6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 1

FETTE AMERICA
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 2

Table of Contents

Page
Help Text ____________________________________________________________________ 1
Weight Control _______________________________________________________________ 2
Tablet Press Operation ________________________________________________________ 3-4
Fine Tuning _________________________________________________________________ 5-6
Features for New Users _______________________________________________________ 7
Troubleshooting ______________________________________________________________ 8 -11
Controls Overview ____________________________________________________________ 12 -13
Reference Data / Quick Tips ____________________________________________________ 14 -16
TSM Reference Drawings ______________________________________________________ 17 -18
Fette Support ________________________________________________________________ 19
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 3

Help Text 1

For details and a better understanding of the parameter simply select the parameter and press F1.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 4

Weight Control 2
Control Loop 1
(Parameter 32)

When activated, control loop 1 is comprised of parameters that correspond with adjustment devices in order
to maintain a specified condition or value which is specified in parameter #5 - Main Compression Force.
A deviation of +/- 1% from the specified value in parameter #5 will result in the press automatically adjusting
the filling depth to maintain the specified value.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 5

Tablet Press Operation 3

BEFORE running your Fette tablet press!
• Verify punches are lubricated. • Adjust parameter 6 Tablet Filling Depth and parameter 18
• Rotate the turret an entire revolution by hand to listen for Tablet Cylinder Height Main Compression until batch
strange noises, etc. specifications for final tablet hardness are achieved.
• Adjust parameter 19 Tablet Cylinder Height
Running a Fette press: Pre-Compression until your granulation is now slightly
• After loading the product hopper with granulation, press compressed and is de-aerated.
the letter K (Setting Run) on the keyboard, so that all • The following steps should be taken prior to starting good
product produced will be sent to the reject bin. production.
• Press F10 on the keyboard to fill the 1. Increase the speed of the machine (parameter 1)
fill-o-matic with granulation. until batch guidelines are met.
• Press F12 on the keyboard and jog the press until a 2. Start the machine and observe the Main
tablet appears on the discharge chute and then place it Compression Force SREL. If the deviation is high,
on a scale. If a tablet cannot be compressed and check the speed of the fill-o-matic (parameter 3) and
granulation appears on the scale, decrease parameter 18 increase the set value.
Tablet Cylinder Height Main Compression until you are 3. Press L (Standard Run) to initiate good production
able to jog the machine with tablets appearing at the count (parameter 14).
discharge chute. 4. Insert the actual value in the set column for
• After weighing the sample tablet, use the following parameter 5 Main Compression Force and
formula in order to quickly get the batch running weight. parameter 13 Pre-Compression Force.
Actual Fill Depth (mm) X Target Weight = Target Fill Depth (Par.6) 5. Place a 1 in the set column for parameter 32.
Adjust on 1/2/3, as this will activate force control.
Actual Weight (mg)
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 6

Tablet Press Operation Continued 4

• Start the machine and verify tablet weight and tablet

hardness are ok.
• Observe parameter 8 Main Compression Force SREL 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 Main Compression Force SREL
Max 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.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 7

Fine Tuning 5
Fine tuning while the machine is running with 3. The force of the tablet has been changed, so now
force control on: observe parameter 5 Main Compression Force
• Tablet weight is good but the tablets are soft and need and match the set and actual values.
adjustment - 4. Enter a 1 in the set column for parameter 32 to
turn on force control.
1. Enter 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. Decrease the set value in parameter 18 Tablet and needs adjustment. There are 2 ways to adjust
Cylinder Height Main Compression until desired tablet weight while utilizing force control.
hardness is achieved.
3. The force of the tablet has been changed, so now 1. Increase the set value for parameter 5 Main
observe parameter 5 Main Compression Force Compression Force, which will force parameter 6
and match the set and actual values. Tablet Filling Depth to increase in order to satisfy
4. Enter a 1 in the set column for parameter 32 to the setting for parameter 5.
turn on force control. NOTE: Remember - force control works to
maintain the set and actual at parameter 5 Main
• Tablet weight is good but the tablets are hard and Compression Force.
need adjustment - NOTE: With this adjustment we added material,
but the cylinder height stayed the same, so check
1. Enter a 0 in the set column for parameter 32 to
the hardness.
turn off force control.
2. Increase the set value for parameter 18 Tablet
2. Increase the set value in parameter 18 Tablet
Cylinder Height Main Compression, which in turn
Cylinder Height Main Compression until desired
will immediately decrease the actual force at
hardness is achieved.
parameter 5 and this will cause parameter 6 to
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 8

