HYDRAULIC PRESS BRAKE

OPERATORS MANUAL
X40882E

BP 40040 95912 Roissy aroport CDG cedex Tel.: +33 (0)1 49 90 30 00, Fax: +33 (0)1 49 90 31 99

Issue 09/2003

Index A

Issue 02/2000

Updated by

Details of revision First issue of HF Medium Tonnage operators manual

07/2001

O. Nossa

C 02/2002 M. Ahmed

Consideration taken for NC CD2000 . Maintenance relating to optional and modular elements now being transferred in the relating appendices. Complete proof reading of the manual.

Insertion of missing data in the tables in Chapter 2, pages 15 16 & 19 for AIF. Update to cater for common electric cabinet. Suppression of the SA2 key selector switch. Auxiliary function F5 replace it now. - SA1 key selector switch is now replaced by a selector switch without key. - Addition of 320 and 400 T machines in middle tonnage range. Ch. 3 pages 6 to 9. Ch. 4 pages 9 to 11. Ch. 6 pages 3 to 7, 9 and 10.

12/2002

M. Ahmed

09/2003

Ph. Jacquet

Updated, add the Akas option, controls panels and USA machines cycles.

Read the manual carefully to obtain a thorough knowledge of this machine. Strictly follow the installation, operating and maintenance instructions given in this manual to avoid the risk of operator injury and damage to the press brake. Keep this document to hand, and refer to it whenever necessary. 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 HF MEDIUM TONNAGE OPERATORS MANUAL X40882E

LIST OF ADDENDA Modification coming from Reason Destination Application

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HYDRAULIC PRESS BRAKE OPERATORS MANUAL

IMPORTANT NOTE
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 can 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 On 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.

FOR ALL PROBLEMS DURING MACHINE INSTALLATION Telephone ? .................................................. +33 (0)1 49 90 30 00 Fax ? ............................................................. +33 (0)1 49 90 31 99

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CONTENTS HF MEDIUM TONNAGE OPERATORS MANUAL X40882E

CONTENTS
1. GENERAL DESCRIPTION................................................................................................ 1 1.1. DESCRIPTION ............................................................................................................... 3 1.2. PRINCIPLE ..................................................................................................................... 5 2. ACCEPTANCE, INSTALLATION AND SAFETY MEASURES .................................. 1 2.1. GENERAL INFORMATION.......................................................................................... 3 2.1.1. MARKING ............................................................................................................... 3 2.2. PREPARING THE SITE................................................................................................. 7 2.2.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED .......... 9 2.2.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED ................... 10 2.2.3. LONG STROKE WITH STANDARD SPEED ..................................................... 11 2.3. MACHINE RECEPTION.............................................................................................. 12 2.4. RECEPTION & HANDLING ....................................................................................... 13 2.4.1. LIFTING................................................................................................................. 13 2.4.2. BASIC PRINCIPLES ............................................................................................. 15 2.4.3. EQUIPMENT ......................................................................................................... 25 2.4.4. SPECIAL PARTS FOR TRANSPORT ................................................................. 26 2.5. ELECTRICAL CONNECTIONS.................................................................................. 28 2.5.1. GENERAL CHARACTERISTICS OF THE MAINS SUPPLY ........................... 28 2.5.2. EARTH................................................................................................................... 28 2.5.3. MAINS-RELATED AND ENVIRONMENT-RELATED INTERFERENCE...... 29 2.5.4. POWER SUPPLY CABLE CHARACTERISTICS............................................... 31 2.6. WORKSTATION LIGHTING...................................................................................... 32 2.7. SAFETY PRECAUTIONS............................................................................................ 33 2.7.1. GENERAL POINTS .............................................................................................. 33 2.7.2. REGULAR INSPECTION AND SAFETY POLICY............................................ 38 2.7.3. ARRANGEMENT OF WORKSTATIONS........................................................... 39 2.7.4. CONTROL DEVICES ........................................................................................... 41 2.7.5. RULES FOR SAFE OPERATION ........................................................................ 43
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2.8. MACHINES OPERATING AND STORAGE CONDITIONS................................... 50 2.9. MACHINE CHARACTERISTICS ............................................................................... 51 2.9.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED ........ 51 2.9.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED ................... 52 2.9.3. LONG STROKE WITH STANDARD SPEED ..................................................... 53 2.10. INFORMATION ON NOISE...................................................................................... 54 2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS....................................... 55 3. COMMISSIONING.............................................................................................................. 1 3.1. CLEANING..................................................................................................................... 2 3.2. INSTALLATION OF CONTROL DEVICES ................................................................ 2 3.3. CHECKING THE MAINS POWER SUPPLY ............................................................... 4 3.4. MACHINE LEVELLING ............................................................................................... 4 3.5. PUTTING THE MACHINE INTO OPERATION ......................................................... 5 3.6. OVERALL CHECK ........................................................................................................ 6 4. TECHNICAL DESCRIPTION ........................................................................................... 1 4.1. MECHANICAL STRUCTURE ...................................................................................... 3 4.2. MECHANICAL CONNECTIONS ................................................................................. 4 4.3. ELECTRONIC STROKE CONTROL AND PARALLELISM BALANCING ............. 6 4.3.1. ELIMINATING SOURCES OF ERROR ................................................................ 9 4.3.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY 9 4.3.3. PRECISE CENTRING OF THE BEAMS ............................................................. 10 4.4. LOCATION OF CONTROL AND SIGNALLING DEVICES .................................... 11 4.5. PRESS BRAKE OPERATING LIMITS IN OFF-CENTRE WORK ........................... 12 4.6. PRESSURE GAUGE .................................................................................................... 12

