TABLET PRESS
REFERENCE
GUIDE
TABLE OF CONTENTS
Page
Help Text __________________________________________________________________________ 1
Weight Control______________________________________________________________________ 2-3
Tablet Press Operation_______________________________________________________________ 4-5
Fine Tuning_________________________________________________________________________ 6-9
Troubleshooting_____________________________________________________________________ 10 -14
Reference Data _____________________________________________________________________ 15
Disassembly Position________________________________________________________________ 16
Fette Support_______________________________________________________________________ 17
HELP TEXT 1
For details and a better understanding of the parameter simply select the parameter and press F1.
WEIGHT CONTROL 2
Control Loop 1
(Parameter 32 –
set at 1)
Control Loop 1 – Force Control – Standard
When activated, control loop 1 is comprised of parameters that monitor and adjust various components in
order to maintain the compression force which is specified in parameter 5 - Main Compression Force.
A deviation of +/-1% from the value defined in parameter 5 will result in the press automatically adjusting
the filling depth to maintain the correct value.
WEIGHT CONTROL CONTINUED 3
Control Loop 2
(Parameter #32-
Set at 2)
Control Loop 2 – Force & Weight Control with In-Process Control Unit
The introduction of an in-process control unit (Checkmaster or AT-4), will help improve the results of your batches by
allowing the press to monitor the tablets using force and weight. When using a Checkmaster/AT-4, the machine will
maintain the specified tablet weight in parameter 22 by automatically adjusting the actual main compression force
cylindrical height entered in parameter 18. A difference of +/- 1% of parameter 22 will result in an adjustment.
TABLET PRESS OPERATION 4
BEFORE running your Fette tablet press!
• Verify punches are lubricated.
• Rotate the turret an entire revolution by hand to listen for • A djust parameter 6 and parameter 18 until batch specifications
strange noises, etc. for final tablet hardness are achieved.
• Inspect parts for wear and loose pieces. Check to ensure • Adjust parameter 19 until your granulation is now slightly
feeders are secure and shrouds are not rubbing (check all compressed and is de-aerated.
clearances). • The following steps should be taken prior to starting good
production.
Running a Fette press:
1. Increase the speed of the machine (parameter 1) until
• After loading the product hopper with granulation, press
batch guidelines are met.
the letter K (Setting Run) on the keyboard, so that all tablets
2. S tart the machine and observe parameter 8. If the
produced will be sent to the reject bin.
deviation is high, check the speed of the Fill-O-Matic
• Press F10 on the keyboard to fill the Fill-O-Matic with
(parameter 3) and increase the set value.
granulation.
3. P ress L (Standard Run) to initiate good production count
• Press F11 to jog punch to punch to ensure there is no binding.
(parameter 14).
• Press F12 on the keyboard and jog the press until a tablet
4. Insert the actual value in the set column for parameter 5
appears on the discharge chute and then place it on a scale.
and parameter 13.
If a tablet cannot be compressed and granulation appears on
5. P lace a 1 in the set column for parameter 32.
the scale, decrease parameter 18 until you are able to jog the
machine with tablets appearing at the discharge chute.
• After weighing the sample tablet, use the following formula in Actual Fill Depth (mm) X Target Weight = Target Fill Depth (Par.6)
order to quickly get the batch running weight.
Actual Weight (mg)
TABLET PRESS OPERATION CONTINUED 5
• Start the machine and verify tablet weight and tablet
hardness are ok.
• Observe parameter 8 and place a value in the set column
that is 2-3 points higher than the actual. If the actual
value in parameter 8 exceeds the set value the green
status lights will begin to flash and alert the operator that
the actual SREL is increasing.
• Observe parameter 9 and place a value in the set column
that is 2-3 points higher than the parameter 8 set value.
If the actual value exceeds the set value the press will
stop, the red status lights will be observed and the alarm
condition will be shown on the touch screen controller.
FINE TUNING 6
Fine tuning while the machine is running 3. T
he force of the tablet has been changed, so
with force control on: now observe parameter 5 and match the set and
•T
ablet weight is good but the tablets are soft and need actual values.
adjustment. 4. E
nter a 1 in the set column for parameter 32 to
turn on force control.
1. E
nter a 0 in the set column for parameter 32 to
turn off force control. • Tablet hardness is good but the tablet weight is low
2. D
ecrease the set value in parameter 18 until and needs adjustment. There are two ways to adjust
desired hardness is achieved. tablet weight while utilizing force control.
3. T
he force of the tablet has been changed, so
1. I ncrease the set value for parameter 5, which will
now observe parameter 5 and match the set and
force parameter 6 to increase in order to satisfy
actual values.
the setting.
4. E
nter a 1 in the set column for parameter 32 to
N
OTE: Remember, force control works to
turn on force control.
maintain the set and actual at parameter 5.
•T
ablet weight is good but the tablets are hard and N
OTE: With this adjustment we added material,
need adjustment. but the cylindrical height stayed the same, so
check the hardness.
1. E
nter a 0 in the set column for parameter 32 to 2. Increase the set value for parameter 18, which in
turn off force control. turn will immediately decrease the actual force
2. Increase the set value in parameter 18 until at parameter 5 causing parameter 6 to increase
desired hardness is achieved. until the set and actual match parameter 5.