Fine Tuning Continued 6

increase until the set and actual match at
parameter 5. NOTE: With this adjustment we reduced the
NOTE: Remember - force control works to amount of material, but the cylinder height
maintain the set and actual at parameter 5 Main stayed the same, so check the hardness.
Compression Force.
NOTE: With this adjustment we increased the 2. Decrease the set value for parameter 18 Tablet
cylinder height and then added granulation. With Cylinder Height Main Compression, which in turn
this adjustment we adjusted the thickness slightly will immediately increase the actual force at
(0.01), so check the hardness. parameter 5 and this will cause parameter 6 to
decrease until the set and actual match at
• Tablet hardness is good but the tablet weight is high parameter 5.
and needs adjustment. There are 2 ways to adjust NOTE: Remember - force control works to
tablet weight while utilizing force control. maintain the set and actual at parameter 5 Main
Compression Force.
1. Decrease the set value for parameter 5 Main NOTE: With this adjustment we decreased the
Compression Force, which will force parameter 6 cylinder height and then removed granulation.
Tablet Filling Depth to decrease in order to With this adjustment we adjusted the thickness
satisfy the setting for parameter 5. slightly (0.01), so check the hardness.
NOTE: Remember - force control works to
maintain the set and actual at parameter 5 Main
Compression Force.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 9

Great Features For New Users 7

The T screen allows the user to set individual parameters on one run screen.

F5 Graphics
All relevant
parameters are
shown when a
change is
necessary.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 10

Troubleshooting 8
Troubleshooting: The method of ruling out possible 4. Incorrect fill cam parameter 39
causes for abnormal, as well as, normal operation • Observe the actual filling depth and verify it is
and/or results. The process of elimination involves approximately 80% of the actual fill cam.
taking actual results and/or conditions and coupling • Quick tip for fill cam selection:
them with known causes. This enables the operator Thickness of tablet x 2 + 2 = fill cam
to isolate the direct cause for undesired results. 5. Ledge cam
• Remove the apron exposing the dosing station.
Tablet Weight Variation Start the machine and verify the ledge cam is
1. Poorly flowing granulation snug but also floats slightly.
• Check the granulation for proper flow 6. Fill-o-matic parameter 3
characteristics. • Increase / Decrease the speed of the fill-o-matic
• Check the hopper valve and adjust if necessary - and observe the impact on the SREL. May need
you may need a stirring rod or a vibrator. to install round wire paddles.
2. Tooling 7. Scraper 2 assembly
• Working length is out of specification (tooling • If the scraper blade is not flush to the die table
working lengths should be routinely inspected to and does not float, it can lead to burn marks.
ensure they are within TSM specification). • The tail over die should sit flush on the die table.
Please see reference drawings on page 17-18. 8. Vacuum parameter 49
3. Die seating • The amount of vacuum on the machine is
• If granulation is leaking under the scraper blade regulated through parameter 49. If the vacuum
it may be an indication of a damaged blade. regulation option was not purchased, adjust your
• Dies should be flush with the die table surface. house supply manually.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 11

Troubleshooting Continued 9
9. Re-circulation scoop 13. Critical parameters not used correctly.
• The blade of the scoop should be approximately • Parameters 47 and 48 deal with tooling
.0001 inches from the bottom of the channel. lubrication and must be set correctly. These
10. Penetration parameters 20 & 21 values vary due to product characteristics, but a
• The actual penetration measured in mm good starting point is 90 seconds for the lowers
identifies where the tablet is being compressed and 120 seconds for the uppers.
in the die. • Parameter 57 Statistic No. of Tablets updates
• 2 mm is a good starting point. key parameters 5, 8 and 13, while parameter 59
• Adjustments are typically made in .5mm Filling Depth Regulation sets the adjustment
increments cycle for the dosing station. A good starting point
11. Machine speed parameter 1 for these parameters is 2X the number of die
• As machine speed increases, you may want to table stations.
increase your fill-o-matic speed (parameter 3).
Also verify the 80% rule for the fill cam.
12. Punch retention
• With the apron off and machine running, observe
the lower punches to verify punches are not
dropping. If the punches are dropping replace
damaged punch seals, the retaining band can
be adjusted or replaced and the metal clamp
can be adjusted.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 12

