SAS Stampex 6+ User manual

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INSTRUCTIONS MANUAL
FOR USE AND MAINTENANCE
OF THE MACHINE
SOAP PRESS TYPE:
STAMPEX 6 +
SERIAL NUMBER: 133/07.
CONSTRUCTION YEAR: 2007.
CUSTOMER: UNILEVER
CUSTOMER: Bangladesh.
ORDER N.: our proforma invoi e n. 001/07
ORDER N.: and offer n. 6556/06 – B.

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INDEX
1. PARTICULARS AND SAFE USE OF THE PRESS........................................................ 4
1.1. PREAMBLE.
1.2. INTRODUCTION.
1.3. GENERAL SAFETY RULES.
1.4. SAFE USE OF THE MACHINE.
1.5. DANGER CONDITIONS FOR THE OPERATOR.
1.6. EMERGENCY SITUATIONS.
1.7. GUARANTEE.
1.8. NOTES FOR THE EMPLOYER.
2. WORK SITE LAYOUT ............................................................................................ 14
2.1. DANGER ZONE LAYOUT.
2.2. OPERATOR AND MAINTENANCE MAN ZONE LAYOUT.
3. TRANSPORT, INSTALLATION AND SETTING UP .................................................. 16
3.1. PACKING AND STORING.
3.2. ACCEPTANCE.
3.3. HANDLING.
3.4. PREARRANGEMENT FOR A CORRECT INSTALLATION.
3.5. NEEDED SPACE FOR INSTALLATION.
3.6. PREARRANGEMENT OPERATIONS.
3.7. ACCEPTANCE TEST AND DELIVERY.
3.8. SCRAPPING.
4. FORESEEN USE CONDITIONS AND TECHNICAL SPECIFICATION .................... 33
4.1. PURPOSE AND USE OF THE MACHINE.
4.2. TECHNICAL SPECIFICATIONS OF THE PRESS.
4.3. GENERAL FEATURES.
4.4. OPTIONALS.
4.5. COMPONENTS AND COLOURS.
4.6. INFEED SOAP CHARACTERISTICS.

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. PUSH-BUTTON PANEL AND USE OF THE PRESS .................................................. 43
5.1. CONTROL PANEL.
5.2. START-UP.
5.3. MECHANICAL ADJUSTMENTS.
6. PNEUMATIC CIRCUIT .......................................................................................... 60
6.1. PRESSURE REDUCERS.
7. COOLING SYSTEM .............................................................................................. 63
7.1. CHILLER FOR COOLING.
7.2. CLEANING OF THE COOLING CIRCUIT.
8. MAINTENANCE OF THE PRESS ............................................................................ 66
8.1. ACCIDENT INSTRUCTIONS.
8.2. MAINTENANCE OPERATIONS.
8.3. PERIODICAL CONTROL AND PREVENTIVE MAINTENANCE.
8.4. SETTINGS OF THE ELECTRONIC CAM POSITIONER.
8.5. ELECTRONIC DEVICES.
8.6. RECOMMENDED SPARE PARTS.
9. DIMENSIONAL DRAWINGS AND SPARE PARTS ................................................. 78
9.1. PURCHASE ORDER FORM.
9.2. DRAWINGS LIST.
10. CE CERTIFICATION AND CONFORMITY OF SAFETY COMPONENTS ............. 79
11. ELECTRIC INSTALLATION .................................................................................. 80
12. ENCLOSURES ..................................................................................................... 81

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1. PARTICULARS AND SAFE USE OF THE PRESS.
1.1. PREAMBLE.
The instru tion manual:
-is an integral part of the ma hine;
-is the essential instrument for the use, the management and the maintenan e of
the ma hine;
-has to be onserved in optimal onditions for all the duration of the ma hine
and an be eliminated only after the s rapping of the same;
-has to be onsigned with the ma hine in ase the same is sold to another
ustomer.
1.2. INTRODUCTION.
This do ument has been prepared for the SAS press’s operators and for the
maintenan e men, it has been drown up in a ordan e to CEE 89/392 dire tive
and EN 292-2 p5 rule.
In this manual it is possible to find all ne essary indi ations for the use and
maintenan e of the ma hine.
It is ne essary to follow these dire tions to obtain an optimal effi ien y and a
orre t operation of the ma hine.
In the next paragraphs the following phases are dealt:
-handling
-installation
-des ription
-use
-maintenan e
to provide information, useful to maintain performan es of the SAS press.

