Specac Advanced Solid Pack User Manual

Advanced Solid Pack
User Manual
2I-01160 Issue 5
Advanced Solid Pack
Advanced Solid Pack
User Manual
2I-01160 Issue 5
3
User Manual
Advanced Solid Pack P/N GS01160
CONTENTS - USER MANUAL
1. INTRODUCTION ................................................................................. 5
2. UNPACKING AND INSTALLATION OF THE PRESS. .................................. 6
3. CHECKLIST OF CONTENTS ............................................................... 10
4. THE ATLAS™ MANUAL 15T HYDRAULIC PRESS ................................ 11
SPECIFICATIONS ............................................................................ 12
5. GENERAL OPERATION OF THE MANUAL 15T PRESS .......................... 13
SAFETY CONSIDERATIONS .............................................................. 13
OPERATION OF THE PRESS ............................................................. 14
CONTROL OF A MAXIMUM APPLIED LOAD ......................................... 17
LEAD SCREW ASSEMBLY ................................................................ 19
FAULT FINDING, CAUSES AND REMEDY ............................................ 20
LOSS OF PRESSURE IN THE PUMPING SYSTEM ................................. 23
FAILURE TO ACHIEVE PRESSURE IN THE PUMPING SYSTEM .............. 21
BLEEDING AIR FROM THE PUMP BLOCK ASSEMBLY ........................... 22
BLEEDING AIR FROM THE PISTON ASSEMBLY ................................... 24
PISTON DOES NOT RETURN WHEN PRESSURE IS RELEASED ............ 25
6. LEGEND (BUBBLE NUMBER PART IDENTIFICATION) ........................... 26
7. INSTRUCTIONS FOR USE OF EVACUABLE PELLET DIES ...................... 35
SAFETY DATA FOR POTASSIUM BROMIDE (KBR) .............................. 43
8. USE OF 13MM DIAMETER PELLET HOLDER ....................................... 44
© April 2016 Specac Ltd. All rights reserved.
Brilliant Spectroscopy is a trademark of Specac Ltd.
Other product names mentioned herein may be trademarks
of their respective owners.
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Advanced Solid Pack
1. Introduction
Thank you for purchasing a Specac product.
The Advanced Solid Pack P/N GS01160 consists of the Specac
Atlas™ Manual 15T Hydraulic Press P/N GS15011, offered together
with a 13mm diameter Evacuable Pellet Die P/N GS03000 for the
formation of 13mm diameter KBr pellets/discs typically used for the
study of solid samples by transmission IR spectroscopy. Additional to
the pack of parts is a pellet holder P/N GS03410 to hold a 13mm
diameter KBr pellet that is made, an agate pestle and mortar set P/N
GS03600 and a bottle (50g) of KBr powder P/N GS03610.
The Advanced Solid Pack can be offered alone as a cost effective way
to procure a manual hydraulic press and 13mm evacuable pellet die
combination, but when combined with particular liquid and gas pack
offerings, forms a part offering for the analysis of solid samples from
the individual Specac Starter Kit options that are available.
The Starter Kit options from the liquids, solids and gas pack
combinations available are as follows:Basic Starter Kit P/N GS01180 (Consists of Liquid Pack P/N
GS01140 and Basic Solid Pack P/N GS01150).
Analyst Starter Kit P/N GS01185 (Consists of Liquid Pack P/N
GS01140 and Advanced Solid Pack P/N GS01160).
Research Starter Kit P/N GS01190 (Consists of Liquid Pack P/N
GS01140, Basic Solid Pack P/N GS01150 and Quest ATR Accessory
P/N GS10802).
Advanced Starter Kit P/N GS01195 (Consists of Liquid Pack P/N
GS01140, Advanced Solid Pack P/N GS01160 and Quest ATR
Accessory P/N GS10802).
A Gas Pack P/N GS01170 can be offered for inclusion to any of the
above Starter Kit offerings. Respectively, the Starter Kit part numbers
become GS01181, GS01186, GS01191 and GS01196 with inclusion of
the Gas Pack.
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User Manual
2. Unpacking and Installation of the Press
From the Advanced Solid Pack P/N GS01160 offering, the Atlas™
Manual 15T Hydraulic Press and 13mm Evacuable Pellet Die and
other parts are shipped in appropriate packaging, primarily for safe
transportation of the press itself.
Beware! This press is very heavy and care must be taken
to transport it properly. This will protect you and the press
from accidental damage or injury.
The press leaves the factory in specially designed packaging. It sits on
a wooden pallet and has a thick outer cardboard casing held to the
pallet by three tie straps. There are direction arrows on the casing
indicating which way up the press is to be handled. To unpack the
press first cut the three straps with a sharp knife and lift up the outer
cardboard casing from the pallet.
Leadscrew
Handle
Pump
Handle
Four Packing
Pieces to Remove
Pressure/Load
Gauge
Wooden
Pallet
Fig 1. Atlas™ Manual Hydraulic Press Provided as Packaged
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Advanced Solid Pack
The press has internal transport packing around the top, by the lead
screw handle. (See Fig 1.) This packing is four pieces of cardboard
stacked on top of each other, held tight by the lead screw handle and
supporting the pump handle in an upright position. To remove these
four pieces loosen the lead screw handle (turn anticlockwise) and then
carefully lift them up and over the lead screw handle.
The press is now ready to be lifted off of the wooden pallet. There are
two holes in the upright frame supports on the sample pressing side of
the press (used for vacuum tubing when an evacuable pellet die is in
the press – see Fig 2.). These two holes can be used to lift up and
position the press by passing strong nylon rope through them to
provide a sling. If available, a hoist can be used to lift the press via this
sling. If a hoist is not available, then a minimum of two people will be
required to lift the press. Use heavy-duty gloves and lift the press from
underneath by the base casting. DO NOT ATTEMPT TO LIFT THE
PRESS BY THE LEAD SCREW HANDLE OR PUMP HANDLE.
