTOMATIC CYCLE
20 = AUTOMATIC CYCLE IN PROGRESS
2nd) Coding of the secondary stage

1 = PLUNGER DOWNSTROKE
2 = BRAKING DURING PLUNGER DOWNSTROKE
3 = DE-AERATION
4 = START OF PRESS-STROKE
5 = END OF PRESS-STROKE
6 = DELAY TIME FOR PLUNGER UPSTROKE
7 = PLUNGER UPSTROKE
3rd) Coding of number of press-strokes

0 = FIRST PRESS-STROKE
1 = SECOND PRESS-STROKE
2 = THIRD PRESS-STROKE
POWDER LOADING (ACP) 0 X X X X H

{
1st 2nd 3rd

st
1 ) Coding of the main stage
01 = IN MANUAL MODE
02 = IN SEMI-AUTOMATIC MODE
03 = IN AUTOMATIC MODE
2nd) Not used.
3rd ) Coding of type of operation

0 = LEFT-HAND MOVEMENT
F = RIGHT-HAND MOVEMENT
ALM 0 X X X X H
{
1st 2nd 3rd

st
01 = IN AUTOMATIC MODE
02 = IN SEMI-AUTOMATIC MODE
03 = RESETTING
2nd) Not used.
3rd) Coding of secondary stage

1 = HOPPER GATE OPENING
2 = LOADING
3 = HOPPER GATE CLOSING
4 = ALM FORWARD
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BRUSH 0 X X X X H
{
1st 2nd 3rd
st
00 = BRUSH PROGRAM NOT BEING EXECUTED
FF = BRUSH PROGRAM BEING EXECUTED
2nd) Coding of secondary stage
1 = STOP BEFORE REVERSING
2 = REVERSE ROTATION
3rd) Coding of type of operation

0 = COUNTER-CLOCKWISE OPERATION
F = CLOCKWISE OPERATION
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12.6 SET UP OPERATIONS AND ENCODERS RESET PAGE (O)

O
Photograph 26
This page is used to reset the absolute encoders installed on the press and to perform a number of special operations,
adjustments, self-learning procedures, etc…
12.6.1 ENCODER RESET
When an encoder is reset, the home (0) position of the parts (plunger, filler box, etc) controlled by that particular encoder
is determined.
To reset, press the button for the encoder to be reset. The following conditions must be satisfied in order to enable the
reset buttons:
- safety bar raised
- mode selector turned to SET UP.
The following may be reset:
- PLUNGER
To reset, move the plunger fully up (end of stroke), make sure the conditions required to reset are satisfied and then
press the relative key.
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- ISOSTATIC/DIFFERENTIATED BOOSTER
To reset, move the booster to the position in which the cylinder is completely back (against end stop), make sure
the conditions required to reset are satisfied and then press the relative key.
- FILLER BOX
To reset, move the move the part into the desired 0 position, make sure the conditions required to reset are satisfied
and then press the relative key.
- REVERSE FILLER BOX ENCODER COUNT (YES/NO)

If the value of the FILLER BOX ENCODER on the DATA page counts down at start up (i.e. the number decreases
while the filler box approaches the press or vice versa), change the setting of this data item.
- PROP. KNOCKOUT
To reset, move the proportional lift system with rods fully down (against end stop), make sure the conditions required
to reset are satisfied and then press the relative key.
- ALM
To reset, move the move the ALM into the desired 0 position, make sure the conditions required to reset are satisfied
and then press the relative key.
- ACP
To reset, move the move the base ACP into the desired 0 position, make sure the conditions required to reset are
satisfied and then press the relative key.
NOTE
Encoders reset differently may be installed on the press or accessories. For more detailed information concerning the
encoder RESET procedure, consult the ADJUSTMENTS chapter in the USER’S MANUAL that deals with the press.
12.6.2 SPECIAL OPERATIONS
To start a procedure, press the key given beside the description. The description of the selected procedure becomes
green. Once a procedure has been selected, the list of conditions that must be satisfied in order to perform the procedure
appears at the top right side of the page. The following procedures are available:
0 = no adjustments
1 = check accumulator pressure (only for PCH)
2 = YV309 self-learning (only for PCH)
3 = check YV309 self-learning (only for PCH)
10 = plunger and press cycle proportional solenoid valve self-learning
11 = YV100 self-learning (only with differentiated press cycle)
12 = booster encoder not reset (only for presses with external booster)
14 = YV21P self-learning (only with rod type proportional knockout)
15 = YV21P offset reset(only with rod type proportional knockout)
19 = booster drain (only for presses with external booster)
21 = clean plunger and press cycle proportional valves
22 = clean SPE proportional valves with oil
23 = clean SPE proportional valves without oil
Press F5 to go to the page that contains the chart regarding YV309 self-learning (only for “Power” series presses without
external booster).
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12.6.3 HYDRAULIC CIRCUIT PRESSURE CHARTS
Photograph 25
The pressure-voltage chart appears in the top section while the pressure-measured pressure chart appears in the
bottom section.
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12.6.4 “VOLTAGE - PRESSURE” CHART
The chart illustrates the pressure curve of the hydraulic circuit controlled by the proportional valve (YV309) according
to the voltage used (expressed in valve points).
The progressive numbers used by the PLC to pilot the proportional valve are given on the X co-ordinate in the chart.
Each numeric valve corresponds to the voltage applied at the input of the card used to pilot the valve.
The pressure values of the circuit read by transducer BP4 (expressed in bar) are given along the Y co-ordinate.
This curve is drawn up during the self-learning procedure.
For further information on how to execute the “self-learning procedure” see the DESCRIPTION OF THE KEYS
paragraph.
12.6.5 “MEASURED PRESSURE - REQUIRED PRESSURE” CHART
The chart illustrates the pressure curve of the hydraulic circuit controlled by the proportional valve (YV309) according
to the pressure required by the operating program. The chart is displayed on if SET-UP OPERATION NO. = 3 (pressure
check)
The required pressure values (expressed in bar) are given along the X co-ordinate.
The pressure values of the circuit read by transducer BP4 (expressed in bar) are given along the Y co-ordinate.
This curve actually serves to check the values measured during the “self-learning procedure” dealt with in the previous
chapter.
For further information on how to execute the “self-learning procedure” see the DESCRIPTION OF THE KEYS
paragraph.
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13 QUALITY CONTROL AND PRODUCTION DATA Q
13.1 PRODUCTION METERS AND COUNTERS (Q)
Photograph 27
The values of the production counters and meters (partial and total values) are shown on this page. In addition, the status
of the actual production batch are given.
The production data are divided into two columns:
PARTIAL
Production data related to the batch carried out from the last time the reset procedure was performed (resettable).
TOTAL
Production data regarding the service life of the machine (not resettable).
Zero setting partial values
To zero set the partial values, use F5. A window appears that asks if you are sure you want to reset the values.
Select OK to reset the values. Use “Cancel” to annul the operation.
When the production counters and meters are set to zero, the statistics regarding deviations from the set-points
displayed with the trends are also reset (see paragraph 13.4).
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13.1.1 PRODUCTION DATA
PUMP OPERATING TIME: TOTAL (h)

Operating time of the main pumps. The scheduled maintenance is calculated based on this time.
PRESS OPERATING TIME PARTIAL (min) TOTAL (h)

Amount of time the press has run in automatic or semi-automatic mode.
13.1.2 NUMBER OF CYCLES/PIECES PRODUCED
NO. OF CYCLES PERFORMED: PARTIAL, TOTAL

Number of cycles completed by the machine. The scheduled maintenance is calculated based on the total
number of cycles.
MAT. OUTPUT: PARTIAL (m2) TOTAL (m2)

Amount of material produced by the machine during the automatic or semi-automatic cycle.
13.1.3 DOWNTIMES
STOP TIME DUE TO POWDER: PARTIAL (min)

Amount of time the press has stopped because the upstream line has shutdown and, as a result, no powder is
being fed to the hopper.
STOP TIME DUE TO PRESS: PARTIAL (min)

Amount of time the press has stopped due to malfunctioning.
STOP TIME DUE TO DRIER: PARTIAL (min)

Amount of time the press has stopped because the downstream line (drier) has shutdown stopping the discharge
roller conveyor.
ENERGY CONSUMED: PARTIAL (kWh)

Amount of power used by the press (only for machines equipped with an ENERGY METER).
ENERGY CONSUMED: (Wh/CYCLE)

Amount of power used by the press each cycle (only for machines equipped with an ENERGY METER).
13.1.4 PRODUCTION BATCH
The status of the current production batch is displayed.
M2 PRODUCT
Square meters of material of the batch already produced.
M2 LACKING
Square meters of material remaining to complete the production batch.
M2 TOTALS
Square meters of material that make up the batch.
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13.2 PRODUCTION HISTOGRAMS (R) R
Photograph 28
The following types of histograms are provided:
Daily histogram
The data regarding the last 31 days are displayed in the daily histogram. To read the exact value for a particular day,
move the cursor to the number of the day (under the horizontal line of the histogram). The corresponding value will be
displayed in the box on the top right-hand side. Use the PGUP and PGDOWN keys to scroll the daily histograms.
Monthly histogram
The data regarding the last 12 months are displayed in the monthly histogram. To read the exact value for a particular
month, move the cursor to the number of the month (under the horizontal line of the histogram). The corresponding value
will be displayed in the box on the top right-hand side. Use the PGUP and PGDOWN keys to scroll the monthly
histograms.
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Yearly histogram
The data regarding the last 15 years are displayed in the yearly histogram. To read the exact value for a particular year,
move the cursor to the number of the year (under the horizontal line of the histogram). The corresponding value will be
displayed in the box on the top right-hand side. Use the PGUP and PGDOWN keys to scroll the yearly histograms.
Histograms based on work-shifts
The data regarding the last 10 work-shifts are displayed in this histogram. To read the exact value for a particular work-
shift, move the cursor to the name of the work-shift (to the right of the histogram). The corresponding value will be
displayed in the box on the top right-hand side. use the PGUP and PGDOWN keys to scroll the histograms based on
work-shifts.
Histograms for batches
The data regarding the last 10 production batches are displayed in this histogram. To read the exact value for a particular
batch, move the cursor to the name of the batch (to the right of the histogram). The corresponding value will be displayed
in the box on the top right-hand side. use the PGUP and PGDOWN keys to scroll the histograms based on batches.
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13.3 CONSUMPTION PAGE (S) S
Photograph 29
This page is divided into two parts.
Top section
The amount of electrical power, water and powder used per production batch along with the time taken and material
produced are shown in the top section. If the work-shifts have been set, the press operating time will also be displayed
as a percentage of the set work-shift times. As a result, percentages greater than 100% may appear if the press has
also operated outside the work-shifts.
Data regarding the last production batch completed are displayed when this page is opened.
To view the previous batches, use the PGDOWN and PGUP keys or function keys F9 and F10.
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Bottom section
The same data items regarding the present day compared to an average based on the previous day’s data are shown
in the bottom section. Two colored bars are given for each variable. The one to the left represents the average values
based on the data regarding the previous days. The bar to the right displays the present day values. The average value
will be calculated based on the set number of days (not including non-productive days) the next time the page is
accessed.
Water (liters/min) and powder (weight per tile) usage can be set on the Manual data input page (par. 10.7). If an energy
meter is not provided, the hourly consumption rate for electrical power has to be set.
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13.4 TREND SUBMENU (T) T
Photograph 30
Select the operating trend you wish to display from this menu.
The following variables are shown:
1) Pressure errors
2) Thickness errors
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3) Time for filler-box forward stroke (only with linear filler-boxes or filler-boxes with crank - connecting
rod mechanism)
4) Time for filler-box return stroke (only with linear filler-boxes or filler-boxes with crank - connecting
rod mechanism)
5) Die-set upstroke position, Cylinder A (only with proportional ejector). If the machine works with a
proportional rod lift system the “die-set upstroke position” chart is displayed.
6) Die-set upstroke position, Cylinder B (only with proportional ejector)
7) Die-set downstroke position, Cylinder A (only with proportional ejector). If the machine works with
a proportional rod lift system the “die-set downstroke position” chart is displayed.
8) Die-set downstroke position, Cylinder B (only with proportional ejector)
9) Pressure error during 1st press stroke
To display the desired page, select the item in question and then the button.
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13.4.1 TRENDS AND DEVIATION HISTOGRAMS
Photograph 31
The trends are displayed to the left and the histograms showing the deviations in relation to the set-points appear to
the right.
Trends
The trend of the difference between the selected variable and its set-point is shown here. A new value is stored for each
work-cycle. As a result, you can verify whether the error is constant over time or if it tends to increase and therefore needs
to be corrected.
Cursor
A cursor, which appears as a vertical white line, can be moved along the chart to display the value of a variable shown
at a precise moment in numeric form. The cursor control buttons and boxes that show the date and time regarding the
position of the cursor (boxes to the left of the buttons) are located at the top of the chart. The box that shows the value
of the variable at the moment it is pointed out by the cursor is given just beneath the buttons to the right. The number
of records corresponding to the position of the cursor is displayed directly underneath the buttons.
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Use the middle of the five buttons to deactivate the cursor. The two buttons to the right and left activate the cursor and
move it to the right and left respectively.
The boxes underneath the chart shows the date and time the first value was displayed (to the left) and the last value
was displayed (to the right).
Scale
The high and low limits used (maximum and minimum value that can be displayed) in the chart are shown to the right
of the chart along with the mid-scale value. To change the maximum and minimum values, move the cursor to the values,
enter the new value and then press ENTER.
Deviation histograms
A chart showing how the variables deviate from their set-points is displayed on the right-hand side. The values are
expressed in percentage.
To zero set the histograms, press F5. The partial production counters displayed on the page that deals with
the production counters and meters are also reset.
Cursor control buttons
Cursor date Value recorded during

}
indicated press-stroke
Cursor time
Max end-scale value
(settable)
Mid-scale value
Min end-scale value

(settable)
Time data display
starts
Time data display ends
Date data display

}
starts
Date data
Keys for scrolling display ends
window
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13.5 EVENTS PAGE (U) U
Photograph 32
This page displays the list of events recorded by the system together with the corresponding date and time each event
took place.
The following events are recorded:
· When the machine is turned on

· When a user accesses the system (login)
· When a user quits the system (logout)
· When a data item in the operating program is changed
· When the operating program is saved
· When an operating program already saved is retrieved
· Start and end of the workshift
Each operation is recorded along with date and time it took place. Use buttons F9 and F10 or the
Page Up and Page Down keys on the keyboard to scroll through the list.
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There are two ways to filter the information:
· Press button F6 and select the month required from among those suggested in the window which appears
in order to filter the events by month.
· Press button F7 and indicate the password in the field provided in the window which appears in order to
filter the events by description.
Once the filter by month has been performed another filter can be carried out using the description as criteria. The
opposite cannot be carried out.
Button F5 is used to print out the list of operations displayed. Obviously a printer must be installed.
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14 SYSTEM SETTINGS
14.1 SET-UP PAGE (V) V
Photograph 33
Some of the system operating parameters can be set on this page.
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Local language selection (first column)
The language in which the texts are displayed can be changed with the
buttons found on the side of the page. To change the language, simply select
the button for the desired language.
Note 1. Some buttons may be disabled (“blackened”) if the translation

has not been added to the interface.
2. Only level 3 or higher users can access these buttons.
3. A light blue box appears around the language actually selected

(see note, third figure).
4. A box appears to the right of these

buttons that may be:
a. blackened: when the in line help is

disabled or the corresponding
language is not available;
b. white: in line help available;
or it may contain the help symbol: when

the manual is present for the language
actually selected.
The button used to display the Strings personalization page appears at the
bottom of this column. Each individual string displayed on the interface can be
edited from this page. The type of strings used (current) is shown under this
button:
* SACMI database;
* Databases set by user
Work-shifts and password (second column)
Four buttons are found in the middle column that execute the following functions:
Work-shift setting page
User management page

“Password modification” dialog window
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Transponder key management page (optional)
“Inactivity time” setting
Setting the date and time (fourth column)
Use the button found in the box at the top right side of the page to set the date and time.
Setting the savescreener function (fourth column)
The savescreener function can be activated or inactivated from this block (by using the check mark
). In addition, the number of seconds the keyboard and mouse remain inoperative after which
the savescreener function is activated can also be set.
To set the seconds, move the cursor to the displayed number, press ENTER and type the new value
in the dialog window. The minimum allowable value is 30 seconds. If a value less than 30 seconds is
entered, the system will automatically reset the minimum allowable value.
Setting manual data input request function (fourth column)
The block on the bottom right-hand side is used to activate the function that requests manual data input
after a certain time.
Once the time (in minutes) set in this block has elapsed, the system will make the request for manual data
input.
To activate or inactivate this function, click the corresponding check box with the mouse (on or off).
Once the function has been activated, set the minutes, move the cursor to the displayed number, type the
new value and then press ENTER.
As a result, once the set time is over, a message appears requesting manual data input:
- if the user accepts to enter the data (clicking OK), the page for manual data input is opened;
- if the user does not accept to enter data manually (clicking CANCEL), the page present when the
message was displayed remains.
Displaying the tips (fourth column)
The box on the bottom right side of the page allows tips (e.g. ) to be displayed according to how
the mouse is moved.
Whenever the interface is restarted, the function to display tips is set to OFF.
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14.1.1 STRING PERSONALIZATION PAGE
Photograph 34
The operator can set the data base that contains the texts shown on the pages on this page.
A copy of the data base made in Sacmi can be copied for each language. After which any desired changes can be made
to adapt the interface program to the operator’s specific needs (personalization).
Note: the strings in the following languages cannot be edited (they are part of the program):
• Italian;
• Chinese;
• Russian;
• Greek;
• Hungarian.
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Page layout
The illustration to the side shows how the page is divided into
five section, each of which provides specific information:
1 language actually set for the interface (see Setup page);
2 buttons for the languages available for the interface.

When selected, these buttons perform the following
operations:
• set the language that corresponds to the selected

button (shown in zone 1);
• display the strings of the database in the selected

language in zone 4;
• display a blue box under the selected button that

indicated the language being edited.
(note: some buttons may be disabled if the interface does

not have the respective translation)
3 bar used to search a string in the selected database along

with key “Undo” ( );
4 strings of selected database are displayed: only the right

hand column can be edited (local language);
5 two buttons used to export and import the various

databases.
Editing one or more strings in the desired database
Follow the directions given below to edit one or more strings in the desired database:
1. First of all select the language to be edited in zone 2 (“Italian” cannot be edited);
2. The selected database will be loaded and displayed in zone 4;
3. At this point, find the string to be edited.

This can be done in two ways:
a) scroll the database with the two buttons to the side and displayed on the right side of
the page;
(**) b) the desired string can be searched by selecting the grey box to the side, displayed
in zone 3;
4. Once the string has been located, click the button found to its right which will open a dialog window used
to edit the string;
5. Lastly, press button Ok to confirm and made the new string operative.
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(**) Search window
Click the left Mouse key (or the Enter key on the keyboard) on
the search bar to open the dialog window. Type the string to be
searched in the database here.
As soon as the Ok key is pressed, the string entered will be
searched. This will be done per line in both “Italian” and the “local
language”.
The first string found will be highlighted in red. To find the next
one, press button Succ. (Next) (next string).
Buttons available
If a mistake is made when entering the new string, press key “Undo” to cancel the operation. This button
cancels only the last entry.
Note. This button is disabled until a string is edited.
These buttons scroll the selected database up and down, twenty one lines at a time: once the beginning
or end of the file is reached, the corresponding button is disabled.
Strings with special characters.
If the string to be searched has special characters (letters with accents, etc…) press the “Ins. Char”. key to enter them.
The following dialog window appears when this key is pressed:
Button used to enter uppercase characters.
Button used to make entry operative.
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Editing strings
Press the button to the side to open a dialog window similar to the one used to search a string:
The string contained in the database , field where

the new string is to be entered and buttons “Ok”,
“Ins. Char” and “Cancel” are displayed.
Database management buttons
Changes to the interface strings are made to a copy of the database supplied by Sacmi: as a result, the program can
use the strings “ set by SACMI” or “set by the user” at any time.
If the plant has two or more of the same machines (two MTCs, two ATMs, etc…), it is possible to edit the strings in just
one of these machines and then export the databases to all the other machines that are the same.
Zone 5 of the page has two buttons used to perform the following operations with the databases:
Data base import

Used to import the databases edited in another machine.
Data can be imported either through the network with the shared C:\Export folder or with a floppy disk.
Before pressing this button, place the relative databases in one of the two folders mentioned above.
Data base export

The changes made to the translations can be exported to another machine that is the same.
Data can be exported either through the network with the shared C:\Export folder or with a floppy disk.
In order to export the databases with a floppy disk the floppy disk must be able to hold all the data
bases otherwise they can be exported only through the network.
Note: to copy the files exported in folder “ C:\Export\” to another machine, hook up another PC to the network and copy
all the cLang_*.Dbf files in folder “ C:\Export\” of the destination machine.
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14.1.2 SETTING THE WORK SHIFTS
Photograph 35
Setting the work-shifts
Follow the directions given below to set the work shifts:
1. Enter the number of work-shifts in the week (1 – 48);
2. Set the “Connection btw last and first workshift (weekly) ” data item that determines if the two work-shifts are to be
considered as one (e.g. the work shift starts at 8:00 p.m. on Sunday and ends at 4:00 on Monday);
3. Enter the time and day each shift starts and ends.
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Setting the time
To set the time move the cursor to the digit to be modified, type the new value and press ENTER.
Be careful to use the hh.mm format.
Note:
• A colon (“:”) has to be entered to separate the hours and minutes.
• If the minutes entered are greater than 59 (maximum 99), the system subtracts sixty from the value of the minutes
and increases the hours by one.
• The time cannot exceed 24.00 (12:00 a.m.)
Setting the day:
The days of the week are increased and decreased with the PGUP and PGDN keys. The left mouse key can be used
as an alternative. Whenever the key is pressed the day is increased from “Monday” to “Sunday”.
Note: the actual work-shift settings are shown in green.
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14.1.3 TRANSPONDER KEY MANAGEMENT PAGE
Photograph 36
Press the button shown to the side on the setup page to go to this page where the keys used to access
the machines can be created, edited or canceled.
Note: these operations can be performed only by operators who have user class 5 authorities.
The page is divided into two parts:
Left side The following are set here:

• User name;
• Password;
• Key code.
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The following keys are also provided here:
Read key:
Reads the information set in the key and displays them on the page.
Reset:
Removes all the information saved in the key.
Write key
Saves the settings
Right side The following are set here:

• Name of machine the key is enabled for;
• Rights and privileges associated to each machine.
The following keys are also provided here to edit the settings:
Machine
Privileges
Cancel line settings
View machines
When the page is accessed, the first 15 machines set are displayed. To
view the remaining machines press the button to the side (up to 20
machines can be set).
Note:
1. To enable the buttons used to select the machines and associated privileges, enter the “User name” and
“Password” of the user to be changed.
2. Each key can be enabled for different machines (up to 20).
3. The minimum level that can be assigned to each machine is 1;
4. Several levels can be set for each machine.
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14.1.4 USER MANAGEMENT PAGE
Photograph 37
This video page, wich can be accessed by users having access privileges 5, shows the machine users who are allowed
to log onto system.
The table contains the list of users set for the system. Each column in the table “means” the following:
1st column: a progressive number is shown here that allows the user to be identified in a long list;
2nd column (User Name): the operator’s “user name” is shown here;
3rd column (Password): the symbols used to hide the user’s password are given here;
4th column (Privileges): the privileges associated to the user are given here.
Buttons used to edit, cancel or create system users are given on the right side of the table.
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Creating new users and changing existing users

The window for creating user names allows the name, password and level (1, 2, 3, 4 or multiple rights) of the
user name being created to be set.
The new user name is recorded in the system and is enabled to perform the operations specified for the level.
The fields of the window are used for the following purposes:
Username user name to be entered when accessing the system

Password the password the new user has to use to access the system is entered here
Repeat password to prevent errors from being made, the password needs to be entered twice
Category this category determines the rights the new user has to access the pages, according to the
criteria given in the table below:
CATEGORY PAGES THAT CAN BE ACCESSED ACCESS MODE

data read-out pages (first column on menu
none page) read
system information page
page)
controller pages (first column on menu page) read
events log pages
setup page and system information page
1 data input pages (second column on menu
page) * Note 2
recipes page (third column on menu page) * Note 2 read and write
fault tracing page (fourth column on menu
page) * Nota 2
page) read
2 system information page
Quality pages excluding the events log page read and write
(fifth column on menu page)
3 page) read
system information page
page) read
4 system information page
production pages (fifth column on menu page) read and write
5 full privileges on all pages read and write
Note 1: Combinations of the categories given above can be assigned.

