Schmidt HydroPneumaticPress User manual

Translation of the Original-Assembly instruction
SCHMIDT®HydroPneumaticPress
for press systems with force/stroke-monitoring

Further applicable documents
2SCHMIDT®HydroPneumaticPress 361-376 –V3.1
Further applicable documents
This instruction for use contains information about the delivered press. The
essential information includes the following:
Mounting and commissioning of the press
Operation and functions of the press
Maintenance and servicing of the press
Information describing the press system used, its design, operation and
maintenance is contained in separate instructions.
For further information, refer to the "Instructions for Use - SCHMIDT Manual
workstation" respectively the "Assembly Instructions - SCHMIDT
Components for automation".
Information describing the control and its design is contained in separate
instructions.
For further information, refer to the operating instructions of the control unit.
Information about the user interface of the control unit and the integrated
functions is contained in separate instructions.
For further information, refer to the "Operating Instructions –SCHMIDT PRC
HMI".
Order-specific information can be found in the "Technical Documentation".
These can include:
Declarations of conformity or incorporation
Test protocols
Spare parts lists
Circuit diagrams
© 2007 SCHMIDT Technology GmbH
All rights reserved. Technical changes reserved.
Edition and revision date:
V3.1 - 09/2021

Table of contents
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 3
Table of contents
1Safety..................................................................4
1.1 Designated use.....................................................................................4
1.2 Organizational measures of the owner.................................................4
1.3 Residual risks........................................................................................5
1.4 Noise emission of the press..................................................................6
1.5 Standards and regulations....................................................................6
2HydroPneumaticPress.......................................7
2.1 HydroPneumaticPress ..........................................................................7
2.2 Pneumatic block (optional)....................................................................8
3Assembly and start-up....................................11
3.1 Delivery ...............................................................................................11
3.2 Transport.............................................................................................11
3.3 Installation of the press.......................................................................12
3.4 Mounting tools.....................................................................................14
3.5 Adjusting the working height...............................................................16
3.6 Adjusting the working stroke...............................................................19
3.7 Connecting the compressed air..........................................................20
3.8 Setting the stroke takeover .................................................................21
4Maintenance and servicing.............................22
4.1 Checking the compressed air preparation..........................................23
4.2 Cleaning the press and the ram..........................................................23
4.3 Checking the ram guiding ...................................................................23
4.4 Checking the hydraulic hoses.............................................................24
4.5 Adjusting the force measurement.......................................................25
4.6 Checking the stroke sensor ................................................................25
4.7 Checking the oil level..........................................................................26
4.8 Check height adjustment ....................................................................27
4.9 Troubleshooting ..................................................................................28
4.10 Customer service................................................................................29
5Decommissioning and disposal.....................30
5.1 Decommissioning................................................................................30
5.2 Disposal ..............................................................................................30
6Appendix..........................................................32
6.1 Technical data.....................................................................................32
6.2 Pressure/Force diagrams....................................................................33
6.3Air consumption ..................................................................................34
6.4 Tightening torques ..............................................................................34

1 Safety
4SCHMIDT®HydroPneumaticPress 361-376 –V3.1
1 Safety
The press is designed and built in accordance with the valid safety
regulations and state-of-the-art methods and is tested for function and
safety. The press is/will be a component of the press system.
To ensure operational safety, note:
Chapter "Designated use"
Chapter "Organizational measures of the owner"
Chapter "Residual risks"
Chapter "Standards and regulations"
Independently of the indications specified in this manual, the current country
specific regulations regarding work safety and health protection are valid.
1.1 Designated use
The press can be used as follows:
As component in a SCHMIDT manual workstation during pressing
processes with manual loading and unloading.
OR
As part of a press system together with SCHMIDT components for
automation. In this case, the press system/tool has to be designed in
such a way that is not possible to reach into the hazard zone.
Any other use for any purposes other than those described above is
considered contrary to its designated use. The manufacturer cannot be held
liable for damages resulting from this.
Please do not make any changes to the components. The manufacturer
cannot be held liable for damages resulting from this. These changes are at
the sole risk of the owner.
Designated use also includes
compliance with the documentation and
compliance with the inspection and maintenance instructions of the
manufacturer
1.2 Organizational measures of the owner
The press may only be operated in technically perfect condition.
The instructions concerning start-up, operation and maintenance described
in this manual must be observed.
This manual must be stored within easy reach at the workplace.
The persons responsible for the work on the press must have read the
manual and, in particular, chapter "1 Safety" before starting work. This also
applies to persons who work on the machine only occasionally.
Manual
Personnel