Holes in Frame
Supports that
can be used for
Lifting
Base Casting
Fixing Holes
(Other in
Opposite Corner)
Fig 2. Lifting Holes and Base Casting Fixing Holes
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User Manual
Place the press in its working position. In certain circumstances, it may
be necessary to attach the press permanently to a laboratory bench.
Two 10 mm diameter holes are provided in the base casting for this
purpose. (See Fig 2.) It is recommended that M8 diameter bolts are
used to secure the press and that the bench top is at least 25 mm thick
to take the weight of the press.
The press is supplied filled with hydraulic oil and is ready to use. The
only preparation required before operation is to remove the nylon vent
screw (37) from the pump plate (36) of the pump block assembly.
36
37
Fig 3. Nylon Vent Screw (Transportation Screw) to Remove
Note: A light smearing of oil is applied around the main pressing piston
area (4 and 5) when the press is supplied as new. It is perfectly
normal and not a sign that oil is leaking.
Please keep the press packing materials for future transportation.
Replacing a press in its packaging is the reverse of the procedure
described previously.
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Advanced Solid Pack
For any inquiries to Specac regarding the press the serial number
must be quoted. The serial number is a five digit number preceded by
a letter of the alphabet e.g. H, and is found engraved on the press at
the rear of the pump block assembly. The serial number is also on the
Test Certificate found at the rear of this manual.
If you need to contact Specac regarding a service or repair issue
relating to an Atlas™ Manual Hydraulic Press, please be as specific as
possible regarding the nature of the enquiry. Please quote the serial
number for the press, identify how the press is being used and provide
as much information as you can.
Where possible, if contacting by email, please provide photographs too
as these can help greatly to understand the nature of the enquiry.
Serial Number
Location
Fig 4. Rear View of 15/25 Ton Atlas™ Manual Hydraulic Press
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User Manual
3. Checklist of Contents
Once the press has been removed from it packaging and safely
positioned to where it will be used, check that the following items have
been supplied in the Advanced Solid Pack.
• P/N GS15011 Atlas™ Manual
15T Hydraulic Press.
• P/N GS03000
13mm Evacuable Pellet Die.
• P/N GS03410 13mm diameter pellet
holder (3” x 2” slide mount plate)
for 13mm diameter KBr pellets.
• P/N GS03600 Agate pestle and mortar.
• P/N GS03610 Bottle of KBr powder (50g).
• Instruction manual for Advanced Solid Pack.
Please refer to instructions in the following Sections of this instruction
manual for operation and understanding of the Atlas™ 15T manual
hydraulic press (Sections 4, 5 and 6), the 13mm evacuable pellet die
(Section 7) and the 13mm diameter pellet holder (Section 8).
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Advanced Solid Pack
4. The Atlas™ Manual 15T Hydraulic Press
This instruction manual for the press has been written in three main
Sections. Section 4 is the general introduction and specifications.
Section 5 is for instruction on general everyday operation of the press.
Section 6 is for the diagrams bubble part number explanations and for
the respective spare parts.
The Specac Atlas™ Manual 15T Hydraulic Press has been designed
for a wide variety of pressing applications, but is specifically suited to
the preparation of KBr discs using Specac evacuable pellet die
assemblies.
The press can be adapted to provide heated pressing surfaces with
Specac Atlas™ Heated Platens and a Temperature Controller
(GS15515). Heated pressing surfaces can be used for the preparation
of thin films with the Atlas™ Constant Thickness Film Maker accessory
(GS15640). The Atlas™ High Temperature Constant Thickness Film
Maker accessory (GS15800) can also be used with the Specac
presses (the Atlas™ Heated Platens are not required with the high
temperature version).
The press works by pumping a hydraulic fluid (oil) to raise a piston and
compress a sample held in the pressing area. The press consists of a
pump block assembly, where the oil is pressurized by the simple
pumping action from a handle, and the sample pressing side, where
the pressurized oil is forced under the piston assembly. When
resistance is offered by a sample, the pressure build up in the system
is shown on the 15 ton load gauge, located on the pump block
assembly.
In addition to the standard version of the press providing a maximum
tonnage load of 15 tons, there are gauge conversion kits available
allowing for finer load readings over smaller ranges. These ranges are
from 0-1 tons, 0-2 tons and 0-5 tons. The lower tonnage gauges are
connected in line with the standard 15 ton gauge. With these lower
tonnage gauges switched on, the press can only be used up to the
maximum limit of the lower gauge.
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User Manual
Specifications - Atlas™ Manual 15T Hydraulic Press
Maximum Height (at pump handle)
Maximum Width
Maximum Depth
Weight
Lower Piston Stroke
Upper Lead Screw Travel
Minimum Daylight (Distance Between Pressing Faces)
Maximum Daylight (Distance Between Pressing
Faces)
Lower Pressing Face Diameter
Upper Pressing Face Diameter
Maximum Width Of Sampling Area (side to side)
Maximum Depth Of Sampling Area (back to front)
Oil Capacity
Oil Type
12
610 mm
310 mm
190 mm
50 Kg
25.4 mm
89 mm
38 mm
152 mm
86 mm
32 mm
134 mm
141 mm
0.284 Liters
(0.5 Pint)
Shell Tellus
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Advanced Solid Pack
5. General Operation of the Manual 15T Press
Safety Considerations
The Atlas™ Manual Hydraulic Press is provided with front and rear
safety guards (65). These must be kept closed (lowered) at all times
when a sample is being pressed. The guards will fall to the lowered,
safe position if not purposefully raised or kept open by other means.
Note: The use of press guards is a
requirement for any high tonnage load
applications. When using the Specac Film
Making Accessories P/N's GS15640 and
GS15800, although the tonnage loads to
apply are typically 1 to 2 tons, Specac
advise that the safety guards are used
wherever possible.
When using a Film Making Accessory it is
a requirement that the pressure relief
valve assembly (66 to 72) on the Atlas™
Manual Hydraulic Press is adjusted to
read a 2 tons maximum load at the load
gauge (31) for safety and prevention
of tonnage overloading to the Film Making
Accessory itself.
