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