5. FORMING TECHNIQUE & TOOLING........................................................................... 1

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5.1. GENERAL POINTS........................................................................................................ 3 5.2. AIR BENDING ............................................................................................................... 7 5.3. COINING ........................................................................................................................ 8 5.4. LIST OF STANDARD TOOLS ...................................................................................... 9 5.5. TOOL INSTALLATION .............................................................................................. 11 5.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM .......................................... 11 5.5.2. AMACLIP PUNCH CLAMPING SYSTEM ..................................................... 15 5.5.3. EXPERT CLAMPING SYSTEM MANUAL VERSION (OPTION) .......... 20 5.5.4. EXPERT PNEUMATIC CLAMPING SYSTEM AUTOMATIC VERSION (OPTION)......................................................................................................................... 23 5.5.5. TOOLING INSTALLATION PROCEDURE ....................................................... 25 5.6. OPTIONS AND ACCESSORIES ................................................................................. 30 5.7. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES ............................ 31 5.8. PUNCHING................................................................................................................... 36 6. OPERATION ........................................................................................................................ 1 6.1. START-UP ...................................................................................................................... 2 6.2. DESCRIPTION OF CYCLES (OUT OF US MARKET).............................................. 3 6.2.1. LAYOUT OF CONTROLS PANELS ..................................................................... 4 6.2.2. DESCRIPTION OF CONTROL AND SIGNALLING DEVICES ....................... 11 6.2.3. BASIC VERSION OF MACHINE (WITHOUT LIGHT GUARD OR LAZERSAFE OPTION) 13 6.2.4. MACHINE EQUIPPED WITH SICK LIGHT GUARD OPTION........................ 16 6.2.5. MACHINE EQUIPPED WITH LASER BEAM OPTION.................................... 16 6.1. MOBILE EMERGENCY STOP ................................................................................... 19 6.2. START-UP .................................................................................................................... 19 6.3. DESCRIPTION OF CYCLES....................................................................................... 20 6.2.6. LAYOUT OF CONTROLS PANELS ................................................................... 21 6.3.1. BASIC VERSION MACHINE (WITHOUT LIGHT GUARD)............................ 23 6.3.2. MACHINE VERSION WITH LIGHT GUARD.................................................... 24 6.3.3. MACHINE VERSION WITH TWO HAND CONTROL OPTION ONLY ......... 25 6.3. LISTE DES MESSAGES AUTOMATE ...................................................................... 28 6.3.1. MACHINE FAULT MESSAGES.......................................................................... 28 6.3.2. MACHINE STATUS MESSAGES ....................................................................... 47
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6.3.3. OPERATOR MESSAGES ..................................................................................... 51

