Operating Instruction

Synthesis 700ZS

Ref. No.: 007.2/SYN7ZS/BA/en

Date: 02.12.2009

Translation of the original operating instruction

Transmission and copying of this document, commercial use and communication of its contents are
not permitted without explicit consent. Infringements are subject to compensation. All rights in the case
of award of patents or registered designs reserved.
(According to DIN 34)

IMA KILIAN GmbH & Co. KG

Scarletallee 11
D-50735 Köln (Cologne)
Phone: +49 (0)221 / 7174-0
Fax: +49 (0)221 / 7174-110

Illustration 1: ISO 9001 Certificate

 Technical Documentation
Operating Instruction
Synthesis 700ZS Change control

Contents
1 Change control 9

2 General information 10
2.1 General 10
2.2 Storing the technical documentation 10
2.3 Modification service and copyright 10
2.4 Measures of conversion 10
2.5 Duty of care of the machine operator 11
2.6 Guarantee and technical support 11
2.7 Installation conditions of the tabletting system 12
2.8 Symbols in the documentation 12
2.9 Structure of the documentation 12
2.10 Using the documentation 13
2.11 Functioning of a tablet press 14

3 Safety 16
3.1 General 16
3.2 Levels of safety instructions in the documentation 16
3.2.1 Level 1: CAUTION Damage to property 16
3.2.2 Level 2: CAUTION Personal injury 16
3.2.3 Level 3: WARNING 17
3.2.4 Level 4: DANGER 17
3.3 Safety instructions for specific operating phases 18
3.3.1 Service and cleaning 18
3.3.2 Transport with industrial trucks 19
3.3.3 Air shipment 19
3.3.4 Crane transport 20
3.3.5 Disposal 20
3.4 Instructions 20
3.4.1 Notice regarding other dangers 20
3.4.2 Notice concerning proper usage 20
3.4.3 Notices concerning explosion prevention 21
3.5 Electrostatic charging 21
3.6 Safety devices 22
3.6.1 Operating status signal lamp 23
3.7 General safety instructions 23
3.8 Electrical equipment 24
3.9 Noise emission 24
3.10 Lubrication 25
3.11 Hydraulic accumulator 26
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4 Technical data 27
4.1 General 27
4.2 Punch configuration 28
4.3 Pressure dwell times 28
4.4 Dimensions 31
4.5 Connections 33
4.6 Nameplate 34
4.7 Fill quantities 35
4.8 Lubricants 35
4.9 Product-contacting components 35
4.10 Noise emission 36
4.11 Certificates 37

5 Transport 39
5.1 General 39
5.2 Packing 39
5.2.1 Symbols 40
5.2.2 Tilting indicator 41
5.2.3 Unpacking the machine 42
5.3 Transport safety instructions 47
5.3.1 Crane transport 47
5.3.2 Air shipment 48

6 Installation 50
6.1 Subassemblies 50
6.2 Preparations 50
6.2.1 Operating material 52
6.3 First commissioning 52

7 Commissioning 53

8 Usage 55
8.1 General 55
8.1.1 Usage 55
8.1.2 Password levels 62
8.2 User login 63
8.2.1 Changing a password 64
8.3 Overview control elements 65
8.3.1 Overview control elements machine 65
8.3.2 Overview operating terminal 67
8.4 Menu description Tabletting 77
8.4.1 Menu tree Tabletting 77
8.4.2 Tabletting – Set-up 78
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8.4.3 Tabletting – Manual 92

8.4.4 Tabletting – Display 98
8.4.5 Tabletting – Reports 105
8.5 Menu description System 108
8.5.1 Menu tree System 108
8.5.2 System – Machine 109
8.5.3 System – Configuration 128
8.5.4 System – Info 131

9 Operation 132
9.1 Switching on the system 132
9.2 Production – Set-up 132
9.3 Modifying production pre-sets 136
9.4 Batch change 139
9.5 Production start 140
9.6 Production check 141
9.7 Switching the machine off 141
9.8 In-process control 141
9.8.1 Tablet Control Units (TCU) 141
9.8.2 Limiting values in-process control 142
9.8.3 Evaluation limits 143
9.8.4 Tolerance limits 145
9.8.5 Manual tablet check 147
9.9 Reports 150
9.9.1 General 150
9.9.2 Structure of the reports 151
9.9.3 Header 152
9.9.4 Cover page 153
9.9.5 Reports of machine data 153
9.9.6 Report view 155
9.9.7 Master data reports 155
9.9.8 Software modules independent of the press station 157
9.9.9 Calibration reports 157
9.9.10 Reports of the batch data 158
9.10 Regulation 175
9.10.1 Precondition for regulation 175
9.10.2 Primary regulation 176
9.10.3 Secondary regulation (readjustment) 176
9.10.4 Setting the regulation type 179

10 Service 180
10.1 Cleaning 181

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10.2 Removal/fitting of the die table 183

10.2.1 Removing the die table 183
10.2.2 Fitting of the die table 192
10.3 Sealing ring at die table 199
10.4 Tool 201
10.4.1 Single punch bellow 202
10.4.2 Oil collecting cap 204
10.4.3 Upper punches 205
10.4.4 Lower punches 207
10.4.5 Storage of tools 209
10.4.6 Scraper 210
10.4.7 Dies 211
10.4.8 Filling tube 217
10.5 Fillshoe 220
10.5.1 Replacing the sealing segment 229
10.5.2 Replacing the product scraper 230
10.5.3 Fillshoe base 232
10.5.4 Suction unit 237
10.6 Cover 240
10.7 Support arm 242
10.8 Tablet scraper 246
10.9 Tablet chute 252
10.9.1 Tablet chute (tablet diameter ≤ 20 mm) 252
10.9.2 Tablet chute (tablet diameter > 20 mm) 258
10.9.3 Supplementary parts for sampling unit from the good
channel 260
10.10 Covering segment with product scraper 262
10.11 Punch guide 265
10.11.1 Upper cam track 265
10.11.2 Lower cam track 273
10.11.3 Upper pressure roller block 285
10.11.4 Lower pressure roller block 292
10.12 Machine compartment 296
10.12.1 Lubrication 296
10.12.2 Hydraulics 306
10.12.3 Air filter 317
10.12.4 Pneumatics 318
10.13 Operating terminal 319
10.14 Batteries and rechargeable batteries 321
10.14.1 CPU module 322
10.14.2 UPS module 323
10.14.3 M1 processor module 325
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10.15 Data backup 326

10.15.1 Data backup Visualisation 326
10.15.2 Data backup Control 326
10.15.3 Service work on the industrial PC of the control system 326
10.16 Service schedule 328

11 Converting from a double press to a bi-layer press 330

11.1 Setting on control device 330
11.2 Required parts 331
11.3 Main pressure roller of press station 1 332
11.4 Removal of the pull-down cam 332
11.5 Removal of the double press ejection bar 334
11.6 Removal of catch cam and control cam 335
11.7 Removal of the double press dosing unit 336
11.8 Fitting of the bi-layer press dosing unit 337
11.9 Fitting of the control cam with console 338
11.10 Fitting of the intermediate piece 340
11.11 Fitting of the bi-layer press ejection bar 340
11.12 Fillshoe 342
11.13 Bi-layer press scrapers 342
11.14 Suction unit 343

12 Converting from a bi-layer press to a double press 344

12.1 Settings on the control system 344
12.2 Required parts 345
12.3 Main pressure roller of press station 1 346
12.4 Structure 347
12.5 Removal of the bi-layer press ejection bar 348
12.6 Removal of the control cam 351
12.7 Removal of the dosing unit 353
12.8 Fitting of the double press dosing unit 354
12.9 Fitting of control cam and catch cam 356
12.10 Pull-down cam 357
12.11 Fitting of the double press ejection bar 358
12.12 Fillshoe 359
12.13 Scrapers 359
12.14 Suction unit 359

13 Decommissioning and storage 360

14 Accessories 362
14.1 Standard Accessories 362
14.2 Optional Accessories 371
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15 Contact to the manufacturer 372

16 Glossary 373
16.1 General 373
16.2 Supplier list 374
16.3 Technical terms 385
16.4 Abbreviations 393
16.5 Standards and Instructions 395
16.6 SI Units Used 396

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Change control
General

1 Change control
Version Date Update
007.0 05.03.09 Revised version (torquemotor) and adaptation to new
corporate design.
007.1 13.10.2009 Adaptation chapter Suction (bi-layer)
007.2 02.12.2009 - Advice to paint-coated die table sealing ring
- Advice lubrictants-list

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 Technical Documentation
Operating Instruction
Synthesis 700ZS General information
General

2 General information
2.1 General
This section provides information regarding general operation. Read this section
carefully prior to commissioning.
This documentation must be read by all persons who transport, erect, operate or
service the product.
If the product is sold to a third party, the complete technical documentation must be
supplied with it.

Note:
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this document.

2.2 Storing the technical documentation

The technical documentation must be stored carefully and must accompany the
product during all changes of owner during its service life.
Protect the technical documentation against soiling, heat and moisture!
Any sections of the entire technical documentation must not be removed, destroyed or
modified.
IMA KILIAN can provide further copies of the technical documentation on the
customer’s demand and against reimbursement of costs and expenses.
The complete technical documentation must be kept with the product. It must be
guaranteed that all persons working on the product have permanent access to this
documentation.
In addition to the technical documentation, the operator of the product also has to
provide instructions in terms of the German Law on Health and Safety at Work and the
valid regulations for the use of work equipment (SOP).

2.3 Modification service and copyright

This documentation contains information protected by copyright. Thus, without prior
consent of IMA KILIAN, this documentation – or any portion of it – must not be
photocopied, reproduced, translated or recorded on storage media.

Notice:
This documentation is not subject to the modification service of
IMA KILIAN.
Thus, modifications to this documentation and all rights are
reserved.

2.4 Measures of conversion

After a conversion of the product without authorization, IMA KILIAN is possibly no
longer considered as manufacturer of the product. In these cases, all parts of the
procedure for achieving the CE marking have to be carried out anew.

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Duty of care of the machine operator

2.5 Duty of care of the machine operator

This product was designed and constructed after having thoroughly selected the
harmonized standards to be observed and according to further technical
specifications. Consequently, it corresponds to the state of the art and ensures
maximum safety.
However, this level of safety can only be achieved in practice, if all necessary
measures are met.

Note:
It is in the duty of care of the machine operator to plan the
measures to be taken and to assure their realisation.

In particular, the operator has to assure that:

• the product is only operated in complicance with its intended use (see also
chapter "Proper usage").
• the device is in proper condition and ready for operation.
• the safety devices are regularly checked for proper functioning.
• the required personal protective equipment for the operating, maintenance and
servicing personnel is made available and utilized.
• the technical documentation is always available in legible and complete form at
the service site of the product.
• operation, maintenance, and service of the machine is only done by sufficiently
qualified and authorised personnel.
• this personnel is regularly instructed in all relevant topics of occupational safety as
well as environmental protection and is furthermore familiar with the operating
instructions and with the contained safety instructions in particular.
• all safety instructions and warnings attached to the product remain visible and
legible.

2.6 Guarantee and technical support

Over a specified period of time, IMA KILIAN products are covered by a guarantee,
which is defined in the contract stipulations. If, during the stipulated period of time,
machine components covered by this guarantee conditions malfunction or fail, IMA
KILIAN cares for the repair or exchange of the defect parts after having checked the
product and the case of damage in advance.
In case of machine modifications realised by the user without prior explicit, written
consent of IMA KILIAN, the guarantee becomes null and void and IMA KILIAN is
released from each liability for damages caused by a defective product.
Damages resulting from non-observance of this operating instruction are not covered
by this guarantee and IMA KILIAN shall not be liable anymore for damages caused by
a defective product. This applies above all to modifications of the safety devices
leading to a restricted efficiency.
Only use original IMA KILIAN spare parts or spare parts which are authorized by IMA
KILIAN in writing. Damages resulting from spare parts which are not authorized in
writing are not covered by this guarantee and IMA KILIAN shall not be liable anymore
for damages caused by a defective product. For repairs or malfunctions, always
contact the IMA KILIAN Customer Service.

Note:
In mask System Info all versions of the individual software
components are displayed. Please indicate the version number with
all questions addressed to IMA KILIAN!

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 Technical Documentation
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Synthesis 700ZS General information
Installation conditions of the tabletting system

2.7 Installation conditions of the tabletting system

The tabletting system must be installed as determined when placing the order (see
provided layout). Otherwise, the manufacturer does not assume any liability for
possibly occurring faults or too short connecting cables. The floor space plan provided
by the customer with the specified dimensions is taken as a base.
The space for installing the tabletting system must be sufficient to enable operation
and maintenance of the machine, i.e. opening of all windows and doors must be
possible and unhindered access to the media and product connections must be
assured.
Furthermore, free acess must be given to the emergency stop buttons on the tablet
press, the control cabinets and possibly existing peripheral equipment.
Check the ventilation openings on the electrical control cabinets. A sufficient air
circulation must be guaranteed.
Make sure that a permissible floor load is guaranteed at the installation site of the
machine, as described in chapter "Technical data".
All machine connections (cables, hoses, and pipelines) are to be laid such that each
possibility of stumbling over them is avoided. When laying the machine connections
(cables, hoses, and pipelines ) the specified bend radii must be strictly observed.
Malfunctions may occur due to improperly laid lines.

2.8 Symbols in the documentation

This symbol refers to a general advice, to notes or
recommendations for handling the tablet press.

This symbol stands for optional functions and equipment,

according to machine equipment and configuration.

This symbol indicates a list.

This symbol indicates a handling instruction.

Please refer to chapter "Safety" for the explanation and

classification of the warning messages!

2.9 Structure of the documentation

The documentation is subdivided in the following sections and can vary according to
type and special equipment of the tablet press:

• General information
• Safety
• Technical data
• Transports
• Commissioning
• Usage
• Operation
• Service and repair
• Replacement parts and supplies
• Decommissioning and storage
• Glossary

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Using the documentation

2.10 Using the documentation

The following aids are provided to assist you with orientation within the
documentation:
Header

• Type of machine or device

• Type of documentation
• Title of the chapter

Bottom line

• Inside: Reference number of the respective document

- The reference number is structured as follows:
Example: SYN5/BA/de
§ Short name of the device or machine type
§ Short form of the document type

§ Abbreviation of languages

Note:
If the reference number begins with a six-digit number, the latter
refers to the tablet press order number (e.g. 705914.0). This
indicates that a special documentation with reference to this
specific order has been drawn up. The respective revision status is
indicated by the last digit.

- Outside: Page number and total number of pages

Note:
For queries regarding the documentation, please always indicate
the reference number.

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Functioning of a tablet press

2.11 Functioning of a tablet press

Note:
The following chapter describes the principal functioning of a tablet
press. The construction can be different in details, acc. to the type
of the tablet press.

The die table of the tablet press guides the upper and lower punches in punch
reception bores. The die table rotates and thus forces the punches to move in
horizontal direction. The punch heads run in cam tracks which force them to move in
vertical direction during the rotation of the die table.

Illustration 2: Cam track of the tablet press

1 Die table 7 Lower pre-pressure roller

2 Push down cam 8 Control cam
3 Upper pre-pressure roller 9 Catch cam
4 Upper main pressure roller 10 Dosing cam
5 Ejection cam 11 Pull-down cam
6 Lower main pressure roller

For filling the tablet die, the lower punch moves down in the die to its lowest position.
The material to be pressed drops down into the empty space. The final fill quantity is
determined by the lower punch moving back into the fill compartment (volume dosing).
At the end of the fill unit, the material is smoothed out at the die edge. Behind the
fillshoe, the upper punch moves down into the die and thus closes the fill
compartment.

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Functioning of a tablet press

The tablet press presses the tablet in two working steps. First upper and lower
punches run in pairs between the pre-pressure rollers. Here the distance between the
punches decreases to the pre-set value. The tablet powder is pressed into the
remaining volume between the punches. By this so-called pre-pressure, the material
between the punches are de-aerated and pre-pressed. Following the pre-pressure
rollers, this procedure is repeated with an even smaller distance between the punches
and thus with a higher pressure between the main pressure rollers. The final tablet is
formed with its specified thickness.
Following the main pressure, the punches move apart and the lower punch pushes the
finished tablet out of the die. With the rotational movement of the die plate, the ejected
tablet moves against the tablet scraper and drops from the die plate into the tablet
chute.

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General

3 Safety
3.1 General
This chapter provides information regarding proper usage and general and specific
dangers. Read this chapter carefully prior to commissioning the tablet press.
The safety instructions must be complied with.
The operating company is responsible for ensuring that all safety instructions are
taken note of and observed.
This technical documentation must be read by all persons who transport, erect,
operate or service the tablet press.
If the tablet press is sold to a third party, the complete technical documentation must
be supplied with it.

Note:
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this documentation.

3.2 Levels of safety instructions in the documentation

3.2.1 Level 1: CAUTION Damage to property
These safety instructions refer to instructions or precautions for the prevention of
damage to property which do not entail personal injury.
An example is given below for a safety instruction of level 1:

CAUTION
Insufficient lubricant properties or quantity!
Machine damage due to insufficient lubrication because of
improper lubricants or insufficient quantity of lubricant.
Ø Use specified lubricants only and observe the required fill
quantities and filling level heights.

3.2.2 Level 2: CAUTION Personal injury

These safety instructions refer to instructions or precautions for the prevention of
reversible personal injuries which depend on a behaviour pattern (action, omission).
An example is given below for a safety instruction of level 2:

CAUTION
Risk of injury through hot components!
When the tablet press has run for quite a long time, heat
develops, resulting in hot surfaces at different components (motor,
gear).
Ø Do not touch the hot surfaces.

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Levels of safety instructions in the documentation

3.2.3 Level 3: WARNING

These safety instructions refer to instructions or precautions for the prevention of
severe (irreversible) personal injuries which depend on a behaviour pattern (action,
omission).
An example is given below for a safety instruction of level 3:

WARNING
Danger through unhealthy noise level!
The tablet press can produce an unhealthy noise level, which with
longer exposure can lead to permanent hearing damage.
Ø Wear ear protection in case of longer stays in the immediate
vicinity of the operating tablet press.

3.2.4 Level 4: DANGER

These safety instructions refer to instructions or precautions for the prevention of an
imminent danger. Non-observance can result in severe (irreversible) personal injuries,
including death.
An example is given below for a safety instruction of level 4:

DANGER
Danger to life!
Hazard through bruising of body parts. There is a risk of severe
injuries of body parts through the upward and downward
movement of the punches.
Ø Do not operate the machines without windows. When working
on the open machine, the machine must be secured against
unauthorized starting through third parties.

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Safety instructions for specific operating phases

3.3 Safety instructions for specific operating phases

3.3.1 Service and cleaning
Depending on the material compressed, special cleaning methods and cleaning
agents shall be applied and special safety measures taken.
In addition to this technical documentation of the tablet press, generally applicable
statutory and other mandatory regulations concerning accident prevention and
environmental protection shall be observed.

Note:
When using cleaning agents please also observe the customer
information "Cleaning instructions".

Note:
Servicing and cleaning work on the tablet press may only be
carried out by qualified staff or by someone instructed under the
supervision of qualified staff.

DANGER
Danger to life! Personal danger through risk of electric
shocks.
The machine operates at voltages of > 220 V with
correspondingly high amperages. As amperages above 250 mA
may be fatal, please take reasonable precautions!
Ø Switch the tablet press off with the main switch prior to
servicing and cleaning work and protect it against being
switched on unintentionally.
Ø Erect appropriate warning signs.

Note:
Observe details for cleaning, dismantling, and assembly of the
tablet press or its subassemblies concerning cleaning and
servicing work from the "Service" chapter.

CAUTION
Surface damage through improper cleaning agents!
Do not use any solvent-based, scouring or abrasive cleaning
agents. Surfaces can be affected when using cleaning agents with
a pH value > 9!
Ø Only use cleaning agents which are acknowledged by IMA
KILIAN.
Ø Observe the manufacturer's instructions.

WARNING
Hazard through corrosive or toxic cleaning agents!
Avoid coming into contact with these substances, as the cleaning
agents and disinfectants and possibly their vapours can damage
the skin, eyes and mucous membranes.
Ø When using cleaning agents, wear protective equipment in
compliance with the manufacturer's specification.

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Safety instructions for specific operating phases

For efficient and gentle cleaning of the tablet press and in particular of the punches,
we recommend the solvent-free concentraded cleaner "deconex HT 1191" from Borer
Chemie, CH-4528 Zuchwil. The cleaning and anticorrosive agent is food-grade and
can be used for manual cleaning as well as cleaning in an ultrasonic bath.

Note:
Prior to cleaning the tablet press, all openings into which no
cleaning agent may penetrate for safety and/or functional reasons,
shall be covered or closed.
Do not use a steam jet or similar high-pressure apparatus! After
cleaning remove all covers again.

Do not use alcohol or cleaning agents containing alcohol for

cleaning the windows. This causes the plexiglass windows to
become brittle and fragile.

Note:
After servicing, the tablet press must be released for operation by a
responsible person designated by the plant operator.

3.3.2 Transport with industrial trucks

DANGER
Danger to life! Capacity of the industrial truck does not
match the load!
The load has not been loaded in consideration of the centre of
gravity and topples over.
Ø Please observe the weight information of the tablet press in
the technical data when choosing an industrial truck.
Ø Transport the machine using the specified points only.
Ø Move both forks as near as possible towards the machine feet
from the inside.

CAUTION
Damage to the tablet press.
Pay attention not to damage the tablet press when inserting the
forks.
Ø Keep a corresponding distance to the housing or place a
protection in between.

3.3.3 Air shipment

CAUTION
Leaking auxiliary materials (lubricants)!
The tablet press must be prepared in a special way for air
shipment.
Ø It must be guaranteed that auxiliary materials (lubricants)
cannot leak. Please observe chapter "Transport" .

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Instructions

3.3.4 Crane transport

DANGER
Danger to life! Lifting accessories or crane loading capacity
do not match the load and will break.
The load has not been loaded in consideration of the centre of
gravity and topples over.
Ø Do not stand under suspended loads!
Ø The transport crane and the lifting accessories must be
designed for a load in compliance with the details given in the
technical data!
Ø Transport the machine using the specified points only.

3.3.5 Disposal
Note:
Discharge the tablet press and dispose of the lubricants, sewage,
and excessive cleaning agents according to the local regulations
and the general guidelines to avoid harm to the environment!

3.4 Instructions
3.4.1 Notice regarding other dangers
The tablet press has been built to the state of the art and in compliance with the
recognised technical safety rules and relevant standards. Sources of danger have
been eliminated or safeguarded against with appropriate devices as far as possible.
However other dangers can occur when using the tablet press.
Dangers for the operator or a third party, or damage to the press and other goods can
occur, if:

• it is operated by an unqualified person in an improper way,

• it is not used as indicated,
• it is improperly serviced and repaired.

3.4.2 Notice concerning proper usage

The tablet press is designed exclusively for pressing tablets made from powdery
materials.
Appropriate use also includes compliance with the operating instruction and with the
cleaning and service instructions.
Any other or additional use is not in line with its intended use. IMA KILIAN shall not be
liable for any damage resulting therefrom.
The pressing of explosive hazardous materials in the tablet press is not in line with its
intended use.

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Electrostatic charging

3.4.3 Notices concerning explosion prevention

Notice:
Tablet presses of the Synthesis series can be assigned to category
II 3D c T 4 (non-conductive dust). It is assumed that the use of the
tablet press corresponds to its proper usage only.

Explosion prevention in suction systems

Certain materials can easily explode in form of dust and can then result in a danger to
life. This particularly applies inside of suction systems, as the dust is reduced to very
small particles by vortexing and as discharge sparks may arise in case of lacking
grounding. There are several methods to reduce explosion hazards:

• Prevention of sources of ignition by proper grounding

• Installation of spark-extinguishing installations
• Pressure surge protected execution of the installation
• Isolation to prevent explosion through self-actuating quick-action gate valves

Depending on dust formation, dust explosion class and installation characteristics

some or all of the above-mentioned measures may be necessary to protect a suction
system from explosions.

3.5 Electrostatic charging

WARNING
Hazard through electrostatic charging
Depending on the material to be pressed, the containers used and
the conditions on site there may be electrostatic charging.
Static electricity may damage the sensible components inside the
electrical installation.
Ø Please observe the requirements according to EN 100 015 - 1
to minimize or avoid possible damage through abrupt
electrostatic discharges.
Ø The discharge systems used must be properly grounded or
other protective measures must be provided.

Note:
To avoid the risk of injuries the plant operator is responsible to
ground the discharge systems used according to the regulations or
to provide other protective measures.
Also observe the VDE regulations or the corresponding regulations
of your home country.

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Safety devices

3.6 Safety devices

Before commissioning the tablet press, all safety-relevant components must be
visually inspected for damage. The functioning of the operating status signal lamp is
briefly self-checked by the system when switching on the tablet press, at which point
all signal lamps (red, yellow and green) illuminate briefly.
Plan a regular safety check. For this you may consult the IMA KILIAN Customer
Service. IMA KILIAN recommends an annual inspection of the safety-relevant
components in the tablet press.

04-120
Illustration 3: Safety devices

Pos. Designation Function

1 Emergency stop button Emergency stop of the tablet press
2 Main switch Switching off the tablet press
3 Operating status signal lamp Indication of the operating status of the tablet press
4 Window switch Safety switch for windows
(windows opened or closed)
5 Door switch Safety switch for doors
(doors opened or closed)

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General safety instructions

3.6.1 Operating status signal lamp

04-119
Illustration 4: Operating status signal lamp

Colour Function Description

Red Steady light A monitoring function has responded with the tablet press not running.
Flashing light A monitoring function has responded with the tablet press running.
Yellow Steady light The tablet press is ready to start.
Green Steady light The tablet press is running.

3.7 General safety instructions

CAUTION
Damaged or by-passed safety devices
Accidents with damage to property and personal injuries!
Ø Only use the tablet press when in technically sound condition.
Ø Refrain from any activity which might endanger safety.
Ø Operate the tablet press only if all protection systems are
active and all subassemblies are secured to the tablet press,
so that access to the machine compartment and compression
chamber is not possible when the tablet press is running.
Ø The safety devices may be neither by-passed nor
disassembled.
Ø Check the tablet press at least once per shift for visible
damage and defects, and eliminate these.
Ø Faults which impair safety are to be reported immediately to
the responsible person designated by the operating company.
Ø Use only original IMA KILIAN spare parts or supplies released
by IMA KILIAN.
Ø Please get in contact with IMA KILIAN Customer Service if
any faults occur or for any servicing.

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Electrical equipment

WARNING
Explosion hazard! A dust explosion hazard exists!
Severe injuries and damage to property!
Ø The tablet press may only be operated along with a properly
functioning dust suction device. Kilian offers suction
monitoring as an option. Please take the minimum
performance of the dust suction device from the Technical
Data chapter.
Ø The operating company must ensure through suction that the
concentration of dust is kept to a minimum.
Ø The surface resistance, measured under normal temperature
conditions (23 °C / 50%) must be less or equal to 109 Ohm in
order to avoid dangerous charging (see UVV "BGR 132")!

3.8 Electrical equipment

è Do not switch on the electrical main connection unless all connections to
peripheral equipment have been made.
è Place the plugs carefully into the sockets, with the power off.
è When pulling out plugs, pull on the plugs, never on the cables.
è Use only original fuses of the correct rating.

Note:
Work on the electrical system of the tablet press may be carried out
only by an electrician or trained staff under the supervision of an
electrician in compliance with the applicable rules of electrical
engineering.
The electrical system of the tablet press shall be inspected at
regular intervals. Fix any loose cable connections and replace
defective cables immediately.

3.9 Noise emission

The noise level generated by the tablet press is mainly dependent upon the machine
output (revolutions of the die table), the pre-set compaction forces and the
surrounding conditions (e.g. size of room, wall composition).

WARNING
Unhealthy noise level
The tablet press can produce an unhealthy noise level, which with
longer exposure can lead to permanent hearing damage.
Please observe the information given in chapter "Technical data".
Ø Take care that during machine operation the acoustic
protection devices (doors and windows) at the tablet press are
firmly closed.
Ø Wear ear protection in case of longer stays in the immediate
vicinity of the operating tablet press.

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Lubrication

3.10 Lubrication

CAUTION
Wrong and improper application of lubricants!
Machine damage or damage of components through insufficient
lubrication!
Ø When handling lubricants, observe the safety instructions
applicable to the respective product.
Ø Use only specified lubricants and observe the required fill
quantities and filling level heights.
Ø Drain the sump tank at regular intervals. Watch the colour of
the waste oil. Major discolorations are an indication of
excessive loading (heat, moisture).
Ø Do not mix different types of oils.
Ø Dispose of the lubricants according to the local regulations
and the general guidelines to avoid harm to the environment.
Ø Please observe the lubricant information given in chapter
Technical data.
Ø Do not use a pneumatically supported grease gun for
lubrication! The increased pressure in the lubricating system
may cause leakages!
Only use manually operated grease guns!

Please observe the certificates for lubricants in the documentation

Lubricants.

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Hydraulic accumulator

3.11 Hydraulic accumulator

CAUTION
High pressure in the hydraulic system!
Injuries through improper opening of lines and components under
pressure.
Ø Exchanging or servicing of hydraulic accumulators may only
be carried out by qualified staff.
Ø If pressure tanks in hydraulic systems are exchanged,
acceptance testing is not necessary, if
– they are replaced by equivalent pressure tanks,
– the gas blanket is separated from the hydraulic oil by a
membrane or a pocket, and
– no change to the equipment has been carried out.
Ø You may only install hydraulic accumulators which have been
supplied by IMA KILIAN.
Ø Hydraulic accumulators may not be opened, risk of injury as
the hydraulic system is under high pressure.
Ø The hydraulic accumulators and their connections may not be
opened or damaged with improper tools.
Ø If there is more than one accumulator in the tablet press,
replacement should not be carried out simultaneously.
Replace one accumulator at a time. First of all, the
accumulator with the smallest N2 gas pressure (receiver
pressure) is changed.
Ø Dispose of defective hydraulic accumulators properly.

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General

4 Technical data
4.1 General
This section provides information regarding the technical data of the tablet press.
Read this section carefully prior to commissioning.
This documentation must be read by all persons who transport, erect, operate or
service the product.
If the product is sold to a third party, the complete technical documentation must be
supplied with it.

Note:
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this document.

Technical data

Mass of the tablet press 5200 kg

Mass of the control cabinet 360 kg
Minimal load of the transport crane 50 kN
Existing floor load (surface pressure) with the machine feet 94 N/cm²
screwed on
Installed power 16 kW
Drive power 28,7 kW
Voltage 380 - 480 V
Modifications are possible with reference to the country of destination, please refer to the rating 50/60 Hz
plate.

Minimal fuse protection 40 A

Suction unit 600 m³/h
1800 Pa
Compressed air for activating the solenoid valves 12 l/min
Hydraulic pressures 405 bar

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Punch configuration

4.2 Punch configuration

No. of punches 85 77 63 51 51 37
Punch type EU-B EU-B EU-B EU-D 28 / 32 45 / 54
IPT-B IPT-B IPT-B IPT-D
TSM-B TSM-B TSM-B TSM-D
Die type BBS BB B D 38/23 55/47
Die diameter 21 24 30,16 38,1 38,1 55 mm
Die height 22,22 22,22 22,22 23,81 23,81 41 mm
Max. tablet diameter 11 13 16 24 26 44 mm
Max. filling 18 18 18 20 25 30 mm
Main pressure max. 80 80 80 100 120 120 kN
Pre-pressure max. 60 60 60 60 60 60 kN
Min. production output (1) 188000 170000 139000 112000 112000 81000 tabl./h
Max. production output (1) 1020000 924000 753000 550000 489000 311000 tabl./h
(1) The production output is halved in double layer operation.

4.3 Pressure dwell times

To be able to indicate the pressure dwell times at rotating tablet presses, various
simplifications for calculation must be determined:

1. Due to the eccentric pressure roller adjustment the upper and lower pressure
rollers are never vertically superposed (axle offset). Thus the pressure dwell time
is further reduced compared to the theoretical values indicated in the graphs. The
values in the graphs refer to the ideal assumption of a penetration depth of the
upper punch amounting to 2.5 mm and a tablet wall dimension amounting to 3
mm.
2. The „elasticity" of the press (pressure roller abutment), which results in another
distortion of the pressure dwell time, is neglected.
3. As the pressure dwell time is mainly dependent on the surface diameter of the
punch head, the smaller surface diameter is used for tool types where upper
punch and lower punch are different. In addition, these diameters are rounded
(see table).

The other essential influence values for the pressure dwell time, reference diameter
and number of revolutions and of the die table, are taken from the press
specifications and summed up in the table below.

Surface diameter [mm]

Tool type
Upper punches Lower punches Rounded value
TSM-B 9,31 9,31 10

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Pressure dwell times

The following formulae have been taken as a basis for calculation:

VU = rotational speed [ms-1]

nM = die table speed [min-1]
UT = circumference of the reference circle [mm]
DT = diameter of the reference circle [mm]
dSK = surface diameter of the punch head [mm]
tv = pressure dwell time [ms]

Die table speed

Machine type Reference [min-1]
diameter [mm]
min max
Synthesis 700/700 712 10 100
WIP

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Pressure dwell times

Synthesis 700/700 WIP

1000,0

100,0
[ms]

10,0

1,0
0 10 20 30 40 50 60 70 80 90 100
[rpm]

EU/TSM-B & KIL-20/28 Pharma

TSM-D EU-D u. 25/32 u 32/32
KIL-28/32 441 u. 50/54
KIL-30/40 KIL-40/45
KIL-45/54 KIL-38/45
03-710
Illustration 5: Pressure dwell times

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Dimensions

4.4 Dimensions

04-175
Illustration 6: Dimension plan

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Dimensions

max. 756

max. 786

966
ø
13
0

936

04-128
Illustration 7: Foundation plan

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Connections

4.5 Connections

Illustration 8: Position of connections

Connection Symbol Remarks

Electrical main connection • Prior to connection compare the electrical connection

data with the electrical diagram and rating plate inside the
control cabinet.

00-101

Suction unit • Push the suction hose onto the flange and lock it with a
clip.

• Observe the suction volume.

- Suction volume too high: Product loss

- Suction volume too low: Heavy fouling of the

compression chamber

Compressed air • Push the compressed-air hose (ø 9 mm) onto the

reception coupling and lock it with a hose clamp.

- Too low a level of compressed air will result in

malfunction when separating reject tablets.

Peripheral equipment A • For connections please refer to the electrical diagram of

the corresponding unit.

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Nameplate

4.6 Nameplate
Machine

Illustration 9: Machine nameplate

1 Order 4 Version
2 Weight 5 Type
3 Year of construction

Electrical cabinet

Illustration 10: Electrical cabinet nameplate

1 Order 5 Nominal current in ampere

2 Year of construction 6 Type of current
3 Nominal voltage in volt 7 Control voltage in volt
4 Nominal frequency in hertz 8 Electrical diagram No.

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Fill quantities

4.7 Fill quantities

The tablet press has been provided with the corresponding fill quantities during
assembly in the factory. With the exception of the worm gear, food-grade oil is filled in
as a standard.

CAUTION
Machine damage caused by wrong or not permitted lubricant.
Do not blend different oil types!
Ø Before changing from mineral oil to food-grade oil clean the
pump and the lines from old mineral oil residues!

Subassembly Fill quantity (litre)

Lubrication pump 2
Hydraulic system 3
Hydraulic unit 2,5

4.8 Lubricants
Note:
For information about the lubricants and the alternative lubricants
please refer to the enclosed documentation Lubricants.

CAUTION
Do not blend different oil types! Only use oil types which are
recommended and acknowledged by IMA KILIAN and
observe the application instructions of the manufacturer!

4.9 Product-contacting components

IMA KILIAN herewith declares that the materials used for production of the tablet
press (materials and surfaces of the components with direct contact to the press
material) correspond to the required international guidelines and regulations relating to
food compatibility.
The suppliers' original certificates can be requested or viewed at IMA KILIAN in the
respective language of the supplier.

Note:
Please observe the manufacturer’s declaration contained in the
technical documentation and the list of materials and surfaces of
the components with direct contact to the press material.

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Noise emission

4.10 Noise emission

The noise level generated by the tablet press is mainly dependent upon the machine
output (revolutions of the die table), the pre-set compaction forces and the
surrounding conditions (e.g. size of room, wall composition).

Note:
Take care that during machine operation the acoustic protection
devices (doors and windows) at the tablet press are firmly closed.

Note:
Please mind the separate sound ranging report.

CAUTION
Unhealthy noise level!
The tablet press can produce an unhealthy noise level, which with
longer exposure can lead to permanent hearing damage.
Ø Wear ear protection in case of longer stays in the immediate
vicinity of the operating tablet press.

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Certificates

4.11 Certificates

Illustration 11: CE Declaration

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Certificates

Illustration 12: EMC certificate

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General

5 Transport
5.1 General
This section provides information regarding transport, unpacking, and packing of the
IMA KILIAN machine and peripheral equipment. Read this section carefully prior to
transport and/or unpacking.
This documentation must be read by all persons who transport or install the product.
If the product is sold to a third party, the complete technical documentation must be
supplied with it.

Note:
The safety instructions must be complied with. The plant operator
is responsible for ensuring that all safety instructions are taken
note of and observed.
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this document.

5.2 Packing
Dimensions of the packing

Notice:
The packing varies in dimensions and weights according to the
scope of the order. Pay attention to the shipping documents and
information on the packing.

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Packing

5.2.1 Symbols
Note:
The most important precautions to be observed regarding the
goods packed are printed on the respective packing boxes and
crates of the components!
Please observe the symbols on the packing!

Protect against moisture!

Indicates that the box must be stored in a dry place.

Transport vertically!
Indicates the correct vertical position of the packing.

Observe centre of gravity!

Indicates the centre of gravity of the packing (rough information).

Fragile (Handle with care)!

This means that the contents of the packing is fragile and must be
handled with care.

Sling here!
Indicates where the load hooks for lifting the packing must be
positioned.

Forklift truck here!

This symbol indicates at which locations the fork of the forklift truck
must be applied.

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Packing

5.2.2 Tilting indicator

The use of tilting indicators supports the compliance with handling instructions and
thus avoids transport damages. The indicators used, which are attached to each
package visibly on the outside, are activated when a specified limiting value is
exceeded. The explanations on the indicator are unequivocal; we ask you, however, to
observe the following points:

1. Do not decline acceptance even if the indicator is activated. A missing indicator is

equivalent with an activated indicator.
2. An activated indicator does not necessarily mean that the goods are damaged, but
only that they have been treated improperly.
3. Note on the way bill / delivery note that the indicator is activated. Please have the
driver of the forwarding company confirm this on the shipping documents.
4. Please note outer damage, too, in a statement and have it confirmed by the driver
of the forwarding company.
5. Please pay attention that the following information is transmitted to IMA KILIAN so
that the claims assessment and settlement can be carried out by us.
a. Signature / name of the receiving person
b. Date/time
c. Signature / name of the delivering person
d. Number of packages / Are all indicators activated?
e. Colour of the indicators

The machine must only be transported in

one position, it must not be tilted during
transport! The tilting indicator shows
whether these shipping instructions were
violated!

01-197
Illustration 13: Tilting indicator

The attached warning sign indicates the

functioning of the tilting indicator to the
forwarder as well as to the receiver.

01-198
Illustration 14: Warning sign tilting indicator

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Packing

Note:
Take precise details regarding the weight of the tablet press from
the rating plate and the technical data.
The centre of gravity of the tablet press is above the machine
compartment. For crane transport thus always use the transport
bolts (see Illustration 450: Removal aid ) contained in the supplies;
screw them into the header plate of the tablet press prior to
transport.

5.2.3 Unpacking the machine

WARNING
Excessive floor load through the weight of the tablet press!
The floor for the installation site of the tablet press is not permitted
for the load caused by the weight (see Technical data).

DANGER
Danger to life! Capacity of the industrial truck does not
match the load!
The load has not been loaded in consideration of the centre of
gravity and topples over.
Ø Please observe the weight information of the tablet press in
the technical data when choosing an industrial truck.
Ø Transport the machine using the specified points only.
Ø Move both forks as near as possible towards the machine feet
from the inside.

Transport the box near the installation

site.
The transport box should not be
unpacked until it is located near the
installation site.

01-172
Illustration 15: Transport box

Note:
One side of the transport box and the header plate are fixed by
screws. These wooden elements must be removed first. Thus an
easier dismantling of the other side panels is ensured.

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After removing the lid and all side panels

the silvery protective film must be
removed.
Remove possibly existing strapping belts.

01-195
Illustration 16: Protective film for transport

Take all boxes and other parts contained

in the scope of delivery from the pallet.

01-196
Illustration 17: Supplies

After removing the silvery protective film,

the water-vapour-proof film must also be
removed.
Remove the film carefully without
damaging the surfaces of the tablet
press.

01-176
Illustration 18: Water-vapour-proof film

Note:
So-called desiccation bags are packed under the film. Please
dispose of these bags according to the local regulations in your
country.

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Packing

Desiccation bag
The desiccation bags are used in
combination with water-vapour-proof
films. Inside this barrier layer packing, the
desiccation bags ensure a low humidity
and thus prevent corrosive and damaging
influences through moisture (DIN 55474)
The air volume in a packing is sealed
from the outer climate together with the
goods packed and the desiccant by a
barrier layer envelope. It is important that
this envelope is water-vapour-proof as far 01-194
as possible. Illustration 19: Desiccation bag

Note:
The sealed air volume inside the envelope is dryed by the desiccant
so far that damage through moisture is avoided. This is, however,
guaranteed for a specified period of time only. The time of
transport/storage must be known to the manufacturer, as the
quantity of desiccation bags must be adapted accordingly.

Screw the transport bolts (from

the supplies) into the specified
bores in the head part.

Illustration 20: Head part of the tablet press

WARNING
Please observe the instructions concerning crane transport
in chapter "Safety"!
The weight of the tablet press must be observed! Also refer
to chapter "Technical data" here!

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Unscrew the fixing points of the pallet in the four corners (at the bottom of the
machine).

01-171
Illustration 21: Fixing points (illustration may differ from the scope of delivery)

Lift the machine off the pallet using a crane.

Remove the pallet.

WARNING
Unintentional lowering of the suspended machine.
Severe hand injuries.
Ø Secure the machine against unintentional lowering by
corresponding supports (observe the load).

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Align the machine using a water level.

Adjustment is made via the adjusting
screws (1) at the machine feet (2). 1

01-598
Illustration 22: Adjusting screws of machine feet

Note:
Unpacking the other transport boxes (peripheral equipment) is
done correspondingly.

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Transport safety instructions

5.3 Transport safety instructions

5.3.1 Crane transport
DANGER
Danger to life! Lifting accessories or crane loading capacity
do not match the load and will break.
The load has not been loaded in consideration of the centre of
gravity and topples over.
Ø Do not stand under suspended loads!
Ø The transport crane and the lifting accessories must be
designed for a load in compliance with the details given in the
technical data!
Ø Transport the machine using the specified points only.

è Remove the plastic caps from the head piece.

è Fit the transport bolts (supplies) in the header plate and tighten them.

Illustration 23: Position of the transport bolts

è Transport the tablet press to the new location.

è Remove the transport bolts and place them back with the supplies.

Note:
Ensure to replace the plastic caps. They prevent dirt from entering
the head piece.

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Transport safety instructions

5.3.2 Air shipment

CAUTION
Leaking auxiliary materials (lubricants)!
The tablet press must be prepared in a special way for air
shipment.
Ø It must be guaranteed that auxiliary materials (lubricants)
cannot leak. Please observe chapter Transport .

Notice:
The tablet press must be prepared in a special way for air
shipment. It must be guaranteed that auxiliary materials (lubricants)
cannot leak.

Prior to air shipment

Hydraulic system
For the following work steps please observe chapter "Service", section
"Hydraulics", page Fehler! Textmarke nicht definiert..
è Depressurize the system.
è Open the vent screws.
è Discharge the hydraulic system into an appropriate container.
è Fit the sealing plug in place of the fill and vent plug of the hydraulic unit.

Lubrication pump
For the following work steps please observe chapter "Service", section
"Lubrication pump", page 300.
è Open the lid of the pump.
è Drain the contents of the pump into an appropriate container.
è Close the pump with the lid.
è Discharge the sump tank into an appropriate container.
è Clean the sump tank.

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After air shipment

Hydraulic system
For the following work steps please observe chapter "Service", section
"Hydraulics", page Fehler! Textmarke nicht definiert..
è Replace the sealing plug by the vent screw. Place the sealing plug with the
supplies.
è Refill the hydraulic fluid.

Notice:
For information about the specification and quantity of the oil
please refer to the tables in chapter "Technical data".

è Vent the hydraulic system.

è For this open the shut-off valve at the valve block of the hydraulic unit using an
Allen key (5 mm) to release the pressure.

Lubrication pump
For the following work steps please observe chapter "Service", section
"Lubrication pump", page 300.
è Fill with lube oil.
è For information about the specification and quantity of the oil please refer to the
tables in chapter Technical data.
è Vent the lubrication system.

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Synthesis 700ZS Installation
Subassemblies

6 Installation
6.1 Subassemblies
The following subassemblies may have been dismantled for transport and thus require
reassembly prior to commissioning:

Subassembly/components See chapter Service

Force feed fillshoe 220
Material hopper 217
Product scraper 260
Tool 201
(punch, oil wiper, punch bellow and die)
Tablet chute 252
Tablet scraper 246
Control system 319
Table 1: Fitting of subassemblies

6.2 Preparations
First cleaning
è Clean the tablet press thoroughly after unpacking (for cleaning see chapter
"Service"). Ensure that preservation and anticorrosive agents are completely
removed.

For queries regarding the preservation and anticorrosive agents used, please contact
the IMA KILIAN Customer Service.

Notice:
Instructions for cleaning as well as assembly and dismantling of
the subassemblies can be taken from the section "Service".

Connections
Notice:
Have the machine connected by IMA KILIAN Customer Service or
an authorized electrician only!
For the designations of the different connections please refer to the
electrical diagram.

The electrical and compressed-air connections are located at the rear of the machine.

Notice:
Details of the location and description of the connections for the
machine can be found in the section "Technical data"!
The connections can also be found in the electrical drawings and
pneumatic diagrams for the machine as well as the corresponding
peripheral equipment.

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Preparations

Connection to the tablet press

Notice:
Prior to connection compare the electrical connection data with the
electrical diagram and rating plate inside the control cabinet.

è Connect the tablet press to the power supply.

Suction connection
è Push the suction hose onto the flange and secure it with a hose clamp.

è Observe the suction volume.

- Suction volume too high: Product loss

- Suction volume too low: Heavy fouling of the compression chamber

Notice:
The suction volume can be adjusted on the vacuum cleaner (see
the operating instructions for the vacuum cleaner "Nilfisk CFM").

Compressed-air connection
è Push the compressed-air hose onto the flange and secure it with a hose clamp.

- Too low a level of compressed air will result in malfunction when separating
reject tablets.

Notice:
Incoming compressed air also comes into contact with the product
and therefore must be dry and oil-free.

Notice:
Have the machine connected by IMA KILIAN Customer Service or
an authorized electrician only!
For the designations of the different connections please refer to the
electrical diagram.

The electrical and compressed-air connections are located at the rear of the machine.

Notice:
Details of the location and description of the connections for the
machine can be found in the section "Technical data"!
The connections can also be found in the electrical drawings and
pneumatic diagrams for the machine as well as the corresponding
peripheral equipment.

Notice:
Prior to connection compare the electrical connection data with the
electrical diagram and rating plate inside the control cabinet.

Caution
Compare the data for compressed air, current and voltage
prior to the first commissioning. Guarantee a sufficient and
safe power supply in compliance with the local regulations.

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First commissioning

6.2.1 Operating material

Before each commissioning please check all oils and other operating material and
refill as required.

Notice:
Please refer to the section "Technical data" for information
regarding oil types and fill quantities.

6.3 First commissioning

During first commissioning you should carry out all the work steps detailed in chapter
"Installation" and in section "Cleaning" (see chapter "Service").

è Unpack the tablet press.

è Install the tablet press.
è Mount the add-on parts.
è Connect the tablet press.
è Clean the tablet press.

Notice:
The first set-up, safety and functional inspection may be carried out
by an IMA KILIAN technician only.

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First commissioning

7 Commissioning
Starting the system
è Set the main switch to position "ON".
Ø All operating status signal lamps are illuminated.
Ø The control system starts up. The progress of starting is indicated by a blue
bar at the bottom of the screen. This bar extends to the right as the program
is being started.

