TOMRUK 012345 User manual
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
INDEX –USERS MANUAL
1SAFETY INSTRUCTIONS and PRECAUTIONS ..................................... 5
1.1 Test-Run Before Shipment............................................................................................... 5
1.2 Protection Of The Users Manual...................................................................................... 5
1.3 Safety Components ......................................................................................................... 5
1.4 Special Instructions, Warnings and Precautions ...............
1.5 Intended Use....................................................................
1.6 Points Of Continuous Attention.........................................
2PRESS TECHNICAL SPEC.................................................................... 6
2.1 Press Table Plan ..............................................................
3SHIPMENT PROCESS............................................................................ 7
3.1 Preparing for Transportation............................................................................................ 7
3.2 Assembly..........................................................................
3.3 Dissembly.........................................................................
3.4 Foundation Plan
4PRESS OPERATION PROCESS .................
4.1 PRESS SET-UP...............................................................
4.1.1 Ram Lock ..................................................................
4.1.2 Press Stroke Adjustment ...........................................
4.1.3 Pressure Settings ......................................................
4.2 OPERATIONS MANUAL ..................................................
4.2.1 General Specifications...............................................
4.2.2 Running The Press................................................................................................... 8
4.2.3 Press Operation Modes.............................................
4.2.4 Control Panel............................................................................................................ 8
4.2.5 Double Hand Control Panel .......................................
4.2.6 Operator Panel .........................................................................................................9
4.2.7 Manometers...............................................................
4.2.8 Press Noise Level......................................................
4.3 Hydraulic and Electrical Circuit .........................................
4.3.1 Hydraulic Circuit Plan.................................................
4.3.2 Hydraulic Component List....................................................................................... 12
4.3.3 Electrical Circuit Plan.................................................
4.3.4 Electrical Component List ..........................................
4.3.5 Electric Terminal List .................................................
5SPARE PARTS LIST............................................................................. 15
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
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6.1 Hydraulic Circuit................................................................
6.2 Hydraulic Oil.....................................................................
6.3 Electric Circuit...................................................................
6.4 Mechanics Of The Press...................................................
6.5 Maintenance List And Points Of Attention.........................
6.5.1 Maintenance after first month of operation.................
6.5.2 Maintenance Every Three Months .............................
6.6 Spare Parts, Authorized Service.......................................
7APPENDIX............................................................................................. 16
7.1 Training Form ................................................................................................................ 16
7.2 Press Service Report..................................................................................................... 17
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
GENERAL VIEW
1. Hydraulic Tank
2. Main Motor
3. Pilot Motor
4. Hydraulic Unit
5. Service Platform Fences
6. Main Cylinder
7. Electrical Pannel
8. Main Cylinder Piston
9. Half –Moon Flange
10. Piston Connection Plate
11. Ram –Lock
12. Operator Pannel
13. Ram Table
14. Two Hand ontrol Pannel
15. Optical Curtains and Guards
16. Foot
17. Press Table
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
1 SAFETY INSTRUCTIONS and PRECAUTIONS
This manual contains information about shipment, operating, maintenance and repair process of
the hydraulic press.
Please read this manual carefully, before activating the press.
For safe and productive use of the press, follow the instructions sequentially in this manual.
1.1 Test-Run Before Shipment
All Tomruk presses are being shipped after test-runs. So be sure not to change any connections in
hydraulic or the electric circuit while commissioning the press.
1.2 Protection Of The Users Manual
This manual should be preserved with the press during its entire operation life. In case of loss,
order a new manual. If the press is sold to a 3rd company, please deliver the manual to buyer
company and inform us about the buyer company’s name and adress.
1.3 Safety Components
❑Optical Guards on Front Face
❑Fixed Guards on both Lateral Sides
❑Ram Lock at upper-end of the press stroke
❑Emergency Button
❑Pressure Safety Valves
❑Safety Relays
Bridging electrical components or removing any of the components above, endangers both the
operator and the press safety. If there is a need for removing or modifying of a safety component
for a desired operation mode, please consult with Tomruk engineers. In this way, your modification
needs can be realized in line with press safety rules.
CAUTION
Please read this manual thoroughly, before activating the machine.
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 6 -
PRESS TECHNICAL SPEC.
Model........................ ........................................................ TP1000
Production Date........ ........................................................ 2013
Press Power............. ........................................................
Press Stroke............. ........................................................
Blank Holder Stroke . ........................................................
Table ........................ ........................................................
Press Daylight.......... Max.................................................
................................. Min..................................................
Column Daylight....... ........................................................
Working Pressure..... ........................................................
Motor 1 Power.......... ........................................................
Motor 2 Power.......... ........................................................