1 Safety
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 5
The press must be operated, checked and maintained properly. The
competences for these operations must be defined clearly.
Use the press only if all the required protective devices have been installed
completely and are in a functional state. The protective devices must not be
bypassed or deactivated.
Depending on the working process, tool, size and work piece material, an
additional working area protection may be needed. The owner is responsible
for this.
According to the country-specific regulations, perform risk assessment and
take the appropriate safety measures if necessary.
1.3 Residual risks
Safe press operation requires proper interaction of press, control, pressing
tool, safety device(s) and action of the users in accordance with safety
procedures.
Certain places at the press cannot be protected without limiting the
functionality and usability of the press. Therefore, despite all constructive
safety measures, there is still a residual risk.
DANGER
Injuries or death caused by touching live parts
When carrying out assembly and maintenance work, you may come into
contact with parts that carry dangerous voltage during operation. Touching
live parts may cause death.
Any work on the electrical system or equipment must be carried out
only by trained electricians or by specially instructed persons under the
control and supervision of a trained electrician and in accordance with
the applicable electrical engineering rules and regulations.
WARNING
Risks for persons
When working with the press, the operator must not endanger
himself/herself or other persons.
Operate the press only if no other person is in the hazard zone.
WARNING
Risk of burns from heated parts
Press operations can heat up tools and workpieces. There is a risk of
coming into contact with the heated parts. This can result in burns to the
body. Heated parts can also cause fires.
Wear protective clothing.
Install an appropriate protective device.
Protective devices
Risk assessment

1 Safety
6SCHMIDT®HydroPneumaticPress 361-376 –V3.1
Further information regarding the safe operation of the press can be found in
the corresponding chapters of this manual.
1.4 Noise emission of the press
WARNING
Different noise emission values
Noise emission values determined according to the EN ISO 16092-1
(Machine tools safety - Presses - Part 1: General safety requirements)
standard, Appendix F, may underestimate the noise emissions of the
machine under real operating conditions.
The noise level value emitted by the press can be found in chapter "6.1
Technical data".
Measures for noise reduction
The stroke speed of the press has a significant influence on the noise level
value. Reducing the speed reduces the noise emission.
For further information, refer to chapter "3.6 Adjusting the working stroke".
1.5 Standards and regulations
Some important standards and regulations to be observed when operating a
press are listed below.
However, this list serves merely for your information. SCHMIDT Technology
cannot be held liable for the completeness of this list.
Machine directive 2006/42/EC
EN ISO 12100 (Safety of machinery - General principles for design -
Risk assessment and risk reduction)
EN ISO 13854 (Safety of machinery - Minimum gaps to avoid crushing
of parts of the human body)
EN ISO 13857 (Safety of machinery - Safety distances to prevent hazard
zones being reached by upper and lower limbs)
EN ISO 16092-1 (Machine tools safety - Presses - Part 1: General safety
requirements)
EN ISO 16092-4 (Machine tools safety - Presses - Part 4: Safety
requirements for pneumatic presses)

2 HydroPneumaticPress
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 7
2 HydroPneumaticPress
2.1 HydroPneumaticPress
Figure 1: Structure
1
Hydro-Pneumatic cylinder
2
Press head
3
Ram
4
Fixture mounting plate
5
Height adjustment
6
Frame
7
H frame
Figure 2: Functional principle
1
Air connection
2
Air connection
3
Feed piston
4
Air connection
5
Working piston
6
Air connection
7
Ram
8
Transmission piston
Rapid approach stroke
Structure
Function

2 HydroPneumaticPress
8SCHMIDT®HydroPneumaticPress 361-376 –V3.1
In the rapid approach stroke, the air connection (4) is pressurised with
compressed air. The air connections (1) and (6) are depressurised. The
working piston (5) and the feed piston (3) are moving with low force until the
ram (7) encounters resistance.
Power stroke
When the ram (7) encounters resistance, a valve switches the compressed
air from (2) to connection (1), and the transmission piston (6) moves
downwards. In doing so, it separates the hydraulic connection between feed
piston (3) and working piston (5). The ram (7) moves downwards with
increased force.
Return stroke
For the return stroke, the connections (1) and (4) are depressurised and the
connections (2) and (6) are pressurised with compressed air. Working (5)
and transmission (6) pistons move back simultaneously. After the hydraulic
connection between working (5) and feed (3) pistons has been reopened,
the feed piston (3) pressurized with oil pressure moves to the home position.
An evaluation of the result of a working process (e.g. quality of a press joint)
can be made by means of the force/stroke monitoring of the working stroke.
During monitoring the ram position and the force are measured. The sensors
and amplifying electronics integrated in the machine provide the data for the
process data acquisition. Process monitoring is done on the basis of the
predefined quality parameters.
2.2 Pneumatic block (optional)
Single-channel control block
Figure 3: Single-channel pneumatic control block (example)
1
On-off valve (K1)
2
Pressure switch (B2)
3
Solenoid valve (K2)
4
Silencer
5
Manometer
6
Compressed air connection (P1)
7
Filter regulator (FDM)
Force/stroke
monitoring
Structure