1
65
If you ever need to move or reposition the press, always lift it from
underneath the base casting (1). Do not move it by pulling or lifting the
pump handle (32), load gauge (31), or lead screw handle (20). It is
recommended that a minimum of two people are used to lift or move
the press.
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User Manual
Operation of the Press
(The text for “bubble part” number identification also refers to the 2D
Diagrams Figs 13. to 18. found on pages 28 to 33 of this manual).
The press is supplied filled with hydraulic oil and is ready to use. The
only preparation required before operation is to remove the nylon vent
screw (37) from the pump plate (36) of the pump block assembly.
(Please refer to Fig 3. on page 8.)
21
20
65
33
23
32
31
5
4
30
Fig 5. Front View of 15 Ton Atlas™ Manual Hydraulic Press
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Advanced Solid Pack
Raise the front safety guard (65) and place the work to be pressed on
the lower bolster pressing face (5) covering the piston (4). Ensure that
the work is positioned centrally and lower the safety guard. Screw
down the top bolster pressing face (23) attached to the lead screw
(21), by turning the lead screw handle (20) clockwise.
Important: Ensure that all the components of the work to be pressed
(usually a die set) have been squeezed tightly together
before starting to pump a pressure. However, leave a 1mm
gap between the top of the die set and the top bolster (23)
pressing surface to allow for some initial travel of the
pressing piston (4) on the press.
Rotate the pressure release handle (30) clockwise until it has tightened
firmly. This closes the pumping system so that it is ready for you to
build up the pressure with the pump handle grip (33).
Warning: Ensure that the safety guard is lowered before pumping.
Now start to pump the press by pulling and pushing gently, but
smoothly, on the pump handle grip (33). (The correct leverage and
force is applied by holding at the rubber handle.) It will take a few
strokes to build up pressure in the oil, but once resistance is offered by
the work to the raising of the piston, the load will be indicated on the
load gauge (31). Keep on pumping until the required load is achieved.
There is a maximum piston (4) travel of 25 mm. There is a red ring
around the piston (4) showing when the limit is reached (See Fig 6.)
DO NOT CONTINUE PUMPING WHEN THIS RED RING SHOWS.
If you do not stop pumping, you will cause damage to the press
mechanism.
There is an internal spring stud (16) within the piston (4) assembly that
is designed to break, protecting the press if the allowed piston travel is
exceeded. This spring stud (16) allows the action of the piston spring
(19) to pull the piston (4) back down when the oil pressure in the
system is released. If the stud (16) breaks, the spring (19) is not
compressed when the piston (4) is pumped, consequently the piston
will not return easily to the start position once the pressure is released.
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User Manual
23
31
5
4
Red
Ring
Fig 6. Maximum Limit of Piston (4) Travel (Red Ring Showing)
If the work (e.g. a sample in a die set) is compressing to the extent that
the piston (4) has travelled to show the red line but the compression
load has not been reached, release the pressure by turning the
pressure release handle (30) anticlockwise (slowly) by about one
complete rotation. This will allow the piston (4) to return to rest. The
work will sink down with retraction of the piston (4) and a gap will be
created between the work and the top bolster pressing face (23). Turn
the lead screw handle (20) clockwise to bring the top bolster pressing
face onto the work again, and reapply the load from the piston (4) retighten the release handle (30) and pump via pump handle (33).
Note: This procedure should be followed with samples that are highly
compacted when compressed within an evacuable pellet die.
When the required load is indicated on the load gauge (31), stop
pumping. The pressure and applied tonnage load against the work will
be held for as long as required. You may observe a slight decrease in
the pressure applied, indicated at the load gauge (31), as the work
(sample) being pressed may relax over time. You can bring the
pressure back up to the required load if desired by pulling gently on the
pump handle grip (33) again.
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Advanced Solid Pack
Note: If the applied tonnage load set at the load gauge (31) drops by
more than one ton over a 15 minute period, this may indicate
that there is a fault in the system for holding the applied
pressure, rather than from any relaxation in the work being
pressed. The press system may require bleeding of any trapped
air in the oil to function correctly. (See Fault Finding, Causes and
Remedy, pages 20 to 25.)
To release the load on the work turn the pressure release handle (30)
anticlockwise, slowly, by about one complete rotation. (There is no
need to turn this handle completely open.) Slow rotation of the release
handle (30) allows for a gradual and controllable release of the
pressurised oil within the system (indicated by a gradual drop of the
applied tonnage load at the load gauge (31)), to drain back into the oil
reservoir and helps to reduce the possibility of any bubbles that might
form in the oil from a rapid release of pressure.
Control of a Maximum Applied Load
Beneath the pressure gauge (31) there is a pressure relief valve
assembly (66 to 72) which may be set so that any load between 0-15
tons is the maximum load that can be obtained. (See Fig 7.)
The relief valve set knob (69) can be rotated clockwise to increase the
maximum pressure in the system, and hence the applied load, or
rotated anticlockwise to decrease the pressure in the system.
Note: When supplied the pressure relief valve will be set for a 10 ton
load on the 15 ton press.
To set a specific maximum load, first rotate the relief valve set knob
(69) anticlockwise until it is held loosely by a couple of screw threads.
(Be careful, as if you unscrew the knob completely the relief valve ball
bearing (70) held behind the knob (69) could fall out of position and be
lost. (If the ball bearing (70) does fall out just simply place it into the
knob (69) head recess and screw back into position.)
Place a piece of work to be pressed in the usual way, close the
pressure release handle (30) and start to pump. If the pressure relief
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User Manual
32
30
31
69
66-72
Fig 7. Pressure Relief Valve for Setting a Maximum Load
valve is fully open, there will be no pressure build up in the system (the
pressure/load gauge (31) indicator will not rise and show a load) and
excess pressure being pumped will vent off at the relief valve. Now,
start to turn the relief valve set knob (69) clockwise, (one complete
rotation at a time) and continue pumping. Eventually, pressure will
begin to build up in the system and the gauge (31) indicator will rise to
show a tonnage load. Once the load limit for the setting of the pressure
relief valve knob (69) has been reached, excess pressure will once
again vent off at the relief valve. Continue to turn the relief valve set
knob (69) clockwise until the required pressure/load is reached.
