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3630 X-Press

By Stephen Owens,2014-04-25 19:39
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3630 X-Press

    3630 X-Press Users manual

    用户手册

Read this first !

    Addendum(附录) to the 3630 X-Press instruction manual;安装手册; The following replace a section of paragraph 2.section 3.3

Remember: before proceeding, unplug(拔去) the unit.

To access the oil filter port more easily, a door has been incorporated on the right side of the unit.

    Instead of removing the side top and side covers to bleed the unit or to add oil (as stated in your

    instruction manual), you now simply remove the door by unscrewing the four screws fastening it.

    After refilling the unit with oil according to the instructions in the manual, replace the door.

Contents

Introduction

    Press layout

    Press specifications

    1. Preparation for use

    1.1 Unpacking

    1.2 Setting up your x-press

    1.3 Performing a test run

2. Running your x-press

    2.1 Front panel controls

    2.2 Turning the x-press on and off 2.3 Programming the x-press

    2.4 Saving new default values

    2.5 Running an automatic cycle

    2.6 Manual operation

    2.7 Emergency stops

3. Maintenance

    3.1 General procedures

    3.2 Removing the cover

    3.3 Draining, refilling and checking oil 3.4 Bleeding the air

    3.5 Changing the v-belt

4. Mechanical operation

4.1 Mechanical layout

    4.2 Valve position

    4.3 Error messages

5. Troubleshooting

    Index

Introduction

    The SPEX model 3630 X-press is an automated laboratory press intended for the pressing of sample pellets for spectroscopy. The press is programmable, so that repetitive pellet preparations may be carried out with a minimum of operator workload and a maximum of uniformity. This manual provides basic operating and maintenance procedures for the 3630 X-Press, and is organized into five broad sections:

    1. Preparation for use

    2. Running your X-Press

    3. Maintenance

    4. Mechanical operation

    5. Troubleshooting

    This manual is intended to be as comprehensive as possible. However, in the event you need further technical or application information, you may also contact SPEX Industries sample

    preparation sales department staff at the address and phone number on the front cover of this manual.

Press layout

    Figures 1a-c show the basic layout of your X-Press, with panels removes and partial cutaways made to show important interior details. The views are not to scale.

    The front view (Figures 1a) shows locations of the keyboard and data displays through which the automated press is operated. The sample, with its die and plunger, is placed in the sample compartment on top of a flat platen (not visible here) and secured in place by the upper adjustment screw. A solid aluminum test block is provided as a dummy sample for testing. The manual

    pressure relief valve on the right side of the press brings the hydraulic system pressure to atmospheric in an emergency or for system maintenance: it is left closed during normal press operations.

    The side view (Figures 1b) shows more detail of the platen and the piston underneath, as well as the clear plastic door on the front of the sample chamber. The oil reservoir can be seen near the bottom center of the press, with the drain plug at the bottom and the fill port at the top (the manual pressure relief has been omitted here for clarity). The press motor can be seen at the rear of the press.

    The back view (Figures 1c) shows the locations of the main power switch, power cord receptacle, pump and main valve.

    Figures 1a Front view, 3630 X-Press

    Figures 1b Side view, 3630 X-Press (manual valve handle deleted for clarity) Figures 1c Rear view, 3630 X-Press (motor, belt drive deleted for clarity)

Press specifications

    Force:0-35 tons ram pressure

    Dwell time: 0-90 minutes

    Release time:0-9 minutes

    Platen movement: 1inch (25mm)

    Platen size: 3.25 inches (8mm) diameter

    Daylight: 2.0-6.0 inches (5-15cm)

    Screw adjustment: 3.5 inches (9cm)

    Dimensions: 23H*11W*22.5Dinches (58H*28W*58D cm)

    Power: 800VA, 1/3 HP motor (115 V/60 Hz or 230V/50 Hz)

    Net weight: 130pounds (51Kg)

1. Preparation for use

    1.1 Unpacking

    At the factory, your X-Press is adjusted and tested for proper operation, then drained of oil and carefully packaged for shipping. Upon receipt, you should check for possible shipping damage. If there is any, notify SPEX industries and file a claim with the carrier immediately.