60-057
Illustration 24: Starting screen booting

Once the starting procedure has finished, the mask Tabletting > Set-up is displayed.

Adjustment of upper punch penetration

The factory setting of the upper punch penetration depth is 2.5 mm for pre-pressure
and main pressure (measured from the upper edge of the die (1) to the lower edge of
the punch (2)).

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First commissioning

03-192

Illustration 25: Upper punch penetration depth

è Turn the hexagon screw counter-clockwise in order to remove the cover (1).
è Detach the four fixing screws (2) crosswise one after the other by a quarter-turn
counter-clockwise. Repeat this procedure until all four screws are completely
loosened.
è For lowering the elevating platform turn the hexagonal nut (3) to the left until the
required value is reached.
Ø The new actual value is displayed at the operating terminal in mask
Tabletting > Set-up. (See section Tabletting – Set-up, page 78)
è Tighten the four fixing screws (2) crosswise one after the other by a quarter-turn
each clockwise until reaching the maximum torque of 70 Nm. Repeat this
procedure until all four screws are completely tightened.
è Fix the cover.

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General

8 Usage
8.1 General
This chapter describes the individual control elements of the tablet press as well as
the input masks. Read this section carefully prior to commissioning.
This part of the documentation must be read by all persons who operate or service the
product.
If the product is sold to a third party, the complete technical documentation must be
supplied with it.

Note:
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this document.

8.1.1 Usage
[Link] User management
For login to the system you need the user ID and the password.
Creating a new user and password for the control system is effected via the operating
system (Windows XP) in English language.

On the operating system level, the following three different users are created in
the standard configuration:
• ViCon
- This user is automatically logged in to Windows at auto-start. As it were, he
represents the application. This user has only those rights in the operating
system that are needed for operating the application.
• Service
- Via this interface, IMA KILIAN Service can access the operating system. This
user has administrator rights on the operating system level.
• Superuser
- Via this interface, the customer’s system administrator can access the
visualisation. This user, too, has administrator rights on the operating system.

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General

[Link] Creating a user

è Actuate the global function key System_shut-down in the right screen area of the
visualisation.
Ø The following safety query appears:

60-060
Illustration 26: System_shut-down

è Select <Terminate program>.

Notice:
The button <Terminate Program> is only available with the
password level 5!

þ You are just now on the Windows operating system level.

Notice
The Windows XP operating system is only available in English.

è In the Windows start menu of the task line, select the submenu item
<Settings><Control Panel>.

Illustration 27: Windows Menu <<Settings> <Control Panel>>

è Touch the icon <Administrative Tools> twice.

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Illustration 28: Windows Menu << Administrative Tools >>

è Doubleclick on the icon <Computer Management>.

Illustration 29: Windows Menu <<Computer Management>>

è By touching open the directory <Users>in the left column under <Local user and
groups>.

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Illustration 30: Windows Menu <<Computer Management>>

è In the menu line under <Action> open the Item <New User>.

Illustration 31: Windows Menu <<New User>>

è Enter a new user name in line <User name> .

è The optional fields <Full name> and <Description> can be fullfilled.
è Enter a password of your choice in line <Password> and confirm this
password in the next line.
è Deactivate the selection box <User must change passwort at next logon>
(The user must change the password at next login).
è Confirm the entry via the keys <Create> and <Close>. The newly created user is
now displayed in the window <Local user and groups>.

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Illustration 32: Windows Menu << Local user and groups >>

Now the new user has been created and must still be assigned to a group.
è For this touch the directory <Groups> and select a group by double-clicking, e.g.
<Vicon User>. The window <ViconUser Properties> appears.

Illustration 33: Windows Menu <<ViconUser Properties>>

è Touch the key <Add> and enter the new user to be added to the group. If several
users are entered please separate them by a semicolon.

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Illustration 34: Windows Menu <<User>>

è Click on the key <Check names>. After ending the check routine enter <OK>.
è Click on the key <OK> and then in window <ViconUser properties>.

[Link] Configuring user data

The new user created in Windows is identified and accepted by the ViCon. Specific
user rights within the visualisation must still, however, be assigned.

Notice:
Only a user with administrator rights can carry out the following
steps in the system.

2
1
3

6
7

62-320_en
Illustration 35: System configuration – User management

è Using the pull-down menu select mask <System>.

è Select the submenu item <Configuration>.

è Under Auto. Logout enter the time in minutes, after which the logged user is
automatically logged out if no actions are carried out on the ViCon.
Ø At the Logout the default user is logged on automatically.
è Under <Group> select the user group.
è Under <Default User> select the user who shall be displayed as the standard
user.

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è Under <Login Input> enter how many times a wrong password may be entered
before the user is blocked.
è Under <Popup Hostname> enter the system address of the network
administrator who shall get a pop-up message when a user has exceeded the
number of unsuccessful attempts to log in.
è Under <Domain-Name> you may enter the name of the network domain if the
user groups and users shall be used by the domain controller.

3
2

62-321_en
Illustration 36: System – Configuration – User

1. Via the pull-down menu <Configuration> select the box <User>.

2. For the <User> box select the desired name.
3. Under <Authorisation> activate the boxes for the respective authorisation
levels to be assigned to the user. For the description of levels 0 to 8 please refer
to section Password level.
4. Save the settings using function key <Edit user>.
5. When key <Edit user> is pressed, the safety query "Change settings?"
appears. Confirm the changes with <Yes>.

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8.1.2 Password levels

Eight password levels are provided in the KILIAN basic setting.
User PW Description
level
Guest A user with the authorisation of a guest can view all masks of the
0 visualisation and the reports. He cannot make any inputs nor generate or
print reports.
Technician A user with the authorisation of a technician can start the machine and
1 execute the manual functions.
Operator A user with the authorisation of an operator can set-up and start a batch.
2 He can modify the parameters of formulae and save them. Creating a new
formula is not possible.
Foreman A user with the authorisation of a foreman can change the production
3
mode and can deactivate and activate components.
Engineer A user with the authorisation of an engineer can adjust, zero balance, and
4
calibrate a measuring point.
Manager A user with the authorisation of a manager can view and print production
5
data, as e.g. reports. New formulae can be created and modified.
Administrator A user with the authorisation of an administrator can manage user rights.
6
Free
7 -
Superuser A user with the authorisation of a superuser can do the user management
8
and change the system settings, such as e.g. memory locations.

A user with password level 4 does not automatically get the authorisation for password
levels 0 to 3. This configuration must be defined for each user level separately. Even
an administrator is not automatically granted access to the user levels below his own
one. The setting for the comprehensive levels can be configured in cooperation with
the customer. Thus e.g. the administrator may not be granted access to calibration, as
he does not have sufficient know-how in this field.

Notice:
Passwords are safety elements. Only trained personnel should get
a password.
The password levels are specified by KILIAN and cannot be edited!
The individual password levels for the different input possibilities
can be found in the mask overviews of chapters Tabletting,
Cleaning, and System.

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User login

8.2 User login

A login with user name and password is required to enter and modify values.

Notice:
For creating users and passwords please refer to section User /
password management and following starting on page 56.

Illustration 37: Tabletting – Set-up

At restart, upon expiry of a certain period of time adjustable via the visualisation, and
after user log-out the default user is logged in. The function key in the right column is
labelled <LOGIN>. If another user is logged, the key is labelled <LOGOUT>.

For login please proceed as follows:

è Press the key <LOGIN/LOGOUT>. .
Ø The following window is displayed:

60-058
Illustration 38: Login window

è Select a user under <User:>.

è Enter the password under <Password:>.
è Activate the user entered with the <Login> key in the window.

When pressing the key <Cancel> the current user remains active.

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User login

8.2.1 Changing a password

Notice:
Prior to changing the password the corresponding user must have
logged in to the system with his current password.

For changing the password please proceed as follows:

è Press the key LOGIN/LOGOUT.
Ø The following window is displayed:

60-058
Illustration 39: Login window

è When pressing the key Change password the dialogue for changing the
password is opened:

60-059
Illustration 40: Window Changing a password

è Enter a new password in the first input box.

è Confirm it in the second input box.
Ø When pressing the key OK the password is changed.
Ø When pressing the key Cancel the process is aborted.

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8.3 Overview control elements

8.3.1 Overview control elements machine

2 6

3 1

4
04-118
Illustration 42: Control elements in the machine
04-117 compartment, right
Illustration 41: Control elements of the machine

Position Designation Position Designation

1 Operating terminal 4 Connection for the manual button

2 Operating status signal light (3-colour) 5 Button for the die ejector

3 Emergency stop 6 Die ejector

The main switch (7) and the connecting boxes (8) for network and USB plugs are
located at the control cabinet.

Illustration 43: Control elements at the control cabinet

Position Designation
7 Main switch

8 Connecting boxes for network and USB plugs

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The following control elements are located in the compression chamber:

10

9
04-116
Illustration 44: Control elements in the compression chamber

Position Designation
9 Slide for discharging the fillshoe

10 Butterfly valve of the hopper

11

Illustration 45: Adjustment of upper punch penetration

Position Designation
11 Adjustment of upper punch penetration

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8.3.2 Overview operating terminal

3 5

62-103_en
Illustration 46: General overview Operating terminal

Pos. Designation Page

1 Header 68
2 Global mask-independent function keys 69
3 Bottom line 70
4 Internal range mask 72
5 Machine keys 72

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[Link] Header

1 2 3 4

5
60-104

Illustration 47: Header with press stations

Pos. Description
1 List box/menu tree

2 Operator/machine

3 Batch/product

4 Date/time

5 Tab Selection of press stations

[Link].1 List box/menu tree

A pull-down menu opens when the list box is touched. The selection of an input then
immediately opens the corresponding mask. Possibly existing submenus are opened
or closed again, respectively, when changing to another superior menu item.

[Link].2 Operator/machine
The currently logged operator and the designation of the tablet press are displayed in
the operator and machine box.

[Link].3 Batch/product
The current batch and product names are indicated in the batch and product box. The
product name corresponds to the input in mask Product and not to the name of the
currently loaded production pre-set data record.

[Link].4 Date/time
The current date and time are displayed in the date and time box. The time formats
follow the conventions of the country to which the system is delivered.
The configuration of these formats can be changed via the system control of the
operating system.

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[Link].5 Tab Selection of press stations

The operation mode of the corresponding press station is indicated in the boxes for
press station status. Here, the number of tabs corresponds to the number of press
stations available. For a machine with one press station only P1 is displayed. The
current status of the press stations is displayed as follows:

• Machine at standstill
- Red background: Press station has no release for start
- Yellow background: Press station is ready to start in Set-up mode
- Green background: Press station is ready to start in Production mode
• Machine running
- Yellow background: Press station in Set-up mode
- Green background: Press station in Production mode

[Link] Global function keys

The global function keys at the right edge of the screen masks are assigned with fixed
functions:
Key Description PW
level
PRODUCTION/SET-UP 2
When pressing the function key the selected press station (see Tab Selection of
press stations, page 69) to the operation mode indicated on the key. For multi-layer
machines all press stations are switched to the corresponding mode simultaneously.

HEP 0
- When pressing this function key the help system is started.

LOGIN/LOGOUT 0
- When LOGIN is represented on the key the default user is logged. If another user
is logged, the key is labelled LOGOUT.

SYSTEM SHUTDOWN 0 (5)

- When pressing the function key the following window appears:

60-060
Illustration 48: System shut-down

If you press key "End program" (available only from PW level 5) you will get to the
operating system level. If you press key "Yes" the visualisation is switched off. A
possibly running batch is not finished.

Optional

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[Link] Bottom line

3
2

1
4
60-105
Illustration 49: Bottom line

Pos. Description
1 Function keys

2 Status line

3 Message type

4 Machine keys

[Link].1 Local function keys

• The local function keys are at the screen bottom and are mask-specific. They
allow you to save inputs, to abort, start and/or terminate actions and to generate
views. The following function keys are described with the mask System >
Machine > Measuring points > WSG taken as an example:

60-039
Illustration 50: Example of local function keys

Pos. Designation
1/3 ancel calibration/zero balancing
- When the key is pressed a dialogue window appears (see also section Dialogue window, page 76).

60-115
- If you press key Yes: the corresponding function is executed.
- If you press key No: the function is aborted.
2 Adjustment
- When this key is pressed, the window for the respective adjustment axis appears. The
modifications required for adjustment or calibration (see also section Input keyboards, page 73) can
be entered in this window.

62-003_en

4 Report view/pdf report view

- When pressing the key a report is shown which is specific for the respective mask. The standard
view or pdf view (see also section System – Machine – Report view, page 110) is represented.

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[Link].2 Status line

1 No release for start
60-106
Illustration 51: Status line

Message Background Period of Description

type representation
Status Green Static Status of the tablet press e.g.: "Ready to start in Set-up",
messages "Start-up phase", etc.
Error Red Static Current error message
messages Last error
(1)
Warning Orange Dynamic Current warning
messages 7 seconds
(2)
Info Yellow Dynamic Information about an incorrect input, as e.g.: "Value
messages 7 seconds outside input limits".

(1) Fault messages are shown until the cause of the fault is eliminated and the fault
messages (all fault messages waiting currently at the same time) are acknowledged
by actuating the RESET key.
(2) These messages are provided with a Comes-goes warning mechanism. Thus, the
warning message remains active until the cause for the message does not exist
anymore.

[Link].3 Choice error list/warnings

1 No release for start F W

60-246
Illustration 52: Status line

Selection of error list

When touching the F key to the right of the status line all current error messages are
listed below the status line.
Selection of warning list
When touching the key to the right of the status line all current warning messages
are listed below the status line.

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[Link].4 Machine keys

Machine keys general
The machine keys are only active when a tabletting batch has been started and no
fault has occurred.

Key Description PW
level
- Faults are reset by pressing the RESET key. 2
RESET

- The main drive is briefly switched on by pressing the JOGGING key. 2

JOGGING

- The main drive is switched on by pressing the ON key. 2

ON

- The main drive is switched off by pressing the OFF key. 2

OFF

Table 2: Machine keys

[Link] Mask elements internal range

2 3

1
4

Illustration 53: Internal range of masks

Position Designation
1 Check box for the activation and deactivation of a function
2 List box (pull-down) for the selection of a parameter
3 Actual value display
4 Set-value input with automatic monitoring of the input limits. See also section Input
keyboards, range Numerical keyboard, page 73.
5 Table with output of statistical values. In case of calibration statistics an arrow in the
left column indicates the currently running or the last action. In mask Tabletting >
Manual > Tablet, individual values can be selected using this arrow and can thus be
evaluated graphically.

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[Link].1 Tabs: General

1

60-247
Illustration 54: Tabs

The selection of tabs (1-2) results in the following actions:

Position Designation
1 Selection of a press station
- The values of the selected press station are highlighted in the visualisaton.
Furthermore adjustments and mode changes (set-up/production) are always related
to the selected press station only.
2 Selection of an overview
- The values of the selected overview are highlighted in the visualisation (for example
in-process control or tablet regulation).

[Link].2 Input window

60-248
Illustration 55: Overview Touch Screen

By touching the highlighted elements in the illustration above (actual value, motor or
pressure roller) the corresponding set values (e.g.: fill depth, wall dimension) can be
entered. For this

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• and adjustment window opens:

60-003
Illustration 56: Adjustment window

When entries in input boxes (see section Mask elements internal range) with values
must be made, a

• window for entering figures opens,

Illustration 57: Window for entering figures

Parameter Description
Old Display of the current parameter
New Input box for a new parameter
Pull-down box Possible selections for the reason for editing
Backspace key
- The character last entered is deleted.

Escape key
- Closes the window without adopting any values.

Enter key
- Acceptance of the entered values and closing the window.

Min/Max Display of input limits

- The minimum value must not be undershot and the maximum value must
not be exceeded. Values outside this range are automatically rejected by
the system during the acceptance procedure. The message "7109 Value
is outside the input limits" appears in the status line.

Optional

When entries in input boxes (see section Mask elements internal range) with
characters must be made, a

• window for entering text and/or figures opens,

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Illustration 58: Input window for figures and text

Parameter Description
Old Display of the current parameter
New Input box for a new parameter
Pull-down box Possible selections for the reason for editing
Keypad The inscription of the keys is automatically adapted to the corresponding
special keys, for example upper case letters and the special characters
above the figures are represented if the shift key has been pressed. The
key assignment is automatically adapted to the specified language.

Optional

The input windows automatically close again when

• the values entered are accepted or rejected, or
• the display outside the input window is touched.

Notice:
The input limits are checked when the new value is adopted. In
case of incorrect inputs the input window must be opened anew for
corrections.

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[Link].3 Dialogue window

Safety queries and/or input possibilities open in different windows when values were
input or to confirm actions:

60-115
Illustration 59: Dialogue window "Safety query"

60-114
Illustration 60: Dialogue window "Input request"

[Link].4 Bar diagrams

60-111
Illustration 61: Bar diagrams

Measuring values are also represented as bar diagrams.

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8.4 Menu description Tabletting

8.4.1 Menu tree Tabletting
Notice:
This chapter describes the full equipment. Several masks are
optional and can vary in their functionalities.

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8.4.2 Tabletting – Set-up

60-001
Illustration 62: Tabletting – Set-up

For the descriptions of the general mask control elements please refer to chapter
Overview Control elements section Overview Operating terminal.
The elements in mask <Set-up> have the following functions:

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Menu description Tabletting

Parameter Description PW
level

Representation development view of die table

Fillshoe speed actual value Speed of the fillshoe motor For machines without recording the (2)
actual fillshoe speed, this value represents the set value. The
set value can be edited by clicking on the actual value or on the
fillshoe motor.

Dosing wheel speed actual Speed of the dosing wheel (1) (2)
value

Penetration depth PP/MP Actual value of the penetration depth (1) -

actual value

Wall dimension PP/MP actual Actual value of the wall dimension (1) -
value

Fill depth actual value Actual value of the fill depth (1) -
For multi-layer tablets, this is the filling including the previous
layers which were already pressed.

Compaction force PP/MP Revolution average of compaction force. It is generated using -

actual value all compaction forces within one revolution.

Relative standard deviation Relative standard deviation of the compaction force from the -
compaction force average value in one revolution

Axle PP/MP By clicking on the pressure rollers or on the display boxes for -
the wall dimension or the penetration depth the following
window is displayed:

The elements in the window have the following functions:

Penetration depth set value: 2

Set value of the penetration depth

Penetration depth actual value: -

Actual value of the penetration depth (1)

Penetration depth – 1
Pressing the key reduces the penetration depth (2).

Penetration depth + 1
Pressing the key increase the penetration depth (2).

Positioning 1
By actuating the button, the penetration depth is adjusted to its
set value.

Wall dimension set value 2

Set value of the wall dimension

Wall dimension actual value -

Actual value of the wall dimension (1)

Wall dimension – 1
Pressing the key reduces the wall dimension (2).

Wall dimension + 1
Pressing the key increases the wall dimension (2).

Positioning 1
By actuating the button, the wall dimension is adjusted to its set
value.

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Menu description Tabletting

Parameter Description PW
level

Compaction force set value 2

Set value of the compaction force

Compaction force revolution average -

The compaction force average is generated using all
compaction forces within one revolution.

Option Fast motion -

If this option is not activated, the axle is moved at slow speed
when actuating the buttons +/-. If this option is activated, the
movement is done at higher speed.

Wall dimension layer actual value -

Display of the wall dimension relative of the respective press
station. The field is only shown for multi-layer machines.

Close -
The window is closed by actuating this button.

Axle fill depth By clicking on the fill depth motor or on the display field of the -
fill depth the following window is opened:

60-003

The elements in the window have the following functions:

Fill depth set value 2

Set value of the fill depth. For multi-layer tablets, this is the
filling including the previous layers which were already pressed.

Fill depth actual value -

Actual value of the fill depth (1)
For multi-layer tablets, this is the filling including the previous
layers which have already been pressed.

Fill depth – 1
Pressing the key reduces the fill depth (2).

Fill depth + 1
Pressing the key increases the fill depth (2).

Positioning 1
By actuating the button, the fill depth is adjusted to its set
value.

Option Fast motion -

If this option is not activated, the axle is moved at slow speed
when actuating the buttons +/-. If this option is activated, the
movement is done at higher speed.

Fill depth layer actual value -

Display of the fill depth relative of the respective press station.
The field is only shown for multi-layer machines.

Close -
The window is closed by actuating this button.

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Menu description Tabletting

Parameter Description PW
level

Range Tablet

Weight set value Set value of the tablet weight 2

For multi-layer tablets, this is the total weight of the previous
layers which were already pressed and not the weight of the
respective layer.

Weight actual value Average of the tablet weight of the last measurement cycle. -
For multi-layer tablets, this is the total weight of the previous
layers which were already pressed and not the weight of the
respective layer.

Thickness set value Set value of the tablet thickness 2

For multi-layer tablets, this is the total thickness of the previous
layers which were already pressed and not the thickness of the
respective layer.

Thickness actual value Average of the tablet thickness of the last measurement cycle -
For multi-layer tablets, this is the total thickness of the previous
layers which were already pressed and not the thickness of the
respective layer.

Hardness set value Set value of the tablet thickness 2

For multi-layer tablets, this is the total thickness of the previous
layers which were already pressed and not the thickness of the
respective layer.

Hardness actual value Average of the tablet thickness of the last measurement cycle -
For multi-layer tablets, this is the total hardness of the previous
layers which were already pressed and not the thickness of the
respective layer.

Range General

Machine output actual / set Tablet output of the machine in tablets per hour 2
value This value allows for the number of press stations, a possible
short fitting and a multi-purpose too so that the value
represents the actual tablet output of the machine.
The actual value is an instantaneous record which is used to
calculate the expected tablet output per hour.

Range Function keys

Positioning all When the function key "Positioning all" is pressed, the safety 1
query "Adjust to position?" appears.

60-004
<Yes:>
Adjusting all axles to the set value of the press station
displayed
<No:>
Aborts the function

Set values = actual values When the function key "Set values = actual values" is pressed, 2
the safety query "Accept actual values?" appears.

60-005
<Yes:>
All actual values are accepted as set values
<No:>
Aborts the function

(1) The actual value is only displayed if the measuring point is instrumented and activated.
(2) This adjustment can only be made if the measuring point is motorised, activated and instrumented.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Set-up – Batch

60-006
Illustration 63: Tabletting – Set-up – Batch

The elements in mask Batch have the following functions:

Parameter Description PW
level
Production pre-sets Selection of the data record for the production pre-sets. After 3
confirming the safety query all parameters of this data record
are loaded.
Filling Input of the corresponding value for the choice 3
Filling - is on "Off", the container filling system is deactivated. 3
If the choice … - is on "Tablets", the container is changed after reaching the
pre-set value (good tablets).
- is on "Kilograms", the container is changed after the pre-set
value has been reached.
- is on "Minutes", the container is changed after reaching the
pre-set value (minutes).
Production end Input of the corresponding value for the choice 3
Production end - is on "Minutes", the container is changed after reaching the 3
If the choice … pre-set value (minutes).
- is on "Tablets", the machine is stopped after reaching the pre-
set value (good tablets).
- is on "Kilograms", the machine is stopped after reaching the
pre-set value (in kg).
- is on "Minutes", the machine is stopped after reaching the
pre-set value (production time).
- is on "Fillings", the machine is stopped after reaching the pre-
set value (number of containers filled).
Batch - must be entered to be able to start a new batch. 2
The name of the batch... - can only be used once.
Formula Description of the product formula 2
Customer Customer of the batch 2
Order Order identification of the batch 2
Description Additional information of the batch 2
Range Function keys
Batch start When key "Batch start" is pressed, a new batch is started. 2
During the time from initiation of a batch start up to the end of
the start routine, a progress-bar control is displayed in the
status line.

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

Parameter Description PW
level
Batch end After pressing the key "Batch end" a safety query appears. 2

60-007
- Yes:
Finishes the current batch. During the time from initiation of a
batch end up to the end of the termination routine, a progress-
bar control is displayed in the status line.
- No:
Aborts the function.
Save production data After pressing the function key "Save production pre-sets" the 5
input request "Save production data" appears.

60-008
Save:
- If the key "Save" is pressed and the name proposed for the
production pre-sets is kept, the data record is overwritten with
the current settings.
If the key "Save" is pressed after the name proposed for the
production pre-sets was edited, a data record with the new
name is generated. If this new name already exists, it is
checked by a safety query whether this data record is to be
overwritten or whether the procedure shall be aborted.
Cancel:
- Aborts the function.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Set-up – Production

60-009
Illustration 64: Tabletting – Set-up – Production

The elements in mask Production have the following functions:

Parameter Description PW
level
Tool Selection of the data record for a specific tool type. After 3
confirming the safety query all parameters of this data record
are loaded.
Standard sampling Selection of the data record for the standard sampling. After 3
confirming the safety query all parameters of this data record
are loaded.
Tablet quality check Selection of the data record for the quality sampling. After 3
confirming the safety query all parameters of this data record
are loaded.
Range Pre-pressure regulation
If the choice... - is on "Off", the regulation is deactivated. 5
- is on "With wall dimension", the compaction force regulation is
activated via the wall dimension.
Selection of individual Individual selection of the reject tablets of the pre-pressure is 5
samples ON activated or deactivated.
Range Main pressure regulation

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

Parameter Description PW
level
If the choice... - is on "Off", the regulation is deactivated. 5
- is on "With filling", the compaction force regulation is activated
via filling (the tablet weight is indirectly kept constant).
- is on "With wall dimension", the compaction force regulation is
activated via the wall dimension (the tablet hardness is
indirectly kept constant).
- is on "Weight regulation with MP set value", the compaction
force regulation is activated via filling and the weight regulation
via changing the main pressure set value (the tablet thickness
is indirectly kept constant with variable tablet hardness).
- is on "Weight regulation with wall dimension", the compaction
force regulation is activated via the filling and the weight
regulation via changing the wall dimension (the tablet hardness
is indirectly kept constant with variable tablet thickness).
- is on "With hardness readjustment", the compaction force
regulation is activated via the wall dimension and the hardness
regulation via changing the main pressure set value (the tablet
weight is indirectly kept constant with variable tablet thickness).
- is on "With combined weight and hardness readjustment", the
compaction force regulation is activated via filling and the
weight and hardness regulation via the wall dimension and the
compaction force set value.
Number of tablets for the The number of tablets entered is separated for tablet regulation 5
regulation into the sampling channel.
Readjustment pause Between two control samplings taken for tablet readjustment a 5
pause is made according to the time entered.
Selection of individual Individual selection of the reject tablets of the main pressure is 5
samples ON activated or deactivated.
Separation mode: - is on "Group separation", all tablets required for the sampling 5
If the choice... request are blown out at the same time.
- is on "Single separation", exactly one tablet is separated and
fed for measuring, and it is not until then that the next table is
separated for sampling
Range Function keys
Save tool After pressing the key "Save tool" the input request "Save tool 5
data" appears.

60-010
Save:
- If the key "Save" is pressed and the name proposed for the
tools is kept and the data record is overwritten with the current
settings.
- If the key "Save" is pressed after the name proposed for the
tools was edited, a data record with the new name is
generated. If this new name already exists, it is checked by a
safety query whether this data record is to be overwritten or
whether the procedure shall be aborted.
Save standard sampling After pressing the key "Save standard sampling" the input 5
request "Save standard sampling data" appears.

60-011
Save:
- If the key "Save" is pressed and the name proposed for the
standard sampling is kept and the data record is overwritten
with the current settings.
- If the key "Save" is pressed after the name proposed for the
standard sampling was edited, a data record with the new
name is generated. If this new name already exists, it is
checked by a safety query whether this data record is to be
overwritten or whether the procedure shall be aborted.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

Parameter Description PW
level
Cancel:
- Aborts the function.
Save tablet quality check After pressing the key "Save tablet quality check" the input 5
request "Save IPC data" appears.

60-012
Save:
- If the key "Save" is pressed and the name proposed for the
tablet quality control is kept and the data record is overwritten
with the current settings.
- If the key "Save" is pressed after the name proposed for the
tablet quality control was edited, a data record with the new
name is generated. If this new name already exists, it is
checked by a safety query whether this data record is to be
overwritten or whether the procedure shall be aborted.
Cancel:
Aborts the function

[Link].1 Tabletting – Set-up – Production – Tool

60-013
Illustration 65: Tabletting – Set-up – Production – Tool

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

The elements in mask Tool have the following functions:

Parameter Description PW
level
Multiple punches This value states how many insert punches are present per 5
tool.
Shape (XY) It describes the shape of the tablet (shape of the die). The 5
following options are available:
- round
- oblong
- triangular
- rectangular
- special shape
- oval
Diameter / wide side Depending on the tablet shape, the tablet diameter or the tablet 5
width, respectively, is entered in this input box.
Long side If the tablet is not round in shape, the length of the tablet long 5
side is entered in this input box.
Shape (Z) – Lower punch This describes the convexity of the lower punch. The following 5
options are available:
- half-round
- concave
- convex
- flat
- free
- bevelled edge
Shape (Z) – Upper punch It describes the convexity of the upper punch. The following 5
options are available:
- half-round
- concave
- convex
- flat
- free
- bevelled edge
Convexity radius The convexity radius of the punch is entered here. 5
Stud length The possible stud length of the tools is entered here. 5
Punch load – permitted The maximum permissible punch load is set here. A 5
modification of this value automatically results in a modification
of the compaction force limitation (if the measuring point is
active).
Punch load – theoretical The calculated theoretical maximum punch load due to the 5
punch shape is indicated here.
Blow-out pulse duration The duration of the blow out pulse is set here. 2
Blow-out position An offset of the blow-out position in punch divisions can be 2
entered here. This offset is the punch-dependent part of the
blow-out position.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link].2 Tabletting – Set-up – Production – Quality

60-014
Illustration 66: Tabletting – Set-up – Production – Quality

The elements in mask <Quality> have the following functions:

Parameter Description PW
level
Tablet quality check Input of the corresponding variable for the choice (minutes, 5
tablets, or revolutions).
Cycle of quality checks - is on "Off", no quality samples are separated. 5
If the choice … - is on "Minutes", quality samples are separated every x
minutes.
- is on "Tablets", quality samples are separated every x tablets.
- is on "Revolutions", quality samples are separated every x
revolutions.
Number of additional Number of tablets that are separated in addition to the tablets 5
samplings required for quality sampling.
Range Tolerances
Tolerance limit T0 Plus Positive tolerance limit for average monitoring of the tablet 5
(1)
parameters .
Tolerance limit T0 Minus Negative tolerance limit for average monitoring of the tablet 5
(1)
parameters .
Tolerance limit T1 Plus Positive tolerance limit T1 for single value monitoring of the 5
(2)
tablet parameters .
Tolerance limit T1 Minus Negative tolerance limit T1 for single value monitoring of the 5
(2)
tablet parameters .
Tolerance limit T2 Plus Positive tolerance limit T2 for single value monitoring of the 5
(2)
tablet parameters .
Tolerance limit T2 Minus Negative tolerance limit T2 for single value monitoring of the 5
(2)
tablet parameters .
Valid measurements for Number of valid measurements that are included in the 5
statistics statistics. If the number of valid measurements was undershot,
the sampling is rejected and repeated. If the number of valid
measurements is set to zero this tablet parameter is not
measured.
Range Limiting values
(3)
Evaluation limit Plus Positive ViCon evaluation limit 5
(3)
Evaluation limit Minus Negative ViCon evaluation limit 5
Permitted average values Number of measured averages which may be outside the 5
(4)
outside T0 tolerance limits T0 .
Permitted single values Number of measured single values within a quality sampling 5

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

Parameter Description PW
level
(4)
outside T1 which may be outside T1, but within T2 .
Permitted single values Number of measured single values within a quality sampling 5
(4)
outside T2 which may be outside T2 .
(1) with reference to the set value of the tablet parameter
(2) with reference to the average of the samplings (standard) or to the set value of the tablet parameter
(3) Tablets outside of these evaluation limits are declared as reject measurements and are not included in
the statistics.
(4) If this value is exceeded, the tablet press is switched off with a fault.

[Link].3 Tabletting – Set-up – Production – Sample

60-015
Illustration 67: Tabletting – Set-up – Production – Sample

The elements in mask Sample have the following functions:

Parameter Description PW
level
Cycle Sampling - is on "Off", no samples are separated to the tablet sampler. 5
If the choice … - is on "Minutes", samples are separated to the tablet sampler
every x minutes.
- is on "Tablets", samples are separated to the tablet sampler
every x tablets.
- is on "Revolutions", samples are separated to the tablet
sampler every x revolutions.
Cycle Sampling Input of the corresponding variable for the choice (minutes, 5
tablets, or revolutions).
Number of samplings Number of tablets that are separated to the tablet sampler for 5
sampling.
Sample definition: - is on "Group sampling", x tablets are separated for sampling 5
If the choice... in succession, starting with a random punch.
- is on "Individual sampling", x tablets are separated in "n"
successive revolutions from a specific punch.
- is on "Samplings in sequence", x tablets are separated in
successive revolutions so that the tablet from punch No. 1 is
separated in the first revolution, from punch No. 2 in the second
revolution and so on.
Individual sampling from Number of the punch the tablets of which are separated as 5
punch samples. Input is only possible if the choice is on "Individual
sampling".

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link].4 Tabletting – Set-up – Production – Equipment

60-016
Illustration 68: Tabletting – Set-up – Production – Equipment

The elements in mask Equipment have the following functions:

Parameter Description PW
level
Range Machine
Compaction force limitation The main pressure compaction force limitation of the machine 3
MP can be entered here. The regulation of the compaction force
limitation then keeps this pre-set value constant.
Compaction force limitation The pre-pressure compaction force limitation of the machine 3
PP can be entered here. The regulation of the compaction force
limitation then keeps this pre-set value constant.
Start-up dosing Input of the number of punches for start-up dosing. This is an 3
offset to the minimally required time delay. If zero is entered the
function is deactivated.
Change-over delay main gate Input of the number of punches for delayed change-over of the 3
main gate.
Travel amplified compaction The wall dimension is reduced by this percentage value in case 3
force of the sampling of a tablet layer.
Kind of selection: - is on "Blow-out nozzle", all rejects and sample tablets are 3
If the choice … sorted out by means of compressed air.
- is on "Main gate", all reject tablets are taken out of the good
channel.
Fillshoe type: - is on "Gravity feed fillshoe", the fillshoe activation is disabled. 3
If the choice … - is on "Force feed fillshoe", the fillshoe activation is enabled.
Fillshoe distributor wheel type - is on "Blades", this is stored in the product database. 3
If the choice … - is on "Cranked rods", this is stored in the product database.
- is on "Special shape", this is stored in the product database.
Direction of fillshoe rotation: - is on "Standard", the agitator wheels are driven in the 3
If the choice … standard direction of rotation.
- is on "Inverse", the agitator wheels are driven opposite to the
standard direction of rotation.
Direction of dosing wheel - is on "Standard", the dosing wheel is driven in the standard 3
rotation: direction of rotation.
If the choice … - is on "Inverse", the dosing wheel is driven opposite to the
standard direction of rotation.
Range Peripheral equipment
Reject tablets of metal check Input of the number of permissible metal checks of the metal 3
detector.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

Parameter Description PW
level
Conveyor belt follow-on time Input of the follow-on time of the conveyor belt. 3
Deduster follow-on time Follow-on time of the deduster in seconds 3
Deduster voltage Input of the power of the deduster’s transport helix . 3
Deduster frequency Input of the resonant frequency of the deduster’s transport helix 3
.
Range TCU
Conveying speed transporter Percentage conveying speed of the transporter cup in the RQ. 3
cup
Transport time Venturi Venturi transport time for tablet transport from the machine to 3
the TCU.
Only with special execution of the Advantech deduster unit.

[Link] Tabletting – Set-up – Product

60-017
Illustration 69: Tabletting – Set-up – Product

The elements in mask Product have the following functions:

Parameter Description PW
level
Product name In this field the name of the product can be stored. 5
Range Compaction force MP / PP
Tolerance Plus set value If the compaction force (single values) is higher than the 5
tolerance limit (set value plus tolerance Plus), the result of this
is a reject tablet.
Tolerance Plus actual value Proportional deviation of the revolution minimum from set -
value.
Tolerance Minus set value If the compaction force (single values) is lower than the 5
tolerance limit (set value minus tolerance Plus), the result of
this is a reject tablet.
Tolerance Minus actual value Proportional deviation of the revolution minimum from set -
value.
Range Adjusting limits production MP / PP
(1)
Penetration depth minimum Minimum possible penetration depth . 3
(1)
Penetration depth maximum Maximum possible penetration depth . 3
(1)
Wall dimension minimum Minimum possible wall dimension . 3
(1)
Wall dimension maximum Maximum possible wall dimension . 3
(1)
Fill depth minimum Minimum possible fill depth . 3

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

Parameter Description PW
level
(1)
Fill depth maximum Maximum possible fill depth . 3
(1)
Compaction force set value Maximum possible set value adjustment of the regulation . 5
maximum
(1)
Compaction force set value Minimum possible set value adjustment of the regulation . 5
minimum
Range Tolerance monitoring
No. of permissible reject Input of the permitted number of consecutive reject punches. 3
punches
Permissible revolutions / Input of the permitted number of consecutive revolutions 3
reject punch relating to a reject punch.
(1) Only during operation mode Production.

8.4.3 Tabletting – Manual

60-018
Illustration 70: Tabletting – Manual

The elements in mask <Manual> have the following functions:

Parameter Description PW
level
Range Manual operation
Fillshoe Switch the fillshoe on and off manually. 1
Deduster Switch the deduster on and off manually. 1
Filling Change container manually. 1
Conveyor belt Switch the conveyor belt on and off manually. 1
Dosing wheel Switch the dosing wheel on and off manually. 1
Open/close fillshoe lid Opening and closing the fillshoe lid for each press station 1
manually.
Range General
Illumination of compression Switch on and off the lighting in the compression chamber. 1
chamber
Let the tablet press run empty Tablet press is run empty. 1
Vibrator Switch the vibrator on and off manually. 1

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Manual – Equipment

60-019
Illustration 71: Tabletting – Manual – Equipment

The elements in mask <Equipment> have the following functions:

Parameter Description PW
level
Range General
Lubrication pump 1 Initiate a lubrication pulse of lubrication pump 1. 1
Lubrication pump 2 Initiate a lubrication pulse of lubrication pump 2. 1
Grease lubrication Initiate a lubrication pulse of the grease lubrication pump. 1
Hydraulic brake penetration The brake for the motor-driven penetration depth adjustment is 1
depth adjustment released. Thus the penetration depth can then be adjusted via
a motor.
Range Compaction force limitation
Main pressure Plus Manually increase the compaction force limitation of the main 1
pressure.
Main pressure Minus Manually reduce the compaction force limitation of the main 1
pressure.
Pre-pressure Plus Manually increase the compaction force limitation of the pre- 1
pressure.
Pre-pressure Minus Manually reduce the compaction force limitation of the pre- 1
pressure.
Product feed Manual opening/closing and locking/unlocking of the product 2
feed (PSL flap)

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Manual – Tablet

60-226
Illustration 72: Tabletting – Manual – Tablet (range Selection: Manual feed)

60-225
Illustration 73: Tabletting – Manual – Tablet (range Selection: Automatic feed)

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

60-227
Illustration 74: Tabletting – Manual – Tablet (range Evaluation: Histogram / statistics)

The elements in mask Tablet have the following functions:

Parameter Description PW
level
Tab Selection By selecting this tab the following input options are highlighted:
Range Settings
Number of tablets Number of tablets separated for a manual standard sampling. 2
Feed - is on "Manual", the operator has to insert the tablets into the 2
If the choice … tablet check unit manually after the system has been emptied.
- is on "Automatic", the tablets to be checked are automatically
separated by the system to the tablet check unit.
Separation mode (1) - is on "Group", the tablets are first separated and then 2
If the choice … transported to the TCU together. Separation of the tablets for
measuring is not effected until right on the transporter cup. An
assignment of punch number/main pressure and
weight/thickness/hardness is not possible in this case. No
values are represented for punch number and main pressure.
- is on "Individual", the tablets are separated individually one
after the other, transported to the TCU, and measured. Thus
punch number/main pressure/weight/hardness and thickness
are recorded for each tablet.
Sample definition (1) - is on "Group sampling", the tablets required for manual tablet 2
If the choice... check are separated directly one after the other.
- is on "Individual sampling", the tablets required for manual
tablet check are separated from the punch which was selected
under "Individual sampling from punch".
- is on "Sampling in sequence", the tablets required for manual
tablet check are separated successively from punch No. 1 in
the first revolution through to punch No. n in the nth revolution
(here "n" means the number of tablets per measurement cycle).
Individual sampling from If in sample definition an individual sampling has been chosen, 2
punch (1) the punch number can be input in this input box of that punch
the tablets of which shall be separated.
Range Pre-sets
Weight (2) Input of the set value for the tablet weight in mg. 2
Thickness (2) Input of the set value for the tablet thickness in mm. 2
Hardness (2) Input of the set value for the tablet hardness in N. 2
Diameter / wide side (2) For a round tablet shape the tablet diameter and for a non- 2
round tablet shape the tablet width is entered in this input box.
Long side (2) If the tablet is not round in shape, the tablet length is entered in 2
this input box.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

Parameter Description PW
level
Measuring point active The measurement of the tablet parameter is disabled or 2
enabled, respectively.
Tab Evaluation By selecting this tab the following statistical evaluations are highlighted:
Diagram - is on "Histogram weight", the histogram of the weight values 2
If the choice … is represented in the diagram.
- is on "Histogram thickness", the histogram of the thickness
values is represented in the diagram.
- is on "Histogram hardness", the histogram of the hardness
values is represented in the diagram.
Statistics In the statistics table the statistical values for weight, thickness, 2
and hardness are represented.
Range Function keys
Start When the key Start is pressed, the manual tablet check is 2
started. The text of the key changes to Stop. In the
visualisation, a dialogue box with the request "Please insert
tablets" is displayed only for manual tablet check with manual
feed. No screen change is permitted in the visualisation during
the time between start and the request to insert tablets.
Stop When the key Stop is pressed, the manual tablet check is 2
immediately stopped. The text of the key returns to Start.
Table Single values As no ViCon evaluation limits are preset for the manual tablet 2
check, the operator must have the opportunity to be able to
mark the single values in the table later as valid or invalid. The
measuring values marked invalid are then not included in the
statistics. The statistics are always calculated anew when a
measuring value is selected or de-selected. The diagrams are
updated, too.
Print With this function key the report of the manual tablet check is 2
printed out.
(1) The selection is displayed when "Automatic" was selected for the feed.
(2) This input possibility is only effective for manual feed. For automatic feed the parameter is adopted from
the tool settings of the machine.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Manual – Sample

60-020
Illustration 75: Tabletting – Manual – Sample

The elements in mask Sample have the following functions:

Parameter Description PW
level
Number of tablets Number of tablets separated for a manual standard sampling. 2
Sample definition - is on "Group sampling", x tablets are separated for sampling 2
If the choice... in succession, starting with a random punch.
- is on "Individual sampling", x tablets are separated in "n"
successive revolutions from a specific punch.
- is on "Samplings in sequence", x tablets are separated in
successive revolutions so that the tablet from punch No. 1 is
separated in the first revolution, from punch No. 2 in the second
revolution and so on.
Individual sampling from Number of the (equipped) punch the tablets of which are 2
punch separated as samples. Input is only possible if the choice is on
"Individual sampling".
Range Function keys
Start/Stop - When key "Start" is pressed, the manual standard sampling is 2
started.
- When the key "Stop" is pressed, the manual standard
sampling is stopped immediately.
When the manual standard sampling has been finished, the
inscription of the key automatically changes from Stop to Start.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

8.4.4 Tabletting – Display

60-021
Illustration 76: Tabletting – Display

The elements in mask Display have the following functions:

Parameter Description
Range Press station
Main pressure average Display of the revolution averages of the last x revolutions.
Good production All tablets produced so far (within the current batch) the compaction force
of which was inside the compaction force tolerances.
Next filling in tablets Tablets to be still produced until the next container change.
Next filling in minutes Remaining time – calculated on the basis of the current machine output –
until the next filling in minutes
Range Production
Total production All tablets produced so far (within the current batch) on the machine the
compaction force of which was inside the compaction force tolerances.
Production end in tablets Tablets to be still produced until reaching the pre-set production amount.
Production end in minutes Remaining time (calculated on the basis of the current machine output)
until reaching the pre-set production amount in minutes.

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Display – Compaction forces

60-023
Illustration 77: Tabletting – Display – Compaction forces
The elements in mask Compaction forces have the following functions:
Parameter Description PW
level
Compaction force: - is on "Main pressure", the punch diagram MP is displayed. -
If the choice... - is on "Pre-pressure", the punch diagram PP is displayed.
Range Values
Revolution: - is on "Revolution", the single compaction forces of pre-
If the choice... pressure or main pressure, respectively, of one revolution are
-
displayed.
- is on "Revolution punch", the single compaction forces of pre-
pressure or main pressure, respectively, of the punch selected
under "Punch number" for the last 45 revolutions are displayed.
MP/PP set value (1) Set value of the selected compaction force 2
MP/PP Tolerance Plus (1) If the compaction force (single values) is higher than the 5
tolerance limit (set value plus tolerance Plus), the result of this
is a reject tablet.
MP/PP Tolerance Minus (1) If the compaction force (single values) is lower than the 5
tolerance limit (set value minus tolerance Plus), the result of
this is a reject tablet.
Fillshoe speed set value Speed of the fillshoe motor 2
Revolution average MP/PP Average of all compaction forces of one revolution -
(1)
Revolution maximum MP/PP Maximum compaction force of the revolution -
(1)
Revolution minimum MP/PP Minimum compaction force of the revolution -
(1)
Relative standard deviation Relative standard deviation of the compaction force from the -
MP/PP (1) set value in one revolution.
Fillshoe speed actual value Actual value of the fillshoe speed -
Range General
Machine output set value Tablet output of the machine -
Machine output actual value Actual value of the machine output -
Range Function keys
Absolute / relative When the function key is pressed, the compaction force 2
diagram switches from relative representation to absolute
representation.
(1) Depending on the compaction force selection, values for main pressure (MP) or pre-pressure (PP) are
displayed.

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Display – Tablet

60-186
Illustration 78: Tabletting – Display – Tablet

The elements in mask Tablet have the following functions:

Parameter Description
Weight Display of the tablet weight average of the last x measuring cycles
Thickness Display of the tablet thickness average of the last x measuring cycles
Hardness Display of the tablet hardness average of the last x measuring cycles
Date/time Date/time of the measurement.
Container No. Number of the container
Prod. stage Identification number of the production stage
Measurement cycle Identification number of the measuring cycles
Measurement No. Consecutive measurement number
Weight (mg) Single tablet weight in mg
Thickness (mm) Single tablet thickness in mm
Hardness (N) Single tablet hardness in N
Diameter (mm) Single tablet diameter in mm
Punch No. Identification number of the respective punch
Main pressure (kN) Respective main pressure compaction force in kN
Optional

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link].1 Tabletting – Display – Analysis

60-037
Illustration 79: Tabletting – Display – Analysis – Selection

60-036
Illustration 80: Tabletting – Display – Analysis

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

The elements in mask Analysis have the following functions:

Parameter Description
Range Selection
If the choice... - is on "Current", the analysis is executed for the last measurement
cycle. The cycle selection table is not shown.
- is on "Batch", the analysis is executed for all measurement cycles of
the current batch. The cycle selection table is not shown.
- is on "Container", the cycle selection table is shown with a list of all
containers with at least one measurement cycle from the current batch.
The analysis is executed over all selected measurement cycles.
- is on "Production stage", the cycle selection table is shown with a list
of the production stages with at least one measurement cycle from the
current batch. The analysis is executed over all selected measurement
cycles.
- is on "User-defined", the cycle selection table is shown with a list of
all measurement cycles from the current batch. The analysis is
executed over all selected measurement cycles.
Range Evaluation
If the choice... - is on "Histogram weight", the weight histogram of the selected
measurement cycles (1) is shown in range Selection.
- is on "Histogram thickness", the thickness histogram of the selected
measurement cycles (1) is shown in range Selection.
- is on "Histogram hardness", the hardness histogram of the selected
measurement cycles (1) is shown in range Selection.
Range Single values
The single values refer to the measuring values of the selected measurement cycles (1).
Date/time Date/time of the measurement
Container No. Number of the container
Prod. stage Identification number of the production stage
Measurement cycle Identification number of the measurement cycles
Measurement No. Consecutive measurement number
Weight (mg) Single tablet weight in mg
Thickness (mm) Single tablet thickness in mm
Hardness (N) Single tablet hardness in N
Diameter (mm) Single tablet diameter in mm
Punch No. Identification number of the respective punch
Main pressure (kN) Respective main pressure compaction force in kN
(1) If the previous choice was on "Current" or "Batch", the data of the last measurement cycle ("Current") or
of all existing measurement cycles ("Batch") are displayed.

