DO 138-02-045

Technical Machinery Documentation

Section 5
Thimble Press DE-060307

Technical Machinery Documentation

Section 5:
• Commissioning and operation

Thimble Press

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

Revision Edition Date

Rev. 0 First 05.01.07

Outokumpu Technology GmbH Revision: 0

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

5 Commissioning and operation ................................................................................... 4

5.1 Commissioning ........................................................................................................ 4
5.1.1 Idle and interlocking tests without material...................................................................................4
5.1.1.1 Preparations to the idle and interlocking tests.......................................................................4
5.1.1.2 Idle tests ................................................................................................................................5
5.1.1.3 Interlocking tests....................................................................................................................5
5.1.2 Trial run with material ...................................................................................................................6
5.2 Operation................................................................................................................. 7
5.2.1 Description ....................................................................................................................................7
5.2.2 Functional description...................................................................................................................7
5.2.3 Functional description of the operating steps ...............................................................................8
5.2.4 Interlocking..................................................................................................................................10
5.2.5 Interlocking during production.....................................................................................................10
5.3 Behaviour upon failures ......................................................................................... 11
5.3.1 Failures in the hydraulic system .................................................................................................11

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

5 Commissioning and operation

5.1 Commissioning
The operation of the Thimble Press is strongly influenced by first starting up.
As to starting up of the hydraulic system, see instructions in the sub-suppliers documentation.

CONSIDERING MULTIFARIOUS INFLUENCES, WE URGENTLY

RECOMMEND TO TAKE THE SERVICES OF OUTOKUMPU
TECHNOLOGY STAFF FOR FIRST STARTING UP, NOT ONLY
FOR REASONS OF WARRANTY, BUT AT THE SAME TIME

• the Thimble Press is checked (transport damage, if any, assembly errors)

• the operating staff is familiarised with the system
• additional advice as to operate the Thimble Press is given as well as to maintenance and
repairs
• optimal adjustment of all machine and operating parameters

5.1.1 Idle and interlocking tests without material

5.1.1.1 Preparations to the idle and interlocking tests
• All machines (sets) connected behind must run in the idle run (without material).
• Free inner space of the Thimble Press from foreign bodies (wood, forgotten tools etc.) and
clean all machine parts.
• Check the proper electric assembly as per “Electrical documentation”.
CHECK AND ADJUST THE GUARDS (MOTOR PROTECTION RELAY,
COUNTER ETC.)

• Test the entire control and measuring system as well as the electrical facilities of the
Thimble Press.
• Check the machine guard.
• Check the applied protective measures (e.g. earthing resistor).
• Measure the insulation resistance of all electric motors
• Check the hydraulic actuated machine functions by operating all hydraulic valves by hand
and adjust the following:
• Velocity of movement
• Pressure as per hydraulic schematic
• Actuating of limit switches
• End position of cylinders

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

NEVER TRY TO REACH THE OUT END POSITION OF THE

SQUEEZING OFF CYLINDER!
THIS CYLINDER IS NOT DESIGNED TO BE FULLY EXTENDED
ALLWAYS MAKE SURE THAT BOTH LIMIT SWITCHES INDICATING
UP POSITION WORK PROPERLY AND ARE ADJUSTED CORRECTLY

5.1.1.2 Idle tests

After completion of the installation of the Thimble Press and of the preparations to the idle and
interlocking tests, first, the idle tests must be performed. During these tests the Thimble Press and
the auxiliary sets are operated from the local control panel.
The test includes starting of the Thimble Press, the auxiliary sets (e.g. the hydraulic unit) and the
material feeding and discharging groups to clearly evidence proper functioning of the individual
machines.
The idle tests are terminated when all re-adjusting works required or having become necessary have
been made and it is ensured that all mechanical sets may be operated for the time of the interlocking
tests without further observation.
The idle tests require that the drives coming into question are ready for being connected after
completion of the mechanical and electrical installation and that the sense of rotation has been
checked.
The machine and additional sets will be operated for about 1 hour without load. The bearings have to
be observed for temperatures and abnormal noises.

