car002_manual hydraulic press
Contents
1. NEVER place your hands or any part of your body in the mold area or other dangerous locations NEVER operate service or adjust press or molds without the appropriate training and first reading and understanding this manual NEVER try to pull material either part or scrap out of the mold with your hands If a part sticks in the mold stop the press and call your supervisor Before you start the press check the following remove all maintenance crew equipment from the press area make certain safety blocks are removed from the mold be sure no objects tools nuts bolts clamps bars are laying in the press clamp area carefully look for obstructions left in the mold If your press has been inoperative or unattended even for a moment check all settings before starting the next cycle If your press has multiple platens be sure ALL floating platens are completely open before reaching into the clamp area At the beginning of your shift and after breaks cycle the press several times to verify that the controls press parts molds and auxiliary equipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment When changing press control settings to perform a different mode of operation be sure selector switches are correctly posit2. Belgique Belgi Fisher t l 0388671414 t l 056260260 Bioblock Scientific 0388671168 fax 056260270 email infos bioblock fr email belgium bioblock com Parc d innovation BP 50111 F67403 illkirch cedex www bioblock com www bioblock be Mode d emploi tfno 9151592 34 fax 91 5159235 email ventas bioblock com www es fishersci com 550 00 05 CARVER OPERATION INSTALLATION AND MAINTENANCE MANUAL TWO and FOUR POST MANUAL HYDRAULIC PRESSES IMPORTANT PLEASE READ CAREFULLY BEFORE INSTALLING OR OPERATING THIS EQUIPMENT 2 4540 3 CARVER INC 1569 Morris Street P O Box 544 Wabash IN 46992 0544 PH 219 563 7577 FAX 219 563 7625 NOTE Performance figures stated in this manual are based Standard Atmosphere of 59 degrees 15 degrees and 29 92 Hg 10 331 Kg n at sea level and using 50 Hz electrical current All of these factors are important considerations when selecting a hydraulic press CARVER INC can advise you on proper selection and sizing of systems for the operating environment at your location CARVER INC is committed to a continuing program of product improvement Specifications prices appearance and dimensions described in this manual are subject to change without notice CARVER INC 1996 All Rights Reserved Part 4 1520 2 amp 4PSTUSCE Effective 04 15 96 SECTION ONE TWO 2 1 2 2 2 3 2 5 THR
3. NEVER place your hands or other part of your body within the mold area unless the power is OFF to the press Ifthe press has multiple openings be sure that ALL floating platens are completely open before installing tooling NEVER install adjust or remove molds without the appropriate training and first reading and understanding this manual NEVER move molds or service the press with the electric power on or without blocks in place Clean bolsters platens and molds before installing the mold set Dirt or foreign materials can cause misalignment resulting in operator injury and or press and mold damage ALWAYS lock out the control panel or disconnect switch in the OFF position to prevent unauthorized use or accidental starting of the press NEVER install worn or damaged molds Make sure the clamp pressure is properly adjusted relative to the mold size refer to the Mold Size vs Tonnage chart in the Maintenance Section of this manual Secure all molds to the mold truck before you move them When clamping molds to the press use the appropriate number and size of clamps to hold the molds securely please consult your mold manufacturer if in doubt about appropriate clamp usage After installing molds make all necessary adjustments BEFORE cycling the press 5 Make sure all persons are clear of press and remove all objects from mold area tools nuts bolts clamps bars before cycling Watch the press in
4. CARVER presses that have electrical devices are supplied with a disconnect switch or disconnect plug Connect main power to the press through the disconnect On presses with thermostat control customer is to provide short circuit protection based upon the electrical nameplate current draw WARNING WARNING The voltage phase and current draw information are listed on the serial number tag Line voltage must be within 1090 of the voltage listed on the serial number tag or damage may occur Phase imbalance must be within 590 Fulfill all national state and local safety and electrical code requirements The power drop must include a ground wire CONNECTION SHOULD ONLY BE MADE BY A QUALIFIED ELECTRICIAN Water and Air Inlet Connections If your press 15 equipped with cooling plates then it will be necessary to connect the supplied Teflon lined stainless steel hoses to your plant air and water supplies Each platen comes with an inlet and outlet hose attached Determine which side of the platens you will use as the inlet For this explanation the right side when facing the press will be considered the inlet side and the left the outlet side The hoses are Teflon lined stainless steel with a 3 8 inch NPT female fitting on the end Each inlet hose will be used to supply water air and water air mix to the platen it 1s connected to For this reason the inlet hoses should be connected to a common manifold with the pla
5. the pump close the press and preheat the platens to the set temperature Hot Plates with Thermostats If your press 15 equipped with individual thermostats located in the platen rotate the knob clockwise to increase the temperature Verify the temperature on the integral thermometer and adjust the knobs accordingly CAUTION On presses with thermostat control customer 15 to provide short circuit protection based upon the electrical nameplate current draw Digital Platen Control Systems Select the ON position of the ELECTRICAL DISCONNECT switch located on the front ofthe control panel of presses equipped with digital platen controller s Heated presses equipped with digital controls include solid state heater contactors and digital temperature controllers The platen temperature is controlled with 1 16 DIN digital temperature controller s The controller s are modular and can be removed from their mounting housing They are preset at the factory and no field adjustment other than the temperature setting should be necessary The control panel located on the side of the press includes the ELECTRICAL DISCONNECT switch POWER ON OFF BUTTONS and the temperature controller s Adjust the digital temperature controller s to the desired operating temperature for your process by depressing the ARROW UP or ARROW DOWN key on the temperature controller s To shut down the press select the OFF position on the ELEC
6. Blotters A set of 50 blotters is provided One or two blotters are generally used between the polished plates and the holding plates see Method of Assembling Laminations They are not intended as padding Their main purpose is to prevent heat from entering the stack too rapidly and distribute the heat evenly throughout the stack They also protect exposed surfaces of the polished plates It is not necessary to replace the blotters for each lamination however if they become brittle and hard due to high heat they should be replaced These are special blotters made for this purpose and should last a considerable amount of time Thermometers Each press is supplied with 2 dial faced thermometers with Centigrade C gradations These should be inserted into the holes in each heating plate Care should be taken not to hit the lens of the thermometer or damage may occur Oil 22 Each press is supplied with one pint 47 liters of Special Hydraulic Oil 2170 but this should only be needed if there has been some visible loss Keep this bottle sealed from dirt and dust We advise using only CARVER Hydraulic Fluid or those recommended as substitutes earlier in this manual Spare Seals Each press is supplied with a spare soft copper washer for use in the gauge connection If one seal does not prevent oil leakage two seals may be used LAMINATION This CARVER Laminating Press is the finest equipment of its type available Properly