7. MAINTENANCE.................................................................................................................. 1 7.1. INTRODUCTION ........................................................................................................... 2 7.2. MACHINE PERIODIC MAINTENANCE..................................................................... 5 7.2.1. CHECKS SPECIFIC TO THE HYDRAULIC INSTALLATION .......................... 8 7.2.2. OIL CHANGES...................................................................................................... 11 7.2.3. FILLING PROCEDURE........................................................................................ 11 7.3. RECOMMENDATIONS............................................................................................... 12 7.3.1. SPECIFIC DAILY TEST PROCEDURE .............................................................. 13 7.4. TROUBLESHOOTING ................................................................................................ 26 7.4.1. TROUBLESHOOTING TABLE ........................................................................... 26 7.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL POINTS ............................................................................................................................ 27

APPENDIX A PROGRAMMING MANUAL APPENDIX B MACHINE SCHEMATICS AND LISTING (see in the electric cabinet of the machine) APPENDIX C BACKGAUGE APPENDIX D SPECIAL MACHINES APPENDIX E OPTIONS APPENDIX F SUPPLIERS DOCUMENTATION

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APPENDICES

IMPORTANT NOTE

Quality Control department completes this technical manual by adding certain number of appendices relating to the options & accessories supplied with the machine i.e. the supplied manual complies fully with your machine. 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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1. GENERAL DESCRIPTION

GENERAL DESCRIPTION Chapter 1 HF MEDIUM TONNAGE OPERATORS MANUAL X40882E

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Figure 1.1

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Chapter 1 GENERAL DESCRIPTION HF MEDIUM TONNAGE OPERATORS MANUAL X40882E

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: - HFx 130 - HFx 170 - HFx 220 - HFx 320 - HFx 400
1

(130 tons / 3, 4 meters) (170 tons / 3, 4, 4.5 meters) (220 tons / 3, 4, 6 meters) (320 tons / 4, 6 meters) (400 tons / 4, 6 meters)

All models are delivered: In a basic version without light curtain, Equipped with a A, B or TF800-type back gauge In option: - light curtain, which is used as front protection and as an operation cycle control device or - a laser beam 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.

x is added to specify the level of equipment provided on your machine (T, E, P). 3/8 Issue 09/2003

GENERAL DESCRIPTION Chapter 1 HF MEDIUM TONNAGE OPERATORS MANUAL X40882E

Figure 1.2 F1 and F1 = Bending force A and A = Counter acting points

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1.2. PRINCIPLE This hydraulic press brake is load/unload manually. HF hydraulic press brakes are down stroking machines equipped with a numerical controller for 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 a variety of options (back gauge, front gauge, etc.), all Amada range of tools, and other traditional tools, as well as a range of accessories. (Contact our Regional Sales Representative to discuss your specific requirements.)

For items, heavier than 25 kg, a handling device must be provided for the operator. This device is not included in the Amada supply (see 5.5).

REVIEW OF THE CONVENTIONAL DESIGN OF PRESS BRAKES Traditional press brakes with an operating upper beam exhibit an elastic deformation during bending in opposite directions on each beam due to the reactions of the part under the thrust of the jacks located at the ends. These deformations are detectable by slightly less penetration of the punch in the die in the centre than at the ends (Fig. 1.2).

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AMADA SYSTEM 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 machines 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 Because the small but inevitable elastic deformation of the two beams occurs in the same direction and has the same value, the punch has constant penetration in the die over the entire bending length, thus ensuring a perfect angle. The small deformation of the beams does not affect the linearity of the bend because the stress induced in the worksheet remains well within the elastic region. Up to 220 tons

B A

Fig. 1.3

Valid for 320 and 400 tons

Fig. 1.3

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

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2. ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

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2.1. GENERAL INFORMATION 2.1.1.MARKING The marking on your press-brake corresponds to the following specifications : a) b) c) d) e) f) g) h) i) Name and address of the manufacturer. Type of machine. Serial number. Date machine is manufactured. Weight of the press-brake without any tooling or sub-equipment. If needed, weight of the main parts and sub-equipment to be removed with lifting devices. A specific marking will then be affixed on these items. Maximum tonnage. Data concerning the electric, hydraulic and pneumatic supplies. A specific marking will then be attached to the optional equipments. 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. Warning on residual risks.

j)

On HFT

+ -

+ j

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On HFE

+ -

+ j

On HFP

+ -

+ j

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k) Overall stroke of the beam. l) Noise level (acoustic pressure).