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Display – Messages

60-025
Illustration 81: Tabletting – Display – Messages

The elements in mask Messages have the following functions:

Parameter Description
Type
The following message types Status messages
are displayed:
Error messages

Info messages
Date Date on which the message was generated.
Time Time when the message was generated.
Operator Operator who was logged in at the time when the fault was entered into
the system.
Number Identification number of the message
Message Message text in the relevant language
Info 1 Additional information concerning the message
Info 2 Additional information concerning the message
Range Function keys
Fault When the function key "Error" is pressed, only error messages are
displayed in the list.
Status When the function key "Status" is pressed, only status messages are
displayed in the list.
Info When the function key "Info" is pressed, only info messages are displayed
in the list.
Number When the function key "Number" is pressed, an input box for entering the
number is displayed.. Only messages with the number entered are then
displayed in the list.
Number of today When the function key "Only of today" is pressed, only messages of today
are displayed in the list.
All When the function key "All" is pressed, all messages are displayed in the
list.

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Display – Audit trail messages

60-026
Illustration 82: Tabletting – Display – Audit trail messages

The elements in mask Audit messages have the following functions:

Parameter Description
ID Consecutive number. Herewith, a time displacement can be identified.
Date Date on which the message was generated.
Time Time at which the message was generated.
Operator Operator who was logged in at the time of changing the parameter.
Number Identification number of the Audit Message
Message Message text in the relevant language
Old value Value of the parameter before the change
New value Value of the parameter after the change
Reason Reason for the change

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

8.4.5 Tabletting – Reports

60-027
Illustration 83: Tabletting – Reports

The elements in mask Reports have the following functions:

Parameter Description PW
level
Batch Selection of the available batch data records 2
Report type: is on "Cyclical entry", the cyclical production data which have 2
If the choice... been generated over a time interval or a tablet interval are
filtered from the list of all reports.
is on "Container change", the cyclical production data which 2
have been generated for a container are filtered from the list of
all reports.
is on "Batch end", the batch end is filtered out. 2
is on "Set-up report", the set-up data are filtered from the list of 2
all reports.
is on "In-process control", the data of all quality samplings are
filtered from the list of all reports.
2
The individual reports are then displayed in a list. By selecting a report line a marking arrow is put in the
outer left edge of the list. The individual column titles have the following meanings:
- Print:
By actuating the column title "Print" in the mask all report lines are selected. Individual reports can be
released for printing by ticking the check boxes in the corresponding lines.
- Stage:
Number of the production stage during which the report was generated.
- Cycle:
Number of the cycle within the production stage.
Cycle end:
Date and time when the report was generated
Report type: is on "Operation messages", the messages are filtered out. 2
If the choice... is on "Audit trail messages", the audit messages are filtered
out.
2
Range Function keys
Print When actuating the function key "Print" all reports are 2
transferred to the printer for which the box in the "Print" column
has been selected.
View/PDF view The view or the pdf view of the selected report is displayed. 2

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Reports – View

60-028
Illustration 84: Tabletting – Reports – View

Depending on the function selection in mask Reports (see section Tabletting –

Reports, page 105 the view or the pdf view of the selected report is displayed here.
The following functions are available:
Key Description PW
level
Print If the key "Print" is actuated, the report is printed on the pre-set 2
printer.
Zoom If the key "Zoom" is actuated, the view is zoomed in or out, 2
respectively.
<< If the key "<<" is actuated, the previous report page is 2
displayed.
>> If the key ">>" is actuated, the next report page is displayed. 2
Back If the key "Back" is actuated, the window is closed. 0

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Operating Instruction
Synthesis 700ZS Usage
Menu description Tabletting

[Link] Tabletting – Reports – Settings

60-030
Illustration 85: Tabletting – Reports – Settings

Parameter Description PW
level
Cyclical production report Input of the choice of the corresponding variable 5
Cyclical production report - is on "Off", no report is generated. 5
If the choice... - is on "Minutes", a production report is generated every x
minutes.
- is on "Tablets", a production report is generated every x
tablets.
- is on "Filling", a production report is generated after each
container change.
- is on "Minutes + filling", a production report is generated every
x minutes and after each container change.
- is on "Tablets + filling", a production report is generated every
x tablets and after each container change.
Print out IPC protocol If this input is activated, every IPC report is sent to the selected 5
automatically printer as soon as it is generated.

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

8.5 Menu description System

8.5.1 Menu tree System
The following masks and sub-masks are available in range System:

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

8.5.2 System – Machine

60-137
Illustration 86: System – Machine

The elements in mask Machine have the following functions:

Parameter Description PW
level
Machine data record Selection of the data record for the machine configuration. After 5
confirming the safety query all parameters of this data record
are loaded
Range Machine identification
Machine name Input of a machine name 6
Machine commission Indication of the Kilian Commission No. of the machine -
Machine type Indication of the machine type -
Tool type Indication of the tool type for the machine -
Total number of punches Indication of the maximum number of punches for the machine -
Range Operation mode
Fill hopper level control The level control in the hopper can be deactivated or activated 2
in this function activation field.
Level feed The level control in the feed system can be deactivated or 3
activated in this function activation field.
Separation 1st layer via The separation of the first layer via the ejector can be activated 3
ejector in this function activation field.
Range Lubrication
Pause pump 1 In this field the length of the pause of lubrication 1 can be 3
entered according to the type of pause.
Type of pause pump 1 - is on "Minutes", the lubrication pause is pre-set in minutes. 3
If the choice... - is on "Revolutions", the lubrication pause is pre-set in
revolutions of the die table.
Pause pump 2 In this field the length of the pause of lubrication 1 can be 3
entered according to the type of pause.
Type of pause pump 2 - is on "Minutes", the lubrication pause is pre-set in minutes. 3
If the choice... - is on "Revolutions", the lubrication pause is pre-set in
revolutions of the die table.
Pause pump grease In this field the length of the pause of grease lubrication can be 3
lubrication entered according to the type of pause.
Type of pause pump grease -is on "Minutes", the lubrication pause is pre-set in minutes. 3
lubrication - is on "Revolutions", the lubrication pause is pre-set in
If the choice... revolutions of the die table.
Range Function keys

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

Parameter Description PW
level
Report view / pdf report view Output of a master data report. The standard view or the pdf 3
view of the selected report is displayed here. For the
description of mask report view see section System – Machine
– Report view, page 110.

[Link] System – Report view

xxxxxxxxxxxxxx

60-195
Illustration 87: System – Report view

The elements in mask Report view have the following functions:

Key Description PW
level
Print If the key "Print" is actuated, the report is printed on the pre-set 2
printer.
Zoom If the key "Zoom" is actuated, the view is zoomed in or out,
2
respectively.
If the key "<<" is actuated, the previous report page is 2
<<
displayed.
>> If the key ">>" is actuated, the next report page is displayed. 2
Back If the key "Back" is actuated, the window is closed. 0

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Menu description System

[Link] System – Machine – Components

60-140
Illustration 88: System – Machine – Components

The elements in mask Components have the following functions:

Parameter Description PW
level
Range Pre-sets
Signal delay tablet jam chute Input of the delay time of the tablet jam sensor in the chute. 2
Start-up delay fillshoe Input of the delay time for fillshoe start-up. 2
Signal delay tablet jam Input of the delay time of the tablet jam sensor in the deduster. 2
deduster
Signal delay tablet jam Input of the delay time of the tablet jam sensor on the conveyor 3
conveyor belt belt.
Reset tablet counter Input of the time after which the metal check counter is reset. 3
Container change time Input of the time of a container change impulse. 3
Vibrator switch-on time Input of the switch-on time of the vibrator. 2
Vibrator switch-off time Input of the switch-off time of the vibrator. 2
Range Transmission of pulleys
Teeth drive In this input box the number of teeth of the pulley on the drive 3
shaft has to be entered.
Teeth gear In this input box the number of teeth of the pulley on the gear 3
shaft has to be entered.
Range Speed
Drive - is on "Main drive", the current and speed of the drive can be -
If the choice... entered.
- is on "Fillshoe", the current and speed of the drive can be
entered.
- is on "Dosing wheel", the current and speed of the drive can
be entered
Actual value Display of the actual speed value for the selected drive. -
Actual value measured Input of the value measured by means of a speed counter. 4
Correction factor determined Factor calculated by the system which describes the ratio -
between the set speed value and actual speed value.
Pressing compartment Selection of the pressing compartment coating device. 3
coating device

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

[Link].1 System – Machine – Components – Monitoring

60-141
Illustration 89: System – Machine – Components – Monitoring

The elements in mask Monitoring have the following functions:

Parameter Description PW
level
Range Adjustments
Motor fill depth The motor-driven adjustment of the fill depth can be activated 5
or deactivated in this function activation field.
Motor wall dimension MP The motor-driven adjustment of the wall dimension MP can be 5
activated or deactivated in this function activation field.
Motor penetration depth MP The motor-driven adjustment of the penetration depth MP can 5
be activated or deactivated in this function activation field.
Motor wall dimension PP The motor-driven adjustment of the wall dimension PP can be 5
activated or deactivated in this function activation field.
Motor penetration depth PP The motor-driven adjustment of the penetration depth PP can 5
be activated or deactivated in this function activation field.
Range Peripheral equipment
Tablet jam deduster The tablet back-up control at the deduster can be deactivated 5
or activated in this function activation field.
Tablet jam conveyor belt The tablet back-up control at the conveyor belt can be activated 5
or deactivated in this function activation field.
Range Subassemblies
Back-up control chute The tablet back-up control in the chute can be activated or 5
deactivated in this function activation field.
End position monitoring main The end position monitoring of the main gate can be activated 5
gate or deactivated in this function activation field.
End position monitoring The end position monitoring of the sampling gate can be 5
sampling gate activated or deactivated in this function activation field.
Monitoring selection of The monitoring of the selection of individual samples can be 5
individual samples activated or deactivated in this function activation field.
Rotation monitoring pressure The monitoring of the pressure roller rotation PP can be 5
roller PP activated or deactivated in this function activation field.
Rotation monitoring pressure The monitoring of the pressure roller rotation MP can be 5
roller MP activated or deactivated in this function activation field.
Rotation monitoring break-off The monitoring of the pressure roller rotation of the break-off 5
roller roller can be activated or deactivated in this function activation
field.
Lower punch lubrication The lower punch lubrication can be activated or deactivated in 5
this function activation field.

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Operating Instruction
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Menu description System

Parameter Description PW
level
Turn lower punch The turn of the lower punch can be activated or deactivated in 5
this function activation field.
Sump tank level The monitoring of the sump tank level can be activated or 5
deactivated in this function activation field.
Identification system of the fill The identification system of the fill cam can be activated or 5
cam deactivated in this function activation field.

[Link] System – Machine – Measuring points

60-148
Illustration 90: System – Machine – Measuring points

The elements in mask Measuring points have the following functions:

Parameter Description PW
level
Range Adjustment data record
Adjustment data record Selection of the data record 5
Range Function keys
Save adjustment After pressing the key "Save adjustment" the input request 5
"Save adjustment as" appears.

60-144
Save:
If the key "Save" is pressed and the name proposed for the
adjustment is kept, the data record is overwritten with the
current settings. If the key "Save" is pressed after the name
proposed for the tool pre-sets was edited, a data record with
the new name is generated. If this new name already exists, it
is checked by a safety query whether this data record is to be
overwritten or whether the procedure shall be aborted.
Cancel:
Aborts the function.

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

[Link].1 System – Machine – Measuring points – WSG

60-151
Illustration 91: System – Machine – Measuring points – WSG

The elements in mask WSG have the following functions:

Parameter Description PW
level
Measuring point - is on "Main pressure", the main pressure measuring point can -
If the choice... be initialised and calibrated.
- is on "Pre-pressure", the pre-pressure measuring point can be
initialised and calibrated.
- is on "Ejection force", the ejection force measuring point can
be initialised and calibrated.
- is on "Scraper force", the scraper force measuring point can
be initialised and calibrated.
- is on "Upper punch tightness", the upper punch tightness
measuring point can be initialised and calibrated.
- is on "Lower punch tightness", the lower punch tightness
measuring point can be initialised and calibrated.
- is on "Break-off force", the break-off force measuring point
can be initialised and calibrated.
Measuring point active The WSG measuring point is activated or deactivated in this 3
function activation field.
Actual value This value represents the current measuring value of the -
measuring point.
Switch-off limit minimum If a measured value is lower than this switch-off limit, the 3
machine is stopped.
Switch-off limit maximum If a measured value is higher than this switch-off limit, the 3
machine is stopped.
Range Initialising
Characteristic value gradient The characteristic gradient can be set in this input box. 4
However, the system automatically calculates a new gradient if
the initialisation values are changed.
Characteristic value offset The offset of the characteristics can be set in this input box. 4
However, the system automatically calculates a new offset if
the initialisation values are changed.
Initialisation value 1 Initialisation value 1 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

Parameter Description PW
level
Initialisation value 2 Initialisation value 2 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.
Range Calibration
Measuring value Input box for the measuring value displayed on test standard. 4
Remaining time Remaining time until the next calibration of the respective -
measuring point has to be executed (calibration interval
expired).
Range Function keys
Cancel calibration 4

When the key "Cancel calibration" is pressed, the safety query

"Cancel calibration?" appears.

60-145
Yes:
Finishes the present measurement series.
No:
Aborts the function.
Adjustment When the key "Adjustment" is pressed, the window for the 2
respective adjustment axis appears. The modifications
required for adjustment or calibration can be entered in this
window. See also chapter Control elements General, section
Input keyboards, page 73.

Zero balancing When the key "Zero balancing" is pressed, the safety query 4
"Execute zero balancing?" appears.

60-146
Yes:
The hardware of the corresponding measuring point is zero-
balanced.
No:
Aborts the function.
Report view / pdf report view Output of a calibration report. The standard view or the pdf 2
view of the selected report is displayed here. For the
description of mask report view see section System – Machine
– Report view, page 110.

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

[Link].2 System – Machine – Measuring points – Distance

60-157
Illustration 92: System – Machine – Measuring points – Travel

The elements in mask Travel have the following functions:

Parameter Description PW
level
Range Measuring point
Measuring point - is on "Penetration depth MP", the measuring point for the -
If the choice... main pressure punch penetration can be initialised and
calibrated.
- is on "Wall dimension MP", the measuring point for the main
pressure tablet wall dimension can be initialised and calibrated.
- is on "Penetration depth PP", the measuring point for the pre-
pressure punch penetration can be initialised and calibrated.
- is on "Wall dimension PP", the measuring point for the pre-
pressure punch penetration can be initialised and calibrated.
- is on "Fill depth", the measuring point for the fill depth can be
initialised and calibrated.
Measuring point active The measuring point is activated or deactivated in this function 3
activation field.
Actual value This value represents the current measuring value of the 3
measuring point.
Adjusting limit minimum If a measured value is lower than this adjusting limit, the 3
machine is stopped.
Adjusting limit maximum If a measured value is higher than this adjusting limit, the 3
machine is stopped.
Range Initialising
Initialisation value 1 Initialisation value 1 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.
Initialisation value 2 Initialisation value 2 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.
Characteristic value gradient The characteristic gradient can be set in this input box. 4
However, the system automatically calculates a new gradient if
the initialisation values are changed.
Characteristic value offset The offset of the characteristics can be set in this input box. 4
However, the system automatically calculates a new offset if
the initialisation values are changed.

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

Parameter Description PW
level
Range Calibration
Measuring value Input box for the measuring value displayed on test standard. 4
Remaining time Remaining time until the next calibration of the respective -
measuring point has to be executed (calibration interval
expired).
Range Function keys
Cancel calibration When the key "Cancel calibration" is pressed, the safety query 4
"Cancel calibration?" appears.

60-145
Yes:
Finishes the present measurement series.
No:
Aborts the function.
Adjustment When the key "Adjustment" is pressed, the window for the 2
respective adjustment axis appears. The modifications
required for adjustment or calibration can be entered in this
window. See also chapter Control elements General, section
Input keyboards, page 73.

60-003
Report view / report pdf view Output of a calibration report. The standard view or the pdf 2
view of the selected report is displayed here. For the
description of mask report view see section System – Machine
– Report view, page 110.

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Operating Instruction
Synthesis 700ZS Usage
Menu description System

[Link].3 System – Machine – Measuring points – Others

60-159
Illustration 93: System – Machine – Measuring points – Others – Compaction force limitation

60-160
Illustration 94: System – Machine – Measuring points – Others – Output/speed

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Operating Instruction
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Menu description System

60-161
Illustration 95: System – Machine – Measuring points – Others – Current

The elements in mask Others have the following functions:

Parameter Description PW
level
Range Measuring point
Measuring point - is on "Compaction force limitation MP", the measuring point -
If the choice... for compaction force limitation of the main pressure can be
initialised and calibrated.
- is on "Compaction force limitation PP", the measuring point
for compaction force limitation of the pre-pressure can be
initialised and calibrated.
- is on "Machine output", the measuring point for the machine
output of the tablet press can be calibrated.
- is on "Fillshoe speed", the measuring point for the speed
consumption of the fillshoe can be calibrated.
- is on "Dosing wheel speed", the measuring point for the
speed consumption of the fillshoe can be calibrated.
- is on "Current main drive", the measuring point for the current
consumption of the main drive can be parameterised.
- is on "Current fillshoe", the measuring point for the current
consumption of the fillshoe can be parameterised
- is on "Current dosing wheel", the measuring point for the
current consumption of the dosing wheel can be parameterised
Measuring point active The measuring point is activated or deactivated in this function 3
activation field.
Actual value This value represents the current measuring value of the
measuring point.
Set value This value represents the set value for the measuring point (not 3
available for current measuring points).
Switch-off limit minimum If a measured value is lower than this switch-off limit, the 4
machine is stopped (only available for current measuring
points).
Switch-off limit maximum If a measured value is higher than this switch-off limit, the 4
machine is stopped (only available for current measuring
points).
Range Initialising
(only available for measuring points for compaction force limitation)
Initialisation value 1 Initialisation value 1 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.

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 Technical Documentation
Operating Instruction
Synthesis 700ZS Usage
Menu description System

Parameter Description PW
level
Initialisation value 2 Initialisation value 2 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.
Characteristic value gradient The characteristic gradient can be set in this input box. 4
However, the system automatically calculates a new gradient if
the initialisation values are changed.
Characteristic value offset The offset of the characteristics can be set in this input box. 4
However, the system automatically calculates a new offset if
the initialisation values are changed.
Range Calibration
(not available for current measuring points)
Measuring value Input box for the measuring value displayed on test standard. 4
Remaining time Remaining time until the next calibration of the respective -
measuring point has to be executed (calibration interval
expired).
Range Function keys
Cancel calibration When the key "Cancel calibration" is pressed, the safety query 4
(not available for current "Cancel calibration?" appears.
measuring points)

60-145
Yes:
Finishes the present measurement series.
No:
Aborts the function.
Adjustment When the key "Adjustment" is pressed, the window for the 2
(only available for measuring respective adjustment axis appears. The modifications
points for compaction force required for adjustment or calibration can be entered in this
limitation) window. See also chapter Control elements General, section
Input keyboards, page 73.

60-003
Report view/report pdf view Output of a calibration report. The standard view or the pdf 2
(not available for current view of the selected report is displayed here. For the
measuring points) description of mask report view see section System – Machine
– Report view, page 110.

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Operating Instruction
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Menu description System

[Link].4 System – Machine – Measuring points – Peripheral equipment

60-163
Illustration 96: System – Machine – Measuring points – Peripheral equipment

The elements in mask Peripheral equipment have the following functions:

Parameter Description PW
level
Range Measuring point
Measuring point - is on "Select measuring point", nothing is shown in the mask. -
If the choice... - is on "Balance", the measuring point for the tablet weight in
the TCU can be calibrated.
- is on "Thickness tester", the measuring point for the tablet
thickness in the TCU can be calibrated.
- is on "Hardness tester", the measuring point for the tablet
hardness in the TCU can be calibrated.
Actual value This value represents the current measuring value of the -
measuring point.
Range Calibration
Measuring value Input box for the measuring value displayed on test standard. 4
Remaining time Remaining time until the next calibration of the respective -
measuring point has to be executed (calibration interval
expired).
Range Function keys
Cancel calibration When the key "Cancel calibration" is pressed, the safety query 4
"Cancel calibration?" appears.

60-145
Yes:
Finishes the present measurement series.
No:
Aborts the function.
Report view / report pdf view Output of a calibration report. The standard view or the pdf 2
view of the selected report is displayed here. For the
description of mask report view see section System – Machine
– Report view, page 110.

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Menu description System

[Link].5 System – Machine – Measuring points – Pressure

60-167
Illustration 97: System – Machine – Measuring points – Pressure – Low pressure suction

60-168
Illustration 98: System – Machine – Measuring points – Pressure

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The elements in mask Pressure have the following functions:

Parameter Description PW
level
Range Measuring point
Measuring point - is on "Low pressure suction", the measuring point for the low -
If the choice... pressure of the dust suction unit can be initialised and
calibrated.
- is on "Low pressure compression chamber", the measuring
point for the low pressure of the dust suction unit can be
initialised and calibrated.
- is on "Overpressure machine compartment", the measuring
point for the overpressure in the machine compartment can be
initialised.
- is on "Overpressure head piece", the measuring point for the
overpressure in the head piece can be initialised.
Measuring point active The measuring point is activated or deactivated in this function 3
activation field.
Actual value This value represents the current measuring value of the -
measuring point.
Switch-off limit minimum If a measured value is lower than this switch-off limit, the 3
cleaning unit is stopped (not available for Ex measuring points).
Switch-off limit maximum If a measured value is higher than this switch-off limit, the 3
cleaning unit is stopped.
Range Initialising
(not available for WIP measuring points)
Initialisation value 1 Initialisation value 1 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.
Initialisation value 2 Initialisation value 2 can be entered in this input box to 4
calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.
Characteristic value gradient The characteristic gradient can be set in this input box. 4
However, the system automatically calculates a new gradient if
the initialisation values are changed.
Characteristic value offset The offset of the characteristics can be set in this input box. 4
However, the system automatically calculates a new offset if
the initialisation values are changed.
Range Function keys
Cancel calibration When the key "Cancel calibration" is pressed, the safety query 4
(only available for measuring "Cancel calibration?" appears.
point Low pressure suction)

60-145
- Yes:
Finishes the current measurement series.
- No:
Aborts the function.
Report view/pdf report view Output of a calibration report. The standard view or the pdf 2
(not available for current view of the selected report is displayed here. For the
measuring points) description of mask Report view see section System – Machine
– Report view, page 110.

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[Link].6 System – Machine – Measuring points – Temperature

60-165
Illustration 99: System – Machine – Measuring points – Temperature

The elements in mask Temperature have the following functions:

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Menu description System

Parameter Description PW
level

Range Measuring point

Measuring point - is on "Main drive", the measuring point for the main drive -
If the choice... temperature can be initialised.
- is on "Vertical shaft", the measuring point for the vertical shaft
temperature can be initialised.
- is on "Compression chamber", the measuring point for the
compression chamber temperature can be initialised.
- is on "Cam track push down segment", the measuring point
for the temperature of the cam track push down segment can
be initialised.
- is on "Cam track ejection segment", the measuring point for
the temperature of the cam track ejection segment can be
initialised.
- is on "Upper pressure roller MP", the measuring point for the
temperature of the upper pressure roller of the main pressure
can be initialised.
- is on "Upper pressure roller PP", the measuring point for the
temperature of the upper pressure roller of the pre-pressure
can be initialised.
- is on "Lower pressure roller MP", the measuring point for the
temperature of the lower pressure roller of the main pressure
can be initialised.
- is on "Lower pressure roller PP", the measuring point for the
temperature of the lower pressure roller of the pre-pressure can
be initialised.
- is on "Ejection cam", the measuring point for the ejection cam
temperature can be initialised.
- is on "Fillshoe motor", the measuring point for the temperature
of the fillshoe motor can be initialised.
- is on "Cover", the measuring point for the cover temperature
can be initialised.

Measuring point active The measuring point is activated or deactivated in this function 3
activation field.

Actual value This value represents the current measuring value of the -
measuring point.

Switch-off limit minimum If a measured value is lower than this switch-off limit, the 3
cleaning unit is stopped (only available for WIP measuring
points).

Switch-off limit maximum If a measured value is higher than this switch-off limit, the 3
cleaning unit is stopped (only available for current measuring
points).

Range Initialising
(not available for WIP measuring points)

Initialisation value 1 Initialisation value 1 can be entered in this input box to 4

calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.

Initialisation value 2 Initialisation value 2 can be entered in this input box to 4

calculate characteristics. If this value is changed, the control
reads in the analogue value of the measuring point and adjusts
the measuring point anew.

Characteristic value gradient The characteristic gradient can be set in this input box. 4
However, the system automatically calculates a new gradient if
the initialisation values are changed.

Characteristic value offset The offset of the characteristics can be set in this input box. 4
However, the system automatically calculates a new offset if
the initialisation values are changed.

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[Link] System – Machine – Intervals

60-171
Illustration 100: System – Machine – Intervals

The elements in mask Intervals have the following functions:

Parameter Description PW
level
Range Calibration
Compaction forces pre-set Input of the calibration intervals of the compaction force 4
time measuring points.
Ignore compaction forces If activated, a batch start is possible even if intervals have 4
expired.
Tightnesses pre-set time Input of the calibration intervals of the tightness measuring 4
points.
Ignore tightnesses If activated, a batch start is possible even if intervals have 4
expired.
Position encoder pre-set time Input of the calibration interval of the distance measuring 4
points.
Ignore position encoder If activated, a batch start is possible even if intervals have 4
expired.
Other measuring points pre- Input of the calibration interval of the general measuring points. 4
set time
Ignore other measuring points If activated, a batch start is possible even if intervals have 4
expired.
Peripheral equipment pre-set Input of the calibration interval of the TCUs' measuring points. 4
time
Ignore peripheral equipment If activated, a batch start is possible even if intervals have 4
expired.
Range Service
Cleaning remaining time Display of the time remaining until the next cleaning of the -
machine.
Cleaning pre-set: Input of the cleaning interval of the machine. 4
Ignore cleaning If activated, a batch start is possible even if intervals have 4
expired.
Cleaning OK Confirmation that the cleaning of the machine has been carried 4
out.
Inspection remaining time Display of the time remaining until the next inspection of the -
machine.
Inspection pre-set Input of the inspection interval of the machine. 4
Ignore inspection If activated, a batch start is possible even if intervals have 4
expired.

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Parameter Description PW
level
Inspection OK Confirmation that the inspection of the machine has been 4
carried out.

[Link] System – Machine – Punches

60-172
Illustration 101: System – Machine – Punches

The elements in mask Punches have the following functions:

Parameter Description PW
level
Range Punch fitting
1… In this field the evaluation of punch No. "n" can be disabled or 3
enabled, respectively.

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8.5.3 System – Configuration

60-173
Illustration 102: System – Configuration

The elements in mask Configuration have the following functions:

Parameter Description PW
level
Range Configuration data record
Configuration data record Selection of the data record for the system configuration. After 3
confirming the safety query all parameters of this data record
are loaded.
Range System
Languages In this selection box the language of the visualisation can be 0
chosen from the languages available on the system.
Units system In this selection box the units system to be used for displaying 8
the process variables on the visualisation can be chosen.
Range Printer
Printer name In this selection box the standard printer can be chosen from all 2
the printers available.
Range User management
Automatic Logout Entry of the time in minutes after which the user is 8
automatically logged out if no actions are carried out on the
visualisation. The DefaultUser is logged in then.
Group Selection of the user group. 8
DefaultUser Selection of the user from the selected group. 8
Login input Number of unsuccessful attempts of login that a user can make 8
until he is deactivated by the system
Popup Hostname Name of the network administrator who shall get a pop-up 8
message when a user has exceeded the number of
unsuccessful attempts of login.
Domain name Input of the domain name if the user groups and users shall be 8
used by the domain controller.

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[Link] System – Configuration – Network

60-174
Illustration 103: System – Configuration – Network

The elements in mask Network have the following functions:

Parameter Description PW
level
Range Paths
Hard disk In this field the path for the hard disk is entered. 8
Current data In this field the path for the memory location of the data records 8
of the current batch is entered. The system uses this path
information when a data record shall be accessed.
Batch data In this field the path for the memory location of the finished 8
batches is entered. The system uses this path information
when batch data shall be accessed.

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[Link] System – Configuration – User

60-191
Illustration 104: System – Configuration – User

The elements in mask User have the following functions:

Parameter Description PW
level

Range User

User Display of the selected user name. 6

Range Authorisation

Authorisation Release or block the password level (0-8) for the respective 6
Level 0-8 actual user.

Range User list

User list List of all the users set up in the system. -

Range Function keys

Edit user 6
When key "Edit user" is pressed, the safety query "Change
settings?" appears.

60-192

- Yes:
The changes of the selected user are saved.
- No:
Aborts the function.

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8.5.4 System – Info

60-193
Illustration 105: System – Info

The elements in mask Info have the following functions:

Parameter Description

WSG task Version No. of the WSG task (compaction force consumption)

Regulation task Version No. of the REG task (regulation).

Peripheral task Version number of the PT task (communication with peripheral units).

VT task: Version No. of the VT task (distribution).

Machine control Version No. of the Vicon task (PLC)

TCU Version number of the connected TCU (RQ or TWA)

Visualisation Version No. of the visualisation

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9 Operation
9.1 Switching on the system
è Set the main switch to position "I".
Ø All operating status signal lamps are illuminated.
è Log in to the system. For doing so:
è Enter the user ID and the related password.
è Confirm the inputs with Login.

9.2 Production – Set-up

è Öpen the mask Tabletting > Set-up > Batch.

62-006_en
Illustration 106: Tabletting – Set-up – Batch

Notice:
Ensure that no batch is active.
If there is a batch ID in field "Batch" the respective batch must be
finished.

è For this press the function key "End batch".

Ø After that no batch is active and the field "Batch" in range "Batch ID" is empty.

è Select the production pre-sets and load them.

Ø Now all parameters of the corresponding subordinate data records for tool,
standard sampling and tablet quality check are loaded into the control
system.
è Check in mask Tabletting > Set-up > Production whether the loaded tool data
record is correct.

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62-009_en
Illustration 107: Tabletting – Set-up – Production

è Go back to the mask Tabletting > Set-up > Batch.

è Enter the parameters for the batch ID and start the batch by pressing the key
"Batch start".
þ The status line is now green and shows the message: "3 – Tablet press ready to
start".

Notice:
From the time of "Batch start", all modifications in the current
batch are documented and recorded in the audit trail (only if option
21CFR Part 11 is active). After "Batch start", it is no longer possible
to load new production pre-sets.

è Now open mask Tabletting > Set-up:

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62-001_en
Illustration 108: Tabletting – Set-up

You have the following production options:

• Production of a known product:
When starting the production of a known product and when an existing data
record of a previous production can be used, it is not necessary to correct entries
here. Clear all error messages by eliminating their causes and pressing machine
key "Reset". After loading the production pre-sets and starting a batch, press the
key "Positioning all". As soon as the tablet parameters correspond to the pre-set,
you can produce tablets in Set-up mode and check them for the required
parameters. After that, switch from Set-up to Production.
• Production of a new product:
For the production of a new product load a data record of the production pre-sets
which resembles the product most. Now add the subordinate data records for tool,
standard sampling and tablet quality check by loading them, if required, save the
production pre-sets under a new name and start modifying the new parameters.

In mask Tabletting > Set-up all parameters of the tablet and the required machine
settings such as fill depth, wall dimension and fillshoe speed can be modified. During
production in Set-up mode, the settings can be modified on the basis of the pressing
result.

è Press the key JOGGING briefly to check whether the die table and the fillshoe are
operating properly.
è When the machine is running error-free, press the key ON. The tablet press now
produces in Set-up mode and the tablets produced are routed into the reject
channel.
è Determine the tablet weight and the tablet hardness by means of a sample. The
tablet parameters can be influenced by modifying the fill depth and wall
dimension.

The following dependency applies for the fill depth:

• Tablet weight too high => reduce fill depth
• Tablet weight too low => increase fill depth

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Notice:
Ensure that the adjusted fill depth is within the optimum range of
the pull-down cam mounted.

The following pull-down cams are available:

• 0.5 to 8 mm (medium range = 2.5 – 6 mm)
• 4.5 to 12 mm (medium range = 6.5 – 10 mm)
• 8.5 to 16 mm (medium range = 10.5 – 14 mm)
• 10.5 to 18 mm (medium range = 12.5 – 16 mm)
• 12.5 to 20 mm (medium range = 14.5 – 18 mm)
(not for tools EU-B and IPT-B)

The following dependency applies for the wall dimension (with constant fill depth):
• Tablet hardness too high => increase wall dimension
• Tablet hardness too low => reduce wall dimension

Notice:
Ensure that the entry for "Wall dimension pre-pressure" is higher
than that for "Wall dimension main pressure". Otherwise only pre-
pressure would be used for pressing.

è When the desired tablet quality is reached, press the key "Set values = actual
values". Thus the actual values set in Set-up mode are adopted as set values.

Notice:
The key "Set values = actual values" depends on the press station.
This means that for machines with several press stations (except
for two-layer, three- and two-layer with a core press) the key "Set
values = actual values" must be pressed for each individual press
station.

62-006_en
Illustration 109: Tabletting – Set-up – Batch

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9.3 Modifying production pre-sets

If, for example, a tool change was made prior to production, now open mask
Tabletting > Set-up > Production > Tool.

62-013_en
Illustration 110: Tabletting – Set-up – Production – Tool

è Modify the parameters in the Tool mask.

Note:
The respective subordinate data record must be saved after the
modification in mask "Production".

è Or load a corresponding subordinate data record. Open the mask Tabletting >
Set-up > Production and under Tool select the data record corresponding to the
tool.

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62-009_en
Illustration 111: Tabletting – Set-up – Production

You can follow the same process for the two other subordinate data records for
Standard sampling and Tablet quality check.
When doing so, the parameters for tablet quality checks are set in mask Tabletting >
Set-up > Production > Quality and the parameters for Standard sampling are set in
mask Tabletting > Set-up > Production > Sample and the corresponding
subordinate data record is loaded/saved in mask Production.

62-014_en
Illustration 112: Tabletting – Set-up – Production – Quality

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Illustration 113: Tabletting – Set-up – Production – Sample

Note:
The availability of the masks Quality and Sample depends on the
configuration of a specific machine. This means that the mask
Quality, for example, is only available when a corresponding tablet
control unit (e.g. RQ or TWA) is configured or connected.

After modifying or loading the individual subordinate data record for tool, standard
sampling and tablet quality check, the production pre-sets must be saved again. Thus
the modifications made are saved for the new loading procedure of the production pre-
sets used.

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9.4 Batch change

è Select mask Tabletting > Set-up > Batch and finish the batch using the function
key "Batch end".

62-018_en
Illustration 114: Tabletting – Manual

1. Select the mask Manual and discharge the material hopper and the fillshoe, select
"Fillshoe" " " (activation). Set "Fillshoe" to" automatic mode as soon as the
fillshoe is fully discharged.
2. Clean the tablet press completely.
3. If required, replace the tools.
4. Now proceed as described in the operating step "Production".

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9.5 Production start

62-006_en
Illustration 115: Tabletting – Set-up – Batch

è Select the mask Tabletting > Set-up > Batch and save the production pre-sets.
Thus you have now saved all parameters of the batch for further use.
è Start the Production mode by pressing the key "Production". The press station is
now background-shaded in green.

Note:
In continuous operation the machine output should not exceed 75
% of the maximum rating.

After the start-up phase the main gate of the tablet chute switches. The tablets
produced are routed into the good channel.

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9.6 Production check

Note:
Tablet press heating and external influences can lead to
continuous changing of the values (machine drift). If the tablet
press is equipped with a TCU, this unit monitors the tablet quality
and switches the tablet press off if required. If further regulation
methods are configured, they will be adjusted by the setting values.
Without an in-process control unit the tablet parameters must be
checked manually at regular intervals.

A manual check is performed as follows:

è Press the key "Set-up".
Ø The machine switches from Production mode to Set-up mode
è Change the required values.
è Press the key "Set values = actual values" and, if required, "Positioning all".
Ø Thus the actual values set in Set-up mode are adopted as set values.
è Press the function key "Production".
Ø The machine switches from Set-up mode to Production mode.
þ Production is continued with the changed values.

9.7 Switching the machine off

è Stop the tablet press with the key OFF.
è Press the function key "System shutdown".
è Set the main switch to position "O".

Caution
Switching off the tablet press without proper system
shutdown via the key System shut-down can result in loss of
data!

9.8 In-process control

This part of the documentation describes the production of tablets using in-process
control (IPC). During tablet production, samplings are taken for the IPC to check the
tablet quality parameters and to process them statistically.

9.8.1 Tablet Control Units (TCU)

A TCUsRQ analysis system or a TWA balance is used during in-process control.

The RQ checks the following tablet parameters:

• Weight
• Thickness
• Hardness
The TWA checks the tablet weight.

Note:
The IPC data do not trigger any regulation steps.

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9.8.2 Limiting values in-process control

Several limiting values, which refer to the average, are decisive for the in-process
control:
• Evaluation limit TCU (EL TCU) +/-
• Evaluation limit ViCon (EL ViCon) +/-
• Tolerance limit T2 +/-
• Tolerance limit T1 +/-
• Tolerance limit T0 +/-

BW TCU +
BW ViCon +
T2+

T1+
T0+
Average value
Mittelwert
T0-
T1-
T2-

BW ViCon -

BW TCU -

Anzahl
No. ofTabletten
tabletsaußerhalb
outsideT1T1
Anzahl Tabletten außerhalb T2

Illustration 116: Evaluation limits of the IPC

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9.8.3 Evaluation limits

The plausibility of the measuring value is checked by means of the evaluation limits. If
a chosen number of single values are outside the evaluation limits, the sample is
rejected. The values are not checked for tolerance infringements nor included in the
statistical evaluation.

Illustration 117: Evaluation limits of the IPC

[Link] Evaluation limits TCU

Examples for evaluation limits of the TCU for weight, thickness, hardness and
diameter:

Minimum Maximum Description

0.5 mg 30,000 mg Evaluation limit weight

0.05 mm 10 mm Evaluation limit thickness

5N 449 N Evaluation limit hardness

3 mm 27 mm Evaluation limit diameter

If these minimum or maximum values of the TCU are undershot or exceeded, the
measurement is marked as reject measurement. Thus the infringement of the TCU
evaluation limits can be unambiguously identified later.
If one of the TCU evaluation limits is infringed, an info message is displayed.
If the TCU evaluation limits are infringed 3 times in succession, the machine is
stopped and a corresponding fault message is displayed.

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[Link] Evaluation limits of the visualisation

62-014_en
Illustration 118: Tabletting – Set-up – Production – Quality

The evaluation limits for visualisation are input in mask Tabletting > Set-up >
Production > Quality.

Notice:
If you enter the value zero for one or several input fields,
monitoring is deactivated for that value.

If the measured value is outside the evaluation limits, the measurement is marked as
reject measurement. The measured value is always stored to clearly mark the
infringement of the evaluation limits.
The evaluation limits of the tablet diameter are not evaluated in the ViCon, as this is
not processed further.
If one of the evaluation limits is infringed, an info message is displayed.
If the evaluation limits are infringed 3 times in succession, the machine is stopped and
a corresponding fault message is displayed.
These evaluation limits and the messages depend on the press station.

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9.8.4 Tolerance limits

The tolerance limits are determined for weight, thickness and hardness.
• The tolerance limit T0 Plus / Minus is the maximum or minimum tolerance limit
for the average with reference to the set value.
• The tolerance limit T1 Plus / Minus is the maximum or minimum tolerance limit
for the deviation from the average of the single values measured of the IPC
sampling.
• The tolerance limit T2 Plus / Minus is the maximum or minimum tolerance limit
for the deviation from the average of the single values measured of the IPC
sampling.

Optionally also with reference to the set value.

Example:
Set value = 100

• Tolerance T0 Plus / Minus = 2 %=> Tolerance T0 Plus = 102

Tolerance T0 Minus = 98

Example:
Supposed average = 100.5

• Tolerance T1 Plus / Minus = 3 %=> Tolerance T1 Plus = 100.5 + 3 % =

103.52
Tolerance T1 Minus= 100.5 - 3 % =
97.49
• Tolerance T2 Plus / Minus = 5 %=> Tolerance T2 Plus = 100.5 + 5 % =
105.53
Tolerance T2 Minus= 100.5 -5 % =
94.48

BW TCU +
BW ViCon +
T2+

T1+
T0+
Average value
Mittelwert
T0-
T1-
T2-

BW ViCon -

BW TCU -

No. ofTabletten
Anzahl tabletsaußerhalb
outsideT1T1

No. ofTabletten
Anzahl tabletsaußerhalb
outsideT2T2

Illustration 119: Position of the tolerance ranges T0, T1 and T2 around the average

The infringements are only counted when monitoring is active. Monitoring of individual
or several values is not active if the value zero is entered in the corresponding input
fields in mask Tabletting > Set-up > Production > Quality.

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The reference value for the average limits always is the set value, i.e. the average
must be within the range set value - T0- to set value + T0+.
If the permitted number of average tolerance infringements is exceeded, the machine
is stopped and a fault message is displayed.

[Link] Average value limits

The averages of the samples are monitored against the tolerance limits T0+ and T0-.
The number of permitted limit infringements is freely editable for each tablet
parameter. The permitted limit infringements refer to the whole tolerance range.

BW TCU +
BW ViCon +

T0+
Set value
Sollwert
T0-

BW ViCon -

BW TCU -

No. of tablets
Anzahl outside
Mittelwerte T0 T0
außerhalb

Illustration 120: Average limits of the IPC

The infringements are only counted when monitoring is active. The number of
infringements to date is reset to zero when monitoring is activated.
The reference value for the average limits always is the set value, i.e. the average
must be within the range set value - T0- to set value + T0+.
If the permitted number of average tolerance infringements is exceeded, the machine
is stopped and a fault message is displayed.

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[Link] Single value limits

The single values of each IPC sample are monitored against the tolerance limits T1+,
T1-, T2+ and T2-. The number of permitted limit infringements is freely editable for
each tablet parameter. They refer to the whole tolerance range.

BW TCU +
BW ViCon +
T2+

T1+
T0+
Average value
Mittelwert
T0-
T1-
T2-

BW ViCon -

BW TCU -

Anzahl
No. ofTabletten
tabletsaußerhalb
outsideT1T1
Anzahl Tabletten außerhalb T2

Illustration 121: Single value limits of the IPC

The infringements are only counted when monitoring is active. Monitoring is effected
for each sample separately, thus the counters of limit infringements are reset after
each sample.
The reference value for the single value limits is mostly the average (for Pharmacopöe
regulations); however, it can also be set to the set value (non-pharmaceutical
applications), i.e. AV±T1 or AV±T2 or SV±T1 or SV±T2, respectively.
If the permitted number of single value limit infringements is exceeded, the machine is
stopped and a fault message is displayed.

9.8.5 Manual tablet check

During manual tablet check the tablets can be fed to the tablet control unit
automatically or manually.

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[Link] Automatic feed

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Illustration 122: Tabletting – Manual – Tablet (range Selection: Automatic feed)

In the Selection tab select "Automatic" under Feed.

Press the "Start" key to route out tablets to the TCU according to the sample
definition.
The tablet parameters of the current production pre-set are used as set values for the
manual tablet check. The tablet shape is determined by the current tool set.
The number of tablets entered is used for calculating the statistics for all selected
tablet parameters.
It can happen that the TCU is occupied measuring another sample at the time of start.
In this case the sampling request is rejected and a corresponding info message is
displayed.

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[Link] Manual feed

62-226_en
Illustration 123: Tabletting – Manual – Tablet (range Selection: Manual feed)

In the Selection tab select "Manual" under Feed.

Manual feed is used to measure tablets from other tablet presses. This means that the
tablet parameters weight, thickness, hardness, and shape can be completely different
and have nothing to do with the set values in the production pre-set.
As soon as the function key "Start" is pressed, you will be prompted to place the
tablets manually in the transporter cup of the TCU.
The set values for the manual tablet check can be entered for any tablet parameter to
be measured. The tablet shape (diameter/long side/wide side) must be indicated for
the correct positioning of the rotary table.
The number of tablets entered is used for calculating the statistics for all selected
tablet parameters.
It can happen that the TCU is occupied measuring another sample at the time of start.
In this case the sampling request is rejected and a corresponding info message is
displayed.

[Link] Limiting values and statistical evaluation

The only limiting values for the manual tablet check are the evaluation limits of the
TCU. In contrast to the in-process control, the fault messages displayed there are
displayed as info messages.
Apart from limiting value monitoring, the tablets of the quality sampling are also
evaluated statistically. Here only the single values of good tablets are considered
which are not inside a rejected quality sample.

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9.9 Reports
9.9.1 General
The reports for documenting the batch are not generated at the time of display or
printing, but immediately when the control has transmitted the report to the
visualisation.
At this time, all report data are stored in the database and in addition a pdf file is
generated.
The reports can be viewed in the visualisation and correspond to the print reports.
The following reports are available:

Batch documentation
All reports generated during a batch belong to this group. These are the following
reports:
• Set-up data report
Documents the settings (production pre-sets) of the production.
• Cyclical production report
Documents the production, e.g. number of good productions, over a period of
time.
• Batch end report
Documents the production of the total batch, including the histograms.
• Container change report
Documents container changes (if container filling system has been configured)
• In-process control report
Documents the single values and the statistical evaluation of the in-process
controls (quality sampling) (if IPC has been configured).
• Operation message report
Documents all messages which have occurred during the batch.
• Audit trail report
Documents all audit trail messages which have occured during the batch
(provided that 21 CFR Part 11 has been configured).

Documentation of the machine data

All reports documenting the state of the machine belong to this group. These are the
following reports:
• Calibration reports
Document the calibration of the individual measuring points of the machine
• Master data report
Documents the equipment of the machine.

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9.9.2 Structure of the reports

[Link] Field types
- Input field Grey field, to be filled in manually.
- Display field is automatically filled by the system.
- Pre-set field Definitely entered indicator field.
- Selection field Text field depending on a variable.
Field types reports

[Link] Designations and representations

Parameters of non-available components
• These parameters are represented by zero values in the reports.

Changing the units of measurement

• The reports can be represented in different units.

Size of page
• The structure of the reports is adapted to the use of sheets of US standard size
(sheet length approx. 27.94 cm).

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9.9.3 Header
1 2 3 4

10 9 8 7 6 5
60-234
Illustration 124: Header selection

Position Designation

1 Company logo

2 Designation field
The designation field informs about the machine and the visualisation the batch was
produced on.

3 Title field
The title determines to which part of the validation documents the respective report
belongs.

4 Reference
The report reference is composed as follows:
Ref: Reference
xxx: Continuous version number e.g. 001
/ PV-SUR: Report type (abbreviation)

5 Press station
For reports depending on the press station, the press station which the data are
coming from is displayed in this field.

6 Page numbering
A continuous page numbering is made at this position. With x being the current page
number and y the total number of pages of the respective report.

7 Time field
In this field the time when the report was generated is displayed.

8 Date field
In this field the date when the report was generated is displayed.

9 Batch
In this field the name of the batch is entered which was active at the time of
generating the report.

10 Machine name
Name of the machine on which the report was generated.

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9.9.4 Cover page

1 Cyclical production report

2
Machine commission:
Operator:
Product:

Date printed:
Time printed:

Date / Name / Signature

60-235
Illustration 125: Report cover page

Position Designation

1 Title
Display of the report name

2 Overview field
This field depends on the report.

3 Identification field
In this field the operator can manually enter date, name and signature to document
who generated the report.

9.9.5 Reports of machine data

The reports of the machine data are master data reports and calibration reports. Here
all settings of the tablet press, such as e.g. the dosing cam used or the calibration
data of the main pressure measuring point, are saved.
The reports can be called up in the respective mask.

Example master data report:

• In mask System > Machine select the corresponding master data report using the
function keys "Report view" or "report pdf view".