2 HydroPneumaticPress
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 9
The designations are those of the pneumatic plan from the technical
documentation included in the delivery.
The single-channel pneumatic control block is connected to the compressed
air supply via the compressed air connection (P1).
The filter regulator (FDM) is used to dehydrate and clean (filter pore width 40
µm) the compressed air and preselect a starting pressure of approx. 3 to 6
bar. If you want to reduce the pressing force even further, you will need the
optionally available force output pre-selector (adjustable to approx. 1 bar).
The on-off valve (K1) is switched on and off by the connected control unit.
The pressure switch (B2) is used to monitor the mains pressure. When the
mains pressure drops below a certain value, the control unit will be switched
off. The solenoid valve (K2) is used to activate the working stroke and return
stroke.
Additional pneumatic control elements, such as restrictors for setting the
stroke speed or a pilot-controlled check valve as device for retention of ram
in home position for particularly heavy tools, can be seen from the enclosed
pneumatic plan.
Two-channel safety block
Figure 4: Two-channel pneumatic safety block (example)
1
On-off valve (K1)
2
Home position switch (B5)
3
Home position switch (B6)
4
Blanking plate (optional K11)
5
Solenoid valve (K2)
6
Solenoid valve (K3)
7
Force output pre-selector (optional)
8
Blanking plate (optional additional
valves)
9
Silencer
10
Pressure switch (B2)
11
Compressed air connection (P1)
12
Manometer
13
Filter regulator (FDM)
The designations are those of the pneumatic plan from the technical
documentation included in the delivery.
The two-channel pneumatic safety block is connected to the compressed air
supply via the compressed air connection (P1).
Function
Structure
Function

2 HydroPneumaticPress
10 SCHMIDT®HydroPneumaticPress 361-376 –V3.1
The filter regulator (FDM) is used to dehydrate and clean (filter pore width 40
µm) the compressed air and preselect a starting pressure of approx. 3 to 6
bar. If you want to reduce the pressing force even further, you will need the
optionally available force output pre-selector (adjustable to approx. 1 bar).
The on-off valve (K1) is switched on and off by the connected control unit.
The pressure switch (B2) is used to monitor the mains pressure. When the
mains pressure drops below a certain value, the control unit will be switched
off. The solenoid valves (K2) and (K3) and the home position switches (B5)
and (B6) are used to activate the working stroke and return stroke.
With the pressure sequence valve (K11) the power stroke of
HydroPneumaticPresses is activated.
Instead of the blanking plates you can connect additional valves for
application-specific tasks.
Additional pneumatic control elements, such as restrictors for setting the
stroke speed or a pilot-controlled check valve as device for retention of ram
in home position for particularly heavy tools, can be seen from the enclosed
pneumatic plan.

3 Assembly and start-up
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 11
3 Assembly and start-up
CAUTION
Safety instructions
The press must only be installed and put into operation by a skilled
person.
Any work on the electrical equipment of the press must be carried out
only by trained electricians or by specially instructed persons under the
control and supervision of a trained electrician and in accordance with
the applicable electrical engineering rules and regulations.
Observe the dimensions, weights and setting values listed in the
manual or the data sheets.
Check the press, accessories and all supply lines for possible damage
prior to each start-up.
Switch off a defective press immediately and have the disturbances
repaired as soon as possible.
Improper transport, installation and commissioning is prone to accidents and
can cause damage or malfunctions to the delivered components for which
SCHMIDT Technology does not grant any liability or guarantee.
3.1 Delivery
Check the delivered components for visible transport damage.
Report any transport damage immediately to the following authorities:
the carrier
the dispatch department of SCHMIDT Technology
Packing
Keep the original packaging and transport aids, if present, for later
transports and/or for further storage.
3.2 Transport
Short internal transport distances reduce the risk of accidents.
Use sufficiently dimensioned transport equipment.
During transport, ensure that the component(s) are handled properly.
The components may only be transported on a suitable stable base (e.g.
pallet).
Do not lift the press at the tool magazine area or at mounted parts.
Secure loose parts accordingly before transport.

