OMERA OPI M-400 User manual

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL
CUSTOMER ......................................................
MACHINE MODEL ............................................
SERIAL NUMBER .............................................
OMERA S.r.l.
Via Ponte dei Granatieri, 8
36010 Chiuppano (VI) Italy
Tel [phone] - Fax [phone]
e-mail [email protected] http://www.omera.com I003203EN.DOC

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 2
INDEX OF TOPICS:
1. MACHINE ASSEMBLY DRAWING.....................................................................................................4
2. TEST CERTIFICATE..........................................................................................................................5
2.1 TEST AND INSPECTION DATA (ACCORDING TO SCHLESINGER STANDARDS)...........................6
3. EXPECTED USE CONDITIONS..........................................................................................................7
3.1 BEFORE OPERATING THE MACHINE ........................................................................................7
3.2 DESCRIPTION OF THE MACHINE...............................................................................................8
3.2.1 ACCESSORIES ..................................................................................................................9
3.3 MACHINE USE........................................................................................................................ 10
3.4 RECOMMENDED FLUIDS ........................................................................................................ 11
4. TRANSPORTATION CONDITIONS.................................................................................................... 12
4.1 EQUIPMENT NECESSARY FOR MONOLITHIC PRESS HANDLING............................................. 12
4.2 PROCEDURE FOR UNLOADING FROM THE MEANS OF TRANSPORT...................................... 13
5. INSTALLATION CONDITIONS .......................................................................................................... 14
5.1 INSTALLATION OF PRESSES WITH MONOLITHIC STRUCTURE ................................................ 14
5.2 FILLING OF OIL TANK.............................................................................................................. 15
5.3 CONNECTION TO THE ELECTRICAL MAINS SUPPLY ............................................................... 15
5.4 ILLUMINATION OF THE WORK AREA....................................................................................... 16
6. OPERATION CONDITIONS.............................................................................................................. 17
6.1 ELECTRIC CONTROLS............................................................................................................. 17
6.1.1 MACHINE SETTING CONTROLS ........................................................................................ 17
6.1.2 CONTROL CONSOLE........................................................................................................ 19
6.2 OIL-HYDRAULIC CONTROLS.................................................................................................... 21
6.3 ELECTRONIC CYCLE CAMS.................................................................................................... 22
6.3.1 CONTROL OF SLIDE STROKE........................................................................................... 22
6.3.2 CONTROL OF THE BLANK HOLDER CUSHION .................................................................. 23
6.4 INDUSTRIAL PC SWITCHING ON PROCEDURE ........................................................................ 24
6.5 PASSWORD ........................................................................................................................... 24
6.6 INDUSTRIAL PC SWITCHING OFF PROCEDURE....................................................................... 24
6.7 DEVICE FOR HOLDING THE SLIDE AT T.D.C............................................................................ 25
6.8 KNOCKOUT............................................................................................................................. 25
6.9 FUNCTIONING MODES............................................................................................................ 26
6.9.1 INITIAL CYCLES................................................................................................................ 26
6.9.2 ADJUSTMENT CYCLE....................................................................................................... 26
6.9.3 SINGLE CYCLE WITHOUT BLANK HOLDER....................................................................... 26
6.9.4 SINGLE CYCLE WITH INDEPENDENT BLANK HOLDER...................................................... 26
6.9.5 SINGLE CYCLE WITH DIRECT BLANK HOLDER................................................................. 26
6.9.6 BLOCK RESET FOR SLIDE AND CUSHION OVERSTROKE ................................................ 27
6.9.7 SLIDE UPSTROKE CONTROL AFTER B.D.C. STOP............................................................ 27
6.9.8 DIE LOADING ................................................................................................................... 28
6.9.9 DIE UNLOADING............................................................................................................... 29
6.9.10 OPERATION WITH AUTOMATIC FEEDER.......................................................................... 30
6.9.11 AUTOMATIC CYCLE START.............................................................................................. 30
6.9.12 AUTOMATIC CYCLE STOP................................................................................................ 31

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 3
7. MAINTENANCE.............................................................................................................................. 32
7.1 OIL LEAKS.............................................................................................................................. 33
7.2 OIL FILTER.............................................................................................................................. 33
7.3 TANK AIR FILTER.................................................................................................................... 34
7.4 OIL FILLER CAP...................................................................................................................... 34
7.5 OIL CHANGE........................................................................................................................... 34
7.6 P.L.C. CENTRAL UNIT.............................................................................................................. 35
7.7 MAIN CYLINDER...................................................................................................................... 36
7.8 BLANK HOLDER CUSHION CYLINDER..................................................................................... 37
7.9 TAKE-UP OF SLIDE PLAY ....................................................................................................... 38
7.10 UNIT FOR HOLDING SLIDE AT T.D.C. ....................................................................................... 39
7.11 MAINTENANCE OF LUBRICATION SYSTEM ............................................................................. 39
7.12 ENCODER............................................................................................................................... 40
7.13 TABLE SUMMARIZING MAINTENANCE INTERVENTIONS .......................................................... 41