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Illustration 126: System – Machine

Example calibration report:

• In mask System > Machine > Measuring point > WSG select the corresponding
calibration report using the function keys "Report view" or "report pdf view".

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Illustration 127: System – Machine – Measuring points – WSG

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9.9.6 Report view

The mask Report view has the following functions:

xxxxxxxxxxxxxx

62-195_en
Illustration 128: Report view

Using the key "Print", the selected report can be printed on the selected printer.
Pressing the key "Zoom" zooms in. Pressing the key again returns to the total page
view.
The report view can be scrolled up and down using the keys "<<" and ">>".

9.9.7 Master data reports

A master data report is a report of the basic data of the tablet press, which are
described in the following sections. It is generated at the time of printing.
Viewing or printing reports is effected in mask System > Machine > Report view of
the visualisation.
The old master data report is always overwritten by the current report. Therefore,
there is always only one master data report.

[Link] Machine data independent of the press station

Data Meaning
Machine type Machine type Type designation of the tablet press
No. of punches Current number of punches
Tool type Tool shape (e.g. EU-B)
Overload limit main pressure max. permissible load of the main pressure position
Overload limit pre-pressure max. permissible load of the pre-pressure position
Master data report – Machine data

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[Link] Software modules independent of the press station

Data Meaning

Visualisation Version string of the visualisation

WSG Version string of the WSG task

Regulation Version string of the regulation task

Peripheral equipment Version string of the peripheral task

Distributor task Version string of the distributor task

Machine control Version string of the machine control (PLC task)

Visualisation IP IP address of the visualisation

Machine IP IP address of the machine control

Master data report – Software modules

[Link] Service intervals

Data Meaning
Calibration compaction forces Pre-set value for the calibration interval of the compaction force measuring
points
Calibration tightnesses Pre-set value for the calibration interval of the tightness measuring points
Calibration distance Pre-set value for the calibration interval of the distance measuring points
measuring points
Calibration peripheral Pre-set value for the calibration interval of the measuring points of the
equipment peripheral equipment (e.g. RQ)
Calibration general measuring Pre-set value for the calibration interval of the other measuring points
points
Inspection Pre-set value for the inspection interval of the machine
Cleaning Pre-set value for the cleaning interval of the machine
Master data report – Service intervals

[Link] Measuring point data independent of the press station

Data Meaning

Upper punch tightness Values for offset and gradient at measuring point upper punch tightness

Low pressure compression Values for offset and gradient at measuring point vacuum cleaner
chamber

Compaction force limitation Values for offset and gradient at measuring point compaction force
main pressure limitation MP

Compaction force limitation Values for offset and gradient at measuring point compaction force
pre-pressure limitation PP

Master data report – Measuring point data independent of a press station

[Link] Software modules independent of the press station

Data Meaning

TCU Version string of the TCU

Master data report – Software modules - depending on the pressing station

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9.9.8 Software modules independent of the press station

Data Meaning

Visualisation Version string of the visualisation

WSG Version string of the WSG task

Regulation Version string of the regulation task

Peripheral equipment Version string of the peripheral task

Distributor task Version string of the distributor task

Machine control Version string of the machine control (PLC task)

Visualisation IP IP address of the visualisation

Machine IP IP address of the machine control

Master data report – Software modules

9.9.9 Calibration reports

For each measuring point of the system a separate calibration report is generated. It is
generated when the respective measuring point has been successfully calibrated. If
calibration fails, however, the old report is kept and the calibration values are rejected.

Test standard
The data of the test standard used must be entered by the operator:
• Tool type
• Nominal load
• Next calibration
• Test equipment ID

Settings of the specimen

The specifications in this table vary depending on the measuring point to be
calibrated.

Calibration
Printout of the series of measurements recorded for checking the adjustment with
increasing load of the measuring point.
• Specimen: measurement display at the specimen
• Test standard: measurement display at test standard
• Deviation: Difference calculated of the display values at specimen and test
standard

Acceptance criteria / evaluation

Indication of the acceptance criteria that are stored in the visualisation at the time of
delivery.

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9.9.10 Reports of the batch data

All data occurring during the production of a batch, such as e.g. the compaction force
statistics or the batch end report, are stored in reports for the batch data. The reports
cycle is defined in mask Tabletting > Reports > Settings.

62-030_en
Illustration 129: Tabletting – Reports – Settings

The mask Tabletting > Reports > Settings has the following functions:
• Cyclical production report: Choice of cycle
- Off: Report is not generated.
- Minutes: Report is generated after x minutes.
- Tablets: Report is generated after x tablets.
- Filling: Report is generated after each container change.
- Minutes + filling: Report is generated after x minutes and after each container
change.
- Tablets + filling: Report is generated after x tablets and after each container
change.

In cycles Minutes and Tablets an input box appears before the selection box where an
amount or a time must be entered as a pre-set. When reaching the pre-set the report
is automatically generated and can be printed.
In mask Tabletting > Reports all reports of a batch can be set.

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62-027_en
Illustration 130: Tabletting – Reports

The mask Tabletting > Reports has the following functions:

• Batch: Selection of a current or an already completed batch data record
• Report type: Selection of report type
- Cyclical entry: Printout of the cyclical production report
- Container change: Printout container change report
- Batch end: Printout of the batch end report
- Set-up report: Printout of the report of set-up data
- In-process control: Printout of the in-process control report
- Operation messages: Printout of the operation message report
- Audit trail messages: Printout of the audit trail report

The cycle times of the selected report are listed in the table opposite.

[Link] Set-up data report

The set-up data report is generated when the machine is switched from "Set-up" mode
to "Production" mode. Thus a production stage is always documented completely. All
data stored in the set-up data report cannot be edited any more during the production
stage. Thus the machine must be switched to Set-up mode for editing any values.
When changing to Production mode, a new set-up data report is generated. The set-
up data reports depend on the press station and can be displayed or printed
separately for each press station.

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[Link].1 Set-up data report Machine

Data Meaning

Machine output (set value) Set value of the machine output

Fillshoe speed (set value) Set value of the fillshoe speed

Dosing wheel speed (set Set value for the dosing wheel speed
value)

Penetration depth MP Actual value of the penetration depth of the upper punch in the die at main
pressure

Penetration depth PP Actual value of the penetration depth of the upper punch in the die at pre-
pressure

Wall dimension MP Actual value of the wall dimension (distance between upper and lower
punch at main pressure)

Wall dimension PP Actual value of the wall dimension (distance between upper and lower
punch at pre-pressure)

Fill depth Actual value of the fill depth

Set value MP Compaction force set value of the main pressure

Set value PP Compaction force set value of the pre-pressure

Weight (set value) Set value of the weight

Thickness (set value) Set value of the thickness

Hardness (set value) Set value of the hardness

Set-up data report – Machine

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[Link].2 Set-up data report Batch

Data Meaning

Production pre-set Name of the data record used for the production pre-sets

Filling Set value of the filling interval (1)

Production end Pre-set value for the production end (2)

Set-up data report – Batch

(1) The following units are available for filling:

Off
• No filling active
Tablets
• Filling after x tablets
Minutes
• Filling after x minutes

(2) For production end, cyclical production report and batch end report the
following units are available:
Off
• No trigger active
Tablets
• Trigger after x tablets
Minutes
• Trigger after x minutes
Minutes
• Trigger after x fillings

[Link].3 Set-up data report Production

Data Meaning

Tool Name of the data record used for the tool

Tablet quality check Name of the data record used for the IPC

Standard sampling Name of the data record used for the sampling

Regulation mode MP Method of the selected regulation e.g. weight readjustment via MP set
value

Regulation mode PP Method of the selected regulation e.g. via wall dimension adjustment

Number of tablets for Number of tablets serving for taking the average
regulation

Readjustment pause Pause between two control samplings

Selection of individual Selection of individual samples MP activated or deactivated

samples MP

Selection of individual Selection of individual samples PP activated or deactivated

samples PP

Sampling separation mode Separation mode of the sampling (group/single)

Set-up data report – Production

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[Link].4 Set-up data report Product

Data Meaning

Tolerance PM Plus Upper tolerance limit of the compaction force MP. Tablets exceeding this
limit are blown out

Tolerance MP Minus Upper tolerance limit of the compaction force MP. Tablets undershooting
this limit are blown out

Tolerance PP Plus Upper tolerance limit of the compaction force PP. Tablets exceeding this
limit are blown out

Tolerance PP Minus Lower tolerance limit of the compaction force PP. Tablets undershooting
this limit are blown out

Penetration depth MP Plus Upper limiting value for the adjustment of the penetration depth main
pressure by the regulation

Penetration depth MP Minus Lower limiting value for the adjustment of the penetration depth main
pressure by the regulation

Penetration depth PP Plus Upper limiting value for the adjustment of the penetration depth pre-
pressure by the regulation

Penetration depth PP Minus Lower limiting value for the adjustment of the penetration depth pre-
pressure by the regulation

Wall dimension MP Plus Upper limiting value for the adjustment of the wall dimension main
pressure by the regulation

Wall dimension MP Minus Lower limiting value for the adjustment of the wall dimension main
pressure by the regulation

Wall dimension PP Plus Upper limiting value for the adjustment of the wall dimension pre-pressure
by the regulation

Wall dimension PP Minus Lower limiting value for the adjustment of the wall dimension pre-pressure
by the regulation

Fill depth Plus Upper limiting value for the adjustment of the fill depth by the regulation

Fill depth Minus Lower limiting value for the adjustment of the fill depth by the regulation

Main pressure set value Plus Upper limiting value for the adjustment of the main pressure set value by
the regulation

Main pressure set value Lower limiting value for the adjustment of the main pressure set value by
Minus the regulation

Pre-pressure set value Plus Upper limiting value for the adjustment of the pre-pressure set value by the
regulation

Pre-pressure set value Minus Lower limiting value for the adjustment of the pre-pressure set value by the
regulation

Permitted reject punches Number of permissible revolutions for tolerance infringement of a specific
(single punch / revolutions) punch

Permitted reject punches Number of permissible tolerance infringements of punches in succession

(punch / revolution)

Set-up data report – Product

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[Link].5 Set-up data report Tool

Data Meaning
Tool Name of the tool data record used
Multiple punch Number of inserts per punch
Tool shape Geometrical shape of the punch head
Shape of the lower punch Type of the curvature (e.g. concave) of the lower punch
Shape of the upper punch Type of the curvature (e.g. concave) of the upper punch
Diameter / long side Diameter or length of the tablet
Wide side Width of the tablet
Convexity radius Radius of the punch convexity
Stud length Length of the stud
Theo. punch load Maximum loading capacity of the punch calculated by the system
Permissible punch load Value for the maximum loading capacity of the punch pre-set by the
operator
Pulse length Length of a blow-out pulse
Blow-out position Offset of the blow-out position
Set-up data report – Tool

[Link].6 Set-up data report Quality

Statistics of tablet parameters after selecting the measuring stations. Sum of
measuring cycles within a cycle.
This report is generated only when an IPC is configured.

Data Meaning

Cycle of quality checks Cycle pre-set value: x minutes / x tablets / x revolutions / filling

Number of additional Number of tablets that are separated in addition to the tablets required for
samplings quality sampling.

Set value Set value pre-set

Tolerance T0 + Upper tolerance limit T0 of the tablet quality check.

Tolerance T0 - Lower tolerance limit T0 of the tablet quality check.

Tolerance T1 + Upper tolerance limit T1 of the tablet quality check.

Tolerance T1 - Lower tolerance limit T1 of the tablet quality check.

Tolerance T2 + Upper tolerance limit T2 of the tablet quality check.

Tolerance T2 - Lower tolerance limit T2 of the tablet quality check.

Valid measurements Number of valid measurements that are included in the statistics.

Evaluation limit Plus Positive ViCon evaluation limit. Tablets outside of this evaluation limit are
declared as reject measurements and are not included in the statistics.

Evaluation limit Minus Negative ViCon evaluation limit. Tablets outside of this evaluation limit are
declared as reject measurements and are not included in the statistics.

Permitted average values Number of measured averages which may be outside the tolerance limits
outside T0 T0. If this value is exceeded, the tablet press is switched off with a fault.

Permitted average values Number of measured single values within a quality sampling which may be
outside T1 outside T1, but within T2. If this value is exceeded, the tablet press is
switched off with a fault.

Permitted average values Number of measured single values within a quality sampling which may be
outside T2 outside T2. If this value is exceeded, the tablet press is switched off with a
fault.

Set-up data report Quality

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[Link].7 Set-up data report Standard sampling

Data Meaning

Cycle sampling Selection

- OFF
- Minutes
- Tablets
- Revolutions
- Filling cycle

Number of samplings Number of tablets taken

Sample definition Selection:

- Group sampling
- Individual sampling
- Sampling in sequence

Set-up data report – Standard sampling

[Link].8 Set-up data report Equipment

Data Meaning

Compaction force limitation Actual value of the compaction force limitation for the main pressure
MP

Compaction force limitation Actual value of the compaction force limitation for the pre-pressure
PP

Start-up dosing Number of punches for the start-up dosing

Change-over delay Main gate Number of punches for the change-over delay of the main gate

Travel amplified compaction Method of separating the reject tablets

force Kind of selection

Fillshoe type Display of the fillshoe used

Fillshoe distributor wheel type Display of the distributor wheel used in the fillshoe

Fillshoe direction of rotation Display of the direction of rotation of the fillshoe

Dosing wheel direction of Display of the direction of rotation of the dosing wheel
rotation

Reject tablets ofmetal check Number of tablets for the error message of the metal check

Conveyor belt follow-on time Time the conveyor belt continues to run after the press is stopped

Deduster follow-on time Time the deduster continues to run after the press is stopped

Deduster voltage Percentage of the operating voltage during operation of the deduster

Deduster frequency Frequency of the vibration during operation of the deduster

Transporter cup speed Percentage of the maximum speed of the transporter cup

Transport time Venturi Time the Venturi transport system runs

Set-up data report – Tool

[Link] Cyclical production report

The cyclical production report is generated according to an interval (minutes or
tablets) which can be adjusted via the visualisation for the duration of a production
cycle. The cycle is started when the machine is switched to "Production" mode. Thus it
is also guaranteed that there are not several production stages - and thus maybe
different parameters relevant for statistics - in one cycle. The cycle is terminated and
the report is generated for example when the time has elapsed. Time measurement is
interrupted when the machine is switched to Set-up mode or is stopped. The cyclical
production reports depend on the press station.

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[Link].1 Cyclical production report Batch data

The cycle for the batch data in the cyclical production report runs from the start of the
batch to the end of the production cycle.
Data Meaning

Cycle start Time of cycle start

Cycle end Time of cycle end

Good production Number of tablets produced into the good channel until the time of the
cycle end

Rejects Number of tablets routed out as reject tablets in Production mode until the
time of the cycle end

Samplings regulation Number of tablets routed out for regulation until the time of the cycle end

Samplings IPC Number of tablets routed out for the tablet quality check until the time of
the cycle end

Samplings tablet sampler Number of tablets routed out for standard sampling until the time of the
cycle end

Total production Number of tablets produced in Production mode until the time of the cycle
end

Start losses Number of tablets pressed during the start-up period (with main gate not
switched) until the time of the cycle end

Filling number of containers Number of containers which have been filled until the time of the cycle end

Number of metal detections Number of tablets routed out by the metal check until the time of the cycle
end

Running time (hours – Time for which the machine was producing during the current batch
minutes)

Start-up time (hours – Time for which the machine was in start-up phase during the current batch
minutes)

Production time (hours – Time for which the machine was producing in Production mode during the
minutes) current batch

Standstill time (hours – Time for which the machine was not producing during the current batch
minutes)

Fault time (hours – minutes) Time for which the machine was defective during the current batch

Cyclical production report – Batch data

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[Link].2 Cyclical production report Tablet statistics

Statistics of the tablet parameters according to choice of measuring stations P1 / P2 /
P3. This report is generated only when an IPC is configured.
Data Meaning

Tablet parameter average Average over all IPC measurements within the cycle

Tablet parameter absolute Maximum single value over all IPC measurements within the cycle
max

Tablet parameter absolute Minimum single value over all IPC measurements within the cycle
min

Tablet parameter abs Absolute standard deviation calculated over all IPC measurements within
Standard deviation the cycle

Tablet parameter rel. Relative standard deviation calculated over all IPC measurements within
standard deviation the cycle

Tablet parameter IPC measurements which were ≥ T1+ and < T2+
measurements T1+

Tablet parameter IPC measurements which were ≤ T1- and > T2-
measurements T1-

Tablet parameter IPC measurements which were ≥ T2+

measurements T2+

Tablet parameter IPC measurements which were ≤ T2-

measurements T2-

Tablet parameter good Number of IPC measurements which were within the evaluation limits
measurements during the cycle

Tablet parameter reject Number of IPC measurements which were outside the evaluation limits
measurements during the cycle

Tablet parameter Number of IPC samplings during the cycle

measurement cycles

Cyclical production report – Tablet statistics

[Link].3 Cyclical production report Histogram

Graphic representation of statistics on the distribution of the measured tablet values in
% within a production cycle. All histograms for tablet weight, thickness and hardness
are generated via the values, depending on the pressing station, which accumulated
from cycle start to cycle end (data: see table Tablet statistics, page 166).

60-236
Illustration 131: Example histogram

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Description of the axes:

• Number of tablets [percentage]:
On this axis, the number of tablets in percent is entered which were measured
with their respective deviation from the set value. The scaling of the axis must be
adapted to the respective measurement.
• Deviation:
On this axis, the deviation from the set value is entered in percent. On this axis,
deviations in the range of –10% up to +10% are entered. Measuring values with a
higher deviation are summed up and entered next to the limits.
• Number of tablets:
Next to the axis with the deviations, the absolute number of tablets is entered
which have been measured with the respective deviation from the set value.
• Bars:
The bars represent the tablets which have been measured with their respective
deviation from the set value. To be able to better read the percentage, this value is
represented again as a figure at the end of the bar.

[Link] Container change report

The container change report is generated when a container is full (filling reached) and
the machine switches to the next one. The container change reports depend on the
press station.

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[Link].1 Container change report Batch data

The cycle for the batch data in the cyclical production report runs from the start of the
batch to the end of the production cycle.
Data Meaning

Cycle start Time of cycle start

Cycle end Time of cycle end

Good production Number of tablets produced into the good channel until the time of the
cycle end

Rejects Number of tablets routed out as reject tablets in Production mode until the
time of the cycle end

Samplings regulation Number of tablets routed out for regulation until the time of the cycle end

Samplings IPC Number of tablets routed out for the tablet quality check until the time of
the cycle end

Samplings tablet sampler Number of tablets routed out for standard sampling until the time of the
cycle end

Total production Number of tablets produced in Production mode until the time of the cycle
end

Start losses Number of tablets pressed during the start-up period (with main gate not
switched) until the time of the cycle end

Filling number of containers Number of containers which have been filled until the time of the cycle end

Number of metal detections Number of tablets routed out by the metal check until the time of the cycle
end

Running time (hours – Time for which the machine was producing during the current batch
minutes)

Start-up time (hours – Time for which the machine was in start-up phase during the current batch
minutes)

Production time (hours – Time for which the machine was producing in Production mode during the
minutes) current batch

Standstill time (hours – Time for which the machine was not producing during the current batch
minutes)

Fault time (hours – minutes) Time for which the machine was defective during the current batch

Container change report – Batch data

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[Link].2 Container change report Tablet statistics

Statistics of the tablet parameters according to choice of measuring stations P1 / P2 /
P3. This report is generated only when an IPC is configured.
Data Meaning

Tablet parameter average Average over all IPC measurements within the cycle

Tablet parameter absolute Maximum single value over all IPC measurements within the cycle
max

Tablet parameter absolute Minimum single value over all IPC measurements within the cycle
min

Tablet parameter abs Absolute standard deviation calculated over all IPC measurements within
Standard deviation the cycle

Tablet parameter rel. Relative standard deviation calculated over all IPC measurements within
standard deviation the cycle

Tablet parameter IPC measurements which were ≥ T1+ and < T2+
measurements T1+

Tablet parameter IPC measurements which were ≤ T1- and > T2-
measurements T1-

Tablet parameter IPC measurements which were ≥ T2+

measurements T2+

Tablet parameter IPC measurements which were ≤ T2-

measurements T2-

Tablet parameter good Number of IPC measurements which were within the evaluation limits
measurements during the cycle

Tablet parameter reject Number of IPC measurements which were outside the evaluation limits
measurements during the cycle

Tablet parameter Number of IPC samplings during the cycle

measurement cycles

Container change report – Tablet statistics

[Link].3 Container change report Histograms

Graphic representation of statistics on the distribution of the measured tablet values in
% within a batch. All histograms for tablet weight, thickness and hardness are
generated via the values, depending on the pressing station, which accumulated from
cycle start to cycle end (data: see table Tablet statistics, page 166). For further details
on the diagram see section Cyclical production report Histogram, page 166.

[Link] Batch end report

The batch end report is generated at the end of a batch and represents a statistical
evaluation of the batch. In the batch end report, all press stations are listed separately.

[Link].1 Batch end report General

Data Meaning

Batch start Time of batch start

Batch end Time of batch end

Running time Time for which the machine has produced during the batch.

Standstill period Time for which the machine has not produced during the batch.

Fault time Time for which the machine was at fault during the batch.

Batch end report General

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[Link].2 Batch end report of all press stations

Data Meaning

Good production Number of tablets produced into the good channel during the batch.

Rejects Number of tablets routed out as reject tablets in Production mode during
the batch.

Start losses Number of tablets which were pressed during the start-up period within the
batch.

Samplings regulation Number of tablets routed out for regulation during the batch.

Samplings IPC Number of tablets routed out for the tablet quality check during the batch.

Samplings tablet sampler Number of tablets routed out for standard sampling during the batch.

Total production Number of tablets produced in Production mode during the batch.

Number of metal detections Number of tablets routed out by the metal check during the batch.

Batch end report – Sum of all press stations

[Link].3 Batch end report Press station

Data Meaning

Good production Number of tablets produced in the good channel by the respective press
station during the batch.

Rejects Number of tablets routed out as reject tablets in Production mode by the
respective press station during the batch.

Start losses Tablets lost through start-up of the respective press station during the
batch.

Samplings regulation Number of tablets routed out for regulation by the respective press station
during the batch.

Samplings IPC Number of tablets routed out for tablet quality check by the respective
press station during the batch.

Samplings tablet sampler Number of tablets routed out for sampling by the respective press station
during the batch.

Total production Number of tablets produced in Production mode by the respective press
station during the batch.

Filling actual Number of tablets produced in the current container by the respective
press station during the batch.

Filling number of containers Number of containers filled by the respective press station during the
batch.

Number of metal detections Number of tablets separated by the metal check of the respective press
station during the batch.

Production time Time for which the press station was producing in Production mode during
the batch.

Start-up time Time for which the machine was in start-up phase during the batch (main
gate not switched).

Batch data – Press station

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[Link].4 Batch end report Tablet statistics

Statistics of the tablet parameters according to choice of measuring stations P1 / P2 /
P3. This report is generated only when an IPC is configured.
Data Meaning

Tablet parameter average Average of all IPC measurements of the respective press station during
the batch.

Tablet parameter standard Absolute standard deviation calculated of all IPC measurements of the
deviation respective press station during the batch.

Tablet parameter relative Relative standard deviation calculated of all IPC measurements of the
standard deviation respective press station during the batch.

Tablet parameter IPC measurements which were ≥ T1+ and < T2+.
measurements T1+

Tablet parameter IPC measurements which were ≤ T1- and > T2-.
measurements T1-

Tablet parameter IPC measurements which were ≥ T2+.

measurements T2+

Tablet parameter IPC measurements which were ≤ T2-.

measurements T2-

Tablet parameter good Number of the IPC measurements of the respective press station which
measurements were within the evaluation limits during the batch.

Tablet parameter reject Number of the IPC measurements of the respective press station which
measurements were outside the evaluation limits during the batch.

Tablet parameter Number of the IPC samplings of the respective press station during the
measurement cycles batch.

Batch end report – Tablet statistics

[Link].5 Batch end report Histogram

Graphic representation of statistics on the distribution of the measured tablet values in
% within a batch. All histograms for tablet weight, thickness and hardness are
generated via the values, depending on the press station, which accumulated from
cycle start to cycle end (data: see table Tablet statistics, page 166). For further details
on the diagram see section Cyclical production report Histogram, page 166.

[Link] In-process control reports

The single measuring values of a quality sampling are stored in the report of the in-
process control. In addition, a statistical evaluation of the measurement cycle as well
as of all samples measured so far is given.
This report is generated only when an IPC is configured.

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[Link].1 In-process control report Single values

Data Meaning

Date Date by which the measuring value was determined

Time Time at which the measuring value was determined

Sample Number of the measuring value within the measuring cycle

Weight (measuring value) Measured value of the weight

Thickness (measuring value) Measured value of the thickness

Hardness (measuring value) Measured value of the hardness

Diameter (measuring value) Measured value of the diameter

Weight (evaluation) Evaluation of weight measurements

Thickness (evaluation) Evaluation of thickness measurements

Hardness (evaluation) Evaluation of hardness measurements

Punch number Number of the punch for single separation

Main pressure Compaction force of the punch for single separation

In-process control report - Single values

[Link].2 In-process control report Single statistics

Data Meaning

Set value Set values for weight / thickness / hardness

Tolerance T0 + Upper tolerance limit T0 of the tablet quality check (actual absolute value).

Tolerance T0 - Lower tolerance limit T0 of the tablet quality check (actual absolute value).

Tolerance T1 + Upper tolerance limit T1 of the tablet quality check (actual absolute value).

Tolerance T1 - Lower tolerance limit T1 of the tablet quality check (actual absolute value).

Tolerance T2 + Upper tolerance limit T2 of the tablet quality check (actual absolute value).

Tolerance T2 - Lower tolerance limit T2 of the tablet quality check (actual absolute value).

Average Average of all IPC measurements of the respective press station during
the measuring cycle.

Absolute maximum Maximum single value of all IPC measurements of the respective press
station during the measuring cycle.

Absolute minimum Minimum single value of all IPC measurements of the respective press
station during the measuring cycle.

Absolute standard deviation Absolute standard deviation calculated of all IPC measurements of the
respective press station during the measuring cycle.

Relative standard deviation Relative standard deviation calculated of all IPC measurements of the
respective press station during the measuring cycle.

Measurements T1+ IPC measurements which were ≥ T1+ and < T2+.

Measurements T1- IPC measurements which were ≤ T1- and > T2-.

Measurements T2+ IPC measurements which were ≥ T2+.

Measurements T2- IPC measurements which were ≤ T2-.

Good measurements Number of the IPC measurements of the respective press station which
were within the evaluation limits during the measuring cycle.

Reject measurements Number of the IPC measurements of the respective press station which
were outside the evaluation limits during the measuring cycle.

Measuring cycle no. Number of the IPC sampling for the respective press station.
In-process control report - Single statistics

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[Link].3 In-process control report Overall values

Data Meaning

Average Average of all IPC measurements of the respective press station during
the batch.

Absolute maximum Maximum single value of all IPC measurements of the respective press
station during the batch.

Absolute minimum Minimum single value of all IPC measurements of the respective press
station during the batch.

Absolute standard deviation Absolute standard deviation calculated of all IPC measurements of the
respective press station during the batch.

Relative standard deviation Relative standard deviation calculated of all IPC measurements of the
respective press station during the batch.

Measurements T1+ IPC measurements which were ≥ T1+ and < T2+.

Measurements T1- IPC measurements which were ≤ T1- and > T2-.

Measurements T2+ IPC measurements which were ≥ T2+.

Measurements T2- IPC measurements which were ≤ T2-.

Good measurements Number of the IPC measurements of the respective press station which
were within the evaluation limits during the batch.

Reject measurements Number of the IPC measurements of the respective press station which
were outside the evaluation limits during the batch.

Measuring cycles Number of the IPC samplings of the respective press station during the
batch.

In-process control report - Overall statistics

[Link] Manual tablet check reports

The individual measuring values of the last measuring cycle are stored in the Manual
tablet control report. In addition, a statistical evaluation of the measuring cycles is
output.

[Link].1 Manual tablet check report Single values

Data Meaning

Date Date by which the measuring value was determined

Time Time at which the measuring value was determined

Sample Number of the measuring value within the measuring cycle

Weight (measuring value) Measured value of the weight

Thickness (measuring value) Measured value of the thickness

Hardness (measuring value) Measured value of the hardness

Diameter (measuring value) Measured value of the diameter

Punch number Number of the punch for single separation

Main pressure Compaction force of the punch for single separation

Report – Manual tablet check – Single values

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[Link].2 Manual tablet check report Tablet statistics

Statistics of the tablet parameters according to choice of measuring stations P1 / P2 /
P3. This report is generated only when an IPC is configured.
Data Meaning

Tablet parameter set value Set value pre-set

Tablet parameter average Average of all measurements of the respective press station during the
measuring cycle

Tablet parameter absolute Maximum single value of all measurements of the respective press station
max during the measuring cycle

Tablet parameter absolute Minimum single value of all measurements of the respective press station
min during the measuring cycle

Tablet parameter abs Absolute standard deviation calculated of all measurements of the
Standard deviation respective press station during the measuring cycle

Tablet parameter rel. Relative standard deviation calculated of all measurements of the
standard deviation respective press station during the measuring cycle

Tablet parameter good Number of measurements of the respective press station which were
measurements within the evaluation limits during the measuring cycle

Tablet parameter reject Number of measurements of the respective press station which were
measurements outside the evaluation limits during the measuring cycle

Report - Manual tablet check - Tablet statistics

[Link] Operation messages report

The operation messages report is started at the beginning of a batch, i.e. all operation
messages are stored related to the batch. The following types of operation messages
are recorded in the report:
• Error messages
• Status messages
• Info messages

[Link] Audit trail report

The Audit Trail report is started at the beginning of a batch, i.e. all Audit Trail
messages are stored related to the batch.

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9.10 Regulation
This section describes the regulation types implemented in the system. Adjustments
are no longer necessary because an auto-adaptive control unit is used.
Set value means a value determined during the set-up phase used to achieve defined
tablet properties.

The following variables (tablet parameters) can be influenced during the production of
a tablet:
• Weight
• Thickness (or wall dimension)
• Hardness

In a tablet press, the wall dimension, the distance between upper and lower punch
(the tablet thickness results from this) and the amount of powder to be pressed (the
tablet weight results from this) can be varied. The relations between the adjustable
parameters of the press and the required tablet parameters are:
• tablet weight to fill depth (condition: the density of the product must be constant
and it must be guaranteed that the product can be filled into the die with constant
quality)
• tablet thickness to wall dimension (condition: the filling must be sufficient to press
a tablet.)
• tablet hardness to compaction force of main pressure (condition: limited hardness,
product must be sufficiently pressed for a tablet, in case of excessive pressing the
hardness is reduced in spite of the increasing main pressure)

9.10.1 Precondition for regulation

To accept the compaction force single values for forming the average the following
conditions must be fulfilled:
• The tablet press produces.
• The tablet press is in "Production" mode.
• The punch is considered as fitted.
• The compaction force single value is greater than zero.
• The tablet has not been identified as reject tablet (compaction force higher or
lower than the tolerance limits).

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9.10.2 Primary regulation

The primary regulation enables rapid adjustment of the tablet parameters weight,
thickness and hardness during production. This is done via the auxiliary quantity
compaction force of the main pressure press station. The compaction force MP can be
determined for every pressing procedure. Primary regulation can be performed using
the fill depth or wall dimension. The compaction force MP is kept constant by means
of the filling volume in the so-called primary regulation.
A WSG measuring point in the tablet press records the pressure on the pressure
rollers when pressing the filled-in product. These peak values, the so-called
compaction force single values, then serve as a basis for compaction force regulation.
For compaction force regulation, the compaction force average of the regulation is
used.

Note:
Within control hysteresis the control system does not react to
deviations from the average.
The hysteresis (dead zone) determines in which range no
readjustments are made if deviations from the set value occur.
Without hysteresis the regulation of the control system would
immediately react to the tiniest deviation from the set value.

[Link] Compaction force regulation MP via filling

The main pressure adjusts itself between the main pressure rollers via the wall
dimension and the fill depth. If the wall dimension is kept constant, the main pressure
only depends on the fill depth. As the fill depth is a measure for the weight of the
tablet, the main pressure, too, is an indirect measure for the tablet weight with a
constant distance between the punches. If the fill quality is increased the compaction
force also rises and hence the tablet weight.

[Link] Compaction force regulation MP via wall dimension

The main pressure adjusts itself between the main pressure rollers via the wall
dimension and the fill depth. If the filling is kept constant, the main pressure only
depends on the wall dimension. The wall dimension is primarily a measure for tablet
thickness. If, however, the filling volume is kept constant, the wall dimension also
influences the hardness of the tablet.

• The main pressure is then adjusted via the wall dimension, whereby the wall
dimension, and thus the thickness of the tablet, no longer remain constant. The
weight, too, can only be considered constant if the filling volume and the density of
the product are also constant or consistent throughout the total production. For the
respective product, the necessary main pressure compaction force, the wall
dimension and the fill quantity are determined in the set-up process of the tablet
press.

[Link] Compaction force regulation PP via wall dimension

The pre-pressure adjusts itself between the pre-pressure rollers via the wall dimension
and the fill depth. The filling must not be influenced by the pre-pressure regulation, as
otherwise coincidences with the compaction force regulation of the main pressure
could occur. The pre-pressure only depends on the wall dimension.

• The pre-pressure is regulated via the wall dimension to obtain an even deaeration
of the product.

9.10.3 Secondary regulation (readjustment)

For readjustment the following values must be parameterised:

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• Number of tablets for the regulation:

The number of tablets for average calculation determines the quality of the
average. A large number of tablets measured guarantees an accurate average.
• Readjustment pause:
If the average determined of the tablet parameters to be adjusted is inside the
hysteresis, no readjustment is necessary. The readjustment pause then
determines the time until the next sampling. The readjustment pause is started
when the tablet parameters to be adjusted are within the hysteresis.

To ensure that the tablet has the required tablet parameters when the auxiliary
quantity is set correspondingly, the tablet parameters are additionally measured in a
TCU. These measuring values are then used for readjustment, also called secondary
adjustment. During secondary adjustment, the tablet parameters weight and/or
hardness are measured and readjusted.
For determining the tablet parameters the following peripheral equipment (TCU= tablet
check unit) is used:

• RQ 100
- Weight
- Thickness
- Hardness

• TWA 100
- Weight

Note:
For information regarding the operation of the RQ 100 or TWA 100
please refer to the corresponding operating instructions.

After starting the tablet press and switching to the operating mode "Production",
control samplings are immediately routed out. Subsequently tablets are routed out
from running production at set intervals (readjustment pause). These are used for
average calculation.
The weight hysteresis is ± 1/3 of the tolerance limites T0. If the weight average is
within the weight hysteresis, no regulation step is made and the readjustment pause
starts. Only when the readjustment pause has elapsed, tablets are again routed out
and checked.

[Link] Weight regulation via main pressure set value

With this regulation mode, tablet thickness is kept constant, while the hardness of the
tablet varies.
If the weight average is within the weight hysteresis, no regulation step is made and
the readjustment pause starts. Only when the readjustment pause has elapsed,
tablets are again routed out and checked.
If the weight average is outside the weight hysteresis, the set value of the main
pressure is adjusted automatically by the machine. When the main pressure set value
has been adjusted and the compaction force regulation (primary regulation) (in this
case via the wall dimension) has accepted this new set value, new samples are routed
out for checking. The change of the main pressure set value is limited by adjusting
limits (production limits). If the calculated change exceeds the adjustment limits, the
machine is stopped with the appropriate fault message.

[Link] Weight regulation via wall dimension main pressure

In this regulation mode, tablet hardness is kept constant, however without directly
checking it, which the thickness of the tablet varies.
If the weight average is outside the weight hysteresis, the wall dimension of the main
pressure is adjusted. This results in a change of the current main pressure compaction
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force. The compaction force regulation (primary regulation) then readjusts the
compaction force via the filling. If the actual value matches the set value again, new
samples are routed out for checking.

[Link] Combined weight/hardness check

Tablets from running production are routed out after starting the tablet press and
switching to "Production" mode and after that at pre-set time intervals (readjustment
pause). These are used to calculate the average value.
If only the weight is outside the weight hysteresis, filling must be adjusted. In order not
to change the current hardness, the wall dimension of the main pressure must be
adjusted at the same time.
If only the hardness is outside the hardness hysteresis, the wall dimension of the main
pressure must be adjusted. In order not to change the current weight (compaction
force regulation (primary regulation) is in mode via filling and would react to the
inevitable change of compression force), the set value must be adjusted at the same
time.
If weight and hardness are outside the hysteresis, they are adjusted simultaneously in
one regulation step.

[Link] Summary of secondary regulation

Secondary regulation can be summarised as follows:
• Secondary adjustment
- Weight readjustment via compaction force set value (keeping tablet weight
and thickness constant)
- Weight readjustment via the wall dimension (keeping tablet weight constant)
- combined weight and hardness check (keeping tablet weight and hardness
constant)

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9.10.4 Setting the regulation type

Regulation for main and pre-pressure is set in the selection field Main pressure
regulation or Pre-pressure regulation in the screen Tabletting > Set-up >
Production.

62-009_en
Illustration 132: Tabletting – Set-up – Production

Main pressure regulation

If the choice... - is on "Off", the regulation is deactivated.
- is on "With filling", the compaction force regulation is activated via filling
(the tablet weight is indirectly kept constant).
- is on "With wall dimension", the compaction force regulation is activated
via the wall dimension.
- is on "Weight regulation with MP set value", the compaction force
regulation is activated via filling and the weight regulation via changing the
main pressure set value (the tablet thickness is indirectly kept constant
with variable tablet hardness).
- is on "Weight regulation with wall dimension", the compaction force
regulation is activated via the filling and the weight regulation via changing
the wall dimension (the tablet hardness is indirectly kept constant with
variable tablet thickness).
- is on "With hardness readjustment", the compaction force regulation is
activated via the wall dimension and the hardness regulation via changing
the main pressure set value (the tablet weight is indirectly kept constant
with variable tablet thickness).
- is on "With combined weight and hardness readjustment", the
compaction force regulation is activated via filling and the weight and
hardness regulation via the wall dimension and the compaction force set
value.
Number of tablets for the The number of tablets entered is separated for tablet regulation into the
regulation sampling channel.
Readjustment pause Between two control samplings taken for tablet readjustment a pause is
made according to the time entered.
Selection of individual Individual selection of the reject tablets of the main pressure is activated or
samples ON deactivated.
Pre-pressure regulation
If the choice... - is on "Off", the regulation is deactivated.
- is on "With wall dimension", the compaction force regulation is activated
via the wall dimension.
Selection of individual Individual selection of the reject tablets of the pre-pressure is activated or
samples ON deactivated.

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Synthesis 700ZS Service

10 Service
This section provides information regarding general service and maintenance and
cleaning of the tablet press. Read this section carefully prior to commissioning or
service work.

Note:
For useing cleaning agents also observe the Customer information
„Cleaning Notes“.

This documentation must be read by all persons who operate or service the product.
If the product is sold to a third party, the complete technical documentation must be
supplied with it.

Note:
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this document.

Notice:
For all servicing work observe the instructions given in the Safety
chapter.

Operating safety and service life of the tablet press depend on proper servicing and
lubrication.
Regular servicing and lubrication is imperative.

CAUTION
A removal of the torquing motor is to be advised against
urgently.
An inappropriate dismantling of the motor causes irreparable
damage.
For interferences or problems with the motor please contact
the IMA Kilian service.

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Cleaning

10.1 Cleaning

CAUTION
Also observe the instructions for cleaning in chapter Safety!

Cleaning shall be carried out:

• at the end of a production day
• at batch end
• at production end of a product
• prior to starting the servicing work
• before and after longer standstill periods
• before and after transport or storage

Notice:
During cleaning wear adequate personal protective equipment!

Use for cleaning

• only lintfree cloth which does not damage the surfaces in the compression
chamber or cause any reaction with the press material
• only light cleaning agents (pH value 7–8, free from chlorine and/or chloride)

CAUTION
Surfaces can be affected when using cleaning agents with a
pH value ≥ 9!

• no solvent-based, scouring or abrasive cleaning agents

• no steam jets (high-pressure cleaner). The high pressure and hot steam damage
the seals.
• no compressed air
• no water for cleaning the die table

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Cleaning

Generally proceed as follows:

• Vacuum the compression chamber to remove product residues
• Clean the compression chamber using cloth and detergents
• Remove oil and product residues on connections and union joints; after cleaning
check these for leaks, damage or loose connections

For minor cleaning proceed as follows:

• Remove the material hopper
• Remove tablet chute and tablet scraper
• Remove the product scraper
• Empty the fillshoe, dismantle and clean it
• Remove the upper punches and clean the guides
• Clean the compression chamber
• Clean the suction unit

For major cleaning proceed as follows:

• Execute all steps of the minor cleaning and in addition:
- Remove the lower punches and clean the guides
- Carefully clean the bores of the dies with the cleaning scraper
- Clean the die table with alcohol

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Removal/fitting of the die table

10.2 Removal/fitting of the die table

10.2.1 Removing the die table
[Link] Preparing removal
Notice:
The following steps are described for one press station only. They
must be executed analogously for the second press station, too.

Dismantle the parts below in the following sequence:

1. Tablet scraper (see section Tablet scraper).
2. Tablet chute (see section Tablet chute).
3. Fillshoe (see section Fillshoe).
4. Product scraper (see section Covering segment with product scraper).
5. Suction unit (see section Suction).
6. Removal of the filling tube (see section Filling tube).
7. Pressure roller block (see section Upper pressure roller block).

[Link] Preparing the cams

Detach the fixing screws (1) of the pull-
down cam. Now detach the adjusting 2
1
screw (2) at the pull-down cam and
separate the cam to the stop.

1
04-075
Illustration 133: Opening the pull-down cam

Open the right machine door.

Loosen the adjusting screws at the
1 2
catch cam (1) and the control cam (2)
until they are at their limit stop.
Close the machine door.

01-480
Illustration 134: Opening the catch cam and control cam

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Removal/fitting of the die table

Open the left machine door.

Remove both of the connecting bolts
(1). Remove the ejection bar (2)
between ejection cam (4) and hydraulic
cylinder (3).
1

2
4
1

04-011
Illustration 135: Opening the catch cam at the ejection
cam

Turn the tube of the lower punch

lubrication (1) out of the die table
groove in order not to damage it when
lifting the die table.
Close the machine door.
1

Illustration 136: Lower punch lubrication

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Removal/fitting of the die table

[Link] Preparing the sliding carriage

Unbolt the fixing bolt of the sliding
carriage. Pull the sliding carriage from
the central position until the fixing bolt
engages again.

10-101
Illustration 137: Fixing bolt of sliding carriage

CAUTION
Sharp edges on the sliding carriage at face level!

03-200
Risk of head injuries

Notice:
The correct position of the sliding carriage is electronically
checked. If it is not possible to lift the die table afterwards, please
check the position of the sliding carriage first.

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Removal/fitting of the die table

[Link] Moving out the die table

Lifting the die table

WARNING
There is a high risk of injury when dismantling the die table
due to its weight and its upward and downward movement!
Mind the weight of the die table (approx. 700 kg)!
The die table may only be dismantled or mounted using a lift truck
or an appropriate crane! The transport straps or chains must be
designed for the weight of the die table.
Ø Secure the die table against slipping during transport!

CAUTION
Risk of hand injuries!
If the punches are in the die table, there is a risk of injury caused
by the punch movements when turning the die table or the cam
track!

Open the spring catch (2), detach the

star grip screws (1) and lift the cover 1 2
plates out. Repeat this procedure at
the rear part of the cover. (see page
240).

04-053
Illustration 138: Removal of the cover

Unscrew the tensioning nut (1)

completely off the thread using the
large torque wrench (supplies) until it
automatically lifts to the top. 1

04-097
Illustration 139: Loosening the tensioning nut of the die
table

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Removal/fitting of the die table

Plug the manual switch (1) into the

corresponding plug-in unit (2) (which is
situated on the left side behind the
front door) and turn the switch to the
right. An acoustic signal can be heard
and the ejection cylinder is lifted with
the die table after a short delay.
1

01-365
Illustration 140: Manual switch for lifting the die table

04-096
Illustration 141: Plug-in unit manual switch

When the die table has reached the

topmost position, unlock the sliding
carriage and push it into the
dismantling/fitting position until the
fixing bolt is engaged again.

Illustration 142: Lifting the die table / sliding carriage in

position

007.2/SYN7ZS/BA/en 187 / 409

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Removal/fitting of the die table

Turn the manual switch (1) to the left.

The ejection cylinder slowly moves
downwards.

01-364
Illustration 143: Manual switch Lower die table

Notice:
The correct position of the sliding carriage is electronically
checked. If it is not possible to lower the die table afterwards,
please check the position of the sliding carriage first.

Check whether the tensioning nut (1) is

correctly positioned in the base of the
sliding carriage (2).

01-146
Illustration 144: Lifting the die table / tensioning nut in
sliding carriage base

188 / 409 007.2/SYN7ZS/BA/en

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Removal/fitting of the die table

Extension of the die table

Notice:
To allow the extension of the die table, the two-part fillshoe base
must be swung out and the fillshoe base plate must be removed.

To swing out the two-part fillshoe base the following work must be done in
advance:
è Fillshoe removal (see section "Two-part fillshoe base", page 234).
è Removing the covering segment with the product scraper (see section "Covering
segment with product scraper", page 262).

Detach the locking screw (1).

04-068
Illustration 145: Locking screw of the swivel arm

Swing the fillshoe base away from the

die table.
When you swing the fillshoe base back
towards the die table again, the locking
screw must then be firmly retightened.

04-069
Illustration 146: Swinging out the fillshoe base

Remove the fillshoe baseplate. (see

section "Two-part fillshoe base", page
234).

04-105
Illustration 147: Two-part fillshoe base

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Removal/fitting of the die table

Ensure that the ejection cylinder has

sufficiently moved down to allow the
die table to be pushed out.

01-145
Illustration 148: Position of ejection cylinder

Pull the die table out of the tablet

press to the limit stop.

04-099
Illustration 149: Pulling the die table out

Push the lift truck to the right side of

the tablet press so that the edge of the
lift truck is flush in contact with the
tablet press.

04-106
Illustration 150: Arranging the lift truck

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Removal/fitting of the die table

Pump the elevating platform up so that

the die table (1) is resting on the die 1
table base (2) of the lift truck.
Ensure that the bores are positioned
exactly above the corresponding studs
(3).

3 2
04-103
Illustration 151: Die table base lift truck

Pump the elevating platform further up

so that the tensioning nut in the base
of the sliding carriage does not rest
any longer.

01-151
Illustration 152: Elevating platform lifted / position
tensioning nut

Push the sliding carriage to the back

into the central position.
Carefully tighten the tensioning nut of
the die table by hand (fine thread with
low gradient) in order to secure the die
table on the elevating platform.
Let the elevating platform with the die
table down.

04-094
Illustration 153: Tightening the tensioning nut

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Removal/fitting of the die table

If the machine stands without die table

for a longer time, the machine
compartment partition should be
covered with the cover (supplies).
Swing the tablet chutes and the
pressure roller blocks back into the
machine again.
Close the windows and the doors.
01-367
Illustration 154: Cover of the machine compartment
partition

10.2.2 Fitting of the die table

[Link] Preparing the fitting
Notice:
Check whether pull-down cam, catch cam and control cam are
separated to the stop.

WARNING
There is a high risk of injury when assembling the die table
due to its weight and its upward and downward movement!
Mind the weight of the die table (approx. 700 kg)!
The die table may only be dismantled or mounted using a lift truck
or an appropriate crane! The transport straps or chains must be
designed for the weight of the die table.
Ø Secure the die table against slipping during transport!

CAUTION
Risk of hand injuries!
If the punches are in the die table, there is a risk of injury caused
by the punch movements when turning the die table or the cam
track!

CAUTION
There is the risk of the lower punches getting wedged in the
pull-down cam due to their positioning (1).
Ø Therefore remove six punches to the right of the punch (2)
which is located at the beginning of the pull-down cam.

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Removal/fitting of the die table

Illustration 155: Positioning of lower punches in the pull-down cam

[Link] Retracting the die table

Open the right window.
Move the die table with the lift truck to
the rightt side of the tablet press.

04-098
Illustration 156: Arranging the lift truck

Unscrew the tensioning nut completely

off the thread until it automatically lifts
to the top.