For example, users may be assigned more than one category such as 2, 3 or 2, 4.
Note 2: The table is given for reference purposes only, i.e. pages that can be read and/or
edited by users of a certain class may contain data that can be edited only by higher
level users.
For example, note the case present on the setup page for the destination silos where
the recipe can be set only by a level 5 user while all the other data items given on the
page can be set by a level 1 user.
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Deleting user names

The user name cancel button allows the user to select which user name is to be deleted from amongst the ones
actually recorded in the system (after confirming).
The icons shown below appear in the list to specify whether the operator was created with a key or by hand.
- User name created with key
- User name created by hand
Note 3 The information contained in the key has priority over the information input by hand. For example, if
user names were assigned privileges 2, 3 with a key and then given privileges 2, 4 by hand, the previous
privileges (2, 3) will be restored the next time the key is inserted.
Scrolls up the list of user names recorded in the machine.
Scrolls down the list of user names recorded in the machine.
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“PASSWORD MODIFICATION” DIALOG WINDOW
If the button is pressed on the setup page and level 5 privileges are not enabled, a dialog window opens
where the password written in the key can be modified.
The window shows the user name (cannot be changed) and password written in the key. The new password can be
entered in the underlying boxes (they have to be entered twice to avoid errors).
After entering the new password, press ENTER to confirm or ESC to cancel the operation.
Set the Setting the data page.
“INACTIVITY TIME” DIALOG WINDOW
Press the button on the setup page to view the dialog window shown above. This window is used to set
the number of minutes after which the automatic log out procedure is performed for each user class.
NOTE: to deactivate the function, enter zero for the inactivity time.
To set the inactivity time, bring the cursor to the value to be
changed with the keyboard arrow keys or mouse, enter the new
value and press ENTER.
Purpose
If an operator logs in (for example level 4) to check the system and
leaves the machine without logging out, the log out procedure is
automatically performed if a key is not pressed for the number of
minutes set in the dialog window (level 4). This is done to prevent
a lower level operator from carrying out unauthorized operations.
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DATA AND TIME
Press the button on the setup page to view the dialog window used to set the date and time.
To set the new date and time, simply type them in the respective fields that appear in the dialog window.
- To enter the data and confirm

Use the mouse or move the cursor with the keys to enter the data. Once the new
data have been entered, press ENTER or select button Ok to confirm the entry.
- How to undo the read operation (quit window):

Press ESC or select button Cancel to cancel the operation.
- Note: Be careful to enter the date and time in the required format:
• Date format: dd/mm/yy
• Time format hh.mm.ss
- Restoring the data base

If the new data entered are incorrect and some production data have been
erroneously cancelled, the old data (and old production data) can be recovered
with the “Ripristino database” (Data base recovery) button in the dialog window.
Remarks:
Changing the time If only the time is modified, the change is immediately made so that the production data are still
valid.
Changing the date If the date is changed, all the production data saved up till that moment may not be compatible
with the new date.
To solve the problem, the system performs the following operations:
a. A back up copy of all the production data saved up until that moment is made;
b. A check is made to assure the stored production data are compatible with the new date,
eliminating any data that are not compatible;
c. The interface is restarted to make the modifications operative.
Note: each new back up copy is stored in the computer available so that it can be used in the
future.
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RESTORING THE DATA BASE
If the date is changed, all the production data saved up till that moment may not be compatible with the new date.
To solve the problem, the system performs the following operations:
• A back up copy of all the production data saved up until that moment is made;
• A check is made to assure the stored production data are compatible with the new date, eliminating any data that
are not compatible;
• The interface is restarted to make the modifications operative.
If the new data entered are incorrect and some production data have been erroneously cancelled, the old data (and old
production data) can be recovered with the “Ripristino database” (Data base recovery) button in the date and time
dialog window.
When this button is pressed, the following dialog window appears which contains the dates of all the back up copies
present in the PC.
The date and time each backup copy present in the system was made are displayed in the list: Use the check box (……..)
to select the one to be restored.
When button OK is pressed, the following operations are performed:
• A back up copy of the data present in the system is made that will be put at the end of the queue of the ones present;
• The date, time and production data of the selected backup copy are restored.
• The interface is restarted to make the changes operative.
Press button Cancel to cancel the operation.
Note: the ESC key is disabled in this dialog window: to select the buttons use TAB, ENTER or the mouse.
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14.2 INFORMATION PAGE (W) W
Photograph 38
The typical machine parameters are given on this page, divided into two parts: the main machine configuration
parameters are given on the left side while those regarding the control system appear on the right side.
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14.3 CONFIGURATION SUBMENU (X) X

(Can be viewed by login level 5)
Photograph 39
The functions for setting several “Windows” elements to update the interface program and set other program data for
exporting the production data bases are given in this menu.
The following buttons are provided in this window:
1 Mouse settings
2 Modem settings
3 Printer settings:
4 Network card settings
Buttons 1, 2, 3 and 4 are used to reach/refresh the Windows elements (printer, modem, mouse and network card).
When one of these buttons is pressed, the standard Windows window used to set the periphery opens.
Instructions on how to set these functions are given in the Introduction to Windows manual (supplied along with the
Windows license).
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Note:
• check the relative check box before attempting to set the Modem and Printer.
• option “Negative” for the printer serves to reverse the colors in which the information is printed out. This option is
useful when printing pages on which the information is written in a light color on a dark background. In this case, if
“negative” is selected, the information is printed out black on white with the double advantage of speeding up printing
and reducing the amount of ink used.
5 Program refresh
This button serves to update the interface program. In order to refresh the compact disk containing the updated program
supplied by SACMI must be at hand. The procedure to be carried out to update the program is given in the Software
installation guide for Personal computers.
6 Production data
This button is used to export the following data:
• Recipes
• Production databases
• Files containing the faults and fault messages
• File containing historical data
When the key is pressed, the system asks where the data are to be copied:
• Drive A:\ (a diskette).

• In folder C:\Export\ shared with the outside world (through the Windows network)
7 “Timed” export setting
This button serves to set a time for automatically exporting the following data:
• Recipes
• Production databases
• Files containing the faults and fault messages
• File containing historical data
When this button is selected, a form appears that allows the user to enable or disable the data base automatic export
function. To enable the function, specify the frequency at which data export is to take place. The system copies all the
data bases in the C:\Export\ folder shared with the outside world (through the Windows network).
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8 User’s manual
This button is used to perform the maintenance given in the User’s Manual (fault messages). Once this button has been
pressed, a window opens where the user can select which of the following operations needs to be performed:
OPERATION MODE
Import To import and export the manual containing the fault messages
created by the user, simply select the corresponding check
Export box and press “OK” in the window or “Enter” on the alphanumeric
keyboard.
Canceling a user’s To cancel or edit a message, select the corresponding check
message box and enter the number of the desired message in field “Note
Editing a user’s message code” (e.g. 2001). Finally, press “OK” in the window or “Enter”
on the alphanumeric keyboard.
To cancel any type of operation, press key “cancel” or “Esc” on the alphanumeric keyboard.
Note
1. When exporting, the files regarding help information for the fault messages are copied in the folder.
2. When importing, the files present in the folder are canceled.
3. The functions used to create and cancel a user’s message can be performed from the Viewing/editing help
information for the fault messages page.
9 Restoring the recipe data bases
This button is used to compact the recipe data bases. This needs to be done whenever problems arise when reading,
saving or canceling a program saved on the hard disk.
The PCs are restarted when this button is pressed.
A Serial ports tested.
This button is used to test the computer and modem serial ports.
SACMI service personnel must walk you through this procedure.
B Uninterrupted power supply settings
Function B is used to set the computer’s UPS.
C Resets the project
This button is used to reset the project in the event of malfunctioning.

When this button is pressed, some files (needed for the interface to work properly) that may have been corrupted , are
canceled.
Contact SACMI service personnel to receive authorization before pressing this button as information may be lost.
The PCs are restarted when this button is pressed.
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D Displays rights
This button is used to set, view or hide the rights for setting data. When this button is pressed, a window with four buttons
opens:
• Shows rights
• Hides rights
• Refreshes
• Quit (icon)
The buttons execute the following functions:
• The first two buttons serve to enable or disable the display of the rights set for each data item (when the first button
is enabled, the second one is disabled and vice versa);
If button Mostra diritti (show rights) is selected (it appears in grey), a black box that contains the value of the
set privilege appears to the left of each settable data item.
Example:
To change the first data item in the figure to the side a level “1” user has to log in;
On the other hand, to change the second data item at least a level “3” user has to log in;
• The third button is not used.
• The fourth button closes the window and goes back to the menu page.
Setting the rights:
To change the rights set for a data item (this can be done only with a Master level password), perform the following
operations:
• go to the page that contains the data item/s the rights are to be set for;
• click the data item to be edited with the right mouse key;
• a dialog window opens where the new value is to be entered (ranging from 0 to 5);
• lastly, press button Ok (or Enter on the keyboard).
Note:
• before attempting to set the rights, select button “Mostra diritti” (show rights) mentioned above;
• the changes made to the “rights” will becomes operative only after quitting the page therefore to view the new
value set, quit and go back to the page.
E Battery log
This button is used to read the events log regarding the computer’s UPS.
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F Confirmation message
This button is used to ENABLE/DISABLE the confirmation message.

When it is ENABLED, a window similar to the one given below opens whenever a data item is edited. Press OK to assign
the new value otherwise Cancel to keep the old one.
G Customer code enable
To enable/disable customer code control, access the system using the transponder key with privilege 5.
If it is ENABLED, when the system is accessed with the transponder key, a check is made to assure the customer code
recorded in the key is correct. On the contrary, the log in procedure is not performed.
If it is DISABLED, the check is not made therefore the system can be accessed with a key that has the wrong customer
code.
Other automatic back up mechanisms
The system automatically makes a back up copy of the recipe data bases. This takes place daily at 12:00 in a back up
folder that cannot be seen from the outside.
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15 WHAT TO DO WHEN THE MACHINE STOPS DUE TO MALFUNCTIONING
Machine stoppage when a shutdown message appears.
The machine immediately stops when a “shutdown” message is displayed.
When a “stoppage” message appears the machine stops after completing the cycle in progress.
Read the message shown on the first line on the top of the display and then refer to the FAULT MESSAGES chapter
for information regarding what caused the shutdown or stoppage. In some cases the identification symbol of the device
that detected the fault is given next to the message. In these cases, check the state of the device in question. If everything
is as required, check the electric connections regarding the input in question.
Further information regarding the machine is provided on the following pages:
I/O
The state of all the machine outputs is displayed. Information useful if an axis or accessory fails to move is given on this
page. The state of the outputs is given. As a result, the user can find out which outputs had to be on.
In addition, the state of all the inputs is given on this page.
Once the fault has been cleared (so that the page can be updated), the operator can verify whether the physical inputs
match those read by the controller (by measuring the input voltage of the card: 0V input not activated, 24V input
activated). If the actual state does not coincide with the one read, replace the input card.
Machine status (STATUS)

The status of the machine axes is given on this page.
The status is given in numeric form for each axis (refer to the chapter that deals with this page for the meaning of the
code given).
In the event of machine shutdown, the state is decoded and described in the relevant block.
ALWAYS TAKE DOWN ALL THE INFORMATION MENTIONED ABOVE SO THAT IT CAN BE READILY QUOTED
WHEN CONTACTING SACMI’s SERVICE DEPARTMENT. MACHINE MALFUNCTIONING CANNOT BE PROPERLY
DIAGNOSED IF THIS INFORMATION IS NOT AVAILABLE.
EDITING HELP INFORMATION FOR THE FAULT MESSAGES
When a fault is signaled on the status bar, press the right mouse key on the fault itself or any other fault present on the
Faults page to go Note 1 to this page where:
• the description of the fault present is given;
• a description can be changed or a new one can be set (e.g. a maintenance operation, a detailed list of operations
to be performed to solve the problem, etc…).
Creating or changing the description (level 5 user must log in)
Proceed as follows:
• Place the cursor on the fault message and press the right mouse key to open the page in question.
• Press F5.
As a result, the existing text file for that message opens and can be edited through Windows program Memo or
a new file can be associated to it.
• Enter or change the message from the alphanumeric keyboard and save the file as a normal text file..Note 2
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Note
1. The users given in the following table can access this page:
LOGIN MODE
Class 1 or combination of Display only if at least one description of the active fault
it (1-2, 1-3, etc…) (present in the status bar) is present, otherwise only the page
of the machine manual that deals with that message can be
displayed (by pressing the left mouse key).
Class 5 Read and write.
2. The folder used to export and import help information is: C:\Manuali\ManUser.
3. It is the following button in the button bar:
F5 Press the key to the side to open and edit the file that describes the fault shown on the page. Only
level 5 users can perform this operation.
4. Other operations can be carried out for the “personal” messages by level 5 users with button Config on the Menu
page
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16 FAULT MESSAGES
The fault messages are displayed in the area of the display illustrated in the figure.
Each message is identified by a four digit number (the first digit indicates the category the message belongs to). The
messages are divided into five different categories:
1) SHUTDOWN MESSAGES
These messages are displayed when the machine immediately shuts down. Once the trouble has been remedied,
clear them by pressing the Reset key.
2) PARTIAL SHUTDOWN MESSAGES

These messages are displayed when the machine immediately shuts down. Once the trouble has been remedied,
clear them by pressing the Reset key.
3) MACHINE STOPPAGE MESSAGES

These messages appear when the machine stops at the end of the work cycle in progress. Manual operations are
still enabled. Once the trouble has been remedied, clear them by pressing the Reset key.
4) INFORMATION MESSAGES
These messages do not affect the work-cycle or manual operations. Press the Reset key to clear them.
5) MAINTENANCE MESSAGES
These messages do not affect the work-cycle or manual operations. Press the Reset key to clear them with the key
turned to SET UP.
NOTE: In some cases, messages are displayed by the operating system. A detailed description of these messages
is given in the following chapter.
NOTE: - Some of the messages recommend checking one or more cards for proper functioning (e.g. check the EIA
card). Consult the Hardware Manual for the card in question, in particular the TROUBLESHOOTING
chapter.
- For further information regarding the sensors/actuators consult the LIST OF DEVICES handbook.
- The location of the sensors/actuators indicated in the fault messages is given in the SPARE PARTS
Manual.
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NOTES ON HOW TO REPLACE THE CARDS:

• The set data are stored in the CPU card’s RAM but can be copied in the recipes that reside in the computer’s memory.
In order not to lose the data, save the current program and call it up with the new CPU installed before changing the
CPU.
• The configuration data (serial number, type of PH, type of filler-box, etc…) reside on the E2CBUS card (SMC
085.06.901).
These data are not lost if the CPU is changed.
• The production data that can NOT be reset reside on the E2CBUS card (SMC 085.06.901).
These data are not lost if the CPU is changed.
• The CPU card’s RAM contains other data (not to be confused with the card that stores the program and/or operating
system) that are lost if the CPU is changed or if the AL card malfunctions.
The main data along with instructions on what to do if they are lost are given below:
PLUNGER ENCODER HAS BEEN RESET:

This information is given only in presses with 1, 2 or 3 absolute encoders (i.e. that are reset only once). If the
“PLUNGER ENCODER NOT RESET” fault message is displayed, go to the page used to reset the encoder.
DIE-SET LOCKING ACTIVE:

This information is given only in presses in which the die-set is locked/released from the control keyboard. If the
“PUNCHES NOT FIXED” fault message is displayed, first of all carry out the procedure to lock them.
PROPORTIONAL SOLENOID VALVE SELF-LEARNING PROCEDURE COMPLETED:

This information is given only in proportional presses. If the “PERFORM PLUNGER LEARNING (YV32) fault
message is displayed, perform the self-learning procedure for the plunger upstroke/downstroke.
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16.1 OPERATING SYSTEM MESSAGES
S001 DIVIDE ERROR INTERRUPT (Operating system)
The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears.
S002 NON-MASKABLE INTERRUPT (Operating system)
S003 OVERFLOW INTERRUPT (Operating system)
S004 UNUSED OPCODE INTERRUPT (Operating system)
S005 KEYBOARD ERROR [PE\OE\FE] (Operating system)
Improper communication with the machine control keyboard.

Shut off the electrical power and then turn it on again.
If the trouble does not re-occur it can be ignored, otherwise check the lead between the keyboard and the
Miscellaneous card or replace the keyboard and/or “Miscellaneous” (VA) card.
Parameter: PE (parity error), OE (overrun error), FE (framing error).
S006 INVALID MEMORY (Operating system)
The program is not valid.

Shut off the power supply, make sure the card located on the CPU is properly plugged in and then turn the
power supply back on. If the trouble persists, contact SACMI quoting the alpha-numeric code stamped on the
card.
S007 POWER SUPPLY/FUSES nnV (Operating system)

The protection device on the AL card has come into action or the fuses have blown.
The message provides information about the voltages not provided.
Check the fuses for condition and make sure there are not shorts in the conductors indicated.
S008 DIVIDE ERROR PROG n LINE nn (Operating system)
A division by 0 was made.

S009 OVERFLOW PROG n LINE nn (Operating system)
An instruction has been improperly executed; its result exceeds the set limits.
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S010 PROG n PC nnnn:nnnn COD nn (Operating system)
An instruction not acknowledged was executed. The version of the operating system is probably prior to the
one required by the program.
The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears and the
version of the operating system.
S011 OVERFLOW STACK PROG nLINE nn (Operating system)
The stack pointer is not within the allowable range.

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16.2 SHUTDOWN MESSAGES
1001 SHUTDOWN PUSH-BUTTON (shutdown)
The shutdown push-button on the keyboard has been pressed.

If the push-button has not been pressed, check the keyboard power leads.
If the power lead is properly connected and is not broken, try replacing the control KEYBOARD.
If the keyboard works properly, try replacing the MISCELLANEOUS card.
1002 EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E) (shutdown)
One of the external shutdown pushbuttons has been pressed.

If this is not the case, check the connector blocks of the external shutdown buttons and related wiring
connections. Also check the input card (Led SB1E must be on when the machine has not shutdown) and the
leads/connectors.
1003 ANALOG/ENCODER CARD NOT WORKING (1) (shutdown)
The encoder/analog card (EIA) is malfunctioning. If a proportional knockout is provided the fault is to be found
in the EIA card in location 6/7. Shut off the controller and replace the card.
If the trouble persists, replace the CPU card.
Note: This message only appears if a program version earlier than PH12.01.01 is being used.
1004 PUNCHES NOT FIXED (AJ1/AJ2) (shutdown)
If AJ1, AJ2 or AJ3 does not appear to the right of the fault message the magnetic lock is enabled but it has
not yet been magnetized (see chapter 5.9.16, paragraph “e” in this manual).
The same procedure must be performed if the CPU card has been replaced.
- (AJ1): The input card has not received the feedback signal that the upper punch locks are magnetized.
Check the setting of current control device AJ1 and check the wiring/operation of the upper magnetic lock.
Also inspect the input and output cards (see NOTE).
- (AJ2): The input card has not received the feedback signal that the lower punch locks are magnetized.
Check the setting of current control device AJ2 and check the wiring/operation of the lower magnetic lock.
Also inspect the input and output cards (see NOTE).
- (AJ3): The input card has not received the feedback signal that the lower punch locks are magnetized.
NOTE: For presses using an earlier program version than PH12.01.01, there is only one feedback input signal
(the contacts of AJ1, AJ2 and AJ3 are series connected). This means that, even if the fault message
PUNCHES NOT FIXED (AJ1) appears, the operator must check
whether the fault is in the upper or lower magnetic lock. Then make the required checks.
1005 CHECK PRESET DATA (shutdown)
If this message appears when the machine is started up or after replacing the CPU card, read the stored work
program in use before replacing the CPU card. If no program is stored, check all the set data.
If the VA card has been replaced, take off the removable card from the old VA board and install it on the new
VA board (contains all the saved programs).
If the message appears in other working situations, check the battery (located on the POWER SUPPLY card)
for proper operation.
If the battery works properly, replace the CPU and check all set data.
NOTE: To clear the message, turn the key switch on the machine control keyboard to SETUP and press the
Reset key.
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1006 CHECK 24 VEV (shutdown)
No 24 VEV voltage is being supplied.

Press the Reset key. If the message is not cleared, check safety module AJ100: if power is not being supplied
(“NETZ” Led off or “POWER” off), check the CPU card, the AL card and the leads/connectors. If power is being
delivered but the two signals (S1 and S2) are different or both of them are off, check the internal and external
shutdown buttons, input SB1E and the leads/connectors.
Check three phase rectifier bridge VC 101 located in the power switchboard.
Also check the upper BUS, Section 1.
1007 MODE SELECTOR (shutdown)
The key on the machine control keyboard was turned during RESETTING, CYCLE or SEMIAUTOMATIC
operation.
If the key was not turned, check selector SA9, its connection to the machine keyboard and the keyboard power
lead.
If the lead is properly plugged in and is not broken, replace the control keyboard.
If the keyboard works properly, replace the MISCELLANEOUS card.
1008 ANALOG/ENCODER CARD NOT WORKING (2) (shutdown)
The second encoder/analog card (EIA) in location 10 is malfunctioning. Shut off the controller and replace the
card.
If the trouble persists, replace the CPU card.
If the problem still cannot be resolved, contact SACMI to check the configuration (check the ENCODER data
item).
NOTE: this message only appears when a program version earlier than PH12.01.01 is being used.
1009 MAIN SWITCH TRIPPING (BTn) (shutdown)
This fault message is displayed just before the power to the electrical cabinet is cut off. This happens because
a fault has been detected in one of the die-set heaters (“n” indicates the heater which is malfunctioning):
- output KMn is off and the corresponding input KMn is on.
- the temperature measured by thermocouple BTn is higher than 110°C (80°C if the punches are made of
rubber).
- the temperature measured by BTn is lower than 0°C and output KMn is on. In all these cases, the pumps
are stopped after 5 minutes and then power to the electrical cabinet is cut off.
With program versions earlier than PH12.01.01: check thermocouple BTn, its input module, the EIA card
in location 6/7 and the related leads/connectors. If the problem is the first possibility mentioned, check the
output card, contactor KMn, feedback relay KAn in the electrical cabinet and the input card.
With program version PH12.01.01 or later: check thermocouple BTn, its conversion card in box 38, the IA
card and the related leads/connectors. If the problem is the first possibility
mentioned, check the output card, contactor KMn, feedback relay KAn in the electrical cabinet and the input
card.
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1010 SHORT CIRCUIT YVn (shutdown)
The OD and ODA cards have a control device which checks that the current supplied from each digital output
is correct.
If one of these cards detects a faulty output, this message appears.
Disconnect the output for YVn from the controller and make sure there are no short circuits in solenoid valve
YVn or in the leads/connectors.
If there are no shorts in the cable or solenoid valve, check to see whether there is a +24 V supply for the
solenoid valves. To do this, check the respective Led on the power supply (see INSTRUCTIONS C - paragraph
3.1) and the AL Led on the card which has the short circuited
output.
Make sure there are no false contacts in the power supply for the YVn output card.
If the short-circuited output is part of the first ODA card, check filler-box limit switches SQ59,
SQ53 (Roller conveyor on), SQ66, SQ66A (Filler-box on), SQ51, SQ52 (Safety bar), contact SA9 of the mode
selector as well as contacts AJ101, KA102 and KA103. Also check circuit breaker FS101.
If the problem persists replace the output card.
1011 PRESSURE SWITCH/TRANSDUCER ... bar (shutdown)
The maximum operating pressure for the press cylinder has been exceeded. If “(SP2)” appears to the right
of the fault message this means the problem has been detected by pressure switch SP2: check the pressure
switch and the ID card (if the pressure is within
the set limits led SP2 should always be on) as well as the leads/connectors.
If nothing appears to the right of the fault message this means the problem has been detected by pressure
transducer BP1. In this case the message appears when the transducer detects pressure which is 20 bar
above the maximum allowable. Check transducer BP1, the leads/connectors and
With program versions earlier than PH12.01.01: the input module of transducer BP1 (AP301) and the EIA
card in location 6/7.
With program version PH12.01.01 or later: check the IA card in location 7.
1012 IE CARD (shutdown)
The IE card does not work. Turn off the controller and replace the card. If the problem persists replace the CPU
card.
1013 CONFIG. (shutdown)
This message is for SACMI personnel only.

