HFE M2 Operator's Manual [X41176B]

HYDRAULIC PRESS-BRAKE

OPERATOR’S MANUAL

X41176 B

AMADA Europe S.A. BP 41040 – 95912 ROISSY AÉROPORT CDG CEDEX Tél : 01 49 90 30 00 – Fax : 01 49 90 31 99

Original

Index

Issue

Updated by

Details of revision

A

05/2010

D.Gasior

First issue

B

10/2010

D. Gasior

Updated Ch6: - Initialisation of AKAS III - Bending criteria - Directory management

In order to achieve a thorough understanding of the machine, it is recommended that this manual should be read through carefully. Adhere scrupulously to the detail of the installation operations, operation and maintenance instructions as described in this manual; so as to avoid all risks of accidents. Retain this documentation to hand so that it can be used as a reference whenever required.  Amada, Tremblay, December 2002. Any representation, translation, adaptation or reproduction, even partial, by any method or in any country without prior permission is illegal and would make the offender subject to legal action.

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CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

LIST OF ADDENDA Modification coming from

Reason

CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

Description

Application

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HYDRAULIC PRESS BRAKE OPERATOR’S MANUAL

IMPORTANT ACCEPTANCE We loaded your press brake onto the carrier's vehicle. The carrier acknowledged receiving it in perfect condition. However, in the case of a problem during shipping (which may happen), or if you notice signs of damage (impact marks, etc.) on your machine, we would like to remind you that you should formulate your reservations as follows: A – the delivery voucher submitted to you for acceptance by the carrier. B – By notifying the carrier and us (for information) by registered letter within 48 hours at the latest. C – It is strictly prohibited to use this machine if protective covers have been removed or modified. Only personnel - authorized and qualified by AMADA – is entitled to do so when maintenance operations turn out to be necessary.

FOR ALL PROBLEMS DURING MACHINE INSTALLATION Telephone  ........................................................... 01 49 90 30 00 Fax  ....................................................................... 01 49 90 31 99

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CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

CONTENTS 1. GENERAL DESCRIPTION ............................................................................................... 1 1.1. DESCRIPTION................................................................................................................ 3 1.2. PRINCIPLE ..................................................................................................................... 5 1.3. MACHINE SPECIFICATIONS ...................................................................................... 8 1.3.1. STANDARD STROKE............................................................................................. 8 1.3.2. LONG STROKE ....................................................................................................... 9 1.4. BACK GAUGE ............................................................................................................. 10 1.4.1. BASIC PRINCIPLES .............................................................................................. 10 1.4.2. SPECIFICATIONS ................................................................................................. 11

2. SAFETY MEASURES......................................................................................................... 1 2.1. EC DECLARATION OF CONFORMITY ..................................................................... 2 2.2. MARKING ...................................................................................................................... 4 2.3. SAFETY PRECAUTIONS............................................................................................ 10 2.3.1. GENERAL POINTS ............................................................................................... 10 2.3.2. REGULAR INSPECTION AND SAFETY POLICY............................................. 13 2.4. ARRANGEMENT OF WORKSTATIONS ................................................................. 14 2.5. CONTROL DEVICES................................................................................................... 15 2.6. PERSONAL PROTECTIVE EQUIPMENTS (PPE)..................................................... 16 2.7. RULES FOR SAFE OPERATION................................................................................ 19 2.8. WORKSTATION LIGHTING ...................................................................................... 26 2.9. MACHINE OPERATING AND STORAGE CONDITIONS....................................... 27 2.10. INFORMATION ON NOISE ...................................................................................... 28 2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS ....................................... 29

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3. TECHNICAL DESCRIPTION OF THE MACHINE ...................................................... 1 3.1. MECHANICAL CONNECTIONS.................................................................................. 5 3.2. ELECTRONIC STROKE CONTROL AND PARALLELISM BALANCING SYSTEM................................................................................................................................. 7 3.2.1. ELIMINATING SOURCES OF ERROR ................................................................. 9 3.2.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY. 9 3.2.3. PRECISE CENTRING OF THE BEAMS .............................................................. 10 3.3. LOCATION OF CONTROL AND SIGNALLING DEVICES.................................... 11 3.4. PRESS BRAKE OPERATING LIMITS IN OFF-CENTRE WORK............................ 11 3.5. A-TYPE BACK GAUGE .............................................................................................. 12 3.5.1. DESCRIPTION OF X1 AND X2 AXES ................................................................ 13 3.5.2. DESCRIPTION OF R AXES .................................................................................. 15 3.5.3. DESCRIPTION OF Z1 AND Z2 AXES ................................................................. 17 3.6. B-TYPE BACK GAUGE .............................................................................................. 18 3.6.1. DESCRIPTION OF X1 AND X2 AXES ................................................................ 19 3.6.2. DESCRIPTION OF R AXES .................................................................................. 21 3.6.3. INTERFACE BETWEEN R AXIS MODULE AND Z AXIS CROSS-MEMBER 23 3.6.4. DESCRIPTION OF Z1 AND Z2 AXES ................................................................. 23 3.7. DESCRIPTION OF C-TYPE BACK GAUGE ............................................................. 24 3.7.1. DESCRIPTION OF X-AXES ................................................................................. 25 3.7.2. DESCRIPTION OF R-AXIS................................................................................... 27 3.7.3. DESCRIPTION OF Z1 AND Z2 AXES (FINGERS)............................................. 29 3.8. GENERAL DESCRIPTION OF HA-TYPE BACK GAUGE....................................... 30 3.8.1. DESCRIPTION OF THE X1 AND X2 AXES ....................................................... 31 3.8.2. DESCRIPTION OF THE R AXES ......................................................................... 33 3.8.3. DESCRIPTION OF Z1 AND Z2 AXES (FINGERS)............................................. 35 3.9. DESCRIPTION OF THE FINGER SUPPORTS .......................................................... 36 3.10. DESCRIPTION OF THE LIGHT GUARD ................................................................ 39 3.10.1. MECHANICAL UNIT .......................................................................................... 40 3.10.2. LIGHT GUARD .................................................................................................... 41

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CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

4. TRANSPORT, INSTALLATION AND DISMANTLING............................................... 1 4.1. TRANSPORTATION...................................................................................................... 2 4.2. PREPARING THE SITE ................................................................................................. 7 4.2.1. STANDARD STROKE............................................................................................. 9 4.2.2. LONG STROKE ..................................................................................................... 10 4.3. MACHINE RECEPTION.............................................................................................. 10 4.4. RECEPTION & HANDLING ....................................................................................... 12 4.4.1. LIFTING.................................................................................................................. 12 4.4.2. BASIC PRINCIPLES .............................................................................................. 14 4.4.3. EQUIPMENT .......................................................................................................... 17 4.4.4. SPECIAL PARTS FOR TRANSPORT .................................................................. 19 4.5. INSTALLATION .......................................................................................................... 20 4.6. ELECTRICAL CONNECTIONS .................................................................................. 28 4.6.1. GENERAL CHARACTERISTICS OF THE MAINS SUPPLY ............................ 28 4.6.2. EARTH.................................................................................................................... 28 4.6.3. MAINS-RELATED AND ENVIRONMENT-RELATED INTERFERENCE....... 29 4.6.4. POWER SUPPLY CABLE ..................................................................................... 31 4.7. DECOMMISSIONING.................................................................................................. 32 4.8. DISMANTLING............................................................................................................ 33 5. FIRST COMMISSIONING ................................................................................................ 1 5.1. CLEANING ..................................................................................................................... 2 5.2. INSTALLATION OF CONTROL DEVICES................................................................. 2 5.3. CHECKING THE MAINS POWER SUPPLY ............................................................... 4 5.4. MACHINE LEVELLING................................................................................................ 4 5.5. MACHINE COMMISSIONING ..................................................................................... 5 5.6. OVERALL CHECK ........................................................................................................ 6

CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

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6. OPERATION........................................................................................................................ 1 6.1. START-UP ...................................................................................................................... 2 6.2. DESCRIPTION OF CONTROL UNITS......................................................................... 3 6.2.1. NUMERICAL CONTROL PANEL.......................................................................... 3 6.2.2. DESCRIPTION OF CONTROL AND SIGNALLING DEVICES........................... 4 6.3. OPERATION (WITHOUT LIGHT GUARD) ............................................................. 10 6.4. USE OF THE LIGHT GUARD ..................................................................................... 12 6.4.1. SWITCHING ON.................................................................................................... 12 6.4.2. ALTERNATE PROTECTION MODE . ................................................................. 13 6.4.3. PROTECTION MODE AND « SINGLE PASSING-THROUGH » CYCLE CONTROL. ....................................................................................................................... 15 6.4.4. PROTECTION MODE AND « DOUBLE PASSING-THROUGH » CYCLE CONTROL. ....................................................................................................................... 16 6.4.5. PROTECTION MODE AND « SIMPLE PASSING-THROUGH » CYCLE CONTROL. ....................................................................................................................... 17 6.4.6. PROTECTION MODE AND « DOUBLE PASSING-THROUGH » CYCLE CONTROL. ....................................................................................................................... 19 6.5. MACHINE EQUIPPED WITH A FRONT PROTECTION BY LASER. .................... 21 6.5.1. INITIAL SETTINGS............................................................................................... 21 6.5.2. STOPPING DISTANCE TEST............................................................................... 21 6.5.3. TROUBLESHOOTING - MESSAGES .................................................................. 22 6.6. DISPLAYS .................................................................................................................... 23 6.7. USB KEY....................................................................................................................... 26 6.8. MACHINE INITIALISATION ..................................................................................... 27 6.9. PROGRAMMING ......................................................................................................... 29 6.9.1. PRELIMINARY NOTE CONCERNING PROGRAMMING................................ 29 6.9.2. “MANUAL 1” SIMPLIFIED PROGRAMMING “PROGRAMMING MODE”... 30 6.9.3. “MANUAL 2” MODE: "ANGLE PROGRAMMING" OR "X-ALPHA".............. 35 6.9.4. GRAPHIC MODE PROGRAMMING ................................................................... 42 6.9.5. MULTI-PROGRAM MODE................................................................................... 54 6.9.6. SEMI-AUTOMATIC MODE.................................................................................. 56 6.9.7. AUTOMATIC MODE ............................................................................................ 59 6.9.8. TEACHING MODE ................................................................................................ 62 6.10. EDIT MENU................................................................................................................ 65 6.10.1. PUNCH EDIT ....................................................................................................... 65 6.10.2. PUNCH HOLDER EDIT ..................................................................................... 67 6.10.3. DIE EDIT .............................................................................................................. 68 8/12 Issue 05/2010

CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

6.10.4. DIE HOLDERS EDIT ........................................................................................... 69 6.10.5. DIE BLOCK EDIT................................................................................................ 70 6.10.6. FINGER EDIT....................................................................................................... 71 6.11. DELETE MENU.......................................................................................................... 72 6.11.1. DELETE PROGRAMS ......................................................................................... 72 6.11.2. DELETE PUNCHES............................................................................................. 74 6.11.3. DELETE PUNCH HOLDERS .............................................................................. 75 6.11.4. DELETE DIES ...................................................................................................... 75 6.11.5. DELETE DIE BLOCK.......................................................................................... 75 6.11.6. DELETE DIE HOLDERS .................................................................................... 75 6.11.7. DELETE FINGER................................................................................................. 75 6.12. RENAME MENU ........................................................................................................ 76 6.12.1. RENAME PROGRAMS ....................................................................................... 76 6.12.2. RENAME PUNCHES ........................................................................................... 77 6.12.3. RENAME PUNCH HOLDERS ............................................................................ 77 6.12.4. RENAME DIES .................................................................................................... 77 6.12.5. RENAME DIE BLOCKS...................................................................................... 77 6.12.6. RENAME DIE-HOLDERS................................................................................... 77 6.12.7. RENAME FINGERS............................................................................................. 77 6.13. COPY MENU .............................................................................................................. 78 6.13.1. COPY PROGRAMS ............................................................................................. 78 6.13.2. COPY PUNCHES ................................................................................................. 79 6.13.3. COPY PUNCH HOLDER..................................................................................... 79 6.13.4. COPY DIES........................................................................................................... 79 6.13.5. COPY DIE HOLDERS ......................................................................................... 79 6.13.6. COPY DIE BLOCK .............................................................................................. 79 6.13.7. COPY FINGER ..................................................................................................... 79 6.14. SAVE MENU .............................................................................................................. 80 6.14.1. SAVE PROGRAMS.............................................................................................. 80 6.14.2. SAVE PUNCHES ................................................................................................. 83 6.14.3. SAVE PUNCH HOLDER ..................................................................................... 83 6.14.4. SAVE DIE ............................................................................................................. 83 6.14.5. SAVE DIE BLOCK .............................................................................................. 83 6.14.6. SAVE DIE HOLDER............................................................................................ 83 6.14.7. SAVE FINGER ..................................................................................................... 83 6.15. RESTORE MENU ....................................................................................................... 84 6.15.1. RESTORE PROGRAMS ...................................................................................... 84 6.15.2. RESTORE PUNCHES .......................................................................................... 87 6.15.3. RESTORE PUNCH HOLDER.............................................................................. 87 6.15.4. RESTORE DIES ................................................................................................... 87 6.15.5. RESTORE DIE BLOCK ....................................................................................... 87 CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

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6.15.6. RESTORE DIE HOLDERS .................................................................................. 87 6.15.7. RESTORE FINGER .............................................................................................. 87 6.16. CUSTOM MENU ........................................................................................................ 88 6.16.1. CUSTOMISE PUNCH .......................................................................................... 88 6.16.2. CUSTOMISE PUNCH HOLDER......................................................................... 89 6.16.3. CUSTOMISE DIE................................................................................................. 89 6.16.4. CUSTOMISE DIE BLOCK .................................................................................. 89 6.16.5. CUSTOMISE DIE HOLDER................................................................................ 89 6.16.6. CUSTOMISE FINGER ......................................................................................... 89 6.17. PROGRAM DIRECTORY MENU ............................................................................. 90 6.17.1. CHANGE DIRECTORY....................................................................................... 90 6.17.2. EXPORT DIRECTORY........................................................................................ 91 6.17.3. IMPORT DIRECTORY ........................................................................................ 93 6.18. PARAMETER MENU................................................................................................. 95 6.19. UTILITY MENU ......................................................................................................... 96 6.20. BENDING WITH 2 OPERATORS............................................................................. 98 6.21. BENDING AT THE EXTREMITY OF THE BEAM ................................................. 99 7. FORMING TECHNIQUE & TOOLING .......................................................................... 1 7.1. GENERAL POINTS........................................................................................................ 3 7.2. AIR BENDING................................................................................................................ 7 7.3. COINING......................................................................................................................... 8 7.4. LIST OF STANDARD TOOLS ...................................................................................... 9 7.5. TOOL INSTALLATION............................................................................................... 11 7.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM ........................................... 11 7.5.2. “AMACLIP” PUNCH CLAMPING SYSTEM ...................................................... 15 7.5.3. TOOLING INSTALLATION PROCEDURE (STANDARD) ............................... 21 7.6. OPTIONS AND ACCESSORIES ................................................................................. 29 7.7. PUNCHING................................................................................................................... 29 7.8. MAGNETISM ............................................................................................................... 29 7.9. BENDING CHART ....................................................................................................... 30

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CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

8. SERVICING AND MAINTENANCE................................................................................ 1 8.1. INTRODUCTION ........................................................................................................... 2 8.2. MACHINE PERIODIC MAINTENANCE ..................................................................... 5 8.2.1. CHECKS SPECIFIC TO THE HYDRAULIC INSTALLATION ........................... 9 8.2.2. OIL CHANGES....................................................................................................... 11 8.2.3. FILLING PROCEDURE......................................................................................... 11 8.3. RECOMMENDATIONS ............................................................................................... 12 8.3.1. SPECIFIC DAILY TEST PROCEDURE: .............................................................. 13 8.4. TROUBLESHOOTING................................................................................................. 24 8.4.1. TROUBLESHOOTING TABLE ............................................................................ 24 8.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL POINTS ............................................................................................................................. 25 8.5. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES ............................ 27 8.6. ADJUSTMENT AND MAINTENANCE OF THE LIGHT GUARD .......................... 31 8.6.1. ADJUSTMENT ....................................................................................................... 31 8.6.2. PROGRAMMING................................................................................................... 34 8.6.3. REGULAR MAINTENANCE ................................................................................ 34 8.6.4. DAILY INSPECTION ............................................................................................ 35 8.6.5. MAINTENANCE.................................................................................................... 36 8.7. ADJUSTING AKASIII MAINTENANCE .................................................................. 38 8.8. BACK GAUGE MAINTENANCE ............................................................................... 41 8.8.1. INTRODUCTION................................................................................................... 41 8.8.2. MEANS NECESSARY FOR MAINTENANCE.................................................... 42 8.8.3. MONTHLY FREQUENCY .................................................................................... 42 8.8.4. QUARTERLY FREQUENCY ................................................................................ 43 8.8.5. SEMI-ANNUAL FREQUENCY ............................................................................ 44 8.8.6. EVERY 2 YEARS................................................................................................... 53

9. ERROR MESSAGES LIST................................................................................................. 1 ANNEXE A – ANNEXE B – MACHINE SCHEMATICS AND LISTING (see in the elctric cabinet of the machine). ANNEXE C – SUPPLIERS DOCUMENTATION ANNEXE D – SPECIAL MACHINES ANNEXE E – OPTIONS CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

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APPENDICES

IMPORTANT NOTE

A certain number of appendices – fully complying with your machine - is supplied with this technical manual. The list of these additional documents is part of the Quality Control file, which is delivered with the machine. At the time of delivery, this file is placed inside the document tray attached to the inner side of the electric cabinet door.

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CONTENTS OPERATOR’S MANUAL HFE M2 – X41176B

1. GENERAL DESCRIPTION

GENERAL DESCRIPTION OPERATOR’S MANUAL HFE M2 – X41176B

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Figure 1.1

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GENERAL DESCRIPTION OPERATOR’S MANUAL HFE M2 – X41176B

1.1. DESCRIPTION The purpose of this document is to facilitate the installation of your High Fidelity hydraulic press brake (Fig. 1.1) and its connection to the electrical and pneumatic supply systems. This product line includes the following models: - HFE M2 50 to 400 tons Depending upon the models, lengths start 1.2 meters up to 6 meters Our models are supplied:    

In a « basic » footswitch-controlled version, Equipped with a “A” or “B”-type back gauge (except with 5012) Equipped with a “C”-type back gauge (only with 5012) Equipped with a « HA 5 axes », « HA 2 axes » (only with 320 and 400 T) -type back gauge  in option : - light curtain, which is used as front protection and as an operation cycle control device. Or - laser safety system used as front protection only.

Note :

In this manual, “tons” is very often used instead of international measurement unit “kN”. We remind you that 9.81 kN is equivalent to one ton.

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Figure 1.2 F1 and F’1 = Bending force A and A’ = Counter acting points

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GENERAL DESCRIPTION OPERATOR’S MANUAL HFE M2 – X41176B

1.2. PRINCIPLE The machine is a manual loading/unloading hydraulic press brake. HF-type hydraulic press brakes are down-stroking machines equipped with a numerical control ensuring the control and adjustment of all bending parameters. These press brakes are equipped with a central reaction Lower Beam to ensure bending quality. An electrohydraulic servosystem controls the travel and ensures that the Upper Beam (UB) remains perfectly parallel to the Lower Beam (LB). These machines can be equipped with various options (back gauge, front gauge, etc.), with all Amada tools, and other traditional tools, as well as a range of various accessories. (Contact our Local Sales Representative to discuss your specific requirements.)

For items heavier than 25 kg, a handling device – not included in Amada supply - must be provided to the operator.

REVIEW OF THE CONVENTIONAL DESIGN OF PRESS BRAKES Due to the reactions of the part under the thrust of the cylinders located at both ends, traditional down-stroking press brakes experience an elastic deflection during bending in opposite directions on each beam.

These deflections can be detected by a difference in terms of punch penetration in the die, slightly minor in the center than at the ends (Fig. 1.2).

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AMADA SYSTEM: Slotted beam (for 50 to 100 -ton press brakes). The lower beam is a slotted plate. The arrangement, size, and shape of the slots are designed to allow the lower beam to deflect in the same direction and with the same deflection as the upper beam under the action of the bending force. The lower beam is welded to the flanges (Fig. 1.3). From 130 to 400 tons. The lower beam (A) is assembled between two lateral cheeks (B and B') welded to the flanges through two largely dimensioned pins positioned on both ends of the machine’s central axis (Fig. 1.3) or (Fig. 1.3’). When bending, reaction forces tend to deform the lower beam in the same direction and parallel to the upper beam. (Fig. 1.4). ADVANTAGES Due to the minor but inevitable elastic deflection of both beams in the same direction and with the same value, the punch has constant penetration in the die over the entire bending length, thus ensuring a perfect angle. The minor deflection of the beams does not affect the linearity of the bend because the stress induced in the beam remains well within the elastic region.

Up to 220 tons

B’

B A

Fig. 1.3

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GENERAL DESCRIPTION OPERATOR’S MANUAL HFE M2 – X41176B

Valid for 320 and 400 tons

Fig. 1.3’

Fig. 1.4 F1 and F’1 = Bending force A and A’ = Counter acting points

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1.3. MACHINE SPECIFICATIONS 1.3.1. STANDARD STROKE Description

Units

Nominal force kN Minimum force (1) kN Beam length mm Table width mm Working line height mm Admission mm Cylinder stroke mm Throat depth mm Distance between uprights mm Max. pressure bar Number of cycles Oil capacity litres Length (overall) (2) mm Width (overall) (3) mm Height (overall) mm Total weight(4) kg Number of adj. Dist. pieces (5) Height of distance pieces mm Number of lg 835 mm tools lg 415 mm Motor power (6) kW Pump capacity cm³/t Max. approach speed mm/s Max. working speed mm/s Max. return speed mm/s

MODELS HF 50-12 50-20 80-25 100-30 130-30 170-30 500 40 1270 60 960 370 150 100 1035 270 4 55 2710 2320 2300 3350 6/8 120 1 3 4 8,2 100 10 100

500 40 2090 60 960 470 200 420 1665 270 4 55 3340 2450 2450 4600 10/13 120 2 5 4 8,2 100 10 100

800 70 2570 60 960 470 200 420 2125 275 4 90 3800 2445 2540 5600 13/17 120 4 7 7,5 13,3 100 10 100

1000 75 3110 60 960 470 200 420 2705 280 4 110 4385 2430 2680 6600 15/21 120 4 7 7,5 15,8 100 10 100

1300 150 3140 90 960 470 200 420 2700 296 5 150 4440 2625 2815 8150 15 / 21 120 4 7 11 20,7 100 1 à 10 1 à 100

1700 210 3170 180 960 470 200 420 2700 283 5 235 4470 2625 2900 11600 16 / 21 120 4 7 15 32,6 100 1 à 10 1 à 100

170-40

220-40

1700 210 4230 180 960 470 200 420 3760 283 5 235 5530 2625 2890 13900 21 / 28 120 5 10 15 32,6 100 1 à 10 1 à 100

2200 260 4280 180 960 470 200 420 3760 288 5 295 5560 2625 3085 17100 21 / 28 120 5 10 18,5 41 100 1 à 10 1 à 100

AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to alter their characteristics at any time. (1) - Value affecting the smallest allowable length of tools (§ 7.5). (2) - The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed.. (3) - The dimensions are with the arm and the NC maximum extended in front, and all doors closed.. (4) - Les Weights are approximate and correspond to basic machines, for optional equipment, see § 4.2.1. (5) - Standard distance pieces / Abutting distance pieces. (6) - Machine power = Motor power + 3 kW.

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GENERAL DESCRIPTION OPERATOR’S MANUAL HFE M2 – X41176B

1.3.2. LONG STROKE Description Nominal force Mnimum force (1) Beam length Table width working line height Admission cylinder stroke Throat depth Distance between uprights Max. pressure Number of cycles Oil capacity Length (overall) (2) Width (overall) (3) Height (overall) Total weight(4) Number of adj.dist. pieces (5) Dist. Pieces height Number of lg 835 mm tools lg 415 mm Motor power (6) Pump capacity Max. approach speed Max. working speed Vitesse de retour maxi

Units kN kN mm mm mm mm mm mm mm bar litres mm mm mm kg mm

kW cm³/t mm/s mm/s mm/s

130-30

170-30

MODELS HF 170-40 220-40

320-4

400-6

1300 150 3140 90 960 620 350 420 2700 296 5 150 4440 2625 3140 9000 15 / 21 120 4 7 11 20,7 100 1 to 10 1 to 100

1700 210 3170 180 960 620 350 420 2700 283 5 235 4470 2625 3140 12400 16 / 21 120 4 7 15 32,6 100 1 to 10 1 to 100

1700 210 4230 180 960 620 350 420 3760 283 5 235 5530 2625 3150 14500 21 / 28 120 5 10 15 32,6 100 1 to 10 1 to 100

3200 400 4100 250 960 620 350 420 3230 227 6 350 NC NC 3415 24000 20 120 5 10 37 80,7 75 10 100

4000 400 6100 250 960 620 350 420 5230 280 6 350 NC NC 4035 36000 30 120 7 14 37 80,7 75 10 100

2200 260 4280 180 960 620 350 420 3760 288 5 295 5560 2625 3270 18000 21 / 28 120 5 10 18,5 41 100 1 to 10 1 to 100

AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to alter their characteristics at any time. (1) - Value affecting the smallest allowable length of tools (§ 7.5). (2) - The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed.. (3) - The dimensions are with the arm and the NC maximum extended in front, and all doors closed.. (4) - Les Weights are approximate and correspond to basic machines, for optional equipment, see § 4.2.2. (5) - Standard distance pieces / Abutting distance pieces. (6) - Machine power = Motor power + 3 kW.