TEMPS DE REPONSE TOTAL DU SYSTEME OVERALL SYSTEM RESPONSE TIME REAKTIONSZEIT DISTANCE MINI DE SECURITE MINIMUM SEPARATION DISTANCE KLEINSTER SICHERHEITSABSTAND DIAMETRE DU BARREAU TEST TEST PIECE DIAMETER PRF STABDURCHMESSER

100

ms

Plate for a machine equipped with a light guard (option) i

350

mm

30

mm

Plate for a machine with laser beam protection LazerSafe model.

Plate for a machine with laser beam protection Akas model.

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m) Warning regarding use of high speed machines (concern only high speed version machines). GB WARNING FOR HIGH SPEED OPERATION The safety of the operator during approach speed is given by the Light Guard. This should be muted at the sequence point when the machine changes to bending speed and should give an operating gap of no more than 6mm. If special double action tooling is used such as Hemming Tools and the gap between any part of the tooling is greater than 6mm, the bending speed should be set at 10mm/sec or less. F AVERTISSEMENT POUR LUTILISATION EN GRANDE VITESSE La protection de loprateur est assure par le rideau lumineux pendant la phase dapproche grande vitesse. Le rideau doit tre inhib au point de mute (au moment o la machine arrive sa vitesse de travail) et quand la distance entre la tle et lextrmit de contre v nest pas suprieure 6 mm. Si les outils spcifiques sont utiliss (outil superpos craser) et que lespace entre les parties des outils est suprieur 6 mm, la vitesse de travail doit tre rgle 10 mm/s ou moins. D WARNUNG BEIM BETREIBEN VON HIGH SPEED PRESSEN Die Sicherheit des Bedieners wird whrend der Zustellbewegung durch einen Lichtvorhang gewhrt. Dieser wird am Umschaltpunkt ausgeschaltet, wenn die Maschine in die Arbeitsgeschwindigkeit wechselt und kein grerer Spalt zwischen Stempel und Matrize als 6 mm ist. Wenn besondere Doppelfunktionswerkzeuge wie z.B. Zudrckwerkzeuge benutzt werden under Spalt zwischen Stempel und Matrize grer als 6 mm ist, mu die Arbeitsgeschwindigkeit auf weniger als 10 mm/sec gesetzt werden. I AVVERTENZA PER LIMPIEGO AD ALTA VELOCIT Durante la discesa veloce di avvicinamento, la sicurezza delloperatore garantita della barriere ottiche. Queste vengono escluse quando si raggiunge il punto di cambio velocit (la discesa rallenta alla velocit di piega): in tale condizione la distanza tra lamiera e punzone non deve superare i 6 mm. Se si utilizzano stampi speciali (piega e schiaccia), in cui la corsa superiore a 6 mm, occorre impostare una velocit di lavoro non superiore a 10 mm/s.

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2.2. 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. The press brake must be accessible from all four sides: At the rear, provide a clearance of approximately 1 metre to allow various maintenance operations and backgauge adjustment to be performed. 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. Provide sufficient clearance so that the electric cabinet door can be opened freely for various maintenance work.

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Figure 2.1 - Layout of the machine given as an example

Figure 2.2
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2.2.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED

Description Standard speed High speed With CD 2000 (HFT) With OP 2000 (4) (HFE) With AMNC (5) (HFP) With CD 2000 (3) (HFT) With OP 2000 (4) (HFE) With AMNC (5) (HFP) Height (overall) Machine weight (overall) (6) Distance between uprights Thickness of the sideframe Uprights centre to centre dimension Lenght (overall) (1) Width (overall) (2) MODELS HF 130-30 HF 130-40 HF 170-30 HF 170-40 HF 170-45 HF 220-30 Units HF 130-30 S HF 130-40 S HF 170-30 S HF 170-40 S HF 220-30 S mm mm mm mm mm mm mm Kg mm mm mm 3 995 4 206 4 503 2 020 2 576 2 715 2 820 8 150 2 700 40 2 740 5 055 5 266 5 563 2 020 3 576 2 715 2 900 11 300 3 760 40 3 800 4 025 4 236 4 533 2 020 2 581 2 720 2 900 11 600 2 700 55 2 755 5 085 5 296 5 593 2 020 2 581 2 720 2 920 13 900 3 760 55 3 815 5 375 5 586 5 883 2 020 2 581 2 720 2 920 14 800 4 050 55 4 105 3 055 4 264 4 563 2 020 2 586 2 725 2 940 13 750 2 700 70 2 770 HF 220-40 HF 220-40 S 5 115 5 326 5 623 2 020 2 586 2 725 3 100 17 100 3 760 70 3 830