7. NOT APPLICABLE 3 2 FOUR POST PRESS DESCRIPTION 3969CE 2 1 22 4122 mm 12 12 2 12 H 12 2 NEC UND 12 mma 12 2 CLAMP FORCE US TONS 12 12 12 12 25 25 Kn 106 8 106 8 106 8 106 8 222 5 222 5 MAX TEMP 650 1 343 1 PLATENS 12x12 12x 12 12x12 12x12 12x12 12x12 E 305 x 305 305 x 305 305 x 305 305 x 305 305 x 305 305 x 305 RAM STROKE DAYLIGHT OPENING UNHEATED IN MM HEATED IN FOOTPRINTWxD 18x18 18x18 18x25 18x25 18x18 18x18 457 457 457 457 457 635 457 635 457 457 457 457 HEIGHT 37 37 37 37 43 939 939 939 939 1091 UNHEATED Ibs 810 Kg m 5 A HEATED v 277 374 NOISE LEVEL lt 70db A lt 70db A lt 70db A lt 70db A lt 70db A lt 704 FULL LOAD CURRENT 230V N A N A 21 66A 43 324 N A MAX SYSTEM PRESSURE N A NOT APPLICABLE 3 2 FOUR POST PRESS DESCRIPTION CONT cum 12H cum 12 2H 12 12 2 12H oxaxm 12 2 CLAMP FORCE US TONS 25 25 30 30 30 30 Kn 222 5 222 5 267 267 267 267 650 650 343 343 PLATENS 12x12 12x 12 12x12 12x12 12x 12 12x 12 305 305 305 305 305 305 305 305 305 305 305 305 RAM STROKE 6 5 6 5 6 6 6 6 5 165 165 152 152 152 152 UNHEATED IN MM HEATED IN FOOTPRINTWxD IN 18X25
8. additional seal may be required See reference drawing 110478B in the appendix IMPORTANT DO NOT use more than two 2 seals at one time 12 3 8 RAM FORCE CALCULATION CARVER gauges are calibrated for the specific ram diameter of the hydraulic unit The Mini and Model C 12 ton 107Kn ram 15 3 294 square inches 21 253 square cm and the Model M 25 ton 223 Kn ram area is 5 157 square inches 33 273 square The standard gauge readings display the load or force in pounds as well as metric tons applied between the platen and head of the press Accordingly all calibrations show the load in pounds force applied by the press to the material being pressed For example a 10 000 Ib 44480n load applied to material having an area of one square inch one square mm would be equal to a pressure of 10 000 Ibs per square inch 44480 Newtons per square mm applied to the material Or if the material being pressed has an area of four square inches 258 08 square mm a 10 000 lbs 44480 Newton applied load would be equal to 2 500 Ib per square inch 172 35 bar on the material EXAMPLE 10 000 Ibs FORCE 44480 Newtons 2 500 PSI 172 35 bar 4 square inches 258 08 square mm CARVER gauges are highly sensitive precision instruments Care should be taken to avoid sudden decompression shock loading over pressurization etc which will result in damage to the gauge and void the warranty A variety of standard
9. 18 25 18 X 18 18 X 18 18 25 18 25 MM 457 X 635 457 X 635 457 X 457 457 X 457 457 X 635 457 X 635 HEIGHT 43 43 43 43 43 MM 1091 1091 1091 1091 1091 UNHEATED Ibs N A 520 810 N A N A Kg N A 236 367 N A N A HEATED Ibs 840 N A N A 650 840 Kg 34 381 295 381 NOISE LEVEL lt 70db A lt 70db A lt 70db A lt 70db A lt 70db A lt 70db A FULL LOAD CURRENT 230V 21 66A 43 32A N A N A 21 66A 43 32A MAX SYSTEM PRESSURE 2 9709 8488 8488 8488 8488 669 585 585 585 585 N A NOT APPLICABLE 10 3 3 LAMINATING PRESS DESCRIPTION CATALOG 4130CE 4131CE 4132CE MODEL 150 C 154 M 30 12 L CLAMP FORCE US TONS 12 25 30 Kn 106 8 222 5 267 MAXIMUM TEMP F 500 500 650 C 260 260 343 6 0 PLATENS IN 6x6 9 x 12 12x 12 MM 152 152 228 305 305 305 RAM STROKE IN 5 125 6 5 MM 130 165 152 DAYLIGHT OPENING IN 2 03 2 3 2 0 3 2 4176 2 0 76 2 076 FOOTPRINT W x D IN 16X 18 19 X 19 19 X 19 MM 406 X 459 482 X 482 482 X 482 HEIGHT IN 3 36 42 MM 761 914 1066 WEIGHT Ibs 190 380 575 Kg 3 166 250 NOISE LEVEL lt 70db A lt 70db A lt 70db A FULL LOAD CURRENT 115V 122A 244A N A 240V 61 122A 22 6 MAX SYSTEM PRESSURE PSI 7295 9709 8488 bar 503 669 585 11 INSTALLATION To assist in the installation and operation of this press an assembly drawing including part numbers is included in the appendix of this manual SETTING UP Installation Summary Bolt
10. 2 nas x a x a so me me ze pa A eoj I m saj mara 221 20120 2261 zaj REE SECTION SIX HYDRAULIC OIL 2 9 RECOMMENDED HYDRAULIC OILS FOR CARVER PRESSES The hydraulic fluid is a special grade which conforms to MIL SPEC 17672 CARVER Special Hydraulic Fluid Catalog 2170 is supplied in one pint 47 liters containers Contact CARVER INC Parts department for information Any good grade of mineral base hydraulic oil with anti wear and anti foaming additives in the viscosity range of 150 SSU a 100 F 38 C and a viscosity index of 90 can be used provided it is filtered prior to being added to the hydraulic reservoir IMPORTANT DO NOT use fire retardant ester base oils transmission fluid brake fluid or water glycol mixes Always add clean oil to the reservoir from a clean container through a filter RECOMMENDED SUBSTITUTES Standard A m q SBS Sapan ESET Sapan aspa S a ua Stanoil 21 Mobil ns a DTE 24 Do MM Terrestic 32 ode e e d dde es Rando HD 32 Ud PM E OR 32 Other E Any brand name H
11. Follow these instructions and with proper care your press should give many years of trouble free service 5 1 TROUBLESHOOTING To maintain constant pressure the hydraulic unit may require occasional pumping especially when pressing against a soft or yielding material If the pressure drops slowly as shown on the gauge it should be considered normal If you are experiencing problems with the operation of your hydraulic unit it may be due to any of the following reasons PROBLEM POSSIBLE CAUSE SOLUTION Rapid drop in Low oil level due to leakage a Tighten hydraulic connections and pressure b Open release valve refill with oil c Worn or dislodged internal packing b Close release valve d Dirty valve seat c Replace packing or seals where necessary d Remove release valve amp clean valve seat Hydraulic unit may require flushing with solvent such as agitene e Air entrapment e Purge air from system see Air Bleed Procedure in Section 5 No pressure a Open release valve a Close release valve when pumping b Worn packing in pump b Replace or rebuild hydraulic unit pump c Release valve ball missing c Replace ball d Release valve contaminated d Remove and clean Slow drop in a Open release valve a Close release valve pressure b Worn release valve seat b Contact factory for replacement Worn ram seal c Replace ram seal Oil leakage in a Loose gauge fitting a Tighten gauge fitting gauge c
12. Operating Presses Equipped with Heated 20 Laminating Presses a entera eee eee ei eint GS sassa 21 MAINTENANCE ro bleshoottng ote ie b ER E ERR RE 27 Hydraulic Unit Air Bleed Procedure inini 28 Electrical sis 28 Mold Size versus Tonnage 29 HYDRAULIC OIL INFORMATION 30 SEVEN EIGHT 8 1 8 2 NINE 9 1 9 2 TEN APPENDIX ACCESSORY EQUIPMENT CARVER INC PARTS and SERVICE INFORMATION echnical Assistance a seen A QUN SA HM CAS u as u uu E Returned Material WARRANTY PROCEDURES Warranty Returns ays nananman bee s ae Su sas hye Warranty Statement k tr uku oud waka anu Gb haya eU aw aa wa PICTOGRAM TAG INFORMATION Hydraulic Unit Drawings 12 ton 25 ton Hydraulic Unit Section View Typical Hydraulic Unit Drawing 30 ton Gauge Union Coupling Assembly Typical Hydraulic Cylinder 30 ton Electrical Symbol Cross Reference Electrical Drawings Press Assembly Drawings 31 SECTION ONE INTRODUCTION II D 2o ae a i 1 1 INTRODUCTION We are pleased to supply CARVER Laboratory Equipment for your facility CARVER presses are used in
13. furnished promptly on request NOTICE If you desire to use a press for an application other than that for which it was purchased please contact our factory to verify compatibility of the equipment with the new process Misapplication of the equipment could result in injury to the operator or damage to the equipment SECTION TWO SAFETY 2 1 SAFETY CONSIDERATIONS The terms NOTICE CAUTION WARNING and DANGER have specific meanings in this manual A NOTICE is used to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property A CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury This word will be limited to the most serious situation s The term IMPORTANT emphasizes areas where equipment damage could result or provides additional information to make a step or procedure easier to understand Disregarding information marked IMPORTANT would not be likely to cause personal injury REPORTING A SAFETY DEFECT NOTICE If you believe that your equipment has a defect which could cause injury you should immediately discontinue its use and inform CARVER INC at