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1.4. BACK GAUGE 1.4.1. BASIC PRINCIPLES The B-type backgauge is a valuable complement to your numerical controller. Combining speed and positioning accuracy, the backgauge will meet your needs when producing average or large batch parts, as well as when producing unit parts. The A and C-type backgauges for a hydraulic press-brake, have 2 motorised translation axes which are monitored from the NC The B-type backgauge for a hydraulic press-brake has 3 to 5 motorised translation axes which are monitored from the NC: The HA heavy-type backgauge for an hydraulic press-brake has 2 or 5 motorised translation axes which are monitored from the NC: X: part butting depth. R: part butting height. Z: in-between distance and lateral positioning of the fingers (for 5 axes, only). Depending upon the HFE M2, press-brake tonnage, the following type of backgauge may equip your machine

1) Type A (HFE M2 from 50 tons 2 meters to 220 tons 4 m) 2) Type B (HFE M2 from 50 tons 2 meters to 220 tons 4 m) 3) Type C (HFE M2 from 50 tons 1,2 meter) 4) HA-heavy-type (HFE M2 from 320 to 400 tons)

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1.4.2. SPECIFICATIONS

A-type backgauge

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A-TYPE BACK GAUGE

X1, X2

R

Stroke (mm) For 2 m. press-brakes For 2.5 m. press-brakes For 3 m. press-brakes For 4 m. press-brakes

700

250

X butting depth (mm): Bending axis– finger end Bending axis – secondary gauge distance HF 50/20 to HF 130/3 HF 130/4 to HF 220/4

Z1, Z2 1320 1780 2360 3420

0 - 700 320 – 1020 360 - 1060 300

90

Manual

Motor power rating (watt)

550

550

-

Positioning accuracy (mm)

 0,10

 0,2

Manual

Repeatability (mm)

 0,03

 0,05

Manual

Travel speed (mm/s)

Min. distance between fingers (mm)

110 center to center 10 side to side (inner)

Finger width (mm)

99

Max. distance between fingers (mm) On 2 m press-brake On 2.5 m press-brakes On 3 m press-brakes On 4 m press-brakes

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(AB)

(ED)

1430 1890 2470 3530

1530 1990 2570 3630

GENERAL DESCRIPTION OPERATOR’S MANUAL HFE M2 – X41176B

B-type back gauge

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B-TYPE BACK GAUGE

X1, X2

R

Z1, Z2

Stroke (mm) Max; offset between X1 and X2 (mm) For 2 m. press-brakes For 2.5 m. press-brakes For 3 m. press-brakes For 4 m. press-brakes

700

250

3300 or 2140

Travel speed (mm/s)

500

160

1000

Positioning accuracy (Watt)1

200

200/300

110

0 – 300 :  0.075  300 :  0.100

 0,1

1

 0,01

 0,05

 0,5

Positioning accuracy (mm)

240 320 450 540

Repeatability (mm) Min. distance between fingers (mm)

120 center to cente 20 side to side (inner)

Finger width (mm)

99

Max. distance between fingers (mm) On 2 m press-brakes On 2.5 m press-brakes On 3 m press-brakes On 4 m press-brakes

1

(AB)

(ED)

1445 1900 2460 3500

1545 2000 2560 3600

Puissance variable en fonction de la longueur de la traverse d’axe Z. Voir schéma électrique.

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C-type back gauge

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C-TYPE BACK GAUGE Stroke (mm)

X butting depth (mm) : bending axis – finger end distance bending axis –secondary gauge distance bending axis – back gauge +300 distance

X

R

Z1, Z2

650

160

724

0 – 650 0 – 700 0 – 950

Travel speed (mm/s)

350

160

Manual

Motor power rating (watt)

550

550

-

Positioning accuracy (mm)

0 –650  0,20

 0,12

Manual

 0,005

 0,05

Manual

Repeatability (mm) Min. distance between fingers (mm)

110 11

Center to center Inner Finger width (mm)

99

Max. distance between fingers (mm)

Center to center (AB) Inner (ED)

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5 axes HA back gauge

2 axes HA back gauge

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HA-TYPE BACK GAUGE

5 axes HA

2 axes HA

700 250 * See table next page

700 250 * See table next page

0 - 700 600 – 1300

0 - 700 600 – 1300

475 450 550

0 0 0

X –axis travel speed (mm/s).

200

200

R –axis travel speed (mm/s).

85

85

Z –axis travel speed (mm/s).

700

manual

X –axis Motor power rating (Watt).

300

550

R –axis Motor power rating (Watt).

500

550

Z –axis Motor power rating (Watt).

200

manual

Positioning accuracy in X (mm).

 0,2

 0,2

Positioning accuracy in R (mm).

 0,3

 0,3

Positioning accuracy in Z (mm).

1

manual

X repeatability (mm).

 0,03

 0,03

R repeatability (mm).

 0,03

 0,03

Z repeatability (mm).

 0.5

manual

Min. distance between fingers (Z1-axis to Z2-axis in mm).

120

120

Finger width (mm)

80

80

3220 2690 4690

2930

300

300

150

150

X –axis stroke (mm). R –axis stroke (mm). Z –axis stroke (mm). Butting X depth (mm) : From bending axis to finger end From bending axis to secondary gauge . HF 2204 à HF 400/6. Delta X. - for 220T - for 320T 4m - for 400T 6m

Max. distance between fingers (mm) - on 220T - on 320T 4m - on 400T 6m

Total allowable static load on finger secondary gauges (kg).

allowable static load on a finger end, vertical or driving direction (kg).

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In standard version, a flat finger is fixed on each backgauge finger block assembly. When the worksheet is positioned on the flat part of the finger, the maximum allowable load is around 75 kg For large sized work sheets, the backgauge may be used as a sheet support. In this case, the maximum allowable load is around 120 kg (weight of the sheet when backgauge is used as a sheet support). This value may decrease depending on the type of optional equipment installed on the backgauge. Owing to its design, different types of finger stops may be installed (manual, pneumatic…). Consult our local agent for any customised requirement.

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2. SAFETY MEASURES

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2.1. CE DECLARATION OF CONFORMITY The press brakes listed in Appendix IV of Machine Directive 2006/42/EC have fulfilled the requirements of the Type Testing procedure, as certified by DEKRA, a notified body registered with the European Community by the French Ministry of Labour. Each machine delivered in European Union is therefore accompanied by a declaration of conformity like the following example :

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2.2. MARKING

The marking on your press-brake corresponds to the following specifications : a) Name and address of the manufacturer. b) Type of machine. c) Serial number: specified as follows : A letter (x) specifying the type of Numerical Control and its range (LT, MT) followed by a figure starting at 100001 (ex : x100001) (5012 x= F ; BT x= D ; MT x= K ) d) Date of manufacturing. e) Weight of the press-brake without any tooling or sub-equipment. f) Noise level (acoustic pressure) g) Maximum tonnage. h) Data concerning the electric, hydraulic and pneumatic supplies. A specific marking will then be attached to the optional equipments concerned. i) Overall stroke of the beam. 4/30 Issue 05/2010

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j) Overall response time and minimum separation distance. They are highly dependent upon the type of protection device installed (safety guard for instance). Additional marking is also possible whenever several types of protection devices have been selected. k) Warning on residual risks.

For 2 axes

k

For 5 axes

k

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For 6 axes

k

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Specific plate for a machine equipped with a version 2type light guard

j

Plate for a machine with laser beam protection « Akas » model.

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l) Warning regarding use of high speed machines (concern only high speed version machines).

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On all machines

Risks of pinching or crushing between tools

Risks of plucking or destruction between worksheet and tools during bending.

Risks of injuries by sudden movements of the worksheet during bending.

Electric danger

Refer to the operator’s manual

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2.3. SAFETY PRECAUTIONS 2.3.1. GENERAL POINTS During machine installation, operation, and maintenance, apply all necessary safety measures, and the following in particular: • Do not adjust or service the machine until you have read the manual. • All electrical work must be performed by a qualified and authorized electrician to avoid all equipment damage or physical injury. • Never place your hands between tools for any reason. • Do not modify the control circuits or any component of the machine. • Never use the machine with any of its safety devices removed or disabled. • Do not enter the safety zone or hazardous area protected by safety device. • Inspect the machine daily before starting work, ensuring that: - All protective devices are in place. - The free space between the tools is not obstructed. - The access area for the various devices is clear. - The floor around the machine is free of grease, oil, and water. • Never wear a tie, scarf, or loose clothing when adjusting or operating a press brake.

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• Make it a rule that a single qualified, trained operator performs machine adjustments. When working on large parts, the operator may be helped by an assistant operator whose sole task is to help handle the blank. The assistant must have an equivalent control panel (electric footpedal) to authorise the operator to initiate the cycle. Whenever working with 2 stations (or more), specific equipments may be supplied equipped or not with a light guard - upon request. • Before machine inspection or maintenance, switch off the main electrical isolating switch unless power is required for the procedure concerned. In such cases, only personnel with the appropriate training are authorised to carry out the procedure. • Wear protective gloves whenever possible. • On rare occasions when the user bends parts whose overall size exceeds the length of the machine's beam, protective measures must be implemented to prevent injury to other persons. If this type of job is performed frequently, additional protective measures must be permanently installed, in association with the machine's control circuit where appropriate..

ATTENTION : the use of the machine by non-qualified and nontrained personnel engages the employer's and operator’s liability. Refer to the current and domestic regulation.

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The operation, servicing and maintenance of this machine are strictly reserved to professional, qualified personnel. For this purpose, AMADA provides training for operators, setters, programmers, and maintenance technicians on its own premises or on the customer site. • Fire Prevention & Emission of Harmful Substances HF press brakes present a low risk of fire or emission of harmful substances. We recommend that you keep fire extinguishers for electrical equipment and oil near the machine. • Ensure that the strength and length of the tools used are compatible with the pressure setting (see §1.3 Machine characteristics and §7.5). Press brakes are supplied with the following safety equipment: - A set of two footswitches (closing/opening) according to EN 12622, - Automatically controlled side and rear guards, - Self-controlled electro hydraulic circuit. In option: 1) Light guard to protect the front area.

2) Another control unit for assistant operator, including 2 footswitches (opening/closing)

3) A laser beam, to protect the front area.

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2.3.2. REGULAR INSPECTION AND SAFETY POLICY

NOTE The below-described items are exclusive to France. Each country should refer to its current and domestic regulation.

 The Labour code imposes quarterly-basis visits. The purpose of this regular servicing is to detect any fault liable to cause an accident in advance, so that such faults can be rectified. The results of this service visit are recorded in a safety register opened by the Site Manager and made available to the Health and Safety Executive, should he exist

This measure applies to any manual-feed press working on cold rolled metals. The servicing must be performed under the responsibility of the Site Manager by qualified persons trained in risk prevention, whose names are made available to the labour inspection service.

Whenever using the press-brake, the user should: 1. Use the protection devices in order to secure the front faces on press-brakes. 2. Arrange the working stations through the installation of devices suited to the parts to be bent : part-holder , adjustable table 3. Think out a convenient working organization, to allow the secure passing-through of batches of new parts. 4. As for safety instructions, provide the proper training to operators and particularly to non-experienced benders or temporary workers.

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2.4. ARRANGEMENT OF WORKSTATIONS There are five separate working zones, which are as follows: -

Electrical cabinet 1. Backgauge adjustment 2. Start-up and Programming 3.* Production 4. Assistant Operator 5 when production is carried out by two operators (Caution : the assistant operator should be provided with similar equipment as for the main operator § 2.5).

 







NOTE Visuals, not binding.

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2.5. CONTROL DEVICES The press brake is supplied with a control device composed of one opening footswitch  and one closing footswitch  (Fig. 2.10). When the press brake is controlled by two operators, a 2nd station identical to the first one is required (option). A selector key switch is used to switch it on The teaching will be carried out as follows: -

Through an electronic push button box (Figure 2.11) equipped with a magnetised and movable base see Teaching Mode § 6.9.6. through an optional electronic handwheel equipped with a magnetised and movable base plate (Figure 2.9) (see Teaching Mode § 6.9.6) CAUTION: Working from the rear side of the machine is strictly forbidden..



Figure 2.9

Figure 2.10



Figure 2.11

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2.6. PERSONAL PROTECTIVE EQUIPMENTS (PPE)

The so-called “Personal Protective Equipments” (PPE) are not included in Amada supplies. You will find below as informative examples the type of Personal Protective Equipments possibly required on our machines:      

gloves, helmets, ear guards, goggles, safety shoes, etc.

the user of these so-called PPE should check that they fully comply with the European directive.

The employer is obliged to:        

supply the appropriate PPE, ensure that the appropriate PPE are selected with regards to the risks involved, ensure that the employee is using them efficiently, ensure their compliance with the regulation, inform people who are responsible for the implementation (work shop manager, foremen, etc.), ensure the PPE are in perfect working condition and periodic maintenance is carried out, inform users which potential risks are protected by the use of PPE, train and lead users in the regular use of PPE.

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In any case, the PPE which are in compliance (self certified or certified by a notified body) should have: A CE marking (visible and affixed firmly) and showing:    

the name or the trade mark of the manufacturer, identified either by commercial name or the reference of the PPE, the size, if implies, the expiry date, if implies,

and should be accompanied by the information leaflet and user manual along with the CE declaration

CAUTION: The machine may not be used in an explosive environment.

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Figure 2.12

Figure 2.13

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2.7. RULES FOR SAFE OPERATION  Release the part to be bent as soon as it is gripped between tools (Fig. 2.12).

 Install or remove the tools in full compliance with the procedure described in the Operator’s Manual (§ 7.5) and/or the recommendations specific to your tooling. (Fig. 2.13).

To avoid damage to your tooling or any accident, Amada urge you to follow strictly the procedure below :    

Every time you change a program, select adjustment mode and mute stop. Carryout a dry cycle Check visually that all parameters correspond to the tooling mounted on the machine, the mute point is 6 mm above sheet pinch point and the end of bend is correct. Switch to normal cycle.

CAUTION: Handling devices for heavy parts are not included in the Amada supplies. They must be installed for risk-free use in accordance with ergonomic principles.

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Figure 2.14

Figure 2.15

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

Never attempt to support the end of the worksheet by holding it on either side of the tools. Only install the tool length required for the current job on the machine (Fig. 2.14).



Never place your hand between the worksheet and the backgauge during operation (Fig. 2.15).



Never place your part against/over the backgauge finger before backgauge is positioned on programmed position.



No part of your body must enter the hazardous area during bending operations (Fig. 2.16).

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Figure 2.17

Figure 2.18

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

Beware of sudden movements of the worksheet during bending (Fig. 2.17).



Observe the allowable tool load (Fig. 2.18 and § 7.5).

Par example : - 1,2 T/cm for standard punches, except: - 1,5 T/cm for heavy punches - 0,5 T/cm for punches with extra thin blades (1 T = 10 kN) The specific value for each tool type is shown in the special Tooling catalogue (AMADA or equivalent).

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Figure 2.19

Figure 2.20

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

The dutch bending or hemming tool should be firmly secured to the lower beam (Fig. 2.19). This type of tooling shouldn’t be used on “High Speed” press brakes i.e. where working speed can reach 20 mm/s.



Never hold the sheet by its folded edge; hold it from the sides (Fig. 2.20).

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2.8. WORKSTATION LIGHTING A working area light is available in option in 220v (between phase and neutral) CAUTION: Ensure that the workstation has sufficient lighting for the parts to be machined.

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2.9. MACHINE OPERATING AND STORAGE CONDITIONS To ensure long life for the electronic and hydraulic components, conditions should be maintained within the following limits:

Min Ambient machine storage temp ................................ -10°c Ambient operating temp ............................................ +5°c Oil temp ..................................................................... +5°c Relative humidity ......................................................20 %

Max .................................... .................................... .................................... ...................................

+50°c +35°c +80°c 75 %

For temperatures below 5°C, the NC unit must remain powered to keep the components and circuit at a normal temperature. No equipment that produces swarf, dust, paint flakes, etc. must be installed in the immediate vicinity of the machine. If this is not possible, take all the necessary steps to protect the press brake from all factors likely to induce malfunctioning.

CAUTION: « AMADA Services Department ». will put your machine into operation. Please provide a supply of test sheets for this purpose. Select the material and sheet thicknesses you use most often. Any prior use of the machine will lead to suspension of the guarantee. Validity of the guarantee will not be restored until the installation has been inspected and, where necessary, the machine has been repaired at your expense. Use of the machine by unqualified, untrained personnel engages the employer's and operator’s liability.

CAUTION: To gain maximum benefit from our technician's visit, remember to remove the equipment from its crates and degrease it before the technician's arrival. If the oil temperature is below 5°C, there is a risk of the machine operating incorrectly. To prevent this, press the STOP button, and then press the opening footswitch for 5 to 10 minutes (See § 5.6).

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2.10. INFORMATION ON NOISE

The measurement methods and the operating conditions used comply with EN 31202 standards.

1 – EQUIVALENT ACOUSTIC PRESSURE LEVEL AT WORKSTATION:

5012 5020 8025 10030 1303 17030 17040 22040 32040 4006

2 Axes 74 dB 74 dB 74 dB 74 dB 74 dB 74 dB 74 dB 74 dB 74 dB 74 dB

6 Axes 74 dB 74 dB 74 dB 74 dB 74 dB 71 dB 74 dB 74 dB 74 dB 74 dB

2 – PEAK ACOUSTIC PRESSURE LEVEL AT WORKSTATION: Lpc :

The peak acoustic pressure level at the workstation Lpc is inferior to 130 dB

Measurements were carried out 1 m away from the front side, at the centre of the machine and 1.6m height

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2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS

Normal Use Bending and forming of sheet metals of various types of material and thickness by inserting the blank to be folded in between punch / die, whose shape and size depend on the properties of the material. Bending can be performed using one of the following methods: - Air bending or three-point bending, - Bottoming - Coining In all cases, it is essential to observe the tool unit load limits.

Reservations and Exclusions Punching is not permitted on this type of machine. Bending / forming of any material other than sheet metals, such as plastics (PVC, Makrolon, polycarbonate, etc.) in particular, should not be undertaken without consulting the supplier and checking the mechanical properties (ductility, strength, formability, etc.) of the product concerned.

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3. TECHNICAL DESCRIPTION OF THE MACHINE

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3.1. MECHANICAL STRUCTURE Up to 100 tons

Figure 3.1

Composed of: (Fig. 3.1) 1) A welded frame, including: -

2 uprights (Items 1 and 1’) 2 ground plates (Items 2 and 2’) 1 connecting beam (Item 3) 1 lower beam (Item 6)

2) Removable mechanical components : - 1 mobile upper beam (Item 5)

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From 130 to 220 tons

Figure 3.2

Composed of : (Fig. 3.2) 3) A welded frame, including: -

2 uprights (Items 1 and 1’) 2 ground plates (Items 2 and 2’) 1 connecting beam (Item 3) 2 cheeks on the lower beam (Items 4 and 4’)

4) Removable mechanical components: - 1 mobile upper beam (Item 5) - 1 lower beam (Item. 6)

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Valid for 320 and 400 tons

Figure 3.3 Composed of: (Fig. 3.3) - 2 uprights (Items 1 and 1’) - 2 ground plates (Items 2 and 2’) - 1 connecting beam (Item 3) - 2 cheeks on the lower beam (Items 4 and 4’) - 1 mobile upper beam (Item 5) - 1 lower beam (Item 6)

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3.1. MECHANICAL CONNECTIONS 1) The Upper Beam is supported by the uprights via the two hydraulic cylinders. Four trackeccentric roller assemblies guide the upper beam very well, and are used to provide axial adjustment. A linearity device with a push-pull system located at the rear of the upper beam ensures that this beam is perfectly linear, resulting in straight bends. 2) There are two hydraulic cylinders. Their purpose is to transmit the required bending force to the upper beam, and to provide lateral guidance. The NC unit synchronises them via very high precision linear scales to obtain parallelism and location accuracy to within 1/100e mm. The piston rods press the upper beam via spherical supports. This linkage ensures that the piston is perfectly aligned in the cylinder by maintaining the reaction due to the thrust effects in the axis of the uprights. 3) The lower beam is welded on each side plate of the machine (until 100 tons) 4) The lower beam is mounted in between the two fixed side plates. These side plates are welded for machines from 130 to 220 tons and assembled for 320 and 400 tons to the machine side frames. 5) The lower beam is supported by two large steel shafts located at each side of the press brake axis From 130 to 220 tons

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Valid for 320 and 400 tons

During bending, the reactive forces deform the plate in parallel with the upper beam. Consequently, the deflection of the two beams is of the same value, thereby ensuring that the punch penetration into the die remains constant throughout its entire length, ensuring accurate bending. 6) The reference position of the moving beam is taken completely independently of the side frame to avoid introducing any error resulting from side frame deflection. A uniquely designed external “C” frame that remains rigid under all bending conditions ensures that accurate ram positioning is maintained even with side frame deflection

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3.2. ELECTRONIC STROKE CONTROL AND PARALLELISM BALANCING SYSTEM

The clever design of the catches which are located exactly in the bending axis of the fixed and mobile beams allows the reference positions of the mobile beam to be read accurately, independently of the slightest deformation of the frame. The great rigidity of the strong external “C” frames and the securing of the linear glass scales provide a reading to 1/100th of a millimetre, irrespective of the loads applied to the frame and the beams. Extremely Accurate Incremental Measurement The linear scale is made of glass and has a grid (40- steps). It represents the travel of the upper beam with positioning of 0.01 mm between the punch and the die.

Measurement scale (Y1-Y2) Linear scale

Reference mark

Photoelectric cells

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3.2.1. ELIMINATING SOURCES OF ERROR When it comes to using a press-brake under normal conditions, several parameters have a direct effect on the accuracy of the bending angle.  Oil viscosity (temperature).  Operating pressure (working force).  Position of the parts (if off-centre, this leads to unequal forces on the uprights). Because it is virtually impossible to have full control over all these factors, risks of error likely to affect the bending quality – exist. A new technique allows Amada to eliminate these risks completely.

3.2.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY This extremely sophisticated electronic regulating technique guarantees perfect balancing of the parallelism by making it independent of factors likely to alter it. Two Y1 and Y2 incremental linear sensors are mounted at each end of the upper beam. The sensors are directly connected to the electronics of the machine NC. This controls the oil flow to each cylinder via B and B’ proportional valves. When the upper beam is lowered, the sensors continuously record the changing positions very accurately. These signals are immediately sent to the NC, which checks the respective values. The slightest difference between the data supplied by the sensors automatically triggers oil level compensation and pressure balancing.

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3.2.3. PRECISE CENTRING OF THE BEAMS The upper beam is guided by a set of four pairs of generously sized roller guide assemblies (1) running on hardened ground steel surfaces, securely fastened to the machine uprights. The maximum gap between the upper and lower roller guide assemblies (E max) ensures precise alignment and centring of the beams, with perfect rigidity. Reference cylinder D provides lateral positioning.

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3.3. LOCATION OF CONTROL AND SIGNALLING DEVICES 

ON THE NUMERICAL CONTROL PANEL - See § 6.2.2

3.4. PRESS BRAKE OPERATING LIMITS IN OFF-CENTRE WORK The further a point is from the centre of the machine, the smaller the available resultant force at that point. This information is taken into account by the NC, which calculates the force required according to the user-programmed part position.

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3.5. A-TYPE BACK GAUGE

(2) (1)

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3.5.1. DESCRIPTION OF X1 AND X2 AXES SUPPORT ARMS: -

-

The support arms (item 1) are made out of alloyed aluminium profile having high mechanical characteristics. They are fixed to the inner left side frame for X1-axis and on the inner right side frame for X2-axis, using 7 screws on each side frame. The bearing surfaces are machined on both profiles. Both guiding and translation devices are mounted on each arm together with a drive mechanism. 2 adjusting screws - located in the lower part of each arm - are used to set their inclination.

GUIDING: -

Thomson bar and ball bushing pillow block unit ensure the guiding.

-

The guiding device on X1 and X2 axes ensure the translation of R axes modules.

TRANSLATION: -

The timing belt and the gear belt pulley / ball-screw / motor unit ensures the translation of both X1 and X2 axes.

-

Drive motor is AC-type.

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3.5.2. DESCRIPTION OF R AXES -

Both R1-R2 axes are electrically linked together and connected mechanically to the crossmember. Each R1-R2 axis is composed of an aluminium alloy module having high mechanical characteristics. Each module is then connected to X-axis (item 1) by 2 ballbushing pillow blocks and supports a guiding shaft (item 3) which in turn is connected to Z-axis cross-member (item 2).

HORIZONTAL GUIDING -

This guiding is used to move both modules on X1 and X2 axes support arms. The guiding is based on ball-bushing pillow blocks and Thomson bars.

VERTICAL GUIDING -

This guiding is used to move Z-axes cross-member vertically using R1-R2 axis modules. The device is based on a ball-bushing and guiding shaft.

ADJUSTMENT OF THE VERTICALITY -

The guiding is used to adjust the verticality of R-axis module through a scale fixed in the lower part of X support arms and 2 adjustable eccentric rollers. The whole module rotates with regards to the translation on Thomson bars of the X-axis support arm.

DRIVE MECHANISM -

The timing belt and the gear belt pulley / ball-screw / motor unit ensures the translation of both R1 and R2 axes. Drive motor is AC electrically released spring-applied brake

-

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3.5.3. DESCRIPTION OF Z1 AND Z2 AXES

CROSS-MEMBER -

-

The cross-member (item 1) is composed of a profile made out of aluminium alloy with high mechanical characteristics. This cross-member supports the Thomson bar guiding for the modules, which carries the finger stops. It is designed to protect the Thomson bar guiding which supports the finger stop modules.

POSITIONING OF Z1-Z2 FINGERS - The horizontal positioning of each finger (Z1 and Z2 axes) is manual. - Untighten the V1 screw by half turn with a 6 mm Allen wrench supplied with the pressbrake. - Move the gauge finger laterally until the required position is reached. Slightly tighten the V1 screw.

For safety reasons, this positioning should be done from the rear of the machine.

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3.6. B-TYPE BACK GAUGE

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3.6.1. DESCRIPTION OF X1 AND X2 AXES SUPPORT ARMS: -

-

The support arms (item 1) are made out of alloyed aluminium profile having high mechanical characteristics. They are fixed to the inner left side frame for X1-axis and on the inner right side frame for X2-axis, using 7 screws on each side frame. The bearing surfaces are machined on both profiles. Both guiding and translation devices are mounted on each arm together with a drive mechanism. 2 adjusting screws - located in the lower part of each arm - are used to set their inclination.

GUIDING: -

Thomson bar and ball bushing pillow block unit ensure the guiding.

-

The guiding device on X1 and X2 axes ensure the translation of R axes modules.

TRANSLATION: -

The timing belt and the gearbelt pulley / ball-screw / motor unit ensures the translation of both X1 and X2 axes.