The press cannot perform any movement.
If this message appears when no SACMI engineer is working on the press, contact the After sales Service
Dept. - SACMI, IMOLA
1014 ANALOG CARD DOES NOT WORK (shutdown)
The IA card does not work. Turn off the controller and replace the card. If the problem persists, replace the
CPU card.
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16.3 PARTIAL SHUTDOWN MESSAGES
2001 FAN/FILTERING UNIT (KM11) (shutdown)
Input KM11 has remained inactivated for 30 seconds. The pumps are stopped. Check the thermal cutout and
contactors of the fan and filtering unit motors (KM4 and KM11).
Check the input card (Led KM11 must be on when the motors are running) and the leads/ connectors.
Check the output card (Led KM11 must come on when the motors have to run) and the leads/connectors.
If KM11A, KM13 or KM14 are indicated in the fault message, check the additional heat exchanger.
2002 HYDR. UNIT PUMP (KM1D) (shutdown)
Input KM1D has stayed off for 30 seconds with the main pump running or input signal KM1D has remained
on for 2 seconds while the main pump is being turned off. The main pump is stopped.
Check the thermal cutout and contactor KM1D.
Check the input card (Led KM1D must be on when the motor is running) and the leads/connectors.
Check the output card (Led KM1 must be on when the motor has to run) and the leads/connectors.
2003 LOW PRESSURIZATION (SP3) (shutdown)
Input SP3 has stayed off for 6 seconds. The main pump is stopped.
Check the main pump suction filter for efficiency.
Check pressure switch SP3, the input card (Led SP3 must be on when the operating pressure is within the
allowable range) and the leads/connectors.
2004 OIL LEVEL (SL1) (shutdown)
Input SL1 has stayed off for 6 seconds. The pumps are stopped.
Check the oil level in the reservoir.
Check level sensor SL1, the input card (Led SL1 must come on when the oil exceeds the maximum level mark)
and the leads/connectors.
2005 CONNECT THERMOC. (BT4) (shutdown)
The machine will shutdown when this message appears and the main pump will stop running.
Make sure the thermocouple for the oil is properly connected.
With program versions earlier than PH12.01.01: check the input module of thermocouple BT4 (AP304) and
the EIA card in location 6/7.
With program version PH12.01.01 or later: check conversion card APBT4 (control unit box) and the IA card.
2006 TEMP. TOO LOW (BT4) (shutdown)
The oil temperature has remained at a temperature which is too low (less than 2° C) for 30 seconds. The main
pump is stopped.
Check the thermocouple for proper functioning (replace it if necessary).
If it works properly, find out what is causing the temperature to be too low.
With program versions earlier than PH12.01.01: check the input module of thermocouple BT4 (AP304) and
the EIA card in location 6/7.
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2007 TEMP. TOO HIGH (BT4) (shutdown)
The oil has remained at a temperature which is too high (over 55° C) for 30 seconds. The main pump is
stopped.
If it works properly, find out what is causing the temperature to be too high.
With program versions earlier than PH12.01.01: check the input module of thermocouple
BT4 (AP304) and the EIA card in location 6/7.
The temperature level reached appears to the right of the fault message.
2008 TEMPERATURE HIGH (ST4) (shutdown)
The oil temperature is too high. Input ST4 (oil thermostat ) has detected the problem as it stayed off for 30
seconds.
2009 REPLACE FILTER (SP1) (shutdown)
Input SP1 has remained inactivated and the oil temperature is above 30°C. The main pump is stopped.
Replace the filter in the hydraulic power unit as it is clogged.
If the message is still displayed even after the filter has been replaced, check pressure switch SP1, the input
card (Led SP1 must be on when the filter is not clogged) and the leads/connectors.
2010 OIL LEAK LEVEL (SL4) (shutdown)
Input SL4 has stayed off for 40 seconds. The main pump is stopped.
Check the oil leak level in the oil recovery tank.
Check level sensor SL4, the input card (Led SL4 must come on when the oil is below the low level mark) and
the leads/connectors. If SL11 is given in parenthesis, the message regards the maximum level sensor for oil
leak recovery during the differentiated press stroke.
2011 OIL COCK CLOSED (SQ50) (shutdown)
The pumps are stopped.

If this message appears when the oil cock is open, check limit switch SQ50 (which opens the oil passage),
the leads/connectors and the input card (Led SQ50 must be on when the cock is open).
2012 HIGH PRESSURE IN THE CYLINDER (shutdown)
With the safety bar raised, the pressure in the cylinder exceeds 6 bar. The main pump is stopped.
Check all the logic elements and solenoid valves of the pressing unit and make sure no faults are present.
If there is no pressure in the cylinder, set the pressure transducer of the cylinder (see NOTE).
If the problem persists, replace pressure transducer BP1.
With program version earlier than PH12.01.01:check the input module of transducer
BP1 (AP301) and the EIA card in location 6/7.
NOTE: With program version 12.01.01 or later, cylinder pressure = 2 bar is displayed when the machine is
turned on if digital input SP3 is on (air pressurization approx. 1.5 bar) and the pressure detected by transducer
BP1 is between -3 bar and +7 bar.
To set the transducer, it is necessary to eliminate pressurization, turn off the controller and then turn it on again.
At this point the pressure displayed is that read by the transducer and the operator can therefore proceed with
the setting procedure: see the INSTRUCTIONS FOR SETTING THE TRANSDUCERS Manual.
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Input SP6 has stayed off for 60 seconds and the oil temperature is higher than 30°C.
The ENEA COOLING filter needs to be replaced as it is clogged.
If the message continues to be shown after the filter has been replaced, check pressure switch SP6 and the
input card (with the filter not clogged led SP6 should be on) and the related leads/connectors.
2014 TEMPERATURE TOO HIGH (ST1) (shutdown)
Input ST1 has stayed off for 6 sec. The main pump is stopped. Check the flywheel bearings to see if they are
properly lubricated. Make sure the bearings work properly.
2015 MOTOR M1 POWER HIGH (pump shutdown)
Power M1 delivers to the motor shaft is too high. The machine pump shuts down. Check current limiter T.A.
2016 CHECK (Bpn) (pump shutdown)
Make sure the thermocouple indicated in the fault message is properly connected.
The main pump cannot start running.
If a pressure switch is indicated in parenthesis (SP1, SP4, SP5, SP6, SP7, SP8), check the pressure switch
indicated, the connections and input card.
2021 PUNCHES INSIDE (SQ62) (shutdown)
During the automatic cycle, SQ62 has not been energised within 0.5 seconds of the moment when the plunger
arrived at the top end stop.
Check limit switch SQ62 and the related leads/connectors.
Check the input card (Led SQ62 must be on when the punches are out). Also check solenoid valve YV193,
the leads/connectors and related output card.
2022 HOPPER CLOSING (SQ61) (shutdown)
SQ61 has not been energized within one second of YV221 being de-energized during gate closing.
Check solenoid valve YV221 for proper operation.
Check proximity switch SQ61, the input card (with the hopper closed, switch SQ61 must be energized) and
the leads/connectors.
Check the output card (Led YV221 must go off when the gate has to close) and the leads/connectors.
2023 LAST DIE-SET D.STROKE (SQ6) (shutdown)
During the last die-set downstroke SQ6 was de-energised (see NOTE).
Check solenoid valve YV21 for proper functioning.
Check proximity switch SQ6, the ID card in location 11(when the die-set is lowered, Led SQ6 must be on) and
Check the OD card in location 16 (during the last die-set downstroke, Led YV21 must go out) and the leads/
connectors.
NOTE: SQ6 must be activated once the die-set has completed the first downstroke and must remain activated
during all the other downstrokes as well as during the press-cycle.
With 2-cylinder proportional knockout: if the value of encoder A or B is not lower than 2 mm within 8
seconds from when the signal for the last downstroke was sent:
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Check proportional solenoid valves YV22A/22B, axis cards AP204/205, the related ODA card, synchronization
card AP203, encoder interface module AP206 installed on the SMU, encoders BQ4/5 and:
- With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10.
- With program version PH12.01.01 or later: the IA card and the IE card in location 9.
If the message is displayed during the press-cycle, it means encoders BQ4/5 have read a value less than
-0.5 mm during the press-strokes. Shut off the controller and then turn it back on and reset the encoders.
With 4-cylinder or 2+2 cylinder proportional knockout: if the value of encoder A or B is not lower than 0.8
mm within 8 seconds from when the signal for the last downstroke was sent:
Check proportional solenoid valves YV22A/22B, axis cards AP210, the encoder interface card AP207, the
serial interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and
- With program version earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01 or later: the IE card in location 9.
If the message is displayed during the press-cycle, it means encoders BQ4/5 have read a value less than
-0.5 mm during the press-strokes. Shut off the controller and then turn it back on and reset the encoders.
2024 PLUNGER DOWN DUR. DIE-SET UPSTR. (shutdown)
The plunger is below the value set for its upper-most position when the die-sets begin to move up.
2025 F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59) (shutdown)
The filler box is not completely back when the die-set starts moving up
If “(SQ59)” appears to the right of the fault message, this means the fault has been diagnosed by upper input
SQ59. In this case, check filler box safety switch SQ59 and the IDM card in location 11.
If nothing appears to the right of the message, this means that the fault has been detected by the filler box
encoder. In this case, check the filler-box encoder setting. If the latter does not correspond to the actual
position of the filler box:
- With program version earlier than PH12.01.01:check the EIA card in locations 6/7.
- With program version PH12.01.01 or later: check the IE card in location 9.
2026 2ND FILLER-BOX FORWARD (KA302) (shutdown)
The position of the second filler-box or LB type filler-box is not correct when the die-sets start their upstroke.
Check the trigger pulse for the plunger downstroke (KA302) and the related input card.
2027 DIE-SET UPSTROKE (SQ3) (shutdown)
Proximity switch SQ3 is not energized during the die-set upstroke (see NOTE).
Check solenoid valves YV21/22 and the related hydraulic lines for proper functioning.
Check proximity switch SQ3, the ID card in location 11 (when the die-sets are raised, proximity switch SQ3
must be energized) and the leads/connectors.
Check the OD card in location 16 (while the die-sets are moving up, Leds YV21/22 must come on) and the
leads/connectors.
Check solenoid valve YV64 and the pressure in the service circuit.
With a 2-cylinder proportional knockout: if the setting of encoder A or B does not reach the upper end-stop
setting less 2 mm within 8 seconds from when the signal for the die-set upstroke was sent:
Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis cards AP204/205 and related
ODA card, synchronization card AP203, encoder interface module AP206 installed on the SMU, encoders
BQ4/5 and
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With 4-cylinder or 2 + 2 cylinder proportional knockout: if the setting of encoder A or B does not reach
the upper end-stop setting less 0.8 mm within 8 seconds of the signal for the die-set upstroke being sent:
Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis card AP210,
the encoder interface card AP207, the serial interface card AP208, the OD card in location
14, the ID card in location 13, encoders BQ4/5 and
NOTE: SQ3 should be energized when the die-sets move up (YV21 and YV22 ON) for a max. time of 8
seconds. SQ6 should be de-energised within this time and should be energized when the die-set performs
its first downstroke.
2028 1ST DIE-SET D.STROKE (SQ3/SQ6) (shutdown)
Proximity switch SQ3 is not de-energized or proximity switch SQ6 is not energized within 1 second of the first
downstroke signal (see NOTE).
Check solenoid valve YV22 and related hydraulic lines for proper functioning.
Check proximity switches SQ3/SQ6, the ID card in location 11 (after the first downstroke, SQ6 should be
energized and SQ3 de-energized) and the leads/connectors.
Check the OD card in location 16 (Led YV22 should go out after the first downstroke) and the leads/connectors.
With a 2-cylinder proportional knockout:
2-downstroke cycle: if the setting of encoder A or B is not lower than FCA/2 (FCA = Upper end-stop) within
8 seconds from when the signal for the first downstroke was sent, 3-downstroke cycle: if the first downstroke
setting (with 0.4 mm tolerance) has not been reached within 8 seconds from when the signal for the first
downstroke was sent:
check proportional solenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronization
card AP203, encoder interface card AP206 installed on the SMU, encoders BQ4/5 and
With 4-cylinder or 2 + 2 cylinder proportional knockout: if the first downstroke setting (with 0.8 mm
tolerance) has not been reached within 8 seconds from when the signal for the first downstroke was sent:
Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial
interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and
NOTE: SQ6 should be energized when the first die-set downstroke has been performed and should remain
energized for the rest of the downstrokes and during the press-cycle. SQ3 should be energized as soon as
the die-set starts to move down.
2029 HOPPER OPEN (SQ60) (shutdown)
SQ60 has not been energized within 1 second of YV221 being energized during gate opening.
Check proximity switch SQ60, the input card (with the hopper open, proximity switch SQ60 must be energized)
and the leads/connectors.
Check the output card, (Led YV221 must come on when the gate has to open) and the leads/connectors.
2030 2ND F-BOX TRIGGER P. (KA304) (shutdown)
Digital input KA304 has not come on within 15 seconds from when the signal for starting the 2nd filler-box cycle
was sent (KA401).
Make sure the second filler box/filler-box for double loading works properly.
Check the trigger pulse contact for the intermediate die-set downstroke (KA304), the input card (Led KA304
must be on when the trigger pulse is provided) and the leads/connectors.
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2031 2ND DIE-SET D.STROKE (SQ6) (shutdown)
During the second die-set downstroke (in a 3-downstroke cycle) SQ6 has been deactivated for more than 1
second.
Check proximity switch SQ6, the ID card in location 11 (LED SQ6 should be on) and the leads/connectors.
Check solenoid valve YV170 and related hydraulic lines for proper functioning.
Check the OD card in location 16 and the leads/connectors.
With a 2-cylinder proportional knockout:
3-downstroke cycle: if the first downstroke setting less 0.4 mm has not been reached within 8 seconds from
when the signal for the second downstroke was sent:
(Note: If the set glaze thickness is lower than 0.8 mm, the fault message is not shown) check proportional
solenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronization card AP203,
encoder interface card AP206 installed on the SMU, encoders BQ4/5 and
With 4-cylinder or 2 + 2 cylinder proportional knockout: if the second downstroke setting (with 0.8 mm
tolerance) has not been reached within 8 seconds of the signal for the second downstroke being sent:
Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial
interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and
2032 2ND F-BOX TRIGGER P. (KA302) (shutdown)
Digital input KA302 has not come on within 15 seconds of the second die-set downstroke.
Check that the second filler box functions and moves properly.
Check the trigger pulse contact for the last die-set downstroke (KA302), the input card (Led KA302 must be
on when the last die-set downstroke is triggered) and the leads/connectors.
2033 DIE DOWN (SQ63) (shutdown)
SQ63 has not been energized within 0.5 seconds from when = the plunger reached its uppermost position.
Check sensor SQ63 and the leads/connectors.
Check the input card (with the die up, Led SQ63 must be on).
Check solenoid valve YV172, the leads/connectors and related output card.
Digital input SP5 is off and the oil temperature is higher than 30°C.
The knockout filter must be replaced as it is clogged.
If the message is still displayed after the filter has been replaced, check pressure switch SP5, the ID card in
location 12 (when the filter is not clogged, Led SP5 should be on) and the leads/connectors.
2035 DIE-SET DEVIATION > 2 mm (shutdown)
With a 2-cylinder proportional knockout: during their upstroke, both proportional knockout cylinders have
exceeded the setting for UPPER END-STOP (DIE-SET SET-UP
page) by more than 3 mm.
Try reducing the UPSTROKE SPEED. Check proportional solenoid valves YV22A/22B, axis cards AP204/
205 and related ODA card, synchronization card AP203, encoder interface card AP206 installed on the SMU,
encoders BQ4/5 and
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With 4-cylinder or 2 + 2 cylinder proportional knockout: during their upstroke one or two of the proportional
knockout cylinders have exceeded the setting for UPPER END-STOP (DIE-SET SET-UP
page) by more than 2 mm.
Try reducing the UPSTROKE SPEED. Check solenoid valve YV22S, proportional solenoid valves YV22A/
22B, axis card AP210, encoder interface card AP207, serial interface card AP208, the OD card in location 14,
the ID card in location 13, encoders BQ4/5 and
2036 DIE-SET PARALLELISM ERROR (shutdown)
An excessive difference was found between the value of the right-hand side and the left-hand side while the
proportional knockout was moving.
With 2-cylinder proportional knockout:
1) When moving down cylinder B has exceeded cylinder A by more than 2.5 mm (setting A > setting B).
Cylinder A shut down; check proportional valve A.
2) When moving down cylinder A has exceeded cylinder B by more than 2.5 mm (setting B > setting A).
Cylinder B shut down; check proportional valve B.
3) When moving up cylinder A has exceeded cylinder B by more than 2.5 mm (setting A > setting B).
Cylinder B shut down; check proportional valve B.
4) When moving up cylinder B has exceeded cylinder A by more than 2.5 mm (setting B > setting A).
Cylinder A shut down; check proportional valve A.
5) A misalignment of more than 10.5 mm has been detected between the two cylinders (YV22S is de-
energized).
Proportional valve malfunctioning; check the Moog and ODA cards.
Encoder stopped or not working.
With 4-cylinder or 2 + 2 cylinder proportional knockout:
0) A misalignment of more than 5 mm has been detected between the two cylinders.
2037 DIE-SET UP. ERROR (A=..., B=...) (shutdown)
At the filler-box start, the difference between the value measured by one of the two encoders and the upper
end-stop is > 0.4 mm. The values measured for cylinders A and B of the proportional knockout are indicated
in brackets.
Try reducing the setting for UPSTROKE SPEED.
With 2-cylinder proportional knockout: Check solenoid valve YV22S, proportional solenoid valves YV22A/
22B, axis cards AP204/205 and related ODA card, synchronization card AP203, encoder interface card
AP206 installed on the SMU, encoders BQ4/5 and
With 4-cylinder or 2 + 2 cylinder proportional knockout: Check solenoid valve YV22S, proportional
solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial interface card AP208, the
OD card in location 14, the ID card in location 13, encoders BQ4/5 and
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2038 DIE-SET ENCODER RESET (shutdown)
The die-set encoder reset procedure has failed.

Check the proportional solenoid valves of the die-set (YV22A, YV22B) for proper operation.
Make sure the aux. equipment circuit is under pressure.
Make sure the SPE is under pressure (solenoid valves YV22S, YV25).
With proportional 2+2 or 4-cylinder knockout:
0) No zero-set pulse is emitted from one or both encoders.
1) During the first 1 mm upward travel, the encoder on side A has not recorded an adequate movement
2) During the first 1 mm upward travel, the encoder on side B has not recorded an adequate movement
3) During the first 1 mm upward travel, a parallelism error has been found.
4) During the upward travel, the encoder on side A has not recorded an adequate movement.
5) During the upward travel, the encoder on side B has not recorded an adequate movement
6) During the upward travel, a parallelism error has been found.
7) During the upward travel, the die-set has moved up too quickly.
8) At the end of the reset procedure, the value recorded by one or both encoders is not within +0.5 and -
0.5 mm.
9) The zero-point signal of one encoder is not recorded. To locate the fault, refer to item “Zero Position” on
the Die-Set display
12) With the SPE encoders not reset, when solenoid valve YV 25 (YV22S in the 4-cylinder SPE) is energised
to deliver oil to the SPE, the die-set has moved up more than 2.5 mm.
Solenoid valve YV25 or YV22S is de-energised.
The proportional solenoid valve has got stuck during upstroke. Check card AX.
BP6/BP7) Pressure transducer BP6 for the upstroke chamber or BP7 for the downstroke one is either not
connected or the pressure in the upstroke chamber is too high. The pressure transducers are
reversed.
(BP7<130) The pressure in the downstroke chamber is too low: the auxiliary equipment pressure may be low.
With proportional 2-cylinder knockout:
Check the “ANALOG” value on the ACTUAL DIE SETTINGS video-page. If the setting of encoder is less than
0.5 mm or higher than 1.5 mm at the end of a reset procedure the ENCODER MUST BE SET UP. (See SETUP
PROCEDURES FOR THE PROPORTIONAL KNOCKOUT ENCODER).
1) At the end of the reset procedure, the analog value read by one or both encoders is not between 0.5 mm
and 1.5 mm.
Check the point of contact between the encoder sensor and the mobile part of the dieset. Check the
encoder setting on the relevant card installed on the die-set. Make sure there are no blockages which
could prevent the knockout from moving down (e.g. powder built up under the die-set).
3) While the cylinders were moving during the second downstroke (YV21), the value read by one or both
encoders has not exceeded the 0.2 mm setting (digital value).
Check for any jammed parts and for hydraulic pressure in the auxiliary equipment control assembly.
Encoder blocked, not working or not connected to electricity supply.
Make sure the thickness gauge is adjusted correctly to a setting greater than 0.2 mm.
4) The values read by each of the two encoders for the second downstroke cylinders with YV21 energized
differs by more than 0.5 mm (digital value).
Check for any jammed parts. The operator has released the encoder but the locking system has remained
engaged.
An encoder has blocked during operations.
5) The value read by one or both encoders has reached 12 mm (digital value).
Encoder not reset (the reset pulse for one or both encoders is not read).
6) A misalignment between the two cylinders of more than 3.5 mm has been detected.
Proportional valves connected the wrong way round or malfunctioning. Make sure the hydraulic lines
have been completely drained.
Make sure the die-set can move freely on both sides without obstructions or excessive friction.
7) A misalignment between the two cylinders of more than 4.5 mm has been detected.
YV22S is de-energized.
A proportional valve is malfunctioning (blocked during upstroke); check the Moog and ODA cards.
8) Both encoders have read a value of more than 14 mm (YV22S is de-energized).
Both proportional valves are malfunctioning (both blocked during upstroke); check the Moog and ODA
cards.
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9) The electrical signal sent by one of the proportional valves has exceeded 16 mm.
Valve malfunctioning (blocked during downstroke) or not connected; check the Moog and ODA cards.
Check for any jammed parts.
10) After an electrical signal equal to zero has been sent by a proportional valve, the dieset does not move
down.
Check for any jammed parts. Proportional valve blocked.
11) During the last stage of the die-set resetting procedure and after a 12 mm electrical signal has been sent
by the proportional valves, one or neither of the cylinders have reached a setting equal to half the signal
sent (6 mm).
Check for any jammed parts.
12) With the die-set not yet reset and following a reset signal, the die-set is found to move up more than 2.5
mm (digital value) as soon as YV22S is energised. YV22S is then deactivated.
Proportional valve blocked during upstroke; check the Moog and EIA cards.
2039 PERFORM DIE-SET LEARNING (shutdown)
Perform the die-set self-learning procedure. See the DIE-SET SET UP page.
2040 CHECK DIE-SET ENCODER (shutdown)
A fault has been detected in one of the die-set encoders (the difference between the analog value and the
digital one is > 1 mm). Check the encoder interface card AP206 installed on the SMU, encoders BQ4 and BQ5
and
With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10.
With program version PH12.01.01or later: the IA card and the IE card in location 9.
2041 DIE SETTING NOT REACHED (shutdown)
2-cylinder SE
During the die-set learning procedure one of the two encoders has reached the value set for UPPER END
STOP ± 2 mm.
Check the proportional solenoid valves of the die-set for proper functioning.
Check solenoid valve YV64, YV225 and the pressure of the service circuitry.
Otherwise reduce the UPPER END STOP setting A or B.
2041 PERFORM SELF-SETTING (YV21P) (shutdown)
SE with rods:
The self-setting procedure for determining the YV21P offset value has to be performed when ejectors with
proportional rods are used (see the DESCRIPTION OF THE KEYS paragraph).
2042 CONTROL UP: PERFORM DIE-SET SELF-LEARNING (shutdown)
The control used to perform the die-set upstroke (or the first downstroke in the case of a 3-downstroke cycle)
is too far up.
Try performing a die-set self-learning procedure.
(See the DIE-SET SET-UP page).
If the problem persists replace the solenoid valves in the die-set.
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2043 AXES CARD ERROR (shutdown)
The card which controls the proportional knockout has emitted a fault signal. Make sure there are no faults
in the die-set (excessive friction, etc...). Check to see whether the dieset encoders work properly.
0) Check signal KA 1006 and the IDM card in location 13. If the problem persists, replace axis card control
AP210 in the controller.
1) The die-set is blocked. Try moving down the die-set with the key switch turned to Set Up and make sure
there are no obstacles which prevent the die-set from moving. If the dieset is still blocked, try moving the
die-set upwards in Set Up mode.
2) The AX card does not work. Check the first module.
3) The AX card does not work. Check the second module.
4) When solenoid valve YV25 is energised (YV22S in the 4-cylinder SPE) to deliver oil to the SPE, the AX
card indicates that there are problems with the feedback of proportional solenoid valve A (left-hand side).
Solenoid valve YV25 or YV22S is de-energised.
Proportional valve A stuck. Check the AX card and the spool signal.
5) When solenoid valve YV25 (YV22S in 4-cylinder SPE) is energised to deliver oil to the SPE, the AX card
indicates that there are problems with the feedback of proportional solenoid valve B (right-hand side).
Solenoid valves YV25 and YV22S are de-energised.
Proportional valve B has got stuck. Check the AX card and the spool signal.
6) AX card does not work: check the third module.
7) AX card does not work: check the fourth module.
8) At the start of the downstroke with the key turned to MAN or AUT, the knockout is at a value greater than
2 mm but the AX card indicates that the previous SPE movement has not been completed.
9) Error during DSP 3 programming (the one for the filler box) for the axis card: card status is not OK.
10) Error during DSP 3 programming (the one for the filler box) for the axis card: incorrect data.
11) Error during DSP 4 programming (the one for the plunger) for the axis card: card status is not OK.
12) Error during DSP 4 programming (the one for the plunger) for the axis card: incorrect data.
2044 DIE-SET ENCODER BLOCKED (SQ4) (shutdown)
The proportional knockout cannot be moved because the encoders are blocked.
Release them.
If the message continues to appear, check the two sensors SQ4 and SQ5, the wiring and IDM card in location
13.
2045 RESET PRESSURE (shutdown)
While the proportional knockout pressure was being reset, one of the two encoders read a
value greater than 0.6 mm (the die-set was not fully down and therefore the reset procedure was not
performed). Make sure the die-set can reach the zero setting. Check encoders BQ4/5, the IE card in location
9 and axis card AP210.
2046 KNOCKOUT BETWEEN PUNCHES (shutdown)
The die-set moves up more slowly than the plunger.