5.1.1.3 Interlocking tests

After completion of the idle tests, the plant is released by those in charge for the electrical and
mechanical installation for the interlocking tests. Before this, the interlocking program has been
entered within the scope of the installation works and internally checked.

DURING THE INTERLOCKING TESTS, NO MECHANICAL RE-

ADJUSTING WORKS CAN BE MADE WITHOUT HAVING
SECURED THE SYSTEM.

For the interlocking tests the Thimble Press is operated from the central control desk.
The interlocking tests serve the purpose to demonstrate the function of, first, the individual plant
groups and then of the groups among them so that it is ensured in case of a failure of one drive that
drives connected in front within the interlocking chain are disconnected immediately or after specified
times. It is absolutely necessary that all drives are correctly interlocked and that the control system
properly operates.
During the interlocking tests, all motors must be running. To ensure this, the couplings must be
disengaged if necessary.
A simulation of running drives with withdrawn fuses or electrical slide-in units must be avoided in the
interest of the subsequent starting up.
The sequence of the interlocking tests is as follows:
• Starting the material feed groups
• Starting the Thimble Press

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

• Starting the material discharge groups

• Check interlocking of the Thimble Press with supply and discharge groups.
• Monitor bearing temperatures.
• Observe abnormal bearing noise.
In this mode, the Thimble Press must be operated for 1 to 2 hours. In this time, all lubricating points
must be re-lubricated as per list of lubricating points.

5.1.2 Trial run with material

Only after termination of the "Idle and interlocking test", the Thimble Press is fed with material.
Follow the steps described below:
• Connect control voltage.
• Start the material feed groups.
• Start the Thimble Press in “Automatic mode”
• Start the material discharge groups.
• Check bearings temperature every hour on the first day.
• After the first 6 operating hours, check all bolted joints for tight seating and re-tighten, if
necessary.
• Check the electric installations.

During the test, observe the following:

• Abnormal running noise
• Leakages of the hydraulic system. Re-tighten all screw union, even if they are not leaking.
• Temperature of the hydraulic oil
• Operating pressures / idle pressures in the hydraulic system

AFTER 50 HOURS OF OPERATING TIME RETIGHTEN ALL BOLTS

BY TORQUE WRENCH. TIGHTENING TORQUES SEE SECTION 3.

All errors and discrepancies noticed during the load test must be immediately eliminated (upon
standstill of the machine). After that, the load test can be run for several cycles in automatic mode.
After the successful termination of the load test, the machine is ready for the performance test.

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

5.2 Operation

5.2.1 Description
The thimble press is a machine which is automatically operating or manually operated and is meant
for pressing the thimbles off the stubs of the anode rod.
The carriage with the anode rod is moved via a transport system (Power + Free) to the resting space
in front of the machine and is, from there, demanded by the automatic control or manually by the
operator.
In its upper area, at the height of the transport system, the overall system comprises the lifting
station and a lock, in its lower area the thimble press proper and the indexer. The indexer is fastened
on a frame together with the thimble press.
The thimble press essentially comprises the massive press frame accommodating in its lower
section the stamp guiding with pressing cylinder. At the top of the press frame, the retaining jaw
device is arranged with the centring device arranged above.
Via the discharge chute, the pressed-off thimbles are directed to a conveyor. Via a blow-off device,
thimble residues, if any, are removed from the pressing stamp tips.
The indexer essentially comprises a long horizontally arranged section with travelling rails. On a
movable frame, a retaining clamp is mounted, which is opened and closed via a pneumatic cylinder.
The retaining clamp is connected to a swivel-type carrier by a connection rod, which is also opened
and closed in this way. The distance between carrier and retaining clamp corresponds to the
distance between the transfer station and the second pressing-off position (position 3) in the lifting
station. Via an electric geared motor, the entire system is moved into the individual working
positions. The precise position of the system is electrically monitored during the movement.