3 Assembly and start-up
12 SCHMIDT®HydroPneumaticPress 361-376 –V3.1
3.3 Installation of the press
WARNING
Lifting heavy loads
If the lifting equipment or lifting gear is insufficiently dimensioned or
incorrectly attached, suspended loads may fall down.
Use a lifting equipment with sufficient load capacity.
Use a sufficiently dimensioned lifting gear to lift the component.
Do not step below suspended components.
WARNING
Falling loads
The lifting screw may become loose from the threaded hole due to
uncontrolled rotation during lifting.
Use pivot-mounted lifting screws.
Always mount all lifting screws for lifting.
Make sure that the component does not rotate during lifting.
The press must be installed safely (in terms of work safety) at its future
operating location.
The future operating location must be designed for the weight of the press,
including tools. Apart from weight of the press itself, the stress caused by the
working process (dynamics and vibrations) must be taken into account.
The space required for the press and any supply lines that may be present
must be taken into account.
Press with frame
CAUTION
Damaging of force/stroke sensors
The force/stroke sensors of the press head will be damaged, if the transport
equipment is fastened at the cylinder, and then the press is lifted up.
Fasten the transport equipment exclusively at the upper crossbeam of
the frame.
Before start-up, the press must be screwed down to the press base (option)
or to another stable mounting plate.
To lift the press and for further transport, a threaded hole to fix a lifting screw
is provided on the frame. Alternatively, you can fasten the transport
equipment at the upper crossbeam of the frame.
Operating location

3 Assembly and start-up
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 13
Figure 5: Press with lifting equipment (example)
If necessary, take the optionally delivered accessories out of the frame.
Fasten the transport equipment at the frame.
Carefully lift the press. The press can swing out.
Observe the center of gravity of the press.
Put the press on the press base or on the table by means of a suitable
lifting equipment.
Check if both axes of the press are horizontal and compensate the
differences, if necessary.
Screw the press down to the press base or table.
Customer-provided frame system
CAUTION
Dimension of frame system not suitable
If you ordered a press without the standard frame from SCHMIDT
Technology, you must install the press onto a suitable frame system. If the
frame system is not adequately dimensioned, problems such as the
production of defective parts or even damage to the press system can
occur.
Choose your frame system according to the maximum force of your
press.
Observe the dimensions and weight of the press used.
Before start-up, the customer-provided frame system must be screwed down
to the press base (optional) or to another stable table plate.
Put the frame system on the press base or on the.
Check if both axes of the frame system are horizontal and compensate
the differences, if necessary.
Screw the frame system down on the press base or on the mounting
plate.
Mounting the frame
system

3 Assembly and start-up
14 SCHMIDT®HydroPneumaticPress 361-376 –V3.1
Before start-up, the press head must be screwed down to a stable support
system.
Place the press head on the frame system.
Screw the press head tight.
To allow the press heads also be used without frame, they have been
provided with fastening bores at the underside.
Figure 6: Other fastening options at the press head
3.4 Mounting tools
DANGER
Injuries caused by closing tools
When working with the press, there is a risk that persons will interfere with
the closing action of the tools. This may result in injuries such as crushed
fingers and hands.
Take necessary safety measures that prevent persons from interfering
with the closing action.
Inform the personnel about this source of risk!
Upper tool
CAUTION
Construction of the tools
The owner or the entrusted construction engineer must make sure that the
construction of the tools complies with the safety regulations and that the
necessary safety measures will be observed.
The upper tool must be constructed in a way that squeezing points
during the return stroke of the press are avoided.
Make sure that the base of the tool flange is not bigger than the base of
the ram.
Observe the maximum allowed weight for the upper tool.
All the presses with an admissible tool weight of > 150 N are equipped ex
works with a SCHMIDT device for retention of ram in home position.
Installation of the press
head

3 Assembly and start-up
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 15
You will find ram dimensions, the maximum dimensions and the maximum
weights for the upper tools in chapter "6.1 Technical data".
For mounting the upper tool, a centric dowel pin hole with a set screw is
available for fixing it.
Insert the clamping pin into the dowel pin hole of the ram.
Fasten the upper tool using the set screw.
Figure 7: Fastening options at the ram
1
Set screw
2
Dowel pin hole
3
Dowel hole
4
Threaded hole
The down holes and the threaded holes offer additional fixing and fastening
methods for the following presses:
Figure 8: Other fastening options at the ram
Lower tool
For mounting the lower tool, a table bore and a T-slot are available.
Place the lower tool on the table plate.
Screw the lower tool down to the table plate.