7.14 COMPARATIVE OIL TABLES.................................................................................................... 42
7.15 WIRING DIAGRAM................................................................................................................... 43
7.16 OIL-HYDRAULIC DIAGRAM ...................................................................................................... 44
7.17 PNEUMATIC DIAGRAM............................................................................................................ 45
7.18 LUBRICATION SYSTEM DIAGRAM........................................................................................... 46
7.19 TABLE DRAWING.................................................................................................................... 47
7.20 SLIDE DRAWING..................................................................................................................... 48
7.21 KNOCKOUT DRAWING............................................................................................................ 49
7.22 OTHER DRAWINGS................................................................................................................. 50

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 4
1. MACHINE ASSEMBLY DRAWING

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 5
2. TEST CERTIFICATE
Customer........................................................................................................_____MODERN FACTORY
Machine model................................................................................................____________ OPI.M - 315
Serial number..................................................................................................________________I003203
Year of manufacture.........................................................................................__________________ 2005
Testing date...................................................................................................._____________ 21/11/2005
Inspector.........................................................................................................__________________ A.N.
Equivalent continuous A-weighted sound pressure level (loadless)............Leq A _____________________66,7
Measurement carried out at 1 metre from the surface of the machine
and at 1.60 metres above the floor.
Minimum/maximum slide force......................................................................kN_____________ 315 - 3150
Maximum slide stroke................................................................................mm___________________ 800
Maximum distance between table and slide .................................................mm__________________ 1300
Table dimensions.......................................................................................mm____________ 1400 X 1200
Slide dimensions .......................................................................................mm____________ 1400 X 1200
Opening in the uprights ..............................................................................mm_____________ 955 X 1010
Blank-holder minimum/maximum force..........................................................kN_____________ 125 - 1250
Maximum blank holder stroke.....................................................................mm___________________ 350
Blank holder working surfaces.....................................................................mm_____________ 1100 X 900
Slide approach high speed....................................................................... mm/s___________________ 580
Slide return high speed............................................................................ mm/s___________________ 500
Cushion return maximum speed............................................................... mm/s___________________ 150
Independent cushion return speed............................................................ mm/s_____________________ /
Minimum/maximum working speed........................................................... mm/s________________ 28 - 64
Oil-hydraulic or mechanical knockout force....................................................kN___________________ 160
Knockout stroke........................................................................................mm___________________ 300
Stopping time................................................................................................s__________________0,098
Die maximum size.....................................................................................mm______________ 936 X 856
Die maximum weight....................................................................................kg__________________ 2500
Main pump motor
Power........................................................................................................kW____________________ 75
Manufacturer...................................................................................................__________________ AEG
Type...............................................................................................................___________AM280ST4Q4
Serial number..................................................................................................______________ 30126917
Auxiliary pump motor
Power........................................................................................................kW____________________5,5
Manufacturer..................................................................................................._____________BRONZONI
Type...............................................................................................................____________0400 3A 112
Serial number.................................................................................................._______________ 0241296
Front photoelectric barrier................................................................................._____________________ /
Front photoelectric barrier type.........................................................................._____________________ /
Resolution.................................................................................................mm_____________________ /
Supply voltage......................................................................................... V/Hz _______________ 380 / 60
Cross-section of wires...............................................................................mm2____________________ 75
Heat exchanger........................................................................................ type_____MG – B131 – 535 - 4
Amount of water required.........................................................................m3/ h_____ 3,7 (water at 20 °C)
Amount of oil............................................................................................litres __________________ 1800
Overall dimensions and foundations..........................................Omera Draw. no. ______________ 17003675
Table drilling...........................................................................Omera Draw. no. ____________ 4P1AG1MF
Slide drilling ...........................................................................Omera Draw. no. ______________4X1A9B00
Oil-hydraulic system diagram...................................................Omera Draw. no. ______________S3020300
Electric system diagram..........................................................Omera Draw. no. _____________ 031BGF01

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 6
2.1 TEST AND INSPECTION DATA (ACCORDING TO SCHLESINGER STANDARDS)
Drawing Subject of measurement Maximum
tolerance mm Measured data mm
Flatness of lower face of slide with respect to the
table on the plane of symmetry of the machine.