14. gauges are available with different calibrated ranges The standard gauge provided with your press is calibrated for full press tonnage If an additional gauge is required for a lower operating range a CARVER 2096CE Two Gauge Manifold will permit simultaneous mounting of two separate gauges FILLING THE OIL RESERVOIR The hydraulic unit is filled with oil at CARVER INC and should not require additional oil In the event there is some oil loss lower the platen remove the sintered breather plug and fill with oil up to the level of the filler hole on 12 amp 25 107 amp 223 Kn ton models Fill 30 ton 267 Kn pump up to within 2 50mm of top of reservoir Only special CARVER 2170 Hydraulic Fluid or a brand name filtered HYDRAULIC JACK OIL should be used Refer to Section 6 for recommended substitutes IMPORTANT Brake fluid and similar products may damage your unit and will void the warranty 3 9 GASES OR DUST REMOVAL If the product you use in the press produces dust or gases that could be harmful to the operator attach an exhaust system to the press This can be done by either attaching the exhaust vent to the top of the guard housing or by cutting a hole in the back of the guard housing and attaching the exhaust vent over the cutout The cutout must be completely covered Airflow will then be drawn up around the material and out through the top of the press 13 CAUTION CONNECTING UTILITIES Electrical Connection
15. is suggested that the thickness of the cards or photographs be kept to a minimum and that it never exceed 2590 of the thickness of the plastic used for each layer that is if two sheets of 015 38mm plastic are used the card or photograph should not exceed 0075 19mm in thickness If two laminations are done in the same layer they should be of the same thickness Don t use too heavy a clamping pressure when transferring the stacks from the heating to the cooling chamber Use just enough pressure to hold the stack together Use the same number of layers per stack each time If fewer than six layers are used the time factor should be reduced proportionately The general rule 15 to allow approximately one more minute than the number of layers being processed If one layer of the stack contains a pair of wallet sized cards it is not advisable to put a long narrow card or photograph in adjacent layer Due to the tremendous pressure involved there is the danger of splitting or wrinkly the long card or photograph 25 9 10 11 12 13 If you find that laminated layer has welded together sufficiently to leave clear edge for trimming it 15 usually possible to put the layer back in the next stack of laminations and go through the same procedure again with a slight increase in time in order to allow thorough lamination Remember that consistency and regularity in operation of this press will pay dividends ina minim
16. of any material authorization must be given by CARVER INC An RMS number will be assigned for the part or equipment to be returned 2 Reason for requesting the return must be given 3 All returns are to be shipped prepaid 4 The invoice number and date or purchase order number and date must be supplied 5 After inspecting the material a replacement or credit will be given at CARVER s discretion if the item is found to be defective in materials or workmanship and it was manufactured by CARVER INC Purchased components are covered under their specific warranty terms WARRANTY CARVER INC warrants all equipment we manufacture to be free from defects in workmanship and materials when used under recommended conditions The Company s obligation under this warranty 15 limited to those parts which within twelve 12 months from delivery of equipment to original purchaser are returned to the factory with transportation prepaid and upon examination shall be found to be defective CARVER neither assumes nor authorizes any other persons to assume any liability in connection with the sale of its equipment except under the conditions of this warranty This warranty does not cover any labor charges for replacement of parts adjustment repair or any other work done This warranty shall not apply to any apparatus which in our opinion has been subjected to misuse negligence or pressures in excess of the limits recommended or which shall
17. press to bench Rotate gauge and tighten coupling Remove plug in jack and replace with sintered breather IMPORTANT DO NOT operate the hydraulic unit with the solid shipping plug in the oil fill hole or damage to the hydraulic unit may occur Verify electrical supply if press is equipped with heated platens The CARVER Laboratory Press was carefully designed with a low center of gravity to remain stable under normal operating conditions For a permanent installation hold down bolts may be used to fasten the press to a workbench Holes are conveniently provided in the base directly in front of the columns for this purpose If the press is equipped with heated platens verify the electrical supply and connect the press to the correct voltage source The correct operating voltage and current draw information is printed on the ELECTRICAL DATA TAG which is located on the side of the press GAUGE INFORMATION This CARVER press features a gauge union coupling for quick and easy alignment and interchangeability While holding the coupling swivel to keep it from turning turn the gauge into the coupling swivel until finger tight and position it for easy viewing by the operator Hold the gauge in this position with a 15 16 open end wrench on the stem directly under the gauge case and usinga second wrench turn the coupling swivel counterclockwise until tight If leakage occurs after tightening the gauge into the union coupling swivel an
18. 110324D Model 12 10 12 Ton 107Kn 3968CE drawing 8100325 Model 12 10 12 Ton 107Kn 4120CE drawing 100329D Model 12 12 12 Ton 107Kn 3969CE drawing 100326D Model 12 12 2 12 Ton 107Kn 4121CE drawing 1003170 Model 150 12 Ton 107Kn 4130CE drawing 81003360 Model 12 12 12 Ton 107Kn 4122CE drawing 1003300 Model 12 12 2H 12 Ton 107Kn 4123CE drawing 100331D Model 25 12 25 Ton 223K n 3855CE drawing 81003270 Model 25 12 2 25 Ton 223K n 4124CE drawing 100318D Model 25 12H 25 Ton 223Kn 3856CE drawing 81003320 Model 25 12 2 25 Ton 223Kn 4126CE drawing 81003330 Model 154M 25 Ton 223Kn 4131CE drawing 8100337 Model 30 12 30 Ton 267Kn 3970CE drawing 8100328 Model 30 12 2 30 Ton 267Kn 4127CE drawing 100319D Model 30 12H 30 Ton 267Kn 4128CE drawing 1003340 Model 30 12 2 30 Ton 267Kn 4129CE drawing 100335D Model 30 12 L 30 Ton 267Kn 4132CE drawing 100338D Manual Pellet 12 Ton 107Kn 3620 3978CE drawing 100377D Manual Pellet 12 Ton 107Kn 4350CE drawing 100450D Threaded columns allow for daylight adjustment between the moving bolster and top bolster To raise the top head bolster 1 Insert a spacer block with parallel surfaces between the moving bolster and top bolster pump the hydraulic unit to build force to the maximum capacity of the press 2 With the press at maximum applied force loosen the column nuts located directly below the top bolster On Four Post presses a brass
19. 3 44 assemble new valve seal Finally screw in valve seal plug This procedure should be carried out in all ball valve circuits If the valves fail to operate properly after they have been cleaned it may be necessary to reseat the valve balls Remove the springs and tap each ball lightly in its respective seat using the 1 4 ball seating tool CP13 42 for the small ball and 7 16 ball seating tool CP13 43 for the large ball Remove balls to make sure they are not stuck to the seats Reassemble pump valves as before RELEASE VALVE If the pump fails to lift or hold a load the release valve may be dirty From back of pump remove release valve plug release ball spring and release ball From front remove release lever pin release lever and release plunger Clean release valve chamber and inspect ball seat If necessary reseat release ball by tapping it lightly on the ball seat using the 3 8 ball seating tool CP13 43 Clean plunger and inspect plunger packing Replace if necessary To reassemble insert ball ball spring and release valve plug Dip release plunger packing in hydraulic oil and carefully insert into plunger chamber Replace release lever and lever pin If the pump fails to lift or hold load after the release valve and pump valves have been checked the overload valve may be dirty To clean valve remove valve plug and valve plug seal Using a screwdriver remove the overload valve screw Tip pu