Try reducing the plunger speed. If the problem persists, try disabling the “knockout between punches” function
to see whether a different fault message appears.
2047 ENCODER FAULTY (BQ4A) (shutdown)
Check BQ4A = position of rod-type knockout (linear absolute encoder) and the related electrical wiring.
Check card IE, location 9.
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2048 TIME-OUT, KNOCKOUT UP (shutdown)
The rod-type knockout has not completed its upward movement within the preset time.
Check YV25S = slow upward movement of the rod-type knockout, YV21G/YV21H= knockout interlock
solenoid valve, YV21P = proportional solenoid valve to control rod-type knockout.
Check card OD, location 14, card OD, location 16, and card ODA, location 17.
Check BQ4A = position of rod-type knockout (linear absolute encoder) and card IE, location 9.
2049 TIME-OUT, KNOCKOUT DOWN (shutdown)
The rod-type knockout has not completed its downward movement within the preset time.
Check YV25D = slow downward movement of rod-type knockout, YV21G/YV21H= knockout interlock
solenoid valve, YV21P= proportional solenoid valve to control the rod-type knockout.
Check card OD (location 14) card OD (location 16) card ODA (location 17).
Check BQ4A= position of the rod-type knockout (linear absolute encoder) and card IE, location 9.
2050 WRONG KNOCKOUT MOTION (BQ4A) (shutdown)
The rod-type knockout has moved in the wrong direction.

Proportional valve YV21P may be blocked.
Check YV21P (proportional solenoid valve to control the rod-type knockout) and card ODA, location 17.
Check BQ4A (position of the rod-type knockout, linear absolute encoder) and card IE, location 9.
2051 PERFORM DIE-SET SELF-SETTING (YV21P) (shutdown)
An error was detected during the self-setting procedure for determining the offset value of the rod-type
ejector’s proportional solenoid valve.
The various cases are examined below, identified by a number that appears to the right of the message:
1) While the slow downstroke was taking place the mode selector was turned from MAN, or the lift failed to
move fully down within 60 seconds. Check YV25D and the relative OD card. As an alternative try entering
a higher value for the DEAD STROKE.
2) While searching for the upstroke offset value, the mode selector was turned from MAN, or the lift failed to
move fully up within 60 seconds. Check YV21P, encoder BQ4A and YV21G/YV21H.
3) While searching for the downstroke offset value, the mode selector was turned from MAN, or the lift failed
to move fully down (DEAD STROKE) within 60 seconds. Check YV21P, encoder BQA and YV21G/YV21H.
4) The offset search procedure was not completed within the maximum allowable time (2 minutes). Check
YV21P.
If problems arise while performing the self-setting operations for YV21P that prevent the offset values from
being correctly calculated, carry out the procedure to assign the recommended values. To carry out the
procedure set NUMBER SET-UP OPERATION = 15.
The following conditions must be satisfied in order to reset the offset values: mode selector turned to SET-
UP and pump shut off. Press keys 28 - 7.
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2052 CHECK (YV...) (shutdown)
A proportional solenoid valve is faulty. The various cases are examined below:
(YV318): during a phase in which the proportional press-cycle solenoid valve should have been closed, the
analog feedback signal detected the solenoid valve is not closed.
Check the electric connection of the feedback signal and IA card. If no problems are found, check
the control signal and relative ODA card (OA card for PH 14.01.01 and later versions). If everything
works properly, check the proportional solenoid valve.
(YV32): before the plunger started to move the analog feedback signal detected the solenoid valve is not
closed.
Check the electric connection of the feedback signal and IA card (AX card in PH 14.01.01 and later
versions). If no problems are found, check the control signal and relative ODA card (AX card in PH
14.01.01 versions). If everything works properly, check the proportional solenoid valve.
(YV70D): before the drain was opened the analog feedback signal detected the proportional solenoid valve
used to adjust the degree to which the drain is open was not closed or was not open during the press-
cycle. Check the electric connection of the feedback signal and IA card. If no problems are found,
check the control signal and relative ODA card (OA card in PH 14.01.01 versions). If everything
works properly, check the proportional solenoid valve.
(SQ303): after the plunger has moved down 5 mm, YV303 is closed (input SQ303 is high).
Or YV303 is already opened before the plunger has moved down (input SQ303 low).
Or when the plunger is brought back up with YV303 deactivated, it is still open (input SQ303 low).
Or while the plunger’s proportional valves are being cleaned with YV303 deactivated it is still open
(input SQ303 low).
Check YV303 and sensor SQ303.
(YV303): at the end of plunger repositioning (after receiving an axes repositioning request or cycle start
signal), YV303 was closed, YV32 was opened during downward movement and the plunger moved
down at a speed higher than 15 mm/s.
Check YV303 that may be stuck open or the output card of YV303.
(SPOOL-YV22A): during SPE balancing, the analog feedback signal detected proportional solenoid valve
YV22A failed to open during the upstroke. Check the electric connection of the feedback signal and
AX card. Go to the INFO page and make
certain the AX card software version is at least 3.00. If everything works properly, check the
proportional solenoid valve.
(SPOOL - YV22B): as stated for YV22A but regarding the other SPE proportional solenoid valve.
(YV22A): during SPE balancing, the die-set has moved more than 0.5 mm up as measured by encoder BQ4.
(YV22B): during SPE balancing, the die-set has moved more than 0.5 mm up as measured by encoder BQ5.
2053 SAFETY BAR UP (shutdown)
The safety bar has been raised.

If the message appears when the safety bar is down, press the Reset key. If the message remains on the
screen, check limit switches SQ51 and SQ52 for secure mounting and proper operation. Also check the ID
card in location 11 and the leads/connectors. This message only appears if LEDS SQ51 and SQ52 (on the
ID card in location 11) are on with
mode selector SA9 turned to MANUAL or AUTOMATIC.
2054 ENCODER FAULTY (BQ6) (shutdown)
A fault has been detected in the system which monitors the setting of an absolute encoder (the name of the
encoder is specified in brackets).
The various cases are examined below:
(BQ6): first plunger encoder: verify the encoder works properly, check the connecting cable and the first IE
card (the AX card for versions PH 14.01.01 and later). Try turning off the system, remove the first
IE card (the AX card for versions PH 14.01.01 and later), plug in the card and turn the system back
on.
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(BQ7): second plunger encoder (optional): verify the encoder works properly, check the connecting cables
and the 1st IE card. Shut off the system, take out the 1st IE card, plug in the card and turn the system
back on.
(BQ8): third plunger encoder (optional). See BQ7.
(BQ11): isostatic circuit booster encoder for differentiated press-cycle (optional): see (BQ7) but in reference
to the 2nd IE card.
(BQ2): linear filler-box encoder: verify the encoder works properly, check the connecting cables and the AX
card. Shut off the system, take out the AX card, plug in the AX card and turn the system back on.
(BQ10): ALM encoder: see (BQ7).
(BQ21): ACP encoder (optional): see (BQ7) but in reference to the 2nd IE card.
(BQ12): external booster encoder for Power presses connected to the 1st IE card.
2055 PUNCHES OVERTRAVEL/LIFT RODS (shutdown)
The lift rod or punch over-travel selectors have been turned on.
If neither of these selectors have been turned on, check the input card in location 12 (Led SA1 must be on
if no contacts are energized) and the leads/connectors.
With 4-cylinder proportional knockout: data item PUNCH OVERTRAVEL = YES has been set on the
S.P.E. die-set set-up page. Enter NO for this setting.
2056 CHECK (SQ68/SQ67) (shutdown)
The device for changing the die-set is activated (it is out). If this is not the case, check sensors SQ68A, SQ68B,
SQ67A, SQ67B (when the hook is in, sensors SQ67 are energized and SQ68 de-energized, whereas when
the hook is out sensors SQ67 are deactivated and SQ68 energized). Check the ID cards and the leads/
connectors.
Input SP4 has stayed off for 0.5 seconds with the oil temperature higher than 30°C.
Replace the filter located on the proportional solenoid valve in the filler-box as it is clogged. If the message
is still displayed even after the filter has been replaced, check pressure switch SP4, the ID card in location
11 (Led SP4 must be on when the filter is not clogged) and the leads/connectors.
2058 PLUNGER ENCODER/ACTUATOR (shutdown)
Approx. 300 msecs. have elapsed since the plunger downstroke began and the plunger speed is still lower
than 4mm/sec.
In “proportional” PHs, this fault message may be displayed during the first few plunger downstrokes just before
reaching the impact position. In this case, try restarting the machine because during each attempt the control
system tries to soften the brake ramp.
Check the plunger encoder, its mount and the leads/connectors.
Make sure the plunger can reach the START PRESS STROKE setting when it moves down.
Check solenoid valve YV32D and the related hydraulic lines for proper functioning.
The first ODA card has to be energized while the plunger is moving down (19th led of the card should be on).
If it is not, check filler box limit switch SQ59, circuit breaker FS101, contactors KA102/102A, KA103/103A,
mode selector SA9, safety module AJ101 and
With program version earlier than PH12.01.01: check the EIA card in location 6/7 if an incremental encoder
is installed or the IE card in location 9 if an absolute encoder is installed.
With program version PH12.01.01 or later: check the IE card in location 8.
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2059 F-BOX ENCODER/ACTUATOR (shutdown)
200 msecs. have elapsed since the filler-box forward stroke signal was sent but the filler box encoder value
has not changed.
Check encoder BQ2, its mount and the leads/connectors.
With rod-crank mechanism filler-box: check proportional solenoid valve YV20 (see NOTE), the related
electrical wiring and hydraulic lines for proper functioning. Check the pressure in the service circuit.
Check solenoid valve YV20S and related electrical wiring. Also inspect YV20 control card AP201 and the OD
card in location 16.
If solenoid valve YV20S does not work, also check circuit breaker FS101, mode selector SA9 and contactors
KA102/102A, KA103/103A.
NOTE: if proportional valve YV20 is not installed, check solenoid valve YV20A and the related electrical wiring;
If the proportional solenoid valve is installed, YV20A becomes YV20S
- With program version earlier than PH12.01.01: check the EIA card in locations 6/7.
With linear filler-box: check digital output KA20E on the ODA card (LED on = filler-box moving) and the
related electrical wiring. Check relays KA20E/20I, inverter U20 and motor M20.
2060 PWD FEED SHUTOFF AT... c.mm (BQ6) (shutdown)
There is no powder in the die-set.

The plunger has reached a value higher than the one set for the STOP DUE TO LACK OF PWD data item.
Alternatively, the plunger has reached a value higher than that set for the STOP DUE TO LACK OF PWD -
1ST data item during the first press-stroke.
The setting of the plunger encoder which caused the alarm is indicated in the message. The number of the
encoder (example BQ6) that detected the fault is given to the right.
2061 FILLER-BOX RETURN (shutdown)
With the rod-and-crank operated filler box, check proportional solenoid valve YV20 and the related hydraulic
lines for proper operation. Also check card VT11023. If the proportional valve is not provided, check solenoid
valve YV20A.
Check encoder E2, its mount, the IE card and the leads/connectors.
Check the output card (when the solenoid valve has to operate, Led YV20A must come on)
and the leads/connectors. Check the pressure in the service circuit.
With a filler box for double loading, check signals KA302 and SQ59 coming from the filler box itself (when the
filler box is fully back, led KA302 on the ID card should come on and led SQ59 should go out). Also check the
ID card and the KA59 relay.
2062 FILLER-BOX FORWARD (shutdown)
With the rod-and-crank operated filler box, check proportional solenoid valve YV20 and the related hydraulic
lines for proper operation. Also check card VT11023. If the proportional valve is not provided, check solenoid
valve YV20A.
Check encoder E2, its mount, the IE card and the leads/connectors.
Check the output card (Led YV20A must come on when the solenoid valve has to operate) and the leads/
connectors.
Check the pressure in the service circuit.
With a filler box for double loading, check signals KA302 and SQ59 coming from the filler box itself (when the
filler box starts moving, led KA302 on the ID card should go out and led SQ59 should come on). Also check
the ID card and the KA59 relay.
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2063 F-BOX ENCODER RESET (shutdown)
The filler-box encoder reset procedure has failed.

With connecting rod/crank filler-box: the encoder zero-point has not been found within 8 seconds of the
signal to reset the filler-box.
Check the encoder for proper functioning. Check proportional solenoid valve YV20 (see NOTE), its electrical
wiring and related hydraulic lines, the service circuit pressure, solenoid valve YV20S and related wiring, YV20
control card AP201 and the OD card in location 16.
If solenoid valve YV20S is not energized check circuit breaker FS101, mode selector SA9 and contactors
KA102/102A, KA103/103A.
NOTE: if proportional solenoid valve YV20 is not installed, check solenoid valve YV20A and related electrical
wiring;
If the proportional valve is installed, YV20A will be identified as YV20S
With linear filler-box: with the reset sensor energised the encoder zero point has not been found.
Check that the encoder is working properly. Check digital outputs KA20E (led on = filler-box moving) and
KA201 (filler-box forwards/back) on the ODA card. Also inspect the related wiring, relays KA20E/20I, inverter
U20 and motor M20.
2064 PLUNGER DOWN AT F-BOX START (shutdown)
The plunger is below the value set for its upper-most position when the filler-box begins its forward/return
strokes.
If an absolute encoder is installed, check that the value read by the encoder when the plunger is against the
end-stop is 0. If this is not the case, repeat the plunger encoder reset procedure (see AXES RESET page).
If the fault persists, try replacing the first IE card (AX card in PH 14.01.01 and later versions).
2065 FILLER-BOX BACKWARD (KA302 - SQ59) (shutdown)
When the automatic or semi-automatic cycle is started, the filler-box for double loading is not fully back. When
the filler-box is fully back, input SQ59 should be off and input KA302 should come on. Check cards ID in
locations 11 and 13.
2066 1ST DOWNSTROKE SIGNAL (KA305) (shutdown)
The signal for the first die-set downstroke sent from the PLC controlled filler-box was not received within 15
seconds of the filler-box start.
Check the connection for the first die-set downstroke signal and the input card in location 13 (when the request
is provided Led KA305 must come on).
2067 3RD DOWNSTROKE SIGNAL (KA306) (shutdown)
The signal for the third die-set downstroke was not received from the filler-box for double loading.
Check the connection for the third die-set downstroke signal and the input card (when the request is provided
Led KA306 must come on).
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2068 WAIT FOR F-BOX TO GO BACK (KA302) (shutdown)
Digital inputs SQ59 and KA302 have not changed over within 15 seconds of the last downstroke (when the
filler-box arrives at the rear end-stop, led SQ59 should go out and led KA302 should come on).
Make sure that the digital input cards in location 11 and 13 receive the filler-box forwards/ back signals SQ59
and plunger down trigger pulse KA302. Also check contactor KA59 and the related press/filler-box leads/
connectors.
2069 CHECK (SQ51/SQ52) or (SQ11A/B/C/D) (filler-box shutdown)
One of the limit switches for the safety bar is faulty.

Check the limit switches, the ID card in pos. 11 and the related leads/connectors (when the safety bar is down
the two leds SQ51, SQ52 for the input card must be off).
After checking, push the safety bar up and press the Reset button.
2070 CHECK (YV20S) (shutdown)
Check solenoid valve YV20S and its monitoring device (SQ20S) for proper functioning.
When the filler-box is operating (output YV20S energized), input SQ20S must be off whereas when the filler-
box is stopped (YV20S de-energized) input SQ20S must be on.
Check the ID input card in location 12.
2071 CHECK (SQ58) (shutdown)
The ejector cylinder is malfunctioning. Check the sensor indicated in the fault message and the ID input card
in location 13 (when the sensor is activated the corresponding Led of the card must be on) and the leads/
connectors.
2072 FAULT, FILLER-BOX DRIVE (U20) (shutdown)
Digital input U20 on the ID card in location 13 is not energized.

The converter that drives the linear filler-box is malfunctioning or is not energized.
Check the two miniature switches SQ20A and SQ20I which, when triggered, shut off the power supply to the
converter.
Check the converter and consult the Instruction Manual to locate what is causing the fault.
If the converter is not faulty, check the input card (when the converter is running, Led U20 must be on) and
2073 CHECK (AJ101) (shutdown)
Press the Reset button. If the message remains on the screen, check safety module AJ101.
If no power is delivered (“NETZ” Led off or “POWER” off) check magnetic-thermal cutout FS100. If power is
being delivered but the two signals (S1 and S2) are different or they are both off, check limit switches SQ51,
SQ52 and SQ66/SQ66A as well as sensors SQ53A/ SQ53B, which monitor the roller conveyor (optional), for
secure mounting and proper operation. If Leds S1 and S2 stay on and the message remains on the screen,
check the input card (Led AJ101 must be on when the safety bar is down) and the leads/connectors.
2074 WRONG DIE-SET OP. (A=..., B=...) (shutdown)
The value of one or both die-set encoders has exceeded the Upper End Stop (FCA) setting by more than 0.5
mm or has fallen below it by more than 1 mm during the filler-box forward stroke (up until the first downstroke).
Refer to fault message 2037 for trouble-shooting instructions.
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One of the 2 sensors that detect when the roller deck is in front of the press is malfunctioning.
Check the 2 sensors, the ID card in location 13 and the leads/connectors (when the roller deck is connected
Leds SQ53 and SQ54 on the ID card must be off). After checking, move the roller deck back and press the
Reset key.
2076 FILLER-BOX DID NOT START (KA302 - SQ59) (shutdown)
Digital inputs SQ59 and KA302 failed to change-over within 60 sec. from the moment in which the start signal
was sent to the PLC controlled filler-box from contact KA20A (when the filler-box begins to move, led SQ59
should light up and led KA302 should go out).
Make sure the start signal from KA20A reaches the filler-box controller (led YV20S on card OD in location 16
ON = filler-box start). In addition, check contactors KA102/102A, KA103/103A, relay KA20A and the leads/
connectors for the relative press/filler-box.
Make sure the digital input cards in locations 11 and 13 receive the filler-box forward/back signals from SQ59
and the signals for the plunger downstroke from KA302. In addition, check contactor KA59 and the leads/
connectors for the relative press/filler-box.
2077 F.BOX/PLUNGER COLLISION (shutdown)
The linear filler-box has exceeded the safety position (set for the FILLER-BOX SAFETY SETTING data item
on the LOADING SET- UP page) and the plunger is lower than the value set for PLUNGER UP (PRESS
CYCLE SET-UP page). Decrease the value set for F.BOX START ADVANCE.
If this is not enough to solve the problem, try reducing the value set for PLUNGER UP or adjust the UPPER
END-STOP PRECISION data item.
2078 TECNO ITALIA TIME OUT SIGNAL (KA311) (filler-box shutdown)
Trigger pulse KA311 did not arrive from Tecno Italia. If Tecno Italia sent it correctly, check the input and related
wiring.
2079 FILLER BOX REVERSE (filler-box shutdown)
The filler box encoder is counting down.

Reverse the value set for data item “filler box encoder reverse” on the setup page in program versions PH
14.xx.01 and PH 15.xx.01.
2080 PLUNGER / DIE DOWN (KA410) (shutdown)
During the filler-box cycle for double loading trigger pulse KA410 was de-energized due to one of the following:
• the plunger has moved more than 1 mm down in relation to its upper end-stop.
• the lower die has moved down (SQ63 de-energized).
2081 MIXER (KM22A) (shutdown)
Digital input KM22 has not come on within 300 msecs. of the KM22A signal being sent.
Check the thermal cutout and ACP contactor KM22A for proper functioning.
Check the input card (Led KM22 must be on when the motor is running) and the leads/connectors.
Check the output card (Led KM22A must be on when the motor has to run) and the leads/connectors.
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2082 HOMOGENIZER (shutdown)

(U21)
The digital signal from the ACP inverter (U21) signals inverter malfunctioning.
(R.H.)
ACP movement towards the set R.H. end-stop (expressed in mm) was not completed within the set time (45
seconds).
(KM21A/SQ21)
Digital input SQ21 has not come on within 20 seconds of the KM21A signal being sent.
Check the thermal cutout and the ACP contactor.
Check sensors SQ21 and SQ22 (when KM21A is energized SQ21 has to be activated) and the related input
card.
Check the output card (when the motor has to run, Led KM21A must be on) and the leads/connectors.
2083 MIXER (KM22B) (shutdown)
Digital input KM22 has not come on within 300 msecs. of the KM22B signal being sent.
Check the thermal cutout and ACP contactor KM22B for proper functioning.
Check the input card (Led KM22 must be on when the motor is running) and the leads/connectors.
Check the output card (Led KM22B must be on when the motor has to run) and the leads/connectors.
2084 HOMOGENIZER (KM21B) (shutdown)

(L.H.)
ACP movement towards the set L.H. end-stop (expressed in mm) was not completed within the set time (45
seconds).
(KM21B/SQ22)
Digital input SQ22 has not come on within 20 secs. of the KM12B signal being sent.
Check the thermal cutout and the ACP contactor.
Check sensors SQ21 and SQ22 (when KM21B is energized SQ22 has to be activated).
Check the output card (when the motor has to run, Led KM21B must be on) and the leads/connectors.
2085 MOBILE HOPPER (KM23I) (shutdown)
The ALM failed to complete its loading stroke correctly.

ALM with encoder:
- If the ALM does not reach the setting for the end of the forward stroke within 25 secs.,
- If the ALM accidentally performs an overtravel beyond the setting for end of backstroke and does not return
to the end of backstroke setting within 25 seconds, check ALM encoder BQ10, the IE card in location 10 and
ALM with sensors: If limit switch SQ24 is not energised within 15 seconds (the ALM must be at the maximum
distance from the press)
check sensor SQ24 and the input card (with the ALM at the maximum distance from the press, led SQ24 should
be on).
Check contactor KM23I and the OR output card (when the ALM moves away from the press, led KM23I should
be on) and the leads/connectors.
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2086 MOBILE HOPPER (KM23A) (shutdown)
ALM with encoder: if the ALM does not reach the setting for the end of the backstroke within 25 seconds;
check ALM encoder BQ10, the IE card in location 10 and the leads/connectors.
ALM with sensors: if limit switch sensor SQ23 is not energised within 15 seconds (the ALM should be near
the press).
Check sensor SQ23 and the input card (with the ALM near the press, led SQ23 should be on).
Check contactor KM23A and the OR output card (when the ALM moves near the press, led KM23A should
2087 MOBILE HOPPER (SQ23/SQ24) (shutdown)
- With the fixed ALM, limit switch SQ23 is not energized at the filler-box start (the ALM should be near the
press).
Make sure that digital input SQ23 on the ID card in location 12 is on.
- Limit switch SQ24 has not been energised within 15 seconds during a manual operation or ALM reset
procedure.
Try increasing the ALM speed.
2088 MOBILE HOPPER (U23) (shutdown)
Digital input U23 on the ID card in location 11 is not energized.