(1) (2) (3) (4) (5) (6)

The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. The dimensions are with the arm and the NC maximum extended in front, and all doors closed. With light guard, add 140mm to this dimension. With a laser beam protection, add 100mm to this dimension. For transport, reduce by 140mm. For transport, reduce length by 256mm and width by 380mm. For transport, reduce length by 553mm and width by 580mm. Add to the machine weight, depending on the options, corresponding weight from the following table :

HF MT

Material Description
AMACLIP sectionalised distance pieces Sick light guard system LazerSafe system Akas system Fixed front table/support Single manual finger stop assembly Programmable front table Work follower Single arm Work follower Twin arms Work follower Single arm + Parking Work follower Twin arms + Parking Sick light guard system for Parking WILA hydraulic clamping

Units
Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg

3m
13 250 90 40 14 12 240 480 680 660 860 280 160

4m
17 250 90 40 14 12 280 520 720 700 900 280 200

4.50 m
18 250 90 40 14 12 300 540 740 720 920 280 216

6m
24 250 90 40 14 12 360 600 800 780 980 280 280

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2.2.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED

With OP2000 (4) (HFE) With AMNC (5) (HFP) Height (overall) Machine weight (overall) (6) Distance between uprights Thickness of the sideframe Uprights centre to centre dimension
(1) (2) (3) (4) (5) (6)

Width (overall) (2)

Description Standard speed High speed With CD 2000 (HFT) With OP2000 (4) (HFE) With AMNC (5) (HFP) With CD2000 (3) (HFT)

MODELS
Units HF 130-30L HF 130-30LS HF 130-40L HF 130-40LS HF 170-30L HF 170-30LS HF 170-40L HF 170-40LS HF 220-30L HF 220-30LS HF 220-40L HF 220-40LS HF 220-60L HF 220-60LS

Length (overall) (1)

mm mm mm mm mm mm mm Kg mm mm mm

3 995 4 206 4 503 2 020 2 576 2 715 3 140 9 000 2 700 40 2 740

5 055 5 266 5 563 2 020 3 576 2 715 3 120 12 000 3 760 40 3 800

4 025 4 236 4 533 2 020 2 581 2 720 3 140 12 400 2 700 55 2 755

5 085 5 296 5 593 2 020 2 581 2 720 3 150 14 500 3 760 55 3 815

3 055 4 264 4 563 2 020 2 586 2 725 3 150 14 800 2 700 70 2 770

5 115 5 326 5 623 2 020 2 586 2 725 3 270 18 000 3 760 70 3 830

6 776 7 073 2 741 2 880 3 840 30 000 5 210 70 5 280

The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. The dimensions are with the arm and the NC maximum extended in front, and all doors closed. With light guard, add 140mm to this dimension. With a laser beam protection, add 100mm to this dimension. For transport, reduce by 140mm. For transport, reduce length by 256mm and width by 380mm. For transport, reduce length by 553mm and width by 580mm. Add to the machine weight, depending on the options, corresponding weight from the following table :

HF MT

Material Description
AMACLIP sectionalised distance pieces Sick light guard system LazerSafe system Akas system Fixed front table/support Single manual finger stop assembly Programmable front table Work follower Single arm Work follower Twin arms Work follower Single arm + Parking Work follower Twin arms + Parking Sick light guard system for Parking WILA hydraulic clamping

Units
Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg

3m
13 250 90 40 14 12 240 480 680 660 860 280 160

4m
17 250 90 40 14 12 280 520 720 700 900 280 200

4.50 m
18 250 90 40 14 12 300 540 740 720 920 280 216

6m
24 250 90 40 14 12 360 600 800 780 980 280 280

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2.2.3. LONG STROKE WITH STANDARD SPEED

Description With CD2000 Length (1) L
(HFT)

Units mm mm mm mm mm mm mm Kg mm mm mm

MODELS HF 320-4 L 4 395 4 980 5 150 2 100 2 541 2 680 3 410 24 000 3 230 80 3 310 HF 400-4 L 4 395 4 980 5 150 2 100 2 541 2 680 3 410 24 000 3 230 80 3 310 HF 320-6 L 6 395 6 980 7 150 2 100 2 541 2 680 4 035 36 000 5 230 80 5 310 HF 400-6 L 6 395 6 980 7 150 2 100 2 541 2 680 4 035 36 000 5 230 80 5 310