    To unpack your X-Press, first remove the outer and inner protective boxes nailed to the wooden base of the shipping crate. Remove the protective plastic cover and any foam packing material. Lift the press out of the crate base and place it on a sturdy laboratory bench. CAUTION: The X-Press weighs about 130 pounds. Be sure to have adequate personnel and/or lifting equipment on hand when moving the unit.

    You should also find the following accessory items packed with your X-Press: -Filter cap for fill port

    -Power cable

    -Fuse and fuse holder

    -Handwheel handle

    -One pint of hydraulic oil

    -10-32*1 screw (for lifting platen off its piston)

    -Oil bleed nipple

    -Plastic tubing for nipple

1.2 Setting up your X-Press

    1) You will need to remove the top and right-side metal panels of the rear portion of the X-Press

    to access the interior for filling and bleeding. Follow the instructions in section 3.2,

    Removing the cover.

    2) At our plant, your X-Press was filled with hydraulic oil, tested, and drained for shipping. You

    must now refill it with fluid. Using the pint of oil included with the unit, follow the

    instructions in section 3.3, draining, refilling and checking oil, to refill the X-Press.

    3) Replace the solid plastic cap on the fill port, with which the X-Press is shipped, with the filter

    cap included with the accessories. The press will not work properly with solid in place.

    4) Insert the fuse and fuse holder into the press at the bottom rear edge. Plug the power cord into

    the receptacle next to the fuse holder socket, and then into a grounded wall outlet.

    WARNING: avoid contact with the exposed electrical component of the press. They involve hazardous voltages! Do not activate the power switch until it is necessary to do so. 5) You next need to bleed the air from the hydraulic loops in the press. Follow the instructions in

    section 3.4, bleeding the air. The press is activated with the toggle switch on the lower rear

    edge of the unit. Do not turn the unit on until necessary. When the air has been bled, unplug

    the unit and replace the covers.

    6) For protection of the polycarbonate door on the front of the unit, foam plastic has been

    wedged into the upper part of the door track. Remove the foam and slide the door up. When

    the door has been raised about 5.5 inches (14cm) from the bottom of the track, a slight

    forward push on the knob will secure the door in an open position. Since the door acutates a

    safety switch, it must be closed during press operations.

    7) Attach the handle to the handwheel on the top of the unit by screwing it into the threaded hole.

    Tighten it using an 8 mm or adjustable wrench on the flats at the base of the handle. Now turn

    the handwheel to free the aluminum test cylinder. The handle should rotate freely as the

    handwheel is turned.

1.3 Performing a test run

    You can test your X-Press as soon as the above setup procedure has been performed, because the unit arrives already programmed with a test cycle. You can use this programmed cycle to check the operation of the press, the program your own cycle by following the instructions in section 2.4. To turn your 3630 X-Press on, flip the switch at the very back of the unit, on the bottom edge. The factory-programmed information stored in memory will come up on the units left-side

    display:

    Tons:25 hold time:0.3 rel time: 1.1

    Raise the plastic window and prop it open with a slight push. Place the test block in the press between the platen and the screw. Center this block on the platen and turn the handwheel until the adjustment screw makes contact with the top of the block, then back it off about 1/8 for this test.

    Close the window.

    Press the RUN key (upper left corner of the keypad). The unit will run through the automatic cycle:

    1) the units main valve will close, the PRES indicator will light and the pump will pressurize

    the piston underneath the platen. The platen will rise until the top of the test block contacts the

    screw.

    2) The TONS display will show the increasing force being exerted on the piston. The unit will

    stop pumping when the display reaches the programmed value of 25 tons.

    3) The unit will pause for 0.3 minutes (18 seconds) while the force is kept constant and the

    HOLD TIME display counts down the remaining pauses time.

    4) At the end of the hold period, the main valve will open and the TONS display will show the

    decreasing force on the test block. The REL TIME display will show the time remaining in

    the release period. The release period will last 1.1minute (66 seconds).

    5) When the release period ends and the applied fore is zero. The X-Press will beep, the message

    End will appear in the HOLD TIME display and the message pd (pump down) will appear in

    the TONS display as the piston will be pumped down to its normal rest position. The front

    window can be opened, or another cycle can be run by pressing the RUN key again.