Pump 1..................... ........................................................
Pump 2..................... ........................................................
Cooler Motor Power . ........................................................
Electricals................. Supply.............................................
................................. Control............................................
................................. Valve...............................................
PLC .......................... ........................................................
Oil Volume................ (Hydraulic Oil #46)..........................
Table ........................ ........................................................
Fast Approach Speed.........................................................
Pressing Speed........ ........................................................
Return Speed........... ........................................................
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 8 -
1) Dissembly of the press is explained in Chapter 3.3. To transport the press safely after
dissembly, follow the instructions below and drawing1 and drawing2 in previous page. The
press is dissembled as explained in chapter 3.3.The basement bolts are unscrewed.The
press is lifted up by a crane. The crane’s hooks are tied to upper ribs holes shown in the
picture above.The press is tilted by two cranes, so that it lies horizontally in the face down
or side down.Finally, the carrier drives under the press.Front and back optic guard
•Lamp test module
•Two alternative return modes ot the press; by pressure or by switch.
2.1.1 Running The Press
If the automatic cycle does not start and signal on the control panel is flashing, this means the
press is not at its starting origin point.
Press back button on the control panel should be pressed to raise the press to its starting position.
In automatic mode the press back button has a secondary operational stop function besides
driving the press to its origin point. If this button is pressed while the press is running, the press
stos. If it is pressed while the press is on hold, the press raises to its starting origin po
Control Panel
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
Web: www.tomruk.com e-mail: info@tomruk.com
- 9 -
SIGNALS
MAIN SWITCH : The main board has power
OPTIC GUARD : Optic guard in front and back is interrupted.
Continuously : A cycle can be started in automatic mode.
Operator Panel
2.1.1.1 HOME PAGE
It is the first displayed page when the operator
turns on the main swtich.
All of these different buttons are selectable.
If the press is de-energized and to be
energized again, press needs to be
referenced. In this case, referencing buttons is
appeared in a free field below the page and
the "FAULT" tab is flashing.
2.1.1.2 SETTINGS
This page has all the links to adjustment
pages of the press.
2.1.1.2.1 MODES
Press Modes :
•Off
2.1.1.2.1.1 LOCKED PUNCH
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 10 -
Locked punch stroke, speed and ram pressure
values are adjusted for 3 levels.
If you would like to turn Level 2 and 3 off, you
should click their buttons.
2.1.1.2.1.2 SLIDE LUBRICATION
Slide lubrication period during the press's
working time is adjusted and ıf you need,
manual slide lubricaton can be triggered.
2.1.1.2.1.3 ACTUAL
This page is displayed real pressure and
Administrator password is required for entering
die bank page.
All parameters related to the die is saved in the
memory and if required, it can be relcalled.
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 12 -
Hydraulic Component List
POS.
NO
COMPONENT NAME
BRAND
CODE / TYPE
QTY
1
PRESSURE GROUP 1
1,01
LOGIC VALVE
TOMRUK
3
1,02
LOGIC VALVE COVER NG-25
3
1,03
PRESSURE RELIEF VALVE
3
1,04
DIRECTIONAL CONTROL VALVE
3
1,05
CHECK VALVE
1
1,06
LOGIC VAVLE
2
1,07
LOGIC VAVLE COVER NG-25
2
1,08
DIRECTIONAL CONTROL VALVE
2
1,09
DIRECTIONAL CONTROL VALVE
2
1,10
LOGIC VAVLE COVER NG-25
2
1,11
HYDRAULIC BLOCK
1
2
2,01
PRE-FILL VALVE
1
2,02
MAIN CYLINDER
2
2,03
ELEVATOR CYLINDER
2