With OP2000
(4) (HFE)

With AMNC (5) (HFP) With CD2000 (3) (HFT) With OP2000 (4) (HFE) With AMNC (5) (HFP) Height machine H Machine weight (overall) (6) Distance between uprights Thickness of the sideframe Uprightscentre to centre dimensions
(1) (2) (3) (4) (5) (6)

Width (2) P

The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. The dimensions are with the arm and the NC maximum extended in front, and all doors closed. With light guard, add 140mm to this dimension. With a laser beam protection, add 100mm to this dimension. For transport, reduce by 140mm. For transport, reduce length by 256mm and width by 380mm. For transport, reduce length by 553mm and width by 580mm. Add to the machine weight, depending on the options, corresponding weight from the following table : HF HT

Material Description
AMACLIP sectionalised distance pieces Sick light guard system LazerSafe system Akas system Fixed front table/support Single manual finger stop assembly Programmable front table Work follower Single arm Work follower Twin arms Work follower Single arm + Parking Work follower Twin arms + Parking Sick light guard system for Parking WILA hydraulic clamping

Units
Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg Kg

4m
17 250 90 40 14 12 N/C N/C N/C N/C N/C N/C N/C

6m
24 250 90 40 14 12 N/C N/C N/C N/C N/C N/C N/C

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2.3. MACHINE RECEPTION 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 support arm,* Mechanical guards, C frame (Goosenecks), Machine covers, Backgauge.

Refer to Section 2.3 to identify the recommended floor support areas.

IMPORTANT NOTE 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 2.3

* With NC type : OPERATEUR 2000 and AMNC.

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2.4. RECEPTION & HANDLING 2.4.1. LIFTING Before the vehicle arrives, it is customers responsibility to provide a crane with sufficient capacity to unload the press brake from the vehicle and ensure that the access doors are sufficiently tall 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 (see fig. 2.4). 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 the responsibility of Amada.

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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

Figure 2.4
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2.4.2. 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).

Centre of gravity Machine type 130-3 130-4 170-3 170-4 170-4.5 220-3 220-4 130-3 L 130-4 L 170-3 L 170-4 L 220-3 L 220-4 L 220-6 L 320-4 L 400-4 L 320-6 L 400-6 L X 1198 1198 1220 1220 1290 1250 1250 1268 1268 1218 1218 1278 1278 1384 1250 1250 1400 1400 Y 1340 1170 1310 1190 1190 1330 1210 1540 1370 1510 1390 1530 1410 1700 1550 1550 1550 1550 Z 1368 1899 1390 1918 2100 1408 1936 1368 1899 1390 1918 1408 1936 2675 1695 1695 2695 2695

Side frame thickness mm 40 40 55 55 55 70 70 40 40 55 55 70 70 70 80 80 80 80

Machine weight kg 8150 11300 11600 13900 14800 13750 17100 9000 12000 12400 14500 14800 18000 30000 24000 24000 36000 36000

of the anchoring holes mm 65 65 65 65 65 65 65 65 65 65 65 65 65 60 80 80 80 80

NOTE For options, see 2.2.1, 2.2.2 and 2.2.3.

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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. 2.4).

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

Example B : (90 angle) 75 % of load weight on each sling.

WE RECOMMEND NOT TO EXCEED AN ANGLE OF 90.

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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 130-3 130-4 170-3 170-4 170-4.5 220-3 220-4 220-6 320-4 400-4 320-6 400-6

Distance between uprights mm 2700 3760 2700 3760 4050 2700 3760 5210 3230 3230 5230 5230

Minimum length of the slings mm 3800 5300 3800 5300 5750 3800 5300 * 4800 4800 7600 7600

The handling operation can be carried out using lifting beam if the indications in the above table is followed. * The safe handling of 220-6 model can only be performed using a lifting beam, suitable to bear the machine load and the distance between uprights (5210 mm) or by using two independent cranes capable of handling 15 tons each.

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Up to 220 tons

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

Figure 2.5

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CAUTION: The choice of footing or anchoring points other than those specified in Fig. 2.4 and Fig. 2.5, is prohibited. Incidents resulting from a failure to comply with these instructions may lead to the suspension of your machines guarantee.