5.2.2 Functional description

In the beginning of production, a readiness signal for the machine is released to the Power + Free
conveying system for transporting anode rods to stop point 1.
The carriage with the anode rod is transported from the P+F to the transfer station (position 1,
INDEXER PICK UP) in front of the thimble press and uncoupled from the conveying system. Stop
point 1 in the transfer station is closed.
When the anode rod is in this position, the retaining clamp of the indexer can be closed. Then, stop
point 1 is opened and the carriage with anode rod brought into the lifting station (position 2) above
the thimble press via the indexer. When the carriage has passed a certain distance, stop point 1 is
closed again. The indexer is executed such that, when moving from position 1 to position 2, it
simultaneously pushes the carriage from position 3 to the POWER RAIL ENGAGEMENT position 4.
In position 2, the two first thimbles are pressed off. When the anode rod has been brought into this
position, the centring clamp of the thimble press is closed and the retaining clamp of the indexer
opened.
Then, all retaining jaws are closed which then span the two stubs of the anode rod yoke. Then, the
centring clamp is opened again.
At the same time, when extending the pressing cylinder, also the lifting station with carriage and
anode rod is lifted. Here, the two stubs are directed through the retaining jaws, their thimbles coming
into contact with the retaining jaws and, upon further advancing of the press stamp, are pressed off.
When the topmost position is reached, the retaining jaws are opened. Then, the press stamp and the
lifting station are brought again into their bottom-most position.

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

Now, the retaining clamp of the indexer is closed. The anode rod is then moved into position 3 for
pressing off the two other thimbles.
When position 3 is reached, the procedure described for position 2 is analogously repeated for
pressing off.
If the pressing force is not sufficient to press off both thimbles at a time, after a specified time has
been exceeded, the pressing cylinder is retracted or the lifting station lowered and a failure signal is
released. In this case, the machine for pressing off these two thimbles is operated only manually.
They are then pressed off one after another, only one pair of retaining jaws being opened.
Thereafter, the automatic mode of operation can be continued.
During pressing off in position 3, the indexer returns to the transfer station in position 1 with opened
retaining clamps.
Before the carriage with the anode rod is pushed from position 3 via the carrier of the indexer to
position 4 (POWER RAIL ENGAGEMENT), the release signal of the Power+Free must have been
given. Then, it is ensured that a collision with another carriage in the P+F conveying system is safely
avoided. At the same time, an anode rod has been brought into position 2 for a new cycle.

The basic position of the machine is defined by:

• - stop point 1 closed
• - lifting station in its bottom-most position
• - retaining clamp of the indexer opened
• - centring clamps A and B opened
• - retaining jaws 1 / 2 and 3 / 4 opened
• - press stamp in its bottom-most position

5.2.3 Functional description of the operating steps

Also see drawing: Sequence Diagram drwg.-No.: 117-05-003UB

Hydraulic Schematic drwg.-No.: 117-21-004UB
Function Process drwg.-No.: 138-02-051UA

Beyond main pump 1, the hydraulic system also comprises a main pump 2 serving as stand-by unit.
The control to one of the two pressure stages of main pump 1 is realised by operating solenoid Y102
for 100 bar or solenoid Y103 for 250 bar. The control to one of the two pressure stages of main
pump 2 is realised by operating solenoid Y104 for 100 bar or solenoid Y105 for 250 bar.
The carriage with anode rod stands in the transfer station (INDEXER PICK UP) in position 1 (limit
switch ZS20 is activated) in front of the closed stop point 1(limit switch ZS23 activated).
First, the indexer retaining clamp is closed (solenoid Y42 activated). When the retaining clamp is
closed, limit switch ZS42 is activated.
Then, stop point 1 is opened (solenoid Y23 activated). The limit position is not monitored.
Driven by the geared motor, the indexer with the anode rod moves from position 1 to position 2 to
press off the first two thimbles. After a certain distance, stop point 1 is closed again (solenoid Y23