04-094
Illustration 157: Tensioning nut, screwed off the thread

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Removal/fitting of the die table

Unlock the sliding carriage and move it

from the central position in the
direction of the lift truck.
Pump the elevating platform so high
that the tensioning nut can be inserted
in the sliding carriage.

Illustration 158: Fitting the die table / positioning the

sliding carriage

Let the elevating platform somewhat

down to make the tensioning nut click
into place in the sliding carriage base.
Mind the correct position of the
tensioning nut in the sliding carriage.

01-163
Illustration 159: Fitting of the die table / tensioning nut in
the base

Ensure that the ejection cylinder has

sufficiently moved down to allow the
die table to be pushed in.
Let the elevating platform down and
push the lift truck aside.

01-145
Illustration 160: Ejection cylinder of die table

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Removal/fitting of the die table

Unlock the sliding carriage and push it

with the die table into the central
position.

04-100
Illustration 161: Moving the die table in

Turn the die table so that the red-

marked bolt (1) on the die table on the
plate of the vertical shaft and the
punch No. 1 (2) are aligned with each 2
other.

01-528
Illustration 162: Fitting the die table

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Removal/fitting of the die table

Using the manual switch, lift the die

table so high that the tensioning nut in
the sliding carriage is lifted.
Unlock the sliding carriage and move it
from the central position to the rear.
Make sure that the ejection cylinder is
correctly fitted in the die table.
Turn the manual switch to the left to
lower the die table.

01-151
Illustration 163: Lifted tensioning nut

Notice:
Check whether the die table rests on the plate of the vertical shaft.

Tighten the tensioning nut (1) with a

tightening torque of 70 Nm.
1

04-097
Illustration 164: Tightening the tensioning nut of the die
table

CAUTION
Tightening torque
Absolutely use a torque wrench to avoid damage to the threads.
Ø Tightening torque: 70 Nm

196 / 409 007.2/SYN7ZS/BA/en

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Removal/fitting of the die table

[Link] Closing the cams

Mounting the cams
Notice:
After refitting the die table, check the oil filling of the lube oil
channel in the die table, as described in chapter "Lubrication",
section "Lube oil filling following die table cleaning", page 300.

Open the left machine door.

Turn the tube of the lower punch
lubrication (1) back into the groove of
the die table.

Illustration 165: Lower punch lubrication

First carefully tighten the adjusting

screw (2) at the pull-down cam. 2
1
Afterwards tighten both of the fixing
screws (1).
Close the machine door.

1
04-075
Illustration 166: Closing the pull-down cam

Open the right machine door.

Tighten the adjusting screws at the 1 2
catch cam (1) and at the control cam
(2).
Close the machine door.

01-480
Illustration 167: Closing the catch cam and control cam

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Removal/fitting of the die table

Open the left machine door.

Mount the ejection bar (2) between
ejection cam (4) and hydraulic cylinder
(3). Fit the connecting bolts (1).
Close the machine door.
1

2
4
1

04-011
Illustration 168: Closing the catch cam at the ejection
cam

[Link] Finishing the fitting

Reassemble the parts below, as described on the corresponding pages in the
following sequence:
1. Pressure roller block (see section Upper pressure rollers).
2. Suction unit (see section Suction)
3. Fillshoe (see section Fillshoe)
4. Product scraper see section Covering segment with product scraper)
5. Tablet chute (see section Tablet chute)
6. Tablet scraper (see section Tablet scraper).

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Sealing ring at die table

10.3 Sealing ring at die table

01-003
Illustration 169: Sealing ring with lip seal

 Die table in profile

 Lip seal

 Lubricating paste at lip seal

(Klüberpaste UH1 14-151)
 Sliding surface of the sealing ring

Note:
Please also observe the lubricant certificates in the documentation
Lubricants.

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Sealing ring at die table

Notice:
Paint-coated sealing rings (1) are
maintenance-free and must not be
lubricated.
Lubrication only for non-paint-coated 1
sealing rings (2). Proceed as described in
section Lubrication before assembly.

00-203
Illustration 170: Die table sealing rings (in
detail for better representation)

Lubrication before assembly

è Grease the lower surface of the sealing ring (4) and the sliding surface of the
sealing ring (2) on the intermediate frame with lubricating paste (3).
è Use Klüberpaste UH1 14-151for this.

Lubrication after assembly

To renew the lubricating film, proceed as follows:
è Lift the lip seal with a small object and push some lubricating paste under the lip
seal.

Note:
Do not apply any lubricating paste on the outer surface of the lip
seal. This would result in the contamination of the powder to be
pressed.

200 / 409 007.2/SYN7ZS/BA/en

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Tool

10.4 Tool
7

6
2
5

3
01-241
Illustration 171: Tool with single punch bellow

1 Die fixing screw 5 Punch bellow holding ring

2 The 6 Single punch bellow lower punch
3 Lower punches 7 Upper punches
4 Scraper 8 Single punch bellow upper punch

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Tool

10.4.1 Single punch bellow

Removal
Pull the punch bellows (1) off the
upper punches. 1

01-504
Illustration 172: Pulling the upper punch punch bellow
off

Notice:
For removal of the punch bellows at the lower punches, the lower
punches must be removed (see section "Lower punch", page 207).

1. Punch bellow for upper punch

2. Punch bellow for lower punch
1 2

Illustration 173: Punch bellow for upper / lower punch

202 / 409 007.2/SYN7ZS/BA/en

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Tool

Fitting
Notice:
Mind the different punch bellows for upper and lower punches.
After manual cleaning of the punch bellows (in dismantled
condition) these must be completely dry inside prior to assembly.
This prevents corrosion of the upper and lower punches.

The punch bellows of the upper

punches can (after fitting of the upper 1
punches) be easily mounted on the
correspinding bases at the fixing clip
(1) and groove (2) of the upper punch.
2

Illustration 174: Punch bellow at upper punch

After fitting the punch bellows (1) of

the lower punches the lower punches 1 2
(2) can be re-assembled. (see page
207).

04-104
Illustration 175: Equipped die table

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Tool

10.4.2 Oil collecting cap

Removal and fitting
Pull the oil collecting caps (1) off the
upper punches.
For fitting, the upper punch oil
collecting caps can be easily fixed on
the corresponding bases at the groove
(2) of the upper punch.

1 2

Illustration 176: Pulling the upper punch oil collecting

caps off

Clean the oil collecting caps with an oil-

dissolving cleaning agent in warm water.

01-713
Illustration 177: Rubber ring of die table

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Tool

10.4.3 Upper punches

Removal
Detach the fixing screw on the
dismantling piece of the upper cam
track and remove the dismantling
piece.

04-071
Illustration 178: Dismantling station

Pull out the upper punches upwards.

01-382
Illustration 179: Removal of upper punches

For turning the die table use the

manual button (supplies).
Connect the manual button (the
connection is located behind the
right machine door).

04-087
Illustration 180: Connecting the manual button

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Tool

Warning
Risk of injury!
Hazard through bruising of body parts. By actuating the manual
button the die table starts moving slowly. Risk of severe injuries
through the upward and downward movement of the punches!
Ø The operator must close all other doors and windows prior to
actuating the manual button. During the entire procedure it
must be guaranteed that no other person may be injured in
the compression chamber and/or in the machine
compartment.

Turn the die table slowly by pressing

the button until the next punch position
is reached and thus successively
remove all upper punches.

04-088
Illustration 181: Actuation of the manual button

Fitting
è Fitting of the upper punches is effected in reversed sequence.
è When fitting the upper punches oil them slightly.

CAUTION
The compaction surfaces must not be oiled.
This may result in the contamination of the tablets.

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Operating Instruction
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Tool

10.4.4 Lower punches

Fitting and removal of lower punches
Removal
Detach the clamping lever (1) of the
tablet chute and swing the tablet chute
out. (see section "Tablet chute", page
252).

04-022
Illustration 182: Tablet chute

Open the left machine compartment

door and dismantle the dismantling
station.

01-383
Illustration 183: Dismantling station lower punches

Notice:
For easier removal of the lower punches you may dismount the
ejection cam in addition to the dismantling station. This allows
access to several punches.

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Tool

Remove the connecting bolts (1) by

pressing the center pins.
Remove the ejection bar (2) between
ejection cam (4) and ejection cylinder
(3). 4
1
2

Illustration 184: Ejection bar lower punches

Pull out the lower punches

downwards.

04-009
Illustration 185: Removal of the lower punches

For turning the die table use the

manual button (supplies).
Connect the manual button (the
connection is located behind the
right machine door).

04-087
Illustration 186: Connecting the manual button

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Tool

Warning
Risk of injury!
Hazard through bruising of body parts. By actuating the manual
button the die table starts moving slowly. Risk of severe injuries
through the upward and downward movement of the punches!
Ø The operator must close all other doors and windows prior to
actuating the manual button. During the entire procedure it
must be guaranteed that no other person may be injured in
the compression chamber and/or in the machine
compartment.

Turn the die table slowly by pressing

the button until the next punch position
is reached and thus successively
remove all lower punches.

04-088
Illustration 187: Actuation of the manual button

Fitting
è Mount the punch bellows (see page 202) prior to fitting the lower punches on the
corresponding bases the fixing clip. Mounting the punch bellows after fitting the
lower punches is not possible.
è Fitting of the lower punches is effected in reversed sequence.
è When fitting the lower punches oil them slightly.

Caution
The compaction surfaces must not be oiled.
This may result in the contamination of the tablets.

Notice:
When fitting the dismantling station the hydraulic pump will start to
run briefly to lower the ejection cylinder.

10.4.5 Storage of tools

è After removal clean the tools with cleaning agent and a soft cloth.
è Spray the tools with a preservation agent.
è Wrap the tools in special plastic sleeves available as spare parts from IMA
KILIAN. In addition the compaction surface should be fitted with impact protection
(foamed material or polystyrene).

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Tool

10.4.6 Scraper
Removal
è For removing the scrapers the respective upper/lower punches must be removed.

Lever the scrapers (2) out of the

punch bores. For doing so, use a 4
corresponding hook (4)-, e.g. made of
bent welding wire -.
When preparing the hook the ends 1
must be rounded. Thus damage to the
punch bore through sharp edges can
be avoided.
The fixing clip (1) for the punch bellow
is stuck in the die table (3) and must
not be damaged. 3
2
01-505
Illustration 188: Removing the scrapers

Note:
For replacing defective fixing clips please contact the IMA KILIAN
Service.

Fitting
For fitting distort the scraper in the
shape of an "8" and insert it through
the fixing clip (1) into the base (2). In
doing so, the "crown" of the scraper
must face the punch bellow.
Then push the scraper into the base
using your finger.
1

3
2
01-506
Illustration 189: Fitting the scraper

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Tool

10.4.7 Dies
Removal
Preparation:
è Dismantling the tablet chutes (see section Tablet chute) and
è remove the lower punches (see section Lower Punches).
è Remove the suction, as described in section Suction.

Loosen the die fixing screws (1) to the

left and to the right of the 2
corresponding die (2).

Illustration 190: Die fixing screws

04-005
For die removal use the die ejector
(supplies).
Insert the die ejector (1) into the
punch bore so that the flat side 1
points to the outside. Thus the
influence of the brake magnets on
the tool is avoided.
Press the dies out of the bore
manually with the die ejector (1).

Illustration 191: Die ejector

Notice:
If the dies should be jammed during removal, proceed as follows:

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Tool

04-006
Put the cap (1) for the die ejector
(supplies) onto the swivel head of
the ejection cylinder.

Illustration 192: Cap for die ejector

04-003
Secure the cap for the die ejector
with a pin (1) of the ejection bar.

Illustration 193: Securing the cap for the die ejector 04-004

Insert the die ejector (1) (supplies)

into the punch bore from below.
Insert the die ejector (1) into the
punch bore so that the flat side
points to the outside. Thus the
influence of the brake magnets on
1
the tool is avoided.
Put the movable lower part of the
die ejector down on the cap.

Illustration 194: Die ejector in punch bore

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Tool

Notice:
The die ejector must be positioned on centre over the ejection
cylinder.

Actuate the key (1) on the intermediate

bottom. By doing so, the die is pressed
out of the die table by the ejection
cylinder.
Remove the die and the die ejector.

04-086
Illustration 195: Key die ejector

For turning the die table use the

manual button (supplies).
Connect the manual button (the
connection is located behind the
right machine door).

04-087
Illustration 196: Connecting the manual button

Warning
Risk of injury!
Hazard through bruising of body parts. By actuating the manual
button the die table starts moving slowly. There is a risk of severe
injuries of body parts through the upward and downward
movement of the punches.
Ø The operator must close all other doors and windows prior to
actuating the manual button. During the entire procedure it
must be guaranteed that no other person may be injured in
the compression chamber and/or in the machine
compartment.

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Tool

Turn the die table slowly by pressing

the button until the next punch position
is reached and thus successively
remove all of the dies.

04-088
Illustration 197: Actuation of the manual button

Fitting
Prior to fitting the die carefully clean
the bore (2) in the die table with the
cleaning scraper (1) (supplies). 1
2

01-452
Illustration 198: Cleaning the die bore

Clean the die with a cleaning agent

and a soft cloth.

00-050
Illustration 199: Die

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Tool

CAUTION
Dimension tolerances of the grooves at the dies with
different tool sets.
Thus the die can move (in case of too large tolerances) and may
be pushed out of the bore by the lower punch. This would result in
damage to the fillshoe and to the scrapers.
Ø Use dies of one set only! In case of several sets there is the
risk that the dimensions of the groove for the fixing screws
vary.

Place the die (2) in the bore of the

die table. Ensure that the die is not
tilted. 1
Insert the die fitting tool (1)
(supplies) through the upper punch 2
bore.

01-452
Illustration 200: Fitting the die

Using the torque wrench (1)

(supplies), loosen the fixing screws
of the dies so far that the dies fit
into the bores without tilting.
Beat in the die carefully into the 2
bore using the die fitting tool (2)
until the upper edge of the die is
level with the upper edge of the die
plate. Do not tilt the die!
Fit all dies.

01-454
Illustration 201: Die screws

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Tool

Check with the straight-edge (1)

(supplies) whether all dies are fitted
level with the upper edge of the die
plate.

01-455
Illustration 202: Check with the straight-edge

Retighten the die fixing screws only

with the torque wrench (supplies).
The required torque for the die
fixing screws is 10 Nm.

00-051
Illustration 203: Torque wrench < 10 kN

CAUTION
If the die fixing screws are not tightened with the torque
wrench, dies and die table will be damaged!
The die fixing screws may not protrude from the die table!

è Fix the suction as described in section Suction.

Notice:
Check the die fixing screws weekly for tightness.

Final work
è Tilt the ejection cam upwards and fit the ejection bar between ejection cam and
ejection cylinder (see page 275).
è Insert the dismantled lower punches in the punch bore of the die table.
è Rotate the die table carefully using the manual button until the lower punch is
guided into the pull-down cam. Fit all lower punches. (see section "Lower punch",
page 207).
è Fit the dismantling station of the lower cam track again. (see page 274).
è Reinsert the tablet chutes (see section "Tablet chute", page 252).

216 / 409 007.2/SYN7ZS/BA/en

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Tool

10.4.8 Filling tube

Structure

04-130
Illustration 204: Filling tube

 Rubber ring

 Cable connection box

 Light barrier sensor

 Light barrier sensor

 Hopper housing

 Butterfly valve

 Clamp

 Sliding sleeve

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Tool

Removal
è Close the product feed and discharge the filling tube.
è Cut the connection to the product feed from the filling tube above at the head
piece.

Manually discharge the filling tube and the fillshoe.

è Empty the fillshoe and the filling tube. For doing this please refer to page 220 and
following.

CAUTION
Rotating parts in the fillshoe housing!
There is the risk of personal injury and damage to property
through rotating parts!
Ø Do not reach into the fillshoe through the chute and do not
insert any objects.

Remove the sliding sleeve between

filling tube and fillshoe.

04-083
Illustration 205: Sliding sleeve

Detach the six fixing screws (1) of the

filling tube above at the head piece.
Carefully remove the filling tube to the
top. Pay attention that the butterfly
valve is closed and that the lever is 1
properly positioned in the repository.

03-088
Illustration 206: Fixing srews of the filling tube

CAUTION!
Mind the weight of the filling tube!
Empty weight approx. 7 kg.

218 / 409 007.2/SYN7ZS/BA/en

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Tool

Fitting
Notice:
Pay attention that the butterfly valve is closed and that the lever is
properly positioned in the repository.

è Carefully insert the filling tube from the top into the head piece.
è Fitting is effected in reversed sequence.

Cleaning the filling tube

è Cleaning the filling tube should not only be done in case of a product change, but
also in case of longer standstill periods.
è Cleaning can be performed with a steam jet or in a dip tank when the filling tube
has been dismantled.
è Dry the filling tube after each manual wet cleaning prior to refilling it with any
product.

Notice:
Moisture affects the flow properties of the product.

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Fillshoe

10.5 Fillshoe
Structure

1
1
2

2 4

04-085
Illustration 207: Fillshoe

 Drive shafts of the agitator wheels

 Star grip screw, large (for fillshoe removal)

 Star grip screw, small (for dismantling the fillshoe)

 Sliding sleeve

Removal
Notice:
If the fillshoe and the filling tube should already be empty, continue
with item Removing the sliding sleeve on page 221.

Notice:
If the machine cannot be opened for emptying, fillshoe and filling
tube can also be emptied by producing tablets. For this the product
supply must be closed.

CAUTION
Rotating parts in the fillshoe housing!
There is the risk of personal injury and damage to property
through rotating parts!
Ø Do not reach into the fillshoe through the chute and do not
insert any objects.

220 / 409 007.2/SYN7ZS/BA/en

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Fillshoe

Open the right window.

Close the butterfly valve at the filling
tube. Place a container underneath the
fillshoe chute (1) of the fillshoe base or
hold a suction hose under the opening.
Pull the slide of the fillshoe base to the
front.

1
04-019
Illustration 208: Pulling out the slide of the fillshoe base

Discharge the fillshoe manually.

è At the operating terminal, activate "Fillshoe" in menu:
Tabletting – Manual.
Ø By activating the function "Fillshoe" the agitator wheel drive is switched on.
þ Thus the fillshoe can be run empty manually. Vacuum-clean the product residues.

Notice:
After emptying the fillshoe the fillshoe drive must be switched off
again. On the operating terminal deactivate the function
"Fillshoe" in menu:
Tabletting – Manual.

04-007
Set the knurled screw (1) of the
product scraper with the arrow tip
pointing upwards, so that the scraper
is lifted and does not damage the die
table when the fillshoe is being
removed.

Illustration 209: Height adjustment of the scraper

Push the sleeve upwards.

04-048
Illustration 210: Loosening the sliding sleeve

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Fillshoe

Push the coupling sleeves (1) of the

two fillshoe drives (left and right of the 1
filling tube) upwards.
Position the upper coupling part behind
or beside the lower one, in order not to
damage the couplings when removing
the fillshoe.

04-051
Illustration 211: Drive clutch left

00-104
Illustration 212: Drive clutch of force feed fillshoe

 Drive shaft

 Coupling sleeve

 Agitator wheel shaft

 Safety bolt

222 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Notice:
The plug-in safety bolts securing the agitator wheel shafts must not
yet be detached. Otherwise the agitator wheels would drop down
into the fillshoe housing when removing the fillshoe.

Loosen the two large star grip screws

(1) front left and back right beside the
filling tube.

04-008
Illustration 213: Loosening the star grip screws (large)

Lift the fillshoe slightly and remove it to

the front.

04-067
Illustration 214: Removing the fillshoe

CAUTION
Mind the weight of the fillshoe (approx. 8.5 kg).

007.2/SYN7ZS/BA/en 223 / 409

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Fitting
Position the fillshoe in the press.

Illustration 215: Positioning the fillshoe

Tighten the two large star grip screws.

04-008
Illustration 216: Tightening the fillshoe

Push the two coupling sleeves

upwards and connect the drive shafts
to the agitator wheel shafts. Push the
coupling sleeves over the clutches.

01-209
Illustration 217: Clutch of fillshoe drive

224 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Set the knurled screw of the product

scraper with the arrow tip pointing
downwards so that the product scraper
is lowered.

04-084
Illustration 218: Height adjustment of the scraper

Move the sliding sleeve of the filling

tube back over the base at the fillshoe.

04-083
Illustration 219: Connection filling tube / fillshoe

Cleaning

CAUTION!
Hazard through product residues inside the machine.
Health detriment through side effects of the previously pressed
material.
Ø Thorough pre-cleaning must be carried out prior to opening
the machine. Ask the respective responsible person of the
operating company.

Notice:
Do not only clean the force feed fillshoe in case of product change
(manually or automatically), but also manually in case of longer
standstill times.

007.2/SYN7ZS/BA/en 225 / 409

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

For cleaning, the force feed fillshoe must be removed and dismantled:

Position the dismantled fillshoe with

1
the star grips pointing upwards.
Loosen the two small star grip screws
(1) and lift the upper part of the fillshoe
from the fillshoe housing. Deposit it
carefully.

01-438
Illustration 220: Fillshoe

Remove the plug-in safety bolts of the

agitator wheels.

01-434
Illustration 221: Safety bolts of agitator wheels

Remove the agitator wheels (1) with

the wheel shafts from the bearing
pedestals (2).

1 2

01-435
Illustration 222: Removing the agitator wheels

è Vacuum the product residues and clean the fillshoe. The housing of the fillshoe
can be completely cleaned in a dip tank.
è Dry the fillshoe after each wet cleaning prior to its reassembly. Moisture affects
the flow properties of the product.

226 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Fitting
è Fit the agitator wheels with the wheel shafts in the bearing pedestals.

Ensure that the drive pin (2) engages

properly in the corresponding bore (1) 2
at the agitator wheel.

01-436
Illustration 223: Drive pin

Secure the agitator wheels with the

safety bolts. Ensure that the balls in
the safety bolt fit into the
corresponding base.
The screw (1) must not be adjusted. Is
is set by the manufacturer.

01-437
Illustration 224: Correct position of the safety bolts

Check the mobility of the agitator

1
wheels (1). For this turn the agitator
wheels in both directions to check the
mobility and thus the function of the
agitator wheels.

01-557
Illustration 225: Agitator wheels

007.2/SYN7ZS/BA/en 227 / 409

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Synthesis 700ZS Service
Fillshoe

Check the mobility and the function of

the pressure springs at the product
scraper. For this push on the product
scrapers to check the mobility of the
product scrapers and thus the function
of the pressure springs.

01-456
Illustration 226: Lower surface of fillshoe housing with
product scraper

Notice:
If the mobility of the product scrapers is not guaranteed, these
must be dismantled, cleand, and possibly replaced.

Screw the cleaned upper part of the

fillshoe and the housing together again.

01-440
Illustration 227: Fillshoe housing/upper part of the
fillshoe

228 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Fillshoe

10.5.1 Replacing the sealing segment

4
1
5

4
2
3

01-229
Illustration 228: Fillshoe housing with sealing segment

 Sealing segment

 Fillshoe housing

 Eccentric adjustment for product scraper

 Product scrapers

 Pressure springs

Note:
Replace the product scrapers if major scoring on the surface is
discernible.

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Replacement of product scrapers (magnetic)

è Remove the fillshoe (see section Fillshoe removal).
è Place the fillshoe with the star grips pointing upwards.

Remove the old segment (1) and clean

the fillshoe housing in this area.
Install the new sealing segment (is
fixing throgh Magnets). Observe to the
right position of the alignment pins of
the sealing segment in the fillshoe
case. 1

01-516
Illustration 229: Sealing segment (magnetic)

10.5.2 Replacing the product scraper

Replace the product scrapers if the surface shows major scoring or if the
product is no longer scraped.
è Removal and dismantling of the fillshoe.

Unscrew the fixing screw (Allen screw)

of the eccentric shaft. It must not be
removed completely.

Illustration 230: Fixing screw of eccentric shaft

230 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Pull the eccentric shaft out of the

fillshoe housing.
Remove the used product scrapers
and replace them. 1

01-432
Illustration 231: Product scraper

Mind the pressure springs (1) of the

product scrapers. 1

01-433
Illustration 232: Pressure springs of product scraper

è Fitting is effected in reversed sequence!

007.2/SYN7ZS/BA/en 231 / 409

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

10.5.3 Fillshoe base

Structure

4 3

04-090
Illustration 233: Fillshoe base

 Fillshoe base

 Fillshoe support

 Slide

 Fillshoe chute

232 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Fillshoe

Swinging out the fillshoe base

To swing out the fillshoe base the following work must be done in advance:
è Fillshoe removal (see section "Fillshoe", page 220).
è Removing the covering segment with the product scraper (see section "Covering
segment with product scraper", page 262).

Detach the locking screw (1) of the

fillshoe base.

04-068
Illustration 234: Detaching the fillshoe base

Swing the fillshoe base away from the

die table.
When you swing the fillshoe base back
towards the die table again, the locking
screw must then be firmly retightened.

04-069
Illustration 235: Swinging out the fillshoe base

Cleaning the fillshoe base

è Clean the fillshoe base in case of soiling and when changing the die table.

Two-part fillshoe base

Notice:
The right fillshoe base is two-part; the fillshoe base plate must be
removed for fitting / removal of the die table.

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Fillshoe

Structure

00-105
Illustration 236: Two-part fillshoe base

 Fixing screws

 Fillshoe base

 Fillshoe baseplate

Removal
• Remove the fixing screws (1) of the fillshoe baseplate (3). The screws an be
detached at the fillshoe base (2).
• Lift the fillshoe baseplate out.

Fitting
• Fitting is effected in reversed sequence.

234 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Aligning the fillshoe base

1 2 3 5 6
7

4
A 8

4
10
Illustration 237: Align fillshoe base

1 Die plate 6 Cover

2 Straight-edge 7 Pivot 1
3 Fillshoe base 8 Adjusting screw, turn around pivot 2
4 Clamping screws for the parallel 9 Adjusting screw, turn around pivot 1
adjustment
5 Adjusting screw parallel adjustment 10 Pivot 2

Note:
The fillshoe base must only be aligned parallel in height. The
adjustment around the pivots (7 or 10) is made in the
manufacturer's plant.
The air gap (A) between the upper edge of the fillshoe base (3) and
the die plate (1) must be equal in the whole area.
The air gap shall correspond to approx. 0.05 mm.

Caution
The die table must not be moved while the fillshoe base is
adjusted.

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Basic setting
è Remove the fillshoe and the covering segment with product scraper.
è Remove the cover.
è Detach the clamping screws for parallel adjustment (only slightly, do not remove
them).
è Set the height adjustment of the fillshoe base via the adjustment screw parallel
adjustment
è The upper edge of the fillshoe base and the die table must be flush.
è Check this level with a straight-edge (supplies) at a minimum of 3 points

Note:
The fillshoe base must be aligned parallel to the die plate!

Fine adjustment
è Turn the adjustment screw parallel adjustment to increase or decrease the air gap
between fillshoe base and die table a bit.
è Measure the air gap between straight-edge and die table along the entire range of
the fillshoe base with a feeler gauge (supplies).
è Tighten the clamping screws for parallel adjustment.
è Install the fillshoe and verify by manually turning the die table that the fillshoe does
notcontact the die plate.

Note:
If the air gap in the area of the sealing segment is considerably
uneven, check the wear of the sealing segment!
The optimum air gap is dependent on the product applied. If the air
gap is too small, the die table will be damaged; if it is too large, this
will result in high product losses.

236 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

10.5.4 Suction unit

Structure

Illustration 238: Ring suction

1 Star grip screw 4 Fixing clamp

2 Suction nozzle 5 Cover plate (front and rear)
3 Connecting with suction hose - --

Notice:
Removal is done in a similar way for both sides (front and rear).

Detach the star grip screw (1) at the

product scraper behind the fillshoe and
remove the product scraper. 1

04-183
Illustration 239: Removing the product scraper behind
the fillshoe

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Operating Instruction
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Fillshoe

Detach the hose piping (1) and, if

04-184
required, (2). .

1 2

Illustration 240: Detaching the hose piping

Detach the star grip screw (1) and

04-185
swing the suction nozzle away from
the die table.

Illustration 241: Swinging away the suction nozzle

Pull out the suction nozzle upwards

04-186
and take it out.

Illustration 242: Taking the suction nozzle out

Detach the fixing clamps (1).

1

04-017
Illustration 243: Fixing screws of the cover plate

238 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Fillshoe

Remove the cover plate.

04-018
Illustration 244: Taking out the cover plate

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Operating Instruction
Synthesis 700ZS Service
Cover

10.6 Cover
Structure

04-026
Illustration 245: Cover

 Cover plate, front

 Star grip screws for fixing the rear cover plate

 Cover plate, rear

 Catch

 Star grip screws for fixing the front cover plate

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Operating Instruction
Synthesis 700ZS Service
Cover

Removal
Notice:
Removal is done in a similar way for the front and the rear part of
the cover.

Remove the fillshoe. For this purpose

detach the sliding sleeve of the
fillshoe. Loosen the drive (1) and the
star grip screw (2). Lift the fillshoe out.
1
(see section "Fillshoe", page 220).

04-050
Illustration 246: Dismantling the fillshoe

Open the spring catch (2), detach the

star grip screws (1) and lift the front 1 2
cover plates out.

04-053
Illustration 247: Removal of the cover

Fitting
• Fitting is effected in reversed sequence.

Cleaning
At product change and after longer standstill periods.
• Cleaning can be performed with a steam jet or in a dip tank.

007.2/SYN7ZS/BA/en 241 / 409

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Synthesis 700ZS Service
Support arm

10.7 Support arm

Swivel arm for the tablet scraper
Tablet chute and tablet scraper are both mounted on one swivel arm.

Notice:
The vertical position of the swivel arm is factory-set and does not
generally require correction. The distance of the tablet scraper to
the die table should be 0.5 mm.

If the tablets are not scraped trouble-free, the vertical position of the swivel arm
may be corrected:
• For extremely thin tablets, the distance of the tablet scraper to the die table must
be below 0.5 mm.
• For strongly concave tablets, the distance must if necessary be above 0.5 mm.

CAUTION
Tool break by tablet scraper.
The die table, dies or lower punches may be damaged!
Ø Thoroughly check that the tablet scraper does not touch the
die table at any point.

04-027
Illustration 248: Aligning the swivel arm

 Fixing screw of the swivel arm

 Cover

 Clamping lever of swivel arm

 Fixing screw cover

 Eccentric screw

242 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Support arm

Detach the fixing screw of the cover

with a 3 mm Allen key (1) and remove
the cover plate.

04-079
Illustration 249: Detaching the fixing screw

Detach the fixing screws (1) of the

swivel arm.

04-081
Illustration 250: Fixing screws of the swivel arm

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Support arm

Align the swivel arm so that a gap of

about 0.8 mm remains between the
scraper and the die table. Check the
distance with a feeler gauge
(supplies).

00-006
Illustration 251: Feeler gauge

Connect the manual button and turn

the die table carefully by jogging to
ensure that the tablet scraper does not
touch the die table at any point.

04-088
Illustration 252: Actuating the manual button

Warning
Risk of injury!
By actuating the manual button the die table starts moving slowly.
Risk of severe injuries through the upward and downward
movement of the punches!
Ø The operator must close all other doors and windows prior to
actuating the manual button. During the entire procedure it
must be guaranteed that no other person may be injured in
the compression chamber and/or in the machine
compartment.

244 / 409 007.2/SYN7ZS/BA/en

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Support arm

Retighten the fixing screws (1) of the

swivel arm.

04-081
Illustration 253: Fixing screws of the swivel arm

Put on the cover and tighten the fixing

screws with the Allen key (1).

04-079
Illustration 254: Tightening the fixing screw

Counter-check the distance of the

tablet scraper and realign it, if
required, until the distance is approx.
0.5 – 0.7 mm.

00-006
Illustration 255: Feeler gauge

Check whether the tablets are being scraped correctly with the new setting.

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Operating Instruction
Synthesis 700ZS Service
Tablet scraper

10.8 Tablet scraper

Structure
• The tablet scraper is mounted on the swivelling tablet chute.

01-726
Illustration 256: Swivel arm with tablet scraper

 Tablet scraper

 Clamping lever of the tablet scraper

 Cover

246 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Tablet scraper

Removal
Detach the clamping lever of the swivel
arm (1).

04-022
Illustration 257: Clamping lever of swivel arm

Swing out the tablet chute.

Illustration 258: Swivel arm with tablet chute and

scraper

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Operating Instruction
Synthesis 700ZS Service
Tablet scraper

Detach the clamping levers (1) of the

tablet scraper and remove the cover. 1
The plugs and connections for the
solenoid valve and the compressed air
are situated under the cover.

04-047
Illustration 259: Detaching the cover

Pull the plug off the connection for the

compressed air (1) and off the
connection for the solenoid valve (2) 1 2
and close it with the protective lid.

04-042
Illustration 260: Connections for compressed air and
solenoid valve

Remove the complete tablet scraper.

04-043

Illustration 261: Tablet scraper

248 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Tablet scraper

Re-fix the cover over the connections

and close them completely by pushing
the protective lid (1) up.

04-044
Illustration 262: Closing the cover

Fitting
• Fitting is effected in reversed sequence.

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Operating Instruction
Synthesis 700ZS Service
Tablet scraper

Adjustment of the tablet scraper

Notice:
• Correct the adjustment of the tablet scraper only when
changing the tools, if the tablet diameter and/or the tablet shape
have changed considerably.
• The tablet scraper must be set in such a way that the tablets do
not jump but enter the tablet chute on an orderly path.

01-727
Illustration 263: Tablet scraper

 Locking plate

 Fixing screw

 Solenoid valve connection

 Compressed-air connection

 Bore for blowing out individual tablets

 Guide channel for reject tablets

250 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
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Tablet scraper

Caution
The tablet scraper may not contact the die table; otherwise
the die table or the lower punches are damaged!

Vertical positioning
è The vertical position is factory-set and does not require correction. The vertical
distance to the die table should be 0.5 mm.

Caution
For extremely thin tablets, the distance to the die table must
be below 0.5 mm, if required. In this case thoroughly check
that the tablet scraper does not touch the die table at any
point. Otherwise the die table, dies or lower punches are
damaged!

Change of tablet diameter

If various dies with different tablet diameters are used, the tablet scraper must
be adapted accordingly.
• Remove the tablet scraper.
• Detach the fixing screw and turn the locking plate. With the standard version the
following ranges of tablet diameters can be set:
- 5 – 6 mm
- 7 – 9 mm
- 10 – 12 mm
- 13 – 17 mm
• Retighten the fixing screw.

Notice:
If other tablet diameters are applied, please contact KILIAN
Customer Service.

Cleaning
• Clean the tablet scraper at product change, after longer standstill periods and in
case of heavy soiling.
• Ensure that the bores for blowing out individual tablets are always open.

Notice:
Do not clean the tablet scraper with individual ejection by blow-out
in a dip tank.

007.2/SYN7ZS/BA/en 251 / 409

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Operating Instruction
Synthesis 700ZS Service
Tablet chute

10.9 Tablet chute

10.9.1 Tablet chute (tablet diameter ≤ 20 mm)
Structure

04-028
Illustration 264: Tablet chute (tablet diameter ≤ 20 mm)

 Locking screws of cover

 Outlet for good tablets

 Outlet for reject tablets

 Outlet for sample tablets

 Gates

 Rotary magnets for the gates

 Initiator tablet jam monitoring

 Wing screw

252 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Tablet chute

Removal
Notice:
The tablet chute has a weight of approx. 4.5 kg.

Detach the clamping lever (1) of the

tablet chute.

04-022
Illustration 265: Clamping lever of the tablet chute

Swing out the swivel arm.

After swinging the tablet chute back
towards the die table tighten the
clamping lever again.

04-023
Illustration 266: Swinging out the swivel arm with the
tablet chute

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Synthesis 700ZS Service
Tablet chute

Detach the cable connection (1) and

the compressed-air connection (2) and
remove the tablet scraper (for this see
also page 248).

2
04-033
Illustration 267: Tablet scraper, view from below

Remove the cover by detaching the

screws (1). 1

04-041
Illustration 268: Tablet chute cover

Pull out the gates (1) straight upwards.

1

04-039
Illustration 269: Sampling gate and main gate

254 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Tablet chute

Detach the wing screw (1) of the tablet

chute base.

04-035
Illustration 270: Tablet chute

Take out the tablet chute by lifting it

straight upwards.

04-036
Illustration 271: Removing the tablet chute

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Operating Instruction
Synthesis 700ZS Service
Tablet chute

Fitting
Clean the tappets (1) of the rotary
magnets prior to fitting. 1

04-037
Illustration 272: Tablet chute base

Put the tablet chute onto the tappets

from the top.

04-038
Illustration 273: Tablet chute

Fix the tablet chute using the wing

screw.

04-035
Illustration 274: Fixing the tablet chute

256 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Tablet chute

Put the gates on the tappets of the

rotary magnets. The gates must click 1
into place.

04-034
Illustration 275: Sampling gate and main gate

Mount the cover and screw it tight (1).

1

04-041
Illustration 276: Cover tablet chute

Cleaning
Clean the tablet chute at product change, after longer standstill periods and in case of
heavy soiling.

Caution
Risk of short circuits
The electrical components, in particular the rotary magnets, may
not be wet-cleaned!
Ø To wet-clean the tablet chute remove the back-up control. Do
not clean the cover with abrasive detergent.

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Operating Instruction
Synthesis 700ZS Service
Tablet chute

10.9.2 Tablet chute (tablet diameter > 20 mm)

Structure

04-029

Illustration 277: Tablet chute (tablet diameter > 20 mm)

 Locking screws of cover

 Outlet for good tablets

 Outlet for reject tablets

 Gate

 Rotary magnet for the gate

 Initiator tablet jam monitoring

 Wing screw

258 / 409 007.2/SYN7ZS/BA/en

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Operating Instruction
Synthesis 700ZS Service
Tablet chute

Removal
Notice:
The tablet chute has a weight of approx. 4.5 kg.

Notice:
Removal is done in the same way as for the chute ≤ 20 mm with the
exception that only one gate must be removed.

Fitting
Notice:
Fitting is done in the same way as for the chute ≤ 20 mm with the
exception that only one gate must be fitted.

Cleaning
Clean the tablet chute at product change, after longer standstill periods and in case of
heavy soiling.

Caution
Risk of short circuits
The electrical components, in particular the rotary magnets, may
not be wet-cleaned!
Ø To wet-clean the tablet chute remove the back-up control. Do
not clean the cover with abrasive detergent.

Removal
• Detach the fixing screw (5) and lift the good channel without sampling unit off the
guide pin.

Fitting
• Put the good channel with sampling unit on the guide pin and tighten the fixing
screw.
• Plug the plug for the activation of the gate into the female plug at the machine
door below the tablet chute.

Notice:
When you have changed the tablet chute or attached the good
channel with sampling unit, you must load the new machine data
record in mask "System > Machine" and reboot the tablet press.

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Synthesis 700ZS Service
Tablet chute

10.9.3 Supplementary parts for sampling unit from the good channel

Notice:
For tablet diameters > 20mm: If the tablet press was ordered
without the connection for the gate control, it can be retrofitted by
an IMA KILIAN service technician.

1
5

3 04-030
Illustration 278: Supplementary parts for sampling unit from the good channel

 Gate for sampling unit from good channel

 Activation of the gate

 Channel for sampling unit

 Good channel

 Fixing screw

260 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Tablet chute

Removal
• Detach the fixing screw (5) and lift the good channel without sampling unit off the
guide pin.

Fitting
• Put the good channel with sampling unit on the guide pin and tighten the fixing
screw.
• Plug the plug for the activation of the gate into the female plug at the machine
door below the tablet chute.

Notice:
When you have changed the tablet chute or attached the good
channel with sampling unit, you must load the new machine data
record in mask "System > Machine" and reboot the tablet press.

Re-starting the tablet press

When loading configuration or machine data records the tablet press must be
re-started in order to activate the data record.
• Select mask System > Machine and perform a system shutdown using the key
"Finish ViCon".
• Switch the tablet press off with the main switch and wait for a few seconds.
• Switch the tablet press on again with the main switch.

The new settings have now been adopted.

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Covering segment with product scraper

10.10 Covering segment with product scraper

04-031
Illustration 279: Covering segment with product scraper

 Product scraper

 Star grip

 Fixing screws of product scraper

 Covering segment

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Covering segment with product scraper

Removal
è Remove the suction (see section Suction).

Detach the star grip (1) on the covering

segment. 1

04-055
Illustration 280: Detaching the covering segment

Remove the complete covering

segment.

04-057
Illustration 281: Covering segment with product
scraper

Fitting
Put the covering segment onto the
fillshoe base.

Illustration 282: Covering segment

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Covering segment with product scraper

Check the covering segment for

correct fit and tighten the star grip (1) 1
to manual tightness.

04-055
Illustration 283: Tightening the star grip

è Reinsert the suction (see section Suction).

Cleaning
• Clean the covering segment at
product change, after longer
1
standstill periods and in case of
heavy soiling.
• Detach the fixing screws (1) of the
product scraper and remove the
product scraper.
• Clean the covering segment and
the product scraper.
• Re-fit the product scraper and
tighten the fixing screws (1).
04-059
Illustration 284: Product scraper

Notice:
Check the covering segment for wear at regular intervals. The
covering segment should be replaced if the surface shows major
scoring.

Replacement of the product scraper

• Detach the fixing screws of the product scraper.
• Remove the product scraper and replace it.
• Retighten the fixing screws.

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Punch guide

10.11 Punch guide

10.11.1 Upper cam track
Structure

8 10 9 1
6
3
4
7
5

5
7
4
8
2
6
1 10
3 9 03-054
Illustration 285: Upper punch guide (cam track)

1 Fixing screws of push-down segment 6 Fixing screws of ejection segment

2 WSG sensor (upper punch tightness) 7 Lubrication unit
3 Push-down segment 8 Ejection segment
4 Dismantling piece 9 Intermediate piece below the pressure roller
5 Star grip 10 Fixing screws of intermediate piece

Cleaning
Clean the upper cam track in case of heavy soiling and punch tightness, at tool
change and oil change.
The work described below must be carried out prior to cleaning or replacement
of the individual cam track components:
è Dismantle the die table cover. (see section "Cover", page 240).
è Tilt out the upper pressure roller block. (see section "Upper pressure roller block",
page 285).

Notice:
Removal is done in a similar way for both sides (front and rear).

007.2/SYN7ZS/BA/en 265 / 409

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Punch guide

Detach the star grip screw (1), open

the spring catch (2) and lift the front 1 2
cover plates out.

04-053
Illustration 286: Removal of the cover

Detach the star grip screw and remove

the dismantling piece by lifting.
Remove all upper punches. (see
section "Upper punch", page 205).

04-071
Illustration 287: Dismantling station

Loosen the retaining screws (1) in the

pressure roller block with the large
1
torque wrench (supplies). Use the
removal aid from the accessories if
necessary.

04-113
Illustration 288: Detaching the retaining screws

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Punch guide

Turn the retaining screws (1) until they

are hanging loose in their guide.

04-109
Illustration 289: Retaining screws

Pull the centering bolt.

04-110
Illustration 290: Centering bolt

Swing the pressure roller block some

way outward so that you are able to 1
detach the lock coupling of the
lubrication line (1) and the measuring
cable of the WSG sensor (upper 2 1
punch tightness) (2).

2
01-320
Illustration 291: Lock coupling for connections of
pressure roller block

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Punch guide

Swing the pressure roller block out.

04-111
Illustration 292: Swinging the pressure roller block out

Clean the internal surfaces of the cam

track.
Lubricate the internal surfaces lightly.
Use Klüberpharma UH1 4-200 for this.
Also pay attention to the lubricants list
in chapter Technical data

04-121
Illustration 293: Cleaning of cam track

Notice:
When using cleaning agents please also observe the customer
information "Cleaning instructions".

CAUTION
Protect the WSG sensor (upper punch tightness) against
moisture!

268 / 409 007.2/SYN7ZS/BA/en

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Punch guide

[Link] Push-down segment

Notice:
Replace the push-down segments in case of wear. Prior to removal,
the cover of the die table must be dismantled.

Removal
The following work must be carried out prior to replacing the individual cam
track components:
è Dismantle the die table cover. (see section "Cover", page 240).
è Tilt out the upper pressure roller block. (see section "Upper pressure roller block",
page 285).

Unscrew the WSG sensor for

upper punch tightness. For doing
this loosen the 2 Allen screws (M
5) (1) directly at the WSG
sensor. The sensor can be
removed to the top.
Put the WSG sensor aside. Mind
the connecting cable!

04-125
Illustration 294: Removal of WSG sensor

Detach the fixing screws (1) of

the [Link] segments.
Remove the push-down
segments by lifting them
upwards.

04-124
Illustration 295: Push-down segment of die table

Fitting
è Fitting is effected in reversed sequence.

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Punch guide

WSG sensor structure

1
A A-A
2

3 A 01-264

Illustration 296: WSG sensor upper punch tightness

The upper punch tightness is measured with a wire strain gauge (3). The upper punch
is pressed down approx. 1 mm by a sliding gear (2) in the area of the dismantling
piece. During this process, the measuring system records the force needed to do this
over the incised area (1) of the mounting plate. The springs in the four fixing points
serve as overload protection.

Notice:
A mechanical adjustment of the WSG unit for upper punch
tightness is not necessary.

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Punch guide

[Link] Ejection segment

Notice:
Replace the ejection segments in case of wear. When replacing the
ejection segments the connections of the lubrication units must be
disconnected and plugged on the new ejection segments.

Removal
The following work must be carried out prior to replacing the individual cam
track components:
è Dismantle the die table cover. (see section "Cover", page 240).
è Tilt out the upper pressure roller block. (see section "Upper pressure roller block",
page 285).

Disconnect the connections of the

lubrication units (1).

04-122
Illustration 297: Connections of lubrication units

Detach the fixing screws (1) of the

ejection segments.
Remove the ejection segments by
lifting them upwards.

04-123
Illustration 298: Fixing screws of the ejection segments

Fitting
è Fitting is effected in reversed sequence.
è Reconnect the connections of the lubrication units.

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Punch guide

[Link] Intermediate piece

Notice:
Replace the intermediate pieces in case of wear only.

Removal
The following work must be carried out prior to replacing the individual cam
track components:
è Dismantle the die table cover. (see section "Cover", page 240).
è Tilt out the upper pressure roller block. (see section "Upper pressure roller block",
page 285).

Detach the fixing screws (1) of the

intermediate pieces.
Remove the intermediate pieces by
lifting them upwards.

04-127
Illustration 299: Fixing screws of the intermediate
pieces

Fitting
è Fitting is effected in reversed sequence.

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Punch guide

10.11.2 Lower cam track

Structure

2 1
2
12
11 3
10 4
9
6
8

7
8

6
9
4 10
11
3 12
2 2
1 03-055
Illustration 300: Lower punch guide (cam track)

1 Intermediate piece for pressure roller block 7 Pull-down cam

pre-pressure
2 Pressure roller 8 Safety cam for dismantling station
3 Link track 9 Catch cam for ejection cam
4 Control cam 10 Pin for catch cam
5 Dosing cam 11 Ejection cam
6 Catch cam for dosing cam 12 Ejection roller for separating the tablets

Cleaning / lubrication
Clean the lower cam track in case of heavy soiling and punch tightness, at tool
change and oil change.
Cleaning and lubrication should also take place in any case after dismantling
the die table. Here, the access to all lubrication points is much easier.
è Dismantle the die table, as described in section Die table removal / fitting

007.2/SYN7ZS/BA/en 273 / 409

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Punch guide

Clean the internal surfaces of the cam

track with a non-fuzzing cloth.
Lubricate the internal surfaces lightly.
Use for this: Klüberpharma UH1 4-220;
(see lubricants list in section Technical
data).

04-126
Illustration 301: Lower cam track with dismantled die
table

Note:
When using cleaning agents please also observe the customer
information "Cleaning instructions".

[Link] Oscillating ejection crank

Removal
Notice:
Replace the ejection cam in case of wear.

Open the left machine compartment

door and remove the dismantling
station of the lower punches.

01-383
Illustration 302: Dismantling station lower punches

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Punch guide

Remove the connecting bolts (1) by

pressing the center pins.
Remove the ejection bar (2) between
ejection cam (4) and ejection cylinder
(3).
1

2
4
1

04-011
Illustration 303: Ejection bar

Take the ejection cam and the die

ejection unit off.

01-404
Illustration 304: Ejection unit

Unscrew the fixing screw (1) (Allen

screw).