2,04
RAM EJECTOR CYLINDER
2
2,05
RAM LOCK CYLINDER
1
2,06
BLANKHOLDER CYLINDER
2
2,07
MOTOR - M4
1
2,07A
COUPLING - K4
1
2,08
PUMP - P4
1
2,10
OIL FILTER
1
2,11
CHECK VALVE WITH SPRING
1
2,12
COOLER
1
2,13
AIR FILTER
3
2,14
LEVEL INDICATION
1
2,15
MAGNET
1
2,16
DISCHARGE VALVE
2
2,17
PUMP - P1
1
2,18
MOTOR - M1
1
2,18A
COUPLING - K1
1
2,19
CHECK VALVE
4
2,20
PUMP - P2
1
2,21
MOTOR - M2
1
2,21A
COUPLING - K2
1
2,22
PUMP - P3
1
2,23
MOTOR - M3
1
2,23A
COUPLING - K3
1
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 13 -
2,24
SPEED ADJUSTMENT VALVE
4
2,25
GLOBE VALVE 3/8"
1
2,26
PRESSURE TRANSMITTER
4
3
3,01
PROPORTIONAL PRESSURE
RELIEF VALVE
1
3,02
ELECTRONIC CARD
1
3,03
DIRECTIONAL CONTROL VALVE
2
3,04
DIRECTIONAL CONTROL VALVE
1
3,05
DIRECTIONAL CONTROL VALVE
1
3,06
LOCK VALVE
2
3,07
PRESSURE REDUCER VALVE
1
3,08
CHECK VALVE
2
3,09
CHECK VALVE
1
3,10
DIRECTIONAL CONTROL VALVE
1
3,11
HYDRAULIC BLOCK
1
4
4,01
CHECK VALVE
1
4,02
PRESSURE RELIEF VALVE
1
4,03
POPPET VALVE
1
4,04
MANOMETER
1
4,06
CHECK VALVE WITH SPRING
1
4,07
OIL FILTER
1
4,08
HYDRAULIC BATTERY
1
4,09
HYDRAULIC BLOCK
1
5
5,01
DIRECTIONAL CONTROL VALVE
1
5,02
LOGIC VAVLE
1
5,03
LOGIC VAVLE COVER
1
5,04
PRESSURE RELIEF VALVE
1
5,05
PRESSURE RELIEF VALVE
1
5,06
ORIFICE
1
5,07
POPPET VALVE
1
5,07A
SOLENOID
1
5,08
LOGIC VAVLE
1
5,09
LOGIC VAVLE COVER
1
5,10
ORIFICE
1
5,11
POPPET VALVE
1
5,11A
SOLENOID
1
5,12
LOGIC VAVLE
1
5,13
LOGIC VAVLE COVER
1
5,14
PRESSURE RELIEF VALVE
1
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 14 -
5,15
POPPET VALVE
1
5,15A
SOLENOID
1
5,16
SETSCREW
1
5,17
HYDRAULIC BLOCK
1
6
6,01
DIRECTIONAL CONTROL VALVE
2
6,02
PRESSURE RELIEF VALVE
4
6,03
CHECK VALVE
4
6,05
CHECK VALVE
2
6,06
HYDRAULIC BLOCK
1
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 15 -
3 SPARE PARTS LIST
Part
Brand
Model / Serial
Hydraulic Oil
-
Cst 46
Oil Filter
F520-25
Air Filter
TOMRUK
LNN
SEALS
Part
Dimensions
Number
Press Cylinder Ø 500 Part List
PTFE Band
Omegat Seal
Nutring
Wiper
Active Punch Cylinder Ø 290 Part List
PTFE Band
Omegat Seal
Nutring
Wiper
Active Punch Rod Ø 310 Part List
PTFE Band
Omegat Seal
Nutring
Oil Filter : Always a micron filter must be used.If the dirty sensor is
on red area oil cartridge must be changed.
If the oil cartridge is blown torn out.
•Take the press to its upper most position.
•Empty the oil tank while filtering it.
•Clean the hydraulic tank with a featherless cloth using fuel oil
•Fix the new filter cartridge and filter the tank with oil using the filter on.
•If the press motor does not run when the start button is pressed the phase line up should be
check. FSR relay on the electric board has a led showing status. If this led is not lightning
the phase line up should be changed.
•If the press starts running but start button is the press but stop immediately when the button
is released, the ram table must be touching one of the safety limit switches. All switched
must be realigned suitable levels. Then the press should be switched on to manual
operation mode. In this mode the press ram must be moved to an appropriate position
using instructions in the electric manual.
•The Emergency Stop Button must be controlled and checked its position either on or off.
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 16 -
3.1 APPENDIX
3.2 Training Form
Tomruk Personnel in charge for Training
Elec. Eng.
Hyd. Tech.
TRAINING SUBJECTS
TRAINER
OK (√ )
Operating of Control Panel
Press Settings on Operator Touch Panel (if press has o.p.)
General Operation of Hydraulic System
Important Points about Die Changing
Statement about Maintenance Procedure
(Extra)
(Extra)
TOMRUK PRES
TOMRUK Hidrolik Pres Endüstri A.Ş.
Çınar Cad. 25, Yenibosna TR-34197 ISTANBUL Tel: +90-212-552 02 55, 552 11 89 Fax:+90-212-503 24 16
- 17 -
3.3 Press Service Report
Company
City
Telephone
Press
Model
Press No
Manufacturing
Date
Adress :
Date :
Reporter /Authorized Person :
Completion
Date :
Reported Problem :
Diagnose :
Work Done :
Materials Used :
Result :
TOMRUK Pres A.S. Company :
Authorized Person :
Signature: Signature
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