If you overshoot the pressure and hence load limit you require from
over-adjustment clockwise of the knob (69) and continuous pumping of
the handle (32), simply release the pressure from the system by
opening the pressure release handle (30) and then closing the release
handle again. Turn the pressure relief valve knob (69) anticlockwise to
reduce the load limit and re-pump the press via the handle (32).
Repeat the process as necessary to achieve the maximum applied
load setting required.
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Advanced Solid Pack
Tip: This is a useful feature for pressing applications where a
maximum load limit is required. For example, 10 Tons maximum
for 13 mm evacuable pellet dies P/N GS03000.
Beware! With the pressure relief valve set knob (69) turned fully
clockwise it is possible that the press will reach and go
beyond the maximum load rating for the press; that is beyond
the 15 ton load indiaction. Therefore, the pressure relief
valve knob (69) must only be turned clockwise as far as to
obtain the 15 ton gauge division indication when a maximum
load is being applied.
Over pressurization of the pressure gauge will cause
damage to the gauge mechanism resulting in the need for
replacement.
Lead Screw Assembly
In operation the lead screw assembly (handle (20) and lead screw
(21)) is used to adjust for the height of the work to be pressed.
Rotating the lead screw clockwise lowers the lead screw bolster (23)
pressing face towards the work and turning the lead screw
anticlockwise raises the bolster (23) away from the work.
20
22
23
21
Fig 8. Lead Screw Assembly and Top Bolster Parts of the Press
The bolster (23) push fits into the hollow of the lead screw (21) and is
retained by an O-ring (22). Any pressing of work must always be
carried out using the bolster (23) pressing face suitably attached
into the lead screw (21) assembly via the O-ring (22) fixing.
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User Manual
Fault Finding, Causes and Remedy
The Atlas™ Manual 15T Hydraulic Press should give years of trouble
free operation, if used and cared for correctly. If there is a failure of the
press operation, it is recommended that you contact your local Specac
representative immediately, particularly if your press is still within a
warranty period of usage. It will be a requirement to identify your press
from its unique serial number found at the rear of the press and
provide a brief and clear description of the fault. For technical faults
Specac may be contacted via email at [email protected].
However, certain faults can be easily identified and repaired without
the potential need for return of the press to Specac. The following
information is provided to identify faults and carry out the necessary
repairs and adjustments should you decide to do so.
Fault: Loss of Pressure in the Pumping System
Cause 1:
Oil Seal or Gasket Has Failed. This will be evident by
excessive oil leaks around the piston, cylinder block,
or pump block.
Remedy:
It may only be necessary to re-tighten the six cylinder
block securing screws (3), and/or the four pump block
securing screws (29). If the oil leak continues, it will be
necessary to renew the individual seal(s) and
gasket(s), depending on age and usage. (Seals and
gaskets that may need replacing are numbered (8), (9)
(2 off), (11), (27), (28), (38), (43), (44), (48), (53), (57)
and (67). Instructions on how to replace these seals
and gaskets are found in the Atlas™ Manual
Hydraulic Press Servicing Guide.
Cause 2:
Non-Return Valve is Leaking. (This is a ball bearing
(50) trapped in position by the load gauge (31).) It is
likely that the non-return valve ball bearing (50) is not
seating correctly due to foreign matter adhering to the
seat or the ball.
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Advanced Solid Pack
Remedy:
By pumping the press without the pressure release
handle (30) tightened, the foreign matter may be removed
from the valve seat by a flow of oil washing through the
system. Pump the press about ten times. If this does not
work, then you will need to gain access to the non-return
valve ball bearing (50) for inspection. The procedure to
gain access to this ball bearing is found in the Atlas™
Manual Hydraulic Press Servicing Guide.
Cause 3:
Release Valve Leaking. (This is a ball bearing (58)
trapped behind the pressure release handle (30).) It is
likely that the ball bearing (58) is not seating correctly due
to foreign matter adhering to the seat or to the ball.
Remedy:
Similar to the non-return valve procedure, pumping the
press without the pressure release handle (30) tightened
may remove the foreign matter from the valve seat by a
flow of oil washing through the system. Pump the press
about ten times. If this does not work, you will need to gain
access to the ball bearing (58) for inspection. Unscrew the
pressure release handle (30) completely. A small dribble
of oil may flow from the hole when the release handle
assembly (30) is removed, but the amount lost is not
significant. Check the O-ring (57) for signs of wear or
cracks etc and replace if necessary. The ball bearing (58)
can be seen inside the hole resting in the area of the valve
seat. To remove the ball bearing the press needs to be
tipped over slightly, allowing the ball to roll out. Be careful
when lifting the press as it is heavy, and also be careful
not to lose the ball bearing if it rolls out onto the work
bench. Inspect the ball bearing, clean and replace in the
hole. Ensure that it rolls back into its valve seat area.
Replace the pressure release handle (30), tighten and repump.
Fault: Failure to Achieve Pressure in the Pumping System
Cause 4:
The oil filter (55) is blocked.
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User Manual
Remedy:
The procedure to gain access to the oil filter (55) for
cleaning and/or replacement is found in the Atlas™
Manual Hydraulic Press Servicing Guide.
Cause 5:
Airlock in Pump Assembly.
Remedy:
The pump block assembly and possibly the piston side of
the press must be bled of air trapped within the oil. The
procedure can be split into two distinct operations:
Bleeding air from the pump block assembly and bleeding
air from the piston assembly.
Bleeding Air from the Pump Block Assembly
To gain access to the oil bleed screw (40), the pump plate (36) must
first be removed. (In Fig 9. the transport screw (37) is shown but
normally this has been removed for use.)