01-482
Illustration 305: Fixing screw of the ejection cam

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Punch guide

Push the shaft (1) of the ejection cam

out to the front and remove the
ejection cam. 1

01-483
Illustration 306: Ejection cam shaft

Fitting
è Fitting is effected in reversed sequence.

Setting the ejection cam

Detach the counter nuts (1) and (2) on
the pressure cylinder.

01-466
Illustration 307: Setting the ejection unit

276 / 409 007.2/SYN7ZS/BA/en

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Punch guide

Detach the counter nut on the ejection

bar and loosen the stud screw (1).

01-509
Illustration 308: Ejection unit setting screw

Adjust the ejection cam via the

adjusting nut (1) in such a way that the
lower punch protrudes approx. 0.3 mm
from the die.
Retighten the counter nut.

01-511
Illustration 309: Setting the ejection unit

Retighten the stud screw (1) and

retighten the counter nut on the
ejection bar.

01-509
Illustration 310: Ejection unit setting screw

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Punch guide

[Link] Pull-down cam

Note:
• Replace the pull-down cam in case of wear or if this is required
by a change of the fill range.
• Fit a pull-down cam providing a dosing of at least 2 mm above
the average range of the filling you require.

The tablet press is equipped with a pull-down cam featuring one of the fill
ranges:
• 0.5 to 8 mm (medium range = 2.5 – 6 mm)
• 4.5 to 12 mm (medium range = 6.5 – 10 mm)
• 8.5 to 16 mm (medium range = 10.5 – 14 mm)
• 10.5 to 18 mm (medium range = 12.5 – 16 mm)
• 12.5 to 20 mm (medium range = 14.5 – 18 mm)
(not for tools EU-B and IPT-B)

Note:
• For optimising tablet production, the fill depth should be in the
medium range of the pull-down cam.
• If the fill depth reaches the adjusting limit of the pull-down cam,
fit another pull-down cam in compliance with the fill depth
required.
• The pull-down cam is equipped with an electronic identification
of the model installed.

Removal
Open the left machine compartment
door and dismantle the dismantling
station.

01-383
Illustration 311: Dismantling station lower punches

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Punch guide

Detach the front and rear quick-

release locks of the lubrication (6). 3 4 5 6
Detach the fixing screws (2) of the pull-
down cam.
Loosen the adjusting/centering screw
(4) to the stop.
Detach the screw at the fixing device
of the pull-down cam (1).
Pull the complete pull-down cam (5),
including the fixing device (3),
downwards to remove it. 2 1
Remove the pull-down cam from the
01-467
fixing device.
Illustration 312: Pull-down cam

Fitting
Note:
Prior to fitting, pull the punches in the area of the pull-down cam
downwards by approx. 10 mm to guarantee the centering of the
punches in the newly fitted pull-down cam.

Loosen the adjusting/centring screw

so that the pull-down cam is opened
as wide as possible.

Illustration 313: Pull-down cam

Turn the bases (1) on the fixing device

so that the two flat sides face each
other.

01-484
Illustration 314: Fixing device of pull-down cam

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Punch guide

Mount the new pull-down cam on the

fixing device. Fit the pull-down cam in
between the four centering bolts on
the fixing device and mind the guide
beside the bases (2). 2
Re-fit the front and rear quick-release
locks of the lubrication (6).

01-486
Illustration 315: Pull-down cam

Fit the pull-down cam (5) with the

fixing device (3) into the machine. 3 4 5 6
Retighten the screw (1) of the fixing
device.
Carefully tighten the
adjusting/centering screw (4). Ensure
that no punch is stuck in the pull-down
cam.
Slowly turn the die table using the
handwheel for at least one revolution
and check the mobility of the punches. 2 1
Tighten the fixing screws (2) of the
pull-down cam. 01-467
Install the dismantling station and Illustration 316: Pull-down cam
tighten the star grip screw.

Note:
• Check the new limiting values for the fill range on the operating
terminal.

280 / 409 007.2/SYN7ZS/BA/en

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Punch guide

[Link] Dosing cam, catch cam, control cam and link track
Structure
Note:
Replace the dosing cam, catch cam, control cam and the link track
in case of wear.

3 4

1
7 6

Illustration 317: Unit of dosing cam, catch cam, control cam and link track

1 Fixing screw of the unit of dosing cam, catch 5 Link track fixing screw
cam, control cam and link track
2 Catch cam adjusting screw 6 Link track
3 Catch cam centering screws 7 Control cam centering screws
4 Control cam adjusting screw

Removal

Caution
Open the catch cam using the adjusting screw (2) and the
control cam using the adjusting screw (4).
Otherwise the cams might be damaged when adjusting the fill
depth!

è Set the adjusting limits MAX for the fill depth to 20 mm on the operating terminal.

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Punch guide

Detach the fixing screw (1) and pull

out the unit of dosing cam, catch cam,
control cam and link track to the front.
Put the unit on a workbench.

1
01-468
Illustration 318: Fixing screw of the unit of dosing cam,
catch cam, control cam and link track

Remove the catch cam for the dosing

1 2
cam (screws 1 and 4) and the control
cam (screws 2 and 3).
Mind the springs on screws 1 and 2!

4 3
01-474
Illustration 319: Catch cam / control cam

Detach the corresponding fixing 1

screws of the cams to be replaced
(e.g. the fixing screws of the dosing
cam (1)) and remove the
corresponding cam.

01-471
Illustration 320: Dosing cam fixing screw

Fitting
Dosing cam

Put the dosing cam on the centering 1

bolts (1).
Tighten the dosing cam with the fixing
screws (2).

2
01-473
Illustration 321: Dosing cam

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Punch guide

Catch cam / control cam

Put the spring on the adjusting screw

1 2
(1) and fasten the catch cam of the
dosing cam with the adjusting screw
(1).
Tighten the centring screws (4) and
the adjusting screw (1).
Put the spring on the adjusting screw
(2) and fasten the control cam with the 4 3
01-474
adjusting screw (2).
Illustration 322: Catch cam / control cam
Tighten the centring screws (3) and
the adjusting screw (2).
For assembling the mounting plate (1) 1
of the control cam, screw (2) must be
tightened.

2
01-476
Illustration 323: Mounting plate control cam

Note:
With the control cam and the corresponding mounting plate the
lower punch tightness is measured. The corresponding proximity
switch is situated in the housing of the dosing unit.

Link track

Put the spring (3) on the fixing screw

3 1
(2) and fasten the link track (1) with the
fixing screw (2).

2
01-475
Illustration 324: Link track

Unit of dosing cam, catch cam, control cam and link track
è Fitting is carried out in reversed sequence of removal.
è Move the dosing cam to the required set value.

007.2/SYN7ZS/BA/en 283 / 409

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Punch guide

[Link] Ejection roller

Removal
The ejection roller is intended for detaching the tablets. Replace the ejection
roller in case of wear.

Note:
Optionally, the ejection roller can be equipped with a WSG
measuring point. Thus the force needed for separating the tablets
can be recorded.

Dismantle the valve for the floor drain.

For this remove the conduction (1) and
the four fixing screws (2) of the valve.

01-478
Illustration 325: Floor drain valve

Fitting
è Fitting is effected in reversed sequence.

284 / 409 007.2/SYN7ZS/BA/en

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Punch guide

10.11.3 Upper pressure roller block

5 2 1

3 1

04-114
Illustration 326: Upper cam track, torque support

 Fixing points of the torque support

 WSG sensor (upper punch tightness)

 Lubrication unit

 Torque support

 Sealing cap of the lubrication lines

Remove the cover (see section

"Cover", page 240).
1
Loosen the retaining screws (1) in the
pressure roller block with the large
torque wrench (supplies).

04-113
Illustration 327: Loosening the retaining screws

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Punch guide

Turn the retaining screws (1) until they

are hanging loose in their guide.

04-109
Illustration 328: Retaining screws

By pushing the centre pin detach the

connecting bolt of the torque support
and swing the latter out.

04-108
Illustration 329: Detaching and swinging out the torque
support

Swing the pressure roller block some

way outward so that you are able to 1
detach the lock coupling of the
lubrication line (1) and the measuring
cable of the WSG sensor (upper 2 1
punch tightness) (2).

2
01-320
Illustration 330: Detaching the lines

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Punch guide

Pull the centering bolt.

04-110
Illustration 331: Centering bolt of pressure roller block

Swing the pressure roller block out.

04-111
Illustration 332: Swinging out the pressure roller block

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Punch guide

Tilting in the upper pressure roller block

Connect the cable Lubricating oil line
(1) and the measuring point Upper 1
punch tightness (2) in the pressure
roller block.
2 1

2
01-481
Illustration 333: Connections at the pressure roller block

Swing the upper pressure roller block

back into the machine.

04-112
Illustration 334: Swinging in the pressure roller block

Put the mounting aid (supplies) onto

the retaining screws and tighten them.

01-128
Illustration 335: Mounting aid of the pressure roller
block

288 / 409 007.2/SYN7ZS/BA/en

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Punch guide

Tighten the retaining screws with the

large torque wrench (supplies) (70
1
Nm).

04-113
Illustration 336: Tightening the retaining screws of the
pressure roller block

Removal of the upper pressure rollers

Notice:
Replace the upper pressure rollers in case of wear.

CAUTION
Mind the weight of the pressure rollers (approx. 25kg)!
Risk of injury through a pressure roller falling down
Ø The removal of the pressure rollers must absolutely be done
by several persons!

Disconnect cables and lubrication lines

1

2 1

2
01-320
Illustration 337: Lines at the upper pressure roller block

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Punch guide

Remove the screws at the lid (1) and

remove the lid.

01-174
Illustration 338: Fixing lid

Loosen the 4 fixing screws (1) and

remove the adjusting toothed wheel
(2).

2 1

01-580

Illustration 339: Fixing screws and adjusting toothed

wheel

Carefully take the pressure roller out to

the rear.

01-581
Illustration 340: Fixing screws and adjusting toothed
wheel

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Punch guide

CAUTION
Mind the weight of the pressure rollers (approx. 25kg)!
Risk of injury through a pressure roller falling down
Ø Only detach the pressure roller by tapping when it is secured
against dropping down by several persons!

CAUTION
Do not tighten the retaining screws of the pressure roller
block too firmly!
The screws may break in case of too high a tightening torque.
Ø Tighten the retaining screws with a torque wrench (supplies).
Tightening torque: 70 Nm

Fitting the upper pressure rollers

è Fitting is effected in reversed sequence.

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Punch guide

10.11.4 Lower pressure roller block

Removal of the pressure roller blocks

1. Screws of the covering

components
2. Side openings for the screws of 1
the covering components
3. Rear cover
4. Allen screws with guide pillars 2

1
3
2
4
01-290
Illustration 341: Removing the covering components

Note:
If you want to remove the pre-pressure roller block, first remove the
unit of dosing cam, catch cam, control cam and link track. If you
want to remove the main pressure roller block, first remove the
hose of the suction.

è Detach the cover plate at the rear of the pressure roller block.
è Remove the cover. For doing this remove the two Allen screws to the top.
è Turn the two Allen screws into the side bores of the cover.
è Lift the cover by means of the screws.
è Turn the screw that can be inserted more deeply into the cover a little bit further.
Thus the cover is clamped unter the pressure roller.
è Move the pressure roller downwards so far that an air gap of approx.1 mm
remains (visual inspection).
è Remove the cover plate on the top of the pressure roller block.

292 / 409 007.2/SYN7ZS/BA/en

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Punch guide

1. Fixation
2. Guide pillar
3. Allen screw
4. Pressure plate

Illustration 342: Removing the pressure roller block

è Unscrew the fixation out of the top of the pressure roller block.
è Take the pressure plate out of the pressure roller block.
è Detach the Allen screw.

Note:
Mind the thread. The guide pillar and the dismantling tool have a
left-handed thread.

• Turn the dismantling tool

(supplies) onto the guide pillar
• Lift the Allen screw and secure the
screw against falling down. For
this slide the safety sheet of the
dismantling tool under the screw
head.

00-013
Illustration 343: Removing the covering components

007.2/SYN7ZS/BA/en 293 / 409

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Punch guide

1. Pressure roller
2. Sleeve of the probe 1

01-292
Illustration 344: Position of the probe

• For this pull the sleeve of the

probe (2) downwards and put a pin
(e.g. a hexagon wrench) into the
bore of the sleeve to secure the
probe in this position.
• Tighten the dismantling device
(supplies) with the fixing screw to
00-015
the pressure roller block.
Illustration 345: Dismantling device

CAUTION
Mind the weight of the pressure roller blocks (approx. 60 kg)!
Risk of injury through a pressure roller block falling down
Ø Lift the pressure roller blocks only with appropriate hoists or
with several people!

è Remove the pressure roller block

Fitting the pressure roller blocks

CAUTION
Note that the weight of the presssure roller blocks is approx.
60 kg!
Risk of injury by roller block falling down.
Ø Use adequate equipment or several persons to lift the
pressure roller blocks!

Assembly is effected in reversed sequence of disassembly.

294 / 409 007.2/SYN7ZS/BA/en

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Punch guide

[Link] Removal of pressure rollers

Dismantling the lower pressure

Note:
The pressure roller must be exchanged in case of wear.

1. Screw of the bearing shaft

1
2. Support plate
3. Fastening screws of the support
plate
4. Fastening screws of the
dismantling tool

3 4 3

01-293
Illustration 346: Dismantling of ressure roller

è Loosen the fastening screw of the bearing shaft (1).

è Loosen the fastening screws (3).
è Remove the support plate (2).
è Loosen the fastening screws below the support plate.
è Lift out the pressure roller together with the axle.

Assembly of the lower pressure roller

Assembly is effected in reversed sequence of disassembly.

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Machine compartment

10.12 Machine compartment

10.12.1 Lubrication
Lubrication system

04-093
Illustration 347: Lubrication system: Position and size of the dosing valves

Lubrication coupling
Lubrication unit upper cam track
Lubrication pump
Vent screw A (at the distributor strip)
Vent screw B (at the lubrication unit)

296 / 409 007.2/SYN7ZS/BA/en

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Machine compartment

[Link] Lower pressure roller block

Grease lubrication of upper and lower pressure rollers
Notice:
Pressure rollers are provided with lifetime lubrication when
delivered. Lubrication channels for possible regreasing are
available, but are closed by a screw.

Notice:
After greasing the pressure roller must be easily turnable by hand.

CAUTION
Component breaks are possible through insufficient grease
lubrication as well as through excessive grease!
The grease lubrication of the pressure rollers must be checked
monthly.

Oil inlet 1 2
Dosing
elements
Oil outlet
Hardened steel 3 3
bushings
Sealing ring

4 4

5 5

00-106
Illustration 348: Oil lubrication of the lower pressure roller block

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[Link] Venting the lubrication system

Notice:
If the lubrication system has been opened it must be vented
afterwards (e.g. after maintenance work). If the lubrication system
has only been opened at the lubrication coupling, it must not be
vented (e.g. when removing the die table).

01-269
Illustration 349: Vent screw of lubrication system

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Remove the cover of the dosing case.

For this, remove the six screws (1) of
the cover.

01-795
Illustration 350: Dosing unit cover

Loosen the vent screw (A).

Trigger a manual lubrication pulse (see
chapter Usage, Tabletting > Manual >
Equipment93) until some oil emerges
from the vent screw (A). A
Close the vent screw (A) as soon as
bubble-free liquid emerges.

01-553
Illustration 351: Venting the lubrication system

Notice:
The venting has to be performed below and above at the die table.

Repeat this procedure for vent screw

B.
B

00-107
Illustration 352: Lubrication unit with vent screw B

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[Link] Lubrication pump

04-076
Illustration 353: Lubrication pump

 Oil feed tube

 Strainer

Lubrication interval of the pump

The lubrication pause, i.e. the time between two cycles, is set by IMA KILIAN and
should only be changed if the lubrication rate requires improvement.

Notice:
The pause time depends on the production output:
• High production output: short pause time
• Low production output: long pause time
The setting of the pause time is specified to 3 minutes by the
programme!

Servicing the pump

è Check the oil level in the lubrication pump weekly.
è Replace the strainer in the lubrication pump annually.

Oil make-up fill

è Fill in the oil at the feed tube until the oil level has reached the marking "Max".

CAUTION
Do not blend different oil types!
Please refer to chapter "Technical data" for information
regarding oil types and fill quantities.

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Changing the dosing valves

In case of clogging or leaks, the dosing valves must be replaced.

CAUTION
The dosing valves fitted as standard are tuned relative to one
another and may not be mixed.

• Pull the lubrication line out of the defective dosing valve.

• Screw the dosing valve out and replace it. For the size of the dosing valve please
refer to "Lubrication system overview" (see page 296).
• Put the lubrication line on again and vent the lubrication system.
• When replacing the dosing valves in the lubrication unit proceed as follows:

Fixing screw lid

B 1 2
Allen screw
Vent screw

00-108
Illustration 354: Lubrication unit

• Remove the fixing screw (1) and lift off the lid.
• Remove the Allen screw (2) and remove the insert with the dosing valves mounted
thereon.
• Replace the defective dosing valves and then vent the system at vent screw B.

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Lube oil filling following die table cleaning

Notice:
In the die table there is a lube oil channel ensuring the lower punch
lubrication. When the die table is refitted after cleaning this channel
must be sufficiently pre-filled with lube oil. Thus the lubrication of
the lower punches is sufficiently ensured for the first revolutions of
the die table.

Caution
If there is not enough lube oil in the lube oil channel, the
lower punches, the die table and the pull-down cam may be
damaged!

2 2

Illustration 355: Additional lubrication of lower punches

 Lube oil channel

 Automatic lubrication

 Manual lubrication pump

Make-up fill should be made before fitting the die table. Thus the access to the lube oil
channel (bottom side of the die table) is facilitated.
Using a pump, fill about 0.2 l lube oil (see lubricants table in section Technical data)
into the lube oil channel (1) of the die table.

Notice:
The quantity may vary, depending on the die table type.

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[Link] Sump tank

A sump tank (1) is located in the
machine compartment. 1

04-091
Illustration 356: Sump tank

Notice:
Empty the sump tank after every make-up fill of the lubrication
pump.

è Remove the sump tank.

è Dispose of the waste oil in an environmentally acceptable manner. Please
observe the valid local regulations when disposing of waste oil!
è Reinsert the sump tank.

Notice:
Watch the color of the waste oil when emptying. Major
discolorations are an indication of increased wear.

[Link] Lubrication problems

If the lubrication points are not optimally supplied, please check:
1. whether the lines are clogged or defective,
2. the union joints of the lubrication lines,
3. whether the strainer of the lubrication pump is clogged,
4. the setting of the lubrication intervals.

Note:
In case of major lubrication problems please contact the IMA
KILIAN Service.

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[Link] Grease lubrication

Grease lubrication of upper and lower pressure rollers (pre-
pressure and main pressure rollers)
Notice:
Pressure rollers are provided with lifetime lubrication when
delivered. Lubrication channels for possible regreasing are
available, but are closed by a screw.

If regreasing is required proceed as follows:

Remove the lids at the upper pressure

rollers and insert a lubrication nipple A
(not contained in the supplies) in bore
(A).
Continue to fill in grease at (A) until a
resistance is felt when manually
turning the pressure roller.
Remove the lubrication nipple from the
bore and screw the two lids on again.

01-582
Illustration 357: Grease lubrication of the upper
pressure roller

Remove the locking screws at the

lower pressure rollers and insert the
lubrication nipples (not contained in
the supplies) in bore (A).
Continue to fill in grease at (A) until a
resistance is felt when manually
turning the pressure roller.

01-554
Illustration 358: Grease lubrication of the lower pressure
rollers

Caution!
Component break
Component breaks are possible through insufficient grease
lubrication as well as through excessive grease.
Ø The grease lubrication of the pressure rollers must be
checked monthly.

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Grease lubrication of the vertical shaft

04-010
Illustration 359: Grease lubrication of vertical shaft at the lubrication nipple (1)

The vertical shaft should be greased once every 6 months.

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10.12.2 Hydraulics

2
5 6

01-597
Illustration 360: Hydraulic system (for better representation, the illustration shows the hydraulic system in
the manufacture of the machine)

 Die table ejection unit

 Die ejection unit

 Control block

 Hydraulic unit

 Lower pressure roller block pre-pressure

 Lower pressure roller block main pressure

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03-056
Illustration 361: Hydraulic diagram

• Pump capacitiy 1.1 l/min

• System pressure 405 bar
• Drive motor 0.55 kW
• Motor voltage 230/400 V - 50 Hz
• Valve voltage 24 V/DC

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Pos. Description Pos. Description

1 End plate 18 Safety valve

2 Hydraulic unit 19 Transfer/check valve

3 Transfer/check valve 20 Transfer/check valve

4 Throttle valve 21 Hydraulic pump

5 Rotary feed-through 22 Hydraulic unit

6 Bulkhead coupling 23 Pressure control valve

7 Stub 24 Throttle valve

8 Screw-in cylinder 25 Pressure valve

9 Transfer/check valve 26 Diaphragm type accumulator

10 Transfer/check valve 27 Diaphragm type accumulator

11 Block cylinder 28 Diaphragm type accumulator

12 Throttle valve 29 Swiveling measuring joint

13 Transfer/check valve 30 Pressure transducer

14 Measuring joint 31 Hydraulic pressure compensation

15 Pressure reducing valve 32 Shut-off valve

16 Measuring joint 33 Control block

17 Drain valve - -

Legend for hydraulic plan

CAUTION
Risk of injury through components and lines under high
pressure!
Ø The system must first be depressurized before checking the
oil level, executing an oil change or replacing components.
(See the following chapter Depressurizing the hydraulic
system).
Ø Attach signs/labels to the curent supply unit saying that it
must not be switched on, as the hydraulic system is
automatically pressurized when the machine is switched on.
Ø The line connections of the individual components must be
regularly checked for damage or porosity by visual inspection.
IMA KILIAN recommends an annual safety check of all
components under pressure!
Ø Check the hydraulic system for oil leakage monthly!

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CAUTION
High pressure in the hydraulic system!
Injuries through improper opening of lines and components under
pressure.
Ø Valves, hydraulic accumulators and choke coils must not be
opened by force!
Ø Exchanging or servicing of hydraulic accumulators may only
be carried out by qualified staff.
Ø If pressure tanks in hydraulic systems are exchanged,
acceptance testing is not necessary, if
– they are replaced by equivalent pressure tanks,
– the gas blanket is separated from the hydraulic oil by a
membrane or a pocket, and
– no change to the equipment has been carried out.
Ø You may only install hydraulic accumulators which have been
supplied by IMA KILIAN.
Ø Hydraulic accumulators may not be opened, risk of injury as
the hydraulic system is under high pressure.
Ø The hydraulic accumulators and their connections may not be
opened or damaged with improper tools.
Ø If there is more than one accumulator in the tablet press,
replacement should not be carried out simultaneously.
Replace one accumulator at a time. First of all, the
accumulator with the smallest N2 gas pressure (receiver
pressure) is changed.
Ø Dispose of defective hydraulic accumulators properly.

Depressurize the system, as described

on page 310.
Replace the respective component.
Now vent the hydraulic system as
1
described in the following section
Venting the hydraulic system.

03-071
Illustration 362: Hydraulics of vent valve

Notice:
For a component's change at or before the control block, the shut-
off valve must be closed to prevent air from escaping into the
upper sector of the hydraulic system. If you need to replace
components in the upper sector of the system, this sector must
also be vented. For this see section Venting the hydraulic system,
page 313.

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Depressurize the system, as described

on page 310.
Close the shut-off valve (1) using a 5 1
mm Allen key.
Replace the respective component.
Now vent the control block, as
described in the following section
Venting the control block.

01-589
Illustration 363: Hydraulics of shut-off valve

[Link] Depressurising the hydraulic system

Deactivate the measuring point
(1) Compaction force limitation
MP in mask System > Machine
> Measuring points > Others
to prevent the hydraulic pump
from re-generating the reduced
pressure immediately.

60-303
Illustration 364: Measuring point Compaction force limitation MP

Connect a manometer
(indication up to at least 400 2
bar) to the measuring joint (2).

01-526
Illustration 365: Hydraulics of measuring joint

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Open the outlet valve (3) using a

5 mm Allen key.
Check the falling pressure on
the manometer. When the
pressure is "zero", close the
outlet valve and remove the 3
manometer.
You can now perform the
corresponding maintenance
operations such as oil change.

01-594
Illustration 366: Hydraulics of outlet valve

[Link] Check of oil level

First depressurize the system, as
described on page Fehler! Textmarke 2
nicht definiert..
Check whether the oil sight glass (1) is
filled to at least 2/3.
Open the oil feed tube (2).
Using a hose and a hopper, re-fill oil as
required.
1

01-592
Illustration 367: Hydraulic tank

CAUTION
Risk of injury through components and lines under high
pressure!
Ø Imperatively check the line connections of the individual
components for damage or porosity by visual inspection if oil
is missing. IMA KILIAN recommends an annual safety check
of all components under pressure!

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Caution
The oil level must not drop below 2/3!
Please refer to the chapter Technical data for information
regarding oil types and fill quantities.

Activate the measuring point (3)

Compaction force limitation MP
in mask System > Machine >
Measuring points > Others to
ensure that the hydraulic pump
re-generates the required
pressure.

60-304
Illustration 368: Measuring point Compaction force limitation
MP

First depressurize the system.

Open the oil feed tube (1).
1
Suck the existing oil off using a
hose and e.g. a syringe.
Refill oil until the oil sight glass
(2) is filled to at least 2/3.

01-593
Illustration 369: Hydraulic tank

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Activate the measuring point (3)

Compaction force limitation pre-
pressure and main pressure in
mask System > Machine >
Measuring points > Others to
ensure that the hydraulic pump
re-generates the required
pressure.

60-304
Illustration 370: Measuring point Compaction force limitation MP

Note:
Check the oil level of the hydraulic unit weekly.

Note:
The hydraulic oil must be changed every 10,000 operating hours.

Notice:
If the required compaction force limitation cannot be reached,
insufficient venting may be the cause.

For venting the entire hydraulic

system it is necessary to dismantle
the lower pressure roller blocks (see
section “Upper pressure roller 1
block”).

3 2

01-490
Illustration 371: Position of the vent screw

 Pressure roller

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 Vent screw

 Pressure roller block

CAUTION
Mind the weight of the pressure roller blocks (approx. 60 kg)!
Risk of injury through a pressure roller block falling down
Ø Lift the pressure roller blocks only with appropriate hoists or
with several people!

Carefully lift the pressure roller

block. Put the block down so that
the vent screw (1) is free.
2

01-620
Illustration 372: Position of the vent screw

Detach the Allen screw.

01-621
Illustration 373: Detaching the vent screw

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Ensure that a cloth is available to

absorb emerging oil.
Select mask Tabletting > Manual > 1
Equipment. Increase the value for
compaction force (1) carefully in
steps until a small amount of oil
emerges.
As soon as there is a smooth flow of
bubble-free liquid, retighten the vent
screw.

60-306
Illustration 374: Compaction force adjustment

CAUTION
Do not increase the pressure in the hydraulic system too
much while the vent screw is loosened.
There is a risk of injury and soiling!

[Link] Venting the control block

Note:
If the required compaction force limitation cannot be reached,
insufficient venting may be the cause.

Connect the supplied vent hose

(1) to the measuring joint (2).

Illustration 375: Venting the hydraulics of the control block

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Select mask Tabletting >

Manual > Equipment. Increase
the value for compaction force 3
(3) carefully in steps until a
small amount of oil emerges.
As soon as there is a smooth
flow of bubble-free liquid, you
may remove the vent hose and
re-connect the measuring stub.

60-308
Illustration 376: Compaction force adjustment

Re-open the shut-off valve on

the control block (4).
4

01-605
Illustration 377: Hydraulics of measuring joint

Activate the measuring point (5)

Compaction force limitation pre-
pressure and main pressure in
mask System > Machine >
Measuring points > Others to
ensure that the hydraulic pump
re-generates the required
pressure.

60-309
Illustration 378: Hydraulics of measuring joint

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10.12.3 Air filter

Illustration 379: Fan for machine compartment

Air filter check

è Check the air filter daily and clean it in case of visible soiling. Replace it, if
required (the filter mat can be cleaned up to 20 times if handled with care).

CAUTION
The tablet press shall be started with fitted filter mat only in
order to prevent fouling of the motor.

Cleaning / replacement of the filter mat

è Switch the tablet press off.
è Wait until the fan has come to a standstill.
è Remove the filter cover of the air filter.
è Remove the filter mat.
è Clean the interior of the filter housing.
è Beat the filter mat, vacuum it or clean it with compressed air.
è Alternatively you can clean it by washing in water (up to approx. 40° C with the
addition of mild detergents), or for greasy soiling, wash with petrol or in warm
water with fat-soluble detergent.
è Reinsert the old or new filter mat and reapply the filter cover.

CAUTION
Do not wring out the filter mat or treat it with a powerful water
jet!

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10.12.4 Pneumatics

04-012
Illustration 380: Pneumatic diagram

1 Water separator (semi-automatic)

2 Tablet blow-out / individual ejection (tablet scraper, coding colour: yellow)

3 Deburrer / deduster (coding colour: blue)

4 AZO vacuum system (coding colour: black)

5 Optionally conveyor belt , container filling system

6 Tablet conveyor 6.1 Transport nozzle (coding colour: red)

6.2 Rotational drive for suction (coding colour: red)

7 DL product scraper

8 Compressed-air screwdriver

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Operating terminal

10.13 Operating terminal

Structure

01-408
Illustration 381: Operating terminal with USB port

Removal
Remove the cover plate at the
connection of the operating terminal.
Detach the plug-type connectors of
the cables to the tablet press.
Remove the fixing screw of the
operating terminal.
Carefully pull the operating terminal
off the swivel arm. For this, the cables
must be fed through the opening at
the connection of the operating
terminal.

01-493
Illustration 382: Connection operating terminal

Caution
Ensure that the cables are not damaged when pulling the
operating terminal off the swivel arm.

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Operating terminal

Fitting
è Fitting is carried out in reversed sequence of removal.

Vacuum the dust deposits on the housing. To clean the housing and the touch screen
use only a moistened cloth and a mild cleaning agent. Depending on the press
material, use other cleaning methods or take special safety measures.

Caution
Damage to the touch screen surface through wrong cleaning
agents!
The operating terminal and touch screen may be damaged
beyond repair as a result.
Ø Pay special attention to the cleaning instructions for the press
material!
Ø Do not use any solvents, scouring or abrasive cleaning
equipment or cleaning agents!
Ø Also observe the cleaning instructions in the operating
instruction of the respective tablet press!
Ø

The foil and the housing may be cleaned with a non-abrasive cleaning agent, water
and a soft cloth.

Absolutely ensure that no moisture enters the disk drive. This

would result in destroying the drive.

Polyester foil and filter screen

Resistant
The polyester foil and filter screen fitted to the front panel are resistant without visible
changes for more than 24 hours against influences of the following chemicals acc. to
DIN 42115-2: resistant to ethanol, cyclohexanol, glycol, isopropanol, glycerine,
methanol, ethanal, aliphatic hydrocarbons, benzine, toluol, xylol, benzole, acetone,
methyl-ethyl ketone, dioxane, fluoric chlorinated hydrocarbons, perchloroethylene,
1.1.1 trichloroethane, thrichloroethylene, ethyl acetate, diethyl ether, ammonia < 2 %,
caustic soda < 2 %, alkaline carbonates, bichromates, potassium ferrocyanides,
sodachlorine < 20 %, hydrogen peroxide < 25 %, potash soap, washing agent
solutions (tensides), softeners, formic acid < 50 %, ethanoic acid < 5 %, phosphoric
acid < 30 %, hydrochloric acid < 10 %, nitric acid < 10 %, boring emulsions, diesel oil,
varnish, liquid paraffin, castor oil, silicone oil, turpentine oil replacements

The polyester foil is resistant to vinegar for a period of 1 hour

without visible damage acc. to DIN42115-2.

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Batteries and rechargeable batteries

Not resistant
The polyester foil and the filter screen fitted to the front panel are not resistant to
benzyl alcohol, methylene chloride, concentrated mineral acids, concentrated alkaline
solutions, high-pressure steam above 100 °C
The polyester foil and the filter screen fitted to the front panel are not resistant to:

• benzyl alcohol,
• methylene chloride,
• concentrated mineral acids,
• concentrated alkaline solutions,
• high-pressure steam above 100°C

10.14 Batteries and rechargeable batteries

WARNING
Electric shock!
Open the devices only when the power is OFF!
Ø The following work may only be carried out by a skilled and
trained electrician or by the manufacturer himself!

WARNING
Explosion hazard!
There is an explosion hazard when the battery is not properly
exchanged!

Environmental note:
Lithium batteries must not be disposed of with household waste!
Please return used batteries to the battery manufacturer or dispose
of the battery acc. to the national recycling and waste disposal
regulations.

Caution
Destruction of electronic components through electrostatic
discharge!
Subassemblies with electrostatic risks can be damaged by
voltage levels far below the perception limit of man. These
voltages even occur when touching the connections of a
subassembly if they are not electrostatically discharged. The
damage caused by this is often not recognized immediately, but
only after a longer operating time.
Ø Please observe the directives for handling subassemblies with
electrostatic risks.

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10.14.1 CPU module

The battery in the CPU module must be replaced when the message "Battery is low"
appears (during booting).
Type designation of the CMOS battery: Lithium battery CR2032 3 V

01-215
Illustration 383: Position of the battery

Note:
Lithium batteries have a service life of approx. 5 years.
Use batteries of the same type only!

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Batteries and rechargeable batteries

10.14.2 UPS module

UPS 24/16 Bachmann

01-216
Illustration 384: Position of the UPS in the control cabinet

Note:
Replacement and disposal of the rechargeable battery only through
Messrs. G. Bachmann Electronic GmbH!
G. Bachmann Electronic GmbH
Kreuzäckerweg 33
A-6806 Feldkirch-Tosters
Phone +43 5522/3497-0
Fax +43 5522/3497-102
[Link]

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Technical data
• +24 V/DC / 1,6 Ah
• 4.0 A nominal output current
• 7.5 A peak current
• Self-discharge in approx. 200 h
• Controllable function via serial interface

Service time
The service time of the rechargeable battery depends on a lot of factors. For example:
• Ambient temperature
• Additional cooling
• Frequency of buffering
• Extent of discharge
and so on

Note:
Therefore a guaranteed indication of the service time is not
possible.
When operating the UPS 24/16 at 30 ° ambient temperature in the
specified installation position it is recommended to check the
capacity or replace the battery after a period of four years.
In case of higher temperatures the rechargeable battery must be
replaced earlier.

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10.14.3 M1 processor module

01-217
Illustration 385: M1 module in the control cabinet

For the processor module MP2xx/E the SDRAM and the system time are battery-
buffered.
The accumulator of the NV RAM keeps the data for 3 months (from 0° -40° a
guaranteed indication is not possible). Processor modules can therefore be stored for
a maximum time of 3 months with the power off without data loss.

Note:
Loading an empty buffer battery takes approx. 48 hours.
The accumulator has a typical lifetime of 10 years.

Note:
Replacement and disposal of the rechargeable battery only through
Messrs. G. Bachmann Electronic GmbH!
G. Bachmann Electronic GmbH
Kreuzäckerweg 33
A-6806 Feldkirch-Tosters
Phone +43 5522/3497-0
Fax +43 5522/3497-102
[Link]

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Data backup

10.15 Data backup

Note:
For this observe the SOP VA 73-04 Disaster recovery system (SOP=
Standard Operating Procedure) of IMA KILIAN.

CAUTION
To ensure a proper data backup, a system shutdown must be
executed prior to switching off the tablet press.

10.15.1 Data backup Visualisation

As backup for the visualisation PC an image file of the harddisk is generated. This has
the advantage that the complete installation can be restored in one operation, i.e.
various new installations are not required.

10.15.2 Data backup Control

The PcCard contains programs for the "Bachmann M1 control used here. The
program applied for data backup can also be used for saving the data memory
including the entire settings.

10.15.3 Service work on the industrial PC of the control system

As with every Personal Computer, the following items are indispensable for the
proper handling of the industrial PC of the tablet press:
è Shut the PC properly down prior to switching it off.
è Do not install any additional software. Sole exception: printer driver
è Service and driver installation must be carried out by competent personnel (IT
department).
è Regular servicing and data saving

The regular work for service and data saving comprises:

Weekly:
• Check the functioning of the uninterruptible power supply (UPS) by switching OFF
the main switch of the machine without previously shutting the PC down.
– A window must open on the screen where the safe shut-down can be observed
(finishing the applications, shutting Windows down …)

Note:
If the screen goes out immediately when the main switch is
switched OFF, the UPS must be repaired or replaced!

Monthly:
• Accumulating data waste must be deleted from the hard disk at regular intervals. 2
actions are required for this:
- Clean up each drive under "Properties""Clean-up"
- Delete all temporary files using "Execute – cmd" and the command line del
/q %temp%\*.*
This procedure can be automated in a batch file which is automatically carried
out each time the computer is started (Auto Start function).
• Saving the accumulated batch data.
In order to relieve the operating system from data that have to be saved for
archiving purposes only, all batch data must be copied to an external archive and

326 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Data backup

deleted from the hard disk at regular intervals. This process can be automated as
far as possible using appropriate means (USB memory stick, Auto Run function).
• Checking the "state of health" of the hard disk.
This comprises on the one hand the analysis of the file system and on the other
hand the analysis of the user interface. Checking is executed for each drive
separately under "Properties" - "Extras" - "Error checking"
It is important here that both boxes are ticked in the window that opens up in order
to execute the logical as well as the physical analysis. The analysis itself is not
executed until the next system start, as the exclusive access to the files is
required.

After configuration changes:

• Whenever a change of the configuration has been carried out, when a software
upgrade has been executed or when system settings have been changed it is
necessary to carry out a system backup using the KILIAN backup CD. In doing
this, the saving of the M1 controller data on partition C\: and the storage of the
partitions C\: (system) and D\: (data) is executed in a Norton Ghost Image on
partition E\: (Backup).
This image should be externally saved under Windows (by means of the
Explorer).

Note:
If an additional safety level is required (e.g. against hard disk
failure), it is very simple to generate an identical copy of the hard
disk using the program "Acronis True Image" (program of an
external supplier) and an external USB hard disk drive (clone).

007.2/SYN7ZS/BA/en 327 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Service schedule

10.16 Service schedule

The times specified refer to a production day of 8 hours.
D = daily, W = weekly, M = monthly, S = soiling, F = fault, P = product change
Subassembly Element Service work D W M F F P
Control Lamps Check Lamp test
elements
- - - - -
EMERGENCY STOP Check Function
button
- - - - -

Pressure rollers Upper + Lower Check Wear and smooth

running
- - - -
Top Lubricate With grease gun
- - - - -

Fillshoe Agitator wheels Check Deposits, wear of

- - - -
agitator wheels and
smooth running of
bearings
Housing Check Wear of sealing
- - - - -
segment
Covering segment with Check Wear and smooth
product scraper running (check of
- - -
spring force)
Material hopper Clean Product residues
- - - -
Fillshoe base Check Distance to die table;
- - - - -
wear of scrapers

Cam track Upper Check Wear of punch guide

- - - -
Lower Check Wear of punch guide
- - - -

Hydraulics Hydraulic unit Check Oil level

- - - -
Pressure accumulator Check Seals and housing for
- - - -
fissures and oil loss
Lines Check Tightness, oil loss
- - - -

Air suction Filters Check Condition

- - -
Filter mat Clean
- - - -
Fan Check Function
- -

Machine Machine compartment Check Oil slicks or heavy

- - - -
compartment soiling
Motor Check Temperature (main
drive and fillshoe
- - - -
motor)
Safety switch Check Condition and test of
- - - - -
safety switches

Die table Brake magnets Check Function -

- -

328 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Service
Service schedule

Subassembly Element Service work D W M F F P

Sealing ring to Check Tightness
- - - - -
machine compartment
partition
Punch bores Clean Clean with brush and
oil slightly
- - - -
Dies Check Measure wear, polish,
replace as required
- - - -
V seal Lubricate At die table change,
after each cleaning or
- - -
weekly

Measuring Force measurement Check Switch-off function of

- - - - -
points limit value indicators
by reducing upper limit

Pneumatics Connections and lines Check Connections for air

leakage
- - - - -
Water separator Autom. Container for water
discharge
- - - - -

Compression Compression chamber Clean Vacuum product

- - -
chamber residues
Windows inside Clean
- - -
surfaces
Tablet chute Clean
- - -
Check Function of rotary
- - - -
magnets
Blow out nozzle Clean Hoses, valves and
- - - -
blowout bore
Suction unit Clean Hoses and suction
- - -
nozzle

Control cabinet Inside Clean Remove dust deposits

- - - - -

Lubrication Lubrication pump / Check Empty the sump tank

- - - -
system sump tank after each filling of the
lubrication pump
Grease lubrication Lubricate With grease gun
- - - - -
Lines Check Condition, connections
- - - -
and tightness of lines

Tool Oil trap cap at upper Check Condition and fit at

- - - -
punch punch
Shafts Check Measure wear, polish,
- - -
replace as required
Scrapers Check Visual inspection
- - -

Note:
Dispose of the lubricants according to the local regulations and the
general guidelines to avoid harm to the environment.

007.2/SYN7ZS/BA/en 329 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Setting on control device

11 Converting from a double press to a bi-layer

press
11.1 Setting on control device
If the plate press should function during bi-layer operation then the control device must
be set as follows.

è Ensure that the machine is in Set-up mode.

è Open mask System > Machine.
è Load the machine data record for double press operation, "machine_zs.mdb" as
in the example illustrated.
è Additionally load the adjustment data record in mask System > Measuring points
> Machine.

Illustration 386: System – Machine

Notice:
After downloading the data records the machine must be turned off
and then re-started.

è Set the fill depth to the desired value in mask Tabletting > Set-up.
Ø Set the penetration depth PP for press station 1 to 2.5 mm.
Ø Set the penetration depth MP for press station 1 to at least 1.5 mm more than
the required filling for press station 2.
è For removing the dosing unit set the wall dimension pre-pressure of press station
2 to at least 21 mm.

330 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Required parts

62-001_en
Illustration 387: Tabletting - Set-up

11.2 Required parts

Notice:
The part numbers vary according to version and tool. Please take
the numbers from the order-related spare parts list.

The following components are necessary for the conversion:

Designation
Block for control cam
Control cam
Transition cam for fixing devices
Ejection bar block
Ejection bar
Product scraper
Fillshoe 2
Fillshoe 2 base
Cam track

Notice:
The conversion from double press to bi-layer press can be
executed both with fitted and with dismantled die table. For a better
representation the following photos show the conversion with the
die table dismantled.

007.2/SYN7ZS/BA/en 331 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Main pressure roller of press station 1

11.3 Main pressure roller of press station 1

Notice:
Prior to fitting the cam track the main pressure roller at press
station 1 must be lifted by approx. 8-9 mm to make way for the 5
mm thick cam track.

• Swing the upper pressure roller block out, as described in chapter Service, section
"Pressure roller block".

è Fix the cam track – Part-No. 243202 -2

– to the pressure rolle block with two M8
Allen screws. Threaded bore (1) for M8
Allen screws
1

Illustration 388: Cam track for fixing to the main

pressure roller of press station 1

• Swing the upper pressure roller block back, as described in chapter Service,
section "Pressure roller block".

11.4 Removal of the pull-down cam

Notice:
Store and preserve the dismantled parts so that they are kept as a
conversion kit for a possible re-conversion.

The pull-down cam must be replaced by a transition cam for bi-layer press operation.

è Remove the dismantling station.

04-152
Illustration 389: Removing the dismantling station

332 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Removal of the pull-down cam

è Detach the toggle (2) and dismantle the

pull-down cam with the console. 1

è Detach the lubrication lines (1).

04-154
Illustration 390: Pull-down cam, complete with console

è Connect the ends of the lubrication lines

with a connecting piece.

04-158
Illustration 391: Connecting the lubrication lines

007.2/SYN7ZS/BA/en 333 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Removal of the double press ejection bar

11.5 Removal of the double press ejection bar

Notice:
Store and preserve the dismantled parts so that they are kept as a
conversion kit for a possible re-conversion.

The longer ejection bar used for double press operation must be replaced with the
short ejection bar with block for bi-layer press operation.

è Detach the connecting bolts by pressing

the center pins and remove the ejection
bar for double press operation.

04-157
Illustration 392: Removing the ejection bar

334 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Removal of catch cam and control cam

11.6 Removal of catch cam and control cam

Structure

1 2 3

4
4
5
04-145

Illustration 393: Catch cam and control cam

1 Catch cam

2 Spring

3 Control cam

4 Positioning screws

5 Adjusting screws

è Detach the positioning screws and the

adjusting screw and remove the catch
cam. Proceed in the same way with the
control cam.

04-159
Illustration 394: Dismantling the catch cam

007.2/SYN7ZS/BA/en 335 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Removal of the double press dosing unit

11.7 Removal of the double press dosing unit

è Detach the lubrication line of the dosing
unit for double press operation.

04-150
Illustration 395: Detaching the lubrication line

è Detach the fixing screw of the dosing

unit.

04-144
Illustration 396: Detaching the dosing unit

è Remove the dosing unit.

04-160

336 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Fitting of the bi-layer press dosing unit
Illustration 397: Removing the dosing unit

11.8 Fitting of the bi-layer press dosing unit

1

2
04-142

Illustration 398: Dosing unit for bi-layer press operation (1) and double press operation (2)

è Mount the dosing unit for bi-layer press

operation and connect the lubrication
line (1). 1

04-161
Illustration 399: Fitting the dosing unit for DL operation

007.2/SYN7ZS/BA/en 337 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Fitting of the control cam with console

11.9 Fitting of the control cam with console

Structure

1
2

5
3

04-136
Illustration 400: Control cam with console for bi-layer press operation

1 Control cam

2 Control cam adjusting screw

3 Console of the control cam

4 Fixing screws of the console

5 Positiong screws of the control cam

338 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Fitting of the control cam with console

è Mount the console of the bi-layer press

control cam with the fixing screws.

04-156
Illustration 401: Fitting the console for the control cam

è Insert the spring into the control cam

and screw the adjusting screw into the
dosing unit through the spring. Leave
the adjusting screw in dismantling
position and do not tighten it firmly until
the die table has been fitted. Firmly
tighten the fixing screws.

04-162
Illustration 402: Fitting the control cam

007.2/SYN7ZS/BA/en 339 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Fitting of the intermediate piece

11.10 Fitting of the intermediate piece

è Mount the complete bi-layer press
transition cam with console and tighten 1
the toggle (2) and the star grip screw
(1).

04-163
Illustration 403: Fitting the intermediate piece

11.11 Fitting of the bi-layer press ejection bar

è Actuate the die ejector so that the piston
rod (1) is lifted by means of the
hydraulics. Insert the block required for
the shorter ejection bar.

04-164
Illustration 404: Lifted piston rod

340 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Fitting of the bi-layer press ejection bar

è Insert the ejection bar.

04-165
Illustration 405: Inserting the ejection bar

è Fix the ejection bar with the connection

bolts (1).
1

04-166
Illustration 406: Fixing the ejection bar

007.2/SYN7ZS/BA/en 341 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Fillshoe

11.12 Fillshoe
è Mount the fillshoes for bi-layer operation
at both press stations (see also chapter
"Service", section "Fillshoe") for bi-layer
press operation. Please take the part
numbers for fillshoe upper parts (1) and 1
lower parts (2) from the spare parts list.

04-168
Illustration 407: Installing the fillshoe

Notice:
The spare part numbers vary depending on the version. Plase take
these numbers from the order-related spare parts list.

Notice:
Due to the necessity for an exact level setting, the fillshoes for
pressing position 1 should not be mixed up with those for pressing
position 2.

11.13 Bi-layer press scrapers

è Replace the scrapers with the scrapers
for bi-layer operation. At press station 1
the scraper (1), at press station 2 the
scraper (2).
1

04-169
Illustration 408: Scraper for bi-layer operation

Notice:
The scrapers for pressing position 1 and pressing position 2
should not be mixed up with each other.

342 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a double press to a bi-layer press
Suction unit

11.14 Suction unit

è Mount the ventilation in front of the
fillshoe (1) and connect the ventilation
support with the suction hose (2).

04-170
Illustration 409: Mounting the ventilation

007.2/SYN7ZS/BA/en 343 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Settings on the control system

12 Converting from a bi-layer press to a double

press
12.1 Settings on the control system
If the tablet press is to be run in double press operation, the control system must be
set as follows.

è Ensure that the machine is in Set-up mode.