-

drive motor is of CC type

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3.6.2. DESCRIPTION OF R AXES -

Both R1-R2 axes are electrically linked together and connected mechanically to the crossmember. Each R1-R2 axis is composed of an aluminium alloy module having high mechanical characteristics. Each module is then connected to X-axis (item 1) by 2 ballbushing pillow blocks and supports a guiding shaft (item 3) which in turn is connected to Z-axis cross-member (item 2).

HORIZONTAL GUIDING -

This guiding is used to move both modules on X1 and X2 axes support arms. The guiding is based on ball-bushing pillow blocks and Thomson bars.

VERTICAL GUIDING -

This guiding is used to move Z-axes cross-member vertically using R1-R2 axis modules. The device is based on a ball-bushing and guiding shaft.

ADJUSTMENT OF THE VERTICALITY -

The guiding is used to adjust the verticality of R-axis module through a scale fixed in the lower part of X support arms and 2 adjustable eccentric rollers. The whole module rotates with regards to the translation on Thomson bars of the X-axis support arm.

DRIVE MECHANISM -

The timing belt and the gear belt pulley / ball-screw / motor unit ensures the translation of both R1 and R2 axes.

-

Both motors are CC-type (4).

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(*)

(*)

V1

(*)Depending on backgauge version

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3.6.3. INTERFACE BETWEEN R AXIS MODULE AND Z AXIS CROSS-MEMBER This interface permits to compensate the offset X1X2 and R1R2. X1X2 OFFSET COMPENSATION -

Two points of articulation situated on each R module ensure this offset compensation and the translation guide, fixed on module of R2 (module of R1 is used as a reference), works to compensate variations in the pitch of R modules.

R1R2 OFFSET COMPENSATION -

It is ensured by 2 points of articulation fixed at each end of R modules and by the translation guide, fixed on R2 module (module R1 is used as a reference), works to compensate variations in the pitch of R modules. This system compensates over the whole stroke in R (250mm) in case of electronic control system failure.

3.6.4. DESCRIPTION OF Z1 AND Z2 AXES CROSS-MEMBER -

-

The cross-member (item 1) is composed of a profile made out of aluminium alloy with high mechanical characteristics. This cross-member supports the Thomson bar guiding for the modules, which carries the finger stops. It is designed to protect the Thomson bar guiding which supports the finger stop modules.

DRIVE MECHANISM – 5 AXES TYPE GAUGE -

A motorised rack and pinion unit ensures the horizontal movement of Z1 and Z2 axes (finger stop modules). Each module’s drive motor is of DC type for HFE M2 range and brushless for HFP and HDS range of machines.

POSITIONNING OF Z1-Z2 FINGERS – 3 AXES TYPE GAUGE -

The horizontal positioning of each finger (Z1 and Z2 axes) is manual. Untighten the V1 screw by half turn with a 6 mm Allen wrench supplied with the pressbrake. Move the gauge finger laterally until the requested position is reached. Slightly tighten the V1 screw.

For safety reasons, this positioning should be done from the rear of the machine.

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3.7. DESCRIPTION OF C-TYPE BACK GAUGE

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3.7.1. DESCRIPTION OF X-AXES

-

Both X-axis Thomson bars (1), Ø 50 mm, are mounted on 2 supports (2) where 1 of them is fixed with three M10 screws (3) at the front on a bearing surface machined on the lower beam.

-

This front support is positioned with a pin (4) also used when adjusting the sub-assembly geometrically.

-

The translation is provided by a ball screw (5) whose nut is fixed to the R-axis subassembly which is moving along two Ø 50 mm Thomson bars through 4 ball bushing pillow blocks.

DRIVE MECHANISM: -

Toothed belt and gear ensure the link between the motor and the ball screws and ensure the translation of X-axis.

-

The motor is of alternating current (AC) - type.

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3.7.2. DESCRIPTION OF R-AXIS -

R-axis (6) is mechanically welded

-

The guiding is based on 2 guiding rails and 4 bearing supports (7)

-

The up/down movement is transmitted through a ball screw (8)

DRIVE MECHANISM

-

Toothed belts and gear ensure the link between the ball screws.

The motor is AC electrically released spring-applied brake type

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3.7.3. DESCRIPTION OF Z1 AND Z2 AXES (FINGERS) CROSSMEMBER -

The crossmember (9) is composed of a profile which has been mechanically welded then machined. This crossmember supports the Thomson bar guiding for the modules, which carries the finger stops.

POSITIONING OF Z1-Z2 FINGERS -

The horizontal positioning of both Z1 and Z2 axes is done manually.

-

With a 6 mm Allen wrench, supplied with the press-brake, unscrew the screw pos.10 by a half turn.

-

Move the finger unit laterally until the required position is reached. Slightly tighten the screw pos.10.

For safety reasons, positioning of the fingers should be done from the rear of the machine.

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3.8. GENERAL DESCRIPTION OF HA-TYPE BACK GAUGE 5 axes HA back gauge

(1)

(2)

2 axes HA back gauge

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3.8.1. DESCRIPTION OF THE X1 AND X2 AXES SUPPORT ARMS: -

The support arms (item 1) are made out of steel U-shaped profile having high mechanical characteristics. They are fixed to the left side frame for X1-axis and on the right side frame for X2-axis, using 4 fixing screws. Both guiding and translation devices are mounted on each arm. 2 adjusting screws (item 2) are used to set the inclination of each arm.

GUIDING: -

A mono rail and carriage-type linear guiding unit ensures the guiding.

-

The guiding on X1 and X2 axes ensures the translation of R axes modules.

MOTORISATION : -

On 5 axes HA type back gauge, each arm X1 or X2 is equipped with a unit motor/pulleys/toothed belt/ball screw. The motors are direct current type.

-

On 2 axes HA type back gauge, both X guiding are moved simultaneously by a unit motor/pulleys/toothed-belt/ball screw. The motors are induction type.

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3.8.2. DESCRIPTION OF THE R AXES -

Both R axes are connected mechanically to the crossmember and linked to the common drive mechanism through a toothed belt. Each R axis is composed of a steel U-shaped module with high mechanical characteristics. Each module is then connected to X-axis (item 1) by a mono rail and carriage-type linear guiding unit (3) which in turn is connected to Z-axis crossmember (item 2).

VERTICAL GUIDING -

This guiding is used to move Z-axis crossmember vertically using R axes modules. The guiding is based on a mono rail and carriage- type linear unit.

ADJUSTMENT OF THE VERTICALITY (5 AXES TYPE) -

-

The guiding is used to adjust the verticality of this axis with regards to the machine axis through a scale fixed in the lower part of the support arms and 2 adjusting screws. (see picture below) The whole module rotates with regards to the machine axis.

DRIVE MECHANISM -

The vertical translation on R axis is ensured by a motor/pulleys/toothed belt/ball screw unit. Current based brakes and encoder are used on a continuous current-type motor (item 4) for 5 axes type back gauge. Electrically released spring-applied brake type and asynchronous motor type are used for 2 axes type back gauge.

R-axis Adjustment of the verticality

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Adjusting screw

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3.8.3. DESCRIPTION OF Z1 AND Z2 AXES (FINGERS) CROSSMEMBER -

The crossmember (item 1) is composed of a set of tubes with high mechanical specifications.

HORIZONTAL GUIDING -

The upper part of the crossmember is fitted with a linear guiding composed of two guiding rails (2) where the Z fingers can be moved.

ADJUSTMENT OF THE PARALLELISM (5-AXE TYPE) -

This operation - aiming at ensuring that this axis is parallel to the table plane – is carried out through a scale fixed on the vertical R arm and 2 adjusting screws (See picture below). The whole module rotates with regards to the machine axis.

POSITIONING OF Z1-Z2 FINGERS (5 AXES TYPE) -

On 5 axes type back gauge, the movement and horizontal positioning of Z1 and Z2 axes are ensured by a DC-type motor, fitted with a converter and an encoder, through a pinion and a rack (3).

For safety reasons, this positioning should be done from the rear of the machine.

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3.9. DESCRIPTION OF THE FINGER SUPPORTS -

-

-

Each finger support is composed of a steel plate supporting the horizontal guiding elements (on the cross-member), based on ball-bushing pillow blocks for Thomson bars. Two ball-bushing pillow blocks are positioned at the rear of each support and one at the front. Each interchangeable finger is fixed on the finger support and can be articulated over a maximum allowable scope of 45° angle.

In the motorised version, the finger support is equipped with a CC motor.

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-

In the manual version, the finger support is manually positioned as required and it is held tight with screw V1. For safety reasons, finger module displacement operations should only be carried out from the rear side of the machine.

Tightening screw V1

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-

-

The design of the finger support allows addition of other types of finger stop (Consult Amada). The replacement of the backgauge fingers should only be carried out from the rear side of the machine (as opening the back door stops the machine totally including motor-pump unit). To unscrew the finger fixing screw (item 1) use the special wrench (item 2) supplied with the machine.

The adjustment of the backgauge parallelism in relation to the bolster (square of the lower beam) has been carried out in the factory with 2 screws positioned on both fingers. The operator should not modify it.

Safety is ensured only when all operations on the backgauge fingers (adjustment / replacement etc) are carried out from the rear side of the machine. A special dismounting tool for the backgauge fingers is supplied with the machine.

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3.10. DESCRIPTION OF THE LIGHT GUARD

The so-called Light Guard or light curtain is composed of 2 main units : 1) Mechanical unit 2) Light guard

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3.10.1. MECHANICAL UNIT It is composed of the supports fitted on each sub-unit equipped with the emitting/receiving cells and of the lateral protection preventing any access to the C-frames. Notes : 1) For the horizontal guard, due to the lower beam depth on press-brakes and the maximum authorized 40mm in-between distance for non-protected pass-through, 3 patterns have been pre-set when setting up doors (see below) :

The round cut on the 150mm guard support component can be seen, as a reference, through the see-through door from the C-frame protection. Markings corresponding to the 3 mounting positions refer to :  BT (For any low-tonnage press-brake)  MT 130T (for middle tonnage press-brakes= 130 tons)  MT 170T 220T (for middle tonnage press-brakes = 170 and 220 tons) Note: a single fixing position applies to 5012, 320T and 400T press-brakes. Studs and nuts - fixing the 150 mm guard support - have been sealed on the frame and used - through white painting - as a reference of their location, should dismounting operations be needed

White markings on both studs and nuts

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2) On Middle and High tonnage press-brakes, 7 beams from the lower receiving cell have been automatically and electronically disabled and obstructed (see below).

Obstructed receiver

3.10.2. LIGHT GUARD Refer to SICK appendix documentation.

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4. TRANSPORT, INSTALLATION AND DISMANTLING

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4.1. TRANSPORTATION The press-brake has been loaded onto the truck and fixed with the handling equipment provided by AMADA Europe factory in full accordance with the instructions given by the carrier so as to ensure a full balance likely to guarantee both stability and safety of the vehicle during transportation. All press-brakes have been protected with a dust-proof (micro-porous) tarpaulin provided by the plant. Caution: non waterproof tarpaulin.

TABLE specifying the minimum recommended anchoring equipment and the type of trailer depending upon the type of machine Machine type

Trailer type Unsheathing tilt type Press-brakes : 5012 / semi-trailer Taut liner to 5020 / 8025 / 10030 be removed from the rear

Press-brakes: 1303

Unsheathing tilt type semi-trailer Taut liner or low loading removable or flat bed trailer with tarpaulin

Low loading removable Press-brakes: 1703 / or 1704 / 2204 flat bed trailer with tarpaulin

Extra-low loading with Press-brakes: 32040 / tarpaulin (max. height 40060 400 mm more specifically for HT 6m)

Minimum anchoring equipment 4 Span-set-type straps minimum per machine, 5T strength minimum

4 Span-set-type straps minimum per machine, 5T strength minimum or 4 chains with turnbuckles per machine

5 Span-set-type straps minimum per machine, 5T strength minimum or 4 chains with turnbuckles per machine

12 Span-set-type straps minimum per machine, 5T strength minimum or 6 straps and 4 chains with turnbuckles

For weight and handling equipments, refer to § 4.4

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Inner flange Lifting Bracket

fragile zones

Bracket

C N protect straps

2 higher straps or chains with turnbuckle

lower straps in the bracket

Figure 1

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In order to avoid any sliding risks, it is highly recommended to use so-called « grip » rubber or carton pads beneath press-brakes or shearing machines.

1

1

Up to 130 tons Secure the press-brakes with at least 4 Span-set-type straps, 5T-force minimum, and fix them to the pre-set sling points (specified by AESA staff) (see photos 2 and 1).

2

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For 170 and 220 tons Secure the press-brakes with at least 5 Span-set-type straps, 5T-force minimum, and fix them to the pre-set sling points (specified by AESA staff) (see photos 3 and 1).

3

3

For 320 and 400 tons Secure the press-brakes with at least 12 Span-set-type straps, 5T-force minimum, or 6 straps equipped with 4 chains fitted with a turnbuckle on the top of it to the pre-set sling points (specified by AESA staff) (see photos 4 and 1).

4

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4

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As for the transportation of the 400-ton, 6m press-brake, the lower beam should be dismantled and fixed at the rear of the press-brake.

CAUTION : owing to the massive 36-ton weight of your machine . we strongly advise you to seek professional assistance when unloading this machine . For information on this point, do not hesitate to contact Amada.

Lifting hole

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4.2. PREPARING THE SITE The press brake must be installed on a stable, rigid floor. A concrete slab 120 to 150 mm thick with a flat surface (maximum tolerance 2 mm per metre) must be laid in the work area. Please contact our technical department for the installation requirements. HF press brakes are manufactured as welded box structures with a low centre of gravity. Anchoring them to the floor is therefore optional. To facilitate the access to the press brake: -

At the rear, it is advised to allow clearance of approximately 1 metre to allow various maintenance operations and backgauge adjustment to be performed.

-

It is advised to allow a clearance slightly greater than the maximum bending length of the machine on at least one of the two sides. The purpose of this is to allow worksheets that are at least as long as the press brake to be unloaded from the side.

-

It is also advised to allow sufficient clearance so that the electric cabinet door can be opened freely for various maintenance work.

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Figure 4.1 - Ideal machine layout

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4.2.1. STANDARD STROKE

Description

Units

Machine length (1) mm Machine depth (2) mm Machine height mm TOTAL net weight (3) kg Distance between uprights mm Thickness of the uprights mm Centre dist. betw. upright axismm

MODELS HF 50-12 50-20 80-25 100-30 130-30 170-30 2710 2320 2300 3350 1035 35 1070

3340 2450 2450 4600 1665 35 1700

3800 2445 2540 5600 2125 35 2160

4385 2430 2681 6600 2705 35 2740

4440 2625 2815 8150 2700 40 2740

170-40

220-40

5530 2625 2890 13900 3760 55 3815

5560 2625 3085 17100 3760 70 3830

4470 2625 2900 11600 2700 55 2755

(1) - The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. For transport, reduce by 435 mm for LT (except 5012 540 mm) and 490 for MT (2) - The dimensions are with the arm and the NC maximum extended in front, and all doors closed. - For transport, reduce by 540 mm . (3) - Add to the machine weight if your machine is equipped with the following options:

Material description AMACLIP sectionalised distance pieces Sick light guard AKAS system Single manual finger assembly Work follower – Single arm Work follower – Twin arms Work follower – Single arm + Parking Work follower – Twin arms + Parking

Units 1,20 m Kg Kg Kg Kg Kg Kg Kg Kg

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5 250 40 12

2m

2,5 m

3m

4m

6m

8 250 40 12 185 310 345 470

10 250 40 12 195 322 355 482

13 250 90 12 205 332 365 492

17 250 90 12 225 352 385 512

24 250 90 12 245 372 405 532

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4.2.2. LONG STROKE

Description

Units

Machine length (1) mm Machine depth (2) mm Machine height mm TOTAL net weight (3) kg Distance between uprights mm Thickness of uprights mm Centre dist. betw.upright axismm

130-30

170-30

4440 2625 3140 9000 2700 40 2740

4470 2625 3140 12400 2700 55 2755

MODELS HF 170-40 220-40 320-40 5530 2625 3150 14500 3760 55 3815

5560 2625 3270 18000 3760 70 3830

NC NC 3415 24000 3230 80 3310

400-60 NC NC 4035 36000 5230 80 5310

(1) - The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. - For transport, reduce by 490 for MT (2) - The dimensions are with the arm and the NC maximum extended in front, and all doors closed. - For transport, reduce by 540 mm. (3) – Add to the machine weight if your machine is equipped with the following options:

Material description AMACLIP sectionalised distance pieces Sick light guard AKAS system Single manual finger assembly Work follower – Single arm Work follower – Twin arms Work follower – Single arm + Parking Work follower – Twin arms + Parking

Units

3m

4m

6m

Kg Kg Kg Kg Kg Kg Kg Kg

13 250 90 12 205 332 365 492

17 250 90 12 225 352 385 512

24 250 90 12 245 372 405 532

4.3. MACHINE RECEPTION

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Recommendations before handling and installation. Prohibited procedures: Never press against, or attach handling equipment (slings, hooks, straps, etc.) to the following components: -

Lower beam. Upper beam. Electrical cabinet. NC pendant arm. Mechanical guards. “C” frame (Goose necks) Machine covers. Backgauge.

Refer to Section 4.4.2 to identify the recommended floor support areas.

IMPORTANT CERTAIN AREAS OF THE MACHINE ARE NOT DESIGNED TO WITHSTAND THE WEIGHT OF A PERSON WITHOUT DEFORMATION. THESE AREAS ARE IDENTIFIED BY THE LABEL SHOWN BELOW.

Figure 4.3

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4.4. RECEPTION & HANDLING 4.4.1. LIFTING Before the vehicle arrives, it is customer’s responsibility to provide a crane with sufficient capacity to unload the press brake from the vehicle and ensure that the access doors are sufficiently large (high and wide) to receive the machine, or its case (in case of sea worthy packing). To handle the press brake, use the two sling holes located towards the front on the upper part of the side frames CAUTION: Lifting forces should only be applied to the sling points provided for this purpose. Never apply force to the underside of the beams, electrical cabinets, covers, etc. For all machine handling operations, observe the following recommendations: 

Attach the lifting beam directly, with a load per strand, not exceeding the maximum allowable load.



Lift and set down the machine gently, avoiding any side impact on the machine, or any impact on lowering it to the floor.



Only press on the frame or its packaging to direct the machine during handling; never press on the beams, electrical cabinets, covers or guides.

CAUTION: When a press brake has been crated for sea transport, handling it and removing it from the crate are tricky operations. We strongly advise you to seek professional assistance. For information on this point, do not hesitate to contact Amada. The instructions in this section are given for information only, and do not engage Amada responsibility.

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LIFTING BEAM Only use these holes for anchoring lifting beam or slings

Only use these holes for anchoring lifting beam or slings

Centre of gravity

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4.4.2. BASIC PRINCIPLES Lifting forces must only be applied to the sling points provided for this purpose. A lifting beam may be used for handling or use directly the slings (except for 220.6 where a specific beam should be used to provide safe handling conditions).

X

Y

Z

mm

kg

 of the anchoring holes Mm

5012

807.5

1400

500

35

3350

65

5020

870

1400

770

35

4600

65

8025

926

1400

950

35

5600

65

1003

1026

1400

1150

35

6600

65

1303

1198

1340

1368

40

8150

65

1703

1220

1310

1390

55

11600

65

1704

1220

1190

1918

55

13900

65

2204

1250

1210

1936

70

17100

65

1303 L

1268

1540

1368

40

9000

65

1703 L

1218

1510

1390

55

12400

65

1704 L

1218

1390

1918

55

14500

65

2204 L

1278

1410

1936

70

18000

65

3204 L

1250

1550

1695

80

24000

80

4006 L

1400

1550

2695

80

36000

80

Centre of gravity Machine type

Side frame thickness

Total weight

NOTE For options, see § 4.2.1 and 4.2.2.

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The holes at the top front and back of the side frames are used to anchor the machine during transport, but only the front holes are used to handle the machine (Fig. 4.4).

LOAD DISTRIBUTION ACCORDING TO SLING ANGLES. Example A : (45°angle)  50 % of load weight on each sling.

Exemple B : (90°angle)  75 % of load weight on each sling.

WE RECOMMEND NOT TO EXCEED A 90° ANGLE

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The table below specifies the distance between uprights as well as the minimum length of the slings to be used for the handling operation.

Press brake

Distance between uprights mm

Minimum length of the slings mm

5012

1035

2000

5020

1665

2400

8025

2125

3100

1003

2705

4000

1303

2700

3800

1703

2700

3800

1704

3760

5300

2204

3760

5300

3204

3230

4800

5230

7600

4006

*

The handling operation can be carried out using a lifting sling if the indications in the above table is followed. * The safe handling of these models can be performed using a lifting beam, suitable to bear the machine load and the distance between uprights or by using two independent cranes capable of handling each, the half total weight of the machine.

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4.4.3. EQUIPMENT Handling operations must be performed as follows: - Using lifting gear such as a gantry or crane. Use the sling points. These holes can directly receive the shackles to which the hoist rings are attached. - If appropriate lifting equipment is not available, the press brake can be moved on skates (Fig. 4.5 et 4.6).

CAUTION: Strictly observe the authorised support areas as shown in figure 4.7.

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Figure 4.5

Figure 4.6

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4.4.4. SPECIAL PARTS FOR TRANSPORT For transport purposes, the upper beam is mechanically held at top dead centre using two props (Item 1), the back gauge cross member is immobilised using two spacers (Item 2). These accessories are to be removed by the Amada technician who commissions the machine. They should be stored safely for use when the machine is moved in the future



Up to 220 tons

Valid for 320 and 400 tons





CAUTION IN NO CASE SHOULD AN UPPER BEAM LOWERING COMMAND BE GIVEN WHEN THE IMMOBILISING DEVICES ARE IN POSITION.

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4.5. INSTALLATION

Up to 220 tons

Prohibited areas Areas authorised for shipping/transport . Mandatory ground footing areas for installation or for moving on skates.

Figure 4.7

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CAUTION: The choice of footing or anchoring points other than those specified in Fig. 4.4 and Fig. 4.7, is prohibited. Incidents resulting from a failure to comply with these instructions may lead to the suspension of your machine’s guarantee.

The following table gives the load distribution on the footing:

Machine type 5012 5020 8025 1003 1303 1703 1704 2204 1303 L 1703 L 1704 L 2204 L

LOAD (KG) ON EACH GROUND PLATE Front Rear 920 1400 1850 2270 2965 4355 5220 6450 3175 4205 4920 6520

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630 900 950 1030 1110 1445 1730 2100 1325 1995 2330 2480

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It is possible to fix the machine thanks to holes in the front soles. In seismic risk zones it is also possible to fix the machine thanks to holes in the rear soles

ANCHORING TO THE GROUND: Up to 100 tons

Figure 4.8 NOTE All dimensions are in mm. Machine type

A (mm)

B (mm)

E (mm)

5012

1 200

1 236,5

894

5020

1 840

1 305

1 535

8025

2 320

1 305

2 015

1003

2 900

1 405

2 595

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Valid for 130 and 220 tons

It is possible to fix the machine thanks to holes in the front soles. In seismic risk zones it is also possible to fix the machine thanks to holes in the rear soles.

Figure 4.9 NOTE All dimensions are given in mm. Machine type 1303

A (mm) 2825

B (mm) 1515

E (mm) 2385

1703

2845

1555

2405

1704

3905

1555

3465

2204

3945

1575

3505

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Valid for 320 and 400 tons Prohibited areas. Areas authorised for shipping/transport.

“Machine pit » for working line height at 820mm.

Figures 4.10 - above for 4 meter machines. - below for 6 meter machines (for working line height at 960mm, no “Machine pit »)

« Lower beam pit ».

Sealing holes for anchoring.

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ANCHORING TO THE GROUND (320 and 400 tons) :

Figure 4.11

Figure 4.12

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Upright

Levelling screw (4 for each upright). Upright bed-plate Ground fixing hole (4 for each upright).

Ground bed-plate Figure 4.13

ANCHORING TO THE GROUND (320 and 400 tons) Once the levelling has been completed (Fig.4.13), the machine should be fixed to the ground through 8  H holes in the machine footing and through M24 minimum anchors (not supplied) sealed to the ground (Fig. 4.11 and 4.13).

ATTENTION : In areas with a high sismic risk (earthquake), the machine should be fixed on special foundations (Fig. 4.12).

Dimensions (in mm)

A

B

C

D

E

F

G

H

I

J

K

L

Machine type

3204

3580 1750

270

900

3120

800

190

32

200

525

750

2820

4006

5580 1750

270

900

5120

800

190

32

200

525

750

4820

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For 400T 6m machines, an additional pit is required to accomodate the part of the lower beam inferior to the support level of the machine. (see layout C28038 below)

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4.6. ELECTRICAL CONNECTIONS Correct operation of an electrical system depends on the quality of its power supply; it must be stable and free of interference. The installation must be designed and built in accordance with the local regulatory requirements in force. 4.6.1. GENERAL CHARACTERISTICS OF THE MAINS SUPPLY - Power supply:

Three-phase (according to mains). 10% in steady-state, 20% in transient (20 ms).

- Pulse mode: 50% of rated value, maximum duration 5 ms - Harmonics: Maximum 5% - Frequency: 50 or 60 Hz (according to mains). - Electrical power supply line: Special supply line for the EXCLUSIVE use of the system from the main LOW VOLTAGE panel. The entire system is powered by a single threephase + earth cable.

4.6.2. EARTH Any equipment without double insulation requires an earthing connection. This is also important for operation and leak-off to the ground of spurious interference. The earthing conductor must have a sufficient cross-section. It must be connected to the terminal board of the power supply panel. Like the electrical installation, this earthing connection must be periodically checked by an approved organisation. The resistance of the earthing connection measured must comply with the applicable laws and standards. The green/yellow earthing conductor is exclusively reserved for the system. It is directly connected to the earthing terminal.

