Hi Rick, I was reading your comment #4 on the hydraulic safety valve. I am wondering where bouts on the machine would I be able to find this?
You have a lot of static in your control you need a better ground.
Assuming correcting all related problems, using a high quality oil should reduce system heat, reduce energy consumption, extend machine life, extend drain intervals w/oil analysis.
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One key comment that I see is that these are “new” machines. It might be warranted to get a service tech to your facility to ensure proper installation and program troubleshooting. How new are the machines. When the Engel press I have was delivered there was a service rep not far behind to ensure the machine was capable. My situation is a R&D facility in which a closed loop control option was the product we were integrating which required some software “tweaking” to get to the desired performance level we desired and we received assistance over the phone as well as getting upgrades to load via e-mail. For the most part I find that Engel is cooperative and will even perform warranty work.
I have Filtroil auxillary (by-pass) filters on all my Engels. They filter to 0.1 Microns. Elements get changed at least every six months. Press tank was filled with a filtering oil cart. Oil gets analyzed every six months.
Knock on wood, I haven't had the problems you describe. One gate safety valve coil burned out, but real hydraulic problems, no.
The water to the heat exchangers is super clean Chicago water from Lake Michigan. The oil temp averages around 106°F with low alarm set at 86 and hi at 115.
I do lube more often than called for but I love my Engels, a couple run 12 second cycles, others 20, and others 22-30 seonds.
Well let's look at the list and see what comes to mind.
""We have numerous troubles with:
1. pump proportional valves going bad: this has gotten better since we have removed motor/pump cabinet doors. Seems to be heat related. OIL TEMP SHOULD BE 40°C.
2. y-valves for clamp flaking out. THIS CAN BE DUE TO IMPROPER ADJUSTMENTS/CALIBRATIONS.
3. pumps and valves reatedly needing adjustments to offset voltages or ramping parameters. POOR INCOMING POWER, INCORRECT CALIBRATIONS OR EXCCESSIVE OIL TEMP. HAVE YOU HAD THE MACHINES CHECKED FOR PROPER PUMP ROTATION/POWER PHASING?
4. hydraulic closing safety alarms that will not clear easily, seems that the E-8 Valve is hanging up. E8 CAN HAPPEN WITH POORLY CONDITIONED OIL (DIRTY?OVER HEATED), IMPROPER REPLACEMENT (KNICKING OF VALVE COMPONENTS).
5. Pressure buildup monitoring alarms: pump not making psi in time. THIS ALARM FEATURE CAN/SHOULD BE TURNED OFF IF RUNNING LATER MODEL DUO'S. THE EARLIER STYLES WITH THE CLAMPING CYLINDER THAT HAD A STATIONARY PISTION HEAD AND A/B ROOMS WILL GIVE TROUBLE UNTIL HYDRAULIC PARAMETERS ARE SET AT THE OPTIMUM SETTINGS (FOR THAT INDIVIDUAL PRESS).
6. Tie bar positioning and high speed locking calibration not working correctly. IMPROPER CALIBRATION OF THE CLAMP LOCKING/TIEBAR POSITIONS. THERE IS A PROCEDURE FOR THIS THAT WHEN DONE CORRECTLY, WILL MAKE EVERY DIEHEIGHT POSITION RUN W/O TROUBLE.
7. Level of "support after the sale"" WE HAD A TEMPORARY SETBACK WITH THIS WHEN ONE PERSON WAS OVER A PARTICULAR DEPARTMENT, DUE TO HIS DEMEANOR/HANDLING OF OUR PROBLEMS. YOU CAN'T CALL WITH A PROBLEM AND WHEN ASKED "WHAT MACHINE IS IT", REMARK "A BIG ONE, BLUE AND YELLOW"!!!!! WE HAVE SETTLED OUR PROBLEMS AND ENJOY A GOOD RELATIONSHIP, I CONSIDER THE SERVICE TECH. A CLOSE FRIEND OF MINE!
I think many of your worries are due to a lack of experience with the control and workings of the press. Read the manual several times so you can better understand the press and any special options installed. The majority of our machines are from Austria...sometimes when you first call York doesn't even have the prints yet!! But it will get better. One close shop here doesn't like their machines. Well they bought standard machines with few options and huge screws. The actually required small screw for the cavity psi their parts require!! Hope this helps, Rick.