20. EE 3 1 3 2 34 3 5 3 7 3 8 3 10 FOUR 4 1 42 4 3 4 4 4 5 FIVE 5 5 2 5 3 5 4 SIX TABLE OF CONTENTS TITLE PAGE INTRODUCTION Introduction uy sQ baee ee npe deret t egre 1 I 1 Customer S tVICe ien esce teet riesce repe einen ep euet ec peu pad EE E eu 1 SAFETY Safety 2 General Responsibility ss rere OUR a ees 3 Operator Responsibility ee to ee RU QUSS HENRI REI ee 3 Mold Setters Responsibility o ARR Sn eee he A OT Rad amd ics 5 Maintenance Responsibility nsa Seo A aon and da es AER editis 6 INSTALLATION Two Post Press Description 8 Four Post Press Description 9 Laminating Press Description da hahaa da hha deine taste tes 11 Installation EEG 12 Setting Up cire RR TR TAREAS 12 Gauge Information ARA tee 12 Ram Force Calculation 13 Filling the On Reservoir crecer trie HEU tans ces E E RIGHT AERE IRIS 13 Gases or Dust Removal eite e reete toe re as a be ee ee dec 13 Connecting Utilities eee ee e Ee eR EH HER 14 OPERATION Operator Safety 16 Operating Hydraulic Press 17 Daylight Adjustment u kz shh RUNG ERR 18
21. Hydraulic Oil when refilling NEVER USE BRAKE FLUID PUMP PISTON Leakage of oil around the pump piston indicates worn or damaged piston packing To replace packing a Remove piston actuating linkage b Remove piston See piston drawing c Remove all packing See piston drawing d Clean all parts and dry with compressed air e Install new packing wipers and static seals being sure packing sealing lips face down toward the pressure Dip each part into clean hydraulic oil before assembly f Open the release valve to allow air to bleed from piston barrel back to reservoir and insert the piston g Replace piston linkage h NOTE With release valve open stroke pump about a dozen times to bleed air completely from pump PUMP VALVES Ifthe pump fails to supply pressure or if the pump piston is under pressure at all times the pump valves may need a cleaning Stand pump in upright position while removing valve plug and valve seal Tilt pump to remove valve springs and balls Allow oil to drain from the reservoir through these valve holes to wash foreign matter from hole Lay pump on its side to clean and inspect valve chamber Be careful not to mar or nick ball valve seats Clean valve balls and spring in a solvent Replace rusted or corroded balls Do not stretch ball springs To reassemble insert in sequence small ball small spring large ball and large spring in cleaned chamber Using the valve seal inserting tool CP1
22. M PART NAME STAR PART 2A Large Piston 5 2 2B Small Piston incl pin CP13 4RP 4A Large Piston Packing 5 4 4B Small Piston Packing CP13 5RP 6 Piston Wiper 5 6 10 Piston Pin incl rings CP14 10RP 11 link Pin incl rings CP13 10RP 12 Pump Valve complete P1 12RP 13 Overload Valve complete CP13 13RP 14A Release Plunger complete CP13 17RP 14B Release Valve complete PAC 18Rp 15 Lever Handle with grip CP13 23 16 Breather Screw P1 16 17 Pump Socket CP13 9 18 Pump Link CP13 12 19 Relief Valve complete CP13 25RP 24 Release lever Pin incl rings CP13 10RP 25 Cam Release Lever CP13 14 CARVER 3789 REPR KIT WABASH 995 00157 CARVER 329071 329072 329042 329043 329044 329073 329065 329045 329046 329051 329048 329161 329074 329066 329076 329050 329077 329078 MAINTENANCE In servicing hydraulic units cleanliness is of the utmost importance A clean work place and proper tools are necessary to insure efficient and effective repair Special tools can be furnished on request AIR BLEEDING Air accumulation in a hydraulic system will cause erratic action This may appear as pump failure to the inexperienced user For this reason it is advisable to air bleed each pump before attempting to operate To remove air from the pump open release valve with the pump in an upright position Operate the pump slowly through the full piston stroke about a dozen times Close the release valve Pump should
23. NOTES
24. TRICAL DISCONNECT switch or press power off button WARNING When operating a press with heated platens wear the appropriate personal safety gear such as insulated gloves to protect arms and hands from burns 4 5 LAMINATING PRESSES 20 Introduction We are pleased to provide a CARVER Laminating Press for your operations Although this equipment is a standard apparatus for general laminating work these presses have wide use for other applications where heating and chilling under pressure is required Many of these presses are in daily use by the Armed Forces Government Agencies Universities and Industry for important jobs where securities ease of operation and quality production are essential Description The press is a complete self contained hand operated unit ready for connection to an electrical outlet and cooling source No special wiring or plumbing is required for installation nor is any previous skill needed for operation Press Models 150 C and 154 M are supplied complete with all operating accessories including hose connections extension cord polished plates blotters holding plates polished chrome plates thermometers interval timer oil and operating instructions in the service manual Model 30 12 L is not supplied with any laminating accessories Features CARVER Laminating Presses incorporate two separate openings The upper chamber features heating plates while the lover chamber utilizes channeled cooling
25. aulic unit to build force to the maximum capacity of the press 2 Whth the press at maximum applied force loosen the column nuts located directly below the top bolster Move these column nuts to the position required to create the desired daylight On Four Post presses a brass tipped setscrew must be loosened on each nut before nuts are loosened 3 Release hydraulic force and remove the spacer allowing the top bolster to rest on the lower column nuts 4 Tighten the upper column nuts finger tight against the top surface of the top bolster 5 Follow steps thru 10 as described above IMPORTANT Four Post models utilize a set screw in the column nuts These must be loosened prior to adjusting daylight and retightened after adjusting daylight WARNING After adjusting the daylight be sure the top bolster is parallel to the top surface of the base bolster before applying pressure IMPORTANT cases size the spacer block so the maximum stroke of the hydraulic unit is not exceeded 19 Refer to Section 3 to determine maximum stroke of your press WARNING Spacer block must be centered on moving bolster or platen Be certain that spacer is strong enough to withstand maximum applied force of press and that its area 1s great enough to prevent coining the bolster or platen surface 4 4 OPERATING PRESSES EQUIPPED WITH HEATED PLATENS Close energize the ELECTRICAL DISCONNECT switch Tighten the pressure release knob
26. be ready for use TROUBLE Pump will not hold pressure Pump fails to supply pressure Pump piston does not draw a full charge This is evident by a cushion effect at the top of the pump stroke Pump piston raises by itself under pressure Pump functions properly but will generate only a given pressure below its normal pressure maximum Pump fails to supply greater output at no load than under load POSSIBLE CAUSE Release valve ball not seating properly Ball Valves not seating properly Overload valve ball not seating properly Large pump relief valve seal faulty Lack of oil Air bound pump Release valve ball not seating properly Small ball in ball valve circuit not seating properly Overload valve ball not seating properly Large pump relief valve seal faulty Air bound system Lack of oil Large ball in ball valve circuit not seating properly Overload valve not set properly Large pump relief valve not set properly CORRECTIVE REPAIR INSTRUCTIONS Refer to pump Repair Section er Release Valve er Pump Valve er Overload Valve er Large Pump Relief Valve er Oil Air Bleeding Section er Release Valve er Pump Valve er Overload Valve er Relief Valve Air Bleeding Section er Oil er Pump Valve er Overload Valve er Relief Valve If the pump fails to operate check oil level before attempting any repairs CAUTION Use only