2. Running your X-Press

    Your 3630 X-Press permits both manual and automatic sample pressing. The unit operates in three modes:

    Auto mode, in which a programmed pressing cycle is executed automatically by the X-Press; Program mode, in which the auto mode pressing cycle is programmed into the X-Press; Manual mode, in which sample pressure is increased or reduced by manual keyboard inputs. The next sections describe how to use the press in each of these modes.

2.1 Front panel controls

    Your 3630 X-Press has a keypad on which manual operations, programming and automatic operations are performed (figure 2). The MAN (manual) and RST (reset tonnage) keys are used for manual operations while the other are used to program and run automatic pressing cycles. The use of all these keys is described in detail in sections 2.3 and 2.4.

    Along with the keypad there are three numeric displays:

    TONS displays the piston force, from 0 to 35 tons, with a resolution of one ton, when the unit is in auto mode or manual mode. In program mode, the peak tonnage of the programmed cycle is shown.

    HOLD TIME, in program mode, shows the time for which the maximum pressure will be maintained at the top of the cycle. In manual mode, the setting of the main valve is displayed (see section 4.2).

    REL TIME, in program mode, shows the time for which system pressure will be bled to zero during an automatic cycle. In auto mode, the remaining bleed time is displayed. In manual mode, the display is blank.

    There are also four indicator lights to inform you of the operating status of the press. PRES

    (pressing) lights when the pump is running. HOLD indicates the hold portion of an automatic

    cycle. REL (release) indicates the bleed portion of an automatic cycle, while MAN (manual)

    indicates whether the press is in manual mode.

2.2 Turning the X-Press on and off

    To turn your X-Press on, flip the power switch at the bottom rear of the unit. The press will be fully activated, coming up in auto mode, with the values of the default pressing cycle displayed on the left side.

    If the unit does not activate, check to see that it is properly plugged in. if it is, check the fuse on the back of the unit. Unplug the press, squeeze the small tab on the fuse holder cover against the cover itself, and pull the cover forward to pull the fuse holder out of the unit. Check the fuse to make sure the center conductor is intact. If not, replace it with a 3AG 10-amp slow-blow fuse. Replace the fuse holder and plug the press back in.

    There are two ways to turn your X-Press off. You can simply flip the switch at the back off, cutting power to the unit. You should first make sure there is no pressure in the system, by pressing the red STP (stop) button.

    You can also put the X-Press in a standby mode by pressing the PWR (power) button. This

causes the press to automatically depressurize. The MAN indicator will then flash on and off for

    ten seconds, allowing you to store the current program as the default program (section 2.4), and then the unit will shut down in a low-power mode. In this state, the indicator lights in the middle of the front panel will sequentially light to let you know the unit is in standby. Another press of the PWR button will reactivate the unit in manual mode. (To return to auto mode, press the MAN key

    so that the MAN indicator light is out.)

2.3 Programming the X-Press

    You can program the pressing cycle you want into the X-Press when the unit is in program mode. A particular key sequence is used do that it is unlikely the programmed cycle can be changed by accident.

    To put the X-Press into program mode, the press must first be in auto mode. (The MAN indicator

    must be out. Press the MAN key if the MAN indicator is lit.) To enter program mode, you must

    simultaneously press the TON, HLD and REL keys. All four indicator lights in the middle of the

    panel will flash, signaling that you are in program mode. (If the unit beeps, release all keys and try again.)

    You can now program a cycle by selecting three values (Figure 3):

    Maximum tonnage-press the TON key to enter the maximum force to be applied during the cycle; the TONS display will flash. Using the number keys, enter the maximum tonnage value, which may be set from 5 to 35 tons, in increments of 1 ton. Press the ENT (enter) key to store the new

    tonnage value.

    Hold time-press the HLD key to enter the hold time at maximum tonnage; the HOLD TIME

    display will flash. Using the number keys, enter the hold time value in minutes and tenths of minutes, from 00.0 to 90.0 minutes. (A tenth of a minute is six seconds.) Press ENT to store the

    new hold time value.