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4.6.3. MAINS-RELATED AND ENVIRONMENT-RELATED INTERFERENCE

CAUTION: Never solder or weld a component to the machine using any process whatsoever. This could damage the mechanical, electrical, and electronic components. Certain electronic components may be subjected to abnormal or excessive voltages or currents liable to cause their destruction. The installation of adapter components without a galvanic connection to the mains (voltage stabiliser, inverter, converter unit, transformer, isolating transformer, etc.) may need to be considered. If necessary, the quality of the electrical power supply should be checked by an approved organisation, and an analysis of the results should determine the type of equipment required. The following types of interference can be considered as a disturbance to any electronic system: • Electrostatic Discharge Electrostatic discharge is particularly critical where the ambient relative humidity is low. It is not unusual for a person or group of people on the move to generate discharges amounting to several thousand volts when touching a door handle or metal frame. It may be necessary to install antistatic equipment. The machine has passed tests to European Standard EN 50370-2 concerning immunity to electrostatic discharge. • Mains Transients Transients are spurious pulses propagating along mains conductors which may affect system operation. They may be from an internal source, e.g. welding unit, or any other machine generating mains interference, or they may be from an external source, e.g. stormy weather, neighbouring factory, etc. The machine has passed tests to European Standard EN 61000.4.4 concerning immunity to fast transients. • Stormy Weather The charges that accumulate during a storm cause transients in electrical lines or connecting cables. Do not use excessively long overhead lines.

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• Magnetic Fields A variable magnetic field causes induction in circuit loops—a major source of interference voltage. Cathode ray tubes are sensitive to magnetic fields, and display this sensitivity by a change in image chromatics or geometry. This is why they are equipped with protective shielding.

• Medium- or High-Frequency Electromagnetic Radiation This type of interference can cause many problems in systems (operational amplifiers, computer memory, etc.). In general, the extent of the disturbance depends on the duration and intensity of the radiation. It may be caused by nearby radar systems or radio transmitters (military, police, FM radio station, etc.), or even by poorly filtered cathode ray tubes. Although the machine has passed tests to European Standards EN 55011, for optimum operation of your machine, install the press brake in an environment that is free of the disturbances mentioned above (reference values : field 0.2 to 0.5 V/m, frequency band 10 kHz to 1 GHz).

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4.6.4. POWER SUPPLY CABLE The characteristics of the power supply cable must comply with the safety regulations in force. Cable cross-sections (mm²) are given for a line less than 20 m long for the whole models in the product range, and for a 400-V power supply. For any other specifications, refer to the currently applicable standards. Manufacturer-recommended cross-section Country Voltage / Frequency ≤ 15.5 kW 18 kW 20 kW 23,5 kW 31,5 kW 38,5 kW

Europe 400 V / 50 Hz 4 mm² 6 mm² 10 mm² 10 mm² 16 mm² 25 mm²

See electric diagram on how to pass the incoming power supply cable through the electric cabinet. The power supply cable should never be passed through the “C” frame in front of the electrical cabinet. The machine is equipped with its own current protection devices, but the supply line must be equipped with a cut-off device to protect it from short circuits and over currents (not included in Amada supplies). The cable and its mechanical protection devices, if any (cable troughs, raceways, sheaths, etc.) must have a protection rating according to the mechanical risks and corrosive agents to which they are liable to be exposed (not included in Amada supplies). The routing of cables and their protective equipment must not create any hazard (falling) to operators or maintenance personnel. Connect the three power supply wires directly to the corresponding terminals of the circuit breaker, with the earth wire (green/yellow) directly on the earth terminal intended for this purpose. The circuit breaker is designed to accommodate up to three padlocks. We recommend that you install a padlock immediately, to prevent the system being switched on until the AMADA technician arrives to put your machine into operation.

CAUTION: All work on electrical installations must be performed by qualified personnel trained for the purpose in order to prevent any accidents or damage to equipment.

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4.7. DECOMMISSIONING

Follow the instructions below to decommission the machine (removal, reselling, etc.) 1 While the machine is running, make sure the upper beam is in high position. 2 Move the back gauge to the front of the machine 3 Turn the machine off, lock and cut off power. 4 Lock the back gauge and the upper beam with equipment specific to transportation (see § 4.4.2) 5 Fix the footswitch onto the fixing spacer on the back gauge 6 Protect the numerical control and clamp it against the Upper Beam 7 Protect the electrical cabinet against humidity 8 Lock any mobile part to prevent it from moving during transportation 9 Lubricate metallic parts 7 Protect the whole machine with a micro-perfored plastic film. (in order to avoid condensation)

The machine is ready for handling operations ATTENTION: as for 400 Tons 6 meters machine, since decommissioning implies dismounting the lower beam, this tricky operation should be operated or checked by AMADA personnel.

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4.8. DISMANTLING Non re-usable equipment should be disposed of on the same day as dismantling, in compliance with the applicable rules of the country where it is installed Units Châssis, tabliers Groupe hydraulique Hydraulic unit motor

Material Steel Steel, cast iron, plastic, aluminium, electric components

Remarks

Contains oil

Electric components

Hoses, flexibles and hydraulic Steel, rubber, plastic cylinders Cables Electronic components

Contains oil

Back gauge motor

before these parts are recycled, remove all the Steel, electronic components, batteries and deposit batteries or accumulator them following the requirements of the manufacturer Steel, aluminium

Back gauge motor

Electric components

Packing sheet

Plastic

Transportation plates

Protective grid

Steel Steel, aluminium, electronic components Steel

Rollers, bearings

Steel, plastic

Operator's panel, Electrical cabinet Armoire électrique

Light guard

Contains oil

CAUTION : be sure to comply with European Standards : 2002/95/CEE RoHS 2002/96/CEE WEEE

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5. FIRST COMMISSIONING

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5.1. CLEANING To gain maximum benefit from our technician's visit, we strongly recommend that you remove the equipment from its crates and degrease it before the technician arrives. Use paraffin to remove the grease or storing polish, and oil the machined surfaces to prevent oxidation. CAUTION: Never use abrasive products or solvents liable to damage surfaces with protective coatings.

5.2. INSTALLATION OF CONTROL DEVICES The footpedal is supplied wired and connected. It is in a box secured to the backgauge.

CAUTION: Do not remove this box. Our technician will do so.

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IMPORTANT NOTE AFTER LEVELLING, TIGHTEN THE TWO NUTS OF THE ADJUSTMENT SYSTEM ON BOTH THE UPRIGHTS. Up to 220 tons

1

Figure 5.1

Valid for 320 and 400 tons

2 Figure 5.2 FIRST COMMISSIONING OPERATOR’S MANUAL HFE M2 – X41176B

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5.3. CHECKING THE MAINS POWER SUPPLY As supplied, the machine is intended to run on a three-phase 400 V 50/60 Hz power supply. Any other voltage requires a transformer (not supplied).

5.4. MACHINE LEVELLING To set your machine up with the correct geometry, apply the following procedure strictly. Because your press is designed not to be anchored to the floor, the concrete slab must be flat to within 2 mm per metre. Horizontal levelling does not require great accuracy; 1 mm per metre is sufficient. Up to 220 tons The levelling of each upright is performed using each of the two screws (ref. 1) at the rear of the machine (Fig. 5.1). The perpendicularity reference is taken with a precision level (accurate to 0.05 mm/m) placed on a straightened rule which is in turn resting on two dowel pins in each of the uprights. Tolerances: 0.05 mm/m per upright, and 0.05 mm/m with respect to each other. Valid for 320 and 400 tons The levelling of each upright is performed using four M30 screws (ref 2 figure 5.2) at the rear of the machine. The perpendicularity reference is taken with a precision level (accurate to 0.05 mm/m) placed on a straightened rule which is in turn resting on two dowel pins in each of the uprights. Tolerances: 0.05 mm/m per upright, and 0.05 mm/m with respect to each other.

IMPORTANT THE MACHINE MUST NOT REST ON SUPPORTS OTHER THAN THOSE DEFINED IN FIG. 4.8 4.9 and 4.10 (CHAPTER 4) OF THIS MANUAL. For specific installation conditions, contact Amada’s Technical Department.

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5.5. MACHINE COMMISSIONING START-UP  SEE § 6.1.

DIRECTION OF ROTATION  Check the direction of rotation of the hydraulic unit motor; to do so: - Start the pump by pressing icon. - Compare the direction of rotation of the motor blades to the red arrow on the motor casing. - If the direction does not match, stop the pump rotation by pressing icon - After switching off the main circuit breaker of the machine swap 2 phases at the supply terminals.

NOTA Switch off the press-brake by pressing icon Then, turn the handle of the main circuit breaker.

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5.6. OVERALL CHECK  Check the mountings of all covers and casings.  Check that no foreign body is present on the ball screws of the backgauge axes or the guide rails.  Check that the cables are secure in the stuffing boxes (electrical power supply cable), and check the cable grip at the bottom of the electrical cabinet (footswitch). In the electrical cabinet, check that the earthing wires are properly connected to the terminal blocks.  Check that the limit switches are operating correctly.  Check that no cover is liable to be caught during movement.  Check that all the indicator lights, machine stops and key switches are operating correctly.  Check that the light guard (if any) is operating correctly. Refer to the specific Appendix concerning the light guard.(see § 6.4 and § 6.5).

WARM-UP In the event of a low ambient temperature, it may be necessary to warm up the hydraulic circuit.. To do so, turn the machine on, start the motor-pump unit and raise temperature for 5 to 10 minutes.

NOTA Opening of the rear door doesn’t stop the hydraulic unit motor, but only opening beam is possible from the footpedal

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Only trained and qualified operators are authorized to work on pressbrakes.

6.1. START-UP 1

Turn the handle of the main circuit breaker to Position 1.

2

Sta rt the motor by pressing icon . The motor starts running.

3

Icon lights up

1. At a low ambient temperature, the oil becomes less fluid and the amber filter clogging alarm light may light up. 4 The alarm light goes off as soon as the oil temperature rises. If the alarm light remains lit, the filter is clogged. The NC is on and is ready to be reset.

NOTE  If the machine is equipped with AKAS light beam, see § 6.5

NOTE Switch off the press-brake by pressing icon Then, turn the handle of the main circuit breaker.

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6.2. DESCRIPTION OF CONTROL UNITS

6.2.1.NUMERICAL CONTROL PANEL Machine equipped with a « ANMB » numerical control, with or without an optional light guard

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6.2.2. DESCRIPTION OF CONTROL AND SIGNALLING DEVICES 

ON THE NUMERICAL CONTROL PANEL

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« Manuel 1 » Mode : simplified programming

« Manuel 2 » Mode : angle programming

« Graphic » mode

« Multi-program » mode

« Semi-automatic» operating mode to allow corrections

« Automatic » operating mode

« Start » key used for positioning axes, enabling the folding process and resetting reference cycle « Stop » key, will stop all axes movement.

« On / Off» hydraulic unit

« Maintenance » access

1-operator cycle control

2-operator cycle control

Return to previous page HOME return Main Display

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- safety mode keyswitch locked by a password due to prevent anyone from modifying the position of the keyswitch whenever processing parts. Only the main operator or adjuster should be aware of this password. See § 6.18 Default value is « 55 »

Save password (see display below ) and validate by pressing

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: Machine equipped with a “Sick” light guard: Seven-position CYCLE selector key switch: - Manual mode for tool setting or adjustment.

- Selector in OFF position, machine out of operation.

- Footswitch controls full machine cycle (when machine is not equipped with light guard-the approach speed remains inferior to 10 m/s but with light guard it moves at high speed) - Single “passing through” mode: single breakage of the light beam triggers the beam approach phase and ensure total operator protection, beam stops at mute, then operator finishes the cycle using footswitch. - Double “passing through” mode: double breakage of the light beam triggers the beam approach phase and ensure total operator protection, beam stops at mute, then operator finishes the cycle using footswitch - Single “passing through” mode: single breakage of the light beam triggers the cycle where light guard is active throughout the cycle, with or without a mute stop. - Double “passing through” mode: double breakage of the light beam triggers the cycle where light guard is active throughout the cycle, with or without a mute stop.

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: Machine is equipped with « AKAS » laser safety system : Three-position mode selector key switch : - Manual mode for tool setting or adjustment.

- Selector in OFF position, machine out of operation.

- Machine normal operating mode with optional Akas beam protection : Machine emergency stop

NOTA Switch off the press-brake by pressing icon Then, turn the handle of the main circuit breaker..

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NOTE The machine cycle depends on:  The programming mode selection on the NC unit.  The mute point.  Presence or absence of a light guard or laser protection system.

The Opening footswitch always overrides any other controls.



Above

Sheet pinch point

0



Below

Below the sheet pinch point, the Opening footswitch must be kept depressed for slow opening. Above the sheet pinch point, the Opening footswitch may be released. In this case, the press brake opens until it reaches the programmed opening dead centre. A second press of the footswitch takes it from the programmed opening dead centre to the mechanical opening dead centre.

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6.3. OPERATION (WITHOUT LIGHT GUARD) CYCLE 1 : SO-CALLED « ADJUSTMENT » CYCLE WITH MOBILE BEAM STOPPING AT MUTE POINT  Control: Closing footswitch.  Enable « plotted stop » function, may be programmed bend by bend if required  Select position

BREAKDOWN OF CYCLE:  Over entire stroke: working speed 10 mm/s.  Outside the mute position, pressing the Closing footswitch closes the press brake up to the mute point.  Stop at mute point.  Release the Closing footswitch.  Press the Closing footswitch again to continue the cycle. CYCLE 1 : ADJUSTMENT CYCLE MOBILE BEAM NOT STOPPING AT MUTE POINT  Control: Closing footpedal.  Do not enable « plotted stop » function, may be programmed bend by bend if required.  Select position

BREAKDOWN OF CYCLE:  Over entire stroke: working speed 10 mm/s.  No stop at mute point.

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CYCLE 2 WITH MOBILE BEAM STOPPING AT MUTE POINT  Control: Closing footpedal.  Enable « plotted stop » function, may be programmed bend by bend if required.  Select position

BREAKDOWN OF CYCLE:  Above mute position, pressing the Closing footpedal closes the press brake beam at low speed until the mute point is reached ( 10 mm/s).  Stop at mute point.  Release the Closing footpedal.  Press the Closing footpedal again to continue the cycle at working speed. CYCLE 2 MOBILE BEAM NOT STOPPING AT MUTE POINT  Control: Closing footpedal.  Do not enable « plotted stop » function, may be programmed bend by bend if required.  Switch SA4 on position

BREAKDOWN OF CYCLE:  Above the mute point, lowering at low speed ( 10 mm/s).  No stop at mute point.  Working stroke continues below the sequence point in working speed.

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6.4. USE OF THE LIGHT GUARD 6.4.1. SWITCHING ON Turn on the light guard by selecting one of the five positions through operating mode switch .

Turn on the light guard either through :  

adjustment position « O ».position

of the operating mode switch.

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6.4.2. ALTERNATE PROTECTION MODE. Cycle 2 mobile beam stopping at mute point.  Control unit: Closing footswitch.  Enable « plotted stop » function

Select position

BREAKDOWN OF CYCLE :  mute position, pressing the Closing footswitch closes the press brake either:  

at slow speed (< 10 mm/s), until the mute point is reached if light guard is broken. at high speed (> 10 mm/s), until the mute point is reached if light guard is free.

 Stop at mute point.  Once the mute point is reached, the light used to disable the light guard comes on. The light guard is inactive in the so-called « safety zone », opening inferior to 6mm.  Release the Closing footswitch.  Press the Closing footswitch again to continue the cycle at working speed.

Once the press-brake is opened to its ODC, a new cycle may start. In this operating mode, the light guard is used as a protection between ODC and mute point. Any breakage of the field during the approach phase in high speed (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC). The operator shall release the footpedal before initiating a new cycle.

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Cycle 2 mobile beam not stopping at mute point.  Control unit: Closing footswitch.  Disable « plotted stop » function

Select position

BREAKDOWN OF CYCLE : Above the mute point, pressing the Closing footswitch closes the press brake either:  

at slow speed (< 10 mm/s), until the mute point is reached if light guard is broken. at high speed (> 10 mm/s), until the mute point is reached if light guard is free.

 no stop at mute point.  Once the mute point is reached, the light used to disable the light guard comes on. The light guard is inactive in the so-called « safety zone ». opening inferior to 6mm.  Release the Closing footswitch.  Press the Closing footswitch again to continue the cycle at working speed.

Once the press-brake is opened to its ODC, a new cycle may start. In this operating mode, the light guard is used as a protection between ODC and mute point. Any breakage of the field during the approach phase in high speed (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC). The operator shall release the footpedal before initiating a new cycle.

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6.4.3. PROTECTION CONTROL.

MODE

AND

« SINGLE

PASSING-THROUGH »

CYCLE

Cycle 3: mobile beam systematically stops at mute point.  Control unit: light guard and closing footswitch.  Programming « Plotted stop » function will have no effect in this cycle.

Select position

The light guard is used as a protection and control device between ODC and mute point. BREAKDOWN OF CYCLE:  Above the mute point, breaking the light guard by a single passing-through (obstruction  removal of obstruction) of one part of the operator’s body causes the press-brake to close in high speed (> 10 mm/s), up to the mute point if the field is free.  Stop at mute point.  Once the mute point is reached, the light used to disable the light guard comes on. The light guard is inactive in the so-called « safety zone ». opening inferior to 6mm.  Press the closing footpedal to continue the cycle in working speed. In this operating mode , any breakage of the field during the approach phase (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC). Then press either « Start » the light guard..

button or « PU start-up»

to run a cycle controlled by

CAUTION : a stop longer than 30 seconds between the previous end of cycle and the beginning of next cycle outside the safety zone causes a fault and a reset is then required by either : - Starting the hydraulic unit or - Pressing « Start » key

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6.4.4. PROTECTION MODE AND CONTROL.

« DOUBLE PASSING-THROUGH » CYCLE

Cycle 4: mobile beam systematically stops at mute point.  Control unit: light guard and closing footswitch.  Programming « Plotted stop » function will have no effect in this cycle.

Select position

The light guard is used as a protection and control device between ODC and mute point. BREAKDOWN OF CYCLE:  Above the mute point, breaking the light guard by a double passing-through (obstruction  removal of obstruction obstruction  removal of obstruction) of one part of the operator’s body causes the press-brake to close in high speed (> 10 mm/s), up to the mute point if the field is free.  Stop at mute point.  Once the mute point is reached, the light used to disable the light guard comes on. The light guard is inactive in the so-called « safety zone ». opening inferior to 6mm.  Press the closing footpedal to continue the cycle in working speed. In this operating mode , any breakage of the field during the approach phase (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC).

Then press either « Start » the light guard.

button or « PU start-up»

to run a cycle controlled by

CAUTION : a stop longer than 30 seconds between the previous end of cycle and the beginning of next cycle outside the safety zone causes a fault and a reset is then required by either : - Starting the hydraulic unit or Pressing « Start » key

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6.4.5. PROTECTION CONTROL.

MODE

AND

« SIMPLE

PASSING-THROUGH »

CYCLE

Cycle 5: mobile beam stops at mute point.  Control unit: light guard.  Enable « Plotted stop » function

Select position

The light guard is used as a protection between the ODC and the mute point and as a control device of the cycle between ODC and end of bend. BREAKDOWN OF CYCLE:  Above the mute point, breaking the light guard by a single passing-through (obstruction  removal of obstruction) of one part of the operator’s body causes the press-brake to close in high speed (> 10 mm/s), up to the mute point if the field is free.  Stop at mute point.  Once the mute point is reached, the light used to disable the light guard comes on. The light guard is inactive in the so-called « safety zone ». opening inferior to 6mm.  Press the closing footpedal to continue the cycle in working speed.  breaking the light guard by a single passing-through (obstruction  removal of obstruction) of one part of the operator’s body causes the press-brake to close in working speed, up to the end of the bend if the field is free.  During the working phase, breaking the guard field causes the beam to stop. Resume the cycle as soon as the field is free (removal of obstruction). In this operating mode, any breakage of the field during the approach phase (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC). Then press either « Start » the light guard.

button or « PU start-up»

to run a cycle controlled by

CAUTION : a stop longer than 30 seconds between the previous end of cycle and the beginning of next cycle outside the safety zone causes a fault and a reset is then required by either : - Starting the hydraulic unit or - Pressing « Start » key

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Cycle 5: mobile beam not stopping at mute point.  Control unit: light guard.  Disable « Plotted stop » function

Select position

The light guard is used as a protection between the ODC and the mute point and as a control device of the cycle between ODC and end of bend. BREAKDOWN OF CYCLE:  Above the mute point, breaking the light guard by a single passing-through (obstruction  removal of obstruction) of one part of the operator’s body causes the press-brake to close in high speed (> 10 mm/s), up to the mute point if the field is free.  No stop at mute point.  Once the mute point is reached, the light used to disable the light guard does not come on. The light guard is enabled in the so-called « safety zone ». The closing of the press-brake continues in working speed, up to the end of the bend if the field is free.  During the working phase, breaking the guard field causes the beam to stop in position. Resume the cycle as soon as the field is free (removal of obstruction). In this operating mode, any breakage of the field during the approach phase (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC).

Then press either « Start » the light guard.

button or « PU start-up»

to run a cycle controlled by

CAUTION : a stop longer than 30 seconds between the previous end of cycle and the beginning of next cycle outside the safety zone causes a fault and a reset is then required by either : - Starting the hydraulic unit or - Pressing « Start » key

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6.4.6. PROTECTION MODE AND CONTROL.

« DOUBLE PASSING-THROUGH » CYCLE

Cycle 6: mobile beam stops at mute point.  Control unit: light guard.  Enable « Plotted stop » function

Select position

The light guard is used as a protection between the ODC and the mute point and as a control device of the cycle between ODC and end of bend. BREAKDOWN OF CYCLE:  Above the mute point, breaking the light guard by a double passing-through (obstruction  removal of obstruction obstruction  removal of obstruction) of one part of the operator’s body causes the press-brake to close in high speed (> 10 mm/s), up to the mute point if the field is free..  Stop at mute point.  Once the mute point is reached, the light used to disable the light guard does not come on. The light guard is enabled in the so-called « safety zone ». The closing of the press-brake continues in working speed, up to the end of the bend if the field is free.  During the working phase, breaking the guard field causes the beam to stop in position. Resume the cycle as soon as the field is free (removal of obstruction).

In this operating mode, any breakage of the field during the approach phase (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC).

Then press either « Start » the light guard.

button or « PU start-up»

to run a cycle controlled by

CAUTION : a stop longer than 30 seconds between the previous end of cycle and the beginning of next cycle outside the safety zone causes a fault and a reset is then required by either : - Starting the hydraulic unit or - Pressing « Start » key

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Cycle 6 : mobile beam not stopping at mute point.  Control unit : light guard.  Disable « Plotted stop » function

Select position

The light guard is used as a protection between the ODC and the mute point PMO and as a control device of the cycle between ODC and end of bend. BREAKDOWN OF CYCLE:  Above the mute point, breaking the light guard by a double passing-through (obstruction  removal of obstruction obstruction  removal of obstruction) of one part of the operator’s body causes the press-brake to close in high speed (> 10 mm/s), up to the mute point if the field is free.  No stop at mute point.  Once the mute point is reached, the light used to disable the light guard does not come on. The light guard is enabled in the so-called « safety zone ». The closing of the press-brake continues in working speed, up to the end of the bend if the field is free.  During the working phase, breaking the guard field causes the beam to stop in position. Resume the cycle as soon as the field is free (removal of obstruction). In this operating mode, any breakage of the field during the approach phase (between ODC and mute point) will systematically stop the press-brake (and depending upon machine parameters, provoke the opening of the press-brake up to the ODC).

Then press either « Start » the light guard.

button or « PU start-up»

to run a cycle controlled by

CAUTION : a stop longer than 30 seconds between the previous end of cycle and the beginning of next cycle outside the safety zone causes a fault and a reset is then required by either : - Starting the hydraulic unit or - Pressing « Start » key

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6.5. MACHINE EQUIPPED WITH A FRONT PROTECTION BY LASER. 6.5.1. INITIAL SETTINGS First, the machine is switched ON, by operating the machine’s main isolator switch (consult machine’s operator manual for details). In adjustment mode,

reset the press-brake.

6.5.2. STOPPING DISTANCE TEST In normal mode This automatic test is necessary to check on a regular basis the compatibility between the ® press-brake and AKAS system. During a stopping command, it will check that the distance run by the ram is inferior to the distance between the punch tip and the laser band.

This test will be run automatically a. whenever starting the press-brake. b. further to 30 continuous operating hours (in accordance with the current regulation) Specific cases beyond these operating 30 hours: The test is run when the press-brake has reached the ODC (opening dead center) regardless of the position of the ram (above or at mute point). During a bending operation, the test will be run only when the ODC has been reached, at the end of the bending cycle. The test will be implemented in 1 phase. Phase 1 : Checking the stopping distance When closing in fast speed, the ram should be stopped to stopping distance maximum authorized.

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Running the stopping test Phase 1 message 295 displayed on the NC « STOP TEST, PUSH CLOSING PEDAL . »

Operate "CLOSING" foot switch. The beam closes in fast speed and stops when the laser is interrupted after 40 mm further down.

The test related to the stopping distance is now over. Closing or opening of the beam possible. The operation in NORMAL mode may be started.

6.5.3. TROUBLESHOOTING - MESSAGES

Phase 1 If ram stops during the stopping (beam broken). Message 300 will be displayed on the NC: « STOP TEST ERROR, PUSH OPENING PEDAL». If the press beam has reached the muting point without interruption of laser. Message 296 will be displayed on the NC: « STOP TEST CAM NOT FOUND».

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6.6. DISPLAYS

MODE 1

OPERATION OPERATOR’S MANUAL HFE M2 – X41176B

MODE 2

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GRAPHIC MODE

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MULTI-PROGRAM

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SEMI AUTO MODE

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CYCLE MODE

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USER MODE

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6.7. USB KEY Your Press Brake was delivered with 2 USB keys.

-

A system key that contains every system file saved by the plant and specific to the client’s machine (key lock, to keep in a safe place).

-

A program key, to save all your programs and tools.

The USB key can be inserted in the USB drive located on panel as shown below.

CAUTION: It is strongly advised to remove the USB drive once its use is completed to prevent its deterioration (shock).

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6.8. MACHINE INITIALISATION Prior to any axis movement control, this initialisation is necessary. Otherwise, message "FUNCTION PROHIBITED MACHINE RESET" will be displayed.