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In ase of breakdown or fault, or for any need:
SAS MARIANI TOMMASO – ASSISTANCE SERVICE
di Mariani Pietro e Carlo s.n. .
via Tos anini, 46
p.o. box 17
20038 SEREGNO (MI) ITALY
TEL. ++39 0362 - 239 988
FAX ++39 0362 - 328 413
V.A.T. 02202570962
www.sasoap. om
is at disposal of his Customers.

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1.3. GENERAL SAFETY RULES.
The use of this ma hine is demanding, so it requests a good instru tion of the
operators, moreover the ma hine is manufa tured with high te hnology
omponents that require assistan e operators with spe ifi preparation.
So, the use and maintenan e of the press, request a ertain attention for the
interventions in the following zones:
-working zone
-infeed zone
-ele tri devi es
THE FIRST TWO ZONES CAN BE REACHED ONLY BY OPERATORS WHICH HAVE BEEN
EDUCATED TO THE SYSTEM USE AND ALSO INFORMED ON THE CONSEQUENCES DUE
TO AN IMPROPER USE AND INTERVENTION ON THE SYSTEM, WHILE:
INTERVENTIONS INTO THE ELECTRIC DEVICES ARE ALLOWED ONLY TO QUALIFIED
EXPERTS.
THE FOLLOWING PREVENTIONS RULES FOR CUSTOMER’S CARE ARE COMPULSORY:
-Maintain a urately free and lean the pla e of work;
-wear always personal prote tions means (CEE 89/686 e CEE 89/656);
-before starting to work, ontrol that all safety devi es are on and effi ient;
-during work, prote tions or guards have to be onne ted;
-IT’S ABSOLUTELY FORBIDDEN TO CLEAN THE ELECTRIC CONTROL PANEL OR ANY
ELECTRICAL EQUIPMENT UNDER VOLTAGE, WITH JET OF WATER;
-operators are obliged to signal to person in harge any defi ien y and/or
potential situation of danger that ould happen;
-the Customer has the duty to inform immediately the supplier in ase any
defe t and/or malfun tion of prote tion safety system are found. Same goes
for every situation of presumed danger that he dis overs;
-the ma hine an not be use in pla es with high ele tromagneti fields that
an ause an storage of stati harge;
-the level of ambient lighting should be su h to guarantee full fun tionality of
the plant with maximum safety. When performing maintenan e and related
a tivities limited to se tions and/or parts of the plant not suffi iently illuminated
it is obligatory to provide for a portable sour e of light, taking are to avoid
shadow zone that an interfere with above mentioned a tivities.

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1.4. SAFE USE OF THE MACHINE.
SAS has adopted all measures and attentions to draw,
manufa ture and define use pro edure of the press so
to ensure the highest safety degree during the use of
the system supplied.
The omponents are onformable to the re ent rules;
the up-dated safety devi es are assembled to ensure
the highest safety degree.
THE PRESS CAN BE USED ONLY BY EXPERT OPERATORS INSTRUCTED ON THE SAFE
FUNCTIONING.
1.4.1. DEFINITION.
OPERATOR = in harge of the fun tioning, adjustment and leaning of the press.
The operator must be expert of soap pro essing and properly instru ted on the
disposition, use and lo ation of the push-button panel and ontrol board of the
SAS press and also on the presen e and the use of safety devi es.
The operator must know in detail the fun tioning modes, the harge and
dis harge pro edures, the risks onne ted to the pro essing, damages to persons
and goods in ase of improper use, abuse and tampering of the SAS press and
foreseen safety devi es.
MAINTENANCE MAN = spe ialized me hani an/or ele troni prepared, trained
and instru ted on the SAS press in ase of fault or maintenan e.
MANUFACTURER’S TECHNICIAN = qualified te hni ian entrusted by the supplier to
exe ute ompli ated repairs under parti ular situations, in a ordan e wit the
ma hine sales ontra t.
WORK SITE = dangerous zone where, for safety reasons, the introdu tion of parts of
the body of people when the press is running is not allowed.
MAINTENANCE ZONE = when the SAS press is running, this zone an be rea hed
only by expert and instru ted maintenan e men.
OPERATOR’S ZONE = zone where the operator an stay while the SAS Press is
running, to ontrol the pro essing operations.