(The slide can only lean forward)
For machines with up to a maximum pressure of:
Up to 50T.
from 50 to 250 T.
over 250 T.
0,03/300
0,05/300
0,08/300 0,015/300
As above but on the perpendicular plane
For machines with up to a maximum pressure of:
Up to 50T.
from 50 to 250 T.
over 250 T.
0,03/300
0,05/300
0,08/300 0,03/300
Perpendicularity of the direction of slide movement
with respect to the table on the plane of symmetry of
the machine.
For machines with up to a maximum pressure of:
Up to 50T.
from 50 to 250 T.
over 250 T.
0,03/300
0,05/300
0,08/300 0,03/300
As above but on the perpendicular plane
For machines with up to a maximum pressure of:
Up to 50T.
from 50 to 250 T.
over 250 T.
0,03/300
0,05/300
0,08/300 0,018/300

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 7
3. EXPECTED USE CONDITIONS
3.1 BEFORE OPERATING THE MACHINE
Before carrying out any installation operation and/or using the machine, the instructions in this manual should
be read thoroughly and adhered to. Current regulations relating to accident prevention and safety in the
workplace should also be observed.
The warnings given to safeguard personnel working on the machine are classified in this manual under special
headings, the meaning of which is given below:
NOTE: this introduces important information relating to the product, the use of the product or part of
this manual which demands special attention.
CAUTION: this means that minor injury or damage may result if the relevant safety regulations are not
observed.
DANGER: this means that death, serious injury or damage may result if the relevant safety regulations
are not observed.
In order to quickly identify the type of professional person who has an interest in reading this manual, the
following symbols have been used:
OPERATOR: the person in charge of operating the machine for production
purposes.
The operator is familiar with the measures taken by the
manufacturer of the machine to eliminate sources of safety
hazards in the workplace and observes the operation rules.
HOOK-UP MAN: The person in charge of handling the machine or parts of the
machine. The hook-up man is aware of the possible difficulties
regarding the safe transportation of the machine or parts of the
machine; for this reason adequate lifting equipment should be
used, in compliance with the instructions supplied by the
manufacturer of the machine.
FITTER: the person in charge of preparing the machine for normal
operation. The fitter is familiar with the measures taken by the
manufacturer of the machine to eliminate sources of safety
hazards in the workplace and observes the operation rules. The
fitter should take the necessary precautions so that he is
working in totally safe conditions.
MAINTENANCE ENGINEER: the person in charge of carrying out maintenance on
the machine. The maintenance engineer is aware of possible
hazards that may arise during his work and takes the necessary
precautions to prevent the risks of accidents in the workplace.
ELECTRICIAN: the person in charge of carrying out maintenance operations on
the electrical system of the machine. The electrician is aware of
possible hazards that may arise during his work and takes the
necessary precautions to prevent the risk of accidents in the
workplace.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 8
3.2 DESCRIPTION OF THE MACHINE
The "OPI" oil-hydraulic presses with two uprights are composed of the following parts:
Structure: made of welded sheet metal, in thickness required for maximum rigidity.
Before being machined, the structure undergoes heat treatment and sand-
blasting in order to eliminate residual internal stress.
The machine has a monolithic structure.
