INSTALLATION & COMMISSIONING

1. Installation of Press Machine

1.1 Handling and acceptance inspection

1.1.1 Acceptance inspection

(1). Each KINGLAN press will be packed well before transportation for the purpose of being undamaged when arriving at the destination.
(2). When collecting machine, please firstly check the surface of machine and observe whether there is any damage on it. If yes, please inform our company and the carrier person to check.
(3). If machine is undamaged, then subsequently check standard accessories and special accessories as per attached accessory list. If there is any loss, please also inform our company and the carrier person to check.

1.1.2 Handling Instruction

Because the press itself is of large volume and weight, an ordinary mechanical lifting method is not workable. Therefore, the loading capacity of crane and wire rope should be taken into consideration when handling and the safety of the machine bulge areas must be paid attention at any time.

1.1.3 Lifting Instructions

(1). Check whether the surface of the wire rope is damaged.
(2). Wire rope 90 ° lifting method is prohibited.
(3). When lifting corners, the relevant wire rope sections should be covered with wasted cotton cloth.
(4). Do not use the lifting chain.
(5). When the machine must be moved by manpower, it can only be pulled and cannot be pushed forward
(6). Keep a safe distance in lifting.

1.1.4 Lifting Steps

(1). According to the weight of press model, the appropriate wire rope is selected to be fixed to the bottom hole of the machine body and the C-type lifting ring in a cross-shaped manner.
(2). Place the crane hook in a proper place, slowly leave the floor and adjust the load appropriately to maintain the balance of the machine.
(3). Be careful to lift and handle after confirming safety.

1.1.5 Unloading instructions

The back of the machine is uneven. There are tonnage meters, photoelectric controllers, and air piping on both sides. Therefore, it cannot be tilted backwards and backwards. The only way is to put the front of the screen as shown in the figure. Of course, it is best to use wooden blocks to avoid hurting the external side of machine.

The length of the selected block must be greater than the width of the sides of the press.

If the height of the factory gate is lower than the height of the press, or the lifting of the crane is inconvenient, the press can be inverted and a short distance displacement can be implemented with a round stick, but care must be taken to prevent accidents.

The selected board must be able to withstand the load of the press.

1.2 Foundation

1.2.1 Basic construction steps

(1).Preparations before construction
1). Dig pits based on the foundation map, the perimeter of the base, its width, and the height above the installation location.
2). Terrestrial endurance must meet the requirements stated on the schedule. If it is insufficient, it must be reinforced.
3). The bottom is arranged with pebbles, which are about 150mm to 300mm high.
4). A pit is reserved in the foundation, and the board is made into a spare in advance according to the dimension indicated on the drawing surface, and is placed in a predetermined position when the concrete is poured.
5). When reinforcements are needed, they should be properly placed in advance.

(2). After the preparation of the above item is completed, the concrete shall be filled with 1:2:4 concrete.
(3). After the concrete is dried, remove the planks and trim them except for the base screw holes. For those facilities that have oil sumps, the bottom surface should be trimmed to have an inclined surface so that the oil can flow smoothly to the oil sump.
(4). When installing the machine, the machine and the base screws, leveling plates, etc., are first installed in this position, and the level of the machine body is adjusted and poured concrete into the base screw position pit a second time.
(5). After the dry, repair it.
Note: The pedals on the periphery of the machine are filled by the customer with appropriate materials.
If anti-shock device is required, add a layer of fine gravel (about 150mm wide groove) to the periphery of the foundation. If the customer needs this base map, request it separately and provide it separately!

1.3 Installation

1.3.1 Installation of machine body and working table

(1). Please follow the standard foundation diagram we sent beforehand. If the customer site is weak, please reinforce it properly.
(2). During transportation, the machine is rubbed with anti-rust oil. Please wipe it clean before installation.
(3). During installation, please use a precision leveler to measure the level and adjust it to within 0.1mm.
(4). When measuring the level of the table, check whether the table is locked.
(5). If working table is installed by customer, it should be noted that the contact surface between the table and the machine body should be kept clean. Do not leave foreign objects such as paper, metal fragments, plugs, gaskets, dirt, etc. on the contact surface.
Note: The gasket is at least as large as the foot of the press so that the foot contact surface bears the weight of the press on average.

1.3.2 Transmission part installation

The main drive motor should be combined with the press as much as possible. If the transportation is limited, the motor must be removed. The reinstallation method is as follows:
(1). Unpack the part and inspect it for damage.
(2). Clean the motor, motor sheave, flywheel groove, bracket, and do not drip the solution in the motor. Clean the V belt with a cloth. Do not use the solution to clean the belt.
(3). Mount the motor to the engaged position, but do not tighten it completely. Use a sling to support the weight of the motor before the screws are locked.
(4). Use measuring tool to measure the alignment of the motor sheave and the flywheel, and move the motor to the correct alignment. The proper alignment of the sheave and the pulley will cause the belt groove and the motor bearing to wear, and the alignment screw will tighten the motor seat screw.
(5). Move the motor slightly toward the flywheel and allow the V-belt to slide in the pulley without strain.
Note: Do not install the belt on the groove strongly. The tightness of the belt after installation is preferably about 1/2″ under the thumb pressure.