36
Pump Plate
Securing
Screws
37
Fig 9. Pump Plate Removal
Loosen and remove the four securing screws and lift the pump plate
and the pump block upper gasket (38) clear. Be careful not to tear the
gasket material. Loosen, but do not remove the oil bleed screw (40) by
turning anticlockwise. (See Fig 10.)
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Advanced Solid Pack
Take a piece of work (for example, a block of metal) and place it into
the pressing area on the lower pressing face, and press it in the usual
way (Close pressure release handle (30) and pump via the pump
handle (32)).
Pump Plate and
Upper Gasket
Removed From
Manual Hydraulic
Press
40
Fig 10. Oil Bleed Screw on Pump Block Assembly
As the pressure tries to build up in the system, any trapped air in the
pump block will start to bubble out from the opened oil bleed screw
(40). Keep on pumping until the oil flows clearly, without bubbling.
(See Fig 11.)
32
40
30
Fig 11. Bleeding Air from the Oil in the Pump Block Assembly
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User Manual
Retighten the bleed screw (40) and wipe away any expelled oil. Now
release the pressure from the system (open the pressure release
handle (30)) and remove the work from the press. Carefully replace the
pump block upper gasket (38) and the pump plate (36) and secure with
the four fixing screws.
The pump block assembly side of the press has now been primed and
purged of air in the oil. The press may now operate but it is advisable
to also purge the piston assembly side of the press.
Bleeding Air from the Piston Assembly
The pump block assembly side of the press should have already been
purged of air (see pages 22 to 23). If any trapped air remains in the
system, it will be in the piston assembly pressing side of the press.
4
6
Fig 12. Bleeding Air from Oil in the Piston Assembly
There is a second oil bleed screw (6) on the top of the piston (4).
Remove the lower bolster pressing face (5) on the piston, to gain
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Advanced Solid Pack
access to the bleed screw (6). (The bolster simply lifts clear of the
piston. There may be some suction due to a thin film of oil on the
bolster and piston contact faces). Loosen, but do not remove this bleed
screw and take a piece of work (e.g. a block of metal) and place it on
the piston (4), but do not obscure the bleed screw (6). Press the work
in the usual way. As pressure tries to build up in the system, any
trapped air in the piston will start to bubble out from the open oil bleed
screw (6). Keep on pumping until the oil flows clearly, without bubbling.
Retighten the bleed screw (6) and wipe away any expelled oil. Now
release the pressure from the system (open the pressure release
handle (30)) and remove the work from the press. Replace the lower
pressing face bolster (5) onto the piston (4).
The piston pressing side of the press has now been primed and
purged of air.
Fault: Piston Does Not Return When Pressure is Released
Cause 1:
Foreign matter has become lodged between the
piston (4) and the cylinder block (2).
Remedy:
It will be necessary to remove the piston and clean or
replace any damaged parts. The procedure to do this is
found in the Atlas™ Manual Hydraulic Press Servicing
Guide.
Cause 2:
The piston has been pumped beyond the warning red
ring causing damage to the return mechanism.
Remedy:
It will be necessary to remove the piston and clean or
replace any damaged parts. The procedure to do this is
found in the Atlas™ Manual Hydraulic Press Servicing
Guide.
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User Manual
6. Legend (Bubble Number Part Identification)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
26
Description
Base casting
Cylinder block
Cylinder block screw *
(6 off)
Piston
Piston lower bolster
Piston bleed screw *
Bleed ball 3/16” dia.
Piston wiper O-ring
Piston O-ring (2 off)
Upright screw * (4 off)
Cylinder block O-ring
Spring housing *
Copper sealing washer
(3 off)
Piston spring housing
screw * (3 off)
Piston spring spacer
Piston spring stud *
Piston spring locking
nut *
Piston spring nut and
washer
Piston spring
Lead screw handle
Lead screw
Lead screw top bolster
O-ring
Lead screw top bolster
Oilway plug seal ball
9/32” dia.
Oilway plug screw *
Pump block *
Pump block lower
gasket
Item
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Description
Pump block O-ring
Pump block screw *
(4 off)
Pressure release
handle *
Load gauge
Pump handle
Pump handle grip
Upright screw * (8 off)
Upright dowel (16 off)
Pump plate
Pump vent screw (not
needed)
Pump block upper
gasket
Gauge connector
Pump bleed screw *
Bleed ball 3/16” dia.
Pump piston
Pump piston seal
Pump piston O-ring
Pump piston sealing
housing
Pump piston gasket
(not needed)
Pump piston screws *
(4 off)
Pressure gauge seal
Non-return valve
spring
Non-return valve ball
9/32” dia.
Inlet ball stop
Non-return valve ball
9/32” dia.
Advanced Solid Pack
Item
53
54
55
56
57
58
59
60
61
62
63
Description
Oil intake seal
Oil intake pipe
Oil intake filter
Oil intake circlip
Release handle O-ring
Release ball 9/32” dia.
Crank pin circlip
Crank
Crank shaft
Crank shaft bearing
(2 off)
Crank fixing spiral pin
(2 off)
Item
64
65
66
67
68
69
70
71
72
73
Description
Crank pin
Safety guard
Relief valve body
Relief valve O-ring
Relief valve plunger
Relief valve set knob
Relief valve ball 3/8”
dia.
Relief valve spring
Relief valve ball 1/16”
dia (24 off)
Relief valve seating
Spare Parts
The above list of parts can be ordered as spares from Specac.
Note: When ordering spares, you must include a full description of the
item (from the parts list) and where marked with an asterisk *
also provide the serial number of your press.
Parts (20) and (21) (lead screw handle and lead screw) are supplied as
a complete assembly.
The O-ring seals and gaskets from parts (8), (9), (11), (13), (22), (27),
(28), (38), (43), (44), (48), (53), (57) and (67) have been collected
together for the Atlas™ Manual Hydraulic Press Seals and Gaskets Kit
as P/N GS15100.