Slide: made of welded steel plate which has undergone heat treatment.
The guide action is provided by eight lubricating sliding blocks equipped with a
device for the take-up of play.
The lower surface has T-shaped milled grooves to accommodate the dies.
Table: made of extra-thick steel to prevent bending, it has T-shaped milled grooves
and holes to accommodate the blank-holder pressure pins.
Cylinder: made of steel, in single-piece casting, internally ground and lapped.
Piston: made of ground and tempered steel.
The piston is guided by special bronze bushes.
The piston is sealed by means of a series of gaskets.
Blank holder cushion: with oil-hydraulic operation, is made up of one steel cylinder fitted under the
table fastened to the press.
The blank-holder table slides on ground and hardened steel columns.
The force of the blank holder can be adjusted.
Oil-hydraulic unit: mounted on the machine top and includes: an oil tank, variable delivery piston
pump with constant power regulator and driven by an electric motor; filling and
quick exhaust valve with wide port; down-stroke control blocks and safety
devices using logical elements.
In addition, the motor pump unit for the low pressure auxiliary circuit is used to
pilot the valves and cool the oil.
Cycle cams the intervention sequence of the solenoid valves which control the slide and
blank holder is governed by a programmable electronic device which detects
the position of the two mobile elements by means of a wire encoder.
Electric control panel built in compliance with current accident-prevention regulations and contains
all the electrical equipment for the operation, control and protection of the
machine as well as the safety of the operator.
All the components in the electrical and oil-hydraulic systems are supplied by
top-quality brands, guaranteeing their reliability and availability in the event of
replacement.
Control and adjustments: the machine is equipped with a hanging push-button board which contains the
start and motor stop buttons, with corresponding indicating lights, and the
selector for choosing the press work cycle (adjustment cycle or single cycle).
The different machine devices are operated using the INDUSTRIAL PC.
Moreover indicators are fitted to signal the main causes of malfunctioning.
The control console which accommodates the slide and blank holder up/down
movement push buttons is located on the front part of the machine.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 9
3.2.1 ACCESSORIES
Illumination of the work area: the press can be equipped with a lighting system in the work area
connected to the electrical system of the machine.
Die locking and lifting: the machine can be equipped with an oil-hydraulic unit complete with
check and control elements to automatically lock and release the die.
With the same unit it is possible to control the die lifting device fitted on
the table.
Automation interface: when the machine is loaded automatically by a sheet metal feeder the
electric system needs to be modified to permit a perfect interfacing
between the two machines.
DANGER: Even if the machine is prearranged for the connection of one automatic sheet metal feeder,
as in this case, the safety barriers must be modified/adapted by the user according to the
new use of the press.
With this respect, we recommend to carry out any modifications in keeping to the
Harmonised European Standard EN 294 “Safety of machinery - Safety distances to prevent
danger zones being reached by upper limbs.
Oil-hydraulic knockout on request, the press can be equipped with an oil-hydraulic knockout
fitted inside the slide piston. The main function of this device is to
ensure the removal of the drawn piece from the upper part of the die
during slide upstroke; upon request it can be also used as a cushion
with “THIRD EFFECT” during slide downstroke and after some adequate
modifications have been made.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 10
3.3 MACHINE USE
The "OPI" oil-hydraulic presses with two uprights are usually double-effect machines with slide and cushion
control; they are used to blank, coin and draw steel plates into shapes and sizes which should be in line with
the technical specifications of the relevant model.
For further information regarding the above, refer to the machine test certificate at the beginning of this operation
and maintenance manual.
DANGER: The press is not intended for machining materials which can entail risks of parts being flung
about.
There is only one planned working position for the manual loading and unloading of the piece and this is located
at the front of the machine where the control console complete with safety distance ring is situated.
The machine has been designed to be operated by only one operator.
DANGER: It is forbidden to operate the machine if other people are in or around the machine danger zone.
The control console should be positioned so that the operator can control the slide and the blank-holder
cushion in safe conditions.
To prevent the operator from entering the machine danger zone from the front, a spacer ring is attached to the
control console; the dimensions of this ring depend on the stopping time of the slide measured during the rapid
downstroke movement.