    Release time-press the REL key to enter the length of time you want the unit to release tonnage from the maximum to zero. The REL TIME display will flash. Enter the release time value in

    minutes and tenths of minutes fro 0.0 to 9.0 minutes.

    Press the RUN key to exit program mode. You are now ready to run automatic cycle with these new values. The press will remember these values until the power switch in the back is shut off.

2.4 Saving new default values

    The X-Press stores one set of values (the default values) for the automatic cycle indefinitely,

    even after the power to the press is turned off the press will use the default values to run automatic cycle unless programmed otherwise, as in the last section.

    You can change the default values at any time, while in program mode. To save new values indefinitely in the press, you must first program them into the press as described in the previous section. Then, you must press the PWR key o shut off the press. The press will pump the piston

    down, and then the press will shut off. However, the MAN indicator light will blink on and off for

    ten second. If the ENT key is pressed during this time, the new cycle values will be saved to the permanent memory. If it is not, the old default values will remain intact.

    Your X-Press is shipped with an initial set of default values: 25 tons, 0.3 minutes hold, 1.1 minutes release. These will remain the default values until you change them.

2.5 Running an automatic cycle

    Before running a cycle, be sure that an appropriate amount of sample powder fills the die, that the plunger is properly seated in the die, and that the die is centered in the press. Turn the handwheel to take up any slack. Close the sample chamber door. The manual pressure relief valve on the right side of the unit must be closed (turned as far clockwise as possible).

    To run the default cycle (or the current cycle, if you have made changes), make sure that the MAN

    indicator light is out (press the MAN key if need be). Then press the RUN key:

    1) The main valve will close, the PRES indicator will light, and the unit will pump up to the

    selected maximum tonnage. The TONS display will show the changing tonnage.

    2) The unit will then hold at maximum tonnage for the specified hold time, the HLD indicator

    will light, and the HOLD TIME display will count down the hold time.

    3) At the end of the hold period, the main valve will open, the REL indicator will light, the REL

    TIME display will count down the time remaining and the TONS display will show the

    changing tonnage.

    4) When the pressure reaches zero. The piston will be brought back to its rest position, the

    beeper will sound and the HOLD TIME window will display the message End.

    To halt the cycle at any point and return the tonnage to zero, press the red STP (stop) button.

    The cycle may be run again immediately after the previous one is complete. Remember: the door of the press must be closed during the cycle. If it is not, the safety interlock will prevent the unit from running its cycle. If the door is opened during the cycle, the cycle will be stopped, pressure will be bled off at maximum speed, and the beeper will sound until the unit pressure is zero. The HOLD TIME window will display the message Int (interlock) to indicate that the door interlock

    has been activated, and will continue to display this until the door is closed. The press is automatically put into manual mode after an interlock interruption. To re-renter auto mode, press the MAN key so that the MAN indicator light is out.

2.6 Manuel operations

    Your 3630 X-Press can be operated manually. Press the MAN key to enter manual mode. (The

    MAN indicator must be lit.) The manual pressure relief valve handle on the right side of the unit must be closed (turned fully clockwise).

    Pressure can now be applied by pressing the up-arrow RST (reset tonnage) key: holding the key

    down will continuously increase pressure, while short presses of the key will increase the pressure in increments. The current tonnage is displayed in the TONS window.

    To decrease pressure, press the down-arrow RST key. Tonnage will continuously decrease if the

    key is held down. Short presses of the key will decrease the pressure in increments. You will notice numbers being displayed in the HOLD TIME window during these operations.

    These indicate the open condition of the main valve. At zero, the valve is completely closed; this occurs during pump-up of the piston when tonnage is being applied. When the valve is partly open the numbers run from 1 to about 300, which corresponds to a fully-open condition. The door of the X-Press must be closed during manual operations; otherwise, the piston is automatically depressurized and the message Int (interlock) is displayed in the HOLD TIME

    window.

    To halt operations and return the tonnage to zero, press the red STP key. The press will

    automatically pump down to a depressurized state. The TONS window will display Pd (pump

down), and the HOLD TIME window will display the message STP as the pressure is relieved.

    Pressing and holding the REL key down in manual mode will rapidly decrease tonnage without

    pumping the piston down to its rest position.