The inverter which drives the ALM is malfunctioning.
Check inverter U23, the input card (Led U23 must be on when the inverter is running) and the leads/
connectors.
2089 MOBILE HOPPER (SQ25) (shutdown)
Sensor SQ25 was not activated during the ALM loading cycle.
Check sensor SQ25, the input card and the leads/connectors.
Check the related cam: SQ25 must be energized before the ALM activates SQ24.
2090 REDUCE ALM OPENING DELAY TIME (shutdown)
This fault message is provided with 2-LINE LOADING of the ALM when the second cam for SQ25 or limit switch
SQ24 is activated before the time set for OPENING DELAY for the gate has elapsed.
Decrease the value set for the OPENING DELAY data item found on the FITTINGS SET UP page.
2091 MOBILE HOPPER (SQ24S) (shutdown)
Sensor SQ24S was activated while the ALM was being moved back in manual mode or being reset. Check
sensor SQ24S and the input card (when the ALM is at the end of its return overtravel stroke, Led SQ24S must
If the return stroke of the filler-box is to be carried out in manual mode, move the ALM to the end of its return
overtravel position with the manual control for the back stroke before carrying out the operation. If a semi-
automatic loading cycle is required, move the ALM forwards before carrying out the operation.
2092 FILLER-BOX FORWARD (shutdown)
If the ALM has to be moved back in manual mode or be reset, move the filler-box fully back before carrying
out the operation.
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2093 MOBILE HOPPER (shutdown)
- With the fixed ALM, the value read by the ALM encoder BQ10 differs from the rear end stop value by more
than 20 mm.
Check encoder BQ10, the IE card in location 9 and the leads/connectors.
- The ALM has not reached the rear end-stop position within 25 seconds during a manual operation or while
being reset.
Try increasing the ALM speed.
- With an ALM with sensors, make certain limit switches SQ23 and SQ24 are not activated at the same time.
Check the ID card in location 12.
- In power presses, the speed set to reposition the ALM may be too low.
2096 MOBILE HOPPER (SQ10) (shutdown)
With ALM with incremental encoder

- The position of the ALM during the filler-box return stroke, with the filler-box nearly at the end of the
backstroke, is not correct (reset sensor SQ10 should be energized).
- Reset sensor SQ10 was not energized within 25 seconds while the ALM was being operated in manual
mode or was being reset.
Try increasing the ALM speed, check reset sensor SQ10, the IE card in location 9 and the leads/
connectors.
- The ALM encoder zero-point was not found with reset sensor SQ10 energized.
Check the ALM encoder BQ10 and the leads/connectors.
With ALM with absolute encoder
- It a request is made for the filler box to go beyond the end stop during the return stroke in manual mode
it means the ALM has either not been reset or the ALM is not at the encoder’s 0.
2097 ALM ACTUATOR/ENCODER (shutdown)

(ALM)
The ALM encoder (BQ10) has not detected any movements in 750 ms from the moment in which the trigger
pulse was sent to the ALM inverter.
Make sure the encoder works properly. Check the ODA card in position 18, OR card in position 20 (when the
ALM has to move, one of outputs KM23A/KM23I should be energized), relays KA23A/KA23I, IE card in
position 10, inverter U23, motor M23 and the connecting cables/connectors.
(ACP)
The ACP encoder (BQ21) has not detected any movements in 750 ms from the moment in which the trigger
pulse was sent to the ACP inverter.
2098 CHECK (U24) (shutdown)
With the pump running, mode selector SA9 in the manual or automatic position and safety modules AJ100
and AJ101 in operating mode, digital input U24 is off.
Make sure inverter U24 is in operating mode and check the ID card in location 12 (with inverter U24 in operating
mode, digital input U24/KM22AB should be on) and the leads/ connectors.
2101 CARRY OUT LOADING (shutdown)
A press-cycle has been attempted before carrying out a loading cycle.
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2102 CYLINDER PRESSURE TRANSDUCER (BP1) (shutdown)
The pressure measured by transducer BP1 before the plunger begins its downstroke is more than 10 bar.
Check pressure transducer BP1, the leads/connectors and
With program versions earlier than PH12.01.01: check the input module of transducer BP1 (AP201) and
the EIA card in locations 6/7.
2103 PLUNGER DOWNSTROKE (shutdown)
- If the plunger encoder value does not reach the IMPACT POSITION setting within 8 seconds during a
downstroke in manual mode;
- if the plunger encoder value does not reach the IMPACT POSITION - BRAKING SPACE setting (both data
items can be set) within 8 seconds in automatic mode;
Check that the setting for IMPACT POSITION can be reached. Also check solenoid valve YV32D and related
hydraulic lines for proper operation, inspect the plunger encoder and make sure it is securely mounted, check
the leads/connectors, the ODA card (when solenoid valve YV32D is energised, the corresponding green LED
should be on) and
With program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if the incremental
encoder is installed or the IE card in location 9 if the absolute encoder is installed.
With program versions from PH12.01.01 onwards, check card IE in location 8.
In proportional presses, check proportional solenoid valve YV32, card ODA (location 17), potentiometer card
AP32. This problem may arise when the press has started moving up after receiving a downstroke signal. In
this case, replace YV32 and/or card ODA – location 17 (YV32D or YV32S with non-proportional presses).
2104 EXCESSIVE BRAKING (shutdown)
- The plunger encoder value does not reach the setting for IMPACT POSITION while the plunger is moving
down.
- The plunger encoder value does not reach the setting for PLUNGER UP while the plunger is moving up.
Make sure that the setting for IMPACT POSITION can be reached. Check solenoid valves YV32D and YV32S
and related hydraulic lines for proper operation. Also check the plunger encoder and make sure it is securely
mounted, check the leads/connectors, the ODA card (when solenoid valve YV32D is energised, the green
LED should be on) and
With program version PH12.01.01 or later: check the IE card in location 8.
If this problem arises during the upstroke with a proportional press, decrease the value set for UPPER END-
STOP PRECISION. If the problem persists, perform a self-learning procedure for the plunger upstroke and
downstroke (see chapter DESCRIPTION OF THE KEYS).
2105 BRAKING (shutdown)
Make sure that the braking space set is sufficient so that the solenoid valve can work properly.
Check solenoid valve YV47 and the related hydraulic lines for proper functioning. Inspect the plunger encoder,
its mount, card EIA and the leads/connectors.
Check the output card (when the solenoid valve has to operate, Led YV47 must come on) and the leads/
connectors.
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2106 DIE-SETS UP (SQ3/SQ6) (shutdown)
The die-set is not down when the plunger begins its downstroke. Proximity switch SQ6 is inactivated or SQ3
is activated.
Check proximity switch SQ6, the input card (Led SQ6 must be on when the die-sets are down) and the leads/
connectors. Do the same for SQ3.
The same fault message will appear on the display when the filler box is moved manually and the
PROPORTIONAL KNOCKOUT is 0.4mm higher than the set value. In this case move the die-set manually
so as to bring it into the correct position.
2107 F-BOX FORW. DUR. PLUNGER DOWNSTROKE (shutdown)
The filler-box is not all the way back when the plunger begins to move down. Check the filler box encoder
setting which should be lower than the REAR END STOP. Try increasing the REAR END STOP setting. If the
problem persists check YV20 and card VT 11023.
2108 F.BOX SAFETY SW. (SQ59) (shutdown)
The filler-box is not completely back when the plunger begins its downstroke.
Check limit switch SQ59, its mount, the input card (Led SQ59 must be off when the filler box is fully back) and
If limit switch SQ59 is working correctly, check the filler box encoder.
2109 2ND F.BOX SAFETY SW. (KA302) (shutdown)
When the plunger begins its downstroke the trigger pulse from the 2nd filler-box or the LB type filler-box is not
provided. Check limit switch KA302, its mount, the input card (Led KA302 must be on when the 2nd filler-box
or LB type filler-box is fully back) and the leads/connectors.
2110 PLUNGER UPSTROKE (shutdown)
In manual mode: the manual upstroke keys have been kept pressed for more than 8 seconds.
In automatic mode: if upstroke with braking has been selected and plunger encoder has not reached the “end
of braking during upstroke” setting;
check that the setting for END OF BRAKING DURING UPSTROKE can be reached, check solenoid valves
YV32S and YV47 and related hydraulic lines for proper functioning.
Check the plunger encoder, its mount and the leads/connectors. Also check the OD card in location 16 (when
solenoid valve YV32S is energised, the related green LED should be on) and
With program versions from PH12.01.01 onwards: check card IE in location 8.
In proportional presses, check proportional solenoid valve YV32, card ODA (location 17), potentiometer card
AP32. The problem may arise when the press has started moving down after receiving an upstroke signal.
In this case, replace YV32 and/or card ODA - location 17 (YV32D or YV32S with non-proportional presses).
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2111 PLUNGER ENCODER RESET (shutdown)
The plunger encoder reset procedure has either failed or has not been performed yet.
With incremental encoder: the encoder zero-point has not been found with reset sensor SQ1 energised.
Check solenoid valves YV31D and YV31S.
Inspect the plunger encoder, its mount, the plunger reset sensor, the EIA card and the leads/ connectors.
Check the reset signal for the plunger encoder (see the USER’S MANUAL).
With absolute encoders:
- If only one encoder is installed: the encoder value is < - 8 mm with the safety bar raised
- if both encoders are installed: the difference between the values of the two encoders is > 5 mm.
If the plunger has two encoders or just one absolute encoder reset the encoders (see the RESETTING THE
AXES page).
If the message continues to appear, try replacing the IE card. If led HL7 on the IE card does not come on when
the encoder is reset, try replacing the CPU card.
The fault message may be displayed when plunger repositioning starts if the encoder does not count when
YV31D (slow downstroke) is energized.
2112 1ST PRESS STROKE (shutdown)
The set pressure has not been reached within 4 seconds.

Check solenoid valve YV40 and the related hydraulic lines for proper functioning.
Check pressure transducer BP1, the ODA card (when the solenoid valve is energized, green LED YV40
should be on) and the leads/connectors.
With program version PH12.01.01 or later: check the IA card in location 7 and, if the proportional press-
stroke is delivered, also check solenoid valve YV318, related hydraulic lines and the ODA card in location 17.
2113 RAISE SAFETY BAR (plunger shutdown)
Raise the safety bar so that the control system can check efficiency of the limit switches triggered by the bar.
2114 DIRECT PRESS STROKE (shutdown)
The set pressure was not reached within 4 seconds.

Check solenoid valve YV19 and the related hydraulic lines for proper functioning.
Check pressure transducer BP1, the ODA card (when the solenoid valve is energized, green LED YV19
should be on) and the leads/connectors.
stroke is delivered, also check solenoid valve YV318, related hydraulic lines and the ODA card in location 17.
2115 BOOSTED PRESS STROKE (shutdown)
The set pressure was not reached within 4 seconds.

Check solenoid valves YV38/41 and the related hydraulic lines for proper functioning.
Check pressure transducer BP1, the ODA card (when the solenoid valves are energized, green LEDs YV38/
41 should be on) and the leads/connectors.
stroke is delivered, also
check solenoid valve YV318, related hydraulic lines and the ODA card in location 17.
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PH 383.85.050 Rev. 00 Date 27.02.2006
2116 PRESSURE NOT RECUPERATED (shutdown)
The press was not able to restore the correct pressure.

PH400 - PH3590: If the cylinder pressure is not lower than the pump pressure + 30 bar (the set pump pressure
is approx. 200 bar) within 2 seconds after the end of the press-stroke;
PH4200: if the cylinder pressure is not lower than the pressure in the accumulators as detected by transducer
BP3 + 4 bar within 2 seconds after the end of the press-stroke;
Check solenoid valves YV19 and YV19A and the related hydraulic lines for proper functioning.
Check pressure transducers BP1 and BP3 (BP3 only with PH4200), the ODA card (when the solenoid valves
are energised, green LEDs YV19 and YV19A should be on), the leads/connectors and
the EIA card in locations 6/7. With program version PH12.01.01 or later: check the IA card in location 7 and,
if the proportional press-stroke is delivered, also check solenoid valve YV318, related hydraulic lines and the
ODA card in location 17.
Sensors SQ67A/B and SQ68A/B have remained de-energised for more than 5 seconds.
The die-set changer has not been correctly activated or inactivated.
Check pneumatic valve YV292 and proximity sensors SQ67A/B, SQ68A/B: when the hook is used, only
sensors SQ68A/B must be activated, when the hook is not used only sensors SQ67A/B have to be activated.
Check the input card and the leads/connectors.
2118 CHECK (BQ1) (shutdown)
The plunger has carried out a stroke which is longer than the allowable one.
Reset the plunger encoder (see the USER’S MANUAL).
2119 POWDER IN DIE-SET BELLOWS (shutdown)
With 2-cylinder proportional knockout: the difference between the analog and digital values during the
press-cycle is greater than 1 mm and the encoder value is > 0.6 mm.
Check encoder interface card AP206 installed on the SMU for proper operation. Also check encoders BQ4/
5 and
- With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10.
- With program version PH12.01.01 and later: the IA card and the IE card in location 9.
With 4-cylinder proportional knockout: the value of one or both encoders is > 0.6 mm during the press-
cycle.
Check axis card AP210, encoder interface card AP207, serial interface card AP208, encoders BQ4/5 and
- With program versions earlier than PH12.0.01: the EIA card in location 10.
- With program version PH12.01.01 and later: the IE card in location 9.
2120 INCORRECT PLUNGER PARALLELISM (BQ6 - BQ7) (shutdown)
The max. difference (value to be entered in INCORRECT PLUNGER PARALLELISM on the PRESS CYCLE
SET-UP page) on the diagonal of the plunger has been exceeded. The detected value is the difference
between encoders BQ6 and BQ7.
The pair of encoders that detected the difference is indicated to the right: e.g. BQ6-7 indicates that the
difference was detected between encoders BQ6 and BQ7. In addition, when a positive value is given for the
left value it means that the plunger has moved further down on side BQ6 whereas a negative value indicates
the plunger has moved down more on side BQ7.
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PH 383.85.050 Rev. 00 Date 27.02.2006
With the oil temperature higher than 30°C, digital input SP7 has stayed off for more than 2.5 seconds.
Replace the filter of the control line of proportional solenoid valves YV32 and YV318 as it is clogged. If the
message is still displayed on the screen after the filter has been replaced, check pressure switch SP7 and the
input card (LED SP7 should be on if the filter is not clogged) and the leads/connectors.
2122 ACCUMULATOR CHARGE (shutdown)
While the accumulators were being re-charged, the line pressure is less than the pressure of the accumulators
or the pressure of the accumulators has not reached the required value within 5 sec. Make sure there is no
pressure loss in the main hydraulic circuit line or line for the accumulators. Check pressure transducers BP2
and BP4, the cables and IA card. Carry out the self-learning procedure for YV309 again (see message 2124).
2123 PERFORM PLUNGER LEARNING (YV32) (18) (shutdown)
The number of the proportional solenoid valve the fault was detected in during the self-learning procedure is
given in parenthesis. The number given to the right is explained below.
For program versions PH 13.03.01.7TR and later and PH14.xx.01.7TR:
The self-learning cycle for calculating the offset values for proportional valves (YV32, YV318) has been
stopped in an incorrect manner.
The various cases are examined below. The number that appears on the right side of the message is given.
1. The mode selector switch has been turned from the MAN position or the plunger has not moved down
1 mm with YV31D energized. Check the solenoid valve for the slow downstroke, the relative cables and
OD card in location 16. If the plunger moves down but the encoder does not count, check plunger encoder
BQ6 and the IE card in location 8.
2. The mode selector switch has been turned from the MAN position or the plunger has not moved down
15 mm (19 mm for P1-14200) with YV318 open 35%. Check proportional solenoid valve YV318, the
relative cables and OD card in location 17.
Check the solenoid valve for the booster downstroke: solenoid valve YV32M (it should be energized
during this stage), solenoid valve YV40 (it should be energized during this stage) and solenoid valve
YV70/71 (it should be energized during this stage).
3. The mode selector switch has been turned from the MAN position or the plunger has not reached the
IMPACT POSITION - 40 mm with YV31D energized.
Check the value set for the IMPACT POSITION data item on the press-cycle set-up page. Check the
solenoid valve for the slow downstroke, the relative cables and OD card in location 16.
4. During the stage in which the offset value for YV32 is determined, the cylinder pressure has exceeded
10 bar to keep the plunger stationary. Check proportional solenoid valve YV318 (it should be closed
during this stage), the relative cables and ODA card in location 17. Check the solenoid valve used to put
the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this stage), logic
element 117 (it should be closed during this stage), solenoid valve YV40 (it should be de-energized during
this stage), logic element 116 (it should be closed during this stage), solenoid valve YV41 (it should be
de-energized during this stage), logic element 131 (it should be closed during this stage), solenoid valve
YV38 (it should be de-energized during this stage), logic element 120 (it should be closed during this
stage), solenoid valve YV70 (it should be de-energized during this stage) and logic element 118 (it should
be opened during this stage).
5. During the stage in which the offset value for YV32 is determined, the mode selector switch was turned
from the MAN position to keep the plunger stationary or the plunger did not move down with YV31D
energized. Decrease the value set for the IMPACT POSITION data item on the press-cycle set-up page.
Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16.
from the MAN position to keep the plunger stationary or the plunger did not move up with YV31S
energized.
Check the solenoid valve for the slow upstroke, the relative cables and OD card in location 16.
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PH 383.85.050 Rev. 00 Date 27.02.2006
7. The mode selector switch was turned from the MAN position or the plunger did not move up with YV31S
energized. The plunger should move up to 26 mm (30 mm for P1-14200).
8. The mode selector switch was turned from the MAN position or the plunger did not move 1 mm down with
YV31D energized. The plunger should move up to 26 mm (30 mm for P1-14200). Check the solenoid
valve for the slow downstroke, the relative cables and OD card in location 16.
9. During the stage in which the offset value for YV318 is determined, the command to the solenoid valve
has exceeded the maximum allowable value (4095 valve points, given on page 110). Check proportional
solenoid valve YV318, the relative cables and ODA card in location 17. Check pressure transducer BP5
for the upstroke chamber, the relative cables and IA card in location 7. Check the solenoid valves used
to charge the upstroke chamber during this stage: solenoid valve YV19 (it should be energized during
this stage), solenoid valve YV70 (it should be energized during this stage).
10. During the stage in which the offset value for YV318 is determined, the pressure in the cylinder has
exceeded 20 bar or the pressure in the upstroke chamber has exceeded 300 bar. Check proportional
solenoid valve YV318, the relative cables and ODA card in location 17. Check pressure transducer BP5
for the upstroke chamber, the relative cables and IA card in location 7. Check the solenoid valves used
to charge the upstroke chamber during this stage: solenoid valve YV19 (it should be energized during
this stage), solenoid valve YV70 (it should be energized during this stage).
11. Once the stage in which the offset value for YV318 is determined has been completed, the command to
the solenoid valve is either too high or null. Check proportional solenoid valve YV318, the relative cables
and ODA card in location 17. Check pressure transducer BP5 for the upstroke chamber, the relative
cables and IA card in location 7.
Check the solenoid valves used to charge the upstroke chamber during this stage: solenoid valve YV19
(it should be energized during this stage), solenoid valve YV70 (it should be energized during this stage).
12. During the stage in which the offset value for YV32 (downstroke) is determined, the plunger has reached
the IMPACT POSITION - 10 mm. Increase the value entered for the IMPACT POSITION data item on
the press-cycle set-up page. Otherwise check proportional solenoid valve YV32, the relative cables and
Check solenoid valve YV303 used for plunger movement (it should be energized during this stage) and
13. During the stage in which the offset value for YV32 (downstroke) is determined, the pressure in the
cylinder has exceeded 10 bar. Check proportional solenoid valve YV318 (it should be closed during this
stage), the relative cables and ODA card in location 17.
Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19 (it should be de-
energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve
stage), solenoid valve YV41 (it should be de-energized during this stage), logic element 131 (it should
be closed during this stage), solenoid valve YV38 (it should be de-energized during this stage), logic
element 120 (it should be closed during this stage), solenoid valve YV70 (it should be deactivated during
this stage) and logic element 118 (it should be opened during this stage).
14. The mode selector switch was turned from the MAN position or the plunger did not reach the IMPACT
POSITION - 20 mm with YV31D energized. Check the value entered for the IMPACT POSITION data item
on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and
OD card in location 16.
15. During the stage in which the offset value for YV32 (upstroke) is determined, the plunger has moved up
to 19 mm (12 mm for the PH1500, 23 mm for PH4200). Check proportional solenoid valve YV32, the
relative cables and ODA card in location 17. Check solenoid valve YV303 used for plunger movement
(it should be energized during this stage) and ODA card in location 17. Try lowering the IMPACT
POSITION on the press cycle set up page.
16. During the stage in which the offset value for YV32 (upstroke) is determined, the pressure in the cylinder
has exceeded 10 bar. Check proportional solenoid valve YV318 (it should be closed during this stage),
the relative cables and ODA card in location 17.
Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19 (it should be de-
energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve
stage), solenoid valve YV41 (it should be de-energized during this stage), logic element 131 (it should
be closed during this stage), solenoid valve YV38 (it should be de-energized during this stage), logic
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PH 383.85.050 Rev. 00 Date 27.02.2006
element 120 (it should be closed during this stage), solenoid valve YV70 (it should be deactivated during
this stage) and logic element 118 (it should be opened during this stage).
17. The mode selector switch was turned from the MAN position or the plunger did not reach the mechanical
end-stop at the end of the self-learning cycle. The booster may not have moved up. Make sure the
solenoid valves allow upward movement: solenoid valve YV32M (it should be de-energized during this
stage) and solenoid valve YV71 (it should be de-energized during this stage).
18. The self-learning procedure has been interrupted because solenoid valve YV32 has got stuck during the
upstroke or downstroke (with solenoid valve YV303 energised and a signal sent to YV32 so that the valve
over-center is closed, the plunger travels at a speed > 40 mm/s).
19. When determining the lowest value that opens drain (YV70D), either the mode selector was turned to a
different position or the plunger failed to move down with YV31D energized.
20. When determining the lowest value that opens drain (YV70D), the maximum closing signal was provided
with the pressure in the upstroke chamber (BP5) increased 50 bar.
21. When determining the lowest value that opens drain (YV70D), the cylinder pressure has gone over 10
bar or the plunger has moved too far down.
22. The YV70D offset value is too high.
23. The offset value of YV32 is too high (more than 250 valve points): check YV303 and the power supply
to the output card of YV303. Check proportional solenoid valve YV32 and the output card.
24. The downstroke offset value for YV32 is too high. (more than 250 valve points): check YV303 and the
power supply to the output card of YV303. Check proportional solenoid valve YV32 and the output card.
25. The upstroke offset value for YV32 is too high. (more than 250 valve points): check YV303 and the power
supply to the output card of YV303. Check proportional solenoid valve YV32 and the output card.
For program versions PH 12.xx.01.7TR and PH 15.xx.01.7TR