è Open mask System > Machine.
è Load the machine data record for double press operation, in the example given file
"[Link]".
è In addition, load the data record for adjustment in mask System > Measuring
points > Machine.

60-137
Illustration 410: System – Machine – Data record

Notice:
After loading the data record the machine must be switched off and
then re-started.

è In mask Tabletting > Set-up, set the same standard values for P1 and P2 for the
penetration depth for prepressure and main pressure.
è In mask Tabletting > Set-up, set the wall dimension pre-pressure for press
station 2 to at least 21 mm to make the removal of the dosing unit possible.

344 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Required parts

62-001_en
Illustration 411: Tabletting – Set-up

12.2 Required parts

Notice:
The part numbers may vary, depending on version and tool. Please
refer to the order-related spare parts list for the numbers.
Designation
Fixing device for pull-down cam
Pull-down cam
Dismantling station
Ejection bar
Catch cam
Control cam
2 fillshoes
2 fillshoe bases
2 scrapers

Notice:
The conversion from bi-layer press to double press can be
executed both with fitted and with dismantled die table. For a better
representation the following photos show the conversion with the
die table dismantled.

007.2/SYN7ZS/BA/en 345 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Main pressure roller of press station 1

12.3 Main pressure roller of press station 1

The cam track, 5 mm thick (part No. 243202), mounted to the main pressure roller of
press station 1, must be removed.

è Swing the upper pressure roller block out as described in chapter Service, section
"Pressure roller block".

è Unscrew the M8 Allen screws fixing the

cam track to the pressure roller block
from their sockets (1) and remove the
cam track.
1

Illustration 412: Cam track to be mounted to the main

pressure roller press station 1

è Swing the upper pressure roller block back as described in chapter Service,
section "Pressure roller block".

346 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Structure

12.4 Structure
5
1

2 6

7
3

04-132
Illustration 413: Lower cam track zone

Transition cam for bi-layer operation

1
Ejection bar
2
Ejection bar block
3
Hydraulic cylinder
4
Dosing unit
5
Control cam
6
Fixing device of control cam
7

007.2/SYN7ZS/BA/en 347 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Removal of the bi-layer press ejection bar

12.5 Removal of the bi-layer press ejection bar

The short ejection bar with the block used for bi-layer operation must be replaced with
a longer ejection bar for double press operation.

è Press the centre pins of the connecting

bolts (1) and remove them.

04-133
Illustration 414: Removing the connecting bolts

è Remove the ejection bar.

04-134
Illustration 415: Short ejection bar with block

348 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Removal of the bi-layer press ejection bar

è Loosen the star grip screw (1) and the

toggle (2) and remove the bi-layer press 1
transition cam complete with the
console.

04-135
Illustration 416: Removing the intermediate piece

è Actuate the die ejector (1).

04-137
Illustration 417: Actuating the die ejector

007.2/SYN7ZS/BA/en 349 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Removal of the bi-layer press ejection bar

è The piston rod (1) is lifted by means of

the hydraulics so that the block (2) can
be removed.

04-138
Illustration 418: Lifted piston rod

350 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Removal of the control cam

12.6 Removal of the control cam

1
2

5
3

04-136
Illustration 419: Control cam with console for bi-layer press operation

1 Control cam

2 Control cam adjusting screw

3 Console of the control cam

4 Fixing screws of the console

5 Positiong screws of the control cam

007.2/SYN7ZS/BA/en 351 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Removal of the control cam

è Loosen the positioning screws (outside)

and the adjusting screw (centre) of the
control cam and remove it.

04-139
Illustration 420: Dismantling the control cam

è Loosen the fixing screws of the fixing

device and remove it.

04-140
Illustration 421: Fixing device of control cam

352 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Removal of the dosing unit

12.7 Removal of the dosing unit

1

2
04-142

Illustration 422: Dosing unit for bi-layer press operation (1) and double press operation (2)

è Loosen and remove the fixing screw (1)

of the dosing unit of press station 2.
1

04-141
Illustration 423: Loosening the fixing screw

007.2/SYN7ZS/BA/en 353 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Fitting of the double press dosing unit

è Disconnect the lubrication line (1) and

remove the dosing unit – part No.
10242658 K06.
1

04-143
Illustration 424: Removing the dosing unit

12.8 Fitting of the double press dosing unit

è Install the dosing unit for double press
operation.

04-151

04-144
Illustration 425: Fitting the dosing unit

354 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Fitting of the double press dosing unit

è Pay attention that the eye for lower

punch tightness detection is put onto the
corresponding pin (1).

04-146
Illustration 426: Pin for the eye

è Fix the lubrication line of the dosing unit.

04-150
Illustration 427: Lubrication line of dosing unit

007.2/SYN7ZS/BA/en 355 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Fitting of control cam and catch cam

12.9 Fitting of control cam and catch cam

Structure

1 2 3

4
4
5
04-145

Illustration 428: Catch cam and control cam

1 Catch cam

2 Spring

3 Control cam

4 Positioning screws

5 Adjusting screws

è Insert the spring (1) into the control cam

and screw the adjusting screw into the 1
dosing unit through the spring. Leave
the adjusting screw in dismantling
position and do not tighten it firmly until
the die table has been fitted. Firmly
tighten the fixing screws.

04-147
Illustration 429: Fitting the control cam

356 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Pull-down cam

è Repeat the procedure with the catch

cam (2).

04-153
Illustration 430: Fitting the catch cam

12.10 Pull-down cam

The transition cam must be replaced by a pull-down cam for double press operation.

è Connect the lubrication lines (1) to the

pull-down cam. 1
è Insert the pull-down cam complete with
the console and fix it by turning the
toggle (2).

04-148
Illustration 431: Installing the pull-down cam for double
press operation

007.2/SYN7ZS/BA/en 357 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Fitting of the double press ejection bar

12.11 Fitting of the double press ejection bar

è Install the ejection bar and fix it with the
connecting bolts.

04-149
Illustration 432: Fitting the ejection bar

è Install the dismantling station.

04-152
Illustration 433: Fitting the dismantling station

358 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Converting from a bi-layer press to a double press
Fillshoe

12.12 Fillshoe
è Install the fillshoes for double press
operation on both press stations. Please
refer to the spare parts list for the part
numbers of the upper part (1) and lower
part (2) of the fillshoe. 1

04-168
Illustration 434: Fitting the fillshoe for double press
operation

Notice:
The spare part numbers may vary depending on the version. Please
refer to the order-related spare parts list.

12.13 Scrapers
è Replace the scrapers by the scrapers for double press operation.

Notice:
Please refer to the order-related spare parts list for the part
numbers.

12.14 Suction unit

è Disconnect the venting unit in front of
the fillshoe (1) from the suction hose (2)
and remove the venting unit.

04-170
Illustration 435: Removing the venting unit

007.2/SYN7ZS/BA/en 359 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Decommissioning and storage
Suction unit

13 Decommissioning and storage

This section provides information regarding decommissioning and storage of the tablet
press. Read this section carefully prior to carrying out the work.
This documentation must be read by all persons who service the product. If the
product is sold to a third party, the complete technical documentation must be
supplied with it.

Notice:
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this document.
The operator of the tablet press is responsible for proper
decommissioning of the machine.

CAUTION
Safeguard the decommissioned tablet press from
unauthorised usage and display the appropriate warning
signs.

If you carry out

è servicing and maintenance work or
è a product change

on the tablet press, it must temporarily be decommissioned.

Proceed as follows:
è Stop the product feed.
è Empty the tablet press. (see chapter Service, page 220).
è Clean the tablet press.
è Depressurize the hydraulic system (see chapter Service, page 310).
è Switch the tablet press off with the main switch and protect the tablet press
against being switched on unintentionally.
è Erect warning signs.
è Switch the suction unit off.
è Switch the peripheral devices off and disconnect them from the tablet press.
è Detach all compressed air connections.
è Carry out service and maintenance works as described in the relevant chapters of
this operating instruction.

CAUTION
After servicing, the tablet press must be released for
operation by a responsible person designated by the plant
operator.

Short-term storage of the tablet press does not require any special actions. It may,
however, only be stored in dry rooms because of the electrical and electronic
components.

360 / 409 007.2/SYN7ZS/BA/en

 Technical Documentation
Operating Instruction
Synthesis 700ZS Decommissioning and storage
Suction unit

Proceed as follows:
è Stop the product feed.
è Empty the tablet press. (see chapter Service, page 220).
è Clean the tablet press.
è Depressurize the hydraulic system (see chapter Service, page 310).
è Switch the tablet press off with the main switch and protect the tablet press
against being switched on unintentionally.
è Erect warning signs.
è Switch the suction unit off.
è Switch the peripheral devices off and disconnect them from the tablet press.
è Detach all compressed air connections.
è Disconnect all electrical connections for current supply.
è Prepare the tablet press so far that it can be transported to the storage site by
means of an appropriate transport device.

Notice:
For storage lasting several weeks you must remove the tools and
preserve them. Spray the die table in addition with a suitable
preservation agent.

CAUTION
Lack of lubricants!
After storage for a longer period, the tablet press must be
thoroughly cleaned and the operating material must be renewed
prior to recommissioning.

If you
è scrap the tablet press this means final decommissioning.

Proceed as follows:
è Stop the product feed.
è Empty the tablet press. (see chapter Service, page 220).
è Clean the tablet press.
è Depressurize the hydraulic system (see chapter Service, page 310).
è Switch the tablet press off with the main switch and protect the tablet press
against being switched on unintentionally.
è Erect warning signs.
è Switch the suction unit off.
è Switch the peripheral devices off and disconnect them from the tablet press.
è Detach all compressed air connections.
è Disconnect all electrical connections for current supply.
è Drain the lubricants and clean the components conducting lubricants.
è Dispose of the tablet press according to the valid regulations.

CAUTION
Discharge the tablet press and dispose of the lubricants
according to the local regulations and the general guidelines
to avoid harm to the environment.

007.2/SYN7ZS/BA/en 361 / 409

 Technical Documentation
Operating Instruction
Synthesis 700ZS Accessories
Standard Accessories

14 Accessories
14.1 Standard Accessories
This section provides information regarding the standard accessories and additonal
components available as options. Read this section carefully prior to commissioning
the tablet press.

Die fitting tool

Tool for fitting the dies.

Illustration 436: Die fitting tool

Die ejector
Tool for manual removal of dies when the die table is dismantled. Only in connection
with an MTS 500/700.

Illustration 437: Die ejector

Feeler gauge
Gauge (0.05 mm) for setting the distance of the fillshoe to the die table

00-006
Illustration 438: Feeler gauge

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Die fixing screws

Screws, complete with taper for fixing the dies in the die table

Illustration 439: Die fixing screw

Protecting cap
for hydraulic die ejector
Protective element for fitting on hydraulic cylinder.

Illustration 440: Protecting cap

Straight-edge (with transport bag)

Setting of the position of the fillshoe base.

Illustration 441: Straight-edge

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Transport bolts
Crane transport equipment

Illustration 442: Transport bolts

Dismantling tool
Lifting the Allen screws in the lower pressure roller block.

00-013
Illustration 443: Dismantling tool

Dismantling device for pressure roller block

For lifting the pressure roller blocks

00-015
Illustration 444: Dismantling device for pressure roller block

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Cleaning scraper
Cleaning the die bore.

Illustration 445: Cleaning scraper

Torque wrench
Torque wrench for die fixing screws with torque 10 Nm

Illustration 446: Torque wrench < 10 Nm

Torque wrench for screws with torque > 10 Nm

Illustration 447: Torque wrench > 10 Nm

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Standard Accessories

Calibration aid
For locking the die table during calibration.

Illustration 448: Calibration aid

Pressure piece
for hydraulic die ejector
Intermediate element for removing the dies

Illustration 449: Pressure piece

Removal aid
Removal aid for detaching the retaining screws of the upper pressure roller block.

Illustration 450: Removal aid

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Manual switch
The manual switch (which is situated behind the front door) is required for
disassembly/assembly of the die table.

Illustration 451: Manual switch

Standard tools
Standard tool (e.g. jaw wrench) for servicing and setting work. The equipment varies
acc. to machine type and/or options.

Illustration 452: Standard tool 1

Illustration 453: Standard tool 2

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Lubrication tools

Illustration 454: Grease gun

Illustration 455: Oil can

Other accessories
Tool scraper (upper/lower punches). The equipment/quantity varies acc. to machine
type and/or options.

Illustration 456: Scraper for upper and lower punches

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For fixing the punch bellows to the die table (upper/lower punches). The
equipment/quantity varies acc. to machine type and/or options.

Illustration 457: Fixing clip for punch bellow (upper and lower punches)

For sealing the tools (upper/lower punches) against product dust. The
equipment/quantity varies acc. to machine type and/or options.

Illustration 458: Punch bellow (upper and lower punches)

Sealing of fillshoe drives. Two pieces are contained in the scope of supply.

Illustration 459: Sealing of fillshoe drive

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The lower punches are prevented from dropping by grippers or so-called brake
magnets. These are mounted in the die table. A certain quantity is contained in the
scope of delivery.

Illustration 460: Brake magnet / gripper

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Optional Accessories

14.2 Optional Accessories

Transport carriage
The transport carriage is intended for the deposit of the dismantled components of a
Synthesis tablet press.

Illustration 461: Representation of a transport carriage for Synthesis 500 WIP

Die table transport system (MTS)

The lift truck is an industrial truck for lifting and transporting the die table (only
Synthesis series) within the plant. The MTS is supplied with electrical drive.

Illustration 462: Representation MTS700 with electrical drive

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Optional Accessories

15 Contact to the manufacturer

Address IMA KILIAN GmbH & Co. KG
Scarletallee 11
D - 50735 Cologne/Germany
Phone +49 (02 21) 71 74 - 02
Fax +49 (02 21) 71 74 - 110
E-mail address info@[Link]
Customer Service +49 (02 21) 71 74 - 120

Transmission and copying of this document, commercial use

and communication of its contents are not permitted without
explicit consent. Infringements are subject to compensation. All
rights in the case of award of patents or registered designs are
reserved." (According to DIN 34)
The IMA KILIAN quality management system has been certified
by TÜV Rheinland acc. to DIN EN ISO 9001 since 1996.

Issue of the Declaration of Conformity and attachment of the CE

sign. Certification about the compliance with the procedure
required for CE marking and the presence of a Technical
Documentation.

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General

16 Glossary
16.1 General
This section provides information regarding the abbreviations and technical terms
used in the documentation and the user interface.
In addition it provides a list of IMA KILIAN suppliers with their respective contact
information. With this, you will find the corresponding information concerning the
respective components, in the languages provided by the supplier.
This documentation must be read by all persons who operate or service the product.
If the product is sold to a third party, the complete technical documentation must be
supplied with it.

Note:
We reserve the right of changes relating to the technical
equipment, operation or function, even if these changes may not
yet be considered in this document.

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Supplier list

16.2 Supplier list

A
Supplier Contact Web site
AirCom Pneumatic GmbH [Link]
AirCom Siemensstraße 18
40885 Ratingen
Phone: +49 (0)2102 / 73390-0
Fax: +49 (0)2102 / 73390-10
E-mail: info@[Link]
AViTEQ Vibrationstechnik GmbH [Link]
AViTEQ Im Gotthelf 16
D-65795 Hattersheim-Eddersheim
Phone: +49 (0)6145 / 503-0
Fax: +49 (0)6145 / 503-200
E-mail: service@[Link]
ARP DATACON GmbH [Link]
Arp Datacon
Waldstraße 23
63128 Dietzenbach
Phone: +49 (0)6074 / 491 100,
Fax: +49 (0)6074 / 491 111
E-mail: verkauf@[Link]
AZO GmbH + Co. Industriegebiet Ost [Link]
AZO
D-74701 Osterburken,
Postfach 1120,
D-74706 Osterburken,
Rosenberger Str.
Phone.: +49 (0)6291 / 92-0,
Fax: +49 (0)6291 / 8928
E-mail: info@[Link]

B
Supplier Contact Web site
Bachmann electronic GmbH [Link]
Bachmann
Kreuzäckerweg 33
A-6800 Feldkirch
Phone: +43 / 5522 / 3497-0
Fax: +43 / 5522 / 3497-102
E-mail: info@[Link]
Baumer GmbH [Link]
Baumer
Pfingstweide 28 m/
D-61169 Friedberg
Phone: +49(0) 6031 60070
Fax: +49(0) 6031 600770
E-mail: [Link]@[Link]
Balluff GmbH [Link]
Balluff Postfach 1160
D-73761 Neuhausen
Phone: +49 (0)7158/173-0
Fax: +49 (0)7158/5010

Franz Binder GmbH + Co. elektrische [Link]

Binder
Bauelemente KG [Link]
Rötelstraße 27
D-74172 Neckarsulm
Phone: +49 (0)7132/325-0
Fax: +49 (0)7132/325-150
E-mail: info@[Link]
Bürklin OHG [Link]
Buerklin
Schillerstraße 41
D-80336 München
Phone: +49 (0)89/55875-0
Fax: +49 (0)89/55875-421
E-mail: info@[Link]

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Supplier Contact Web site

BIJUR LUBRICATING CORPORATION [Link]
Bijur
808 Aviation Parkway
Suite 1400
Morrisville, NC 27560
Christian Bürkert GmbH & Co. KG [Link]
Bürkert Christian-Bürkert-Straße 13-17
D-74653 Ingelfingen
Phone: +49 (0)794010-0
Fax: +49 (0)794010-204
E-mail: info@[Link]
Brabender GmbH & Co. KG [Link]
Brabender
Kulturstraße 51 – 55
D-47055 Duisburg
Phone: +49 (0)203 7788 0
Fax: +49 (0)203 7788 100
E-mail: brabender@[Link]

C
Supplier Contact Web site
CARLO GAVAZZI AUTOMATION SpA [Link]
Carlo Cavazzi
Via Milano 13 [Link]
I-20020 Lainate
Italy
Phone: +39 02 931 761
Fax: +39 02 931 76402
E-mail: website@[Link]
Cisco Systems Europe [Link]
Cisco Systems
11 Rue Camille Desmoulins
92782 Issy-les-Moulineaux
Cedex 9
France
Phone: 33 1 58 04 60 00
Fax: 33 1 58 04 61 00
Costruzioni Elettroniche Industriali [Link]
CEIA
Automatismi
Zona [Link] Viciomaggio
I-52041 Arezzo
Phone: +39 0575 418211
Fax: +39 0575 418296
E-mail: qa-detectors@[Link]
CFM REITEK INDUSTRIESAUGER GmbH [Link]
CFM Reitek
Zeppelinstraße 6
D-53424 Remagen Germany
Phone: +49 (0)2642 / 990880
Fax: +49 (0)2642 / 9908899
E-mail: info@[Link]

D
Supplier Contact Web site
E. DOLD & SÖHNE KG [Link]
Dold
D-78114 Furtwangen
Phone: +49 (0)7723 / 654 0
Fax: +49 (0)7723 / 654 356
E-mail: dold-relays@[Link]
Digitec Vertriebs GmbH [Link]
Digitec
Rheinstraße 12
D-76829 Landau
Phone: +49 (0)6341 / 94 94-50
Fax: +49 (0)6341 / 94 94-59
E-mail: info@[Link]

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E
Supplier Contact Web site
Elektrobauelemente GmbH & Co. KG [Link]
elobau Zeppelinstraße 44
D-88299 Leutkirch
Phone: +49 (0)7561 / 970-0
Fax: +49 (0)7561 / 970-100
E-mail: info@[Link]
ESCHA TSL GmbH [Link]
Escha Elberfelder Str. 1
D-58553 Halver
Phone: +49 (0)23 53 / 66796-0
Fax: +49 (0)23 53 / 66796-99
E-mail: info@[Link]
Measurement Specialties, Inc. – Humirel
entran [Link]
105 avenue du gèral Eisenhower BP 23705
31037 Toulouse Cedex 1 France
Phone: +33 (0)561 / 194 543
Fax: +33 (0)561 / 194 553

F
Supplier Contact Web site
Finder GmbH [Link]
Finder
Eisenstr. 30 [Link]
D-65458 Rüsselsheim [Link]?lang=en
Phone: +49 (0)6142 / 8770
Fax: +49 (0)6142 / 87777
E-mail: info@[Link]
A. Friedr. FLENDER AG [Link]
Flender
Alfred-Flender Str. 77
D-46395 Bocholt
Phone: +49 (0)2871 / 92-0
Fax: +49 (0)2871 / 2-2596
E-mail: contact@[Link]

G
Supplier Contact Web site
GIA mbH Gesellschaft für innovative http:// [Link]
GIA
Automationstechnik mbH
In der Schlenke 32
D-59192 Bergkamen
Phone: +49 (0) 2306 / 94 490-0
Fax: +49 (0) 02306 / 94 490-20
E-mail: info@[Link]
GLATT GmbH [Link]
Glatt
Systemtechnik
D-01277 Dresden
Grunaer Weg 26
Phone: +49 (0) 351 / 2584-0
Fax: +49 (0 )351 / 2584-328
E-mail: info@[Link]

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H
Supplier Contact Web site
HAHN-Gasfedern GmbH [Link]
HAHN Waldstraße 43
D-73773 Aichwald
Phone: (0711) 93 67 05 - 0
Fax: (0711) 93 67 05 - 40
E-mail: info@[Link]
HAPRO Industriegeräte GmbH [Link]
HAPRO Elsässer Str. 14-18
D-42697 Solingen
Phone: +49 (0)212 / 31 73 74
Fax: +49 (0)212 31 73 15
HARTING KGaA [Link]
Harting Marienwerderstr. 3
D-32339 Espelkamp
Phone: +49 (0)5772 / 470
Fax: +49 (0)5772 / 47 400
E-mail: info@[Link]
Häwa GmbH & Co. KG [Link]
Häwa
Industriestraße 12
D-88489 Wain
Phone: +49 (0)7353 / 986-0
Fax: +49 (0)7353 / 1050
E-mail: info@[Link]
HAWE Hydraulik GmbH & Co. KG [Link]
Hawe
Streitfeldstr. 25
D-81673 Munich
After Sales Service
Spare parts
Phone: +49 (0)89 / 43188-363
Fax: +49 (0)89 / 43188-249 or -176
E-mail: spareparts@[Link]
Repair / maintenance
Phone: +49 (0)89 / 43188-491
Fax: +49 (0)89 / 43188-324
E-mail: service@[Link]
Hottinger Baldwin Messtechnik GmbH [Link]
HBM
Im Tiefen See 45,
D-64293 Darmstadt
Phone: +49 (0)6151 / 8030
Fax: +49 (0)6151 / 8039100
E-mail: info@[Link]
HEB Hydraulik-Elementebau GmbH [Link]
HEB
Postfach 10 0117
D - 79120 Freiburg
Bebelstr. 21,
D-79108 Freiburg-Hochdorf,
Phone: +49 (0)761 / 13 0 99-0,
Fax: +49 (0)761 / 13 50 66
E-mail: info@[Link]
Hirschmann Industries GmbH [Link]
Hirschmann
Stuttgarter Str. 45-51
D-72654 Neckartenzlingen
Hirschmann Competence Center
Phone: +49 (0)1805 / 14-1538
Fax: +49 (0)7127 / 14-1551
E-mail: HAC-Support@[Link]
Hugo Müller GmbH & Co KG [Link]
Hugo Mueller Sturmbühlstraße 145-149
D-78054 VS-Schwenningen
Phone: +49 (0)7720 / 80 836
Fax: +49 (0)7720 / 31 083
E-mail: info@[Link]

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Supplier Contact Web site

Hewlett-Packard GmbH [Link]
HP
Herrenberger Str. 140 y/de/de/[Link]
D-71034 Böblingen
Phone: +49 (0)7031 / 14-0
Fax: +49 (0)7031 / 14-2999
E-mail: [Link]@[Link]
Honeywell Deutschland Holding GmbH [Link]
Honeywell Kaiserleistraße 39
D-63067 Offenbach
Phone: +49 (0)69 / 80 64-0
Fax: +49 (0)69 / 81 86 20
E-mail: [Link]@[Link]
Dr. E. Horn GmbH [Link]
Hornel Messgerätefabrik
Im Vogelsang 1
D-71101 Schönaich
Phone: +49 (0)7031 / 63 02 01
Fax: +49 (0)7031 / 65 45 88
E-mail: Dr._E._Horn_GmbH@[Link]
HYDROTECHNIK GmbH [Link]
HYDROTECHNIK Holzheimer Straße 94-96
D-65549 Limburg
Phone: +49 (0)6431 / 4004-0
Fax: +49 (0)6431 / 45308

I-J
Supplier Contact Web site
I
ifm Electronic GmbH [Link]
IFM
Teichstraße 4
D-45127 Essen
Phone: +49 (0)201 / 24 22-0
Fax: +49 (0)201 / 2422-200
E-mail: info@[Link]
INTERCONTEC Produkt GmbH [Link]
Intercontec
Bernrieder Straße 15
D-94559 Niederwinkling
Phone: +49 (0)9962 / 2002-0
Fax: +49 (0)9962 / 2002-70
E-mail: info@[Link]
Innovative Produktionstechnik D. Reisen e.K. [Link]
INPROTEC Sohlweg 25
D-41372 Niederkrüchten
Phone: +49 (0)2163 / 8468
Fax: +49 (0)2163 / 8462
E-mail: info@[Link]
J
JUMO GmbH & Co. KG [Link]
JUMO Moltkestraße 13 - 31
D-36039 Fulda
Phone: +49 (0)661 / 6003-0
Fax: +49 (0)661 / 6003-500
E-mail: mail@[Link]

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K-L
Supplier Contact Web site
K
KALEJA Elektronik GmbH [Link]
KALEJA Strübelweg 14
D-73553 Alfdorf
Phone: +49 (0)7172 / 93711-0
Fax: +49 (0)7172 / 93711-90
E-mail: info@[Link]
KEB Barntrup [Link]
KEB
Karl E. Brinkmann GmbH
Försterweg 36 - 38
D-32683 Barntrup
Phone: +49 (0)5263 / 4010
Fax: + 49 (0)5263 / 401116 E-mail:
info@[Link]
Klüber Lubrication München KG [Link]
Klüber Geisenhausenerstr. 7
D-81379 München
Phone: + 49 (0)89 / 78 76-0
Fax: + 49 (0)89 / 78 76-333
E-mail: [Link]@[Link]
Kuhnke Automation GmbH & Co. KG [Link]
Kuhnke
Lütjenburger Straße 101
D-23714 Malente
Phone: +49 (0)4523 / 402 200
E-mail: service@[Link]
Krämer AG [Link]
Krämer
Grindelstrasse 23
CH-8303 Bassersdorf (SWITZERLAND)
Phone: +41 (0)44 838 44 66
Fax: +41 (0)44 838 44 60
E-mail: sales@[Link]
KROHNE Messtechnik GmbH & Co. KG [Link]
KROHNE
Ludwig Krohne Str. 5
D-47058 Duisburg
Phone: +49 (0) 203 301-0
Fax: +49 (0)203 301- 10 389
E-mail: info@[Link]
Koerfers GmbH [Link]
Koerfers
Lötscher Weg 78 [Link]/
D - 41334 Nettetal
Phone: +49 (0)2153 / 72 05 1 + 73 98 12
Fax: +49 (0)2 153 / 70 97 2
E-mail: koerfers@[Link]
L
U.I. Lapp GmbH [Link]
Lapp
Schulze-Delitzsch-Straße 25
D-70565 Stuttgart
Phone: +49 (0)711 / 7838-01
Fax: +49 (0)711 / 7838-2640
E-mail: info@[Link]
Lenze AG [Link]
Lenze Hans-Lenze-Straße 1 [Link]
D-31855 Aerzen
Phone: +49 (0)5154 / 82 0
Fax: +49 (0)5154 / 82 2800
E-mail: lenze@[Link]
LEMO Elektronik GmbH [Link]
Lemosa Hanns-Schwindt-Str. 6
D-81829 München
Phone: +49 (0)89 / 42 77 03
Fax: +49 (0)89 / 420 21 92
E-mail: info@[Link]

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Supplier Contact Web site

LOCK Inspection Systems Ltd. [Link]
LOCK
Lock House Neville Street /
UK Oldham Lancs
OL9 6LF
Phone: +44 (0)161 624 0333
Fax: +44 (0)161 624 5181
E-mail: marketing@[Link]
LUBE USA INC. [Link]
Lube 781 Congaree Road
Greenville, SC 29607 USA
Phone: +1 864-297-3950
Fax: +1 864-242-1652
E-mail: sales@[Link]

M-O
Supplier Contact Web site
M
ODU Steckverbindungssysteme GmbH &Co. [Link]
MAC
KG
Otto Dunkel GmbH
Pregelstraße 11
D-84453 Mühldorf
Phone: +49 (0) 8631 / 6156-0
Fax: +49 (0) 8631 / 6156-49
E-mail: zentral@[Link]
Marx Transformatorenbau GmbH & Co. KG [Link]
Marx
Gutenbergstraße 7 .html
Transformatoren D-54516 Wittlich
Phone: +49 (0) 6571 / 95200
Fax: +49 (0) 6571 / 952026
E-mail: verkauf@[Link]
MEGATRON Elektronik AG & Co. [Link]
MEGATRON
Industrietechnik
Hermann-Oberth-Str. 7
D-85640 Putzbrunn/München
Phone: +49 (0)89 / 460 94 -0
Fax: +49 (0)89 / 460 94 - 101
E-mail: sales@[Link]
Murrelektronik GmbH [Link]
Murr Elektronik
Falkenstraße 3 m/de/
D-71570 Oppenweiler
Phone: +49 (0)7191 / 47-0
Fax: +49 (0)7191 / 47-130
E-mail: info@[Link]
N
Netter GmbH [Link]
Netter Fritz-Ullmann-Straße 9 m/de/
D-55252 Mainz-Kastel
Phone: +49 (0)6134 / 2901-0
Fax: +49 (0)6134 / 2901-33
E-mail: info@[Link]
Neudecker & Jolitz GmbH & Co. [Link]
Neudecker & Jolitz Venneweg 28
D-48712 Gescher
Phone: +49 (0)2542 / 910 0
Fax: +49 (0)2542 / 910 290
E-mail: info@[Link]
O
Ortlinghaus-Werke GmbH [Link]
Ortlinghaus
Kenkhauser Str. 125
D-42929 Wermelskirchen
Phone: +49 (0)2196 / 85-0
Fax: +49 (0)2196 / 855-444
E-mail: info@[Link]

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Supplier Contact Web site

OMRON ELECTRONICS, INC. [Link]
OMRON
One East Commerce Drive .eu/
Schaumburg, IL 60173
1-800-55-OMRON

P-Q
Supplier Contact Web site
P
Pall GmbH [Link]
Pall Philipp-Reis Straße 6
D-63303 Dreieich
Phone: +49 (0)6103 / 3070
Fax: +49 6103-34037
E-mail: kundenservice@[Link]
Parker Hannifin GmbH & Co. KG [Link]
Parker
Pat-Parker-Platz 1
D-41564 Kaarst
Phone: +49 (0) 2131 4016 0
Fax: +49 (0) 2131 4016 9199
Pepperl+Fuchs GmbH [Link]
Peperl & Fuchs
Königsberger Allee 87 [Link]/[Link]
D-68307 Mannheim
Phone: +49 (0)621 776 / 0
Fax: +49 (0)621 776 / 271111
PHÖNIX Messtechnik GmbH [Link]
Phoenix
Salzschlirfer Straße 13
D-60386 Frankfurt/M.
Phone: +49 (0)69-41 67 42 -20
Fax: +49 (0)69-41 67 42 -29
sales@[Link]
Pfannenberg GmbH [Link]
Pfannenberg
Werner-Witt-Str. 1
D-21035 Hamburg
Phone: +49 (0)40 / 734 12-0
Fax: +49 (0)40 / 734 12-101
E-mail: [Link]@[Link]
SOC. COOP. BILANCIAI CAMPOGALLIANO [Link]
Pfister
A.R.L. g/home_e.shtml
41011 Campogalliano (MO) Via Ferrari, 16
Phone: +39 (0)59 893 611
Fax: +39 (0)59 527 079
E-mail: cb@[Link]
Phytron-Elektronik GmbH [Link]
Phytron
Industriestr. 12
D-82194 Gröbenzell
Phone: +49 (0)8142 / 503-0
Fax: +49 (0) 8142 / 503-190
E-mail: info@[Link]
Q

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R-T
Supplier Contact Web site
R
Rittal GmbH & Co. KG [Link]
Rittal Auf dem Stützelberg
D-35745 Herborn
Phone: +49 (0)2772 / 505-0
Fax: +49 (0)2772 / 505-2319
E-mail: info@[Link]
RECHNER Industrie-Elektronik GmbH [Link]
Rechner
Gaußstraße 8-10
D-68623 Lampertheim
Phone: +49 (0)6206 / 50070
Fax: +49 (0)6206 / 500720
E-mail: info@[Link]
Riegler & Co. KG [Link]
Riegler Schützenstraße 27,
D-72574 Bad Urach
Phone: +49 (0)7125 / 9497-0
Fax: +49 (0)7125 / 9497-97
E-mail: info@[Link]
Ruwac Industriesauger GmbH [Link]
Ruwac
Westhoyeler Str. 25
D-49328 Melle-Riemsloh
Phone: +49 (0)5226 / 9830-0
Fax: +49 (0)5226 / 9830-44
E-mail: ruwac@[Link]
R & S Informations- und Computersysteme [Link]
R&S
GbR
Riedstr. 2
D-53859 Niederkassel
Phone: +49 (0)2208 / 911115
Fax: +49 (0)2208 / 911116
E-mail: info@[Link]/
Helmut Rossmanith GmbH [Link]
Rossmanith
Stuttgarter Straße 159
D-73066 Uhingen
Phone: +49 (0)7161 - 3090-0
Fax: +49 (0)7161 / 3090-90
E-mail: post@[Link]
F
Sartorius AG [Link]
Sartorius
Weender Landstraße 94-108
D-37075 Göttingen
Phone: +49 (0)551 / 308 0
Fax: +49 (0)551 / 308 3289
SAFELINE LTD [Link]
Safeline
MONTFORD ST, SALFORD, IGLATERRA
Phone: +44 (0)161 848 8636
Fax: +44 (0)161 888 2292
SAT GmbH
SAT Bergheimer Str.13
D-53909 Zülpich
Phone: +49 (0)2 252 9447-0
Fax: +49 (0)2 252 9447-47
Schneider Electric GmbH [Link]
Schneider Gothaer Straße 29 [Link]
D-40880 Ratingen
Phone: +49 (0)2102 / 404-0
Fax: +49 (0)2102 / 404-92 56
E-mail: de-schneider-service@[Link]-
[Link]

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Supplier list

Supplier Contact Web site

Georg Schlegel GmbH & Co. KG [Link]
Schlegel
Am Kapellenweg
D-88525 Dürmentingen
Phone: +49 (0)7371 / 502-0
Fax: +49 (0)7371 / 502 49
E-mail: info@[Link]
Schneider Electric GmbH [Link]
Square D Gothaer Straße 29
D-40880 Ratingen
Phone: +49 (0)2102 / 404-0
Fax: +49 (0)2102 / 404-92 56
E-mail: de-schneider-service@[Link]-
[Link]
Siemens AG [Link]
Siemens
Wittelsbacherplatz 2 [Link]/
D-80333 München
Phone: +49 (0)69 / 797 6660
Sontheimer Elektroschaltgeräte GmbH [Link]
Sontheimer Laufamholzstraße 370-372 in_set.html
D-90482 Nürnberg
Phone: +49 (0)911 / 99502-0
Fax: +49 (0)911 / 99502-31
E-mail: info@[Link]
Schuricht Distrelec GmbH [Link]
Schuricht
Lise-Meitner-Str. 4
D-28359 Bremen
E-mail: scc@[Link]
SMC Pneumatik AG, [Link]
SMC
Dorfstrasse 7,
CH-8484 Weisslingen
Phone: +41 (0)52 396 31 31
Fax: +41 (0)52 396 31 91
E-mail: info@[Link]
D
Schneider Electric GmbH [Link]
Telemecanique
Gothaer Straße 29 [Link]
D-40880 Ratingen
Phone: +49 (0)2102 / 404-0
Fax: +49 (0)2102 / 404-92 56
E-mail: de-schneider-service@[Link]-
[Link]
Rockwell Automation [Link]
Tesch
Germany GmbH & Co. KG
Westring 222
D-42329 Wuppertal
Phone: +49 (0)202 / 7391-0
Fax: +49 (0)202 / 7391-115
E-mail: info@[Link]
Hans Turck GmbH & Co. KG [Link]
Turck
Witzlebenstraße 7
D-45472 Mülheim an der Ruhr
Phone: + 49 (0)208 / 4952-0
Fax: + 49 (0)208 / 4952-264
E-mail: more@[Link]
TWK- ELEKTRONIK GMBH [Link]
TWK D-40041 Düsseldorf
Heinrichstr. 85
Phone: +49 (0)211 / 632067
Fax: +49 (0)211 / 637705
E-mail: info@[Link]
Tyco Electronics Corporation [Link]
Tyco
1050 Westlakes Drive m
Berwyn, PA 19312
Phone: +1 610-893-9800

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U-Z
Supplier Contact Web site
U
Unitechnik Automatisierungs GmbH [Link]
Unitechnik Seeplanstraße 1
D-15890 Eisenhüttenstadt
Phone: +49 (0)3364 / 501-0
Fax: +49 (0)3364 / 501-148
E-mail: Unitechnik@[Link]
V
Willy Vogel AG [Link]
Vogel
Motzener Str. 35/37
D-12277 Berlin
Phone: +49 (0)30 / 72002-0
Fax: +49 (0)30 / 72002-111
W
WERMA Signaltechnik GmbH + [Link] [Link]
Werma D-78604 Rietheim-Weilheim
Phone: +49 (0)7424 / 9557-0
Fax: +49 (0)7424 / 9557-44
E-mail: info@[Link]
WAGO Kontakttechnik GmbH & Co. KG [Link]
Wago
Hansastr. 27 [Link]
D-32423 Minden
Phone: +49 (0)571 / 887-0
Fax: +49 (0)571 / 887-169
E-mail: info@[Link]
Würth Elektronik GmbH & Co. KG [Link]
Wuerth Elektronik
Salzstr. 21 [Link]
D-74676 Gröbenzell
Phone: +49 (0)7940 / 946-0
Fax: +49 (0)7940 / 946-400
E-mail: info@[Link]
WACHENDORFF [Link]
WACHENDORFF
PROZESSTECHNIK GMBH & CO KG
Industriestraße 7
D-65366 Geisenheim
Phone: +49 (0)6722 / 9965-0
Fax: +49 (0)6722 / 9965-43
EUGEN WOERNER GmbH & Co. KG [Link]
WOERNER Zentralschmieranlagen
Am Eichamt 8
D-97877 Wertheim
Germany
Phone: +49 (0)9342 / 803-0
Fax: +49 (0)9342 / 803-202
E-mail: info@[Link]
WIKA Alexander Wiegand GmbH & Co. KG [Link]
WIKA Alexander-Wiegand-Straße 30
D-63911 Klingenberg
Phone: +49 (0)9372 / 132-0
Fax: +49 (0)9372 / 132-406
E-mail: support-tronic@[Link]

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16.3 Technical terms

This section provides an overview and explanations of technical terms from the field of
IMA KILIAN tabletting technology. The purpose of this overview is on the one hand to
explain the respective technical terms to the customers, on the other hand to promote
the consistent application of these terms.
Technical term Definition

Filling The good tablets produced can be selected once more via a gate. This
means that several batches can be made from one good production.
Filling is effected by a signal to an external gate or to the IMA KILIAN
discharge system.

Covering segment The covering segment is located behind the fillshoe in front of the pre-
pressure roller. It prevents powder from being expelled from the dies, as
the upper punches are not yet down to prevent this.

Suction unit The suction comprises the total system of the tablet press used for
evacuating surplus press material from the compression chamber and thus
ensuring a reduction of soiling and wear.

Scrapers In the tablet press, two scrapers are used for each press station. The first
is placed in the fillshoe and removes the material which is above the upper
edge of the die table. For this the scraper is mounted at a very small
distance above the die table. The second scraper is placed behind the
main pressure rollers at the very position where the lower punches are put
to zero position. Thus the tablet has already been lifted out of the die at
this position. The scraper pushes the tablet to the outside where the tablet
drops into the tablet chute.

Start losses Number of reject tablets produced in the start-up phase of the die table

Start-up times Sum of production times of reject tablets during start-up and run-down of
the die table.

Start-up phase Production starts when the motor of the tablet press is engaged and the
die table starts to turn. During the first revolutions of the die table there
may be fluctuations of the main pressure. The tablets produced in this
period of time possibly do not meet the requirements. Therefore, with the
selection switched on, the main gate is activated first so that the first
tablets pressed are routed into the reject channel. The time until the set
values are reached is called start-up phase.

Start-up dosing Start-up dosing serves to facilitate starting up the machine under
production conditions (press material in the die between the pressure
rollers). Start-up dosing ensures a reduction of the filling volume in the die
(by raising the dosing cam) and this in turn brings about a reduction of the
compaction pressure.

Link track The link track is part of the lower cam track and represents the connection
between dosing cam / control cam and pre-pressure roller. It prevents the
lower punch from sliding downwards and thus not getting to the pre-
pressure roller properly.

Dismantling segment The dismantling segment is part of the upper cam track. The dismantling
segment has no special function for the production of the tablet. It serves
for the dismantling of dies and upper punches.

Dismantling piece The dismantling piece is part of the lower cam track. It has no direct
function for the production of the tablet. After removing this segment from
the lower cam track the lower punches can be pulled out downwards.

Blow-out position, fine With the fine blow-out position, the blow-out position within a punch
division (between two punches) can be determined more exactly. For this,
a punch division is subdivided in 4 parts, i.e. the fine division is a quarter of
a punch division.

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Technical term Definition

Blow-out position, rough When setting the blow-out time (selection), the period of time between
pressing a tablet and blowing it out is determined. The period of time is not
determined by a specified time interval, but by the number of punch
divisions (or the number of punch stations) between main pressure roller
and blow out nozzle. For the rough blow-out position, the number of whole
punch divisions (number of punch stations) is specified.

Ejection segment The ejection segment is part of the upper cam track. The ejection segment
pulls the upper punch from the die upwards above the fillshoe.

Oscillating ejection crank The oscillating ejection crank is part of the lower cam track. After pressing
the tablet is finished, it moves the lower punches upwards to eject the
tablet.

Ejection bar The ejection bar is part of the lower cam track. After pressing of the tablet
is finished, it moves the oscillating ejection crank upwards to eject the
tablet.

Outlet valve The outlet valve is situated under the fillshoe base. It serves for the
manual discharge of fillshoe and filling tube.

Operating hours Indication of the time the tablet press has been running with the clutch (or
drive) switched on.

Evaluation limit During tablet production, samplings are taken for the in-process control
(IPC) to check the tablet quality parameters and to process them
statistically. Several limiting values, which refer to the average, are
decisive for the in-process control. These include the evaluation limits TCU
(Tablet Check Unit) and VICON as well as the tolerance limits T0 - T2. The
plausibility of the measuring value is checked by means of the evaluation
limits. If a chosen number of single values are outside the evaluation
limits, the sample is rejected.

Batch A batch is a certain number of tablets being produced in one production

run. The batch has a designation and a production pre-set.

Batch end When the production pre-set has been reached, the batch must be
manually terminated by the operator. After batch end the production data
are collected and printed on the report printer

Batch end report The batch end report is a production report containing the production data
of the total production.

Defined force For calibrating the measuring points Main pressure and Pre-pressure a
calibration tool must be used. This calibration tool is positioned between
the pressure rollers and is pressurized. The force measuring unit of the
calibration tool can be used to read the exact force (defined force) and to
enter it into the connected control system or to calibrate displays.

Demineralised water Also called "deionised" or "purified" water. This is water without the
minerals contained in regular spring or tap water (salts, ions).

Distilled water Distilled water is water without the ions, trace elements and contaminants
contained in regular spring or tap water. Distilled water is obtained by
distillation (vaporisation and subsequent condensation) from standard tap
water or from pre-cleaned water (demineralised water). It is largely free of
salts, organic matters and microorganisms.

Thickness (wall dimension) Thickness of the tablets determined by the RQ (quality check unit) through
a sampling. The thickness is determined from the running production
without disturbing or interrupting production. The thickness determined is
also used for readjustment.

WSG The abbreviation stands for a wire strain gauge. WSGs are stuck onto
workpieces which are exposed to a force. By the force, the workpiece is
slightly deformed. The resistance of such a gauge is changed by this
deformation. The signal is processed by measuring amplifiers and is a
measure for the force affecting the workpiece.

Main pressure WSG The measuring point Main pressure consists of a lever, which is exposed
to deformation forces, and of a stuck-on wire strain gauge (WSG) for
measuring the deformation forces. These deformation forces change with
a constant reference to the compaction force and are used for control and
regulation purposes.

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Technical term Definition

Pre-pressure WSG The measuring point Pre-pressure either consists of a lever or a pin, which
is exposed to deformation forces, and of a stuck-on wire strain gauge
(WSG) for measuring these forces. These deformation forces change with
a constant reference to the compaction force.

Dosing cam The dosing cam is situated below the die table in the lower cam track. The
dosing cam can be adjusted in height. Through the height with reference
to the upper edge of the die table, the volume in the die and thus the fill
quantity changes. The dosing cam is part of the lower cam track. The
dosing cam pushes the lower punch upwards again to the dosing unit, as
more material is filled in with the pull-down cam than is needer later (back-
dosing)

Set-up The tablet press must be adjusted to the respective product, i.e. the
material to be pressed, and to the required characteristics of the tablet. For
this, tablets must be pressed on a trial basis. This operation mode of tablet
press and control system is called Set-up.

Penetration depth The measure by which the upper punch penetrates into the die.

Penetration depth main The penetration depth main pressure means how deep the upper punch
pressure penetrates into the die. Measured at the position where the upper punch
passes by the main pressure roller.

Penetration depth pre- The penetration depth pre-pressure means how deep the upper punch
pressure penetrates into the die. Measured at the position where the upper punch
passes by the pre-pressure roller.

Selection of individual The separation of individual tablets is called selection of individual

samples samples. The tablets are sorted out at the tablet scraper by means of
compressed air and are routed into the reject channel of the tablet chute.

Catch cam The catch cam is fixed to the dosing cam and is part of the lower cam
track. It prevents the lower punch from moving too far upwards and
ensures the proper insertion into the control cam.

Fill height The fill height is the distance from the upper edge of the lower punches to
the upper edge of the die table. The fill height is adjusted by means of the
dosing cam.

Fillshoe Above the die table there is a cover containing two counter-rotating
agitator wheels. This cover with the corresponding components is called
fillshoe. The press material drops into the fillshoe from above through a
feed unit. It is distributed by the agitator wheels and drops into the
openings of the die table. In the fillshoe there is a scraper taking off the
surplus material.

Fill depth The fill depth serves to determine the filling volume for the tablet. The fill
depth determines the weight of the tablet. The fill depth can be changed at
the tablet press by entering a set value. The fill depth is also used for
regulation.

Function keys The keys serve for selecting defined functions. Each function key has an
inscription field marking the function.

Total production Number of tablets totally produced, i.e. also all sampling tablets, all reject
tablets which are faulty or have been produced during start-up / run-down
of the die table.

Weight and hardness check During the weight and hardness check, filling and wall dimension are
changed by servomotors to reach the set values for weight and hardness.
Compaction force and tablet thickness are used as aids as well as some
calculated real parameters.

Weight deviation Deviations of the tablet weight actual values from the tablet weight set
value

Weight regulation In the operation mode weight regulation, standard regulation and tablet
check are active. The calculated averages of the tablet weights are used
for readjusting the main pressure set value. The main pressure set value is
then decreased or increased according to the weight deviation. This
readjustment of the main pressure set value is only possible within a
certain range, these limits are called adjusting limits.

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Technical term Definition

Cam track The cam track is a subassembly of the compression chamber. Is consists
of several segments (or cams) and is responsible for the vertical guiding of
the punches in the die table. A distinction is made between upper and
lower cam track.

Good channel There is a gate in the tablet chute of the tablet press which determines the
further way of the tablet. Behind the gate there are several tablet channels.
The tablets having correct values for the regulation are routed into the
good channel.

Main pressure Main pressure means the position where the pressing of the tablet is
terminated. The main pressure determines the characteristics of the tablet.
The main pressure is built up by two rollers that the punches run between.
The distance of the rollers can be adjusted and determines the wall
dimension of the tablets. Apart from the wall dimension, the main pressure
depends on the fill quantity. Therefore, the fill quantity can be determined
and adjusted accordingly by measuring the main pressure.