27. connect one hose of each platen on the same side to a steam source and the other hoses opposite side to a drain line preferably through a steam trap IMPORTANT Do not vent steam line with copper or plastic Use only steel pipe and install to standard steam specifications The outlet manifold must be plumbed downward to drain the platens properly If the manifold 15 plumbed upward CARVER INC recommends the use of a check valve to eliminate backflow into the platens and a pump to recirculate the drain water CARVER INC will not guarantee proper cooling if the drain is not plumbed according to CARVER INC recommendations pressure gauge and regulator are recommended components for your plant air supply A manual shutoff valve in each line will aid in future maintenance procedures 15 SECTION FOUR OPERATION 4 1 OPERATOR SAFETY l The operator should wear safety glasses or a face shield when performing operations under high load conditions to prevent eye or face injury should a test specimen burst and scatter 2 When using caustic or acid test specimens a face shield apron and rubber gloves should be used for the protection of the operator 3 The testing apparatus or test specimen must be centered on the press platen This will prevent tilting of the platen and possible ejection of the work piece under pressure Always avoid uneven loading of the press components Locator plates are available from CARVER INC up
28. ded in your information packet for replacement part numbers CARVER INC SERVICE DEPARTMENT Call from 8 00 a m to 4 30 p m Eastern Standard Time 219 563 7577 Extension 238 or 243 CARVER INC has a qualified Service Department ready to install start up or service your press Gauge calibration services are available Contact Service Department for details CARVER INC SALES DEPARTMENT Call from 8 00 a m to 4 30 p m Eastern Standard Time 219 563 7577 Extension 252 or 237 CARVER products are sold through a worldwide network of independent sales representatives and distributors as well as in house sales personnel Contact our Sales Department for the name ofthe sales representative or distributor nearest you 82 RETURNED MATERIAL POLICY CREDIT RETURNS 1 Prior to return of any material authorization must be given by CARVER INC RMS number will be assigned for the equipment to be returned 2 A reason for requesting the return must be given 3 All returned material purchased from CARVER INC is subject to a 1596 75 00 minimum restocking charge 4 All returns are to be shipped prepaid 5 The invoice number and date or purchase order number and date must be supplied 6 No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale SECTION NINE WARRANTY 9 1 WARRANTY RETURNS 32 1 Prior to the return
29. essure for a sufficient time for lamination to take place the same as before While this second stack is heating the first stack will be cooling The holding clamps may now be removed from the stack cooling and made ready to clamp the second stack in the heating chamber This procedure is continued using the thick stack for the next transfer thereby producing a stack of laminations every six to eight minutes TRIMMING 24 After lamination cards photographs are trimmed using an ordinary 10 12 25 or 30cm straight edge photograph trimming board leaving a border of approximately 1 8 3 2cm of clear plastic around the laminated piece If it is desired to round the corners of the finished laminations this can be done by using a photograph corner rounder Trimming boards and corner rounders can usually be purchased through photographic supply houses NOTES AND SUGGESTIONS The following notes and suggestions are given as a guide toward successful laminating They are the result of past study and observations Although they are based on the use of vinyl or acetate as a laminating medium they should also be considered when using other plastic material Often the best results come after a number of trial runs 1 2 3 4 5 6 7 8 The CARVER Laminating Press is adjustable for use with any of the thermoplastic materials used for laminating Figures given on the preceding pages for temperature pressure and
30. have been repaired or altered outside of the factory Replacement of defective material s will be FOB from the CARVER INC factory Replacement component parts not manufactured by CARVER INC will be limited to the warranty of the manufacturer of such parts SECTION TEN PICTOGRAM TAG INFORMATION WARNING TAGS HOT SURFACE HIGH VOLTAGE INSIDE ENCLOSURE ONLY WARNING TAGS cont SHOCKING HAZARD PUSHBUTTON TAGS 35 POWER ON POWER OFF IDENTIFICATION TAGS TEMPERATURE CONTROL UNIT NUMBER 1 FOR PLATEN 1 TEMPERATURE CONTROL UNIT NUMBER 2 FOR PLATEN 2 TEMPERATURE CONTOL UNIT NUMBER 3 FOR PLATEN 3 TEMPERATURE CONTOL UNIT NUMBER 4 FOR PLATEN 4 36 PLATEN NUMBER 1 PLATEN NUMBER 2 PLATEN NUMBER 3 PLATEN NUMBER 4 PRESS IDENTIFICATION TAG 37 PRESS IDENTIFICATION TAG ELECTRICAL INFORMATION TAG 38 APPENDIX Hydraulic Unit Drawings 12 ton 25 ton Hydraulic Unit Section View Typical Hydraulic Unit Drawing 30 ton Gauge Union Coupling Assembly Typical Hydraulic Cylinder 30 ton Electrical Symbol Cross Reference Electrical Drawings Press Assembly Drawings Hi Lo TWO SPEED PUMP HAND OPERATED MODEL EQCP14 150 with reservoir 321007 Does not include 329161 Lever Pump valve Insertion Tool 329061 1 4 Ball Seating Tool 2329063 7 16 Ball Seating Tool 329064 Threaded Socket Tool 2329080 for release valve removal ITE
31. he meetings Hold daily press inspections in addition to regular maintenance checks You will keep your presses safe for production and exhibit your commitment to safety Please read and use this manual as a guide to molding machine safety This manual contains safety warnings throughout specific to each function and point of operation It is to promote and increase safe press operation in your company OPERATOR RESPONSIBILITY It doesn t end with fast and efficient production The press operator usually has the most daily contact with the press and intimately knows its capabilities and limitations Plant and personal safety is sometimes forgotten in the desire to meet incentive rates or througha casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your press ONLY YOU can make safety work for you by constantly thinking about what is safe and what 15 not It is often the just once that a press operator reaches into a press to remove or adjust material or rest a hand in the ram area while talking to a co worker that results in serious injury Learn and always use safe press operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person
32. ioned Test cycle the press to verify it will operate as planned Locking selector switches should be adjusted only by authorized persons and the keys removed after setting Do not talk to others while operating a press If you must talk stop the press and step away from it until the conversation 1s completed Report the following occurrences IMMEDIATELY unsafe operation or condition unusual press action leakage improper maintenance NEVER stand or sit where you could slip or stumble into the press while operating it 4 DO NOT wear loose clothing or jewelry which can be caught while operating a press Also cover or tie back long hair DAILY clean the press and surrounding area and inspect the machine for loose missing or broken parts Shut off power to the press when it is not in use Lock the control panel or disconnect switch in the OFF position or unplug press from power source MOLD SETTERS RESPONSIBILITY What they sometimes forget is their own safety during the installation or removal of a mold To successfully perform this job the mold setter must gain a good working knowledge of the press molds materials and must know how to use a mold truck and other handling equipment Technical knowledge is not enough The mold setter s sense of personal safety is crucial Installing and testing mold guards and point of operation safety devices is as important as properly mounting the mold to the press DON T FORGET
33. it make certain that the release valve screw is closed finger tight IMPORTANT DO NOT rotate the release valve more than one full turn in the counterclockwise direction 30 ton 267 Kn models are equipped with a lever rather than a knob The cam release lever should be in the vertical position before the press is closed Opening the release valve approximately one half turn releases the pressure and allows the platen to open The release valve is equipped with a mechanical stop to prevent the valve from being turned out to far Pulling the cam release lever toward the operator to the horizontal position will allow the clamp on 30 ton 267 Kn models to open It may be necessary to push the platen down by hand when the press is new After a short period of use the platen will return under its own weight Please keep in mind that no hydraulic unit will maintain constant pressure without some additional pumping This is especially true when pressing against a soft or yielding material Some pumping 15 required to offset normal packing leakage After the desired pressure is obtained an occasional stroke or two will normally maintain the pressure 17 4 3 DAYLIGHT ADJUSTMENT Refer to the following drawings for information describing your press Mini C 12 Ton 107Kn 3989CE drawing 100321D Mini C 12 Ton 107Kn 3850CE drawing 81003220 Model C 12 ton 107Kn 3851CE drawing 1103230 Model M 25 Ton 223K n 3853CE drawing