The self-learning cycle for calculating the offset values for proportional valve YV32 has been stopped in an
incorrect manner.
The various cases are examined below. The number that appears on the right side of the message is given.
1. Not used.
2. Not used.
3. The mode selector switch has been turned from the MAN position or the plunger has not reached the
IMPACT POSITION - 40 mm with YV31D energized.
Check the value set for the IMPACT POSITION data item on the press-cycle set-up page. Check the
solenoid valve for the slow downstroke, the relative cables and OD card in location 16.
4. During the stage in which the offset value for YV32 is determined, the cylinder pressure has exceeded
10 bar to keep the plunger stationary. Check the solenoid valve used to put the cylinder under pressure:
solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed
during this stage), solenoid valve YV307 (it should be de-energized during this stage), solenoid valve
YV70 (it should be de-energized during this stage) and logic element 118 (it should be opened during this
stage).
from the MAN position to keep the plunger stationary or the plunger did not move down with YV31D
energized. Decrease the value set for the IMPACT POSITION data item on the press-cycle set-up page.
Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16.
from the MAN position to keep the plunger stationary or the plunger did not move up with YV31S
energized.
7. The mode selector switch was turned from the MAN position or the plunger did not move up with YV31S
energized. The plunger should move up to 30 mm.
8. If the mode selector was not turned, it means the plunger failed to move down with YV31D energized.
Check the solenoid valve for low speed downstroke and related wiring.
9. When determining the lowest value that opens YV318 during the press stroke, the signal sent to the
solenoid valve has exceeded the maximum allowable value (4095 valve points). Check proportional
solenoid valve YV318 and related wiring. Check solenoid valves YV350 and YV351 which should be
energized and logic elements 346 and 347 that should be opened.
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PH 383.85.050 Rev. 00 Date 27.02.2006
10. When determining the lowest value that opens YV318 during the press stroke, either the cylinder pressure
has exceeded 10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional solenoid
valve YV318 and related wiring. Check solenoid valves YV350 and YV351 which should be energized
and logic elements 346 and 347 that should be opened. Check YV303 that should be de-energized.
11. At the end of the stage in which the lowest value that opens YV318 during the press stroke is determined,
the signal sent to YV318 is either too high or null. Check proportional solenoid valve YV318 and related
wiring. Check solenoid valves YV350 and YV351 which should be energized and logic elements 346 and
347 that should be opened.
12. During the stage in which the offset value for YV32 (downstroke) is determined, the plunger has reached
the IMPACT POS. - 10 mm. Increase the value entered for the IMPACT POS. data item on the press-
cycle set-up page. Otherwise check proportional solenoid valve YV32 and related wiring. Check solenoid
valve YV303 used for plunger movement (it should be energized during this stage) and ODA card in
location 17.
13. During the stage in which the offset value for YV32 (downstroke) is determined, the pressure in the
cylinder has exceeded 10 bar. Check the solenoid valves used to put the cylinder under pressure:
solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed
during this stage), solenoid valve YV307 (it should be de-energized during this stage), solenoid valve
YV70 (it should be deactivated during this stage) and logic element 118 (it should be opened during this
stage).
14. The mode selector switch was turned from the MAN position or the plunger did not reach the IMPACT
POSITION - 20 mm with YV31D energized. Check the value entered for the IMPACT POSITION data item
on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and
OD card in location 16.
15. During the stage in which the offset value for YV32 (upstroke) is determined, the plunger has reached
4 mm. Check proportional solenoid valve YV32, the relative cables and ODA card in location 17. Check
solenoid valve YV303 used for plunger movement (it should be energized during this stage) and ODA
card in location 17. Try lowering the IMPACT POSITION on the press cycle set up page.
16. During the stage in which the offset value for YV32 (upstroke) is determined, the pressure in the cylinder
has exceeded 10 bar. Check the solenoid valves used to put the cylinder under pressure: solenoid valve
stage), solenoid valve YV307 (it should be de-energized during this stage), solenoid valve YV70 (it should
be deactivated during this stage) and logic element 118 (it should be opened during this stage).
17. The mode selector switch was turned from the MAN position or the plunger (encoder BQ6) did not reach
the mechanical end-stop at the end of the self-learning cycle.
18. The self-learning procedure was interrupted has YV32 got stuck either while moving up or down (with
YV303 energized and signal sent to YV32 to have the centers closed, the plunger moves at a speed >
40 mm/s).
19. When determining the lowest value that opens drain (YV70D), either the mode selector was turned to a
different position or the plunger failed to move down with YV31D energized.
20. When determining the lowest value that opens drain (YV70D), the maximum closing signal was provided
with the pressure in the upstroke chamber (BP5) increased 50 bar.
21. When determining the lowest value that opens drain (YV70D), the cylinder pressure has gone over 10
bar or the plunger has moved too far down.
22. The YV70D offset value is too high.
23. When determining the lowest value that opens YV318 during the press stroke, the signal sent to the
solenoid valve has exceeded the maximum allowable value (4095 valve points). Check proportional
solenoid valve YV318 and related wiring. Check solenoid valves YV350 and YV351 which should be
energized and logic elements 346 and 347 that should be opened.
24. When determining the lowest value that opens YV318 during the press stroke, either the cylinder pressure
has exceeded 10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional solenoid
valve YV318 and related wiring. Check solenoid valves YV350 and YV351 which should be energized
and logic elements 346 and 347 that should be opened. Check YV303 that should be de-energized.
25. At the end of the stage in which the lowest value that opens YV318 during the press stroke is determined,
the signal sent to YV318 is either too high or null. Check proportional solenoid valve YV318 and related
wiring. Check solenoid valves YV350 and YV351 which should be energized and logic elements 346 and
347 that should be opened.
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PH 383.85.050 Rev. 00 Date 27.02.2006
26. When determining the lowest value of YV318 during holding), the signal sent to the solenoid valve has
exceeded the minimum allowable value (10 valve points). Check proportional solenoid valve YV318 and
related wiring.
27. When determining the lowest value of YV318 during holding, either the cylinder pressure has exceeded
10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional solenoid valve YV318
and related wiring.
28. At the end of the stage in which the lowest value for YV318 during holding is determined, the signal sent
to YV318 is either too high or null. Check proportional solenoid valve YV318 and related wiring.
29. When determining the lowest value of YV318 during decompression, the signal sent to the solenoid valve
has exceeded the minimum allowable value (10 valve points). Check proportional solenoid valve YV318
and related wiring.
30. During the stage in which the lowest value of YV318 decompression is determined, either the cylinder
pressure has exceeded 10 bar or the plunger has reached the IMPACT POS. - 10 mm. Check proportional
solenoid valve YV318 and related wiring.
31. At the end of the stage in which the lowest value for YV318 during decompression is determined, the
signal sent to YV318 is either too high or null. Check proportional solenoid valve YV318 and related wiring.
32. When determining the lowest value of YV318 during holding, the plunger failed to move down 10 mm with
YV31D energized.
33. When determining the lowest value of YV318 during holding, the plunger failed to move up 10 mm with
YV31S energized.
43. The offset value of YV32 is too high (more than 250 valve points): check YV303 and the power supply
to the output card of YV303. Check proportional solenoid valve YV32 and the output card.
44. The downstroke offset value for YV32 is too high. (more than 250 valve points): check YV303 and the
power supply to the output card of YV303. Check proportional solenoid valve YV32 and the output card.
45. The upstroke offset value for YV32 is too high. (more than 250 valve points): check YV303 and the power
supply to the output card of YV303. Check proportional solenoid valve YV32 and the output card.
2124 PERFORM YV309 LEARNING (shutdown)
The self-learning procedure for proportional solenoid valve YV309 needs to be carried out.
Set NO. OP. SETTING = 2 (on PC page N) with the key turned to Set-up and then press keys 28 and 7. The
procedure takes a few minutes. Once completed, press the Reset key to clear the message.
2125 START OF PRESS-STROKE SETTING NOT REACHED (shutdown)
During its downstroke the plunger had exceeded the IMPACT POSITION setting but has not reached the
START OF PRESS-STROKE POS. (or START OF PRESS-STROKE THICKNESS) - 5 mm - within 5 seconds.
Check that the value set for START OF PRESS-STROKE POS. can be reached (for example it could be
something in the die-set or soft filling that is preventing the downstroke from being performed).
2126 PERFORM SELF-LEARNING (YV32) (shutdown)
The proportional solenoid valve self-learning procedure must be performed before switching the press over
to automatic or semi-automatic mode (refer to the “self-learning for plunger upstroke/downstroke...” item in
the DESCRIPTION OF THE KEYS).
2127 CLEAN PROPORTIONAL VALVE (n) (plunger shutdown)
A problem has been detected while cleaning proportional solenoid valves YV32/YV318/YV70D. Parameter
n gives an indication about the type of problem:
1. Pressure in cylinder over 10 bar.
2. Plunger moved down (encoder BQ6 has exceeded 5 mm).
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PH 383.85.050 Rev. 00 Date 27.02.2006
3. Mode selector not turned to position MAN or filler box back limit switch (SQ59) no longer triggered or the
machine is no longer in a safe condition (AJ101 off) as the safety bar is raised, the fillers box is disconnected
or the roller conveyor in front of the press is not connected.
4. Pressure in secondary circuit (BP2) over 270 bar.
5. Pressure in secondary circuit (BP2) dropped excessively.
6. External booster has shifted more than 10 mm.
2131 BOOSTER RESET (BQ12) (booster shutdown)
A fault arose during the reset procedure for the external flow/pressure booster. If nothing appears to the right
of the fault message it means the booster moved up during the direct press stroke.
2132 BOOSTER UPSTROKE (YV103) (booster shutdown)
If “(YV103)” appears it means the external flow/pressure booster failed to complete half its upstroke during
the repositioning stage.
If nothing appears to the right of the fault message it means the booster moved down during the direct press
stroke.
2133 BOOSTER DOWNSTROKE (YV102) (booster shutdown)
If “(YV102)” appears it means the external flow/pressure booster failed to complete half its downstroke during
the repositioning stage.
If nothing appears to the right of the message it means the booster has moved down during the direct press
stroke.
2134 BOOSTER NOT REPOSITIONED (booster shutdown)
The external flow/pressure booster failed to complete its repositioning stroke when the plunger started its
downstroke.
In the PH3800 this check is made at the beginning of the plunger downstroke.
2141 PAD PRECHARGE TIME-OUT (BQ11) (diff. press-cycle shutdown)
The pad precharge cycle was not completed within the maximum allowable time (30 seconds). Booster BQ11
has not reached the precharge position. Check proportional solenoid valves YV100 and the valves in question.
Check linear absolute encoder BQ11, the IE card in position 8 and the electric connections.
2142 LEARNING (YV100) (diff. press-cycle shutdown)
The self-learning cycle for calculating the offset values for proportional valve YV100 has been interrupted.
The various cases, identified by the number that appears to the right of the message, are examined below:
1. During syringe repositioning (back up), the booster failed to complete the maximum stroke - 10 mm -
within 30 seconds. Check proportional solenoid valve YV100 and the valves in question. Check linear
absolute encoder BQ11, the IE card in position 8 and the electric connections.
2. During syringe repositioning (advancing), the booster failed to complete the maximum stroke - 5 mm -
within 120 seconds. Check proportional solenoid valve YV100 and the valves in question. Check linear
absolute encoder BQ11, the IE card in position 8 and the electric connections.
3. While the offset values used for the return stroke and to keep the booster for YV100 in place were being
established, the speed of the booster failed to drop below 0.2 mm/s within 120 seconds. Check
proportional solenoid valve YV100 and the valves in question. Check linear absolute encoder BQ11, the
IE card in position 8 and the electric connections.
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PH 383.85.050 Rev. 00 Date 27.02.2006
4. While the offset values used for the return stroke and to keep the booster for YV100 in place were being
established, the booster moved either completely back or forward. Check proportional solenoid valve
YV100 and the valves in question. Check linear absolute encoder BQ11, the IE card in position 8 and the
electric connections.
5. Once the offset values used for the return stroke and to keep the booster for YV100 in place were
determined, the booster failed to reach the end of its return stroke 5 mm within 120 seconds while being
repositioned. Check proportional solenoid valve YV100 and the valves in question. Check linear absolute
encoder BQ11, the IE card in position 8 and the electric connections.
6. While the offset value for the forward stroke of YV100 was being established, the speed of the booster
failed to drop below 6 mm/s within 120 seconds. Check proportional solenoid valve YV100 and the valves
in question. Check linear absolute encoder BQ11, the IE card in position 8 and the electric connections.
7. While the offset value for the forward stroke of YV100 was being established, the booster reached the
end of its forward stroke. Check proportional solenoid valve YV100 and the valves in question. Check
linear absolute encoder BQ11, the IE card in position 8 and the electric connections.
8. Once the offset value for the forward stroke of YV100 was determined, the booster failed to reach the end
of its forward stroke - 5 mm within 120 seconds while being repositioned. Check proportional solenoid
valve YV100 and the valves in question. Check linear absolute encoder BQ11, the IE card in position 8
and the electric connections.
9. Not used
10. Not used
11. The booster did not reach the cycle start position while being repositioned for the return stroke within 120
seconds. Check proportional solenoid valve YV100 and the valves in question. Check linear absolute
12. The booster did not reach the cycle start position while being repositioned for the forward stroke within
120 seconds. Check proportional solenoid valve YV100 and the valves in question. Check linear absolute
2143 BOOSTER REPOSITIONING (BQ11) (diff. press-cycle shutdown)
The booster either failed to reach its initial position during the repositioning procedure within 120 seconds or
the precharge position within 60 seconds. Check proportional solenoid valve YV100 and the valves in
question. Check linear absolute encoder BQ11, the electric connections and the IE card in position 8.. .
2144 CHECK PAD PRECHARGE (BP203) (diff. press-cycle shutdown)
During pad decompression, the pad pressure (BP203) failed to drop below 0.3 bar within 60 seconds.
During pad precharging or while precharging is being checked, the pad pressure (BP203) is higher than the
maximum allowable isostatic precharge pressure. Check proportional solenoid valve YV100 and the valves
in question. Check pressure transducer BP203, the electric connections and the IA card in position 7.
2145 LOW CYL. PRESS DUR. DIFF. CYCLE (diff. press-cycle shutdown)
During the differentiated press-cycle, the cylinder pressure (BP1) dropped below the value set for CYLINDER
PRESS. AT DIFF. CYCLE START - 5%.
The pad may be damaged.
Check pressure transducer BP1, the electric connections and the IA card in position 7.
2146 PLUNGER UPSTR. EXCESSIVE DUR. DIFF. CYCLE (diff. press-cycle shutdown)
While the pad pistons are put under pressure during the differentiated press-cycle, make sure the plunger
does not move more than 0.5 mm up in relation to the maximum value reached when the pressure was
discharged from the pistons.
The pad may be damaged.
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2147 HIGH PRESSURE DUR. OIL CHANGE (BP204) (diff. press-cycle shutdown)
The booster (BP204) pressure exceeded 20 bar when the oil was changed. This means the oil pushed by the
booster is not able to flow out.
Check proportional solenoid valve YV100 and the valves in question. Check pressure transducer BP204, the
electric connections and the IA card in position 7.
2148 PISTON POS. UNDER PRESS. NOT REACHED (diff. press-cycle shutdown)
While the pad pistons were put under pressure during the differentiated press-cycle, the booster (BQ11) failed
to reach the value calculated according to the set piston stroke within 5 seconds.
2149 FILTER CLOGGED (SP8) (diff. press-cycle shutdown)
Digital input SP8 stayed off and the oil temperature is higher than 30 °C.
Change the filter of the pressure switch for proportional valve YV100 as it is clogged. If the message is still
displayed even after the filter has been changed, check pressure switch SP8, the ID card in position 13 (when
the filter is not clogged, led SP8 should be on) and the cables/connectors.
2150 PERFORM LEARNING (YV100) (diff. press-cycle shutdown)
The self-learning procedure for proportional valve YV100 needs to be executed. Set SET-UP OPERATION
NO. = 11 (on page O on the PC) with the mode selector turned to Man and then press keys 28 and 7. The
procedure takes a few minutes. Once the procedure has been completed, press Reset to clear the message.
2151 PAD DECOMPRESSION TIME OUT (BP204) (diff. press-cycle shutdown)
The pressure inside the pad (BP204) is checked at the end of the first press stroke. If it is higher than 3 bar,
the cylinder is kept at the first press stroke pressure as long as the pressure in the pad does not fall below 4
bar. As a result, the pad pistons surely move all the way down (this procedure is performed whenever the cycle
starts and the oil is changed). If it stays below 4 bar for 20 sec, a fault is signaled.
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16.4 STOPPAGE MESSAGES
3001 UPPER PUNCH HEATING (KM5) (stoppage)
The heater is turned on (OUT KM5 and KM5B = ON) but spool input KM5 is off.
Check the contacts on contactors KM5 and KM5B (optional) for heating the upper punches as they fail to close.
3002 UPPER DIE HEATING (KM6) (stoppage)
Check the contact on contactor KM6 for heating the upper die as it fails to close.
3003 LOWER DIE HEATING (KM7) (stoppage)
Check the contact on contactor KM7 for heating the lower die as it fails to close.
3004 LOWER PUNCH HEATING (KM8) (stoppage)
Check the contacts on contactors KM8 and KM8B (optional) for heating the lower punches as they fail to close.
3005 CONTACTS STUCK IN CONTACTOR (KM5) (stoppage)
The heater is off (OUT KM5 and KM5B = OFF) but spool input KM5 is on.
Contactor KM5 does not work; its contacts fail to open.
See message no. 3005.
3009 TEMP. TOO HIGH (BT5) (stoppage)
The temperature measured by thermocouple BTn is higher than 110°C (80°C if the punches are made of rubber).
The temperature is too high.
If it works properly, find out what is causing the temperature to be too high.
If it does not work properly, (even after the thermocouple has been replaced), check the input module of the
thermocouple and then try replacing the analog card.
NOTE: n = 5 upper punches
n = 6 upper die
n = 7 lower die
n = 8 lower punches
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3013 BRUSH NOT WORKING (KM2A/KM2B ) (stoppage)
Spool digital input KM2 is off after a signal for brush rotation has been sent (KM2A or KM2B = ON).
Check the thermal cut-out and contactors KM2A and KM2B.
Check the input card (input KM2 must be closed when the motor is running) and the leads/connectors.
Check the output card (Led KM2A or KM2B must be on when the motor has to run) and the leads/connectors.
3014 LACK OF POWDER IN HOPPER (AD1K1) (stoppage)
Digital input AD1K1 is off.

Check the powder level in the hopper.
Check level sensor AD1K1, the input card (Led AD1K1 must come on when the powder exceeds the maximum
level) and the leads/connectors.
If Led AD1K1 is off when the powder exceeds the maximum level adjust the sensitivity of the powder detector
amplifier (AD1).
3015 EXTERNAL STOP (KA300) (stoppage)
Digital input KA300 is off.

The line after the press has stopped.
Check signal KA300.
If the line after the press has not stopped, check the input card (when the line is running Led KA300 must be
on) and the leads/connectors.
3016 STOP PUSH-BUTTON (stoppage)
The automatic cycle stop push-button (located on the keyboard) has been pressed.
If the push-button has not been pressed, check the keyboard lead.
If the lead is properly connected and is not broken, try replacing the control KEYBOARD.
If the keyboard works properly, try replacing the MISCELLANEOUS card.
3017 STOP. DUE TO EXT. SYNCH. (KA301) (stoppage)
The outer synchronization contact has remained closed (when the filler-box starts its travel) for more than the
maximum allowable time (2 minutes).
Check contact KA301, the input card (Led KA301 must be off when the press is running) and the leads/
connectors.
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3018 BATCH COMPLETED (stoppage)
The production batch has been completed as set for the “PRODUCTION BATCH” data item.
3019 SERVICE-ACCUMULATORS (stoppage)
PH with columns
The service pressure has remained lower than the set value - 5 bar for three consecutive cycles.
Check the output card (Led YV64 must come on when the solenoid valve has to operate) and the leads/
connectors.
Check pressure transducer BP2, its input module, the EIA card and the leads/connectors.
See the INSTRUCTIONS FOR SETTING THE PRESSURE TRANSDUCER.
Make sure the SERVICE PRESSURE setting is higher than the operating pressure of the accumulators.
Power series PH presses
The pressure in the secondary circuit (BP2) is more than 50 bar below the value set for “accumulators
pressure” for three consecutive cycles.
3020 DECREASE RP2 (stoppage)
Decrease the value set for the GAIN (RP2) data item to prevent the gain for opening the filler box valve from
becoming too low. This value is given on the ACTUAL LOADING DATA video-page.
If the problem persists check YV20 and card VT 11023.
If the problem persists check the EIA card and the leads/connectors.
3021 INCREASE RP2 (stoppage)
Increase the value set for the GAIN (RP2) data item to prevent the gain for opening the filler box valve from
becoming too high. This value is given on the ACTUAL LOADING DATA video-page.
If the problem persists check YV20 and card VT 11023.
If the problem persists check the EIA card and the leads/connectors.
3022 PLUNGER LEAKS (stoppage)
The plunger has moved down more than 5 mm (2 mm if DIP or double loading are used) in relation to the value
set for PLUNGER UP during the loading cycle. YV31S is energized to move the plunger back up. If the
message is displayed when the cycle is NOT in progress it means YV104 is faulty or plunger leakage is no
longer remarkable.
3023 THICKNESS ERROR > 40 c.mm (stoppage)
A tile thickness deviation greater than 0.4 mm has been indicated. The thickness is automatically adjusted
(the 0.4 mm threshold can be entered).
If the thickness measured does not correspond to the actual thickness, check the plunger encoder, its mount,
the EIA/IE card (EIA if an incremental encoder is installed, IE if an absolute one is installed) and the leads/
connectors.
With SMU and 2-cylinder proportional knockout: Check the automatic filling height control, motor M9 an
contactors KKM9A/KM9B, the OR output card (either output KM9A or KM9B has to be activated when the
filling height is adjusted), the leads/connectors and, only for 2-cylinder proportional knockout:
- With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10.
- With program version PH12.01.01or later: he IA card and the IE card in location 9.
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With SMU and 4-cylinder proportional knockout: Check axis card AP210, encoder interface card AP207,
serial interface card AP208, encoders BQ4/5 and
- With program versions earlier than PH12.01.01: the EIA card in location 10.
- With program version PH12.01.01or later: the IE card in location 9.
3024 CHECK THERMOCOUPLE (BTn) (stoppage)
The die-set heater is on (OUT KMn = ON) but the temperature measured by thermocouple BTn is lower than
1°C.
The temperature measured by a thermocouple for the die-sets is not correct.
Check the connections of the thermocouple indicated in the message.
Check the input module in question.
3025 WRONG DIE-SET OP. (A=..., B=...) (stoppage)
At the filler-box start the value of one or both die-set encoders has exceeded the setting for Upper End Stop
(FCA) by more than 0.4 mm or has fallen below the setting by more than 0.6 mm.
3026 CONNECT THERMOC. (BT5) (stoppage)
See whether the thermocouple is properly connected. If the message is not cleared,
With program versions earlier than PH12.01.01: check the input module of thermocouple BT5 (AP305),
the EIA card in locations 6/7 and the leads/connectors.
With program version PH12.01.01or later: check the IA card in location 7 and the leads/ connectors.
With program versions earlier than PH12.01.01: check the input module of thermocouple BT6 (AP306),
the EIA card in locations 6/7 and the leads/connectors.
With program versions earlier than PH12.01.01:check the input module of thermocouple BT7 (AP307), the
EIA card in locations 6/7 and the leads/connectors.
With program versions earlier than PH12.01.01:check the input module of thermocouple BT8 (AP308), the
EIA card in locations 6/7 and the leads/connectors.
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3030 PUMP STOP PUSH-BUTTON (stoppage)
The pump stop button on the keyboard has been pressed.

If it has not, check the keyboard power cord.
If the cord is properly plugged in and is not broken, try replacing the control KEYBOARD. If the keyboard works
properly, try replacing the MISCELLANEOUS card.
3031 LOW PRESSURIZATION/FILTER (SP3) (stoppage)
Digital input SP3 is off.

Check the suction filter of the main pump.
Make sure the pressurization pressure is sufficient.
Check the ID card in location 11 and the leads/connectors.
3032 CLEANING (stoppage)
Cause of machine stoppage requested by the operator on the “STOPPAGES” page.
3033 DIE-SET CHANGE (stoppage)
3034 SCHEDULED MAINTENANCE (stoppage)
3035 SPECIAL MAINTENANCE/REPAIRS (stoppage)
3036 CHECK TILE/ADJUST MACHINE (stoppage)
3037 PAUSE/WORKSHIFT CHANGE (stoppage)
Cause of machine stoppage requested by the operator on the “STOPPAGES” age.
3038 OTHER PROBLEMS (stoppage)
3039 TURN SELECTOR SA293 TO ON (stoppage)
Open the controller and turn selector SA293 to engage the proportional knockout.
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3040 DIE-SET NOT DOWN (stoppage)
One of the die-set cylinders moved more than 2 mm while the proportional knockout was being locked.
Repeat the procedure for hooking the proportional knockout.
3041 PLUNGER LEAKS (stoppage)
With 2-cylinder proportional knockout: the plunger moved by more than 1 mm while the
proportional knockout was being engaged.
With 4-cylinder proportional knockout: the plunger moved by more than 2 mm while the
proportional knockout was being engaged.
3042 CHECK (KM3) (stoppage)
Output KM3 is energised but feedback digital input KM3 is ff.

The oil leak recovery motor has failed.
Input KM3 must be closed when the motor is running.
Check the input card an the leads/connectors.
Check the output card (when the motor has to run, output KM3 must be activated) and the leads/connectors.
3043 FILLER-BOX BACKWARD (stoppage)
The filler-box is further back than its END OF BACKSTROKE setting when the plunger starts to move down
or the ALM begins its forward stroke. Bring the filler-box into the correct position.
3044 REPOSITION (stoppage)
Before starting the automatic CYCLE perform an automatic repositioning procedure.
3045 REPLACE BRUSH (stoppage)
The maximum allowable brush wear set on the FITTINGS SET-UP page has been reached.
Replace the brush, press Reset and start up again.
3046 CHECK (SQ59) (stoppage)
Miniature switch SQ59 has been energised (input SQ59 off) at the end of the filler-box forward stroke (after
the first downstroke with a double-loading filler-box) in automatic or semi-automatic mode.
Check the filler-box back miniature switch and related ID card (with the filler-box forward the miniature switch
should be inactivated an the input should be on).
3047 OIL CHANGE TIME-OUT (stoppage)
The oil in the pad was not changed within 180 seconds.
3048 PAD PISTONS FULLY DOWN (stoppage)
The pressure in the booster (BP204) failed to reach 90% of the pressure present during the previous cycle
while waiting to reach the CYLINDER PRESS. AT DIFF. CYCLE START value.
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3049 CHECK (FILLER BOX FORWARD/BACK TIME) (stoppage)
The time the linear filler box requires to complete its forward and backward stroke deviates more than 10%
from the pre-determined time
Set the correct time for the filler-box forward and return stroke. If the press does not need to stop, set FILLER
BOX CONTROL ON = NO
3050 HIGH TEMPERATURE (ST115) (stoppage)
The thermostat (or series connected thermostats) marked ST115 has detected the temperature inside one
of the electrical cabinets is too high.
3051 BOOSTER AT END-STOP (n bar, m) (stoppage)
The external flow/pressure booster has reached the end of its stroke,
The cylinder pressure and the pressure present at the moment in which the fault arose are indicated in the
fault message.
If “REPOS.” is displayed it means the booster may not have been put back into the proper position.
3052 OA CARD (1) (stoppage)
A fault has been detected in track 1 of the OA card in position 4. The number given in brackets indicates the
track number (from 1 to 12) of the OA card that is faulty.
3053 TECNO ITALIA NOT IN UNLOADING CYCLE (stoppage)
Signal KA311 was not received from Tecno Italia. If Tecno Italia sends it correctly, check the relative digital
input card and related connections.
3054 SPE BALANCING TIME-OUT (stoppage)
During the SPE balancing cycle the die-set failed to reach the end-stop within 10 seconds.
Encoders BQ4 and BQ5 did not measure a value < 0.8 mm.
3055 LUBRICATION NOT PERFORMED (SP130) (stoppage)
Twenty cycles have been completed without being lubricated.
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16.5 INFORMATION MESSAGES
4001 CYCLE TIME GREATER THAN SYNCH. TIME (message)
The time required for the press to perform a complete cycle is greater than the time set for a synchronized
cycle. The number of cycles per minute set cannot be carried out.
4002 WAIT FOR SYNC. TIME (message)
The press is stationary and is waiting for the internal synchronization time to elapse.
4003 WAIT FOR EXTERNAL SYNCH. (message)
The press is stationary and is waiting for external synchronization contact KA301 to open.
4004 LOADING CORRECTION NOT ALLOWED (message)
Loading cannot be corrected as the die-sets are not down.

On the other hand, if they are down, it means the automatic thickness correction of the base has reached a
saturation value.
4005 TEMP. TOO HIGH (BT5): ... °C (message)
The temperature of the die-set is high.

Do not touch the die-set without wearing heavy duty work gloves.