DANGER: It is forbidden to remove the spacer of the control console.
To prevent the access of the operator from the back, these machines have a (standard) pneumatically
controlled mobile guard in the lower part, governed by electrical limiting devices. In the upper part there is a
fixed guard which can be controlled (as an optional) by a safety liming device.
The 53SA21 selector is used to deactivate the mechanical movable barrier located on the back of the machine
during any operation mode (adjustment, single and automatic). In this case, protection to the operator on the
rear side is provided (by the user) by a set of fixed barriers with access gates (with opening controlled by safety
limit switches).
The guards installed by the user must be constructed and checked according with the following standards in
force:
EN292-2 Safety of machinery - Fundamental concepts, main design principles. Part 2: technical principles
and specifications.
EN294 Safety of machinery - Safety distances to prevent danger zones being reached by upper limbs.
EN953 Safety of machinery - General requirements for designing and constructing (fixed, mobile)
projectors
EN1088 Safety of machinery - Safety of machinery - Blocking and interlocking devices - General principles
and design requirements.
To prevent the operator from entering the machine danger zone from the side, the oil-hydraulic presses with two
uprights are fitted with fixed mechanical barriers controlled by limit switches. Closing position is controlled by
two safety limit switches.
DANGER: It is forbidden to remove the fixed guards or tamper with the mechanical barrier limit switches.
The oil-hydraulic presses with two uprights are provided with an automatic slide hooking device which locks the
slide downstroke due to its own weight when the machine is unattended.
To use this device, refer to chapter “USE CONDITIONS”.
DANGER: Any operations except for piece loading / unloading carried out inside the danger zone of
the press depends on the correct use of the slide locking device and the main pump stop.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 11
3.4 RECOMMENDED FLUIDS
The "OPI" OIL-HYDRAULIC presses have been designed to operate with ESSO NUTO H 46 oil.
If other lubricants are used, check that they have the same characteristics as those described in the
comparative oil tables given below.
Oil type ESSO NUTO H46
Degree of viscosity ISO 46
Density 15/4°C 0,874
Flash point V.A. °C 216
Viscosity St/40°C 44,7
Viscosity cSt/100°C 6,74
Viscosity E°/50°C 3,9
Viscosity 104
Aniline point °C 102
Pour point °C -31

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 12
4. TRANSPORTATION CONDITIONS
The “OPI-N” oil-hydraulic presses with two uprights are already completely assembled on delivery and for the
handling of these, special lifting attachments have been fitted to the upper part of the machine.
The tables below contain the weights of the parts of machine; the user should consult these tables for the type
of lifting means to use and the correct lifting capacity.
NOTE: The total weight indicated for each model has been calculated with empty oil tank.
The following tables are filled in at the time of machine delivery after the weighing of each
individual part.
Type OPI 315
Kg
Total weight 29000
Slide weight 3000
Table weight 3100
DANGER Lifting equipment in line with current safety regulations should be used, especially chains
and cables which should have the "CE" mark of approval.
4.1 EQUIPMENT NECESSARY FOR MONOLITHIC PRESS HANDLING
(to be supplied by the customer):
?4 supporting shims (only if the blank holder unit is protruding) with the following characteristics:
height ............mm (depending on the extent to which the blank holder protrudes from under the press),
base of (300x300)mm is in iron,
or base of (500x500)mm in hard wood.
?4 chains with lifting hooks with a capacity suitable for handling the load.
?2 iron eyebolts suitable for handling the load or with the shape and dimensions given in fig.1.
fig. 1
?2 bolts with a length of 180mm and a diameter of 40mm to fasten the eyebolts to the press feet.
300
60
100
=
=
120
50
60
600

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 13
4.2 PROCEDURE FOR UNLOADING FROM THE MEANS OF TRANSPORT
The machine is transported lying on its side, therefore, proceed as follows to unload the machine:
?fasten the two eye-bolts to the feet “1” (front and back), using the 40mm diameter bolts.
?attach the lifting chains to these eye-bolts and to the lifting points “2” of the head (front and back), making
sure that they are tightened correctly.