34. layers x 3 minutes 18 minutes heat This time may vary according to the thickness and condition of the plastic sheet used See notes and suggestions Use the manual timer provided on the press for timing laminating cycles After the stack has heated sufficiently for lamination to take place it is then transferred to the cold opening The two holding clamps are used to hold the stack of laminations firmly while it 15 being transferred from the hot to cold opening Aside from the fact that they make it more convenient to hold the hot stack the proper use of the clamps 15 essential because they permit the maintenance of proper pressure on the stack to prevent bubbles from forming during transfer Open the guard door and attach the holding clamps to the holding plates gripping the stack at the center of each projecting side near the columns Only firm pressure on the holding clamps is needed just enough to keep the stack from expanding while the transfer is made After the holding clamps are in place on the heated stack close the guard door and open the press by loosening the release valve screw to relieve pressure After the press is open open the guard door and transfer the heated stack form the hot to the cold chamber using the holding clamps as handles While the press 1s open place a fresh stack of laminations between the hot plates Follow by bringing up pressure to the desired point and allow the new stack to remain under heat and pr
35. many applications including research and development specialized or low volume development ituations and quality testing Thousands of presses are in use all over the world for numerous applications in the chemical physical biological and mechanical fields wherever pressing is required 1 2 ACCESSORIES CARVER INC offers a variety of standard accessories for your press including Heated Platens Heating and Cooling or Cored Platens Test Cylinder Outfits French Pressure Cells Swivel Bearing Plates and Cage Equipment All original CARVER accessories are designed and manufactured by CARVER INC These accessories ensure precise results for many applications such as oil determination tests in food products crushing analysis on cement core samples molding of plastic quality control specimens and preparing KBr or tracer pellets etc Each accessory allows you to tailor the hydraulic press to your specific application In addition to these standard items we also manufacture custom presses and accessories for unique applications 1 3 CUSTOMER SERVICE The intent of this manual 15 to familiarize the operator and maintenance personnel with this equipment and help your organization get the maximum service from your press If you have any questions regarding installation service repair custom equipment or applications please do not hesitate to call or write for the information required Prices for presses accessories or repair parts will be
36. mp forward to remove valve spring valve plunger and steel ball Clean valve remove valve spring valve plunger and steel ball Clean and inspect valve hole If the ball seat 15 marred re seat same by lightly tapping ball on seat using tool CP13 45 Remove ball to prevent sticking Reassemble ball plunger spring and valve screw Connect a pressure gauge to the pressure outlet Stroke pump to obtain maximum desired pressure Turn valve screw clockwise to increase pressure reading and counter clockwise to reduce maximum reading After valve is set properly replace valve seal and valve plug LARGE PISTON PUMP RELIEF VALVE If the pump fails to lift faster under no load than it does under heavy load the large piston relief valve may be dirty This valve 15 covered with sealing compound to prevent tampering with large piston changeover point Remove sealing compound relief valve screw valve spring and relief plunger Use threaded socket tool CP13 41 for removing plunger Clean and inspect valve hole Inspect plunger packing and replace if necessary To reassemble dip plunger packing in oil and carefully insert into hole taking care not to damage packing during insertion of plunger Reassemble valve spring and valve screw Tighten screw to obtain desired effort on lever bar at large pump changeover point If screw 15 tightened too far it will restrict the relief valve movement and cause excessive handle effort throughout the high pressure cycle
37. nt air and water supply connected to the manifold CHECK VALVES SHOULD BE INSTALLED IN BOTH WATER AND AIR LINES TO PREVENT CONTAMINATING EITHER SUPPLY LINE WITH THE OTHER IMPORTANT The addition of shutoff valves in both water and air lines will facilitate operation and maintenance After cooling with water residual water should be purged from the platen cores with IMPORTANT compressed air before the next heating cycle The air supply should be a clean dry regulated compressed air source Verify that the water pressure is greater than the air pressure or the water will not enter the 14 platen cooling channels Set regulator below water pressure The following is to be used when determining the cooling medium required for the temperature being used AIR ONLY when temperature is above 600 F 315 C AIR WATER MIX when temperature is between 600 amp 350 F 315 amp 177 C WATER ONLY when temperature is below 350 F 177 C 3 WATER AND AIR OUTLET CONNECTIONS Each outlet hose will be used to drain the water air and water air mix from the platen it 1s connected to The outlet hoses can be connected to a common manifold or separately connected to the plants drain system The outlet manifold or hoses must be connected to a drain vented for steam with a steel pipe 4 STEAM CONNECTIONS Each platen is equipped with an inlet and outlet flexible metal hose for steam heat connections The customer is to
38. on request 4 CARVER INC recommends bolting the press to a work table whenever possible WARNING The use of an extension handle longer than provided with the standard press may cause the press to be unstable and may cause an over pressure condition resulting in damage to the hydraulic unit CAUTION When using a press with hot plates gauntlet gloves should be worn to protect the forearms and hands Steam can be released from a specimen when pressure 15 applied S When the top head has been repositioned the height on both sides must be measured to be sure that the head bolster is parallel with the base CAUTION CARVER recommends the use of safety glasses while operating this equipment 6 Always check the pressure rating of the pressed apparatus prior to pressing to be sure it is rated for the applied pressure IMPORTANT The gauge on the CARVER laboratory press shows the total force exerted by the press It DOES NOT show the pressure on the specimen PSI BAR To find the PRESSURE on the specimen the observed FORCE F reading on the gauge must be divided by the specimen AREA per the equation P F A When using a CARVER test cylinder outfit use the ID measurement to find the actual AREA A of the specimen See Section 3 T To protect against squirting fluid the apparatus may be placed inside a can or wrapped in a cloth 16 OPERATING THE HYDRAULIC PRESS Before attempting to operate the hydraulic un
39. operated it produces superior laminations which are not only pleasing in appearance and feel but are welded or fused together Separation under ordinary conditions is impossible Cards or papers are essentially tamer proof and are protected indefinitely Please take time to read and understand these instructions A little practice is of course necessary but you will be rewarded with outstanding results METHOD OF ASSEMBLING LAMINATIONS Generally laminations are laid up in one layer to stacks of six layers being separated by polished plates see Drawing 110545B In building up a stack of laminations be sure to have plastic sheets cut to the same size or slightly smaller than the polished plates A stack is made up as follows beginning from the bottom 1 One holding plate 2 One or two blotters 3 One polished plate 4 One plastic sheet same size as polished plate 5 Piece to be laminated For smaller pieces two four or more may be laminated in the same layer A border left around the edges for trimming at least 1 4 6 4mm on all sides and 1 2 12 5mm between pieces is necessary 6 One plastic sheet 7 Repeat setups 3 through 6 until the desired number of layers is reached never more than six layers Finish last layer with one polished plate 8 One or two blotters Blotters are used only on the top and bottom of the stack between holding plates and the out polished plates 9 Holding plate The stack 1