4009 F-BOX FORW. RUN TIME (message)
The time taken for the filler-box to perform its forward stroke differs from the set value (F-BOX FORW. RUN
TIME) by more than 5%.
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4010 FILLER BOX RETURN TIME (message)
The time taken for the filler-box to perform its return stroke differs from the set value (FILLER BOX RETURN
TIME) by more than 5%.
4011 OIL TEMPERATURE (message)
The temperature of the oil is less than 30° C. If the safety bar is raised, under these conditions, the oil will
automatically be heated up by solenoid valve YV11R.
It is possible to stop the oil from being heated by lowering the safety bar and pressing the Reset key on the
control keyboard.
4012 ADJUST PREFILLING VALVE (YV307) REDUCER 31 (+/-) (message)
The booster stroke measured during the 1st press stroke is 20 mm longer than the ideal one for the 1st press
stroke. Adjust reducer 31.
4014 WAIT FOR END OF MOBILE HOPPER CYCLE (message)
The press is stationary and is waiting for the ALM to stop moving.
4015 THICKNESS ERROR > 25 c.mm (message)
Tile thickness is wrong. The thickness is automatically adjusted. The deviation falls within 0.25 and 0.4 mm;
the max. threshold (0.4 mm) can be entered.
4016 POWDER IN DIE-SET BELLOWS (message)
With 2-cylinder proportional knockout: the difference between the analog and digital values during the
press-cycle is more than 1 mm and the encoder value is between 0.3 and 0.6 mm.
Check encoder interface card AP206 installed on the SMU, encoders BQ4/5 and
- With program versions earlier than PH12.01.01: input modules P327/328 and the EIA card in location 10.
- With program version PH12.01.01or later: the IA card and the IE card in location 9.
With 4-cylinder or 2 + 2 cylinder proportional knockout: the value of one or both the encoders is between
0.3 mm and 0.6 mm during the press-cycle.
Check axis card A210, encoder interface card AP207, serial interface card AP208, encoders BQ4/5 and
- With program versions earlier than P12.01.01: the EIA card in location 10.
- With program version PH12.01.01or later: the IE card in location 9.
4017 CHECK PLUNGER SETTING (message)
This message is displayed after a program has been read. Go to the PRESS CYCLE SETUP page and check
the data in the square that deals with the PLUNGER.
4018 TOO MUCH TIME TAKEN TO SET DIE-SET (message)
The difference between the value of one or both die-set encoders and the Upper End Stop is > 0.2 mm.
The upward movement of the proportional knockout is not very precise and it takes it longer to reach the value
set for the UPPER LIMIT data item. To avoid slowing down the cycle, set the upstroke of the proportional
knockout.
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4019 1ST DIE-SET D.STROKE (message)
An error greater than 0.4 mm was detected after the proportional knockout completed its first downstroke.
4020 FILLER-BOX FORWARD (message)
A semi-automatic ALM cycle was requested with the filler-box forwards. Move the filler-box fully back and try
again.
4021 LAST DIE-SET D.STROKE (message)
With the proportional knockout carrying out three downstrokes, an incorrect self-learning value for the encoder
of the die-set on the cylinders for the last downstroke (YV21) was detected. Shut the controller off, turn it back
on and then carry out an automatic resetting cycle.
If the message is not cleared, check the die-set for the last downstroke.
4022 FILLER-BOX ENCODER NOT RESET (message)
Carry out an automatic resetting cycle to zero set the filler-box encoder.
For PH 14.02.01 and later versions reset the encoder as directed in the RESETTING THE CONFIG. AXES
paragraph.
4023 DIE-SET ENCODER NOT RESET (message)
Carry out an automatic resetting cycle to zero set the die-set encode.
4024 PLUNGER ENCODER NOT RESET (message)
With versions earlier than PH12.01.01, perform an automatic repositioning procedure so as to reset the
plunger encoder.
For versions after PH12.01.01 reset the plunger encoder as described in chapter CONFIG. AXIS RESET.
4025 FILLER-BOX SAFETY GUARD (SQ66) (message)
The filler-box has been moved from its seat. Make sure limit switches SQ66/SQ66A are correctly installed and
efficient.
Check contact SQ66, the input card (Led SQ66 should be on when the filler-box is detached) and the cables/
connectors.
If either a DAF or DXP filler-box is used, check safety module AJ101.
4026 CONTROL UP PERFORM DIE-SET LEARNING (message)
Carry out the self-learning procedure for the die-set. See the DIE SET SET UP chapter.
4027 WAIT FOR AUTO. RESTART (KA300) (message)
The press is in standby ready to start automatically. No trigger pulse has been sent from the next machine
in line (KA300). When the trigger pulse is emitted the machine will restart.
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4028 CONTROL UP DURING 1ST DOWNSTROKE (message)
It is advisable to perform a die-set self-learning procedure.

See DIE-SET SET-UP chapter.
4029 CARD NOT ENERGIZED (ODA 17) (message)
During the downward movement of the plunger the ODA card is not energized.
Check the 1st ODA card, the filler box miniature switch SQ59 as well as miniature switches
SQ66, SQ66A, SQ51, SQ52, SQ53A and SQ53B (optional), contactors KA102, KA103, circuit breaker FS101,
mode selector SA9 and safety module AJ101.
NOTE: for program versions PH 10.xx.yy the card is the ODA card in position 16.
NOTE: For PH 14.01.01 and later versions the card is the OD card in position 16.
4030 INCORRECT PRESSING (message)
The pressure reached during the last press stroke deviates more than 15 bar in relation to the set value. If the
message continues to appear check the solenoid valves (YV19, YV41, YV38), pressure transducer BP1, the
leads/connectors and
With program versions earlier than PH12.01.01: the input module of transducer BP1 (AP301) and the EIA
card in locations 6/7
With program version PH12.01.01or later: check the IA card in location 7 and, if the proportional press-
stroke is delivered, solenoid valve YV318, the related hydraulic lines and the ODA card in location 17.
4031 CHECK HEAT EXCHANGER (message)
HEAT EXCHANGER = NO has been set on the FITTINGS SET-UP page but the feedback digital input KM11A
of the heat exchanger is on.
4032 PLUNGER LEAKS (message)
The plunger is kept up by the PLC because otherwise it would move down to rest on the dieset because of
too much leakage.
Check the cylinder seal and the hydraulic lines for the downstroke.
4033 WAIT (message)
Wait before performing any machine operation.
4034 DIE-SET NOT LOCKED (message)
The proportional knockout is not locked.

Lock the die-set.
4035 HYDRAULIC JOINT OIL TEMP. (message)
To ensure top performance of the hydraulic joint in the power unit, wait 10 minutes before starting the pump.
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4036 ALM ENCODER NOT RESET (message)
Perform an automatic reset procedure to set the ALM encoder back to zero.
For PH 14.02.01 and later versions reset the encoder as directed in the RESETTING THE CONFIG. AXES
paragraph.
4037 ROLLER CONVEYOR LIMIT SWITCHES (SQ53) (message)
The roller conveyor has been moved away from the press.
Check miniature switches SQ53A/SQ53B, the ID card in location 13 (with the roller conveyor in the work
position, digital input SQ53A should be off) and the leds/connectors.
4038 SELF-LEARNING IN PROGRESS (message)
The press is carrying out the self-learning cycle to calculate the offset values for the proportional valves (YV32,
YV318). Turn the mode selector switch to stop the cycle.
4039 YV32 OFFSET VALUE TOO HIGH ·[O/D/S] (message)
The offset values for YV32, determined during the self-learning procedure, are too high. If (S) appears on the
right side of the message it means the upstroke offset value is too high.
(D) appears to signal the downstroke offset value is too high.
(O) appears to signal the zero offset value is too high.
Carry out the self-learning cycle again with hot oil. If the message is still displayed, replace YV32 (plunger
proportional solenoid valve).
4040 CHECK (…) (message)
The type of fault detected is given in parenthesis.

BP5: While the plunger is moving up, the value in the upstroke chamber read by the pressure transducer
is < 10 bar. Check pressure transducer BP5, its cables and card IA in position 7.
YV70D: during decompression at the end of the last press stroke in which proportional solenoid valve YV70D
is open, its spool that should read 100% (that corresponds to the valve completely open), actually
reads a value below 80%. Check proportional solenoid valve YV70D, the spool signal sent from it and
the connections.
4041 BOOSTER ENCODER NOT ZERO SET (BQ11) (message)
Bring the booster to the desired 0 position (with the key turned to SET UP) and carry out the reset procedure.
See the SETTING AND RESETTING DATA PARAGRAPH.
4042 BOOSTER NOT RESET (BQ12) (message)
Carry out the automatic procedure to reset the encoder for the external flow/pressure booster.
4043 BOOSTER AT END OF STROKE (message)
The pressure/flow booster has reached the end of the stroke at almost the end of the press stroke. When this
message is displayed, the cylinder pressure and the actual pressure present the moment in which the
message appeared are indicated.
If “REPOS.” is displayed it means the booster may not have been put back into the proper position.
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4044 PERFORM LAST DIE DOWNSTR. (message)
Turn the mode selector to either MAN or SET UP and carry out a die-set downstroke in manual mode. The
press can be set to automatic or semi-automatic mode only once this has been done.
If the message is still displayed, replace the AX card.
4045 YV100 OFFSET TOO HIGH [0/F/R] (message)
The offset values for YV100 determined during the self-learning procedure are too high. If (A) appears to the
right of the message it means the offset value for the forward stroke is too high. If (R) appears it means the
offset value for the return stroke is too high.
If (0) appears it means the zero offset is in question.
Carry out the learning procedure with hot oil. If the message is still displayed, replace YV100 (isostatic circuit
proportional solenoid valve).
4046 OIL BEING CHANGED (message)
The oil in the pad is being changed.
4047 PAD DECOMPRESSION IN PROGRESS (message)
The pad decompression cycle is in progress.
4048 WAIT FOR TRIGGER PULSE FROM D.I.P. (KA311) (message)
The press is waiting for a trigger pulse from the D.I.P to indicate that the KA311 is ready to operate.
As soon as the trigger pulse has been emitted (input KA311 signal high) the press restarts cycling. If this does
not happen, make sure the DIP electrical cabinet disables the signal.
Check the IDM card on the press (location 11) and the cables/wiring connectors.
4049 WAITING FOR TRIGGER PULSE FROM TECNO ITALIA (KA311)
The press is waiting to receive trigger pulse KA311 from Tecno Italia.
4050 YV21P OFFSET TOO HIGH (message)
The offset value calculated during the self-setting procedure for the rod-type ejector is too high. If (D) appears
to the right it means the value regards the downstroke offset value. On the other hand, if (S) appears it regards
the upstroke offset value. The rod-type ejector may not be working correctly.
4051 ACP ENCODER NOT RESET (message)
For PH 14.01.01 versions, perform an automatic reset procedure.

For PH 14.02.01 and later versions reset the ACP encoder as directed in the RESETTING THE CONFIG.
AXES paragraph.
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4052 WAITING FOR PRELOAD AT START OF LAST PRESS STROKE (message)
Wait until pad preloading that started at the end of the first press stroke to be completed.
4053 COLUMN LUBRICATION IN PROGRESS (message)
The grease pump motor has been started (relay output KM130 on).
4054 CLEAN PROPORTIONAL VALVES (n) (message)
A problem has been detected while cleaning proportional solenoid valves YV32/YV318/YV70D during the
self-learning procedure. Parameter n identifies the type of problem:
1. Pressure in cylinder over 10 bar.
2. Plunger down (encoder BQ6 has exceeded 5 mm).
4. Pressure in secondary circuit (BP2) has exceeded 270 bar.
5. Pressure in secondary circuit (BP2) has dropped excessively.
6. External booster moved more than 10 mm.
4055 MODEM CONNECTION (message)
The modem port is hooked up. Phone service may be activated.
200
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16.6 LOCAL ALARM MESSAGES
4900 MEMORY READ (message)
This message appears for a few seconds when the machine is turned on.
4901 INVALID DATA IN SERIAL EEPROM (message)
If this message appears when the machine is turned on, contact the CUSTOMER SERVICE DEPT - SACMI
IMOLA.
4902 INVALID DATA AFTER SERIAL EEPROM READ (message)
IMOLA.
4903 SACMI BMOS V.1.X - MINIMUM BMOS V.1.Y (message)
A CPU card with at least a BMOS v. 1.Y operating system has to be installed in order to run the program.
Check the version. If it is earlier than 1.Y, replace the CPU card. If this is not the case, shut off the system and
then turn it back on.
4904 CHECK CONFIGURATION (message)
IMOLA.
4905 ID 13 CARD (message)
The ID card is not present in location 13.

Program execution is interrupted.
4906 CARD X: MODULE NO. / NOT INSTALLED (message)
When the system was turned on, a card or part of a card was missing.
Parameter X indicates the identification number of the faulty card; example IE1 = 1st IE card starting from the
left.
MODULE NO. y NOT INSTALLED (z)
where y indicates the number of the missing module.
In this case, parameter z is 1.
MODULE NO. y WRONG (z)
where y indicates the number of the wrong module and parameter z indicates 0 if it is in current, 1 if it is in
voltage. The TYPE and VERSION of the firmware installed are indicated on the AX card.
NOT INSTALLED
The card with the id number that is the same as parameter X is not present in the rack. “1” appears to the right
to identify an IA card, 0 to identify an IE card.
WRONG FIRMWARE VERSION
The firmware of the card that has the same id number as parameter X has to be updated; the version installed
is given in brackets.
201
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4910 ERROR DURING PRINTING (message)
Make sure the printer is properly hooked up to the machine controller, power is supplied and that it is ON-LINE.
Remember that the CPU card must have an operating system that is a least BMOS 1.8.
4911 EEPROM FAILURE (message)
If this message appears, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA.
4912 PROGRAM NOT AVAILABLE (message)
The user tried to store a back-up copy of the operating program in an area (in the computer’s memory) which
is already occupied by another program. Enter a different program number.
4913 WRONG PROGRAMMED DATA (message)
An error was found while a program was being read. Try to read the program again. If the fault message is
not cleared, erase the program.
4916 OPERATION NOT ALLOWED (message)
A program cannot be read if the machine is set to RESETTING or CYCLE.
202
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16.7 MAINTENANCE MESSAGES
5001 REPLACE FILTER (SPx)WITHIN n h (message)
Make sure that the filters in the hydraulic power unit are not clogged.
Check pressure switch SPx, the input card (Led SP1 must be on when the filters are not clogged) and the leads/
connectors. The number given to the right indicates the number of hours in which the pump can continue
running with the filter clogged.
NOTE: To clear the message, turn the key selector on the keyboard to SET UP and press the RESET key.
The number shown to the right of the message indicates the number of hours the pump can continue operating
with the filter clogged.
5002 SCHEDULED MAINTENANCE (80 hrs) (message)
This message appears after the main pump has operated for 80 hours.
The maintenance operations which are described in the INSTRUCTIONS MANUAL need to be performed.
NOTE: To clear the message, turn the key switch on the machine control keyboard to “SET UP” an press the
Reset key.
5003 SCHEDULED MAINTENANCE (200 h) (message)
Se message no. 5002.
5007 REPLACE DIE-SET (message)
The die-set has already carried out the number of cycles set for the “DIE-SET LIFE IN CYCLES” data item
on the DIE SET SET-UP page. It needs to be replaced. NOTE: The message is cleared by turning the key
on the machine control keyboard to SET UP and pressing the Reset key.
5008 SCHEDULED MAINTENANCE (6,000,000 CYCLES) (message)
5010 AT END OF BATCH LOAD PROGRAM NO. (message)
Perform the operation requested by the controller.
203
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5011 GREASE LEVEL LOW (SQ130) (message)
Grease level low sensor SQ130 has detected the grease level is low (digital input SQ130 off) 4 seconds after
the grease pump motor started running (relay output KM130 on).
5012 LUBRICATION NOT PERFORMED (SP130) (message)
Two minutes have gone by since sensor SP130 was activated or sensor SP130 has not been activated for
at least 500 ms or has not been activated at all.
5013 CHECK ALM CABLES (10000000 CYCLES) (message)
Change the ALM cables as they may break after numerous cycles have been performed (they are mobile).
204
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TABLE OF CONTENTS
1 INTRODUCTION .............................................................................................................................................. 5
2 WARNINGS ...................................................................................................................................................... 6
3 MAIN FEATURES OF THE ELECTRIC SYSTEM ............................................................................................ 7
4 MACHINE CONTROL KEYBOARD ................................................................................................................. 9

4.1 DESCRIPTION OF THE KEYS ............................................................................................................ 10
4.2 DESCRIPTION OF THE LEDS ............................................................................................................. 14
5 PROGRAMMING KEYBOARD ...................................................................................................................... 15
6 PAGE LAY-OUT AND GENERAL INFORMATION ........................................................................................ 16

6.1 STATUS BAR ........................................................................................................................................ 17
6.2 MACHINE STATUS .............................................................................................................................. 17
6.3 STATE OF THE KEY SWITCH ............................................................................................................. 18
6.4 USERNAME ......................................................................................................................................... 18
6.5 OPERATING PROGRAM NUMBER ..................................................................................................... 18
7 ADDITIONAL FUNCTIONS ............................................................................................................................ 19

7.1 BUTTON BAR ....................................................................................................................................... 19
7.2 LOGGING IN AND LOGGING OUT ...................................................................................................... 19
7.3 SETTING THE ORDER OF THE CYCLE STAGES .............................................................................. 20
7.4 MEMO FUNCTION ............................................................................................................................... 21
7.5 STOPS PAGE ....................................................................................................................................... 22
8 HOW TO MOVE AMONG THE PAGES ......................................................................................................... 23

8.1 SCROLLING THE PAGES .................................................................................................................... 23
8.2 CURSOR .............................................................................................................................................. 23
8.3 USE OF THE BUTTONS ...................................................................................................................... 23
8.4 MOVING THE CURSOR IN THE DIALOG WINDOWS ........................................................................ 24
9 MENU PAGE .................................................................................................................................................. 25

9.1 OPERATING DATA READ-OUT ........................................................................................................... 25
9.2 OPERATING PROGRAM DATA INPUT ................................................................................................ 26
9.3 TROUBLESHOOTING .......................................................................................................................... 27
9.4 PRODUCTION DATA AND QUALITY ASSURANCE ............................................................................ 27
9.5 SYSTEM SET-UP ................................................................................................................................. 28
9.6 PRINTING FUNCTIONS ....................................................................................................................... 28
10 OPERATING DATA DISPLAY ........................................................................................................................ 29

10.1 DISPLAY (0) ........................................................................................................................................ 29
10.2 DATA DISPLAY (1) ................................................................................................................................ 30
10.2.1 PAGE LAYOUT ...................................................................................................................... 30
10.2.2 ENCODER SETTINGS ......................................................................................................... 31
10.2.3 HISTOGRAMS ...................................................................................................................... 32
10.2.4 ACTUAL PRODUCTION BATCH .......................................................................................... 32
10.2.5 CHART .................................................................................................................................. 33
10.3 LOADING DATA DISPLAY (2) ............................................................................................................. 34
10.3.1 PAGE LAYOUT ...................................................................................................................... 34
10.3.2 HISTOGRAMS ...................................................................................................................... 35
10.3.3 FILLER BOX MOTION .......................................................................................................... 35
10.3.4 FIRST DIE-SET DOWNSTROKE .......................................................................................... 36
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10.3.5 BRUSH .................................................................................................................................. 36

10.3.6 FILLER-BOX TIMES.............................................................................................................. 36
10.3.7 EXTERNAL DOUBLE LOADING FILLER BOX OR EXTERNAL TILE FEEDER TIMES ...... 37
10.4 PRESS-CYCLE DATA DISPLAY (3) ..................................................................................................... 38
10.4.1 PAGE LAYOUT ...................................................................................................................... 38
10.4.2 OFFSET VALUES OF THE PROPORTIONAL VALVES AND HYDRAULIC CIRCUIT
PRESSURES ........................................................................................................................ 39
10.4.3 TYPICAL PRESS-CYCLE PARAMETERS ............................................................................ 40
10.4.4 BRAKING .............................................................................................................................. 41
10.4.5 PLUNGER POSITION ........................................................................................................... 41
10.5 DIE-SET DATA DISPLAY (4) ................................................................................................................ 42
10.5.1 PAGE LAYOUT ...................................................................................................................... 42
10.5.2 DIE-SET TEMPERATURES .................................................................................................. 43
10.5.3 DIE-SET POSITION .............................................................................................................. 44
10.5.4 DIE-SET DOWNSTROKE ..................................................................................................... 44
10.5.5 DIE-SET CYCLES ................................................................................................................. 45
10.6 DATA READ BY TRANSPONDER ........................................................................................................ 46
10.7 DATA ACQUISITION CHART (5) .......................................................................................................... 48
10.8 PRODUCTION DATA INPUT PAGE (6) ................................................................................................ 50
11 OPERATING PROGRAM DATA INPUT ......................................................................................................... 52

11.1 LIST OF OPERATING PROGRAMS (A) .............................................................................................. 52
11.1.1 SAVING A PROGRAM .......................................................................................................... 53
11.1.2 PROGRAM READ-OUT ........................................................................................................ 53
11.1.3 CANCELLING A PROGRAM ................................................................................................. 53
11.1.4 DATA INPUT .......................................................................................................................... 54
11.1.5 DIALOG WINDOW FOR NUMERICAL DATA ....................................................................... 55
11.1.6 DIALOG WINDOW FOR YES / NO DATA ITEMS ................................................................. 55
11.2 PLUNGER BRAKING DATA INPUT (B) ................................................................................................ 56
11.2.1 PLUNGER BRAKING DURING DOWNSTROKE ................................................................. 56
11.2.2 PLUNGER BRAKING DURING UPSTROKE ........................................................................ 57
11.3 LOADING CYCLE SET-UP PAGE (C) .................................................................................................. 58
11.4 PRESS-CYCLE SET-UP PAGE (D) ...................................................................................................... 62
11.4.1 GENERAL SETTINGS .......................................................................................................... 62
11.4.2 TYPICAL PRESS-CYCLE PARAMETERS ............................................................................ 64
11.5 DIE-SET SET UP PAGE (E) ................................................................................................................. 68
11.5.1 FORMATS ............................................................................................................................. 68
11.5.2 DIE-SET TEMPERATURES .................................................................................................. 70
11.5.3 DIE SET MAINTENANCE ..................................................................................................... 71
11.5.4 DIE-SET BLOWER ................................................................................................................ 71
11.5.5 SFS MANAGEMENT ............................................................................................................. 72
11.5.6 LOWER DIE .......................................................................................................................... 72
11.5.7 MAGNETIC LOCK ................................................................................................................. 73
11.6 PROPORTIONAL EJECTOR SET-UP PAGE (F) ................................................................................. 75
11.6.1 EJECTOR SETTINGS ........................................................................................................... 75
11.6.2 SPEED .................................................................................................................................. 77
11.6.3 LOADING CORRECTIONS ................................................................................................... 77
11.6.4 ADDITIONAL FUNCTIONS ................................................................................................... 79
11.7 FITTINGS AND TIMING SET-UP PAGE (G) ......................................................................................... 81
11.7.1 ALM ....................................................................................................................................... 82
11.7.2 MDR ...................................................................................................................................... 83
11.7.3 BRUSH .................................................................................................................................. 84
11.7.4 SYNCHRONIZATION ............................................................................................................ 88
11.7.5 HEAT EXCHANGER ............................................................................................................. 88
11.8 DATA INPUT PAGE FOR DIFFERENTIATED PRESS-CYCLE (H) ..................................................... 89
11.8.1 DIFFERENTIATED PRESS-CYCLE (READ-OUT) ............................................................... 90
11.8.2 DIFFERENTIATED PRESS-CYCLE (DATA INPUT) ............................................................. 90
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11.8.3 DIFFERENTIATED PRESS-CYCLE DURING PRECHARGE ............................................... 91

11.8.4 DIFFERENTIATED PRESS-CYCLE UNDER PRESSURE ................................................... 91
11.8.5 DIFFERENTIATED PRESS-CYCLE UNDER DECOMPRESSION ....................................... 91
12 FAULT TRACING ........................................................................................................................................... 93

12.1 LIST OF FAULT MESSAGES (J) .......................................................................................................... 93
12.1.1 “FAULT SEARCH” DIALOG WINDOW .................................................................................. 95
12.1.2 FILTER PAGE ........................................................................................................................ 97
12.2 STATISTICS (K) .................................................................................................................................... 98
12.3 SCHEDULED MAINTENANCE PAGE (L) ............................................................................................ 99
12.4 INPUT/OUTPUT STATE PAGE (M) .................................................................................................... 101
12.5 STATE OF WORK-CYCLE EXECUTION (N) ..................................................................................... 103
12.6 SET UP OPERATIONS AND ENCODERS RESET PAGE (O) .......................................................... 107
12.6.1 ENCODER RESET ............................................................................................................. 107
12.6.2 SPECIAL OPERATIONS ..................................................................................................... 108
12.6.3 HYDRAULIC CIRCUIT PRESSURE CHARTS .................................................................... 109
12.6.4 “VOLTAGE - PRESSURE” CHART ..................................................................................... 110
12.6.5 “MEASURED PRESSURE - REQUIRED PRESSURE” CHART ......................................... 110
13 QUALITY CONTROL AND PRODUCTION DATA ....................................................................................... 111

13.1 PRODUCTION METERS AND COUNTERS (Q) ................................................................................ 111
13.1.1 PRODUCTION DATA .......................................................................................................... 112
13.1.2 NUMBER OF CYCLES/PIECES PRODUCED .................................................................... 112
13.1.3 DOWNTIMES ...................................................................................................................... 112
13.1.4 PRODUCTION BATCH ....................................................................................................... 112
13.2 PRODUCTION HISTOGRAMS (R) .................................................................................................... 113
13.3 CONSUMPTION PAGE (S) ................................................................................................................ 115
13.4 TREND SUBMENU (T) ....................................................................................................................... 117
13.4.1 TRENDS AND DEVIATION HISTOGRAMS ........................................................................ 119
13.5 EVENTS PAGE (U) ............................................................................................................................. 121
14 SYSTEM SETTINGS .................................................................................................................................... 123

