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.