1 Liter of CL37 oil is provided as P/N GS15101.
27
User Manual
2D Diagrams of Atlas™ Manual Hydraulic Press
20
21
22
23
6
10
7
5
12
8
4
2
9
11
1
3
Fig 13. Front Cutaway View of Manual Hydraulic Press
28
Advanced Solid Pack
33
32
31
66-72
19
30
26
29
25
18
17
16
15
13
14
24
Fig 14. Front Cutaway View of Manual Hydraulic Press
29
User Manual
33
34
31
31
32
30
26
69
27
28
1
25
Fig 15. Side View of Manual Hydraulic Press
30
Advanced Solid Pack
31
55
58
57
37
30
36
30
31
26
59
Top View
60
61
Underside View
Fig 16. Top and Underside View of Pump Block Assembly
31
User Manual
31
43
44
45-47
41
40
42
61
39
48
49
50
51
60
64
62
52
63
53
54
56
55
Fig 17. Side Cutaway View of Manual Hydraulic Press
32
61
Advanced Solid Pack
67
71
66
69
70
68
72
73
Fig 18. Side Cutaway View of Pressure Relief Valve Assembly
33
User Manual
Test Certificate - Atlas™ Manual Hydraulic Press
Product Number:
GS15011
GS25011
Serial No:___________________ Order No:_____________________
Item
1
2
3
4
5
6
7
8
9
10
Check/Test
Visual inspection of Guard
Visual inspection of gauge nuts
Visual inspection of bolts
Condition of paint
Correct function of gauge
Check for oil leaks
Check piston release
Press able to reach 15 tons / 25 tons
Drop back @ 15 tons /25 tons
= less than 1 ton in 15 minutes
Pressure release valve - set to 10 tons -15011
- set to 15 tons -25011
Checked
Tested By:_________________________________
Approval By:_______________________________ Date:__________
Original to file
Completed TAG Label on Press
34
Drg No.:
3MZ13066
3MZ13067
Advanced Solid Pack
7. Instructions for Use of Evacuable Pellet Dies
Introduction
The Evacuable Pellet Dies available from Specac are manufactured in
a wide range of diameters for both infrared and XRF applications. The
standard dies, made from 440C stainless steel, offer an ideal solution
for preparing sample discs/pellets prior to analysis. However, care
must be taken where extremely hard, corrosive or irregular shaped
samples are to be compressed, as stainless steel dies and pellets can
be damaged.
All of the dies are evacuable, enabling dry, uncontaminated and clear
pellets to be prepared.
Unpacking and Checklist
On receipt of your evacuable pellet die (specifically the 13mm diameter
pellet die P/N GS03000 with Advanced Solid Pack P/N GS01160),
please ensure that the following parts have been supplied.
● 1 Die body (this part carries the evacuation port on dies of 20mm
diameter sizes and above).
● 1 Base (this part requires the evacuation support ring for dies up to
13mm diameter pellet size).
● 1 Plunger (this is stepped on dies smaller than 10mm diameter pellet
size).
● 1 Pair of stainless steel internal pressing pellets (unless stated).
● 1 Extractor ring (in Perspex, Delrin or aluminium depending on size
of die).
Note: Pellet/disc holders for mounting the sample disc in a
spectrometer are not supplied with the dies but can be
purchased separately from Specac. (e.g. P/N GS03410 for the
13mm diameter pellet.) P/N GS03410, a 3” x2” slide mount plate
holder, is supplied as part of the Advanced Solid Pack P/N
GS01160 offering.
35
User Manual
Die Care and Use with KBr Powder
The dies are made from corrosion resistant steel, but because of the
corrosive nature of wet KBr or possibly from other substances used
with the dies, it is necessary to take certain precautions.
A) When not in use always ensure that the die and its component
parts are thoroughly clean and dry. If possible, it is preferable to
store the die and components in a drying cabinet or a desiccator.
B) When cleaning the die pellets, be careful of the polished faces. Do
not use a cloth that has a hard abrasive texture. Always use a soft
cloth or tissue. If KBr powder has been used as a sample for
compression, any remaining powder should be washed away from
the die body, plunger and pellets with distilled water and then
rinsed with methanol. After drying the parts with a soft cloth they
can be placed on a warming plate to keep warm and dry until use
with the next sample.
C) Never exceed the maximum safe load when pressing.
Note: KBr powder P/N GS03610 is supplied in a sealed glass bottle.
The seal should not be broken until using the powder for the first
time. Store the KBr powder in an oven at 50ºC or a desiccator
to prevent absorption of moisture.
Preparing the Evacuable Pellet Die for Use
The die and its component parts are packed at the factory in such a
way that they do not suffer damage during transit. The optically
polished pellets (1) are encapsulated in an easily removed protective
material and the die may be lightly coated with a protective oil. Before
use, the protective material on the pellets should be removed and all of
the component parts must be thoroughly cleaned with an organic
solvent (methanol is suitable) to ensure that the protective oil is fully
removed. The parts should then be wiped clean taking care to use
non-abrasive cleaning cloths on the polished faces of the pellets (1).
36
Advanced Solid Pack
Place the base (2) of the die onto a work surface. (For dies up to
13mm in diameter the base will include a black colored surrounding
evacuation ring and port (5)). For dies of 20mm diameter and above,
the base does not have the surrounding evacuation ring and port. (The
vacuum port is part of the die body). Ensure that the O-ring seal (3) is
correctly positioned into its groove in the evacuation ring or around the
smaller diameter piece of the base for dies of 20mm diameter and
above.
Assembly for Evacuable Pellet Dies of 10mm Diameter
and Above
Assemble the die cylinder body (4) onto its appropriate base (2) as
shown in Figs 19. and 20. Fig 19. is for the 5mm, 10mm and 13mm
dies with a black support ring for the base (2), carrying the evacuation
port (5). Fig 20. is for the larger dies of 20mm and above, including the
evacuation port (5) as part of the die body.
Fig 19.
Fig 20.