FINE TUNING CONTINUED 7
N
OTE: Remember, force control works to 2. D ecrease the set value for parameter 18, which
maintain the set and actual at parameter 5. in turn will immediately increase the actual force
N
OTE: With this adjustment we increased the at parameter 5. This will cause parameter 6
cylindrical height and then added granulation. to decrease until the set and actual match at
This changed the thickness slightly (0.01), so parameter 5.
check the hardness. NOTE: Remember, force control works to
maintain the set and actual at parameter 5.
•T
ablet hardness is good but the tablet weight is high NOTE: With this adjustment we decreased the
and needs correction. There are two ways to adjust cylindrical height and then removed granulation.
tablet weight while utilizing force control. This changed the thickness slightly (0.01), so
check the hardness.
1. D ecrease the set value for parameter 5, which
will force parameter 6 to decrease in order to
satisfy the setting for parameter 5.
NOTE: Remember, force control works to
maintain the set and actual at parameter 5.
NOTE: With this adjustment we reduced the
amount of material, but the cylindrical height
stayed the same, so check the hardness.
FINE TUNING CONTINUED 8
Establishing Reject Limits
Procedure for finding percentage for parameters 10 / 11 & 12
1. Record the target Fill Depth / Main Comp. Force
2. Increase / Decrease the tablet weight to the desired limit.
3. Record the upper and lower limit force.
4. Use the following formulas to find desired percentage
• (#5 actual high force – #5 spec.)
X 100 = % change
#5 spec.
• (#5 spec. – #5 actual low force)
X 100 = % change
#5 spec.
5. Record the desired % in parameters 10, 11 & 12.
6. Place a piece of tape on a specified punch.
7. In Standard Run (L), set parameter 32 to 0 and increase /
decrease weight with parameter 6.
8. Verify proper firing of the sorting gate along with the correct station.
Place a value in parameter 33 as to when you would like the air
sorting to fire.
FINE TUNING CONTINUED 9
Testing Reject Limits
In order to perform this test in Standard Run (L), an upper punch
must be modified. Attach a piece of tape to an upper punch face
and note the punch number.
1. Set the individual upper limit in parameter 10 on parameter list
B 1 to a percentage value (start with 15%).
2. Start the press.
3. Press “F4 reports” then press “actual diagnosis” and verify
that the punch number you taped is rejected.
4. Check for diagnosis 5010. NOTE: Parameter 33 must be set
to 4.
5. Repeat steps 1 – 3 for B2 and check for diagnosis 5011.
TROUBLESHOOTING 10
Tablet Weight Variation 5. Ledge cam
1. Poorly flowing granulation • R emove the apron exposing the dosing station.
• C heck the granulation for proper flow Start the machine and verify the ledge cam is
characteristics. snug but also floats slightly.
• C heck the hopper valve and adjust if necessary 6. Fill-O-Matic parameter 3
- you may need a stirring rod or a vibrator. • Increase / decrease the speed of the fill-O-
2. Tooling Matic and observe the impact on the SREL.
• W orking length is out of specification (tooling May need to install round wire paddles.
working lengths should be routinely inspected 7. Scraper 2 assembly
to ensure they are within TSM specification). • If the scraper blade is not flush to the die table
Please see reference drawings. and does not float, it can lead to burn marks.
3. Die seating • The tail-over-die should sit flush on the die table.
• If granulation is leaking under the scraper blade 8. Vacuum control - Parameter 49 (only with option SH5)
it may be an indication of a damaged blade. • The amount of vacuum on the machine is
• Dies should be flush with the die table surface. regulated through parameter 49. NOTE: If the
vacuum regulation option was not purchased
4. Incorrect fill cam parameter 39 (SH5), adjust your house supply manually.
• O
bserve the actual filling depth and verify it is 9. Re-circulation scoop
approximately 80% of the actual fill cam. • T he blade of the scoop should be approximately
• Quick tip for fill cam selection: .0001 inches from the bottom of the channel.
Thickness of tablet x 2 + 2 = fill cam
TROUBLESHOOTING CONTINUED 11
10. Penetration parameters 20 & 21 13. Critical parameters not used correctly.
• The actual penetration measured in mm • P arameters 47 and 48 deal with tooling
identifies where the tablet is being compressed lubrication and must be set correctly. These
in the die. values vary due to product characteristics, but
• 2 mm is a good starting point. a good starting point is 90 seconds for the
• Adjustments are typically made in .5mm lowers and 120 seconds for the uppers.
increments. • P arameter 57 updates key parameters 5, 8 and
11. Machine speed parameter 1 13, while parameter 59 sets the adjustment
• A
s machine speed increases, you may want to cycle for the dosing station. A good starting
increase your Fill-O-Matic speed (parameter 3). point for these parameters is 2X the number of
Also verify the 80% rule for the fill cam. die table stations.
12. Punch retention
• W
ith the apron off and machine running,
observe the lower punches to verify punches
are not dropping. If the punches are dropping,
you can replace damaged punch seals, the
retaining band can be adjusted or replaced
and the metal clamp can be adjusted.