INITIALISATION PROCEDURE  Turn on the main isolator switch of the machine  When the main menu is displayed on the NC screen : - Start the hydraulic unit

- Press the START key .  If a message is shown: follow the instructions.  INITIALISATION menu is displayed: - "PRESS OPENING PEDAL" (opening footswitch), press and maintain depressed the opening footswitch until all moving axes come to stand still. - At this stage, the following message will be displayed: "PRESS CLOSING PEDAL", Press closing footswitch or optional two-hand push button control, if selected. Maintain footswitch depressed until the back gauge axis starts moving.  Once "General Menu" appears on the screen, the initialisation process is finished. NOTE Pressing the NC STOP key or any emergency stop interrupts the initialisation process with all ongoing movements interrupted. The initialisation is unfinished. Hence, it will be requested again by the NC.

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R REFERENCE, other modes

SH.THICKNESS

DIE REFERENCE R, MODE "MANUAL 1"

DIEHOLDER

S.P.P. Programming Y reference

PUNCH

SPACER PRESSBRAKE TABLE

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6.9. PROGRAMMING 6.9.1. PRELIMINARY NOTE CONCERNING PROGRAMMING Irrespective of the programming mode used, "Y"-axis programming reference point is the sheet-pinch point (S.P.P.). The reference value will be:

Where

S.P.P. = TH + SP + DH + DIE + PUNCH TH : Thickness of sheet to be bent in mm. SP : Spacer height in mm. DH : Die-holder height in mm. DIE : Die height in mm. PUNCH : Punch height in mm.

The "R"-axis zero for programming (except in MANUAL 1 mode) corresponds to the upper surface of the die with the negative values being located below and the positive ones being above the surface. NOTE: In "MANUAL 1" or "simplified programming" mode, "R"-axis’s height is programmed with respect to the press-brake table, considering that no tooling is programmed.

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6.9.2. “MANUAL 1” SIMPLIFIED PROGRAMMING “PROGRAMMING MODE”

After initializing the machine with the "START" key, pressing

activate "MANUAL 1" mode

. This will display the "MANUAL MODE 1" page as shown above.

 Enter the program number (max. 6 digits). If the number is already used in another mode, the NC will generate an error message; otherwise the called-up program will be edited (see example below). Or select key

to select your program from active directory (see §6.17)

 Enter your work-piece reference (max 13 digits), this is an optional field.

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 BEND N°: reference of the currently displayed bend./ NB BEND: number of bends in the program.  Enter the value of the S.P.P. according to the tools used and the sheet thickness (see paragraph "P.P." in the previous chapter) either by entering the value or by teaching the position using the 4 teaching keys.  "Y" Value: If you don’t know this value, confirm the default displays zero then you can make your bend in teaching mode (see "TEACHING"). NOTE The "Y"-axis values are set in respect to the S.P.P. You cannot program positive values: they correspond to an opening between the tools. Programming negative values would correspond to the tool penetration into the sheet.

 Program the desired value for the "X" and "R" axes for A-type backgauge, X1, X2, R1, R2 for B-type backgauge NOTE Pressing the key will confirm the current value in that field as long as its format corresponds to the expected value. If the entered value is over the axis limit, this value will be recalculated by the NC..

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 CYCLE (CY):

Number of repetition for a given cycle. 1 = Bend cycle will be performed only once. n = Bend cycle will be performed "n" times (max. authorised value: 99

 X Step (mm): X" axis distance will move in relation to its current position. This displacement can be programmed either positive or negative. The step is only active if the programmed cycle is greater than 1. NOTE: The STEP will be executed "n" number of times. Control will check if the programmed STEP and the number "n" of CY can be performed in relation to the programmed value of the "X" axis. The value of CY will be corrected automatically if it exceeds the axis limits.  B.G. TIMER.. (s) : temporary hold in seconds, for the positioning of the back gauge, to next bend (98,9 s max) NOTE: Usually, the waiting time of the back gauge is executed between a bend and the next one. Should this waiting time be requested at every single step of one bend, simply program a 0.1 mm retract distance.  MANUAL MOVING BG if activated, the end of temporary hold is obtained when operator presses the "S" key on the hand wheel control panel.  AUX. FUNC.: There are four programmable auxiliary functions. They can be programmed in binary four digits code (Outputs F1; F2; F3 & F4).

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Examples:

000000 100000 010000 001000 111100 ---

= = = = = =

None of the functions are active Function F1 is active: footpedal n°2 is active Function F2 is active: disable front beam if AKAS or PSENVIP Function F3 is active: disable rear beam if PSEN VIP Function F1; F2; F3 and F4 are active. …

 STOP MUTE : plotted stop function 

TONNAGE (KN): Bending force in Kilo Newton. In "Simplified Programming" mode, you must program the bending tonnage, this in accordance with the tools, the material, the length of the bend and the thickness of the sheet being used (see bending chart on machine’s electric cabinet).

 COINING (0 / 1): Selects coining mode for bending process; coining process requires 5 times the force used in air bending. 0 = Working in air bending mode with coining inactive (End of bend in "Y" position reached). 1 = Working in coining mode, folding right at the bottom of the die (end of bend with stop at the movement).  EOB HOLD (s): Under pressure holding time (max 98.9 s). If default value is accepted, the press will hold part under pressure for 200 ms. If zero is programmed, bend accuracy problem may be encountered due to lack of under pressure holding time.  MANUAL OPENING ORDER : if activated, bend change by pressing the opening footpedal  RETRACT DIST (mm): The distance backgauge should retract at S.P.P. (sheet pinch point).  WAITING RETRACT (0/1/2): Backgauge retract conditions. 0 = If “Retract Dist.” is programmed, backgauge will retract simultaneously with the start of bending. 1 = If “Retract Dist.” is programmed, beam will reach S.P.P., backgauge will retract to programmed position then bend will start. 2 = with CY > 1 - The backgauge retract will only be executed at the end of all programmed repetitions if “Retract Dist.” programmed. - BG timer will be activate at the end of all programmed repetitions

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 WORKING SPEED (mm/s): Working speed of the "Y"-axis from 1 to maximum speed between S.P.P. to the end of bend.  RETURN SPEED. (mm/s): "Y"-axis return speed, from end of decompression through to S.P.P. in slow speed then 1 to maximum speed. A zero value causes fast opening right from the end of decompression.  O.D.C. (mm): Open dead center of the "Y"-axis. Beam opening distance in mm after executing the current bend cycle. This distance is in relation to the S.P.P.

To add another bending sequence, press either

or

.

All the information on the current page will be copied to a new page. Then you can modify the desired values to build your programme.

Display your program bends with keys

or

.

key is active at all times so that you can delete a bend.

All the keys used to quit the programming modes will save the program currently edited.

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6.9.3. “MANUAL 2” MODE: "ANGLE PROGRAMMING" OR "X-ALPHA"

After initialising the machine with key activate "MANUAL 2" mode pressing key. This will display the "MANUAL MODE 2" page as shown above.  Enter the programme number (max. 6 digits). If the entered number already exists in another programming mode, the N.C. will indicate an error; otherwise the called-up program will be edited (see below). Otherwise press key

, to select your program from the active directory (see §6.17)

 Enter your work-piece reference (max 13 digits), this is an optional field.

 Punch: Reference of the punch used. Enter punch number in the blank field or press “Punch” to display all the punches in memory and select the punch existing on your machine with keys

, then confirm with key “OK”.

Go back to "MANUAL 2" programming page.

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 Die: Reference of the die. Follow the same procedure as for the punch to select the die fitted on your tooling.  Die Holder: Reference of the die holder. Follow the same procedure as for the punch to select the die holder fitted on your tooling. If "0" is programmed = no die holder.  Die Block: Reference of the die block. Follow the same procedure as for the punch to select the die block fitted on your tooling If "0" is programmed = no die block.  Punch Holder: Reference of the punch holder. Follow the same procedure as for the punch to select the punch holder fitted on your tooling.  FINGER: Reference of the finger. Follow the same procedure as for the punch to select the finger fitted on your tooling.  Punch Reverse: Parameter indicating reverse mounting of the punch. X is programmed to indicate = punch is mounted normally. V is programmed to indicate = punch is reversed. NOTE: The punch-reverse option is only used as a reminder in MANUAL 2 mode.  Die Reverse: Parameter indicating reverse mounting of the die. X is programmed to indicate = die is mounted normally. V is programmed to indicate = die is reversed. REMARK: This only applies to two or four V dies, as they are the only ones that can be reversed: X-axis safety calculations  Material: type of the material to be bent. Use or key to select - among the materials stored in memory - the type of material to be bent, then confirm with key 

Õ : standard strength displayed once the material has been selected. Should the strength be different, enter the tensile strength of material to be used in DaN/mm².

 Thickness : thickness of the material to be bent in mm.  Unfold Length : Just to memory in mode 2.

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 Bend: Indicates the bend number currently displayed on the screen / NB BEND : Indicates total number of bends in the program.  Bend Length: Length in mm of the part to be bent.  Offset Part : Offset part in respect to machine centre-line in mm (used for multi-stage bending or when bending under horns). Input zero if you are folding your job in the centre of the machine.

NOTE : The default value is zero.  Bend Angle : Program value of the angle to be achieved. SPECIFIC CASE: Entering a zero angle value will give access to the teaching mode for "Y" value  "Y" VALUE: This is calculated as soon as data for  is fed in and confirmed. To gain access to "Y" value field, you must enter ZERO for  (teaching mode).

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NOTE The "Y" axes values are set up in respect to the P.P. You cannot program a positive value in this field as they would correspond to an opening between the tools. Programming negative values corresponds to the penetration of the tool into the material. Identical to MANUAL 1 mode, programming of double axes (Y1, Y2…) can be carried out in two ways: 1) If the values are identical, use first value (Y1, X1…). 2) If the values are different, modify second value (Y2, X2…).

 "X" VALUE: In this field, program external flange length if the sheet thickness correction for butting is adjusted in external values mode (see "dXAUTO" developed further down). Otherwise program the flange length after deducting bend allowance.  "R" VALUE: The "R" axis zero reference is the top of the die (see paragraph PRELIMINARY NOTE ON PROGRAMMING).

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 Cycle (CY) :

Number of repetition for a given cycle. 1 = Bend cycle will be performed only once. n = Bend cycle will be performed "n" times (max. authorised value: 99).

 X Step: "X"-axis distance will move in relation to its current position. This displacement can be programmed either positive or negative. The step is only active if the programmed cycle is greater than 1. NOTE: The STEP will be executed "n" number of times. Control will check if the programmed STEP and the number "n" of CY can be performed, this in relation to the programmed value of the "X" axis. The value of CY "n" will be corrected automatically if it exceeds the axis limits.  BG Timer (s) : temporary hold in seconds, for the positioning of the back gauge to the next bend (99 s max)  Manual Moving BG: if activated, the backgauge will only move when operator presses the "E" key on the footswitch control panel  Aux. Functions. : There are six programmable auxiliary functions. They can be programmed in binary four digits code (Outputs F1 ; F2 ; F3 ; F4 ; F5 ; F6).

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Examples :

000000 100000 010000 001000 111100 ---

= = = = = =

None of the functions are active. Function F1 is active : footpedal n°2 active Function F2 is active : disables front beam if AKAS or PSEN VIP Function F3 is active : disables rear beam if PSEN VIP Functions F1 ; F2 ; F3 and F4 are active. …

 Stop Mute : plotted stop function  Tonnage (KN): Bending force in Kilo Newton. In "Simplified Programming" mode, you must program the bending tonnage, this in accordance with the tools, the material, the length of the bend and the thickness of the sheet being used (see bending chart on machine’s electric cabinet).  Coining (0 / 1): Selects coining mode for bending process; coining process requires 5 times the force used in air bending. X = Working in air bending mode with coining inactive (end of bend in "Y" position reached). V = Working in coining mode, folding right at the bottom of the die (bottoming with stop at movement).  EOB Hold. (s) : Under pressure holding time (max 99 s). If default value is accepted, the press will hold part under pressure for 200 ms. If zero is programmed, bend accuracy problem may be encountered due to lack of under pressure holding time.  Manual Opening Order : If activated, bend change by pressing opening footpedal.  Retract Dist (mm): The distance backgauge should retract at P.P. (sheet pinch point) 

Waiting Retract (0/1/2): Backgauge retract conditions. 0 = If “Retract Dist.” is programmed, backgauge will retract simultaneously with the start of bending. 1 = If “Retract Dist.” is programmed, beam will reach P.P., backgauge will retract to programmed position then bend will start. 2 = with CY > 1 - The backgauge retract will only be executed at the end of all programmed repetitions if “Retract Dist.” programmed. - BG timer will be activate at the end of all programmed repetitions



Working Speed (mm/s): Working speed of the "Y"-axis from 1 to maximum speed between P.P. to the end of bend.

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

Return Speed. (mm/s): "Y"-axis return speed, from end of decompression through to P.P. in slow speed then 1 to maximum speed. A zero value causes fast opening right from the end of decompression.



O.D.C. (mm): Open dead center of the "Y"-axis. Beam opening distance in mm after executing the current bend cycle. This distance is in relation to the P.P.



Delta X Auto (1/0) : correction of the sheet thickness for butting V = external quotations X = internal quotations

The continuation of programming process is identical to that of MANUAL 1 mode:

Program another bending sequence using

or

key.

All data from this page will be copied towards another page. All you need is to modify requested values to build your program.

Scroll the different bends from your program by pressing

or

.

key is also active at all times, bending sequences can therefore be deleted.

All keys used to quit the programming modes will generate the back-up of the currently edited program.

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6.9.4. GRAPHIC MODE PROGRAMMING

After initializing the machine with the "START" key, pressing.

activate "GRAPHIC" MODE

This will display the "Tool" page as shown above.

 Enter the program number (max. 6 digits). If the number is already used in another mode, the NC will generate an error message; otherwise the called-up program will be edited (see example above). Or select ,

your program from active directory (see §6.17)

 Enter your work-piece reference (max 13 digits), this is an optional field.  Punch: Reference of the punch used. Enter punch number in the blank field or press “Punch” to display all the punches in memory and select the punch existing on your machine with keys

, then confirm with key “OK”.

Go back to "MANUAL 3" programming page.

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 Die: Reference of the die. Follow the same procedure as for the punch to select the die fitted on your tooling.  Die Holder: Reference of the die holder. Follow the same procedure as for the punch to select the die holder fitted on your tooling. If "0" is programmed = no die holder.  Die Block: Reference of the die block. Follow the same procedure as for the punch to select the die block fitted on your tooling If "0" is programmed = no die block.  Punch Holder: Reference of the punch holder. Follow the same procedure as for the punch to select the punch holder fitted on your tooling.  FINGER: Reference of the finger. Follow the same procedure as for the punch to select the finger fitted on your tooling.  Punch Reverse: Parameter indicating reverse mounting of the punch. X is programmed to indicate = punch is mounted normally. V is programmed to indicate = punch is reversed. NOTE: The punch-reverse option is only used as a reminder in MANUAL 2 mode.  Die Reverse: Parameter indicating reverse mounting of the die. X is programmed to indicate = die is mounted normally. V is programmed to indicate = die is reversed. REMARK : This only applies to two or four V dies, as they are the only ones that can be reversed: X-axis safety calculations  Material: type of the material to be bent. Use or key to select - among the materials stored in memory - the type of material to be bent, then confirm with key 

Õ : standard strength displayed once the material has been selected. Should the strength be different, enter the tensile strength of material to be used in DaN/mm².

 Thickness : thickness of the material to be bent in mm.  Unfold Length: Value automatically calculated when profile is edited.

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CREATION OF THE PROFILE The profile (shape) of the part is specified in accordance with angles and segments. Segments are measured « angle to angle ». (segment in blue during creation) If angle is 90° the end of the segment will be specified by the radius tangent. See picture below.

Part dimensions in Alpha mode

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Use the dynamic display to draw your profile.

Press

« dimension » key to enter the length and angle for each angle.

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Once all dimensions are entered, the shape is highlighted. You may then go to next page « Bending sequence »

touch, allows to select one or many precise dimensions. Each dimension chosen will be make with a bending flange on one of both bends that delimit this segment. The segment or segments selected will be drawn with the color green. Once the activated button, to deselect a segment already selected, select this button a second time. It is possible to select multiple segments if they are not consecutive. The selection of a segment adjacent to a segment already selected deselects it automatically.

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The bending sequence may be either totally automatic or manually (bend to bend) specified by the user. The automatic mode will consider the risks of interference between the part and the machine environment, reduces the number of sheet movements, axes limit. The back gauge position is measured as close as possible to the currently processed bend, with no risk of interference prior or during the bending cycle. The manual selection mode is easier than the automatic one in that the user is given the opportunity to select the bending order, assess the interference risk visually and change the back gauge position.

- unfolded bend , already specified order - current bend - initial process of the part

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Automatic selection of the bending sequence Criteria display Selection of the previous bend for unfolding Selection of the next bend for unfolding Manual selection

Mirror return of the part with regards to the bending axis

Selection of the previous gauge Selection of the next gauge Validation of the solution suggested in automatic mode or validation of each bend in manual mode Review of the order already specified Next bend Previous bend Part display jogging

Zoom out

Zoom in

Zoom total

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In revision mode, for each bending sequence visualized, « axis » and « program parameter» pages allow modifying parameters either calculated or by default, from the bend displayed as well as Z1 or Z2-axes position.

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BENDING CRITERIA (User Parameter)

Gauge support (0=No / 1=Manual / 2=Auto): Gauge in support, selected manually (1) or automatically (2) Front/Back Ratio: minimum ratio from bending axis to the end of the material. (0.9 max) Used both in automatic and manual mode

Maximum intermediate bends for gauging: Number of bends authorized between the gauge and bend to be made (23 max). Used in automatic mode Tolerance for gauging on the edge: angular tolerance on the bending flange on the edge (45° max). Used in automatic mode

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Tolerance for gauging at 90: angular tolerance on the bending flange at 90° (45°max). Used both in automatic and manual mode

Tolerance to the end

Opening (0 = Heavy part / 1 = Light): NC will calculate the minimum opening required to extract the produced component; If the part is to be removed flat to the die, then program 0; program 1 for maximum opening (heavy part)

Opening into Mute (0 = No / 1 = Yes): Possible if no intermediate bend and worksheet pushed for the next bend. Inside Gauging (0=No / 1=Manual / 2=Auto) : Gauge in inside bend, selected manually (1) or automatically (2), (0) for not accepted in any mode

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At the end of the “AUTO” determination of the bend sequence, each angle of the work-piece profile inside the ‘‘WINDOW SHOWING GRAPHICAL REPRESENTATION OF THE PROGRAMMED PART” will be circled. These circles indicate that a solution has been found for the programmed part and in the “GRAPHIC WINDOW PART / MACHINE ”, your workpiece will be positioned on the tool for the execution of the first bend. This current bend will be identified in the ’WINDOW SHOWING GRAPHICAL REPRESENTATION OF THE PROGRAMMED PART’’ by a red/orange circle. The yellow circles represent the bending sequences yet to be accomplished. Selecting the “VISU” function allows you to browse through the entire calculated bending sequence then browse sequences using the enables you to unfold your work-piece.

key. When you reach the last bend,

key

NOTE: If bends are already done they are not circled in the “work-piece window”.

If the following display is shown once “AUTO”

function is validated:

This means that the automatic bend sequence calculation failed. (This situation can be caused by diverse reasons such as unsuitable tools selected for the job or the criterions for the bend simulation are too restricted or even contradictory). To resolve the problem, check if the selected tools are suitable to carry out the job, they are correctly positioned and that the simulation criterions are correct. Re-activate the “AUTO” search for bend sequence after correcting the above. If still no solution is found, switch to “MANUAL” mode to visualise any eventual collisions. The order in which visualisation can be done will always be angle n° 1, angle n° 2 etc.

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“MIR” key will permit you to obtain a different gauging configuration by swapping your work-piece front to back. allows you to choose the gauging position of the backgauge finger when more than one bend exists between the bend in question and the backgauge. Press

for inverse reaction.

After verifying the bend parameters (BEND OFFSET, BG WAIT, RETRACT DIST. …AUX. FUNCTIONS), confirm your manually selected sequence using the

key.

Proceed in the same manner for the remaining bends. One thing you should bear in mind that to determine the bending sequence in “MANUAL”, you should start from the last bend and work through to the first bend i.e. backward. The other usage of the “MANUAL” mode consists of defining the last one or more bends the way you like to carry out, then exiting the “MANUAL” function by pressing the “END/FIN” key. You can then determine the remaining bend sequences using the “AUTO” function.

Quit “GRAPHIC”, by pressing “HOME” carried out.

key, a direct back-up of your program is

.

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6.9.5. MULTI-PROGRAM MODE

After initializing the machine with the "START" key, mode pressing.

activate "MULTI-PROGRAM"

This will display the page as shown above.

 Enter the program number (max. 6 digits). If the number is already used in another mode, the NC will generate an error message; otherwise the called-up program will be edited (see example above). Or select,

your program from active directory (see §6.17)

 Enter your work-piece reference (max 13 digits), this is an optional field. .

To edit your program press key.

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To add a program, press program.

or

to insert a program, with

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you can delete a

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6.9.6. SEMI-AUTOMATIC MODE "SEMI-AUTOMATIC" mode is accessed by pressing Before entering the "SEMI-AUTOMATIC" mode, you will get an intermediate page displayed on the screen as shown below, containing the list of the programs saved in memory (NC or external) together with the name of the program previously edited and displayed as soon as it is automatically selected. Enter the program number or select your program in the current directory (see § 6.17) with key The "SEMI-AUTOMATIC" mode is an intermediate step between programming and producing the work -piece. This mode allows you to make small corrections to your program.

This page is used to correct different axes. Line "ANGLE" is not accessible for programmes created in the "MANUEL 1" mode. The use of other correction fields remains identical whatever the programming mode selected. In this zone, the displayed bend can be changed using

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or

.

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

RULE No 1: The maximum permissible value of correction, positive or negative, is 99.999-mm.



RULE No 2: After input, as soon as the cursor is moved off the programme line, the corrections applied to an axis will be accumulated (algebric sum) and transferred to the bend line.



RULE No 3: The corrections applied to an axis on the program line of a bend are passed on to all the bends having the same angular value within the program.



RULE No 4: The corrections applied to an axis on the bend line cancel out and replace previously entered corrections.

Page « AXIS » is used to visualize axes:

 

“Mem. Pos”: this column includes all the corrections applied to a programmed position. "Real. Pos" : this column shows the actual axes position (where the axes are at a given time)

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Page « Parameter » is used to visualize and modify the different parameters of the current program.

Page « Graphic » is used to display the part (if drawn in graphic mode).

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6.9.7. AUTOMATIC MODE The access to "AUTOMATIC" mode is done by pressing Enter the program number or select your program in the current directory (see § 6.17) with key

The upper part of the screen displays some information related to the program. The following values may be edited: 

"Sub Prog." allows selecting the current sub-program (if the edited program is a multiple one). If not, a "N° S/P" value = "1/1". is then available and cannot be modified.



"Bend" enables the selection of the current bend (which belongs to the current subprogram).

Editing the S/P number and the bend number is accomplished in the same way as for the sequence number in the SEMI-AUTOMATIC mode. 

Required QTY: Place the cursor in this field and enter the number of work-piece required.

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

Finished QTY: Enter zero if none of the parts have been produced or the number of finished parts if some are already produced. NOTE: During the bending operation, the EXECUTED QTY counters increments automatically for each finished part. When EXECUTED QTY = REQUESTED QTY, the N.C. comes out of the AUTOMATIC mode and bending operation stops. The NC displays once again the intermediate AUTO page on the screen to allow eventual selection of another program for execution if required.

Zone for visualising axes position:  Mem. Pos.: this column includes all the corrections applied to a programmed position.  Real. Pos.: this column shows the actual axes position (where the axes are at a given time).

Page « Parameter » is used to visualize and modify the different parameters of the current program.

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Page « Graphic » is used to display the part (if drawn in graphic mode).

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6.9.8. TEACHING MODE Press key to have access to the TEACHING MODE. The data input is only possible if the cursor is positioned to the "P.P" value or on one of the "Y1", "Y2", "X" or "R" axis value while in mode "MANUAL 1" or "MANUAL 2". When the teaching mode is activated the selected axis appears on the screen in reverse video. Once the TEACHING MODE has been validated, use the following keys to modify these values : 

allows an increase of the value (axis in the positive direction) in slow speed.



allows an increase of the value (axis in the positive direction) in high speed



allows a decrease of the value (axis in the negative direction) in slow speed..



allows a decrease of the value (axis in the negative direction) in high speed.

Press this key will quit the TEACHING MODE. The edited value will be saved by copying the value of the modified axis from "ACT. POS." to "MEM. POS". Quit the teaching mode without replacing actual axis values, press

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key, or

.

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TEACHING OF THE PINCH POINT IN MANUAL 1 MODE 1. Place the cursor at the P.P. value (PINCH POINT)

2. Press

key to change over to the "TEACHING MODE" , the P.P. value will be shown

in reverse video

+

3. Place a sample sheet, which is to be bent in between the tooling. 4. Press the closing pedal: the beam does not move. 5. Press one of these Small icon → slow Large icon → fast

keys; the beams will move.

6. Bring down the tool tip in contact with the worksheet. The work sheet should be pinched tightly in between the tools without being folded and you should not be able to move the worksheet, this means that you achieved the correct pinch point position. 7. Once you achieved satisfactory P.P., then press the key on the pedestal control panel to save the beam position. You will automatically quit the "TEACHING MODE" 8. Release the closing pedal. +

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TEACHING A DOUBLE AXIS (Y1 AND Y2) WITH A SIMILAR VALUE. Entering the "TEACHING MODE" when the cursor is located on one of the two axes of the same type (Y1; Y2; …), will teach the same value to both axes ("Y1" and "Y2") unless modified intentionally when entering different values to the keypad. The procedure for teaching "Y" value is identical to the one for pinch point. The procedure for teaching a backgauge axis is similar to the one described for teaching the P.P. with the exception that pressing the closing pedal is not necessary for moving the selected axis.

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6.10. EDIT MENU 6.10.1. PUNCH EDIT

The "EDIT"  "Punches" selection gives access to simplified programming of special punches. It is impossible to edit punches existing in the standard library supplied with the N.C., though using it as a sample for the copy function is possible.

An existing punch may be modified by keying-in its reference number (the values pre-set for each punch parameter are then displayed); a new punch may be edited by keying-in a nonused reference number. Enter the following parameters:    

"ANGLE" : punch angle in degrees " RADIUS" : punch radius in mm " HEIGHT." : punch height in mm (without tail). The punch height is in between punch tip to its load bearing surface. " TONNAGE" : Maximum permissible tonnage for the Punch in KN/m (generally marked on the punch).