Take one of the stainless steel polished pellets (1) and place it
(polished side up) into the bore of the cylinder body (4). (Avoid getting
fingerprints on the polished surface - wear gloves). The pellet is a very
close fit in the bore but will eventually sink to the bottom of the bore in
the cylinder body (4). (You can use the plunger (6) if required to aid in
the travel of the pellet in the bore). When the first pellet (1) is in
position, you can now fill the die body bore with a prepared sample
powder.
37
User Manual
Filling the Evacuable Pellet Die with Sample
This procedure is typically for the filling of a 13mm die, but can be
adapted for your specific sample and size die.
Using a paper chute, funnel or spatula, pour a well ground and mixed
powder (2 to 4mg sample in 175 to 225mg KBr mixture) to be
compacted into the bore of the cylinder body (4). Tap the side of the
die lightly so that the powder is evenly distributed across the face of
the polished pellet (1). You can also use a spatula to smooth over and
level the surface of the powder if tapping of the die is insufficient.
Take the second stainless steel pellet (1) and push this (polished face
first - downwards) into the bore of the cylinder body (4). Take care not
to force or jam the pellet (1) into the bore. If it is placed centrally, it
should sink down in the bore onto the surface of the powder. Insert the
plunger (6), non- chamfered edge end first into the cylinder body (4).
Ensure that the O-ring seal (7) is in place around the plunger and
seated in the chamfer of the cylinder body (4) as shown in Figures 1
and 2. The die is now ready to be placed in the press for compaction of
the sample powder.
Pressing of the Sample Pellet
Place the die assembly into a hydraulic press. Make sure that the die is
central on the bottom pressing face of the press.
If a vacuum supply is to be used on the die whilst pressing, connect
the vacuum line tubing to the evacuation port (5) of the die. Switch on
the vacuum line and maintain the vacuum before, during and after the
pressing process.
Ensure that all safety guards on the press are closed and then start to
press the die. Apply a load to the plunger (6) to produce the desired
glassy quality of KBr/sample pellet. For the 13mm size die, a load of 7
tons indicated at the pressure gauge of the press is usually sufficient.
38
Advanced Solid Pack
Note: The following table gives typical loads to produce good quality
KBr pellets.
Die Size
10mm
13mm
20mm
32mm
40mm
Typical Load
3.00 tons
7.00 tons
18.00 tons
25.00 tons
25.00 tons
Maximum Load Limit
5.00 tons
10.00 tons
25.00 tons
50.00 tons
80.00 tons
Warning : DO NOT EXCEED THE MAXIMUM LOAD.
Hold the load on the die for 10 to 15 seconds and then release both
the load and the vacuum.
Removing the Sample Pellet from the Die
This procedure is the same for all diameter size dies. Take the die out
of the press and remove the base (2). All of the internal components in
the die cylinder body (4) will remain in place due to compaction of the
sample.
Fig 21.
Fig 22.
Invert the die and place the extractor ring (8) into position on the
cylinder body as shown in Figs 21. and 22. (Fig 21. is for the, 10mm
and 13mm dies and Fig 22. for the 20mm die and above).
39
User Manual
Replace this inverted assembly into the press and apply a light load
between the plunger (6) and the extractor ring (8). The load can be
applied by rotation of the lead screw assembly in the manual hydraulic
press or by pumping the piston of the press. As the load is applied
the bottom stainless steel pellet (1) will emerge first from the bottom of
the cylinder followed by the compacted sample pellet and then the top
stainless steel pellet. Usually, once the sample pellet has cleared the
bore of the cylinder body (4), the plunger (6) will immediately pass
through the bore to the limit of its travel, as the weight of the cylinder
body sinks down due to no resistance.
Remove the die parts from the press and carefully extract the
compacted sample pellet with a pair of forceps, taking care not to
damage it in the process. The highly polished surfaces of the stainless
steel pellets (1) aid in easy sample release from these pellets.
Paper Frame Mounting of Sample Pellets
To facilitate the handling of KBr sample pellets, paper frames can be
used which are of a macro, micro or ultra-micro form.
The macro paper frame is a paper annulus of 13mm o.d. and 10mm
i.d. These frames are to be used with the 13mm die only. When using
these paper frames (9) they are inserted into the die prior to addition of
the sample (10). When the sample pellet is extracted a transparent
circular window in an opaque paper frame is produced.
The micro and ultra-micro
frames are also circular
with a 13mm o.d. but
they have a rectangular
aperture of 2mm x 11mm
and 1mm and 4mm
respectively. When using
the micro or ultra-micro
frames it is
recommended that the
die be loaded on the
Fig 23.
40
Advanced Solid Pack
extractor ring (8) as shown in Fig 23. The die is assembled inverted
with the pellet (1) and ultra-micro frame in place. The aperture is
carefully filled with the powder sample such that it is heaped 1 to 2mm
above the surface of the frame (9). The bottom pellet (1) is then put
into place and the base (2) is fixed to the cylinder body assembly. This
whole assembly is then turned the right way up ready to be pressed.
Notes on Sample Pellet Quality
Generally, it is easy to produce a good quality KBr pellet if the die is
used correctly. However, some faults in the produced sample pellet
may occur due to a variety of reasons. Some of these faults and their
remedies are tabulated below. The faults described are for pure KBr or
other halide salts, which do not contaminate the sample. When the
sample is added to the halide salt the clarity of the disc will depend to a
large extent on the quantity and type of sample. Usually 0.1 to 2% of
sample to KBr is perfectly adequate. The overall quality of a pellet is
largely dependent upon the quality of the KBr or halide salt powder
used, which should always be of a spectroscopic grade of purity.
Fault
Sample pellet not
clear. Lacks optical
clarity.
Cause
Sample damp,
contaminated KBr powder
or insufficient pressure
when compacting.
Sample pellet is
clear but shows
opaque spots.
Powder not uniformly flat in
the die, leaving large
particles which do not
vitrify when pressed.
Insufficient evacuation time
or leaky seals.
Sample pellet is
cloudy.
Sample pellet is
clear at first but
quickly becomes
cloudy.