2.7 Emergency stops

    To stop the press: press the red STP key.

    Pressing the STP key in auto mode causes the cycle being run to halt. In both auto and manual modes, the press immediately begins to pump the piston down and release pressure, while the TONS display reads Pd and the HOLD TIME display reads STP. When the pressure is released

    and the piston is pumped down, the unit is put into manual mode.

    To relieve pressure: turn the manual valve counterclockwise.

    If the power is shut off during a pressing, pressure may remain. To relieve this pressure, open the manual pressure relief valve on the right side of the unit. Be sure to close it again when you are ready to continue operations; this valve must be closed for the press to operate properly.

3. Maintenance

    3.1 General procedures

    Your X-Press has been designed to provide trouble-free operation over a long period of time. To assure proper performance, perhaps the most importance factor is cleanliness. Any spilled powders or hydraulic oil should not be exposed to dust, moisture, etc. more than necessary, as those can affect both the mechanical and electronic functions.

    Exposed steel parts, particularly the screw and platen, can be wiped down with rust preventative oil. In doing this, care must be taken not to expose the electronics or cables to oil, which can damage them. The motor bearings are factory-lubricated for ten years of use.

    Before any hydraulic parts of the X-Press are disassembled, the manual pressure-relief valve should be opened by turning the lever on the right side of the press counterclockwise. This will bring all the oil in the press to safe pressure. The valve must be closed again for normal press operations.

3.2 Removing the cover

    The sheet metal enclosure at the rear of the X-Press comes apart for such tasks as exchanging the fill port caps, replacing the motor, changing or adjusting the V-belt, etc.

    Warning: ALWAYS unplug the press before you remove the cover, to avoid hazardous voltages!

    The top panel is fastened to the side panels with nine screws (including one on the front left side of the unit). When these are removed, the top panel may be lifted off. Each side panel has two inward-facing tabs with slots that fit around screws in the press base. To free the side panels, loosen these screws. (You will need a #2 Phillips-head screwdriver with a shank at least 12 long

    to reach the bolts at the base of the side panels.)

    To remove the right side panel, it is also necessary to remove the pressure-relief valve handle by unscrewing one of the plastic balls and sliding the handle out the hole in the valve shaft. Two cable harnessed are affixed to this panel, and must be detached by unbolting them. These bolts require a regular screwdriver.

    You can note panel and screw locations in figure 1b and 1c in the introduction.

3.3 Draining, Refilling and Checking Oil

    Should you need to drain the hydraulic oil, there is a drain plug on the bottom of the oil reservoir, reached through an access hole in the base of the press. Raise the X-Press about 4 off the bench.

    (Two 4*4*14 pieces of wood are adequate to support the press.) Insert a pan with a capacity of about one pint (500ml) under the drain plug. Remove the plug with a 5/32 Allen wrench.

    To refill the X-Press with hydraulic oil, replace the drain plug. Remove the top and right-side panels of the sheet metal enclosure, as described in section 3.2, being sure to unplug the press

    first, and unscrew the metal fill port fixture. Use 20w hydraulic oil, which can be obtained commercially 1-1/8 (3cm) above the bottom of the reservoir.

    To measure the hydraulic oil level without removing the fill port, you will need a 6 rod of about

    1/16 diameter. Take off the filler plug plastic cap and filter media and measure the oil level through the vent hole in the filler plug.

    NOTE: Dirt is a mortal enemy of any hydraulic device. Take suitable precautions to prevent dust and debris from entering the fill port during filling and level-checking.

3.4 Bleeding the Air

    The X-Press hydraulic system should be bled of air a) after shipment, b) whenever hydraulic oil is added, and c) after any repairs to the system. For this operation, have on hand a1/8 Allen wrench

    for the bleed screws, a 3/16 Allen wrench for the bleeder nipple, and the bleeder kit supplied with the X-Press. The bleeder kit consists of the bleeder nipple, 2-1/2 feet of 5/16OD plastic tubing

    and 10-32*1 screw included with the accessories.