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1.4.2. PROTECTION COVER OF THE DANGEROUS ZONE.
The stamping area is the dangerous working zone.
The a ess at this zone is prevented by a prote tion devi e that doesn’t allow the
operator to insert parts of the body in the dangerous zone.
The prote tion devi e is omposed by a front door in lexan or poli- arbonate
(photo 1.3) fixed by hinges and positioned in front of the press, so to lose
ompletely the slide movement area.
A safety swit h prevents the fun tioning of the press with opened door.
The door must always be in position and the safety swit h must always be
fun tioning.
Modifi ations and tampering at the door and at his fun tioning ause the loss of
guarantee and the remission of any responsibility of the press’s manufa turers.
When the door is opened, the press motor is stopped by the brake and so all the
movements of the ma hine are stopped (you an keep a tive the va uum pump
and the harge onveyor belt by the proper settings on the tou h s reen).
Moreover, other lateral prote tion overs in lexan or poli- arbonate (photo 1.1,
1.2) fixed by s rews at the press basement prevent the insertion of operator’s body
parts in the dangerous zone.
Modifi ations and tampering at the prote tion overs ause the loss of guarantee
and the remission of any responsibility of the press’s manufa turers.
PHOTO 1.2
PHOTO 1.1

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NOTE.
MODIFICATIONS AND ELIMINATION OF PROTECTION COVERS AND SAFETY DEVICES,
FORESEEN BY THE SYSTEM, INVOLVE THE IMMEDIATE LOSS OF GUARANTEE.
SAS MARIANI TOMMASO CAN NOT BE CONSIDERED RESPONSIBLE FOR WOUNDS
OR DAMAGES OF ANY TYPE HAPPENED TO PERSONS FOR THE INTRODUCTION
OF PARTS OF THE BODY IN THE DANGEROUS WORKING ZONE,
WHILE THE PRESS IS WORKING, AND ALSO CAUSED BY IMPROPER USE
OR ABUSE OF THE SAS PRESS OR TAMPERING OF PROTECTIONS AND SAFETY DEVICES
OF WHICH THE PRESS IS SUPPLIED.
PHOTO 1.3

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1. . DANGER CONDITIONS FOR THE OPERATOR.
The press is fed by an ele tri harge onveyor belt, so the
feeding is automati .
Please note that when the machine stops because there isn’t any soap billet on the
infeed conveyor (when the function “INFEED PHOTOSWITCH” on the touch screen is
set as “ON”), it will automatically restart when a soap billet is detected by the
photoelectric switch on the infeed conveyor.
The automatic restarting of the machine is
signaled by an electric buzzer, and you can add
other electric signal devices by connecting their
command-relays (max 200 mA) to the terminal
n.07 of the PLC output module U16.1 (photo 1.4)
inside the control panel.
Consult the electric diagram for this operation.
INTERVENTIONS INTO THE ELECTRIC DEVICES ARE
ALLOWED ONLY TO QUALIFIED EXPERTS.
PHOTO 1.4

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During the die- hange pro edure the operator has to wear prote tion gloves, to
avoid damages to himself.
The operator has not the authorization to insert parts of the body in the stopped
press during adjustment or start up, or keep s raps away.
SAS press is supplied with safety devi es and so the ma hine must and has to run
only with losed prote tion overs, but it would be opportune that the operator
has adapted tools (nippers et .) to eliminate eventual pro essing s raps.
Moreover all the transmission devi es are lo ated into the prote tion over fixed
by s rews.
In respe t to the rule CEI EN 60204-1, all ele tri devi es and related equipments,
grant prote tion against ele tri sho k aused by dire t or indire t onta t.
Prote tion against dire t onta t:
all the live parts are insulated inside en losures and have a total insulation.
Prote tion against indire t onta t:
all metalli parts are onne ted to prote tive bonding ir uit.
All ele tri prote tion omponents are installed into the ele tri ontrol panel,
that is prote ted against involuntary openings and dust.

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MOTOR BRAKE.
The motor of the ma hine ontains an ele tromagneti -spring brake.
When the ma hine is supplied with ele tri al power you an start the ma hine by
pressing the push-button “START”: the brake is disengaged and so the ma hine
an run but only if the door in lexan of the stamping area and the door of the
hand-wheel are losed.
When a prote tion over is opened, the brake will automati ally stop the motor to
avoid every movements of the ma hine.
ATTENTION:
WHEN THE BRAKE IS DISENGAGED, THE UPPER (RECIPROCATING) DIE CAN GO DOWN
BECAUSE OF ITS OWN WEIGHT.
SO, IN CASE OF INTERVENTIONS INSIDE THE STAMPING AREA, BE CAREFUL TO AVOID
ACCIDENTS.
1.6. EMERGENCY SITUATION.
There is no parti ular emergen y situation (i.e. fire, dangerous substan es
emission/loss), anyway it is ne essary to have a powder extinguisher for eventual
fire situation (oil, ele tri equipment).