3 Assembly and start-up
16 SCHMIDT®HydroPneumaticPress 361-376 –V3.1
Figure 9: Frame with table plate (example)
1
Table bore
2
T-Slot
For frames with a screwed fixture mounting plate, the fixture mounting plate
is aligned with the ram but not pinned.
3.5 Adjusting the working height
CAUTION
Risk of crushing when adjusting the working height
If the locking screws are not tightened, the height adjustment will be
seriously damaged and there is a high risk of crushing when adjusting the
working height.
Firmly tighten the locking screws before the first test stroke.
Ensure the correct functioning of the height adjustment.
The working height depends on the height of the upper or lower tool used,
on the total stroke as well as on the height of the work piece to be
processed.
Loosen the nuts or the screws of the press head clamping.
Set the desired working height on the height adjustment.
Retighten the screws of the press head clamping.
Presses
type 361, 364

3 Assembly and start-up
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 17
Figure 10: Setting the working height of the presses type 361, 364
1
Press head
2
Height adjustment
3
Locking screws
The press head is connected to the frame via a dovetail guide and locking
screws.
Unscrew the locking screw counter-clockwise until the screw head
makes contact with the pressure plate (noticeable resistance).Attention:
The dovetail guide is under pretension.
Screw the locking screws approx. 1/4 turn counter-clockwise against the
pressure plate.
Set the desired working height on the height adjustment. Make sure that
the last adjusting movement was directed upwards (spindle play).
Retighten the screws of the slide clamping.
Presses
type 362, 365, 368

3 Assembly and start-up
18 SCHMIDT®HydroPneumaticPress 361-376 –V3.1
Figure 13: Setting the working height of press type 362, 365, 368
1
Press head
2
Height adjustment
3
Locking screws
4
Frame
5
Pressure plate
The working height of the presses can only be readjusted with an optional
adjustment bushing to a precision of 100 mm.
Unscrew the set screw (3).
Unscrew the set screw (1). Make sure that the adjusting mandrel
remains secured in the conical nut against falling down.
Unscrew the set screw (2) while holding the adjusting mandrel.
Move the adjusting mandrel to the desired working height.
Rotate the adjusting nut upwards as far as it will go.
Now perform the fine adjustment by means of the adjusting nut (1
graduation mark = 0.1 mm).
Retighten the set screws.
Figure 11: Setting the working height by means of the adjustment bushing
1
Set screw
2
Set screw
3
Set screw
4
Adjusting nut
5
Adjusting mandrel
Presses type 374, 376

3 Assembly and start-up
SCHMIDT®HydroPneumaticPress 361-376 –V3.1 19
3.6 Adjusting the working stroke
The optional restrictor can be used to adjust the speed of the ram in the
downward movement.
To reduce the speed, turn the restrictor on (clockwise).
To increase the speed, turn the restrictor out (counterclockwise).
Figure 12: Setting the stroke speed (example)
1
Restrictor
The speed of the ram in the return stroke is not influenced by the restrictor.
After covering the distance of the power stroke, the working piston stroke
must be limited. For forming work, such as riveting, embossing, clamping,
the stroke is limited by the application. However, in punching the working
piston can move on. This must be prevented by a stroke limit in the tool.
Figure 13: Stroke limit
The tension of the rubber springs must be adjusted to the punching process.
Stroke speed
Stroke limit

3 Assembly and start-up
20 SCHMIDT®HydroPneumaticPress 361-376 –V3.1
3.7 Connecting the compressed air
CAUTION
Observe the operating pressure
Operating the press requires a operating pressure of 3 to 6 bar. It is
prohibited to exceed the maximum operating pressure, since otherwise the
operation safety of the press is no longer guaranteed.
For compressed air mains > 6 bar, the operating pressure must be
limited to 6 bar by means of the filter regulator.
The filter regulator of the press may be loaded with a maximum of 20
bar.
Limit the air pressure with an additional pressure switch if the maximum
permissible air pressure (20 bar) is exceeded by more than 10%.
CAUTION
Reduction of life limit
Proper compressed air preparation helps to avoid malfunctions of
pneumatic components.
Use compressed air according to ISO 8573-1:2010 [7:4:4].
The pneumatic cylinder and the switching valves are maintenance-free, i.e.
the operation takes place with unoiled compressed air. The operating
location must be provided with a compressed air connection (6 bar) offering
the following connections.
Press type
Press with external
activation
Press with pneumatic
block
61, (3)62, (3)65
G 1/4" 8
G 1/4" 12
(3)64, (3)68,(3)74, (3)76
G 1/2" 12
G 1/4" 12
The press is equipped ex works with complete piping and the connection to
the compressed air supply in the customer’s plant must be performed by an
authorized personnel.
Connect the compressed air to the compressed air connection.
Set the operating pressure (max. 6 bar) on the control button of the filter
regulator.