14.1 SET-UP PAGE (V) .............................................................................................................................. 123
14.1.1 STRING PERSONALIZATION PAGE .................................................................................. 126
14.1.2 SETTING THE WORK SHIFTS ........................................................................................... 130
14.1.3 TRANSPONDER KEY MANAGEMENT PAGE ................................................................... 132
14.1.4 USER MANAGEMENT PAGE ............................................................................................. 134
14.2 INFORMATION PAGE (W) ................................................................................................................. 140
14.3 CONFIGURATION SUBMENU (X) ..................................................................................................... 141
15 WHAT TO DO WHEN THE MACHINE STOPS DUE TO MALFUNCTIONING ............................................ 146
16 FAULT MESSAGES ..................................................................................................................................... 148

16.1 OPERATING SYSTEM MESSAGES .................................................................................................. 150
16.2 SHUTDOWN MESSAGES ................................................................................................................. 152
16.3 PARTIAL SHUTDOWN MESSAGES .................................................................................................. 155
16.4 STOPPAGE MESSAGES ................................................................................................................... 187
16.5 INFORMATION MESSAGES .............................................................................................................. 194
16.6 LOCAL ALARM MESSAGES .............................................................................................................. 201
16.7 MAINTENANCE MESSAGES ............................................................................................................ 203
207
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LIST OF FAULT MESSAGES
1ST DIE-SET D.STROKE ..................................................................................................................................... 196

1ST DIE-SET D.STROKE (SQ3/SQ6) .................................................................................................................. 159
1ST DOWNSTROKE SIGNAL (KA305) ................................................................................................................ 169
1ST PRESS STROKE ........................................................................................................................................... 177
2ND DIE-SET D.STROKE (SQ6) .......................................................................................................................... 160
2ND F-BOX TRIGGER P. (KA302) ........................................................................................................................ 160
2ND F-BOX TRIGGER P. (KA304) ........................................................................................................................ 159
2ND F.BOX SAFETY SW. (KA302) ....................................................................................................................... 176
2ND FILLER-BOX FORWARD (KA302) ................................................................................................................ 158
3RD DOWNSTROKE SIGNAL (KA306) ................................................................................................................ 169
A
ACCUMULATOR CHARGE .................................................................................................................................. 179
ACP ENCODER NOT RESET .............................................................................................................................. 199
ADJUST PREFILLING VALVE (YV307) REDUCER 31 (+/-) ................................................................................. 195
ALM ACTUATOR/ENCODER ................................................................................................................................ 174
ALM ENCODER NOT RESET .............................................................................................................................. 198
ANALOG CARD DOES NOT WORK .................................................................................................................... 154
ANALOG/ENCODER CARD NOT WORKING (1) ................................................................................................. 152
ANALOG/ENCODER CARD NOT WORKING (2) ................................................................................................. 153
AT END OF BATCH LOAD PROGRAM NO. ......................................................................................................... 203
AXES CARD ERROR ............................................................................................................................................ 164
B
BATCH COMPLETED ........................................................................................................................................... 189
BOOSTED PRESS STROKE ................................................................................................................................ 177
BOOSTER AT END OF STROKE ......................................................................................................................... 198
BOOSTER AT END-STOP (n bar, m) .................................................................................................................... 193
BOOSTER DOWNSTROKE (YV102) ................................................................................................................... 184
BOOSTER ENCODER NOT ZERO SET (BQ11) .................................................................................................. 198
BOOSTER NOT REPOSITIONED ........................................................................................................................ 184
BOOSTER NOT RESET (BQ12) ........................................................................................................................... 198
BOOSTER REPOSITIONING (BQ11) ................................................................................................................... 185
BOOSTER RESET (BQ12) ................................................................................................................................... 184
BOOSTER UPSTROKE (YV103) .......................................................................................................................... 184
BRAKING .............................................................................................................................................................. 175
BRUSH NOT WORKING (KM2A/KM2B ) .............................................................................................................. 188
C
CARD NOT ENERGIZED (ODA 17) ...................................................................................................................... 197
CARD X: MODULE NO. / NOT INSTALLED ......................................................................................................... 201
CARRY OUT LOADING ........................................................................................................................................ 174
CHECK (…) ........................................................................................................................................................... 198
CHECK (AJ101) .................................................................................................................................................... 170
CHECK (Bpn) ........................................................................................................................................................ 157
CHECK (BQ1) ....................................................................................................................................................... 178
CHECK (FILLER BOX FORWARD/BACK TIME) .................................................................................................. 193
CHECK (KM3) ....................................................................................................................................................... 192
CHECK (SQ51/SQ52) or (SQ11A/B/C/D) ............................................................................................................. 170
CHECK (SQ53/SQ54) ........................................................................................................................................... 171
CHECK (SQ58) ..................................................................................................................................................... 170
CHECK (SQ59) ..................................................................................................................................................... 192
CHECK (SQ67/SQ68) ........................................................................................................................................... 178
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CHECK (SQ68/SQ67) ........................................................................................................................................... 167

CHECK (U24) ........................................................................................................................................................ 174
CHECK (YV...) ....................................................................................................................................................... 166
CHECK (YV20S) ................................................................................................................................................... 170
CHECK 24 VEV ..................................................................................................................................................... 153
CHECK ALM CABLES (10000000 CYCLES) ........................................................................................................ 204
CHECK CONFIGURATION ................................................................................................................................... 201
CHECK DIE-SET ENCODER ................................................................................................................................ 163
CHECK HEAT EXCHANGER ................................................................................................................................ 197
CHECK PAD PRECHARGE (BP203) .................................................................................................................... 185
CHECK PLUNGER SETTING ............................................................................................................................... 195
CHECK PRESET DATA ........................................................................................................................................ 152
CHECK THERMOCOUPLE (BTn) ........................................................................................................................ 190
CHECK TILE/ADJUST MACHINE ......................................................................................................................... 191
CLEAN PROPORTIONAL VALVE (n) ................................................................................................................... 183
CLEAN PROPORTIONAL VALVES (n) ................................................................................................................. 200
CLEANING ............................................................................................................................................................ 191
COLUMN LUBRICATION IN PROGRESS ............................................................................................................ 200
CONFIG. ............................................................................................................................................................... 154
CONNECT THERMOC. (BT4) .............................................................................................................................. 155
CONTACTS STUCK IN CONTACTOR (KM5) ....................................................................................................... 187
CONTROL UP DURING 1ST DOWNSTROKE ..................................................................................................... 197
CONTROL UP PERFORM DIE-SET LEARNING ................................................................................................. 196
CONTROL UP: PERFORM DIE-SET SELF-LEARNING ...................................................................................... 163
CYCLE TIME GREATER THAN SYNCH. TIME .................................................................................................... 194
CYLINDER PRESSURE TRANSDUCER (BP1) ................................................................................................... 175
D
DECREASE RP2 ................................................................................................................................................... 189
DIE DOWN (SQ63) ............................................................................................................................................... 160
DIE SETTING NOT REACHED ............................................................................................................................. 163
DIE-SET CHANGE ................................................................................................................................................ 191
DIE-SET DEVIATION > 2 mm ............................................................................................................................... 160
DIE-SET ENCODER BLOCKED (SQ4) ................................................................................................................ 164
DIE-SET ENCODER NOT RESET ........................................................................................................................ 196
DIE-SET ENCODER RESET ................................................................................................................................ 162
DIE-SET NOT DOWN ........................................................................................................................................... 192
DIE-SET NOT LOCKED ........................................................................................................................................ 197
DIE-SET PARALLELISM ERROR ......................................................................................................................... 161
DIE-SET UP. ERROR (A=..., B=...) ....................................................................................................................... 161
DIE-SET UPSTROKE (SQ3) ................................................................................................................................. 158
DIE-SETS UP (SQ3/SQ6) ..................................................................................................................................... 176
DIRECT PRESS STROKE .................................................................................................................................... 177
DIVIDE ERROR INTERRUPT ............................................................................................................................... 150
DIVIDE ERROR PROG n LINE nn ........................................................................................................................ 150
E
EEPROM FAILURE ............................................................................................................................................... 202
ENCODER FAULTY (BQ4A) ................................................................................................................................. 164
ENCODER FAULTY (BQ6) ................................................................................................................................... 166
209
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ERROR DURING PRINTING ................................................................................................................................ 202

EXCESSIVE BRAKING ......................................................................................................................................... 175
EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E) .............................................................................................. 152
EXTERNAL STOP (KA300) ................................................................................................................................... 188
F
F-BOX ENCODER RESET ................................................................................................................................... 169
F-BOX ENCODER/ACTUATOR ............................................................................................................................ 168
F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59) ............................................................................................. 158
F-BOX FORW. DUR. PLUNGER DOWNSTROKE ............................................................................................... 176
F-BOX FORW. RUN TIME .................................................................................................................................... 194
F.BOX SAFETY SW. (SQ59) ................................................................................................................................. 176
F.BOX/PLUNGER COLLISION ............................................................................................................................. 171
FAN/FILTERING UNIT (KM11) .............................................................................................................................. 155
FAULT, FILLER-BOX DRIVE (U20) ....................................................................................................................... 170
FILLER BOX RETURN TIME ................................................................................................................................ 195
FILLER BOX REVERSE ....................................................................................................................................... 171
FILLER-BOX BACKWARD .................................................................................................................................... 192
FILLER-BOX BACKWARD (KA302 - SQ59) ......................................................................................................... 169
FILLER-BOX DID NOT START (KA302 - SQ59) ................................................................................................... 171
FILLER-BOX ENCODER NOT RESET ................................................................................................................. 196
FILLER-BOX FORWARD .................................................................................................................... 168, 174, 196
FILLER-BOX RETURN ......................................................................................................................................... 168
FILLER-BOX SAFETY GUARD (SQ66) ................................................................................................................ 196
FILTER CLOGGED (SP8) ..................................................................................................................................... 186
G
GREASE LEVEL LOW (SQ130) ........................................................................................................................... 204
H
HIGH PRESSURE DUR. OIL CHANGE (BP204) ................................................................................................. 186
HIGH PRESSURE IN THE CYLINDER ................................................................................................................. 156
HIGH TEMPERATURE (ST115) ............................................................................................................................ 193
HOMOGENIZER ................................................................................................................................................... 172
HOMOGENIZER (KM21B) .................................................................................................................................... 172
HOPPER CLOSING (SQ61) ................................................................................................................................. 157
HOPPER OPEN (SQ60) ....................................................................................................................................... 159
HYDR. UNIT PUMP (KM1D) ................................................................................................................................. 155
HYDRAULIC JOINT OIL TEMP. ............................................................................................................................ 197
I
ID 13 CARD ........................................................................................................................................................... 201
IE CARD ................................................................................................................................................................ 154
INCORRECT PLUNGER PARALLELISM (BQ6 - BQ7) ........................................................................................ 178
INCORRECT PRESSING ..................................................................................................................................... 197
INCREASE RP2 .................................................................................................................................................... 189
INVALID DATA AFTER SERIAL EEPROM READ ................................................................................................. 201
INVALID DATA IN SERIAL EEPROM .................................................................................................................... 201
INVALID MEMORY ............................................................................................................................................... 150
K
KEYBOARD ERROR [PE\OE\FE] ......................................................................................................................... 150
KNOCKOUT BETWEEN PUNCHES ..................................................................................................................... 164
210
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L
LACK OF POWDER IN HOPPER (AD1K1) .......................................................................................................... 188
LAST DIE-SET D.STROKE ................................................................................................................................... 196
LAST DIE-SET D.STROKE (SQ6) ........................................................................................................................ 157
LEARNING (YV100) .............................................................................................................................................. 184
LOADING CORRECTION NOT ALLOWED .......................................................................................................... 194
LOW CYL. PRESS DUR. DIFF. CYCLE ................................................................................................................ 185
LOW PRESSURIZATION (SP3) ............................................................................................................................ 155
LOW PRESSURIZATION/FILTER (SP3) .............................................................................................................. 191
LOWER DIE HEATING (KM7) ............................................................................................................................... 187
LOWER PUNCH HEATING (KM8) ........................................................................................................................ 187
LUBRICATION NOT PERFORMED (SP130) ....................................................................................................... 193
LUBRICATION NOT PERFORMED (SP130) ........................................................................................................ 204
M
MAIN SWITCH TRIPPING (BTn) .......................................................................................................................... 153
MEMORY READ ................................................................................................................................................... 201
MIXER (KM22A) .................................................................................................................................................... 171
MIXER (KM22B) .................................................................................................................................................... 172
MOBILE HOPPER ................................................................................................................................................. 174
MOBILE HOPPER (KM23A) ................................................................................................................................. 173
MOBILE HOPPER (KM23I) ................................................................................................................................... 172
MOBILE HOPPER (SQ10) .................................................................................................................................... 174
MOBILE HOPPER (SQ23/SQ24) .......................................................................................................................... 173
MOBILE HOPPER (SQ24S) .................................................................................................................................. 173
MOBILE HOPPER (SQ25) .................................................................................................................................... 173
MOBILE HOPPER (U23) ....................................................................................................................................... 173
MODE SELECTOR ............................................................................................................................................... 153
MODEM CONNECTION ....................................................................................................................................... 200
MOTOR M1 POWER HIGH .................................................................................................................................. 157
N
NON-MASKABLE INTERRUPT ............................................................................................................................ 150
O
OA CARD (1) ......................................................................................................................................................... 193
OIL BEING CHANGED ......................................................................................................................................... 199
OIL CHANGE TIME-OUT ...................................................................................................................................... 192
OIL COCK CLOSED (SQ50) ................................................................................................................................. 156
OIL LEAK LEVEL (SL4) ......................................................................................................................................... 156
OIL LEVEL (SL1) ................................................................................................................................................... 155
OIL TEMPERATURE ............................................................................................................................................. 195
OPERATION NOT ALLOWED .............................................................................................................................. 202
OTHER PROBLEMS ............................................................................................................................................. 191
OVERFLOW INTERRUPT .................................................................................................................................... 150
OVERFLOW PROG n LINE nn ............................................................................................................................. 150
OVERFLOW STACK PROG nLINE nn ................................................................................................................. 151
P
PAD DECOMPRESSION IN PROGRESS ............................................................................................................ 199
PAD DECOMPRESSION TIME OUT (BP204) ...................................................................................................... 186
PAD PISTONS FULLY DOWN .............................................................................................................................. 192
PAD PRECHARGE TIME-OUT (BQ11) ................................................................................................................. 184
PAUSE/WORKSHIFT CHANGE ........................................................................................................................... 191
PERFORM DIE-SET LEARNING .......................................................................................................................... 163
PERFORM DIE-SET SELF-SETTING (YV21P) .................................................................................................... 165
211
PH 383.85.050 Rev. 00 Date 27.02.2006
PERFORM LAST DIE DOWNSTR. ....................................................................................................................... 199

PERFORM LEARNING (YV100) ........................................................................................................................... 186
PERFORM PLUNGER LEARNING (YV32) (18) ................................................................................................... 179
PERFORM SELF-LEARNING (YV32) ................................................................................................................... 183
PERFORM SELF-SETTING (YV21P) ................................................................................................................... 163
PERFORM YV309 LEARNING ............................................................................................................................. 183
PISTON POS. UNDER PRESS. NOT REACHED ................................................................................................ 186
PLUNGER / DIE DOWN (KA410) ......................................................................................................................... 171
PLUNGER DOWN AT F-BOX START ................................................................................................................... 169
PLUNGER DOWN DUR. DIE-SET UPSTR. ......................................................................................................... 158
PLUNGER DOWNSTROKE .................................................................................................................................. 175
PLUNGER ENCODER NOT RESET .................................................................................................................... 196
PLUNGER ENCODER RESET ............................................................................................................................. 177
PLUNGER ENCODER/ACTUATOR ..................................................................................................................... 167
PLUNGER LEAKS .............................................................................................................................. 189, 192, 197
PLUNGER UPSTR. EXCESSIVE DUR. DIFF. CYCLE ......................................................................................... 185
PLUNGER UPSTROKE ........................................................................................................................................ 176
POWDER IN DIE-SET BELLOWS ............................................................................................................... 178, 195
POWER SUPPLY/FUSES nnV ............................................................................................................................. 150
PRESSURE NOT RECUPERATED ...................................................................................................................... 178
PRESSURE SWITCH/TRANSDUCER ... bar ....................................................................................................... 154
PROG n PC nnnn:nnnn COD nn ........................................................................................................................... 151
PROGRAM NOT AVAILABLE ................................................................................................................................ 202
PUMP STOP PUSH-BUTTON .............................................................................................................................. 191
PUNCHES INSIDE (SQ62) ................................................................................................................................... 157
PUNCHES NOT FIXED (AJ1/AJ2) ........................................................................................................................ 152
PUNCHES OVERTRAVEL/LIFT RODS ................................................................................................................ 167
PWD FEED SHUTOFF AT... c.mm (BQ6) ............................................................................................................. 168
R
RAISE SAFETY BAR ............................................................................................................................................ 177
REDUCE ALM OPENING DELAY TIME ............................................................................................................... 173
REPLACE BRUSH ................................................................................................................................................ 192
REPLACE DIE-SET .............................................................................................................................................. 203
REPLACE FILTER (SP1) ...................................................................................................................................... 156
REPLACE FILTER (SPx)WITHIN n h .................................................................................................................... 203
RESET PRESSURE .............................................................................................................................................. 164
ROLLER CONVEYOR LIMIT SWITCHES (SQ53) ................................................................................................ 198
S
SACMI BMOS V.1.X - MINIMUM BMOS V.1.Y ..................................................................................................... 201
SAFETY BAR UP .................................................................................................................................................. 166
SCHEDULED MAINTENANCE ............................................................................................................................. 191
SCHEDULED MAINTENANCE (200 h) ................................................................................................................. 203
SCHEDULED MAINTENANCE (2000 h) ............................................................................................................... 203
SCHEDULED MAINTENANCE (4000 h) ............................................................................................................... 203
SCHEDULED MAINTENANCE (500 h) ................................................................................................................. 203
SCHEDULED MAINTENANCE (6,000,000 CYCLES) .......................................................................................... 203
SCHEDULED MAINTENANCE (80 hrs) ................................................................................................................ 203
SELF-LEARNING IN PROGRESS ........................................................................................................................ 198
SERVICE-ACCUMULATORS ................................................................................................................................ 189
SHORT CIRCUIT YVn ........................................................................................................................................... 154
212
PH 383.85.050 Rev. 00 Date 27.02.2006
SHUTDOWN PUSH-BUTTON .............................................................................................................................. 152

SPE BALANCING TIME-OUT ............................................................................................................................... 193
SPECIAL MAINTENANCE/REPAIRS .................................................................................................................... 191
START OF PRESS-STROKE SETTING NOT REACHED .................................................................................... 183
STOP PUSH-BUTTON .......................................................................................................................................... 188
STOP. DUE TO EXT. SYNCH. (KA301) ................................................................................................................ 188
T
TECNO ITALIA NOT IN UNLOADING CYCLE ...................................................................................................... 193
TECNO ITALIA TIME OUT SIGNAL (KA311) ........................................................................................................ 171
TEMP. TOO HIGH (BT4) ....................................................................................................................................... 156
TEMP. TOO HIGH (BT5) ....................................................................................................................................... 187
TEMP. TOO HIGH (BT5): ... °C ............................................................................................................................. 194
TEMP. TOO HIGH (BT6) ....................................................................................................................................... 188
TEMP. TOO HIGH (BT6): ... °C ............................................................................................................................. 194
TEMP. TOO HIGH (BT7) ....................................................................................................................................... 188
TEMP. TOO HIGH (BT7): ... °C ............................................................................................................................. 194
TEMP. TOO HIGH (BT8) ....................................................................................................................................... 188
TEMP. TOO HIGH (BT8): ... °C ............................................................................................................................. 194
TEMP. TOO LOW (BT4) ........................................................................................................................................ 155
TEMPERATURE HIGH (ST4) ............................................................................................................................... 156
TEMPERATURE TOO HIGH (ST1) ....................................................................................................................... 157
THICKNESS ERROR > 25 c.mm .......................................................................................................................... 195
THICKNESS ERROR > 40 c.mm .......................................................................................................................... 189
TIME-OUT, KNOCKOUT DOWN ........................................................................................................................... 165
TIME-OUT, KNOCKOUT UP ................................................................................................................................. 165
TOO MUCH TIME TAKEN TO SET DIE-SET ........................................................................................................ 195
TURN SELECTOR SA293 TO ON ........................................................................................................................ 191
U
UNUSED OPCODE INTERRUPT ......................................................................................................................... 150
UPPER DIE HEATING (KM6) ............................................................................................................................... 187
UPPER PUNCH HEATING (KM5) ......................................................................................................................... 187
W
WAIT ..................................................................................................................................................................... 197
WAIT FOR AUTO. RESTART (KA300) .................................................................................................................. 196
WAIT FOR END OF MOBILE HOPPER CYCLE ................................................................................................... 195
WAIT FOR EXTERNAL SYNCH. .......................................................................................................................... 194
WAIT FOR F-BOX TO GO BACK (KA302) ........................................................................................................... 170
WAIT FOR SYNC. TIME ....................................................................................................................................... 194
WAIT FOR TRIGGER PULSE FROM D.I.P. (KA311) ............................................................................................ 199
WAITING FOR PRELOAD AT START OF LAST PRESS STROKE ...................................................................... 200
WAITING FOR TRIGGER PULSE FROM TECNO ITALIA (KA311 ....................................................................... 199
WRONG DIE-SET OP. (A=..., B=...) ............................................................................................................. 170, 190
WRONG KNOCKOUT MOTION (BQ4A) .............................................................................................................. 165
WRONG PROGRAMMED DATA .......................................................................................................................... 202
Y
YV100 OFFSET TOO HIGH [0/F/R] ...................................................................................................................... 199
YV21P OFFSET TOO HIGH ................................................................................................................................. 199
YV32 OFFSET VALUE TOO HIGH ·[O/D/S] ......................................................................................................... 198
213

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D O C U M E N TA Z I O N E

USE OF THE SMC 085

PH 383.85.050 Rev. 00 Date 27.02.2006

Written by : Sig. Monduzzi Matteo Written on : 27.02.2006

Revised by : Ing. Tassoni Alberto Revision No. : PH 02.08.01

Title : Number of pages : 213

USE OF THE SMC 085 MICROPROCESSOR-BASED Service code : 9512

SAFETY PRECAUTIONS TO BE OBSERVED

Device Connection State LED indication

Pushbutton N.O. Pressed Led on

Selector switch Closed in pos. x Led on

Miniature switch N.O. Energized Led on

Proximity sensor N.O. Energized Led on

Contactors-relays N.O. Energized Led on

Vacuum switch N.O. Above set pressure Led off

- To replace the microprocessor system cards:

- To replace the EPROMs which store the machine program:

3 MAIN FEATURES OF THE ELECTRIC SYSTEM

The electric system basically consists of three parts:

1) Microprocessor system for controlling and monitoring machine operation

Power Supply Card (AL or SAL):

Miscellaneous Card (VA)

Encoder/Analog Input Card (EIA)

Analog Input Card (IA):

Encoder Input Card (IE):

Digital Input Cards (IDM):

Digital Output and Relay Output cards (OD, OR):

Digital and Analog Output Cards (ODA)

Analog output card (OA):

Axes card (AX):

2) Switchboard that supplies power to the main points of use

3) Electric wiring of the machine

The entire electric system is tested according to current safety regulations.

MAIN LAWS AND SAFETY STANDARDS USED AS REFERENCES

European Standard CENELEC HD 420

Italian Standard CEI EN 60204-1 (CEI 44-5)

Italian Standard CEI 64-8

European Standard EN 954-1

European Standard EN 292-1

European Standard EN 292-2

European Directive 98/37/EEC

4 MACHINE CONTROL KEYBOARD

4.1 DESCRIPTION OF THE KEYS

FUNCTION 1ST KEY 2ND KEY + KEY SWITCH PUMP

Upper die-set released 31 11 SET-UP

(1) Operation possible only with 2-cylinder S.E. or SMU/LIFT

(2) Operation possible only with 2-cylinder S.E.

(3) Operation possible only in presses with ON/OFF hydraulics

(4) Available only as of version PH 13.01.01

(12)SET-UP OPERATION NO. = 19 must be set (go to page O on the PC).

(18)SET-UP OPERATION NO. = 10 must be set (go to page O on the PC).

(19)SET-UP OPERATION NO. = 11 must be set (go to page O on the PC).

(22)SET-UP OPERATION NO. = 14 must be set (go to page O on the PC).

(24) Available starting from version PH 15.01.01.

(25) Available only with versions PH 12.xx.yy, PH 13.xx.yy and PH 14.xx.yy.

4.2 DESCRIPTION OF THE LEDS

+5 Keyboard supply (+5V)

SL Serial line (comes on if the keyboard is not hooked up to the PLC)

SC Scan control (comes on to indicate that a key is malfunctioning)