The following gives the load distribution on the footing: LOAD (KG) ON EACH GROUND PLATE Front Rear 2965 4110 4355 5220 5650 5190 6450 3175 4235 4205 4920 5365 6525 12000 1110 1540 1445 1730 1750 1670 2100 1325 1770 1995 2330 2040 2480 3000

Machine type 130-3 130-4 170-3 170-4 170-4.5 220-3 220-4 130-3 L 130-4 L 170-3 L 170-4 L 220-3 L 220-4 L 220-6 L

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ANCHORING TO THE GROUND (up to 220 tons) :

Figure 2.5 NOTE All dimensions are in mm. Machine type 130-3 130-4 170-3 170-4 170-4.5 220-3 220-4 220-6 A (mm) 2825 3885 2845 3905 4195 2885 3945 5400 B (mm) 1515 1515 1555 1555 1555 1575 1575 1775 E (mm) 2385 3445 2405 3465 3755 2445 3505 4960

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Valid for 320 and 400 tons

Prohibited areas. Areas authorised for shipping/transport.

Figure 2.6

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ANCHORING TO THE GROUND (320 and 400 tons) :

TABLE AXIS

Figure 2.6a

J bolt for anchoring & nuts HU M30 Ground

Anchoring bolt 40
TABLE AXIS

Figure 2.6b

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ANCHORING TO THE GROUND (320 and 400 tons) : Once the levelling has been done, the machine should be fixed to ground using 8 J bolts protruding through the holes of diameter H in the machine footing (see fig. 2.6a).

NOTE : In the areas where there is a risk of earth quack, the machine should be fixed on special foundations (see fig. 2.6b).

Dimensions (in mm)

A
Machine type

320-4 400-4 320-6 400-6

3580 1750 3580 1750 5580 1750 5580 1750

270 270 270 270

900 3120 900 3120 900 5120 900 5120

800 80 800 800

190 190 190 190

32 32 32 32

200 200 200 200

525 525 525 525

750 750 750 750

2820 2820 4820 4820

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Figure 2.7

Figure 2.8

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2.4.3. 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 (Figs. 2.7 and 2.8).

CAUTION: Strictly observe the authorised support areas as shown in Fig. 2.5 and 2.6.

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2.4.4. 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) and each side door of the C-frame is closed by a tab (Item 3). Before start-up, our technician will remove all these devices including the red spacer in between the motor and the mounting plate (Item 4). 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

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

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2.5. 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. 2.5.1. 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.

2.5.2. 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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2.5.3. 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 61000.4.2 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. Magnetic Fields A variable magnetic field causes induction in circuit loopsa 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.

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 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 50140 and 50141, 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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2.5.4. POWER SUPPLY CABLE CHARACTERISTICS The characteristics of the power supply cable must comply with the safety regulations in force. Cable cross-sections (mm) 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 standard. Example : EN 60204-1 (IEC 204-1). Manufacturer-recommended cross-section Country Voltage / Frequency 12,5 kW 16,5 kW 20 kW 23.5 kW 31.5 kW 38.5 kW Europe 400 V / 50 Hz 4 mm 6 mm 10 mm 10 mm 16 mm 25 mm

See electric diagram on how to pass the incomming 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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2.6. WORKSTATION LIGHTING

CAUTION: Ensure that the workstation has sufficient lighting for the parts to be worked on.

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2.7. SAFETY PRECAUTIONS 2.7.1. 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 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 footswitch) to authorise the operator to initiate the cycle. 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.

CAUTION : Use of the machine by unqualified, untrained personnel engages the employer's liability (Labour Law L 233-5-1) as well as the operator's liability (Labour Law L 230-3). The mentioned labour laws applies to France only.

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Important note relating to 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 that one will require on our machines: gloves, helmets, ear guards, goggles, goggles to protect against laser radiations, safety shoes, etc.

It is the responsibility of the user of the PPE to ensure that the equipment he /she is using fully complies with the European Directive 89/686/CE. This verification should be carried out with in the guide-lines of the European Directive 89/656/CE. The said directive is transposed in the French Labour Law Code de Travail and applies to the employer (Act 93-41 dated 11/01/1993 and article R233-1 and R233-83-3) i.e. all French employers are obliged to: ensure that the appropriate PPE are selected relating the risks involved, supply the appropriate PPE to the employee concerned, 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.