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

deactivated, limit switch ZS23 activated). The respective position of the indexer is recorded by the
distance measuring system ZT40.
Then, at the same time, the retaining clamp of the indexer is opened and the two centring clamps A
and B of the thimble press are closed. Open retaining clamp (solenoid Y41 activated). When the
opened position is reached, limit switch ZS41 is activated. Close centring clamp (solenoid Y116
activated). When the closed position is reached, limit switch ZS02 is activated. Close centring clamp
B (solenoid Y114 activated). When the closed position is reached, limit switch ZS01 is activated.
Now, both pairs of retaining jaws are closed. Close retaining jaw 1 / 2 (solenoid Y110 activated), until
the limit position is reached (limit switches ZS05, ZS06 activated). Close retaining jaw 3 / 4 (solenoid
Y112 activated), until the limit position is reached (limit switches ZS07, ZS08 activated).
Then, the centring clamps are opened again. Open centring clamp A (solenoid Y117 activated).
When the opened position is reached, limit switch ZS04 is activated. Open centring clamp B
(solenoid Y115 activated). When the opened position is reached, limit switch ZS03 is activated.
Now, at the same time, pressing-off and lifting of the lifting station take place.
Lift lifting station (solenoid Y21 activated). When the lifting station reaches its upper position, limit
switch ZS21 is activated.
The pressing procedure starts with the extraction of the pressing cylinder in differential control. For
the direction of extracting, solenoid Y107 is activated and for charging of the reservoir (Item 32),
solenoid Y101 is activated. The valve for the pressure stage = 250 bar (solenoid Y103 (stand-by
Y105)) is activated with a time delay of abt. 50 ms. When the pressure in the pressure line is
increased to 180 bar, a signal is released from pressure switch PSH104 deselecting the differential
control.
To render the entire piston surface effective and, thus, to reach the full pressing force of 2000 kN, in
addition, solenoids Y106 and Y109 are activated. This control position is maintained and is left again
only, if the pressure should fall below 50 bar (signal from pressure switch PSL103). When the
pressing stamp has reached its topmost operating position, limit switch ZS13 is activated and the
solenoid Y103 (Y105) is deactivated. Then, with a time delay of abt. 50 ms, solenoids Y107, Y106,
Y109 and Y101 are deactivated.
The topmost position of the press stamp (pressing cylinder completely extracted) is not required for
pressing off. If the limit position of the pressing cylinder should be reached, the limit switch ZS15
(top) is activated.
Then, the two pairs of retaining jaws are opened. Open retaining jaw 1 / 2 (solenoid Y111 activated),
until the limit position is reached (limit switches ZS09, ZS10 activated). Open retaining jaw 3 / 4
(solenoid Y113 activated), until the limit position is reached (limit switches ZS11, ZS12 activated).
For retracting the pressing cylinder, solenoid Y108 is activated, the valve for the pressure stage =
100 bar (solenoid Y102 (stand-by Y104)) is activated with a time delay of abt. 50 ms. When the
pressing cylinder is retracted, limit switch ZS14 is activated and the solenoids Y108, Y102 (Y104)
are deactivated.
Simultaneously with lowering of the pressing stamp, also the lifting station is lowered (solenoid Y22
is activated). When the lifting station is in the bottom-most position, limit switch ZS22 is activated.
Then, the indexer retaining clamp (solenoid Y42 activated) is closed. When the retaining clamp is
closed, limit switch ZS42 is activated.
After the press stamp has reached again its bottom-most position, also the blow-off valve for
cleaning the two press stamp tips is operated (solenoid Y01 activated).
By operating the geared motor, the indexer with the anode rod moves from position 2 to position 3
(position monitoring for the indexer via ZT40) to press off the two last thimbles.

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

Pressing off of the two residual thimbles in position 3 takes place again as described above for
position 2. However, with opened retaining clamp (limit switch ZS41 activated), the indexer returns to
position 1 of the transfer station (position monitoring of the indexer via ZT40).
If the pressing force should not be sufficient to press off both thimbles at a time (the condition here
is: solenoids Y103 (Y105) , Y101, Y106, Y107, Y109 activated, pressure switch PSH104 releases
the signal p>180 bar and a specified time is exceeded), they must be individually pressed off. To that
end, the lifting station is lowered (solenoid Y22 activated, until limit switch ZS22 activated) and the
pressing stamp lowered (solenoid Y102 (Y104), Y108 activated, until limit switch ZS14 activated).
Then, the machine is switched over from automatic to manual operation. The manual operation is
only related to pressing off of these two thimbles and is left again after the procedure.
When a carriage without anode rod has been brought to the transfer station (position 1, INDEXER
PICK UP), no signal is released from limit switch ZS43. Then, the carriage can directly be moved to
position 3 (position monitoring of the indexer via ZT40).