Troubleshooting Continued 10
Excess Material Loss • Worn dies! (Dies should be visually inspected
and discarded when excess wear rings inside
1. Product buildup between the fill-o-matic the dies are present. Please see reference
and the turret. drawings on page 17-18).
• Adjust the fill-o-matic height
• Adjust the gap between the fill-o-matic table Tooling:
wear strip and the die table.
• Replace the fill-o-matic base plate. 1. Punches binding in the bores
2. Dirty compression chamber • Verify parameters 47 and 48 (lubrication upper /
• Check vacuum (parameter 49) or adjust house lower) are being utilized. Additionally, verify
vacuum manually if option not purchased. safety parameters 45 and 46 (punch stiffness
upper / lower) are being utilized.
Tablet Thickness Variation: • If the punch seals are damaged, product can
build up in the bores and cause friction.
1. Compression rolls • Incorrect handling of tooling can leave rough
• Ensure compression rolls are free of nicks, metal spots, edges or burrs.
deposits and wear. • Loose keys.
2. Tooling • Damaged or insufficient pre compression can
• Working length is out of specification (Tooling prevent a compression roll from turning.
working lengths should be routinely inspected
and within TSM specification).
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 13

Troubleshooting Continued 11
Tablet Capping: Picking and Sticking:
1. Insufficient compression force
1. Trapped air • Increase tablet weight or decrease
• Increase / Decrease penetration (parameters tablet thickness.
20 & 21). • Decrease / Increase pre-compression force.
2. Excessive compression force • Decrease / Increase penetration.
• Increase tablet thickness or decrease tablet
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 America at 973-586-8722.

After hours, please call 1-877-606-5015 for our 24-hour emergency technical service.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 14

Controls Overview X06 12

6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 15

Controls Overview X98 13

6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 16

Reference Data/Quick Tips 14

Controls Description
Part Description

PILZ SAFETY PLC Triple redundant CPU processors for safety.

PTCAN CARD Interface card between CAN bus and entire system.
VME BUS Fast and accurate communication between the boards and the VME rack.
Motorola CPU Main processor of VME system.
PTIDAC Card Analog to digital converter.
B&R Computer Compact industrial computer.
Encoder Provides feedback from necessary motors to the controller card. Example: main motor and station motors.
Lenze VFD Speed controller for the FOM.
Direct drive main motor Reduction in heat and noise, with the elimination of belts/pulleys.
IPOS Card (X98 only) Intelligent positioning controller card controls the servo drives.
Printers Some machines will have inkjets, some have receptacle for network printers.
Main Power Connection Should comply with Local and National Electrical Codes.
Access to Power Cabinet Should be locked at all times and only qualified personnel should have access.
Cables to/from press Position cables so that they cannot be damaged and do not pose a tripping hazard.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 17

Reference Data/Quick Tips Continued 15

Torque Specifications
Part Unit of measurement
Die lock screws 10 - 12 NM
Die segments 40 NM
Dosing station 10 NM
Delrin upper cams 10 NM
Upper stiffness bracket 46 NM
Main drive shaft 50 NM
Upper compression station 195 NM
Manual penetration adjustment 600 NM
Center shaft P1200 400 NM
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 18

Reference Data/Quick Tips Continued 16

Quick Tips
Symptom Possible Fix

Machine will not start Observe the actual diagnosis list.

Diagnosis / Parameter Highlight the diagnosis or parameter and press the F1 key.
descriptions
You press the green button to start
the machine, the lights go on Check the main contactor.
but the machine does not start
Communication failure Check the RJ45 connection on the terminal, press and power cabinet. If all looks good but
there 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 This # identifies the amount of actual alarms at the present time.
the TSC there is a # next to it.
Abbreviations that appear on “P” stands for production sample, “D” stands for checkmaster sample, “E” stands for batch
a Checkmaster production report sample and “M” stands for 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 Limited or no “preventative maintenance”, the key word here is preventative.
not replaced
Machine dirty Inadequate dust control. Check parameter 49 or adjust house vacuum manually.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 19

TSM Reference Drawings 17

6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 20

TSM Reference Drawings Continued 18

6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 21

Fette Support 19

Help is just a phone call away

Fette 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 phone
the client in need. Response times are generally
in the neighborhood of thirty minutes or less.
6731 20 pg Fette Pocket Guide 7/24/07 2:40 PM Page 22

400 Forge Way

Rockaway, NJ 07866
Tel: 973-586-8722
FETTE AMERICA Fax: 973-586-0450