?unload the press from the lorry, lying it on the same side, onto the four resting shims which have already
been positioned near to the machine pit. Make sure that the machine’s parts are not damaged during
handling (e.g. oil-hydraulic pipes, electric cables, motors, etc.).
?position two of the four shims near to the feet “3” so that the press can be straightened by pivoting on these
shims.
?unhook the chains from the two eye-bolts fastened to the feet “1” and then remove the eye-bolts as well.
?straighten the press slowly using the four chains hooked, in groups of two, to the lifting points of the head
“2” (front and back) and by pivoting on the feet “3”.
?before straightening the press completely, place the other two shims (now freed from the weight of the
machine) under the feet “1” so that the blank-holder unit protruding in the lower part is not damaged.
?once the machine has been straightened, hook the chains to all four lifting points of the head (“2” and “4”,
front and back) and place the machine in the foundations.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 14
5. INSTALLATION CONDITIONS
For correct positioning of the machine, the instructions contained in the overall dimensions and foundation
drawing should have been followed. This drawing should have already been supplied to the customer but is also
included at the beginning of this manual.
Installation and commissioning are usually carried out by Omera technicians.
As far as possible, the machine should be installed away from possible sources of electromagnetic interference
(such as welding equipment) and a sufficient amount of space should be left around the machine for routine and
extraordinary maintenance.
The line which supplies electric power to the machine should not undergo variations in voltage which are outside
the range allowed by current regulations.
The area used for manual loading and unloading of the pieces is at the front, so sufficient space should be
allowed for machine use in accordance with safety regulations.
5.1 INSTALLATION OF PRESSES WITH MONOLITHIC STRUCTURE
To install the machine, proceed as follows:
?Position the base (C) on the supporting plates (1) of the
foundations (P) making sure that the holes match the
anchoring bolts which are sunk into the foundation.
?Use the appropriate grub screws (3) to level the base.
?Fill any gaps remaining between the base feet (5) and the
anchor plates (1) with sheet metal shims (2).
?Tighten the log bolt nuts (4) and make sure that the machine is level.
?Attach the removable casings of the electrical connectors to the respective fixed casings; this operation is
aided by the presence of reference marks.
NOTE: After the first 6 months of operation check that the machine is level.
1
2 3 4
C
P
5

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 15
5.2 FILLING OF OIL TANK
First check that the oil-hydraulic circuit is as it should be and that the drainage tap is closed. Then fill the oil
tank.
CAUTION: The instructions given below must be followed otherwise the pump may not be primed and
therefore could be seriously damaged if activated.
1. Open the breather cap and the filler cap (if fitted) located on the head near the pump; the cap is painted red
for easy detection.
2. Fill the tank with ESSO NUTO H 46 oil until the normal level is reached, using a mesh filter with a filtration
rating of 10 µ. After having filled the tank, fill the pump with oil (only if the pump itself is fitted with a filler
cap).
3. After having made sure that the machine is disconnected from the electricity mains, remove the cover of the
fan located on the main motor.
4. Manually turn the motor clockwise until the pump is primed (priming is indicated by an increase in the
resistance of the motor to manual rotation).
5. Refit the fan guard and replace the breather cap and the filler cap (if fitted) making sure that this is correctly
sealed.
5.3 CONNECTION TO THE ELECTRICAL MAINS SUPPLY
CAUTION: Before carrying out any connection to the electrical mains supply, check that the voltage
available on the installation premises is the same as the voltage indicated on the machine
test certificate.
OMERA does not normally supply the general protection device against short-circuits and overloading; this
device should be installed by the user in proximity to the machine and should be capable of sustaining the
maximum current required by the load.
DANGER: The following operations should be carried out with the voltage disconnected.
The cable, which connects the machine to the three-phase electrical mains supply, is inserted into the control
panel through the opening in the bottom and brought to the terminal board where the power terminals L101,
L102, L103 are available. Once the connection has been made, fasten the plastic cases over the terminals in
order to avoid accidental direct contact with the parts supplied with voltage.
The installed electric power and the cross-section of the electric connection cable are stated on the test
certificate attached to this manual.
Furthermore the earth wire of the premises (PE) should be connected to the earth bar in the electric control
panel.