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1.7. GUARANTEE.
1.7.1. SAS PRESS CONFORMITY.
The manufa turer delivers the ma hine in a ordan e with the aim of the order,
and free from defe ts that ould make them not suitable at the foreseen use.
1.7.2. GUARANTEE EXTENSION.
The supplier guarantees the ma hine for a period of 12 (twelve) months from the
date of shipment, under following modes and onditions (unless otherwise
stipulation in the ontra t).
1. During the period of guarantee, the supplier shall repair and repla e free of
harge parts broken be ause of defe ted materials or bad workmanship.
Eventual spare parts will be sent by supplier.
2. Manufa turer and Supplier have no responsibility of breakdown or defe ts of
onformity, and of materials, software, semi finished produ ts, omponents and
any other produ t in orporated or not in the SAS press, supplied, indi ated or
requested by the Buyer or by Third persons.
3. Seller shall have no responsibility for materials of onsumption and/or periodi
maintenan e, omponents subje t to normal wear and tear damaged
be ause of bad maintenan e and/or improper use (belts, seals, fuses, brushes
et …).
4. Manufa turer and Seller shall have no responsibility for breakdowns and defe ts
due to or arising from the non-observan e of the riles foreseen by the instru tion
manual, from wrong or improper use of the press, repair or modifi ations made
at the ma hine, without the written agreement by the supplier.
5. In ase of delivery of disassembled ma hines, that have to be assembled by the
Supplier, any guarantee an be onsidered de lined if the assembling in
Buyer’s fa tory is not made dire tly by the manufa turer or under ontrol of his
spe ialized te hni ians.
6. Reparations and repla ements, out of guarantee, are to take pla e at buyer's
premises. The supplier will invoi e the ost of intervention based on private daily
rate to buyer.
7. Components and equipment installed on the plant but not produ ed dire tly
by the supplier, has the guarantee of the pertinent produ er.
8. After the period of guarantee, eventual te hni al assistan e, spare parts and all
related ost of labour, travel/transfer of staff and materials will be invoi ed at
prevailing daily rate.

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1.7.3. MANUFACTURER’S RESPONSIBILITY.
After the installation of the ma hine in the working site, any damage happened to
persons or things (also when they are parts or parti ulars of the SAS Press) is at
harge of the Buyer.
The Buyer has to insure any eventual residual risk added after the installation of the
ma hine (L.D. 626).
1.8. NOTES FOR THE EMPLOYER.
The operator has to know also the rules in for e on erning the prevention of
a idents. The employer is responsible of the divulgation of this do ument to all
staff operators that are urrently intera ting with the ma hine. He has to make
sure that su h safety instru tions will be read and understood, and that they will be
applied for the use and maintenan e of the ma hine. This is an aid to avoid any
damage to persons or to the ma hine.
We take are in the realization and ontrol of this manual so that all information is
omplete, pre ise and up-dated.
SAS MARIANI TOMMASO an not give you any guarantee on the performan es
and results obtained from the use of this do uments, neither an be onsidered
responsible of damages and benefits aused by the improper use of these
do uments and of relative devi es.
SAS MARIANI TOMMASO an not guarantee that modifi ations to devi es or
softwares supplied by Third, will be ompatible to the information ontained in this
manual and will not modify instru tion and data.
This do umentation is stri tly reserved and has to be divulgated only to persons in
onta t with devi es dis ussed in the manual.
No part of this do ument an be opied, re-produ ed or saved in files, translated
or re orded, without approval of SAS MARIANI TOMMASO.

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2. WORK SITE LAYOUT.
2.1. DANGER ZONE LAYOUT.
The dangerous zone is the dashed one (figure 2.1): none an stay in this zone
when the press is working in automati mode.
FIGURE 2.1

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2.2. OPERATOR AND MAINTENANCE MAN ZONE LAYOUT.
The operator and maintenan e man zone is the dashed one (figure 2.2). It is an
area of about 1,5 meter in front of the ma hine, and 1 meter from the other sides.
Only the operator and the maintenan e man are permitted to stay in this zone
when the press is working or during the maintenan e interventions.
FIGURE 2.2

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3. TRANSPORT, INSTALLATION AND SETTING UP.
3.1. PACKING AND STORING.
Before pa king, all the parts not painted are overed with antirust and antioxidant
produ ts, while the breakable parts are prote ted by plasti pa king material. The
pa ked and well preserved material, an be stored for a period of two years
approximately in a overed area where the temperature ranges between –15°C
and +45°C with a relative moisture of 80%. Different environmental onditions need
a spe ifi pa king.
For ea h type of material pa king, you have to dispose it a ording to laws
prevailing in the ountry of destination.
3.1.1. PACKING FOR LAND TRANSPORT.
In ase of land transport, the press is fixed on a square wooden frame, prote ted
by a plasti over, while the a essories are pa ked in prote ted ases. It is also
possible to put the press dire tly on the vehi le and the a essories on a pallet.
3.1.2. PACKING FOR SEA TRANSPORT.
In ase of sea transport and foreseeable storing, the press with his a essories is
pa ked in wooden ases with the walls overed by tar paper. The ase top is
overed by galvanized sheet iron.
The onstru tion features of the ase require a sturdiness that permits eventual
sta king. To open a pa king ase, keep away the top, then the side walls and the
plasti over.
NOTE: THE CASES HAVE TO BE MOVED BY AN ADEQUATE CRANE.

