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Operation & Maintenance Manual: PCL Ceramics RotoBowl Pressure Casting System. 5.2.9

Replacement of Layflat tubing

Ensure all off the pressure has been vented from the system and the layflat tubing pump is electrically isolated before commencing any work on the layflat tubing system. Ensure that all tools and equipment have been removed from the mould before starting the test procedure.

Layflat tubing mounted at the top and bottom of the side mould frames is used to generate the force to seal the rim and foot mould parts.

Clamp plate

M16 x 100 countersunk bolt

Clamp assembly

Spring assembly

Layflat tubing

Operation & Maintenance Manual: PCL Ceramics RotoBowl Pressure Casting System. Compression feed tubing assembly Feed tube

Flexible feed hose

Feed tube

Spring assembly 10mm & 6mm PVC packing plates

Clamp assembly Mould frame Stainless steel washer

M16 x 100 countersunk bolt

Compression spring Stainless steel washer M12 x 70 set screw

Elongated brass nut

Steel clamping plate Layflat tubing

Operation & Maintenance Manual: PCL Ceramics RotoBowl Pressure Casting System. Dismantling of layflat tubing assembly Ensure all off the pressure has been vented from the system and the layflat tubing pump is electrically isolated before commencing any work on the layflat tubing system.

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Remove any PVC packing plates, if any are fitted. They are held in position by four M6 x 20 button headed screws. Loosen the M12 x 70 setscrews from each of the 4 spring assemblies. The screws are used as a locking device to prevent the elongated brass nuts from working loosening during operation. Loosen and remove the elongated brass nuts from the 4 spring assemblies. Remove the springs and stainless steel washers. Remove the M16 x 100 countersunk bolts and lift out the steel clamping plate. Loosen and split apart the hose from the water feed compression tubing. Loosen the M10 x 60 bolts holding the clamp assemblies together and pull out the steel feed tube. Remove the layflat tubing from under the clamps.

Re-assembly of layflat tubing assembly Feed tube 230 10

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90

Silicone tube

Feed tube

Install a new piece of layflat tubing making sure each end of the tube is pushed fully under the clamps and the tubing lays flat and unruckled. Cut a new feed tube 230mm long making sure to remove any burrs from the ends and fit a new nut and olive. Push a new piece of 12mm silicone tubing onto the feed tube. The silicone tube should be cut 90mm long and pushed on to the tube so that 10mm of the feed tube protrudes from the end of it.

Operation & Maintenance Manual: PCL Ceramics RotoBowl Pressure Casting System. •

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Carefully pass the feed tube through the mould frame and into the layflat tubing, making sure it passes through the groove in the clamp assembly. If necessary rotate the clamp to ensure the groove is parallel to the tubing. The end of the feed tube should protrude into the tube no more than 95mm when measured from the inside of the mould frame. Refit the steel clamping plate and M16 x 100 countersunk bolts. Refit the stainless steel washers, compression springs and elongated brass nuts. Tighten the elongated brass nuts sequentially and consistently so that the steel clamping plate is pressed against the layflat tubing evenly. The brass nuts should be tightened until the springs are compressed evenly and have enough compression left so that the spring does not become spring bound, or the brass elongated nut does not get jammed against the outside of the mould frame, when the tubing is inflated. In general a spring compression length of 105mm is correct. Refit the M12 x 70 locking set screws and tighten. Tighten the M10 x 60 bolts holding the clamp assemblies together. Ensure these are tightened sequentially and evenly to a torque of 58Nm. Make sure that once tightened the mounting blocks are in full contact with the mould frame. Pass a 6mm dia rod through the inside of the feed tube to ensure the clamp has not crushed the tube. If removed, refit the PVC packing plates.

The tubing should be pressure tested to ensure that it is leak free before starting the casting process. Ensure that all tools and equipment have been removed from the mould before starting the test procedure. • • • • • • • • • • • • • • • • • • • • • • •

Switch the machine to the manual mould. Reset the machine safety circuits using the ‘Castell’ key. Select ‘Hydraulic’ from the HMI main menu. Select ‘close moulds’. The mould pack will close. Select ‘Raise and compress’. The hydraulic cylinder will raise into position behind the tailstock and extend to compress the mould pack. Select ‘Close’ to navigate back to the main menu. Select ‘Layflat tubes’ from the main menu. Select the valve associated with the mould that has been worked on. The valve display will change from red to green indicating it has changed state from closed to open. Set the ‘Manual setpoint’ pressure to 10 bar. Select ‘Run pump’. The inverter driven water pump will start and pressurise the layflat tubing until it reaches setpoint pressure (10 bar). A visual check can now be made to determine if the layflat tubing replacement has been successful. Once the visual check is complete the system can be depressurised. Select ‘Stop pump’ to de-energise the inverter driven pump. The button will change from green to red to indicate the pump has been de-energised. Select the ‘Dump’ valve to depressurise the layflat system. Close the dump valve and select the ‘Evacuation valve’ and the ‘Evacuation pump’ to pump out any remaining water from the system. Leave this running for approx 30 seconds. The system will now completely depressurise and the tubing deflate. Turn off the ‘Evacuation valve’ and ‘Evacuation pump’. Select ‘Close’ to navigate back to the main menu. Select ‘Hydraulic’ from the main menu. Select ‘dump and lower’ to decompress the hydraulic cylinder and lower it. Select ‘Close’ to navigate back to the main menu. The test is now complete. Switching the machine to ‘Lock out’ or ‘Automatic’ will reset the layflat tubing valves and pumps if not already reset.