    Thread the 10-32 screw into the tapped hole in the platen; use it to lift the platen out. You will see a small recess on the piston surface with a screw in the center. This is one of the hydraulic loop bleed screws; there is another on the press stage itself, behind the piston. (Figure 4) Place the solid aluminum test block in the piston recess, leaving the piston bleed screw exposed. Turn the handwheel until the screw makes contact with the test block, and close the manual pressure-relief valve by turning it clockwise to its limit.

    Unplug the unit and remove the top and right-side panels of the enclosure (section 3.2). Unscrew the metal fill port fixture.

    Bleeding must be carried out at both bleed screw, with the rear screw bled first. Remove the rear bleed screw with the 1/8Allen wrench. Insert the bleeder nipple into the bleed screw aperture, tightening it with the 3/16Allen wrench. Slide the plastic tubing onto the nipple as far as it will go and insert the other end of the tubing into the oil reservoir after removing the fill port. Plug the unit back in and turn on the power switch.

    WARNING: Do not touch the exposed electrical components of the press during bleeding operations. They present a serious shock hazard!

    The unit will come on, with the default automatic cycle values in the left panel display. Press the MAN key to enter manual mode. (The MAN indicator light in the middle display window must be

    lit.)

    In manual mode, turn on the pump by pressing the up-arrow RST key and continue pumping until

    the oil in the tubing runs free of are bubbles. (several short halts in pumping, followed by a brief opening and closing of the manual pressure-relief valve, may bring more trapped air to the top.)

    Pinching the tubing to prevent oil spillage, remove the tubing from the bleeder nipple and replace and tighten the rear bleed screw, immediately wiping up traces of spilled hydraulic oil. Repeat this operation with the bleed screw on top of the piston.

    When both bleed screws are replaced and tightened, run the press back up to 8 tons (as shown on the TONS display) in manual mode to check for leakage. Finally, press the red STP key to pump

    the piston back down. Remove the test block and replace the platen.

3.5 Changing the V-Belt or motor

    The V-Belt of your X-Press connects the motor with the hydraulic pump. If the pump can not attain maximum tonnage, it may be because the belt is slack and is slipping on its pulleys. To tighten or replace the V-Belt, the sheet metal cover must be disassembled and removed as described in section 3.2. The V-Belt may be tightened, or slacked off and removed, by loosening the motor mounting bolts and shifting the motor. The motor mounting bolts are threaded into the base of the X-Press.

    V-Belt tension may be checked by applying finger pressure to the V-Belt halfway between the motor and pump pulleys. If the V-Belt can be depressed more than 3/8 (10mm) it should be

    tightened. A badly worn V-Belt should be replaced.

    The motor and pump pulleys must be properly aligned. Misalignment can cause excessive operating noise, rapid wear of the V-Belt, and damage to the motor or pump. When viewed on edge, the pulleys should line up with respect to each other.

    Warning: Always unplug the X-Press when opening the cover, to avoid an electric shock hazard. After changing the belt, or motor, make sure that the motor mounting bolts are tightened securely before operating the X-Press.

4. Mechanical operation

    4.1 Mechanical layout

    Figure 5 is a simplified schematic of the mechanical layout of the 3630 X-Press. You should study it to become familiar with the basic operation of your X-Press.

    The press has an oil reservoir maintained at atmospheric pressure, which is open to the air through the fill port prevents particulate matter from entering the hydraulic loop. A drain plug on the bottom of the reservoir allows the oil to be drained out of the system. A pump operated by the units motor draws oil from the reservoir to pressurize the piston beneath the press platen. Two valve-the microprocessor-controlled bleed/safety valve and the manual pressure relief valve-relieve piston pressure by opening the piston passage to the reservoir and atmospheric pressure. The main valve doubles as the units safety valve, preventing over pressurization.

    When the bleed and manual pressure relief valves are closed and the pump is run, pressure builds up in the piston. If the piston is free to move (that is, it is not in contact with a sample), it will extend upward. The piston extends to a maximum of about an inch before coming up against internal stops.

    When the main valve opens, pressure is allowed to escape from the piston, lowering the force (tonnage) on the pellet die.

    Both the main valve and the pump are microprocessor-controlled; you control the amount of force applied to the specimen by use of the keyboard on the front of the unit. Because a microprocessor

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