5.2.4 Interlocking
The interlocking is active for automatic and manual operation.
For repair operation, however, there is no interlocking.

5.2.5 Interlocking during production

The indexer with anode rod may only move, if:

- the lifting station is in its bottom-most position
- stop point 1 is opened
- the retaining clamp is opened (for moving from position 3 to position 1)
- the centring clamps A and B are opened
- the pairs of retaining jaws 1 / 2 and 3 / 4 are opened
- the press stamp is in its bottom-most position

Pressing may only take place, if:

- the indexer retaining clamp is opened
- the centring clamps A and B are opened
- the pairs of retaining jaws 1 / 2 and 3 / 4 are closed (at least however, one pair of retaining jaws is
closed)
- the lifting station is lifted
If no carriage with anode rod is available, within the overall machine comprising thimble press,
indexer and lifting station, all movements can individually be made without mutual influence. It must
be made sure that: when the indexer returns to position 1, the retaining clamp must be opened to
safely avoid a collision with an anode rod in the transfer station.

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

5.3 Behaviour upon failures

Irrespective of the following information, for the operation of the Thimble Press, the local safety
regulations will apply.

WE URGENTLY RECOMMEND TO USE A LOCKABLE LOCAL SWITCH

AVOIDING AN UNINTENDED CONNECTION OF THE MACHINE DURING
REPAIRS OR FAILURES.
OTHERWISE, WE REFER TO THE APPLICABLE ACCIDENT
PREVENTION REGULATIONS OF THE RESPECTIVE EMPLOYERS
LIABILITY INSURANCE ASSOCIATION.

5.3.1 Failures in the hydraulic system

The elimination of failures is facilitated by the circuit diagram of the hydraulic system (see section 8
“Documentation drawings”).
The following examples show:
• Signs for failures
• Causes of failures
• Measures against failures

Signs Cause Measures

Cavitations in the hydraulic pump Suction filter is jammed Clean or recondition

Local restriction in the suction Make valves accessible or
line by e.g. partly closed valve, change pipes or hoses are to be
damaged pipe or kinked hose repaired or replaced
Hydraulic oil too cold Use electric heating to warm
pressure fluid to the
recommended temperature
Formation of steam Reduce operating temperature to
correct value. Refill hydraulic oil
or replace with suitable oil
Completely sealed tank Install ventilation filter
Foam or air in the hydraulic oil Fluid oil level in the tank is too Refill hydraulic oil
low
Wrong hydraulic oil Replace with the correct
hydraulic oil, if necessary,
contact the system supplier
Shaft seal on pump allows air to Replace seal
penetrate
Porous suction hose Recondition hose

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 DO 138-02-045
Technical Machinery Documentation
Section 5
Thimble Press DE-060307

Screw fittings in the suction line Retighten fittings or replace

permit air to enter
Poor air bleeding Vent system
Mechanical vibrations Coupling improperly aligned or Align or tighten
loose
Vibrations in the pipelines Tighten or improve mounting
Pump defective or damaged Repair or replace
Unsuitable drive type Replace with more suitable drive
type
High pump temperature Worn out or damaged pump Repair or replace
Too little fluid viscosity Remove hydraulic fluid and fill
system with a hydraulic fluid with
the viscosity recommended by
the manufacturer
Insufficient cooling Failure of the cooling water Eliminate failure
supply
Deposits in the cooling water Clean cooling water pipes
pipes
Overheated pump Efficiency loss due to wear Repair or replace
Viscosity of oil is too low Remove hydraulic fluid

Whenever parts of the hydraulic system are found to be worn down or damaged, the traces of wear must be
eradicated from the system. In cases of doubt or if valves, pumps or other components should have failed,
the hydraulic unit must be opened, cleaned and filled with fresh, cleaned hydraulic fluid.

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