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3.2. ACCEPTANCE.
It is ne essary to plan an adequate area with a flat surfa e for unload and
assembling operations.
If the ases or the materials, delivered by the Carrier, present signs of damages,
the Consignee must notify to the Carrier the obje tions with due reservations.
Before to a ept the goods, the Consignee must put down in writing the
obje tions on delivery note, with date and signature of the representative, and
send a opy by fax to the Manufa turer.
If Insuran e has been hosen and onta ted by the Manufa turer, he has to
provide to onta t the Insuran e Company for sending the expert to determinate
damages and responsibilities. The obje tions have to be reported at the moment
of a eptan e of the goods also in ase of doubt for hidden damages.
If Insuran e has been hosen and onta ted by the Buyer, he has to provide to
onta t the Insuran e Company for sending the expert to determinate damages
and responsibilities. He has also to send to the Manufa turer opy of the obje tion
by fax. The obje tions have to be reported at the moment of a eptan e of the
goods also in ase of doubt for hidden damages.
Before to move the press to the pla ing point, it is ne essary to he k that there
are all the omponents as indi ated in the pa king list. If the supply is not
omplete, please send us a written obje tion with all the missing parts of the
pa king list.
If the Consignee note damaged parts ontained in the ases, aused by pa king
errors and happened during transportation of normal working, please inform
immediately the Manufa turer and the Carrier. Prepare a te hni al report
in luding sket h or photos, to fa ilitate omprehension and the preparation of the
report for the insuran e over, by the ontra tor of the Insuran e ontra t, asking
for the damages evaluation by an expert.

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3.3. HANDLING.
3.3.1. CRANE HANDLING.
In its upper part, the press is provided with lifting hooks (see drawing).
USE SUPPLIED HOOKS.
USE FLEXIBLE ROPES
HOMOLOGATED AND CONTROLLED,
WITH SUITABLE MINIMUM CAPACITY
FOR THE WEIGHT TO LIFT
DO NOT USE CHAINS
PRESS WEIGHT: ABOUT 6000 KG
3.3.2. FORKLIFT TRUCK HANDLING.
In the lower part of the ma hine there is a spa e for the forks introdu ing of the
forklift tru k (see drawing), so the press an also be moved with a forklift tru k of
suitable apa ity.

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3.3.3. HANDLING BY ROLLS.
It is an emergen y handling. It is possible only if the ma hine is
bolted on the wooden frame or on the bottom of the ase and
if the displa ement happens on a flat surfa e (not on in lined
floor).
During the displa ement it is ne essary to avoid rough
movements or impa ts and keep under ontrol the press, espe ially if the floor is
not perfe tly flat: grip wedges have to be ready for an eventual un ontrolled
displa ement of the press.
NOTE: this is a high risk operation, to be used only in emergency cases by expert
operators, conscious of risks.
3.4. PREARRANGEMENT FOR A CORRECT INSTALLATION.
To obtain the best operational results, the environment where the press will be
pla ed must have the following hara teristi s:
-Clean pla e and without dust
-Flat floor, steady, with anti-dust paint, without vibrations to fix the press.
-Environment with suitable ventilation
-Environment insulated by ele tro-magneti fields produ ed by ele tri devi es
(for example indu tion furna e, transformer or big ele tri motors, high
frequen y instruments, et .) that an produ e an irregular fun tioning of the
ontrol devi es
-Fa tory provided with power supply so ket with grounding ir uit in relation with
safety rules in for e in installation Country.
The equipment needs the following hara teristi s:
-Ele tri onne tion: 400 Volts, 50 Hz;
-Installed power: 10 KW;
-ompressed air: 150 litres/minute (va uum pump: ele tro-me hani al);
-temperature: - 10ºC / + 40ºC;
-moisture: 40 / 80%.
3. . NEEDED SPACE FOR INSTALLATION.
Main dimensions of the equipment are indi ated in the ma hine layout (see
hapter 9).