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Press

to modify the punch profile (X, Y).

For last point, press , the system will calculate automatically the last segment from final point to starting point on the first segment: decimal errors will therefore be avoided.

touch, allows to read a tool profile from DXF file. The drawing of the profile can be composed of segments and arcs contiguous. The arcs are automatically transformed into segments. The tip of the punch and the bottom of the die must be defined by the intersection of two segments.

touch, allows to specify the origin point of the profile, represented by a cross. And regenerate the sequence of segments composing the profile. This is the common point between the first and last segment. The origin point of profile must be positioned on the tip (for punch) and in the bottom of ve (for die). For the others profiles this point must be positioned on the bending line.

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6.10.2. PUNCH HOLDER EDIT Procedure identical to punch edition.



"HEIGHT" : height of the distance piece in mm

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6.10.3. DIE EDIT Procedure identical to punch edition.

     

"ANGLE" : die angle in degrees "SIZE" : die width in mm "Radius" : die edge radius in mm "WIDTH" : die width in mm "HEIGHT." : die height in mm "TONNAGE" : Maximum permissible tonnage for the die in KN/m (generally marked on the die).

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6.10.4. DIE HOLDERS EDIT Procedure identical to punch edition



"HEIGHT" : die-holder height in mm

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6.10.5. DIE BLOCK EDIT Procedure identical to punch edition.



"HEIGHT" : spacer height in mm

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6.10.6. FINGER EDIT Procedure identical to punch edition.

  

"WIDTH" : finger width in mm "LENGTH" : finger length in mm "HEIGHT" : finger height in mm

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6.11. DELETE MENU 6.11.1. DELETE PROGRAMS

"DELETE"  "Programs" function is used to delete program(s) existing in the NC library. An intermediate page will be displayed (see below).

Press

and

to select the programs to be deleted and moved to the right column.

Confirm deletion by pressing then validate with . If you press deletion function is cancelled (the selected program(s) will not be deleted).

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,the

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CAUTION: Deleting program(s) which is/are part of a multiple part program is only possible if you first delete the multiple program which contains it. Otherwise, an error message as below will be shown.

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6.11.2. DELETE PUNCHES

"DELETE"  "Punches" is used to delete punch(s) existing in the NC library. The procedure is similar to the programs deletion.

Press

and

to select the punches to be deleted and moved to the right column.

Confirm deletion by pressing then validate with . If you press deletion function is cancelled (the selected punch(es) will not be deleted).

,the

CAUTION : You cannot delete a punch, which is being used in a program unless you delete the program before. If, in the selected programs, you have a punch which is used inside a part program, then following message "TOOL **** USED" will be displayed and no punch will be deleted when key

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has been pressed.

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6.11.3. DELETE PUNCH HOLDERS The procedure is similar to the punches deletion.

6.11.4. DELETE DIES The procedure for deleting a/several die(s) is exactly the same as for deleting punches with the same restrictions.

6.11.5. DELETE DIE BLOCK The procedure is similar to the punches deletion

6.11.6. DELETE DIE HOLDERS The procedure is similar to the punches deletion

6.11.7. DELETE FINGER The procedure is similar to the punches deletion

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6.12. RENAME MENU 6.12.1. RENAME PROGRAMS

"RENAME" NC memory.

Press

and

 "Programs"

is used to rename the programs contained in your

to select the programs to be renamed, then confirm with

Enter directly the new program number and validate with If you press renamed).

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.

.

, the rename function is cancelled (the selected program(s) will not be

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6.12.2. RENAME PUNCHES The procedure for renaming punch(es) is similar to programs.

6.12.3. RENAME PUNCH HOLDERS The procedure for renaming die holder(s) is similar to programs

6.12.4. RENAME DIES The procedure for renaming die(s) is similar to programs.

6.12.5. RENAME DIE BLOCKS

The procedure for renaming die block(s) is similar to programs.

6.12.6. RENAME DIE-HOLDERS The procedure for renaming die- holder(s) is similar to programs.

6.12.7. RENAME FINGERS The procedure for renaming finger(s) is similar to programs.

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6.13. COPY MENU 6.13.1. COPY PROGRAMS



"COPY" library..

Press

and

 "Programs"

is used to copy program(s) existing in the NC

to select the programs to be copied, then confirm with

Enter directly the new program number and validate with If you press

.

.

,the copy function is cancelled (the selected program(s) will not be copied).

Same procedure for all programs to be copied.

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6.13.2. COPY PUNCHES The procedure is exactly the same as for copying programs(s) with the same restrictions.

6.13.3. COPY PUNCH HOLDER The procedure is exactly the same as for copying programs(s) with the same restrictions.

6.13.4. COPY DIES The procedure is exactly the same as for copying programs(s) with the same restrictions.

6.13.5. COPY DIE HOLDERS The procedure is exactly the same as for copying programs(s) with the same restrictions.

6.13.6. COPY DIE BLOCK The procedure is exactly the same as for copying programs(s) with the same restrictions.

6.13.7. COPY FINGER The procedure is exactly the same as for copying programs(s) with the same restrictions.

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6.14. SAVE MENU 6.14.1. SAVE PROGRAMS

"SAVE"  "Programs" is used to save program(s) existing in the NC library to an external memory. Selecting this function displays an intermediate page (see below)

Press

and

to select the programs to be saved and moved to the right column.

Confirm back-up by pressing then validate with . If you press back-up function is cancelled (the selected program(s) will not be saved).

and

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, the

keys select the whole unit.

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If a selected program has already been saved on the external memory, the program number is shown followed by a message (see below) :

-

only the program specified will be saved

-

all already existing programs will be saved.

-

the program specified will not be saved

-

no already existing program will be saved.

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CAUTION : If the floppy disk is missing from the drive or is either damaged or is read / write protected, then the NC will display the following message.

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6.14.2. SAVE PUNCHES The procedure is exactly the same as for saving programs(s) with the same restrictions.

6.14.3. SAVE PUNCH HOLDER The procedure is exactly the same as for saving programs(s) with the same restrictions.

6.14.4. SAVE DIE The procedure is exactly the same as for saving programs(s) with the same restrictions.

6.14.5. SAVE DIE BLOCK The procedure is exactly the same as for saving programs(s) with the same restrictions.

6.14.6. SAVE DIE HOLDER The procedure is exactly the same as for saving programs(s) with the same restrictions.

6.14.7. SAVE FINGER The procedure is exactly the same as for saving programs(s) with the same restrictions.

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6.15. RESTORE MENU 6.15.1. RESTORE PROGRAMS

"RESTORE"  "Programs" is used to restore a program(s) from the external memory to the NC library. Once selected, an intermediate page (see below) is displayed.

Press

and

to select the programs to be restored and moved to the right column.

Confirm restoring by pressing then validate with . If you press restoring function is cancelled (the selected program(s) will not be restored).

and

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, the

keys select the whole unit.

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If a selected program is already existing in the NC library, the program number is shown followed by a message (see below) :

-

only the program specified will be restored

-

all already existing programs will be restored.

-

the program specified will not be restored

-

no already existing program will be restored.

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CAUTION: If the USB key is missing or is either damaged or is read / write protected, then the NC will display the following message.

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6.15.2. RESTORE PUNCHES The procedure is exactly the same as for restoring programs(s) with the same restrictions.

6.15.3. RESTORE PUNCH HOLDER The procedure is exactly the same as for restoring programs(s) with the same restrictions.

6.15.4. RESTORE DIES The procedure is exactly the same as for restoring programs(s) with the same restrictions.

6.15.5. RESTORE DIE BLOCK The procedure is exactly the same as for restoring programs(s) with the same restrictions.

6.15.6. RESTORE DIE HOLDERS The procedure is exactly the same as for restoring programs(s) with the same restrictions.

6.15.7. RESTORE FINGER The procedure is exactly the same as for restoring programs(s) with the same restrictions.

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6.16. CUSTOM MENU

6.16.1. CUSTOMISE PUNCH "Custom"  "Punches" is used to customize the client library from the NC one. An intermediate page is displayed (see below).

With library.

key, select and move to the right column the punches to be added into the client

Quit this page by pressing

or

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6.16.2. CUSTOMISE PUNCH HOLDER The procedure is exactly the same as for customizing punch(es) with the same restrictions.

6.16.3. CUSTOMISE DIE The procedure is exactly the same as for customizing punch(es) with the same restrictions.

6.16.4. CUSTOMISE DIE BLOCK The procedure is exactly the same as for customizing punch(es) with the same restrictions.

6.16.5. CUSTOMISE DIE HOLDER The procedure is exactly the same as for customizing punch(es) with the same restrictions.

6.16.6. CUSTOMISE FINGER The procedure is exactly the same as for customizing punch(es) with the same restrictions.

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6.17. PROGRAM DIRECTORY MENU 6.17.1. CHANGE DIRECTORY

is used to change the current directory or create a new one. An intermediate page is displayed (see below).

With

and

select the directory to be made current, press

is used to create a new directory, enter the new name and press

to validate

to validate

You can rename a directory, press

is used to delete a directory, if it is empty and it is not current directory, press to validate

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6.17.2. EXPORT DIRECTORY

is used to export one or several program(s) existing in the NC library to a drive and a directory as requested (exporting path).

-

program exported to NC

-

program exported to USB drive.

-

program exported to network.

-

program exported to USB drive under OP format.

-

program exported to network under OP format.

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Following screen allows to select the source directory and destination directory, you can create a new directory with

or rename it with

.

Select the programs to be exported and confirm with

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6.17.3. IMPORT DIRECTORY

is used to import one or several program(s) existing in the NC library to a drive and a directory as requested (exporting path). .

-

program imported from NC

-

program imported from USB drive.

-

program imported from network.

-

program imported from USB drive under OP format.

-

program imported from network under OP format.

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Following screen allows to select the source directory and destination directory, you can create a new directory with

or rename it with

.

Select the programs to be imported and confirm with

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6.18.PARAMETER MENU

Automatic saving of the machine parameters in USB key

Automatic restoring of the machine parameters from USB key

Soft parameter

Modification of the user password Enter the current password, then validate with

Enter the new password, then validate with

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.

.

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6.19.UTILITY MENU

display the bending chart

system parameter

This page is used to: - set on your NC the current date and time. - modify the display color and screen luminosity (2 colors available). - set the dimensions of the screen by clicking 4 corners. - enter the FTP parameters and know the network address.

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Language modification Used to select the language currently spoken in the NC

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6.20. BENDING WITH 2 OPERATORS NOTE : Unless a second control equipment similar to that used for the main operator is added to our machines, they cannot be run by more than one operator. An optional second operator control station may be supplied for the second operator. Nevertheless, due to the occasional use of such a configuration, the following should be observed for safe use of this option : - Select « 2 operators » mode using.

key

- A password is requested to prevent anyone from modifying the keyswitch position whenever processing parts. Only the main operator or adjuster should be aware of this password. See § 6.18 (default value : « 55 ») 

Test correct operation of the option before bending operation using following procedure :

     

Select the adjustment cycle (Safety speed). Press opening footswitch at operator 1 control stations, the beam opens. Press opening footswitch at operator 2 control stand, the beam opens. Press closing footswitch at operator 1 control stations, no beam movement should occur. Press closing footswitch at operator 2 control stations, no beam movement should occur. Press both closing footswitches, the beam should close.

NOTE For the machines equipped with the safety programmable logic controller, the footswitches should be operated within 4 seconds. Should it take longer, both operators should have to release the footswitch before a new cycle can be initiated.

Bending with one operator and 2 control stations (multi staging or multiple bending) A single operator can use two independent control stations. 

Select « one operator » mode using



Program auxiliary function « F » corresponding to the workstation you intend to use in each bend (see § 6.9.2).

key

For instance it is possible to program footswitch 1 in bends 1, 2, 4 and 5 and then footswitch 2 in bends 3, 6 and 7. If wrong footswitch is pressed by the operator or another person, no motion will occur ; an alarm will be generated and displayed on the CNC screen.

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6.21.BENDING AT THE EXTREMITY OF THE BEAM In some cases for bending specific parts, working on one side of the machine may be necessary (box, cone, etc.). Since bending at the end of the beam is rather rare, operating safely implies the following actions:  Select the « adjustment » mode , in this case, beam will only move in safety speed ( 10 mm/s for out of US market machines and  20 mm/s for US market machines) Machines CE



Open only the required side gate. Opening both of them will generate a machine stop, because operator’s visibility is poor for the far end. NOTA Only trained and qualified operators should be entitled to work in this way, taking into full consideration the backgauge movements while bending such parts.



When the machine is equipped with 2 control panels (2 footpedals), it is possible to operate the machine with both side gates open only if machine is operated by two operators. In that case, select « Bending with 2 operators » mode by pressing . Recommendations specified in section « Bending with 2 operators » are totally applicable and should be observed in this case. .

NOTE In this specific case, both foot switches should be pressed within a maximum of 2 seconds. Otherwise, both operators should release the footpedals and re-initiate a new cycle.

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7. FORMING TECHNIQUE & TOOLING

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Figure 7.1

Figure 7.2

Figure 7.3

Figure 7.4

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7.1. GENERAL POINTS Bending consists of forming parts from flat sheets. Deformation is linear and simultaneous over the entire length of the part on a finite machine and tool, and continuous when rollers are used (infinite length). Fig. 7.1 : Punch and die. Press brake.

Fig. 7.2 : Gripper plate and punch. Press. Tangent bending. Hole cut off edge.

Fig. 7.3 : Fixed gripper plate, rotating beam. Folding press.

Fig. 7.4 : Rotating gripper plates.

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Figure 7.5

Figure 7.6

Figure 7.7

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Fig. 7.5 : Fixed guide and rotating gripper plate. Manufacture of shrouds.

Fig. 7.6 : Three rollers. Roll bending machine.

Fig. 7.7 : Flat roller. Infinite bending length. Angular variation limited to each pair of rollers

This list of forming methods is not exhaustive. This chapter only deals with punch-and-die bending. (Fig. 7.1). There are two basic bending techniques: -

AIR BENDING

Commonly performed because it requires relatively low bending forces. -

COINING

Requires forces equal to three to five times those of air bending. Allows the inside radius to be coined, which practically eliminates the elasticity of the material.

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t = thickness

Distance of penetration

Sheet contact

Die = 8 to 10 t

Figure 7.8

Figure 7.9

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7.2. AIR BENDING

During air bending, the sheet metal retains certain amounts of elasticity in the plastic region. An angle more acute than the desired angle must therefore be produced to compensate for the opening due to spring back effect. The calculation made takes into account all the parameters required by air bending. Our standard air bending tools are designed accordingly. The bending chart located in the press brake electrical cabinet gives the required forces and inside radii obtained according to the other characteristics (thickness, die opening, etc.). The sheet is in contact with the tools at three points (A, B1, B2) as shown in Figure 5.8. A necessary consequence of this for bending quality is: die = 8 to 10 times the sheet thickness. (For angles  135°, preferably use a die = 10 to 12 times the sheet thickness). Sheet deformation is interrupted before it reaches its penetration limit in the die.

NOTE If there is a specific requirement for bending, edge dimension, inside radius, etc., use the technique for air bending at the bottom of the die (partial coining) or coining.

AIR BENDING AT BOTTOM OF DIE OR PARTIAL COINING (Fig. 7.9) In this case, the sheet penetrates to the bottom of the die and is supported by the sides, with no increase in the bending force. This type of bending is seldom used because of the inaccuracy of the results obtained. Coining should be chosen over partial coining whenever possible.

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7.3. COINING This type of bending is comparable to stamping. The end of the punch penetrates the sheet at the bottom of the die, rupturing the elasticity of the sheet, which is then bent exactly to the shape of the punch. - In practice, for a 90° bend: - Die width = 5 to 8 times the thickness. - Die angle = 90°. - Punch angle = 90°. The state of the part is similar to that shown in Figure 7.9 for partial coining, except that the forces at the end of bending are 3 to 5 times the air bending forces, which causes the coining of the sheet.

NOTE The choice of punch radius is very important, because it determines the inside radius of the bend (stamping of the punch in the sheet). Coining can be performed with a punch and die of the same angular value only. Very high bending forces must be applied; these may reach values from 3 to 5 times those shown on the air bending chart.

CAUTION: Because coining involves very high forces, take great care to check the strength of your tools. Never exceed the applicable force limits. These values depend on the type of tool, and should normally be shown in tool catalogues (Para. 7.4).

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7.4. LIST OF STANDARD TOOLS (Refer to “Amada’s Press Brake Tooling” catalogue) Qualitative characteristics common to the whole range:     

Easy to store. Easy for one person to handle. Hardened working surfaces. Standardised mounting systems. Special profiles suited to different sheet thicknesses.  Wide range of profiles suited to all applications.  Special custom-designed profiles for sufficiently large production runs.  Rabbeting in the heel preventing the tool from dropping when tool clamp plates are unfastened. Our tools have two standard lengths: 835 mm and 415 mm.

Certain tools are sectionalised in pre-determined dimensions. For details regarding these tools, please refer to “Amada’s Press Brake Tooling” catalogue. These sectionalised tools allow four-sided bending for items such as boxes, drawers, shelves, etc.

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CAUTION: For any issues involving tools or bending materials other than sheet metals (list of range, profile, linear strength, etc.), please contact AMADA. A tooling specialist will analyse your specific problem. A simple telephone call will make your job easier and help you to work in complete safety.

The “Amada’s Press Brake Tooling” catalogue gives you the complete list of available punches and dies. During commissioning, our technician will enter a list of all your tools in your NC unit, and will show you how to input new tools yourself. You will then have the complete list of your punches and dies stored in the NC memory. You must then identify them very carefully when using them to allow the NC unit to calculate the penetration from exact values. If for any reason the number were illegible on the tool, you could identify it by measuring the following parameters: - Height (mm and hundredths) - Tip radius - Angle and then identify it in the NC unit from these three values by scrolling through the list.

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Only trained and qualified operators are entitled to work on pressbrakes.

7.5. TOOL INSTALLATION 7.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM Amada’s standard fast punch clamping system allows an easy and fast mounting of the punches. The use and possibilities are described here after:

Lateral mounting of the punch (short punch lengths)

Punch is clamped

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Punch is released

Lateral extraction of the punch

The procedure remains the same for longer punch lengths:

Lateral mounting of the punch (longer punch lengths)

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Punch is clamped

Punch is released

Lateral extraction of the punch

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Standard clamping system for joined mounting (option). The standard clamping system exist in a special model, for joined mounting of distance pieces. With the joined mounting, the installation of a short tool is possible at any position of a line of joined clamps. To join clamps, from an initial position with space between them: - Untighten by about one turn the two M10 screws of each upper clamp plate that fix the clamp unit to the upper beam. The clamp unit is then maintained in place by heel of the clamp plate that goes into the groove of the clamp unit. - Slide laterally one or more untightened clamp units until contact between them. - Push the clamp unit upwards, while tightening the two M10 screws of each clamp plate. To move the clamp units apart, from a joined position, follow the procedure above in the opposite order. NOTE : Never separate the clamp units by more than 50 mm between them. In case of too high distance, the clamp unit might be overcharged.

CAUTION: Overcharge of a clamp unit line might destroy and/or deform the clamp unit, the upper table and/or the bending tool.

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7.5.2. “AMACLIP” PUNCH CLAMPING SYSTEM To increase safety and flexibility, on top of extra-ordinary qualities of the standard fast punch clamping system, Amada put together a fast clamping system-permitting front loading and unloading of the punches. This solution reduces considerably the tool change time when it comes to frequent punch changes, at the same time remaining totally compatible with standard Amada range of tooling available in Amada’s Press Brake Tooling catalogue. All existing possibilities of the standard fast punch clamping system is conserved, e.g. stacking of the distance pieces for bending deep boxes etc. The use of “AMACLIP” punch clamping system under different condition is explained here after: -

Short length of punches (less than 200 mm)

Front-loading of the punch

It is to be noted that it is still possible to load punch laterally (in this configuration, “AMACLIP” doesn’t offer any advantage over standard fast punch clamping system).

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Punch is clamped (this operation is identical to the one used for standard fast clamping system).

Punch is released (this operation is identical to the one used for standard fast clamping system).

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Front unloading of the punch by pressing the punch releasing lever to allow punch to come off from the bottom.

It is to be noted that it is still possible to unload punch laterally (in this configuration, “AMACLIP” doesn’t offer any advantage over standard fast punch clamping system).

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-

Punches having lengths equal or higher than 200 mm

Front-loading of the punch

It is to be noted that it is still possible to load punch laterally (in this configuration, “AMACLIP” doesn’t offer any advantage over standard fast punch clamping system).

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Punch is clamped (this operation is identical to the one used for standard fast clamping system).

Punch is released (this operation is identical to the one used for standard fast clamping system).

Lateral extraction of the punch (this operation is identical to the one used for standard fast clamping system). NOTA It is mandatory to extract laterally the punch when a single length of punch is clamped by two distance pieces (even though eventually it may be possible to extract the punch from the bottom by pressing simultaneously the two central releasing levers). Because there is a risk that the punch may slip and drop during this manipulation and may cause injuries to the operator. FORMING TECHNIQUE & TOOLING OPERATOR’S MANUAL HFE M2 – X41176B

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Figure 7.10

Figure 7.11

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CAUTION: Tool installation and removal procedures must be performed by trained personnel qualified for the job. Such procedures must be performed in manual setting / adjustment cycle, which enables beam movement at low speed. The maximum tool load in tons / metre must always be taken into consideration. 7.5.3. TOOLING INSTALLATION PROCEDURE (STANDARD) Tool Installation (Fig. 7.10 et 7.11) 1) Place the lower part of the tool into position, depending upon the tools being used i.e.: -

Spacer, Single V die with die holder, Two V die with die holder, which are slid onto the table of the lower beam.

2) Secure using the front clamp plates as shown in the diagram (Fig. 7.10). The rear clamp plates must never be loosened because they provide the reference surface for tool alignment. Note: In the event that a 2 V die requires alignment, ensure the locking screws (Hm8) that attach the die to the die holder are loosened (13-mm flat spanner). 3) Select a program on the NC unit. 4) Go into sheet pinch point TEACH mode (see § 6.9.7). The use of this mode guarantees machine operation at minimum pressure. 5) Enter the stacking value Y consisting of: lower tool height + punch height + 3 mm (Fig. 5.11). 6) Depress the closing footpedal and rotate the remote hand wheel in a clockwise direction1 or press the hand wheel buttons on the keypad until the S.P.P. (Sheet Pinch Point) value corresponding to the y value is obtained.

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7) Release the Closing footpedal. 8) Press the machine emergency stop button. 9) Introduce punch tip into the V groove of the die and slide the punch lengths into the dies, and clamp. 10) Reset the machine emergency stop. 11) Press the green START button on the NC unit. 12) Depress the Closing footpedal. 13) Turn the remote hand wheel on the control clockwise until the displayed value of the sheet pinch point end or use push buttons on the NC which command the closing of the upper beam until change in the displayed value of the sheet pinch point ends. 14) If using dies that require alignment using a punch (e.g. 2V dies), tighten the screws (Hm8) using the 13-mm flat spanner whilst holding down the Closing footpedal. 15) Press the Opening footpedal to raise the upper beam. 16) Set the pressure to a value required to perform the bending operation but do not exceed the maximum value for the tooling being used. The machine is now operational. Special Case 1) Sectionalised tools When sectionalised tools are used, whether dies or punches, there is always a risk that the tool settling force may exceed the tool strength. Each tool type has its own strength, which is given in the sales tool catalogues as well as being marked on each tool. Sectionalised 4 mm gooseneck punch: - Maximum load withstood by this tool: 11 T/M i.e. 110 kN - Total length of sectionalised tool: 800 mm In this case, the maximum force that this tool can withstand is: - Max. load withstood by tool (kN) x total tool length/1000 110 x 800/1000 = 88 kN. If you exceed this value it will create “DANGER”.

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Minimum force values for each type of machine: see Chap 1, § 1.3. The following formula is used to calculate the minimum length required to withstand the minimum force applied by the machine: Minimum force of machine (kN) x 1000 / Maximum load withstood by tool (kN). Example: - Machine: HF 170.4 (170 T, 4 m) - Minimum force applied by this machine: 210 kN - Minimum tool length: 210 x 1000 /110 = 1909,09 rounded off to 1910 mm (due to tool sections) - In this example, a 800 mm sectionalised tool cannot be used to set the tools

-

-

All press brakes are designed to take a maximum authorised tool length. This value is given in Para 1.3, Chap. 1 reminded at the bottom of the Table under Number of Tools ». Do not exceed these limits.

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Note It is technically in-correct to align and set a long length of die using a short length of punch. a) When bending with one or more short lengths of punches (< 835 mm) in combination with a long die, abide the following procedure:  Follow steps 1 to 11 of the procedure where punch length is identical to the die length.  Loosen and remove the punch(es).  Press the Opening pedal to raise the upper beam to top dead centre.

IMPORTANT NOTE Since the next strep within this procedure needs the adjuster’s hands to be introduced between tools, safety should be ensured as much as possible if the machine is set in operating mode (manual, semi-auto, automatic, etc.). The operator should return to the main menu by pressing and trigger the machine stop located either on the NC panel or on the lower beam and message 129 is displayed : « MACHINE STOP PRESSED ».  Position the sectionalised punch(es) by laying them under the distance piece bearing surfaces. b) When bending with a punch longer in length than one or more short die lengths, proceed as follows: Apply the procedure described in “a)”, using a full die length to centre the die & holder, and then remove this die length and replace with the required sectionalised bits.

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TOOL REMOVAL PROCEDURE -

Bring the tip of the punch to about 3 mm from the bottom of the die (refer to installation procedure, Steps 1 to 7).

-

Loosen the punches, and slide them out via one end of the beam.

-

When all the punches have been removed, press the Opening footpedal to raise the upper beam.

-

Remove the dies by loosening the mounting screws from the front clamp plates. The rear mounting brackets should not be removed because they are used as a reference for tool alignment, if this can be avoided.

TOOL STORAGE -

To protect the working edges of your tools, we recommend that you store them in a specially-designed tool cabinets (Part No. F 93010) near your press brake, or lay them on wooden slats or other soft materials.

-

Apply a film of oil to protect them against corrosion.