40. operation to make sure molds and equipment are working properly Before press is used for production replace all guards and applicable safety devices to protect the operator If the press operator is required to load unload parts provide safe and appropriate tools cotton gloves safety tongs vacuum lifters pliers or other mechanical devices for his or her use When changing press control settings to perform a different mode of operation be sure selector switches are correctly positioned Test cycle the press to verify it will operate as planned Locking type selector switches should be adjusted only by authorized persons and the keys removed after setting NEVER change selector switches press during cycle Ifthe press has been inoperative or unattended even for a moment check all settings before starting the next cycle Report the following occurrences IMMEDIATELY unsafe operation or condition unusual press action leakage improper maintenance MAINTENANCE RESPONSIBILITY Safety is essential to the good health of both man and machine If you are a maintenance worker you must make safety a priority in order to effectively repair and maintain press equipment BEFORE REMOVING ADJUSTING OR REPLACING PARTS ON A MACHINE REMEMBER TO BLEED all pressure from system components refer to the Maintenance Section of this manual TURN OFF all air water and hydraulic pressure sup
41. oupling b Gauge not sealing b Add copper gauge seal maximum of two NOTE Refer to the exploded view drawing accompanying this manual for the location of seals packing and gaskets in the hydraulic unit 5 2 HYDRAULIC UNIT AIR BLEED PROCEDURE 21 An occasional cause of hydraulic system malfunction is air entrapment in the hydraulic circuit purge the system open the release valve 1 2 turn or raise the cam release lever on 30 ton 267K n Models and pump the unit about 12 times Close the release valve and test If pressure does not build properly repeat this procedure IMPORTANT _ To avoid damage to the hydraulic unit ram seal DO NOT exceed the maximum ram travel Refer to Section 3 to determine the arm travel of your press Refer to the label on the front of the hydraulic unit 5 3 ELECTRICAL WARNING Before performing any maintenance on the electrical system turn OFF the main electrical disconnect on the press 1 Check all electrical connections Make sure they are tight Loose connections cause overheating which will lead to component failures or short circuits 2 Check all fuses or circuit breakers for open circuits and proper operation 5 4 MOLD SIZE VERSUS TONNAGE CHART 28 Maximum tonnage allowed on different mold sizes before platen coining occurs ppepes os ow s 39 8 Pew 39 5
42. our address listed in this manual The principle factors which can result in injury are l Failure to center the work over the ram in the platen area resulting in eccentric loading tilting and possible movement of the work piece which can then become a projectile 2 Failure to level the top head of the press after it has been repositioned which can produce the same results as in Number One above 3 Fracture of a specimen or part of the apparatus due to overload resulting in flying fragments 4 Occasional squirting of liquid from a pressed specimen 5 Contact with hot plates or heated apparatus can produce severe burns 2 3 GENERAL RESPONSIBILITY NO MATTER WHO YOU ARE Press safety is important Press owners operators mold setters and maintenance personnel must realize that every day all day safety is a vital aspect of their jobs If your main concern is productivity remember this Loss of production always follows an accident involving a press loss of a skilled operator temporarily permanently breakdown of shop morale costly damage to press and or tooling down time An effective press safety program is not only humanitarian but is also economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of t
43. plates This specially developed feature permits simultaneous heating and cooling of separate charges under the exact heat and pressure required to suit the particular plastic used This results in faster more efficient production of laminations Another feature of this press is the variety of standard laminating accessories available These include CARVER polished chrome plates These plates have a highly polished finish and have wide use for laminating molding and similar finishing work where good surface finish is required A variety of sizes are available from stock We also carry in stock laminating type blotters for use with these plates which are available in a variety of sizes Laminating Equipment This press is shipped with various accessories the purpose of each and their proper use is outlined below Holding Plates Six 6 holding plates are supplied They are made of hard aluminum alloy for quick transfer of heat They provide for holding one or more laminations in order to keep the press in continuous operation one heating one cooling and one staged ready for use These holding plates are used on the top and bottom of each lamination as outlined in the section titled Lamination Holding Clamps Optional 21 The holding clamps are used for maintaining pressure on lamination while transferring it from hot to the cold opening of the press see Laminating Procedure The holding clamps are adjustable so that the
44. plies and all accessory equipment at the machine DISCONNECT AND LOCK OUT electrical power and attach warning tags to the press disconnect switch and air shutoff valve If the press has multiple openings be sure ALL floating platens are completely open before servicing When you need to perform maintenance or repair work a press above floor level use a solid platform portable scaffolding lashed to the press or a hydraulic elevator If there 15 a permanently installed catwalk on your press use it The work platform should have secure footing and a place for tools and parts DO NOT climb on presses or work from ladders If you need to repair a large press component use appropriate handling equipment Before you use handling equipment portable a frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts of electrical apparatus electrical component enclosures and the press frame are correctly connected to earth ground with an electrical conductor which complies with current codes Install in accordance with the national and local codes which apply When you have completed the repair or maintenance procedure check your work remove your tools rigging and handling e
45. quipment Do not restore power to the press until all persons clear the area Start and run the press until you are sure all parts are functioning correctly BEFORE you turn the press over to the operator for production install and adjust all guards and safety devices SECTION THREE INSTALLATION 3 1 TWO POST PRESS DESCRIPTION s 3989 3851 3853CE 3968CE EH 4350CE EH 8CE Mini Mini Model Modic M 10 nam 10H Pellet Pellet CLAMP FORCE US E 12 12 12 25 12 12 12 106 8 106 8 106 8 222 5 106 8 106 8 ies 106 8 2121 51515 PLATENS 6x6 4DIA 6x6 9x9 10x7 10x7 4 DIA 4 DIA 152 x 152 102 DIA 152 x 152 228 x 228 254 x 178 254 x 178 102 DIA 102 DIA RAM STROKE IN 5 125 5 125 5 125 6 5 5 125 5 125 5 75 5 50 130 130 130 165 130 130 146 140 DAYLIGHT OPENING UNHEATED OPT HEATED FOOTPRINT WxD 11x16 11x16 16 15 19 19 14x 16 14 16 11x16 11x16 279 x 406 219 x 406 406 381 482 482 355 406 355 406 279 406 279 406 37 37 EU 177 939 939 Es 2 WEIGHT OPT HEATED UNHEATED 50 NOISE LEVEL lt 70db A lt 704 lt 70db A lt 70db A lt 70db A lt 70db A lt 70db A lt 70db A FULL LOAD 1157 12 184 12 18A 2434A N A 174A N A N A CURRENT 240V 5 84A N A 5 84A 11 66A N A 834A N A N A MAX SYSTEM PSI 7295 7295 7295 9709 7295 7295 7295 7295 PRESSURE bar 503 503 503 669 503 503 503 503 N A