1.3.3 Horizontal correction

Horizontal and parallel lines are very important for the precise alignment of the slider on the table surface. Most presses are equipped with the table, but it is necessary to check whether the lock is tight before measuring the level.

Horizontal correction step:
(1). First clean up the table thoroughly to increase the accuracy of the level readings.
(2). Place a precision leveling gauge on the front edge of the table to measure at the front, middle, and back.
(3). If the front and rear edges are measured to be low, the tin gasket can be used to raise the feet of the table and make the left and right completely horizontal.
Note: 1. The gasket is at least as large as the foot of the press, which makes the foot contact surface bear the weight on average.
2. Level should better be tested after one month. (If the error occurs, the base screw can be adjusted slightly to the horizontal), and the other parts are checked once every six months to confirm the mechanical level, so that the performance of the machine can be maintained with great effect. (The value of the leveler before and after adjustment is within 0.1mm.)

2. Preparation for operation

2.1 Preparation for operation

2.1.1 Factory piping

Air piping must be connected from the back of the press (with a pipe diameter of 1/2B). Required air pressure is 5 kg/cm2. However, the distance from the air source to the assembly location must be within 5 meters. First, test the output air and check whether there is residue of dust and dirt in the pipe. Then switch the main valve and install the air inlet in the air connection hole.
Note: For air pressure operation, refer to "Operating System".

1.1.2 Handling Instruction

Because the press itself is of large volume and weight, an ordinary mechanical lifting method is not workable. Therefore, the loading capacity of crane and wire rope should be taken into consideration when handling and the safety of the machine bulge areas must be paid attention at any time.

2.1.2 Air inlet pressure

(1). Before starting the work, be sure to check the factory air line pressure is normal (5kg/cm2) or more. If the air pressure is too low (3kg/cm2), the stamping operation cannot be performed.
(2). The water accumulated in the filter should be drained daily. (However, if using an auto-draining filter, check it once a day.)
(3).If there is an abnormal accumulation of water in the filter (excessive internal water, twice daily excretion), the cause should be investigated, and additional drainage devices should be installed to resolve the problem.

2.1.3 After installation or reinstallation after repair

When the gas is supplied to the machine for the first time, special attention shall be paid to the switching operations of the gate valves, and the air circuits must be sequentially gasified one by one. At this time, the pressure should be increased slowly in order to prevent unforeseen accidents caused by air pressure. After the gas supply is completed, check whether air leakage occurs.

2.1.4 Regulator

The nut of adjusting valve handle can be loosened slightly during the adjustment operation, but usually it must be fully tightened. Adjusting valve handle has seal added by the factory and the nameplate, must not open the seal on their own to adjust. If valve handle is opened up and adjusted so as to cause barriers, our company will not assume any responsibility.

2.1.5 Pressure gauge

The area outside the allowable pressure range of the press is painted red (in some cases, painted in other colors according to the user's instructions). During the operation, the rated pressure should be maintained at all times and must be checked regularly to confirm it. For those parts with the board that have "air pressure and capacity" signs (such as balancers and mold buffers), each air pressure should be adjusted according to the board instructions.

2.1.6 If balancer pressure too high or too low

(1) When the slider is lowered and the slider is adjusted, power consumption will be wasted.
(2) The wear of each bearing part will be accelerated.
(3) Increase the impact of the machine.
(4) There is a direct impact on the accuracy of the press.

2.1.7 Dismantling and cleaning

When dismantling or cleaning pneumatic devices or balance cylinders, factory air supply should be shut off and the air removed.

2.1.8 When connecting an air supply or an air outlet for automation, the valve must be closed in order to prevent unpredictable actions. In addition, remaining pressure must be paid special care.

2.1.9 Vent

When the operation is completed, the cocks of each drain hole should be opened and drained.

2.2 Power connection

First, cut the no-fuse switch NFB-1 to the "OFF" position, and then switch the power switch (S1) on the operation panel to the "OFF" position to isolate the control panel from the power supply. After confirming the fuse is normal, connect the power supply to the connection terminals in the control panel as per press specifications and main motor horsepower.

2.3 Special precautions before installing the power supply

Correct power connection method:

Note: In the event that the electrical component control fails, the R line is grounded, the fuse will be burned and the protection will be promoted.
Wiring method: (a) Measure the voltage-free wire (S-line) with the tester or three-use electricity meter and connect it to the S terminal of the power terminal block of the press control box. The other two wires can be connected to both ends of RT.
(b) If the motor runs in the opposite direction, the RT two-phase lines must not be reversed but cannot reverse with the S line.
Incorrect power supply can cause malfunction of the solenoid valve (SV), which may cause hazards to personnel and equipment. Please pay special attention to the inspection.
When the machine is shipped, strict quality management, thorough inspection and contingency measures have been done, but in order to consider the case of anomalies, the inspection items are all listed, available to the operator for reference and memorized, and also available for transfer. Use it for reference.

3.Check items during trial running

Note: (1) For normal start-up inspection, refer to the "Daily Inspection" section of "Maintenance".
(2) For the inspection of other devices, please refer to the description of each related item.

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