TROUBLESHOOTING CONTINUED 12
Excess Material Loss working lengths should be routinely inspected
and within TSM specification).
1. P
roduct buildup between the Fill-O-Matic • Worn dies! (Dies should be visually inspected
and the turret. and discarded when excess wear rings inside
• Adjust the Fill-O-Matic height the dies are present. Please see reference
• A
djust the gap between the Fill-O-Matic table drawings on page 17-18).
wear strip and the die table.
• Replace the Fill-O-Matic base plate. Tooling:
2. Dirty compression chamber
• Check vacuum (parameter 49) or adjust house 1. Punches binding in the bores
vacuum manually if option not purchased. • Verify parameters 47 and 48 (lubrication upper /
lower) are being utilized. Additionally, verify
Tablet Thickness Variation: safety parameters 45 and 46 (punch stiffness
upper / lower) are being utilized.
1. Compression rolls / Compression Station Shims • If the punch seals are damaged, product can
• E nsure compression rolls are free of nicks, build up in the bores and cause friction.
metal deposits and wear. Inspect and replace • Incorrect handling of tooling can leave rough
compression station load cell shims on regular spots, edges or burrs.
basis. Any movement on stations due to worn • Loose keys.
shims can cause thickness variation. • D amaged or insufficient pre-compression can
2. Tooling prevent a compression roll from turning.
• W orking length is out of specification (Tooling
TROUBLESHOOTING CONTINUED 13
Tablet Capping: Picking and Sticking:
1. Trapped air 1. Insufficient compression force
• Increase / decrease penetration (parameters • Increase tablet weight or decrease
20 & 21). tablet thickness.
2. Excessive compression force • D ecrease / increase pre-compression force.
• Increase tablet thickness or decrease tablet • Decrease / increase penetration.
weight (lower the compression force).
3. Incorrect ejection height
• Increase ejection height and check tablet
take-off.
4. Punch hooking tablet
• Inspect punch tips for damage.
If you need any assistance, please call Fette Compacting America at 973-586-8722.
After hours, please call 1-877-606-5015 for our 24-hour emergency technical service.
TROUBLESHOOTING CONTINUED 14
Quick Tips
SYMPTOM POSSIBLE FIX
Machine will not start Observe the actual diagnosis list
Diagnosis / parameter descriptions Highlight the diagnosis or parameter and press the F1 key
You press the green button to start
the machine, the lights go on but Check the main contactor
the machine does not start
Check the RJ45 connection on the terminal, press and power cabinet. If all looks good but there
Communication failure is still no communication, bypass the machine by connecting the RJ45 crossover cable from the
computer to the back of the VME
When viewing an alarm on the TSC This # identifies the amount of actual alarms at the present time
there is a # next to it
Abbreviations that appear on a “P” Production report update as per parameter 79, “D” Automated checkmaster sample as per
Checkmaster production report parameter 74, “E” Batch complete,“M” Manual sample
Poor yields Indicates improper set up or worn out parts. A poor yield also affects tablet performance and quality
High SREL Check your FOM speed, FOM paddles, FOM table height, punch seals, punch lengths, retaining
band and dosing ledge cam
Worn or damaged parts not
replaced Limited or no “preventative maintenance”, the key word here is preventative
Machine dirty Inadequate dust control. Check parameter 49 or adjust house vacuum manually
REFERENCE DATA 15
Torque Specifications
UNIT OF UNIT OF
PART PARAMETER
MEASUREMENT MEASUREMENT
Die lock screws 10 - 12 NM Parameter 5 Main Compression Force
Die segments 40 NM Parameter 22 Mean Value Weight
Dosing station 10 NM Parameter 18 Tablet Height Main Compression
Delrin upper cams 10 NM Parameter 6 Filling Depth Set Point
Upper stiffness bracket 46 NM Tablet Cylinder Height Pre-
Parameter 19
Compression
Main drive shaft 50 NM
Parameter 33 Air Reject
Upper compression station 195 NM
Parameter 3 Fill-O-Matic Adjustment
Manual penetration adjustment 600 NM
Center shaft P1200 400 NM
DISASSEMBLY POSITION 16
PART UNIT OF MEASUREMENT
6 - Tablet Filling Depth 20.0
18 - Tablet Cyl. Height (Main) 13.90
19 - Tablet Cyl. Height (Pre) 13.90
20 - Penetration - Main -7.9
21 - Penetration – Pre -7.9
HELP IS JUST A PHONE CALL AWAY
Fette Compacting America offers 24-hour emergency technical service via telephone, 7 days
a week, at no cost to the end user. One of our 14 service engineers is always on call to help
guarantee the minimization of machine down-time.
To take advantage of this invaluable service, simply dial 1-877-606-5015 after normal
business hours. The operator will contact our on-call service technician, who will then call you
back. Response times are generally in the neighborhood of thirty minutes or less.
400 Forge Way
Rockaway, NJ 07866
Tel: 973-586-8722
Fax: 973-586-0450
[Link]
[Link]
FETTE COMPACTING AMERICA
400 Forge Way
Rockaway, NJ 07866
parts@[Link]
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