TO INSTALL AND REMOVE TOOLS IN COMPLETE SAFETY, THE OPERATOR MUST APPLY THE ABOVE SAFETY RECOMMENDATIONS, AND MUST BE EQUIPPED WITH PROTECTIVE GLOVES AND APPROVED SAFETY SHOES.

Notified Bodies have harmonised (for both men & women) the weight limit at 25 kg. Beyond this limit, personnel liable to perform such handling operations must receive appropriate training, and the items to be handled must be equipped with a handling device (special machining, tapped holes, etc.).

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Installing 2V-dies Install the 2V-dies as described below. 1. Install the die holders at the top of the lower beam and fix them with the clamps of the lower beam. Since the dies and die holders differ in length as shown in the table below, separate the die holders by about 5 mm as shown in the figure below. L-type length

S-type length

Die holder

830 mm

410 mm

Die

835 mm

415 mm

NOTICE Set the die holders for the 2V-dies so that their step and the V-groove of the die to be used face the rear as shown in the figure above. This orientation is termed “front”. This is to prevent the die from flying toward the operator when it breaks. 2. Loosen the die clamping bolts, slide the die from the operator’s side (the front of the machine) onto the die holder top with the V-groove to be used facing the rear and approximately center the die.

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Installing 1V-dies Install the 1V-dies as described below: 1. Loosen the die clamping bolts, slide the die from the operator’s side (the front of the machine) onto the die holder top and approximately center the die.

If the 1V-dies with a V width of 32 mm or more are installed on the upper beam, they may produce a large clearance between themselves due to the relationship between the open height and stroke. In such a case, use die blocks to reduce the clearance. Install the die blocks by paying attention to their orientation.

NOTICE The rear clamps of the upper beam and die blocks establish the reference surface for centering the tools. Never loosen them.

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Installation of adjusted raises groove H100 Front view of the machine from left to right

Dismantling the tools Remove the tools as described below. When tool origin is not set 1. Select ON/OFF teach button on the remote handwheel control. 2. Press (hold) down CLOSING footpedal, turn the remote handwheel and lower the upper beam until the distance between the punch tip and the bottom of the V-groove becomes 2 to 3 mm. 3. Release CLOSING footpedal and press an emergency stop button. 4. Loosen the punch holder clamps and slide the punch sideways to remove it. 5. Remove the die. 6. Release the emergency stop button. Reset the machine. Turn the teach button to OFF position. 7. Press the OPENING footpedal to raise the upper beam.

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7.6. OPTIONS AND ACCESSORIES See Appendix C.

7.7. PUNCHING Your machine cannot be used for punching, notching

7.8. MAGNETISM During the elaboration of raw materials, and the manufacture of press brakes, high efforts are done to measure and to eliminate the natural permanent magnetism in the framework and other components constituting the press brake. However, according to the form, the thickness and the weight of the part to bend, there can be an attraction effect of the part towards the bending tools. This phenomenon is palpable only on magnetic materials, and by using a punch with sharp angle, i.e. 30°, then of very light parts - mass inferior to some grams/cm bend. Amada can not be held for responsible of expense and damages, following to this discomfort by a combination of the part and chosen tools, but will remain to disposition to study a solution.

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7.9. BENDING CHART This chart was drawn up for mild steel with a shearing strength of 40 to 45 daN/mm². Using the chart, you can normally find the following information if the sheet thickness e and inside bending radius ri are known:  Force (kN) per metre of bent length f  Size of the smallest possible edge b  Opening of the die to be used, V Recommended die openings are shown in shaded boxes. This opening, V, is related to the thickness e of the sheet to be bent. The recommended values are as follows: For e  10 mm V= 8e For e  12 mm V = 10 e If the recommended opening cannot be used (small edge cannot be created, tool not available, insufficient force, etc.), use a die with an opening that is near the recommended value, shown in the light boxes of the chart. This chart is also valid for the bending of other materials (e.g. stainless steel or aluminium); simply apply a correction factor to the values according to the ratio of the mechanical strengths. Example: If the chart, based on 40 daN/ mm² steel, gives a force of 500 kN for a given bend, the force is 250 kN for the same bend on a 20 daN/mm² aluminium sheet.

BENDING CHART LEGEND PLATE

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8. SERVICING AND MAINTENANCE

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CAUTION: Any maintenance operation liable to cause upper beam movement (hydraulic circuit, cylinder, etc.) must be performed with the beam in low position, or using the beam immobilising parts intended for transport purposes (Para. 4.4.2).

8.1. INTRODUCTION This chapter describes the operations required to maintain the qualities and characteristics of your machine. A press brake is exposed to the harsh conditions of a production shop: welding fumes, grinding dust, sheet oil, rust particles, etc. But a modern machine tool like this one is equipped with high-tech precision components: ball screws and guides, notched belt and pulley, proportional hydraulic valves, linear scales, USB, etc, which require periodic maintenance. The frequency of periodic maintenance is based on 8 hours of operation per day under normal working conditions. It must be increased accordingly in the event of production at two or three shifts (16 to 24 hours per day), and does not eliminate the need for maintenance according to condition in the event that oiled or galvanised sheets are used for large production runs.

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IMPORTANT Use this type of ladder whenever accessing the top of the machine (not supplied by AMADA).

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8.2. MACHINE PERIODIC MAINTENANCE - COMPONENTS – List of components subject to periodic maintenance Item

1 2 3 4 5 6 7 8 9 10

-

NC UNIT ELECTRICAL CABINET MEASUREMENT “C” FRAME LOWER/UPPER TOOLS LOWER BEAM PROTECTIVE SIDE GATES BACKGAUGE (SEE CORRESPONDING APPENDIX) ROLLER GUIDE PLATE HYDRAULIC UNIT (MOTOR PUMP) OIL TANK

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FREQUENCY Monthly Twice monthly 2000 hours 2000 hours 2000 hours

PERIODIC MAINTENANCE OF THE MACHINE ITEM APPLIES TO PRODUCT 1 Beam + dist. piece TPFE 5 Roller guide « TARP S » grease 2 Filter H02528* 3 Breather H15147* 4 Oil Shell DS46 or equivalent **

* Always check the part list for correct references. ** ISO VG 46 DIN 51524/2 1st part HL 2nd part HLP AFNOR NF-E 60-200 category HM ISO 11158

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PERIODIC MAINTENANCE OF THE MACHINE FREQUENC FREQUENCY FREQUENCY FREQUENCY Y Monthly

1

Screen

Gentle cleaning agent + soft cloths

Quarterly

3

Linear scale guides

Lithium grease

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MACHINE MAINTENANCE KIT Part No.: M90074 Precautions: Easily flammable liquid - Use and store away from any flame, heat source, or electrical device in operation. Do not smoke. - Spray in short bursts only. - Air thoroughly after use. This kit was specially designed to facilitate the routine maintenance of Amada press brakes and shearing machines. The products it contains are specifically suited to the heavy duty conditions of an industrial environment. An aerosol is easy to use, prevents waste, and provides access without disassembly. The contents are optimised for the latest machines, equipped with micromechanisms, charged rails, and precision tools.

Description: 2 lubricant aerosols: For the ball screws and guides, micromechanisms and notched pulleys. 1 cleaning and anti-seizing aerosol: To correct a maintenance and cleaning deficiency, for guide, ball screw, and precision mechanisms. 1 greasing aerosol: For guides (rails and rollers) of rams and blade holder, as well as chamfered screws. 1 protective aerosol: For the unpainted parts of the machine and press brake tools. Use: The products should be applied according to the instructions in the “Maintenance” chapter of your machine's operator manual, as often as necessary. Clean the surfaces to be treated. Use the cleaning/anti-seizing spray for the inaccessible parts. Spray in brief bursts from a distance of 30 cm away from the part to be treated.

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8.2.1. CHECKS SPECIFIC TO THE HYDRAULIC INSTALLATION The hydraulic installation of your press brake has proportional hydraulic directional control valves. The reliability of these components depends above all on the cleanliness of the oil. Remember these essential rules:  Every hydraulic circuit is contaminated even before the system is assembled. 

Abrasion wear causes additional contamination during system operation.



This also occurs when the circuit is topped up with new hydraulic fluid that is supposed to be clean. For this reason, one should make sure the is filtered before topping up.

 Because of this, you are advised not to top up or perform oil changes too often.  All hydraulic circuits must be correctly filtered: well filtered oil degrades very slowly where as a badly filtered or un filtered oil will increase pollution level which will lead to a faster filter clogging. IMPORTANT NOTE Failure to apply the above maintenance instructions can lead to a total or partial loss of guarantee cover on the units concerned.

CAUTION: The pump must never run without oil.

CAUTION: To continue operating in complete safety, use only original replacement parts.

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Hydraulic circuit drain handle





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8.2.2. OIL CHANGES First oil change: After 1000 hours. Subsequent oil changes: Every 2000 hours or after one year, whichever comes first. Turn off and lock the machine's electrical power supply. Ensure that the upper beam is in its top position. Remove the drain plug (Item 1) and replace it with a hose. Swing the drain handle to open the valve and completely drain the reservoir. Close the drain valve and remove the hose. Replace the drain plug.

8.2.3. FILLING PROCEDURE Remove the air filter (Item 2) to fill in the tank. Fill the reservoir with Shell Tellus 46 or an equivalent ISO 46-compliant oil*. Reservoir capacity: see Chapter 2, Characteristics. Check the level. It should be at the maximum mark on the gauge when the upper beam is in high position. Replace the air filter of the hydraulic tank breather (Item 2), Amada Part No. H02160. (Ensure its the correct reference for your machine using part list).

NOTE After an oil change, do not replace the filter cartridge until the hydraulic unit has been running for half an hour. The purpose of this is to avoid contaminating the new cartridge.

Remove the bowl feeder (Item 3) from the high pressure filter.

* ISO VG 46 DIN 51524/2 1st part HL 2sd part HLP AFNOR NF-E 60-200 category HM ISO 11158

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Replace the oil filter cartridge (for Amada reference see § 7.2 and Parts List). Reinstall the filter bowl feeder.

CAUTION: The legislation in force prohibits the disposal of oil into the environment. Observe the regulations in force in your region.

8.3. RECOMMENDATIONS For these maintenance operations, we have created kits containing the products you need for your machine*:  Machine maintenance kit, Part No. M90074 (see description).  Numerical Control unit maintenance kit, Part No. M90075.

IMPORTANT NOTE Failure to apply the above maintenance instructions can lead to a total or partial loss of guarantee cover on the units concerned.

CAUTION: All maintenance and preventive maintenance operations must be performed with the hydraulic unit shut down, with the power key removed or main circuit breaker locked.

ACCESS For access at a height (e.g. above 1.8 m), additional equipment must be used (such as an inspection platform, ladder, or stepladder). This equipment should be used only after appropriate training (checking fitness for purpose and stability of the equipment). The manufacturer recommends access via the rear of the machine for the hydraulic components. * : Available in option

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8.3.1. SPECIFIC DAILY TEST PROCEDURE: 1. Light guard (see §8.6) 2. “Akas” system (see options §8.7)

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PERIODIC INSPECTION AND CLEANING LIST FOR THE VARIOUS COMPONENTS WARNING THIS PERIODIC MAINTENANCE SCHEDULE IS RELATED TO MACHINE SAFETY.

Upper beam guiding

Tooling



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Lower beam





Main power supply circuit breaker

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

General items

Weekly

- Clean the oil carbon and dust from the following using a shop vacuum cleaner: - The various parts of the backgauge (see appendix “C”) - The working parts of the upper and lower beams - Tooling (die block, spacers punches dies) Use of an air gun should be avoided because it blows off dust into inaccessible areas.

Safety switches

Weekly

-

Item 1 Item 2 Item 3

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-

TIME

Check that the safety switches are operating correctly on : Lateral protection Rear screen door Out-of-parallelism sensor

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UPPER BEAM GUIDING

Upper beam guiding

Fig. 8.2 Fig. 7.1

Lower beam Tooling

Fig. 8.1

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ASSEMBLY

SUBASSEMBLY

Upper beam guiding

ITEM

FREQ.

INSPECTION/METHOD

Fig. 8.1 Fig. 8.2

Twice monthly

- Check the (mounting) screws + rollers. - Dry lubrication Remove the soiled grease and replace it by a clean and new one. Use « TARP S »-type grease on the upper beam guidings.

TIME

- see Appendix: E1.3 « Sick » E1.6 „Akas“ Laser beam protection (option)

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Fig. 8.3

Upper beam bearing surface Sectionalised distance pieces

Upper beam bearing surface

Fig. 8.4

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

TIME

NC cabinet

Fig. 8.3

Monthly - Clean using a cloth soaked in dilute ammonia solution - Screen - Keyboard

Tools

Fig. 8.4

Monthly - After cleaning, protect the unpainted surfaces using PTFE (Teflon) spray-on or protective grease: 1) Adjustable sectionalised distance pieces 2) Bearing surfaces of distance pieces under upper beam

Mechanical

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Breather

Upper beam guide rail

Oil tank

Linear scale guide rail

High pressur

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

TIME

After cleaning use “TARP S “ lithium grease to grease the following: Upper beam

3 months

- Guide rail

Measurement “C” frame

3 months

- Linear scale guide rail (remove cylinder covers)

Hydraulic

2000 hours

-

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Replace oil filters and breathers Drain oil tank

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Fig. 8.5

Mounting s

Fig. 8.6

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

Frame

Fig. 8.5

6 months

- Check machine levelling (see Ch. 3.3)

Motor

Fig. 8.6

6 months

- Check securing of motor to its plates and silent blocks

TIME

Mechanical

Hydraulic/pneum atic pipework (see Checks Specific to the Hydraulic Installation)

6 months

- Check connections - Detect leaks

- Check fan operation 6 months Electrical cabinet Quarterly

- Check machine stop operation (safety devices)

Quarterly

- Visual control + door opening trial

Quarterly

- Visual control + opening trial

Machine stop

Rear grid

Side protections

- Check the operation Quarterly

Opening footpedal

- Check the operation Quarterly

Closing footpedal

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8.4. TROUBLESHOOTING 8.4.1. TROUBLESHOOTING TABLE The purpose of this table is to help you rectify simple problems such as an operating error or blown fuse. If the problem persists, please contact the Amada Department Services (telephone and fax numbers given at the beginning of manual). PROBLEM

SOLUTION

The back gauge is out of parallel with the tools



If the back gauge is outside tolerance for parallelism with the tools, it goes into interlock mode (pump green indicator light goes off). Push or pull the back gauge to reset the pump. For the pump to reset, (X1 – X2) must be within axes off-set limit.

Green indicator light does not light up.



Check the machine stops.

Refer to the Incidents table in the machine electrical drawing.

TO CONTINUE OPERATING IN COMPLETE SAFETY, USE ONLY ORIGINAL REPLACEMENT PARTS

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8.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL POINTS (SEE NATIONAL REGULATION) (FRANCE ONLY) (The Labour Code impose preventive maintenance to be performed on a quarterly basis). The purpose of this regular servicing is to detect in advance, any fault liable to cause an accident, so that such faults can be rectified. These checks are limited to the visible parts and components accessible by removing the covers and cowlings include the following: These checks are limited to the visible parts and components accessible by removing the covers and cowlings include the following: Visual check on the physical condition of the equipment: - Stability of the machine and its accessories: mounting of components liable to fall or be thrown off, - Mounting of protective components, - Condition of equipment: detection of abnormal oxidation, deformation and cracks, - Cleanliness: accumulation of off cuts or dust, - Condition of filters and outlets, - Condition of interfaces and electrical, hydraulic, and pneumatic connectors.  Check of settings and clearances - Fluid levels, - Air and oil pressure, - Limit switch adjustment.  Check on condition of indicators: - Condition of signalling devices: indicator lights and inscriptions.

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The results of this service call are recorded in a safety register opened by the Site Manager and made available to the Health and Safety Executive and the CHSCT (if any) at all times. This measure applies to any manual-feed press working on cold rolled metals. The servicing must be performed under the responsibility of the Site Manager by qualified persons trained in risk prevention. A list of such personnel is made available to the Health and Safety Executive. These provisions came into force on 15 / 01 / 1993.

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8.5. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES A) Purpose

To allow fine adjustment of the line of tools to obtain minimum angular variance over the length of the bend under given conditions. B) Purpose of Adjustment The purpose of the adjustment is to compensate for differences in penetration between the punch and die. It is represented by the distance piece curve.

The various adjustment curves for a given machine have a similar overall appearance. The amplitude of the values varies according to: Type of material, mechanical properties (tensile strength). Length and thickness of sheet to be bent (the adjustable distance piece design enable you to use all the tools in the Amada range). Note The distance piece curve for Amada machines is factory-adjusted according to average values, and checked by the Amada technician during commissioning on the customer site.

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Figure 8.7

Figure 8.8

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C) Adjustment Preparation: On all distance pieces constituting the tool line. Release the adjustment wedge by loosening the screw (Item 6) (6-mm hex socket wrench). Slide the wedge, Item 9, to the bottom of the slot towards the right. Slightly tighten the screw, Item 6, and then firmly tighten the tool spacer using the two screws, Item 8 (8-mm hex socket wrench) (see Fig. 8.7). Settling the Distance Pieces Either use two identical lengths of die + punch, or use two special parts to be manufactured according to Figure 5.13. These parts are moved at the same time and systematically for the settling of each pair of distance pieces. -

Set the press brake for a force of 20 tonnes (200 kN).

-

Settle the two end distance pieces at the same time, and then the next two, and so on. If only one remains at the centre of the press brake, it should be settled using a force of 10 tons (100 kN).

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Figure 8.9

(The distance pieces are set to zero in the factory for the entire HF range except for HF 103-3 machines) Position of standard distance pieces on these machines are as follows:

Figure 8.10

Adjust dimension E using travel dial indicator: Select the lowest distance piece, i.e. the one with the smallest distance E (Fig. 8.9). Immobilise its wedge using the 6-mm (hex socket wrench screw) (Fig. 8.7). Place the travel dial indicator on the lower beam, at the centre of the distance piece, and set the pointer to zero.

Adjust the other distance pieces either: -

By adjusting the values given in the curves (Fig. 8.9). These are off course average values for a given machine.

-

By customising these adjustments according to the operating conditions and the results to be obtained.

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8.6. ADJUSTMENT AND MAINTENANCE OF THE LIGHT GUARD 8.6.1. ADJUSTMENT Align horizontally and vertically all the devices by using “sick laser” tool (sender and receiver in vertical position )(sick AR60).

90°

First beam

First beam

90°

Referenc e plane

Top view Laser beam

- Reduce the inclination until the green led lights up again and tighten the locking screw manually. - Use a Depth Vernier Caliper, measure the actual bracket depth adjustment, correct by 2mm the depth calliper gauge position and lock it at this setting. - Reduce again the inclination by 2mm by using the previously adjusted depth calliper, tighten the screws on the adjustable bracket… - Once achieved, check alignment with laser

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Incline the sender until the control led switches from « GREEN » to « RED ». - Reduce the inclination until the green led lights up again and tighten the locking screw manually. - Use a Depth Vernier Calliper, measure the actual bracket depth adjustment, correct by 2mm the depth calliper gauge position and lock it at this setting. - Reduce again the inclination by 2mm with using the previously adjusted depth calliper, tighten the screws of the adjustable bracket. Once achieved, check alignment with laser.

Ecart / delta ≈ 20 mm

Ecart / delta ≈ 35 mm ≈ 35 mm Check that the setting is reliable by moving each door slightly (simulate machine’s vibrations). Reduce inclination if needed. Once achieved, check alignment with laser.

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Check if the reflection problem still exists: Use a standard sheet, 1.5 mm thick, 200x300 size Position the sheet on the lower beam across the vertical light beam (protect the lower beam) Position the 37 mm-long control bar on the sheet, across the vertical light beam Insert a 5 mm spacer beneath the control bar Check the led condition on the receiver light beam Only the red led should be lit Once finished, fasten the lock nuts.

Axe du rideau Light guard centre

Control bar 37mm Barreau de 37mm

TI

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Spacer 5mm Cale de 5mm

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8.6.2. PROGRAMMING Programming is operated either by PC or CLONE PLUG (refer to appendix SICK manual).

8.6.3. REGULAR MAINTENANCE Light guard optical surfaces should be cleaned on a regular basis, frequency depends on the environment they are subject to, otherwise they will generate intermittent break downs due to clogged optical surfaces. Use a clean and soft cloth to wipe off windows. It is strictly forbidden to use abrasive cleaning products. In that respect, « Windolene-type » products - which prevent any risks of scratches are particularly recommended by Sick manufacturer. Massive dust deposits due to electrostatic chargings will be avoided if windows are merely dried, but not polished.

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8.6.4. DAILY INSPECTION Check mechanical protections (position and condition). Check safety sensors. Check the light guard:  with the ø30mm rod along the 900mm-vertical emitter and receiver  with the ø22mm along the 150mm -horizontal emitter and receiver. The so-called “obstruction in the protected field, movement command inhibited » (Red light on the receiver should remain lit (ON).

Red light ON: obstruction in the protected field. .

Should the green light turn on while the rod is still within the field, do not operate the machine and refer immediately to Amada. Checking operations should also be carried out once adjustments or operating mode changes are completed. Any faults will therefore be detected. NOTE The light guard - as used on this machine - is a low resolution-type device where a 30-mm rod only should be used. As a matter of consequence in such an application , do not use the 14-mm long rod supplied with the machine. Keep it safely to be potentially used later with a high-resolution-type application.

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8.6.5. MAINTENANCE

Remember to :  check the safety sensors on a weekly basis.  check the fixing equipments on emitting/receiving units, the articulated arm , the protective equipment and wirings on a quarterly basis . Since light guards have been designed to protect human beings (Operators and others), it is highly advised to process the checking operations at least once a year. Efficiency and reliability will therefore be reinforced. In that respect, maintenance contracts may be provided by the light guard manufacturer. For further details, please refer to appendix « F » (manufacturer documentation)

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The C4000 receiving cell has 4 operating lights and a 7-segment display:

The 7-segment display is composed of : E System defect. Replace the receiver. 0 1 Poor alignment with emitter. 2 H Operation with the largest range r Operation with reduced resolution and/or desensitizing. Lights Green Red Yellow Orange

Free protection field Start-up command. Obstacle in the protection field, No start-up command. (Blinking) Manual reset needed. Cleaning or alignment need.

Red

The C4000 emitting cell has one operating light and a 7-segment display:

The 7-segment display is composed of : E System defect. Replace the emitter o Equipment in test mode.

Light Yellow

Power supply OK

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8.7. ADJUSTING AKASIII MAINTENANCE

Fig.1

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8.7.1. Transmitter and receiver mechanical adjustment

Position the transmitter and receiver so that the beam is transmitted from the rear, 2.5 mm away from the tool axis and parallel to the tool line. Turn the machine on. Press the emergency stop button. Turn Akas key-switch to « On » position. Break the receiver.

8.7.2. Transmitter adjustment Mount the transmitter in top position. Place both target-marked toolings (D) on the right and left hand-side of the machine and on the first and last distance piece. The adjustment consists in aligning the transmitter beam with the tool line. In that respect, use 3 screws (E) and 2 screws (F) fixed onto the support. During the adjusting operations, check that the plate is continuously fixed with 3 screws (E). Check that the beam is transmitted through 1st marked tooling ; otherwise move the transmitter down. With a level, position the aluminium shape vertically. Check that the beam is aligned with the vertical axis of the 1st marked tooling, otherwise tighten or un-tighten 3 screws (E) until the alignment is obtained. Use a level to check once again that the aluminium shape is vertical. Check the beam position on the 2nd marked tooling so as to be parallel with the tool line ; correct it by adjusting both lower screws located at the rear of the support. Both screws (F) located along the support sides will be used to enable the horizontal adjustment of the beam through its alignment with the same horizontal marking line on both toolings. Block both nuts and lock nuts (C) and 3 nuts (E) while maintaining the adjusting screws in position. Drive the transmitter down and check that the adjustment is correct. The beam should be aligned with both marked toolings in respect with both similar horizontal axes and vertical axis. Remove both marked toolings.

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8.7.3. Receiver adjustment Note the gap between the plate and the rear of the left hand-side support of the machine, apply it on the right hand-side for an approximate adjustment while using a level to ensure that the shape is vertical and check visually that the receiver box is parallel to the bending axis. Position the transmitter in top position. Turn the receiver key-switch to the “ON” fix position. On the receiver, maintain the « RECEIVER UP » button pressed until it is aligned with the transmitter and both units position on the required safety value. Proceed to a very slight adjustment similarly to the transmitter setting so that the beam axis is centred with E3 receiver hole. Block both nuts and lock nuts (C) and 3 nuts (E) while maintaining adjusting screws in position.

8.7.4. Alignment If a punch change implies a change in the distance between the laser beam and the working part of the punch, then the laser height should be modified. Refer to « Setting instructions following a tool change » in the FIESSLER appendix. .

8.7.5. Maintenance The emitter optical windows should be wiped off with a clean and soft cloth at least once a month. The support rod should be lubricated with a proper machine grease every 6 months. AKAS protective equipment provided for press-brakes does not require any servicing, except supports.

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8.8. BACK GAUGE MAINTENANCE 8.8.1. INTRODUCTION This chapter describes the operations required to maintain the qualities and characteristics of your machine. A press brake is exposed to the harsh conditions of a production shop: welding fumes, grinding dust, sheet oil, rust particles, etc. However a modern machine tool like this one is equipped with high-tech precision components: ball screws and guides, notched belt and pulley, proportional hydraulic valves, linear scales, USB, etc. which require periodic maintenance. The frequency of periodic maintenance is based on 8 hours of operation per day under normal working conditions. It must be increased accordingly in the event of production with two or three shifts (16 to 24 hours per day), and does not eliminate the need for maintenance according to condition in the event that oiled or galvanised sheets are used for large production runs.

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8.8.2. MEANS NECESSARY FOR MAINTENANCE. As for the cleaning of the back gauge, use soft clean cloths or preferably single use paper rags specific to hydraulic components. The recommended types of grease are those used at the assembly in factory*. These greases were selected and tested particularly for this application. Their good characteristics of friction reduction, protection against corrosion and temperature limits largely exceeding those of the machine, ensure a reliable operation of the back gauge. Other brands of greases can be used, by checking that the characteristics are the same, while taking into account the miscibility of the lubricants; in this case, contact the manufacturer. Check that adequate greasing equipment are used: - Compatible end pieces of the greasing pump, to the back gauges’ various types of greasing nipples; concave or spherical end. - Greasing pump with dimensions allowing access to the various greasing points. - Greasing pump with known flow capacity in terms of cm3/pump stroke. As guidance, the standard greasing kit, type MG 70 from THK includes an adequate pump, distance tubes and greasing ends pieces. The grease type AFB delivered from THK in cartridges for this kit, is compatible with the original ones used in the factory when the backgauge was assembled.  There are several holes in the protection covers to allow direct access to the greasing points. This avoids dismounting the covers.  For the checking of belts wear, the protection covers can be easily dismounted with a standard Allen wrench. * see maintenance table at the end of chapter..