Once the connection to the three-phase electrical mains supply has been carried out and the auxiliary circuits
have been supplied with voltage by using the controls on the push-button board, motor rotation should be
activated to check that the rotation direction is correct (clockwise); if the motor turns anticlockwise, the two
phases of the power line (L101, L102) should be inverted, observing the recommendations above.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 16
5.4 ILLUMINATION OF THE WORK AREA
When the lighting has to be installed for the work area of the machine and the same electricity line as the line
which supplies the press is to be used, then cabling needs to be carried out inside and outside the electric
panel, in compliance with the relevant technical and work safety standards.
Particular attention should be paid to the following points:
?supply the lights with low voltage using an isolation transformer protected by fuses;
?carry out the earthing of a terminal of the transformer’s secondary winding and the earthing of any metallic
parts outside the electric panel (if necessary install an automatic differential circuit-breaker);
?protect the electric cables located outside the electrical panel with a metallic sheath for industrial use.
?use filament lamps;
?do not use fluorescent lights to avoid stroboscopic effects.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 17
6. OPERATION CONDITIONS
The "OPI" oil-hydraulic presses with two uprights are prepared for normal functioning by using the following
three separate control units:
?Electric controls.
?Oil-hydraulic controls.
?Cycle cams.
6.1 ELECTRIC CONTROLS
The machines are equipped with a hanging push-button board and a control console located in the manual
loading and unloading area.
6.1.1 MACHINE SETTING CONTROLS
The hanging push-button board contains the warning lights indicating anomalous conditions, the cycle set
switches and the main emergency mushroom button.
The functions of the various buttons and switches are given below:
"AUXILIARY CIRCUITS" (51SA1) key switch: in position <1> this switches on the auxiliary circuits of the
machine.
"START AUXILIARY CIRCUITS" (51SB2) luminous white button: if pressed, this switches on the auxiliary
circuits of the machine. The light "51SB2" indicates that the auxiliary circuits supplied with 24V DC are
switched on (power supply to power relays and auxiliaries).
"STOP AUXILIARY CIRCUITS " (51SB1) red button: when pressed this stops the main pump and de-activates
the auxiliary circuits of the machine.
"START AUXILIARY MOTOR " (51SB3) luminous green button: when pressed this starts the auxiliary pump
motor.
"STOP AUXILIARY MOTOR " (51SB4) red button: when pressed this stops the rotation of the auxiliary pump
motor.
"START MAIN MOTOR " (51SB6) luminous green button: when pressed this starts the main pump motor.
"STOP MAIN MOTOR " (51SB5) red button: when pressed this stops the rotation of the main pump motor.
"FUNCTIONING MODE" (52SA3) key switch: this allows the different press functioning modes which are
adjustment cycle, single or automatic cycle to be selected. When in position <0> the slide and the cushion of
the machine cannot be activated.
"RESET" (51SA2) key switch: this allows to re-activate the operation of the press after a slide overstroke alarm
has been given.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 18
"ALARM" (111HL5) red warning light: it indicates that the machine cycle is blocked; the cause of such a failure
is shown in the display of the service panel.
"STOP" (56SB30) mushroom red push button with mechanical lock: when pressed, it stops the movements of
the slide and blank holder.
"FRONT PROTECTION SELECTION" (53SA20) key selector: used to select press front protection represented
by a photoelectric barrier (left-hand position) or by a line mechanical barrier (right-hand position) – not used -.
"REAR PROTECTION SELECTION" (53SA21) key selector: used to select press rear protection represented
by a movable mechanical barrier (left-hand position) or by a line mechanical rear barrier (right-hand position).
"OPERATION OK" (119SB50) blue luminous button: it is used to confirm that the operation previously started
with the INDUSTRIAL PC has been completed; it is particularly used during “automatic die change” and for all
those operations performed by the machine that require the supervision of the operator to be considered as
correctly performed.
“EJECTOR ENABLING” key selector (57SB40): when turned towards the right it enables ejector downstroke in
the adjustment cycle mode. To command slide downstroke in the adjustment cycle mode, it must be turned
towards the left.