Main pressure set value The main pressure set value describes the guide value which is compared
to the main pressure average values in the standard regulation.

Main pressure, permissible The permissible main pressure is automatically determined from the
smaller value of the machine top load main pressure (highest attainable
main pressure force of the tablet press) and the permissible punch load
(calculated from the tool type). If the main pressure measuring value of a
punch exceeds this permissible main pressure, the tablet press is switched
off immediately.

Main pressure roller The main pressure roller is part of the upper and lower cam track. There
are two main pressure rollers per press station. The main pressure rollers
put pressure on the punches for finishing the pressing of the tablet.

Main gate A sheet metal is mounted in the tablet chute of the tablet press which is
moved by an electromagnet or pneumatically. Depending on the position
of the sheet metal, which is called main gate, the tablets slide into the
corresponding product chute. The main gate receives a signal from the
control system if the tablets shall be sorted out.

Histograms In the histograms (tablet statistics), all tablet actual values from production
start until selection are statistically evaluated and their deviation from the
tablet set values are displayed as a diagram. With this diagram production
can be exactly analysed.

Hydraulic pre-set tension The hydraulic pre-set tension is the overload protection of the tablet press.
If the compaction force exceeds this pre-set tension, these can yield via a
hydraulically pre-tensioned gas cushion. This pre-set tension (safety limit)
can be changed, but it must be adapted to the tools.

Hysteresis The hysteresis determines the deviation from the set value, within its limits
the control system does not make any changes. Therefore, the fill quantity
is only changed if there are major deviations, a permanent change is
avoided.

In-process control In-process control (IPC) means the control carried out in the course of a
production process which serves for monitoring and controlling the
process. This is to ensure that the product meets its specification.

Installation qualification The documented proof that a system has been installed according to the
manufacturer's instructions, the agreements made with the customer and
the legal regulations. Ths IQ comprises the identification of all critical
components as well as the check that all process-related and safety-
related critical elements are properly installed and configured.

Calibration The measuring signal coming from the wire strain gauge (WSG) is boosted
in the measuring amplifier. As the measuring signal shall correspond to a
certain force, the measuring signals must be assigned to the
corresponding force. This assignment is called calibration. Calibration is
possible using the characteristic value of the measuring point or a defined
force (calibration tool). Wire strain gauges (WSG), which are used for
measuring forces, have an individual characteristic line showing the
relation between the actual force and the measuring value displayed. By
means of calibration, comparative values are determined serving as
indications for the measuring.

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Technical term Definition

Characteristic value The data supplied by the WSG are converted according to the
characteristic value. The characteristic value is determined by calibration.
The characteristic values for the measuring points are entered in the
report.

Control cam The control cam is part of the lower cam track. It pulls the lower punch
down again to avoid loss of filled-in press material while the dies are still
open. Another function of the control cam is the control of lower punch
tightness.

Manual tablet check In this case, the tablets must be supplied to the RQ100 or the analyser
manually.

Machine data During set-up of the tablet press to the product, characteristic values are
set at the tablet press. Among these are e.g. the wall dimension, the fill
quantity and the pre-pressure. Tablet hardness and the corresponding
main pressure are a result of wall dimension and fill quantity.

Die table The die table is mounted in the centre of the compression chamber, the
tools (dies) are fitted in the die table. The punches run in cam tracks above
and below the die table, they penetrate the die table for pressing the
tablets.

Measurement cycle During a sampling, 10 tablets are separated and routed to the RQ100.
These 10 tablets are defined as a measurement cycle and are used for
tablet check as well as weight and hardness check.

Follow-on time This value serves for automatically determining the follow-on time of the
deburrer after a machine stop or after reaching production end.

Readjustment pause The readjustment pause determines for how much time there is no
readjustment after a correct tablet measurement.

Push-down segment The push down segment is a component of the upper cam track. It pushes
the upper punch down until it penetrates the die.

Holding-down clamp RQ100 For hardness measurement in the RQ100 a holding-down clamp can be
used, which fixes the tablets to be measured to ensure a correct hardness
measurement.

Pull-down cam The pull-down cam is part of the lower cam track. The pull-down cam pulls
the lower punch down for filling the dies with press material, down to the
lowest position (max. filling).

Zero balancing The measuring amplifier shows a certain value even if no force is acting on
the workpiece to which a wire strain gauge (WSG) is fitted. To avoid
converting the values displayed manually, the basic value is measured
with zero balancing. The value determined by zero balancing is
automatically allowed for by the control system.

Sampling The sampling of tablets (sampling) serves for taking tablets out of the
running production without disturbing or even interrupting production. The
separation of individual tablets is effected at the tablet scraper by blowing
out the selected tablet by means of compressed air and routing the tablet
with the sampling gate into the sampling channel.

Sampling cycle Selection of an interval after which the sampling shall take place

Production Apart from the operation mode "Set-up", the control system offers a
second operation mode for production, with and without regulation. The
operation mode "Production" requires the input of additional data, e.g. a
batch must be defined and the manufacturing tolerance must be specified.
During the operation mode Production the production is monitored and
reported.

Production report In the production report, all actual values of the running production are
output.

Report printing The printer (which is not a standard part of the control system) serves for
putting out the batch and the major data as well as the fault messages. For
batch data, manual reports can be selected or the batch data can be
printed in certain intervals (cyclical). A batch report is always printed at
batch end.

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Hysteresis The hysteresis, also called neutral zone, is a regulation parameter

determining for which range of the deviation of the tablet weight average
and tablet hardness average from the set value there is no readjustment.
Without hysteresis the regulation of the control system would immediately
react to the tiniest deviation from the set value. Thus the regulation would
be constantly moving and permanent fluctuations would result from this.
Therefore, the control system does not react to the deviations of the
average within this hysteresis.

Regulation monitoring The regulation monitoring serves to determine the maximum number of
steps which may be successively adjusted in the same direction.

Reject channel After pressing the tablets slide into the tablet chute where the main gate is
situated. This gate is activated by the control system and switches
between two channels. If the parameters measured are outside the
specified tolerance the tablet is routed into the reject channel.

Reject punches, permissible The control system is equipped with a monitoring function for the control of
each individual punch. If a punch produces several reject tablets in
succession, the control system assumes that this punch is defective (tool
break). The number of revolutions during which this individual punch
produces reject tablets is counted and compared to the permissible
number of tolerance limit infringements (per revolution). If the number of
revolutions exceeds the specified limit the tablet press is switched off.

SKID Supply unit for the media required for the washing process (e.g. water,
compressed air, cleaning agent).

Standard regulation In the standard regulation, the filling of the die is changed to keep the main
pressure actual value constant. A constant ratio between tablet weight and
main pressure actual value for the standard regulation is assumed.

Static force measurement For setting up the wire strain gauges (WSG) at the measuring points Main
pressure and Pre-pressure it is practical to determine the really existing
force at the measuring points. This is done by the static compaction force
measurement at main pressure and pre-pressure.

Wall dimension For tablets with rounded surface, only the cylindrical part is measured for
the wall dimension. The wall dimension results from the distance between
upper and lower punch when passing through the main pressure rollers.
The wall dimension must be adjusted to the product during set-up.

Wall dimension main pressure The wall dimension (cylindrical part of the tablet) is the distance between
upper and lower punch during pressing. Adjustment is made via changing
the position of the upper main pressure roller with reference to the lower
main pressure roller.

Wall dimension pre-pressure Wall dimension pre-pressure means the distance between upper and
lower punch. Measured at the position where the punches pass by the pre-
pressure roller.

Punch Punches are used for pressing; these are tools which are inserted into the
die table from above and from below. Depending on the shape of the
required tablet, different punches are used which must match the
corresponding dies in the die table.

Punch load, permissible The maximum mechanical load to which the tool may be exposed results
from the shape of the tool chosen and from the tool type. This is at the
same time the permissible punch load.

Punch fitting The tablet press can be equipped with a reduced number of punches. The
punch fitting shows the number of punches which are really mounted.

Tablet chute After pressing the tablets are pushed out of the die by the lower punch.
They are pushed from the die table into the tablet chute by a scraper. In
the tablet chute there is a gate which can be switched between good
channel and reject channel.

Tablet scraper The tablet scraper is an important element for the production of the tablets.
Here the finished tablet is taken off the lower punch (stripped). For sorting
out reject or sample tablets, there may be two air nozzles in the tablet
scraper which blow out the tablets.

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Technical term Definition

Tablet hardness Tablet hardness indirectly results from the fill quantity and the wall
dimension, apart from that it depends on the characteristics of the press
material.

Tablet check The tablet limits "Weight", "Hardness" and "Thickness" are controlled and
the tablet press is switched off if these limits are exceeded by the average
values.

Jogging mode In jogging mode the main drive is switched in immediately when the key
"Drive jogging" is pressed. During jogging mode, the main drive is
operated at 10% of its maximum speed to protect the mechanical
elements. Switching off the main drive is effected 10 s after last actuating
of the key "Drive jogging". This prevents the main drive from being
accelerated and slowed down too often. The jogging mode is ended
immediately when the "Drive Off" key is pressed.
The machine keys are only active when a tabletting batch has been
started and no fault has occurred.

Tolerance Two percentages can be entered for the deviation, which are referred to as
MAX and MIN in the input mask for the regulation parameters. These
values indicate by how many percent the parameter may deviate from the
set value. If the value is outside the tolerance the tablets are routed into
the reject channel.

Overload limit main pressure The overload limit main pressure is the maximum possible main pressure
compaction force which the tablet press can reach. The overload limits
depend on the machine.

Overload limit pre-pressure The overload limit pre-pressure is the maximum possible pre-pressure
compaction force which the tablet press can reach. The overload limits
depend on the machine.

DI water see "Demineralised water".

Adjusting limit main pressure In the operation modes "Weight check" and "Weight and hardness check",
the main pressure set value is readjusted if the tablet averages deviate
from the tablet set values.

Unbalance For an unloaded measuring point, a certain value is measured during zero
balancing. This unbalance indicates the deviation of the measuring signal
from the zero value. If the unbalance is too high, the zero balancing for the
wire strain gauge (WSG) could not be carried out successfully.

Pre-pressure Pre-pressure means the position where the tablet is pre-pressed to

facilitate the later finish-pressing and to ensure that the tablet powder is
de-aerated. Thus it is avoided that inadmissible air inclusions form inside
the tablet. Pressing is carried out in two working steps. First the punches
pass through the pre-pressure rollers, after that through the main pressure
rollers. The pre-pressure ensures a more even tablet structure as the
pressing procedure is only very short.

Pre-pressure roller The pre-pressure roller is part of the upper and lower cam track. There are
two pre-pressure rollers per press station. The pre-pressure roller puts
pressure on the punches for pre-compressing the press material.

Tool shape oblong For the tool shape "oblong", the permissible punch load is calculated over
the tool length and the tool width.

Tool shape round For the tool shape "round" the permissible punch load is calculated using
the tool diameter.

Tool shape round oblong To calculate the permissible punch load, the exact type of the tablet or of
the tool, respectively, must be defined. A distinction is made between the
tool types half-round and concave (calculation using the convexity radius),
flat (calculation without convexity radius) and free (calculation not possible,
permissible punch load must be entered by the operator).

Tool type flat With this tool type, the tablets have no convexity radius.

Tool type free This tool type has a shape which cannot be classified among the other
three possibilities. The permissible punch load cannot be calculated.

Tool type half-round With this tool type, the tablets are very much concave and have a large
convexity radius.

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Technical term Definition

Tool type concave With this tool type, the tablets are slightly concave. This tool type also
comprises tablet shapes which have a facet edge.

WIP Washing in Place

This Synthesis 500 WIP is capable of cleaning the compression chamber
and peripheral equipment (e.g. RQ100), if any, in an automated process.

Convexity radius With the tool types half-round and concave, the convexity radius must be
entered to calculate the permissible punch load.

Double layer tablet A double layer tablet is a tablet which consists of two layers. At press
station 1, the tablet press starts by pressing the first layer and finishes the
tablet by pressing the second layer at press station 2.

Intermediate piece The intermediate piece is part of the lower cam track. It prevents the lower
punch from sliding downwards and thus not getting to the main pressure
roller properly.

Cyclical reports During production, the operator can call up several reports which are then
automatically printed after a cycle.

Cyclical production report The cyclical production report is a production report which contains all
production data determined since the last cyclical report.

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Abbreviations

16.4 Abbreviations
A-D
Abbreviation Definition
A Ampere, see also chapter "SI Units Used"
AD (A/D) Analogue / Digital
ADU Analogue-digital converter
AI Analogue Input
AO Analogue Output
abs. Absolute
dev. Deviation
cur. Current
AISI American Iron and Steel Institute
gen. General
BA Operating instruction (Betriebsanleitung)
bar Unit for pressure, see also chapter "SI Units Used"
OVU Operator Visualisation Unit
°C Degrees Celsius, see also chapter "SI Units Used"
approx. Approximately
CAN Bus Controller Area Network Bus, serial bus system for establishing a network
of control devices
CFR Code of Federal Regulations
CIP Cleaning-In-Place
DIN Deutsches Institut für Normung (German Standardisation Organisation)
WSG Wire strain gauge
DPTE Double Porte de Transfert Etanche (double door for leak-tight transfer)
pass. Passage

E-H
Abbreviation Definition
EDM (type of measuring amplifier)
EC European Community
EN English
EMC Electromagnetic compatibility
ESC Escape key
PD Penetration depth
poss. Possible
SV Single values
F2 Function key 2
FDA Food and Drug Administration (USA)
FD Fill depth
g Gram, see also chapter "SI Units Used"
tot. Total
good prod. Good production
h Hour
MP Main pressure
AV MP Main pressure average
HEPA High Efficiency Particulate Airfilter
Hz Hertz, see also chapter "SI Units Used"

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I-L
Abbreviation Definition
I/O Input/ Output
IPC In-process control
ISO International Organization for Standardization
kg Kilogram, see also chapter "SI Units Used"
LED Light emitting diode
l/min Litres per minute, see also chapter "SI Units Used"
Ltd. Limited

M-P
Abbreviation Definition
m Metre, see also chapter "SI Units Used"
mA Milliampere, see also chapter "SI Units Used"
max. Maximum
mg Milligram, see also chapter "SI Units Used"
micron Filtering unit, mesh size
min Minimum
mm Millimetre, see also chapter "SI Units Used"
N Newton, see also chapter "SI Units Used"
SL Sea level
Ohm, see also chapter "SI Units Used"
Ω
PA Pascal, see also chapter "SI Units Used"
pH value "Potentia Hydrogeni", measure for the strength of the acid or basic effect
of a hydrous solution

Q-T
Abbreviation Definition
R+I Tubes + installation
RPM Rounds per minute
SOP Standard Operation Procedure
SYN Synthesis
TCU Tablet Check Unit
TÜV Technischer Überwachungs-Verein (German Technical Inspection
Authority)

U-Z
Abbreviation Definition
UK United Kingdom
etc. and so on
V Volt, see also chapter "SI Units Used"
VDE Verband der Elektrotechnik Elektronik Informationstechnik (German
Electrical Engineering Association)
DI water Demineralised water
WIP Washing-In-Place

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Standards and Instructions

16.5 Standards and Instructions

Standards CE declaration
98/37/EC Machine Directive
Still valid until 12-2009

2006/42/EC Machine Directive

Valid from 01-2010

2006/95/EC Low Voltage Directive

89/336/EEC EMC Directive

2004/108/EC

Standards Electro-circuit design

The following harmonized European standards have been applied

Standards Technical Documentation

DIN11042-1 Maintenance manuals, icons, definitions (1978-11) DIN 24420-1 to 2 Spare
parts lists, part 1: General information; part 2 Setup and structure of the texts
(1976-09) DIN 24900 Icons for mechanical engineering DIN EN 61310-1 to 3
Safety of machinery - displays, markings and operation DIN VDE 1000 General
guidelines for the safe design of technical products (1979-03), see also: DIN EN
292-2 ISO/IEC Guide 14 Product information for consumers (1977)
DIN EN 292-1 Safety of Machinery - Basic concepts, general principles for design - part 1:
Basic terminology, methodology (identical to ISO/DIS 12100-1); revision of EN
292-1:1991; German version prEN 292-1
DIN EN 292-2 Safety of Machinery - Basic concepts, general principles for design - part 2:
Technical guidelines (identical to ISO/DIS 12100-2); revision of EN 292-2:1991
and EN 292-2:1991/A1:1995; German version prEN 292-2 (2000-06/standard
draft)
VDI 2890 Scheduled maintenance; instruction for generating maintenance and inspection
plans (1986-11)
ISO 3864-1 to 2 Graphische Symbole - Sicherheitsfarben und Sicherheitszeichen - Teil 1:
Gestaltungsgrundsätze für Sicherheitszeichen in Arbeitsstätten und in
öffentlichen Bereichen (2002-05); Safety colours and safety signs - Part 2:
Design principles for product safety labels (Revision of ISO 3864:1984) (2002-
08)
VDI 4500, page 1 Technical documentation - user information (1995-02)
VDI 4500, page 2 Technical documentation - internal technical product documentation (2000-
11/technical rule, draft)
VDI 4500, page 3 Technical documentation - recommendation for the creation and distribution of
electronic spare parts information (2001-12/technical rule, draft)
DIN 6789, part 1 to 6 Documentation systematics
DIN EN 62079 Creation of manuals - structuring, contents, and representation (IEC
62079:2001); German version EN 62079:2001 (2001-11)
DIN EN 414 Safety of machinery; rules for the formulation and design of safety standards;
German version EN 414:2000 (2000-10)
DIN 31051 Basic principles of maintenance (2001-10/standard draft), see also
Maintenance; terms and measures (1985-01)
DIN 31052 Maintenance; contents and structure of maintenance manuals (1981-06)
DIN 32541 Operation of machines and similar technical work equipment (1977-05)
DIN EN 954-1 Safety of machinery - safety-related parts of control systems - part 1: General
principles for design; German version EN 954-1:1996 (1997-03)
DIN EN 80416-1 General principles for graphic symbols on installations - part 1: Design of
graphic symbols (IEC 80416-1:2001); German version EN 80416-1:2001 (2002-
05)
DIN EN 80416-2 General principles for graphic symbols on installations - part 2: Shape and
application of arrows (ISO 80416-2:2001); German version EN 80416-2:2001
(2002-05)
DIN ISO 5456-1 to 4 Technical drawings - projection methods part 1 to 4 (1998-04)
DIN 1421 Structuring and numbering in texts; chapters, clauses, lists (1983-01)

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DIN 1450 Fonts; legibility (1993-07)

ANSI Z535.1-2006 American National Standard for Safety Colors
ANSI Z535.2-2002 American National Standard for Enviromental and Facility Safety Signs
ANSI Z535.3-2002 American National Standard Criteria for Safety Symbols
ANSI Z535.4-2007 American National Standard for Product Safety Signs and Labels
ANSI Z535.5-2002 American National Standard Safety Tags and Barricade Tapes (for Temporary
Hazards)
ANSI Z535.6-2006 American National Standard for Product Safety Information in Product Manuals,
Instructions, and Other Collateral Materials

16.6 SI Units Used

Abbreviation Definition
A ampere, SI basic unit of electrical current
bar bar, SI-compliant unit for the pressure
°C degrees Celsius, measuring unit for the temperature
g gram, physical unit for the mass
Hz hertz, SI unit for the frequency
kg kilogram, SI unit for the mass
l/min litre, unit for the volume per minute
m metre, SI basic unit for the length
mA milliampere
mg milligram
mm millimetre
N newton, SI unit for the force
Ω ohm, SI unit of the electric resistance
PA pascal, SI unit of pressure, as well as of (mechanical ) stress
V volt, unit of the voltage

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List of illustrations
Illustration 1: ISO 9001 Certificate 2
Illustration 2: Cam track of the tablet press 14
Illustration 3: Safety devices 22
Illustration 4: Operating status signal lamp 23
Illustration 5: Pressure dwell times 30
Illustration 6: Dimension plan 31
Illustration 7: Foundation plan 32
Illustration 8: Position of connections 33
Illustration 9: Machine nameplate 34
Illustration 10: Electrical cabinet nameplate 34
Illustration 11: CE Declaration 37
Illustration 12: EMC certificate 38
Illustration 13: Tilting indicator 41
Illustration 14: Warning sign tilting indicator 41
Illustration 15: Transport box 42
Illustration 16: Protective film for transport 43
Illustration 17: Supplies 43
Illustration 18: Water-vapour-proof film 43
Illustration 19: Desiccation bag 44
Illustration 20: Head part of the tablet press 44
Illustration 21: Fixing points (illustration may differ from the scope of delivery) 45
Illustration 22: Adjusting screws of machine feet 46
Illustration 23: Position of the transport bolts 47
Illustration 24: Starting screen booting 53
Illustration 25: Upper punch penetration depth 54
Illustration 26: System_shut-down 56
Illustration 27: Windows Menu <<Settings> <Control Panel>> 56
Illustration 28: Windows Menu << Administrative Tools >> 57
Illustration 29: Windows Menu <<Computer Management>> 57
Illustration 30: Windows Menu <<Computer Management>> 58
Illustration 31: Windows Menu <<New User>> 58
Illustration 32: Windows Menu << Local user and groups >> 59
Illustration 33: Windows Menu <<ViconUser Properties>> 59
Illustration 34: Windows Menu <<User>> 60
Illustration 35: System configuration – User management 60
Illustration 36: System – Configuration – User 61
Illustration 37: Tabletting – Set-up 63
Illustration 38: Login window 63
Illustration 39: Login window 64
Illustration 40: Window Changing a password 64
Illustration 41: Control elements of the machine 65
Illustration 42: Control elements in the machine compartment, right 65
Illustration 43: Control elements at the control cabinet 65
Illustration 44: Control elements in the compression chamber 66
Illustration 45: Adjustment of upper punch penetration 66
Illustration 46: General overview Operating terminal 67

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Illustration 47: Header with press stations 68

Illustration 48: System shut-down 69
Illustration 49: Bottom line 70
Illustration 50: Example of local function keys 70
Illustration 51: Status line 71
Illustration 52: Status line 71
Illustration 53: Internal range of masks 72
Illustration 54: Tabs 73
Illustration 55: Overview Touch Screen 73
Illustration 56: Adjustment window 74
Illustration 57: Window for entering figures 74
Illustration 58: Input window for figures and text 75
Illustration 59: Dialogue window "Safety query" 76
Illustration 60: Dialogue window "Input request" 76
Illustration 61: Bar diagrams 76
Illustration 62: Tabletting – Set-up 78
Illustration 63: Tabletting – Set-up – Batch 82
Illustration 64: Tabletting – Set-up – Production 84
Illustration 65: Tabletting – Set-up – Production – Tool 86
Illustration 66: Tabletting – Set-up – Production – Quality 88
Illustration 67: Tabletting – Set-up – Production – Sample 89
Illustration 68: Tabletting – Set-up – Production – Equipment 90
Illustration 69: Tabletting – Set-up – Product 91
Illustration 70: Tabletting – Manual 92
Illustration 71: Tabletting – Manual – Equipment 93
Illustration 72: Tabletting – Manual – Tablet (range Selection: Manual feed) 94
Illustration 73: Tabletting – Manual – Tablet (range Selection: Automatic feed) 94
Illustration 74: Tabletting – Manual – Tablet (range Evaluation: Histogram / statistics)95
Illustration 75: Tabletting – Manual – Sample 97
Illustration 76: Tabletting – Display 98
Illustration 77: Tabletting – Display – Compaction forces 99
Illustration 78: Tabletting – Display – Tablet 100
Illustration 79: Tabletting – Display – Analysis – Selection 101
Illustration 80: Tabletting – Display – Analysis 101
Illustration 81: Tabletting – Display – Messages 103
Illustration 82: Tabletting – Display – Audit trail messages 104
Illustration 83: Tabletting – Reports 105
Illustration 84: Tabletting – Reports – View 106
Illustration 85: Tabletting – Reports – Settings 107
Illustration 86: System – Machine 109
Illustration 87: System – Report view 110
Illustration 88: System – Machine – Components 111
Illustration 89: System – Machine – Components – Monitoring 112
Illustration 90: System – Machine – Measuring points 113
Illustration 91: System – Machine – Measuring points – WSG 114
Illustration 92: System – Machine – Measuring points – Travel 116
Illustration 93: System – Machine – Measuring points – Others – Compaction force
limitation 118

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Illustration 94: System – Machine – Measuring points – Others – Output/speed 118

Illustration 95: System – Machine – Measuring points – Others – Current 119
Illustration 96: System – Machine – Measuring points – Peripheral equipment 121
Illustration 97: System – Machine – Measuring points – Pressure – Low pressure
suction 122
Illustration 98: System – Machine – Measuring points – Pressure 122
Illustration 99: System – Machine – Measuring points – Temperature 124
Illustration 100: System – Machine – Intervals 126
Illustration 101: System – Machine – Punches 127
Illustration 102: System – Configuration 128
Illustration 103: System – Configuration – Network 129
Illustration 104: System – Configuration – User 130
Illustration 105: System – Info 131
Illustration 106: Tabletting – Set-up – Batch 132
Illustration 107: Tabletting – Set-up – Production 133
Illustration 108: Tabletting – Set-up 134
Illustration 109: Tabletting – Set-up – Batch 135
Illustration 110: Tabletting – Set-up – Production – Tool 136
Illustration 111: Tabletting – Set-up – Production 137
Illustration 112: Tabletting – Set-up – Production – Quality 137
Illustration 113: Tabletting – Set-up – Production – Sample 138
Illustration 114: Tabletting – Manual 139
Illustration 115: Tabletting – Set-up – Batch 140
Illustration 116: Evaluation limits of the IPC 142
Illustration 117: Evaluation limits of the IPC 143
Illustration 118: Tabletting – Set-up – Production – Quality 144
Illustration 119: Position of the tolerance ranges T0, T1 and T2 around the average145
Illustration 120: Average limits of the IPC 146
Illustration 121: Single value limits of the IPC 147
Illustration 122: Tabletting – Manual – Tablet (range Selection: Automatic feed) 148
Illustration 123: Tabletting – Manual – Tablet (range Selection: Manual feed) 149
Illustration 124: Header selection 152
Illustration 125: Report cover page 153
Illustration 126: System – Machine 154
Illustration 127: System – Machine – Measuring points – WSG 154
Illustration 128: Report view 155
Illustration 129: Tabletting – Reports – Settings 158
Illustration 130: Tabletting – Reports 159
Illustration 131: Example histogram 166
Illustration 132: Tabletting – Set-up – Production 179
Illustration 133: Opening the pull-down cam 183
Illustration 134: Opening the catch cam and control cam 183
Illustration 135: Opening the catch cam at the ejection cam 184
Illustration 136: Lower punch lubrication 184
Illustration 137: Fixing bolt of sliding carriage 185
Illustration 138: Removal of the cover 186
Illustration 139: Loosening the tensioning nut of the die table 186
Illustration 140: Manual switch for lifting the die table 187

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Illustration 141: Plug-in unit manual switch 187

Illustration 142: Lifting the die table / sliding carriage in position 187
Illustration 143: Manual switch Lower die table 188
Illustration 144: Lifting the die table / tensioning nut in sliding carriage base 188
Illustration 145: Locking screw of the swivel arm 189
Illustration 146: Swinging out the fillshoe base 189
Illustration 147: Two-part fillshoe base 189
Illustration 148: Position of ejection cylinder 190
Illustration 149: Pulling the die table out 190
Illustration 150: Arranging the lift truck 190
Illustration 151: Die table base lift truck 191
Illustration 152: Elevating platform lifted / position tensioning nut 191
Illustration 153: Tightening the tensioning nut 191
Illustration 154: Cover of the machine compartment partition 192
Illustration 155: Positioning of lower punches in the pull-down cam 193
Illustration 156: Arranging the lift truck 193
Illustration 157: Tensioning nut, screwed off the thread 193
Illustration 158: Fitting the die table / positioning the sliding carriage 194
Illustration 159: Fitting of the die table / tensioning nut in the base 194
Illustration 160: Ejection cylinder of die table 194
Illustration 161: Moving the die table in 195
Illustration 162: Fitting the die table 195
Illustration 163: Lifted tensioning nut 196
Illustration 164: Tightening the tensioning nut of the die table 196
Illustration 165: Lower punch lubrication 197
Illustration 166: Closing the pull-down cam 197
Illustration 167: Closing the catch cam and control cam 197
Illustration 168: Closing the catch cam at the ejection cam 198
Illustration 169: Sealing ring with lip seal 199
Illustration 170: Die table sealing rings (in detail for better representation) 200
Illustration 171: Tool with single punch bellow 201
Illustration 172: Pulling the upper punch punch bellow off 202
Illustration 173: Punch bellow for upper / lower punch 202
Illustration 174: Punch bellow at upper punch 203
Illustration 175: Equipped die table 203
Illustration 176: Pulling the upper punch oil collecting caps off 204
Illustration 177: Rubber ring of die table 204
Illustration 178: Dismantling station 205
Illustration 179: Removal of upper punches 205
Illustration 180: Connecting the manual button 205
Illustration 181: Actuation of the manual button 206
Illustration 182: Tablet chute 207
Illustration 183: Dismantling station lower punches 207
Illustration 184: Ejection bar lower punches 208
Illustration 185: Removal of the lower punches 208
Illustration 186: Connecting the manual button 208
Illustration 187: Actuation of the manual button 209
Illustration 188: Removing the scrapers 210

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Illustration 189: Fitting the scraper 210

Illustration 190: Die fixing screws 211
Illustration 191: Die ejector 211
Illustration 192: Cap for die ejector 212
Illustration 193: Securing the cap for the die ejector 212
Illustration 194: Die ejector in punch bore 212
Illustration 195: Key die ejector 213
Illustration 196: Connecting the manual button 213
Illustration 197: Actuation of the manual button 214
Illustration 198: Cleaning the die bore 214
Illustration 199: Die 214
Illustration 200: Fitting the die 215
Illustration 201: Die screws 215
Illustration 202: Check with the straight-edge 216
Illustration 203: Torque wrench < 10 kN 216
Illustration 204: Filling tube 217
Illustration 205: Sliding sleeve 218
Illustration 206: Fixing srews of the filling tube 218
Illustration 207: Fillshoe 220
Illustration 208: Pulling out the slide of the fillshoe base 221
Illustration 209: Height adjustment of the scraper 221
Illustration 210: Loosening the sliding sleeve 221
Illustration 211: Drive clutch left 222
Illustration 212: Drive clutch of force feed fillshoe 222
Illustration 213: Loosening the star grip screws (large) 223
Illustration 214: Removing the fillshoe 223
Illustration 215: Positioning the fillshoe 224
Illustration 216: Tightening the fillshoe 224
Illustration 217: Clutch of fillshoe drive 224
Illustration 218: Height adjustment of the scraper 225
Illustration 219: Connection filling tube / fillshoe 225
Illustration 220: Fillshoe 226
Illustration 221: Safety bolts of agitator wheels 226
Illustration 222: Removing the agitator wheels 226
Illustration 223: Drive pin 227
Illustration 224: Correct position of the safety bolts 227
Illustration 225: Agitator wheels 227
Illustration 226: Lower surface of fillshoe housing with product scraper 228
Illustration 227: Fillshoe housing/upper part of the fillshoe 228
Illustration 228: Fillshoe housing with sealing segment 229
Illustration 229: Sealing segment (magnetic) 230
Illustration 230: Fixing screw of eccentric shaft 230
Illustration 231: Product scraper 231
Illustration 232: Pressure springs of product scraper 231
Illustration 233: Fillshoe base 232
Illustration 234: Detaching the fillshoe base 233
Illustration 235: Swinging out the fillshoe base 233
Illustration 236: Two-part fillshoe base 234

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Illustration 237: Align fillshoe base 235

Illustration 238: Ring suction 237
Illustration 239: Removing the product scraper behind the fillshoe 237
Illustration 240: Detaching the hose piping 238
Illustration 241: Swinging away the suction nozzle 238
Illustration 242: Taking the suction nozzle out 238
Illustration 243: Fixing screws of the cover plate 238
Illustration 244: Taking out the cover plate 239
Illustration 245: Cover 240
Illustration 246: Dismantling the fillshoe 241
Illustration 247: Removal of the cover 241
Illustration 248: Aligning the swivel arm 242
Illustration 249: Detaching the fixing screw 243
Illustration 250: Fixing screws of the swivel arm 243
Illustration 251: Feeler gauge 244
Illustration 252: Actuating the manual button 244
Illustration 253: Fixing screws of the swivel arm 245
Illustration 254: Tightening the fixing screw 245
Illustration 255: Feeler gauge 245
Illustration 256: Swivel arm with tablet scraper 246
Illustration 257: Clamping lever of swivel arm 247
Illustration 258: Swivel arm with tablet chute and scraper 247
Illustration 259: Detaching the cover 248
Illustration 260: Connections for compressed air and solenoid valve 248
Illustration 261: Tablet scraper 248
Illustration 262: Closing the cover 249
Illustration 263: Tablet scraper 250
Illustration 264: Tablet chute (tablet diameter ≤ 20 mm) 252
Illustration 265: Clamping lever of the tablet chute 253
Illustration 266: Swinging out the swivel arm with the tablet chute 253
Illustration 267: Tablet scraper, view from below 254
Illustration 268: Tablet chute cover 254
Illustration 269: Sampling gate and main gate 254
Illustration 270: Tablet chute 255
Illustration 271: Removing the tablet chute 255
Illustration 272: Tablet chute base 256
Illustration 273: Tablet chute 256
Illustration 274: Fixing the tablet chute 256
Illustration 275: Sampling gate and main gate 257
Illustration 276: Cover tablet chute 257
Illustration 277: Tablet chute (tablet diameter > 20 mm) 258
Illustration 278: Supplementary parts for sampling unit from the good channel 260
Illustration 279: Covering segment with product scraper 262
Illustration 280: Detaching the covering segment 263
Illustration 281: Covering segment with product scraper 263
Illustration 282: Covering segment 263
Illustration 283: Tightening the star grip 264
Illustration 284: Product scraper 264

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Illustration 285: Upper punch guide (cam track) 265

Illustration 286: Removal of the cover 266
Illustration 287: Dismantling station 266
Illustration 288: Detaching the retaining screws 266
Illustration 289: Retaining screws 267
Illustration 290: Centering bolt 267
Illustration 291: Lock coupling for connections of pressure roller block 267
Illustration 292: Swinging the pressure roller block out 268
Illustration 293: Cleaning of cam track 268
Illustration 294: Removal of WSG sensor 269
Illustration 295: Push-down segment of die table 269
Illustration 296: WSG sensor upper punch tightness 270
Illustration 297: Connections of lubrication units 271
Illustration 298: Fixing screws of the ejection segments 271
Illustration 299: Fixing screws of the intermediate pieces 272
Illustration 300: Lower punch guide (cam track) 273
Illustration 301: Lower cam track with dismantled die table 274
Illustration 302: Dismantling station lower punches 274
Illustration 303: Ejection bar 275
Illustration 304: Ejection unit 275
Illustration 305: Fixing screw of the ejection cam 275
Illustration 306: Ejection cam shaft 276
Illustration 307: Setting the ejection unit 276
Illustration 308: Ejection unit setting screw 277
Illustration 309: Setting the ejection unit 277
Illustration 310: Ejection unit setting screw 277
Illustration 311: Dismantling station lower punches 278
Illustration 312: Pull-down cam 279
Illustration 313: Pull-down cam 279
Illustration 314: Fixing device of pull-down cam 279
Illustration 315: Pull-down cam 280
Illustration 316: Pull-down cam 280
Illustration 317: Unit of dosing cam, catch cam, control cam and link track 281
Illustration 318: Fixing screw of the unit of dosing cam, catch cam, control cam and
link track 282
Illustration 319: Catch cam / control cam 282
Illustration 320: Dosing cam fixing screw 282
Illustration 321: Dosing cam 282
Illustration 322: Catch cam / control cam 283
Illustration 323: Mounting plate control cam 283
Illustration 324: Link track 283
Illustration 325: Floor drain valve 284
Illustration 326: Upper cam track, torque support 285
Illustration 327: Loosening the retaining screws 285
Illustration 328: Retaining screws 286
Illustration 329: Detaching and swinging out the torque support 286
Illustration 330: Detaching the lines 286
Illustration 331: Centering bolt of pressure roller block 287

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Illustration 332: Swinging out the pressure roller block 287

Illustration 333: Connections at the pressure roller block 288
Illustration 334: Swinging in the pressure roller block 288
Illustration 335: Mounting aid of the pressure roller block 288
Illustration 336: Tightening the retaining screws of the pressure roller block 289
Illustration 337: Lines at the upper pressure roller block 289
Illustration 338: Fixing lid 290
Illustration 339: Fixing screws and adjusting toothed wheel 290
Illustration 340: Fixing screws and adjusting toothed wheel 290
Illustration 341: Removing the covering components 292
Illustration 342: Removing the pressure roller block 293
Illustration 343: Removing the covering components 293
Illustration 344: Position of the probe 294
Illustration 345: Dismantling device 294
Illustration 346: Dismantling of ressure roller 295
Illustration 347: Lubrication system: Position and size of the dosing valves 296
Illustration 348: Oil lubrication of the lower pressure roller block 297
Illustration 349: Vent screw of lubrication system 298
Illustration 350: Dosing unit cover 299
Illustration 351: Venting the lubrication system 299
Illustration 352: Lubrication unit with vent screw B 299
Illustration 353: Lubrication pump 300
Illustration 354: Lubrication unit 301
Illustration 355: Additional lubrication of lower punches 302
Illustration 356: Sump tank 303
Illustration 357: Grease lubrication of the upper pressure roller 304
Illustration 358: Grease lubrication of the lower pressure rollers 304
Illustration 359: Grease lubrication of vertical shaft at the lubrication nipple (1) 305
Illustration 360: Hydraulic system (for better representation, the illustration shows the
hydraulic system in the manufacture of the machine) 306
Illustration 361: Hydraulic diagram 307
Illustration 362: Hydraulics of vent valve 309
Illustration 363: Hydraulics of shut-off valve 310
Illustration 364: Measuring point Compaction force limitation MP 310
Illustration 365: Hydraulics of measuring joint 310
Illustration 366: Hydraulics of outlet valve 311
Illustration 367: Hydraulic tank 311
Illustration 368: Measuring point Compaction force limitation MP 312
Illustration 369: Hydraulic tank 312
Illustration 370: Measuring point Compaction force limitation MP 313
Illustration 371: Position of the vent screw 313
Illustration 372: Position of the vent screw 314
Illustration 373: Detaching the vent screw 314
Illustration 374: Compaction force adjustment 315
Illustration 375: Venting the hydraulics of the control block 315
Illustration 376: Compaction force adjustment 316
Illustration 377: Hydraulics of measuring joint 316
Illustration 378: Hydraulics of measuring joint 316

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Illustration 379: Fan for machine compartment 317

Illustration 380: Pneumatic diagram 318
Illustration 381: Operating terminal with USB port 319
Illustration 382: Connection operating terminal 319
Illustration 383: Position of the battery 322
Illustration 384: Position of the UPS in the control cabinet 323
Illustration 385: M1 module in the control cabinet 325
Illustration 386: System – Machine 330
Illustration 387: Tabletting - Set-up 331
Illustration 388: Cam track for fixing to the main pressure roller of press station 1 332
Illustration 389: Removing the dismantling station 332
Illustration 390: Pull-down cam, complete with console 333
Illustration 391: Connecting the lubrication lines 333
Illustration 392: Removing the ejection bar 334
Illustration 393: Catch cam and control cam 335
Illustration 394: Dismantling the catch cam 335
Illustration 395: Detaching the lubrication line 336
Illustration 396: Detaching the dosing unit 336
Illustration 397: Removing the dosing unit 337
Illustration 398: Dosing unit for bi-layer press operation (1) and double press operation
(2) 337
Illustration 399: Fitting the dosing unit for DL operation 337
Illustration 400: Control cam with console for bi-layer press operation 338
Illustration 401: Fitting the console for the control cam 339
Illustration 402: Fitting the control cam 339
Illustration 403: Fitting the intermediate piece 340
Illustration 404: Lifted piston rod 340
Illustration 405: Inserting the ejection bar 341
Illustration 406: Fixing the ejection bar 341
Illustration 407: Installing the fillshoe 342
Illustration 408: Scraper for bi-layer operation 342
Illustration 409: Mounting the ventilation 343
Illustration 410: System – Machine – Data record 344
Illustration 411: Tabletting – Set-up 345
Illustration 412: Cam track to be mounted to the main pressure roller press station 1346
Illustration 413: Lower cam track zone 347
Illustration 414: Removing the connecting bolts 348
Illustration 415: Short ejection bar with block 348
Illustration 416: Removing the intermediate piece 349
Illustration 417: Actuating the die ejector 349
Illustration 418: Lifted piston rod 350
Illustration 419: Control cam with console for bi-layer press operation 351
Illustration 420: Dismantling the control cam 352
Illustration 421: Fixing device of control cam 352
Illustration 422: Dosing unit for bi-layer press operation (1) and double press operation
(2) 353
Illustration 423: Loosening the fixing screw 353
Illustration 424: Removing the dosing unit 354
Illustration 425: Fitting the dosing unit 354
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Illustration 426: Pin for the eye 355

Illustration 427: Lubrication line of dosing unit 355
Illustration 428: Catch cam and control cam 356
Illustration 429: Fitting the control cam 356
Illustration 430: Fitting the catch cam 357
Illustration 431: Installing the pull-down cam for double press operation 357
Illustration 432: Fitting the ejection bar 358
Illustration 433: Fitting the dismantling station 358
Illustration 434: Fitting the fillshoe for double press operation 359
Illustration 435: Removing the venting unit 359
Illustration 436: Die fitting tool 362
Illustration 437: Die ejector 362
Illustration 438: Feeler gauge 362
Illustration 439: Die fixing screw 363
Illustration 440: Protecting cap 363
Illustration 441: Straight-edge 363
Illustration 442: Transport bolts 364
Illustration 443: Dismantling tool 364
Illustration 444: Dismantling device for pressure roller block 364
Illustration 445: Cleaning scraper 365
Illustration 446: Torque wrench < 10 Nm 365
Illustration 447: Torque wrench > 10 Nm 365
Illustration 448: Calibration aid 366
Illustration 449: Pressure piece 366
Illustration 450: Removal aid 366
Illustration 451: Manual switch 367
Illustration 452: Standard tool 1 367
Illustration 453: Standard tool 2 367
Illustration 454: Grease gun 368
Illustration 455: Oil can 368
Illustration 456: Scraper for upper and lower punches 368
Illustration 457: Fixing clip for punch bellow (upper and lower punches) 369
Illustration 458: Punch bellow (upper and lower punches) 369
Illustration 459: Sealing of fillshoe drive 369
Illustration 460: Brake magnet / gripper 370
Illustration 461: Representation of a transport carriage for Synthesis 500 WIP 371
Illustration 462: Representation MTS700 with electrical drive 371

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Index
Dangers.......................................... 13
A Decommissioning ......................... 171
Advice .............................................10 Default User.................................... 10
Agitator wheel shafts .......................44 Die.................................................. 12
Agitator wheels.......................... 46, 47 Die table ......................................... 11
Air circulation...................................10 Different punch bellows................... 22
alignment pins sealing segment.......50 Dimension plan............................... 26
Audit Trail report............................118 Documentation structure
Auxiliary materials Contents .................................... 10
Lubricants............................. 16, 42 Domain-Name ................................ 10
Average..................................... 87, 90 Dosing cam..................................... 12
Drive pin ......................................... 46
B Dust................................................ 17
Batch documentation.......................94 Dust explosion class ....................... 17
Batch end report............................112 Duties of the operator ....................... 9
Bottom line ......................................11 Duty of care ...................................... 9

C E
Cables.............................................10 Eccentric shaft ................................ 50
Calibration report..................... 96, 100 Edit user ......................................... 11
Catch cam .......................................12 Ejection cam ..............................12, 88
CE marking .......................................8 Ejection segment .......................85, 86
Change of owner ...............................8 Electrical cabinet nameplate ........... 29
Change password............................13 Electrostatic charging...................... 18
Cleaning agents ..............................14 Environmental protection ................ 14
Cleaning of upper cam track ............80 Environmetal protection .................... 9
Cleaning the fillshoe base................52 Equipment ......... 8, 23, 34, 5, 124, 184
Cleaning the force feed fillshoe........45 Evaluation limits.........................87, 88
Compaction force statistics ............100 Explosion prevention....................... 17
Components in contact with product 30
Condition...........................................9
F
Connecting cables...........................10 Fill depth......................................... 81
Consent.............................................8 fill quantities.................................... 29
Container change report ................110 Fillshoe discharge ........................... 40
Contract stipulations ..........................9 Fillshoe housing with Sealing segment
....................................................... 49
Control cabinet ................................14
Final decommissioning.................. 172
Control cam.....................................12
Fixing clip ....................................... 23
Conversion ........................................8
Floor load ....................................... 10
Copy .................................................8
Floor space plan ............................. 10
Copyright...........................................8
Foundation plan .............................. 27
Creating a user..................................6
Functioning..................................... 11
Customer service...............................9

D G
Guarantee ........................................ 9
Damage to property.........................13
Guarantee conditions........................ 9
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H P
Handling instruction .........................10 Password.................................... 5, 13
Hardness.......................................118 Password level................................ 11
Header Password levels.............................. 11
Document structure ....................11 Personal injury................................ 14
Histogram.............................. 109, 114 Personal protective equipment .......... 9
Hoses..............................................10 Personnel ......................................... 9
pH value ......................................... 15
I Pipelines......................................... 10
Industrial truck.................................16 Popup Hostname ............................ 10
Instructions........................................8 Pre-pressure roller .......................... 12
Irreversible personal injuries ............13 Product scraper .............................. 50
Production report .......................... 107
K Proper usage .............................. 9, 13
Knurled screw..................................44 Pull-down cam ................................ 81
Punch bellow upper punch .............. 22
L Punch reception bores .................... 11
Push down cam .............................. 12
List ..................................................10
Push-down segment ....................... 83
Login ...............................................12
Login window...................................13
R
Logout .............................................12
Lower punch guide ..........................87 Recommendations
Lubrication units ..............................86 Tips ........................................... 10
Reference number .......................... 11
M Reject measurement....................... 89
Removal of ejection segment .....85, 86
Machine drift....................................86
Removal of push-down segment ..... 83
Machine nameplate .........................29
Replacement of product scrapers.... 50
Main pressure roller.........................12
Report view..................................... 97
Manual tablet control .....................117
Reversible personal injuries ............ 13
Master data report ..................... 96, 98
Revision status ............................... 11
Modification service ...........................8
Modifications .....................................9
S
N Safety bolts..................................... 45
Safety check................................... 18
noise level .......................................30
Safety devices ............................ 9, 18
Non-observance ................................9
Safety instructions........................... 13
O Safety instructions level 1................ 13
Safety instructions level 2................ 13
Occupational safety ...........................9
Safety instructions level 3................ 14
Operating terminal ...........................14
Safety instructions level 4................ 14
Operation messages report ...........118
Sealing segment ............................. 49
Optional functions
Selling ............... 8, 23, 34, 5, 124, 184
Options.......................................10
Set-up data report......................... 102
Order number..................................11
Single value.................................... 91
Order-specific documentation ..........11
Sliding sleeve ................................. 44
Orientation.......................................11
Software versions ............................. 9
Other dangers .................................17

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Solvent-based .................................15 U
SOP ..................................................8
Upper part of fillshoe....................... 48
Sources of ignition ...........................17
Upper punch guide.......................... 79
Spare parts........................................9
Upper punch tightness .................... 85
Specimen ......................................100
User group...................................... 10
Standards..........................................9
User ID ............................................. 5
Star grip screws...............................43
User management .......................... 10
State of the art...................................9
User Service ..................................... 5
Storage ..................................... 8, 171
User Superuser................................. 5
Stumbling ........................................10
Suction............................................55
V
Surface damage ..............................15
Symbols of packing .........................34 Ventilation openings........................ 10
System shut-down .............................5 ViCon ........................................... 5, 9
Volume dosing................................ 12
T
W
TCU ................................................86
Test standard ................................100 Wall dimension ............................... 81
Thickness......................................118 Weight .......................................... 118
Tilting indicator ................................35 Windows........................................... 5
Tolerance limit .................................89 WSG sensor ................................... 85
WSG sensor structure..................... 84

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