Damp powder or damp
atmosphere.
Remedy
Dry the KBr powder
or sample and
increase the
compacting
pressure.
Sieve powder to
extract coarse
grains, then re-grind
and re-press.
Check seals on the
die and lengthen
evacuation period.
Dry the KBr powder
or sample, check
seals on the die and
lengthen evacuation
period.
41
User Manual
To ensure that a sample pellet is produced which will enable accurate
spectra of samples to be obtained, it is essential that the sample be
thoroughly blended with the halide salt powder. Blending can be
achieved either by using a mortar and pestle (P/N GS03600 – supplied
with the Advanced Solid Pack P/N GS01160 offering), or by using a
grinding mill such as the Specamill (P/N GS06000).
Legend for Evacuable Pellet Dies
(1) Polished pellet
(2) Die base
(3) O-ring seal in evacuation ring
(4) Die cylinder body
(5) Evacuation port on die
(6) Plunger
(7) O-ring seal for plunger
(8) Extractor ring
(9) Paper support frames
(10) Paper support frames
Spare Parts for 13mm Evacuable Pellet Die
P/N GS03000 Evacuable pellet die 13mm diameter complete
assembly.
P/N GS03010 Evacuable pellet die 13mm diameter internal pressing
pellets (pair).
P/N GS03020 Evacuable pellet die 13mm diameter O-ring kit.
P/N GS03030 Evacuable pellet die 13mm diameter plunger.
P/N GS03040 Evacuable pellet die 13mm diameter body.
P/N GS03050 Evacuable pellet die 13mm diameter base.
All of the die parts are available for individual replacement. Because of
the wide range of die sizes and parts please contact Specac for any
replacement parts you may require for your specific die size.
42
Advanced Solid Pack
Safety Data for Potassium Bromide (KBr)
General
Medium for making Potassium Bromide pellets for IR spectroscopy.
When fused together as a solid can be polished and used as a transmission window
material. Hygroscopic material similar to Sodium Chloride (NaCl).
Soluble in water, glycerine and alcohols. Slightly soluble in ether.
Fairly good resistance to mechanical and thermal shock.
Molecular formula: KBr.
Chemical Abstracts Service (CAS) No: 7758-02-3.
Physical Data
Appearance: Odourless, white or colourless crystalline solid.
Melting point: 730°C.
Boiling point: 1380°C.
Vapour pressure: 1mm Hg at 795°C.
Specific gravity: 2.75 g cm-3
Solubility in water: 53.48g/100g at 0°C.
Hardness: 6 Kg/mm2.
Refractive Index: 1.54 (at 2000cm-1 - wavenumbers).
Spectroscopic transmission range: 43,500 to 400 cm-1 (wavenumbers).
Stability
Stable.
Incompatible with strong oxidising agents, strong acids, bromine trifluoride and bromine
trichloride.
Toxicology
Harmful if ingested in large amounts, if inhaled, or if in repeated
contact with the skin.
Personal Protection
Always wear safety spectacles and gloves when handling the powder or window
material.
Allow for adequate ventilation.
Storage
Keep powder or windows stored in a cool, dry container.
43
User Manual
8. Use of the 13mm Diameter Pellet Holder
Supplied with the Advanced Solid Pack is the 13mm diameter pellet
holder P/N GS03410. The pellet holder consists of a 3” x “2 slide
mount plate (1) with a central 11.8mm diameter aperture and circular
clip mount and retainer assembly. A 13mm diameter KBr pellet up to
3mm thick is held between the front ring clip part (2) and the central
retainer mount (3). (See Fig 24.)
When a 13mm diameter KBr pellet sample has been prepared from
use of the 13mm evacuable pellet die P/N GS03000 within the 15 ton
press P/N GS15011, the KBr pellet is mounted into the spectrometer
sample compartment by use of the 13mm diameter pellet holder P/N
GS03410 to be installed into a standard 3” x 2” slide mount plate
system as normally provided for the spectrometer.
3
1
2
Fig 24. 13mm Diameter Pellet Holder GS03410
To mount a KBr pellet, pull the ring clip part (2) away from the retainer
(3), carefully insert the KBr pellet and then hold secure by replacement
of the ring clip (2) as a push fit into the retainer (3).
44
Advanced Solid Pack
Notes for Use
45
User Manual
Notes for Use
46
Worldwide Distribution
France
Eurolabo - Paris.
Tel.01 42 08 01 28
Fax 01 42 08 13 65
email: [email protected]
Germany
L.O.T. - Oriel GmbH & Co,
KG - Darmstadt
Tel: 06151 88060
Fax: 06151 880689
email:[email protected]
Website: www.LOT-Oriel.com/de
Japan
Systems Engineering Inc. -Tokyo
Tel: 03 3946 4993
Fax: 03 3946 4983
email:[email protected]
Website: www.systems-eng.co.jp
Spain
Teknokroma S.Coop C. Ltda
Barcelona
Tel: 93 674 8800
Fax: 93 675 2405
email: [email protected]
Switzerland
Portmann InstrumentsAG
Biel-Benken
Tel: 061 726 6555
Fax: 061 726 6550
email: [email protected]
Website:www.portmann-instruments.ch
USA
SPECAC INC.
414 Commerce Drive
Suite 175,
Fort Washington,
PA 19034, USA
Tel: 215 793 4044
Fax: 215 793 4011
United Kingdom
Specac Ltd. - London
Unit 12, Science & Innovation Centre
Halo Business Park
Orpington
Kent BR5 3FQ
Tel:+44 (0) 1689 873134
Registered No. 1008689 England
Brilliant Spectroscopy™
www.specac.com
SPECAC INC.
414 Commerce Drive
Suite 175,
Fort Washington,
PA 19034, USA
Tel: 215 793 4044
Fax: 215 793 4011
SPECAC LTD.
Unit 12, Science & Innovation Centre
Halo Business Park
Orpington
Kent BR5 3FQ
Tel: +44 (0) 1689 873134
Registered No. 1008689 England
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