111HL5 51SB5 51SB6
51SA2
51SA1
51SB3 51SB4
51SB1 51SB2
57SB40 56SB30
52SA3
53SA20
119SB50
53SA21
CONTROLS POSITIONED ON THE ELECTRIC PANEL DOOR
"START/STOP UPS" (102S100) key selector: when turned to the right for a few seconds (after connecting the
auxiliary circuits to the power supply and starting the oil-hydraulic pump motors), it connects the INDUSTRIAL
PC to the power supply.
When turned to the right for a few seconds (after completing the computer switching off procedure), it
disconnects the INDUSTRIAL PC from the power supply.
White "220V-INPUT" (102HL1) warning light: indicates that the 220V-AC electrical line which supplies the
INDUSTRIAL PC is connected to the power. When this light goes out, the industrial PC switching off procedure
must be carried out within a few minutes.
Yellow "220V UPS" (102HL2) warning light : indicates that the INDUSTRIAL PC is correctly supplied with
power.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 19
CONTROLS ON REAR UP-RIGHT
"REAR BARRIER RESET” (54SB8) luminous blue button: it is used to reset the operation of the mobile rear
mechanical barrier after the operator has entered the danger zone of the press.
The "BARRIER RESET" (54SB8) blue warning light, indicates that the mobile rear mechanical barrier must be
reset by pressing the “REAR BARRIER RESET” blue push button on the rear up-right.
NOTE: To prearrange the operation the different press devices please refer to the programming
manual of the INDUSTRIAL PC.
6.1.2 CONTROL CONSOLE
DANGER: The main control pulpit has to be positioned exclusively on the front of the press and has to
be used in order to ensure the manual loading and unloading by the main operator.
The functions of the various buttons are given below:
"CYCLE START" (55SB8 + 55SB9) black mushroom buttons: if pressed at the same time, they control the
downstroke of the slide, provided that adjustment or single operation has been chosen using the relevant
switch.
"SLIDE UP" (108SB14) green button: when pressed this activates the upstroke of the slide up until the T.D.C.
cam; the function switch should be set to die change, adjustment cycle or single cycle position.
This command operates even when the “CYCLE STOP” mushroom push button is pressed, the barriers are
open and the luminous beam of the photoelectric barrier is interrupted.

OIL-HYDRAULIC PRESSES WITH TWO UPRIGHTS
OPERATION AND MAINTENANCE MANUAL 20
"KNOCKOUT DOWN” (57SB20) green button: when pressed this activates the downstroke of the knockout
cylinder as far as the end-of-stroke position; the function switch should be in adjustment position.
To command ejector downstroke, it is necessary that the slide is at TDC and ejector operation is enabled (see
“EJECTOR PROGRAMMING” page); furthermore, the “EJECTOR ENABLING” selector located on the control
push-button panel must be turned towards the right.
"BLANK-HOLDER UP" (108SB15) green button: when pressed this activates the upstroke of the cushion up
until the T.D.C. cam; the functioning switch should be in adjustment position.
"BLANK-HOLDER DOWN" (108SB16) green button: when pressed this activates the downstroke of the cushion
as far as the end-of-stroke position; the function switch should be in adjustment position.
“DIE PISTON” (113SA5) key selector: when turned to the left, it controls permanent activation of the device
which is used to drill the drawn piece at the end of the presswork operation (all pieces are punched); when
turned to the right, it controls permanent deactivation of the device which is used to drill the drawn piece at the
end of the presswork operation (no pieces are punched); when in mid-position, it provides alternate control of
the device which drills the drawn piece at the end of the presswork operation (one piece is punched and the
next not punched).
"STOP" (56SB10) red mushroom button with mechanical lock: when pressed this causes the slide and blank
holder to stop immediately.
The control console is equipped with a spacer ring which prevents the operator from reaching the danger zone
of the machine during operation.
DANGER: It is forbidden to use the control console of the press without the safety spacer ring.
The downstroke of the slide in adjustment or single work cycle only takes place if the operator keeps the
"CYCLE START" buttons pressed down at the same time.
DANGER: It is forbidden to tamper with the electro-mechanical devices which are used to ensure the
contemporaneous activation of the "CYCLE START" buttons. It is also forbidden to carry out
alterations intended to eliminate the need to keep these buttons pressed down by hand.