8.8.3. MONTHLY FREQUENCY 1. With soft cloths, wipe off dust deposit on the back-gauge. 2. General checking: check the correct functioning of the back-gauge, and more specifically: - Any vibration during the operation. - Untightened or missing screws. - Significant wear of the fingers. - Any overload on driving units due to a misalignment of the axes, poor lubrication, etc. - Good condition of the electrical cables and protection guides, of the motors and electrical encoders.

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8.8.4. QUARTERLY FREQUENCY Belt wear : the X and R-axis drive belts are flat and toothed, made of polyurethane reinforced with steel cables. No specific maintenance is necessary ; nevertheless, the gauge will work accurately if the belt is regularly checked ; replace if necessary. Dismount the covers of the X and R axes. Check the wear and pre-loading of the 4 belts. 1. Replace the belt if deeply worn out (when the steel cables can be seen). Mechanical stoppers : 0 reference-setting of the X and R axes is carried whenever turning the machine on. This position is detected by the NC when slightly touching the mechanical stoppers. For accuracy reasons, check that these stoppers are in good condition. Check the stoppers in the front and rear position of X1-X2 axes as well as the upper and lower axes located in the upper part of each R module and the lower part of each R axis ball screw. replace if necessary NOTE Due to the reversibility of the ball screws, working on R-axis belts may provoke the Z crossmember to fall suddenly.

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8.8.5. SEMI-ANNUAL FREQUENCY See the "Maintenance” table, at the end of this chapter, to see the quantities of lubricant to be added. 1. Lubricate both X-axes ball screws at the nut using SKF LGLT2 grease. Lubrication is carried out via the nipple at the rear of R module made of aluminium alloy. Pump in grease until it comes out by the sides of the ball nut. Remove this grease with a cloth, and then clean all the screw. Apply a fine layer of new grease all over the screw. (ref. L1 for A and B-type gauge, ref 13 for C-type gauge. 2. Lubricate both R-axes ball screws using SKF LGLT2 grease. Lubrication is carried out via the nipple through a hole in the aluminium casting and orientated towards the rear of the machine. Pump in grease until it comes out by the sides of the ball nut. Remove this grease with a cloth, and then clean all the screw. Apply a fine layer of new grease all over the screw. (ref. L2 for A and B-type gauge, ref 14 for C-type gauge.) 3. With SKF-LGMT3 grease, lubricate the ball bearings of the X1 and X2 ball screw axes. Lubrication is done on the nipple located the bearing support block, at the rear end of the X aluminium profile. (ref. L6 for A-type gauge, L7 for B-type gauge and ref 15 for Ctype gauge) 4. Clean the guide axes of X, R and Z with a cloth. Check that these axes are in good operating condition, and without any scratch or significant wear-mark. 5. Lubricate X-axes ball bushings using SKF LGMT3 grease. Lubrication is done on the nipples located on the side of the bushing support blocks. (ref. L3 for A and B-type gauge, rep 16 for C-type gauge) 6. Lubricate R-axes ball bushings using SKF LGMT3 grease. Lubrication is done on both nipples at the rear of the aluminium cast R module. (ref. L4) 7. Lubricate the ball bushings of the finger guiding axes using SKF LGMT3 grease. Each finger has 3 nipples, 1 located along the lower beam, 2 to the machine rear. (ref. L5 for A and B-type gauge, ref 17 for C-type gauge) When lubrication is finished, create a program on the numerical controller with maximum displacements on all the axes, and run this for a few minutes to assure a good distribution of the grease. Finally, make an initialisation of the machine, in order to check the good recapture of the positions. This test is also recommended if an end stopper or a belt were replaced or adjusted.

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SERVICING AND MAINTENANCE OPERATOR’S MANUAL HFE M2 – X41176B

L1

X-Axis screw

X-Axis screw

L2 L3

R-Axis screw

X-Axis bushing

L4

Z-Axis bushing

R-Axis bushing

L5

L5

L6

Z-Axis bushing

SERVICING AND MAINTENANCE Chapter 8 OPERATOR’S MANUAL HFE M2 – X41176B

X-screw bearing

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L8

X-screw bearing

L7

L8

L9

L9

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SERVICING AND MAINTENANCE Chapter 8 OPERATOR’S MANUAL HFE M2 – X41176B

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Chapter 8

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SERVICING AND MAINTENANCE Chapter 8 OPERATOR’S MANUAL HFE M2 – X41176B

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A-gauge Frequency

Item

Monthly Monthly Quarterly

L8

Quarterly

L7

Semi-annual

L1

Semi-annual

L2

Semi-annual

L3

Semi-annual

L4

Semi-annual

L5

Semi-annual

L6

Every years

2

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-

Applies to

Product

Wiping off dust Cloths General checking Checking the belts Checking stoppers X-axes screws SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). R-axes screws SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). X-axes ball SKF LGLT2 grease or bushings and equivalent (factory guiding axes mounting). AFB type grease of THK (After Sales Service kit). R-axes ball SKF LGLT2 grease or bushings and equivalent (factory guiding axes mounting). AFB type grease of THK (After Sales Service kit). Z-axes ball SKF LGLT2 grease or bushings and equivalent (factory guiding axes mounting). AFB type grease of THK (After Sales Service kit). X screw bearing SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). Replacement of Solvent, cloths, greases grease

Chapter 8

Quantities

Overflow of the ball screw nut; 3,3 cm3 distributed all over the screw Overflow of the ball screw nut; 1,7 cm3 distributed all over the screw 1,3 cm3 per ball bushing

4,2 cm3 per ball bushing

0,8 cm3 per ball bushing

5,3 cm3 per ball bearing

-

SERVICING AND MAINTENANCE OPERATOR’S MANUAL HFE M2 – X41176B

B-gauge Frequency

Item

Monthly Monthly Quarterly Quarterly Semi-annual

L8 L9 L1

Semi-annual

L2

Semi-annual

L3

Semi-annual

L4

Semi-annual

L5

Semi-annual

L7

Every 2 years

Applies to

Product

Wiping off dust Cloths General checking Checking the belts Checking stoppers X-axes screws SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). R-axes screws SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). X-axes ball SKF LGLT2 grease or bushings and equivalent (factory mounting). guiding axes AFB type grease of THK (After Sales Service kit). R-axes ball SKF LGLT2 grease or bushings and equivalent (factory mounting). guiding axes AFB type grease of THK (After Sales Service kit). Z-axes ball SKF LGLT2 grease or bushings and equivalent (factory mounting). guiding axes AFB type grease of THK (After Sales Service kit). X screw bearing SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). Replacement of Solvent, cloths, greases grease

SERVICING AND MAINTENANCE Chapter 8 OPERATOR’S MANUAL HFE M2 – X41176B

Quantities Overflow of the ball screw nut; 3,3 cm3 distributed all over the screw Overflow of the ball screw nut; 1,7 cm3 distributed all over the screw 1,3 cm3 per ball bushing 4,2 cm3 per ball bushing 0,8 cm3 per ball bushing 5,3 cm3 per ball bearing

-

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C-gauge Frequency

Item

Applies to

Monthly Monthly Quarterly

L8

Quarterly Semi-annual

L7 13

Wiping off dust General checking Checking the belts Checking stoppers X-axes screws

Semi-annual

14

R-axes screws

Semi-annual

15

X-axes ball bushings and guiding axes

Semi-annual

16

R-axes guiding pads/ rails

Semi-annual

17

Z-axes ball bushings and guiding axes

Every years

2

-

Replacement of grease

Product Cloths -

Quantities

-

SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). SKF LGLT2 grease or equivalent (factory mounting). AFB type grease of THK (After Sales Service kit). Solvent, cloths, greases

Overflow of the ball screw nut; 3,3 cm3 distributed all over the screw Overflow of the ball screw nut; 0,8 cm3 distributed all over the screw 4,2 cm3 per ball bushing

1,4 cm3/ per ball bushing; 2,1 cm3/ per ball bushing if grease removed 0,8 cm3 per ball bushing

-

Heavy HA-type back gauge X, R and Z linear guiding: lubricated « once and for all » ; no maintenance necessary

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SERVICING AND MAINTENANCE OPERATOR’S MANUAL HFE M2 – X41176B

8.8.6. EVERY 2 YEARS

To assure a maximum longevity and reliable functioning of the back gauge, it is recommended to clean away any worn grease of ball bushing guide axes, ball-screw and –nuts, and ball bearings. This can be done with an adequate grease solvent, which must not attack the rubber scrapers and plastic housings. Once all worn grease and any impurity removed, dry the parts, and apply new grease, according to the “Maintenance” table.

SERVICING AND MAINTENANCE Chapter 8 OPERATOR’S MANUAL HFE M2 – X41176B

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SERVICING AND MAINTENANCE OPERATOR’S MANUAL HFE M2 – X41176B

9. ERROR MESSAGES LIST

ERROR MESSAGE LIST Chapter 9 OPERATOR’S MANUAL HFE M2 – X41176B

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N° 1

2

Message PLC error.

Cause The PLC is in hold..

Solution Check PLC.

Start the PLC (Programmable Logic Controller)

Fail safe program is stopped.

Turn off and restart; if the problem persists, check that the switch on the controller is in RUN mode.

25

Change in configuration option

26

reserve

28

58

59 60 61 62

63

67

Fault in the machine stop line.

Slow Speed NC output faulty

Change in configuration operated in NC parameters

Turn off the machine then turn on

One of the two channels of the machine stop stayed in close state.

Check for correct operation of the machine stop contact switches. If the LazerSafe option is installed, check the operation of the KAUX1 and 2 relays.

This NC output is not correctly enabled, the transistor on the NC output is either in shortcircuit or stayed open.

Check the output connections. If everything is OK, turn off the press-brake, then turn it on again and reset the Y1 and Y2 axes. If the problem persists, replace the I/O board of the NC.

NC Safety Relay output fault

See fault 58 (NC slow output speed fault). See fault 58 (NC slow NC axis in position (AXP) output speed fault). See fault 58 (NC slow NC ODC output fault output speed fault). See fault 58 (NC slow NC ER output fault output speed fault).

See fault 58 (NC slow speed output fault). See fault 58 (NC slow output speed fault). See fault 58 (NC slow output speed fault). See fault 58 (NC slow output speed fault).

All NC outputs are in short-circuit.

All NC output transistors are in short-circuits or abnormally activated.

Check the output connections. If everything is OK, turn the press-brake off and then on and reset the Y1 and Y2 axes. If the problem persists, replace I/O board of the NC.

Footswitch 2 fault (n.c to 0) at power on.

The normally closed contact of the closing footswitch 2 is abnormally open when PLC unit is turned on.

Check the wiring; replace the contact if necessary.

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Chapter 9

ERROR MESSAGE LIST OPERATOR’S MANUAL HFE M2 – X41176B

N°

68

70

71

72

74 75 125

126

129

130

131

Message

Cause The normally open contact of the closing Footswitch 2 fault (n.o to footswitch 2 is 1) at power on. abnormally close when PLC unit is turned on. The normally open contact of the closing Footswitch 1faulty (n.o to footswitch 1 is 1) at power on abnormally closed when the PLC unit is turned on. The normally closed contact of the closing Footswitch 1 faulty (n.c to footswitch 1 is 0) at power on abnormally open when the PLC unit is turned on. One of the opening Opening footswitch 1 or 2 footswitch is pressed or a faulty at power on. contact is faulty when the PLC unit is turned on. Closing footswitch 1 is Closing footswitch 1 is active at power on. pressed. Closing footswitch 2 is Closing footswitch 2 is active at power on. pressed. The rear gate it is opened The rear gate it is opened. The reset push-button is pressed while the Select operating mode operating mode selector key switch is in stop position. One of the machine stop Machine stop pressed. push button is engaged. When the above-listed fault has been rectified, it Reset machine (machine means that the axes stop had been pressed). concerned are not in fault any longer. The left side gate door is Left hand side gate door open, only adjustment open. mode can be executed.

ERROR MESSAGE LIST Chapter 9 OPERATOR’S MANUAL HFE M2 – X41176B

Solution Check the wiring; replace the contact if necessary.

Check the wiring, replace the contact if necessary.

Check the wiring, replace the contact if necessary.

Check the wiring, replace the contact if necessary. Release the footswitch and reset the fault. Release the footswitch, reset the fault. Close the rear gate Select an operating mode, then reset by pressing push-button. Release the concerned machine stop button. Press reset push-button and restart. If the selected operating mode is not adjustment mode, close the door then reset.

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N°

132

133

134

135 137 138

139

140

141

142

143

144

Message

Cause When the above-listed fault has been corrected, it Reset the machine (Side means that the axes gate doors opened). concerned are not in fault any longer. The right side gate door is Right hand side gate door open, only the adjustment open. mode can be executed. Both side gate doors are open.

Both side gate doors are open.

Every time tool holder is Tools holder unclamped. unclamped, it will initiate a machine stop. Reset the machine (Two Each change in mode will operators mode enabled). initiate a machine stop. Reset the machine A new operating mode is (Single operator mode activated. enabled). Reset the machine (robot This new operating mode is mode enabled during activated. beam movement). Reset the machine (robot This new operating mode is mode disabled during activated. beam movement). If the switch is in 1 operator position, it may be Reset the machine (1 dangerous when both operator, 2 footswitches footswitches are enabled. mode enabled) Operator may forget to switch over to 2 operators mode. When the robot mode is Operating mode non enabled (if robot option compatible with the available), the light guard robot. modes are disabled. Reset the machine; pedal Pedal operating mode operating mode enable. enable Reset the machine (>30 In light guard operated seconds since the last mode, the press-brake was light guard operated inoperative for more than cycle). 30 seconds.

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Chapter 9

Solution Press reset push-button and restart. If the selected operating mode is not adjustment mode, close the door then reset. Opening both doors at the same time is prohibited. Close one of the door then reset to operate in adjustment mode. Clamp tool holders. Reset by pressing push-button Reset by pressing push-button

Reset by pressing push-button

Reset by pressing push-button

Select 2 operators mode and reset.

Change the operating mode and reset. Reset by pressing push-button

Reset by pressing push-button.

ERROR MESSAGE LIST OPERATOR’S MANUAL HFE M2 – X41176B

N°

145

146 148 149 150 151 152 153 154 155 156 157

166

167

168

169

170

Message

Cause In one of the light guard Reset the machine (light operated modes, during the guard broken during high high speed closing phase, speed approach). the light guard has been broken. When the machine is ready Reset the machine. (no fault), but not yet been reset. New working mode is Reset (adjustment mode) enabled. Reset (light guard New working mode is protection) enabled. New working mode is Reset (robot control) enabled. Reset (single passingNew working mode is through mode + footswitch) enabled. Reset (double passingNew working mode is through mode + footswitch) enabled. Reset (single passingNew working mode is through mode) enabled. Reset (double passingNew working mode is through mode) enabled. Reset (robot adjustment New working mode is mode) enabled. Reset (adjustment mode New working mode is enabled) enabled. Reset (production mode New working mode is enabled) enabled. When laser beam Working mode non protection is installed, only compatible with Laser setting and production beam protection. modes can be selected When machines are in Working mode non tandem configuration, only compatible with Tandem setting and production machine configuration. modes can be selected. When machines are in Side gate open. tandem configuration, side gates must remain closed. Whenever separator is Reset machine (SOLO installed on a tandem mode enabled) machine, it will initiate a machine stop . Whenever separator is Reset machine (TANDEM removed on a tandem mode enabled) machine, it will initiate a machine stop .

ERROR MESSAGE LIST Chapter 9 OPERATOR’S MANUAL HFE M2 – X41176B

Solution

Press reset push-button.

Press reset push-button. Reset with the push-button. Press reset push-button. Press reset push-button. Press reset push-button. Press reset push-button. Press reset push-button. Press reset push-button. Press reset push-button. Press reset push-button. Press reset push-button. Change operating mode and reset.

Change operating mode and reset.

Close side gates and reset.

Press reset push-button to start machine in SOLO mode.

Press reset push-button to start machine in TANDEM mode.

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N° 245

246

247

248

249

251

252

253

254

256

257

Message Attente sortie parking accompagnateur N°1

Problem L’accompagnateur N°1 n’est pas complètement sorti de la zone parking Attente sortie parking L’accompagnateur N°2 n’est pas accompagnateur N°2 complètement sorti de la zone parking Attente mise en parking L’accompagnateur N°1 n’est pas accompagnateur N°1 complètement positionné dans la zone parking Attente mise en parking L’accompagnateur N°2 n’est pas accompagnateur N°2 complètement positionné dans la zone parking In « alternate production mode », once the press-brake has been Break light curtain, then turned on or during the first cycle in this mode, break the light reset the machine to curtain to ensure correct operation authorize high speed of the light guard. If this operation approach. is not performed, the press-brake will operate in working speed. If the closing of the press-brake in Control device is light this mode is authorized by the guard. Footswitches light guard, pressing either disabled footswitch produces this message. This message indicates that only footswitch 1 can close the pressFootswitch 1 selected. brake. It is displayed when footswitch 2 is pressed. This message indicates that only footswitch 2 can close the pressFootswitch 2 selected. brake. It is displayed when footswitch 1 is pressed. This message is displayed when Delay between pressing de-synchronisation time between the two footswitches the two footswitches is > 4 exceeded. seconds. Once the press-brake has been turned on, machine reset can only be carried out using both Two-operator mode footswitches if the two operators enabled. mode has been enabled. This message avoid searches for nonexisting faults. This message appears in 2 operators mode to specify that Footswitch 2 is in stand-by footswitch 1 has been activated position. and machine is waiting for 2nd footswitch command to close the

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Chapter 9

Solution Sortir l’accompagnateur N°1 de la zone de parking Sortir l’accompagnateur N°2 de la zone de parking Positionner l’accompagnateur N°1 en zone parking Positionner l’accompagnateur N°2 en zone parking

Break the light guard.

Close the press-brake by breaking the light guard.

Release footswitch 2 and press footswitch 1.

Release footswitch 1 and press footswitch 2. Release both footswitches then press them within 4 seconds at the most.

Close the press-brake by pressing both footswitches, the message disappears once the press-brake has been reset.

Press footswitch 2.

ERROR MESSAGE LIST OPERATOR’S MANUAL HFE M2 – X41176B

press-brake. N°

258

270

295

300

301 310

Message

Problem Solution This message appears in 2 operators mode to specify that footswitch 2 has been Footswitch 1 is in stand-by activated and machine is Press footswitch 1. position. waiting for 1st footswitch command to close the press-brake. Running in mode active. When LazerSafe is Stop range check, press switched on, it is close foot pedal until ram mandatory to launch the Press closing foot pedal stops press brake stop distance check The stopping distance is too large or the closing Error during stop range, foot pedal has been Press opening foot pedal press open foot pedal released during the slow speed closing The stop range check cam Cam check range stop too Check limit switch and cam has been modified or long positions damaged Faulty « PV » out put from PV output fault of AKASIII AKASIII receiver Check 4V line

600

PLC error F06

601

I0.xx input error

602

I0.00 to I0.15 input error

603

I0.16 to I0.31 input error

604

I1.xx or I1.09.xx input error

605

I1.xx input error

PLC unit in stop.

Remplace PLC unit. Check the input cables at I0.xx or use ohm meter and Many errors at input I0.xx electric schematics to trace the fault. Check the input cables at Many errors at the inputs I0.xx or use ohm meter and I0.00 to I0.15 electric schematics to trace the fault. Check the input cables at Many errors at the inputs I0.xx or use ohm meter and I0.16 to I0.31 electric schematics to trace the fault. Check the input cables at Many errors at the inputs I1.xx or use ohm meter and I1.xx electric schematics to trace the fault. Check the input cables at Many errors at the inputs I1.xx or use ohm meter and I1.x electric schematics to trace the fault.

ERROR MESSAGE LIST Chapter 9 OPERATOR’S MANUAL HFE M2 – X41176B

7/12 Issue 05/2010

N° 607

608

609

612

613

614

615

616

617

618

619

620

Message

Solution Check the outputs Tx or Many errors at the outputs O2.xx or use ohm meter and Tx or O2.xx output error Tx or O2.xx electric schematics to trace the fault. Check the outputs Tx or Tx or O2.8 to O2.15 output Many errors at the outputs O2.8 to O2.15 or use ohm error Tx or O2.8 to O2.15 meter and electric schematics to trace the fault. Check the outputs O1.6 or Many errors at the outputs O1.7 or use ohm meter and O.16 or O2.17 output error O1.6 or O1.7 electric schematics to trace the fault. Check the input cables at I0.0 or use ohm meter and I0.0 input error Input error I0.0 electric schematics to trace the fault. Check the input cables at I0.1 or use ohm meter and I0.1 input error Input error I0.1 electric schematics to trace the fault. Check the input at I0.2 or use I0.2 input error I0.2 input error ohm meter and electric schematics to trace the fault. Check the input wiring at I0.3 or use ohm meter and I0.3 input error I0.3 input error electric schematics to trace the fault. Check the input wiring at I0.4 or use ohm meter and I0.4 input error I0.4 input error electric schematics to trace the fault. Check the input wiring at I0.5 or use ohm meter and I0.5 input error I0.5 input error electric schematics to trace the fault. Check the input wiring at I0.6 or use ohm meter and I0.6 input error I0.6 input error electric schematics to trace the fault. Check the input wiring at I0.7 or use ohm meter and I0.7 input error I0.7 input error electric schematics to trace the fault. I0.8 input error

8/12 Issue 05/2010

Problem

I0.8 input error

Chapter 9

Check the input wiring at I0.8 or use ohm meter and electric schematics.

ERROR MESSAGE LIST OPERATOR’S MANUAL HFE M2 – X41176B

N°

Message

Problem

621

I0.9 input error

I0.9 input error

622

I0.10 input error

I0.10 input error

623

I0.11 input error

I0.11 input error

624

I0.12 input error

I0.12 input error

625

I0.13 input error

I0.13 input error

626

I0.14 input error

I0.14 input error

627

I0.15 input error

I0.15 input error

644

I1.0 input error

I1.0 input error

645

I1.1 input error

I1.1 input error

646

I1.2 input error

I1.2 input error

647

I1.3 input error

I1.3 input error

648

I1.4 input error

I1.4 input error

649

I1.5 input error

I1.5 input error

650

I1.6 input error

I1.6 input error

651

I1.7 input error

I1.7 input error

ERROR MESSAGE LIST Chapter 9 OPERATOR’S MANUAL HFE M2 – X41176B

Solution Check the input wiring at I0.9 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.10 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.11 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.12 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.13 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.14 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.15 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.0 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.1 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.2 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.3 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.4 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.5 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.6 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.7 or use ohm meter and electric schematics to trace the fault.

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N°

Message

Problem

652

I1.8 input error

I1.8 input error

653

I1.9 input error

I1.9 input error

672

O/T 2.0 impulsive output error

Pulse output error: wiring or impedance problem.

673

O/T 2.1 impulsive output error

Pulse output error: wiring or impedance problem.

674

O/T 2.2 impulsive output error

Pulse output error: wiring or impedance problem.

675

O/T 2.3 impulsive output error

Pulse output error: wiring or impedance problem.

676

O2.8 output error

677

O2.9 output error

678

O2.10 output error

679

O2.11 output error

680

O2.12 output error

681

O2.13 output error

682

O2.14 output error

683

O2.15 output error

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Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem.

Chapter 9

Solution Check the input wiring at I1.8 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I1.9 or use ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault. Check the output wiring using ohm meter and electric schematics to trace the fault.

ERROR MESSAGE LIST OPERATOR’S MANUAL HFE M2 – X41176B

N°

Message

Problem

688

I3.0 (test sec LS) input error

689

I3.1 (test LED) input error I3.1 input error.

690

I3.2 (nc) input error

I3.2 input error.

691

I3.3 (nc) input error

I3.3 input error.

692

I3.4 (nc) input error

I3.4 input error.

693

I3.5 (nc) input error

I3.5 input error.

700

Erreur sortie TEST PULSE O2.00

701

Erreur sortie TEST PULSE O2.01

702

Erreur sortie TEST PULSE O2.02

703

Output error TEST PULSE O2.03

704

O2.16 output error

705

O2.17 output error

706

O2.18 output error

707

Output error O2.16 to O2.18

708

I3.00 à I3.95 input error

Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Single channel output error: wiring or impedance problem. Redundant output error: wiring or impedance problem. Redundant output error: wiring or impedance problem. Redundant output error: wiring or impedance problem. Redundant output error: wiring or impedance problem. several errors on I3.00 to I3.95 input

I3.0 input error.

ERROR MESSAGE LIST Chapter 9 OPERATOR’S MANUAL HFE M2 – X41176B

Solution Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the output wiring using ohm meter and electric schematics. Check the output wiring using ohm meter and electric schematics. Check the output wiring using ohm meter and electric schematics Check the output wiring using ohm meter and electric schematics. Check the output wiring using ohm meter and electric schematics. Check the output wiring using ohm meter and electric schematics. Check the output wiring using ohm meter and electric schematics. Check the output wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics.

11/12 Issue 05/2010

N° 710

Message I3.00 input error

Cause I3.00 input error

711

I3.01 input error

I3.01 input error

712

I3.02 input error

I3.02 input error

713

I3.03 input error

I3.03 input error

714

I3.04 input error

I3.04 input error

715

I3.05 input error

I3.05 input error

12/12 Issue 05/2010

Chapter 9

Solution Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics. Check the input wiring using ohm meter and electric schematics.

ERROR MESSAGE LIST OPERATOR’S MANUAL HFE M2 – X41176B

APPENDIX TO CHAPTER 8

APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B

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2/8 Issue 05/2010

APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B

APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B

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APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B

APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B

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APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B

APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B

7/8 Issue 05/2010

8/8 Issue 05/2010

APPENDIX TO CHAPTER 8 OPERATOR’S MANUAL HFE M2 – X41176B