46. s prepared as above and is then ready to be placed in the hot opening of the press for lamination If fewer than six layers are used see time temperature pressure recommendations below LAMINATING PROCEDURE 23 Place the stack of laminations between hot plates Tighten release valve screw and pump up press quickly using the short lever As soon as the press openings are closed place the long pump lever over the short pump lever and continue pumping until the hand on the gauge indicates the desired load The load should equal about 350 pounds per square inch 24 1 bar of plastic sheet this figure may vary according to the nature of the particular plastic sheet used The desired load as read on the press gauge can be figured like the following example Using 9 x 12 22 8cm x 30 5cm plastic sheet 9 x 12 22 8cm x 30 5cm 108 sq inch 695 4 sq cm 108 sq inch 3504 psi 695 4 sq cm x 24 1 bar 37 8002 load 168 Initially it 15 always desirable to pump up a few hundred pounds over the computed load to compensate for immediate compression of blotters and plastic Additional pumping to maintain correct pressure may be done for the first two minutes of heating time but should not be done after that time Allow the stack to remain under heat for a period of time roughly determined by multiplying 3 minutes by the number of layers in the stack Thus a six layer stack should take about 18 minutes to heat For example 6
47. time are based on the use of regular plastic sheets either 010 or 015 25 or 38mm thick When using vinylite plastic 010 25mm thick the thermostats should be set to maintain a temperature of approximately 320 160 C The recommended pressure for vinylite is 350lbs per sq inch 21 4 bar of plastic sheet Time required to process a stack of laminations containing six layers will be from 16 to 18 minutes heating time depending on thickness of the vinylite used Temperature and pressure requirements may vary slightly due to local atmospheric conditions therefore figures given are for average conditions You may find that a slight variance in these figures may be needed to suit particular conditions and requirements The pressure may drop as much as several hundred pounds newtons below the desired load without harm This 15 partly due to the softening of the plastic as it heats and compression of the blotters Always have the plastic material cut to the same size as the polished plates Plastic sheets smaller than polished plates tend to spoil the flatness of the plates as well as cause uneven pressures the laminations Having plastic and polished plates of the same size also affords easy registering of the layers in a stack of laminations Store your supply of plastic material in accordance with manufacturers recommendations Preferably in room or enclosure having a high relative humidity approx 50 or 6096 It
48. tipped set screw must be loosened on each nut before nuts are loosened 18 3 Release hydraulic force and remove the spacer allowing top bolster to rest lower column nuts 4 Move the upper column nuts to the position required to create the desired daylight 5 Raise the top bolster against the top nuts and tighten the lower nuts finger tight against the bottom of the top bolster 6 Measure and equalize the distance from the bottom surface of the top bolster to the top surface of the base bolster at two points four points on Four Post presses as far apart as possible Adjust the lower nuts as needed to insure parallelism between the top bolster and base bolster Turn the upper column nuts finger tight against the top bolster T Insert a spacer block with parallel surfaces between the moving bolster and the top bolster spacer must be tall enough to build force on spacer pump the hydraulic unit to build force to the maximum capacity of the press 8 Tighten the lower nuts against the bottom surface of the top bolster as tight as possible 9 This 15 a good time to check nuts on top of the base bolster if necessary retighten 10 Tighten brass tipped setscrews in nuts 1f your press is a Four Post Open press and remove spacer the press is now ready to operate To lower the top head bolster 1 Insert a spacer block with parallel surfaces between the moving bolster and top bolster pump the hydr
49. um of spoilage and retakes In laminating the thermoplastic material used is brought to a semi liquid condition while between heating plates After transfer to the cold opening of the press it is most important that proper pressure be maintained during the cooling cycle for it 15 in the cooling cycle that the plastic sets or changes from a semi liquid to a solid state The press is designed so that the cooling operation will be a little faster than the heating therefore maintaining a continuous flow of production Always keep in mind that a stack of laminations will require the same pressure for cooling as 15 required for heating You cannot cool a stack of laminations have 5 x 6 12 7 x 15 3cm sheets of plastic at the same time you are heating a stack of laminations have 3 x 4 4 x 5 7 6 x 10 2 10 2 x 12 7cm or smaller sheets of plastic It will be readily seen that the two stacks will not have equal pressure per square inch applied to the plastic Many of the thermoplastic materials on the market may be used with the CARVER Laminating Press such as acetate vinylite and certain acrylic materials Pressures temperatures and time for laminating the various materials will however be different SECTION FIVE MAINTENANCE 26 Each CARVER Laboratory Press is thoroughly tested to provide trouble free performance Manufacturing and assembly processes are closely controlled in our factory under rigid inspection and testing procedures
50. y may be use for stacks of laminations of varying thickness The clamps may be adjusted as follows 1 Hold the clamp in one hand with the lever up against the main body of the clamp 2 Back off the adjusting screw by turning it in a counterclockwise direction to the left until the jaws are opened just enough to be placed over the stack of laminations outside the holding plates 3 Open the clamp lever 4 Place the clamp in position on the projecting side of the holding plates 5 Turn the adjusting screw about a half turn or so in a clockwise direction to the right 6 Close the clamp by squeezing on the lever The lever should snap up against the main body of the clamp grasping the stack firmly If it does not adjust the end screw until it performs as specified above IMPORTANT DO NOT GRIP THE STACK TOO TIGHTLY WITH THE HOLDING CLAMPS Just a firm grip enough to hold the stack closed and afford easy transferring is all that is needed Too much pressure on the holding clamps may spring the holding plates and produce bubbles in the laminations Polished Plates Polished plates are supplied in sets of 24 pieces enough to build three stacks of laminations six layers each using seven plates per stack The three extra plates are supplied as spares in case some become scratched or damaged These plates are made of chrome plated steel and are highly polished When using the polished plates be sure to center them on the holding plates
51. ydraulic Jack with above specifications SECTION SEVEN ACCESSORY EQUIPMENT 30 Thank you for the opportunity to supply CARVER equipment for your requirements If there are any questions regarding the operation of this press or other CARVER accessories please contact us for assistance CARVER offers a wide range of accessory equipment to satisfy your specific application s Swivel Bearing Plates Test Cylinders Heated Platens Heating Cooling Plates Heated Test Cylinders Filter Pads KBr Buffer Plates Tile Molds Blotters Polished Plates Cage Equipment Pressure Cells Color Dispersion Molds Pharmaceutical Die Fixtures Low Range Gauges MOST ACCESSORIES AVAILABLE FROM STOCK Our applications Group can also be of assistance with custom instrumentation and special accessories for your application OTHER CARVER EQUIPMENT Manual Pellet Presses Laminating Presses Laboratory Chillers Custom Hydraulic Presses amp Systems Rubber Stamp Presses AutoPellet Presses SECTION EIGHT CARVER INC SERVICES 8 1 TECHNICAL ASSISTANCE 31 CARVER INC PARTS DEPARTMENT Call from 8 00 a m to 4 30 p m Eastern Standard Time 219 563 7577 Extension 237 or 254 The Parts Department at CARVER INC is ready to provide the parts to keep your equipment up and running Original replacement parts ensure operation at design specifications Please have the model and serial number of your equipment available when you call Consult the Parts List inclu
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