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 stating that it complies fully with the European Directive 89/686/CE.

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

The operation and maintenance of this machine are strictly reserved to professional, qualified personnel. For this purpose, Amada Metrecs 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 Para. 2.9, Machine characteristics and Para. 5.5 tool installation). Press brakes are supplied with the following safety equipment : Options: 1) Light guard to protect the front area. o Another control unit for assistant operator, including 2 footswitches (opening/closing). o A laser beam, to protect the front area. A set of two footswitches (closing/opening), Cycle selector key switch, Automatically controlled side and rear guards, Self-controlled electro hydraulic circuit.

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The press brakes listed in Appendix IV of Machine Directive 98/37/CE have fulfilled the requirements of the Type Testing procedure, as certified by NORISKO, 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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2.7.2. REGULAR INSPECTION AND SAFETY POLICY

NOTE The below-explained items are valid for France only. Any other country should refer to its current and domestic regulation.

Article R233.11 of the labour law and the Act dated 5 March 1993, modified by the Act dated 4 June 1993, require preventive maintenance to be performed on a quarterly basis. 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 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. The so-called Bulletin Officiel (Official Information Note) - # 2002/22 dated 5th December 2002 and issued by the Labour Office points out which engagements every head of company is compelled to (implementation scheduled on the 1st September 2003).

For all utilisation of press-brake, the user is obliged of : Use the protection devices in order to secure the front faces on press-brakes. Arrange the working stations through the installation of devices suited to the parts to be bent : part-holder , adjustable table. Think out of a convenient working organization due to secure the passing-through of batches of new parts. As for safety instructions, provide the proper training to operators and particularly to nonexperienced benders or temporary workers.

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2.7.3. ARRANGEMENT OF WORKSTATIONS There are five separate workstations for the following functions: Electrical cabinet location 1 Adjusting the backgauge location 2 Programming location 3* Production location 4 - Assistant Operator location 5 in the event of production being carried out by two operators (Caution : provide the assistant operator with similar equipment as for the main operator : see 2.7.1).

k j

* With NC type OPERATEUR 2000 or AMNC

k j

m
* With CD2000 NC NOTE Visuals not binding.

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Figure 2.9

Figure 2.10

Figure 2.11

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2.7.4. CONTROL DEVICES The press brake is supplied with a control device composed of one opening footswitch j and one closing footswitch k (Fig. 2.10). When the press brake is controlled by two operators, a second unit, identical to the first, is required (option). A selector key switch is used to switch it on. Depending on the type of NC fitted to your machine, the teaching will be carried out as follows: With the help of an electronic hand wheel remote controller having magnetised base plate, supplied as standard accessory and can be moved around (figure 2.9). For further details, see appendix "A2" programming manual (machine equipped with OPERATEUR 2000 NC). Directly using the push buttons on the NC key- pad (figure 2.11). For further details, see appendix A3, programming manual (machine equipped with CD2000 NC). With the help of an electronic hand wheel remote controller having magnetised base plate, supplied as standard accessory and can be moved around (figure 2.9). For further details, see appendix "A4" programming manual (machine equipped with AMNC NC).

CAUTION : Working from the rear of the machine is strictly forbidden.

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Figure 2.12

Figure 2.13

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2.7.5. RULES FOR SAFE OPERATION Release the part to be bent as soon as it is gripped between the tools (Fig. 2.12). Install or remove the tools in strict compliance with the procedure described in the Operator Manual ( 5.5) and / or with 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 (without material). Check visually that all introduced parameters corresponds to the tooling mounted on the machine and the mute point is 6 mm above sheet pinch point and the end of bend is correct. Then and only then choose the normal operating mode for the program in question.

CAUTION: Handling devices for heavy parts are not included in the basic 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

Figure 2.16
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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 job 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 loads (Fig. 2.18 and Para. 5.5).

Tool load 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 values for each tool type can be found in the special Tool catalogue (Amada or other).

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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 shouldnt 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. MACHINES 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. ............................. -10C Ambient operating temp. ......................................... +5C Oil temp. .................................................................. +5C Relative humidity ...................................................... 20%

Max. ................................... +50C ................................... +35C ................................... +80C .................................... 75%

For temperatures below 5C, 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, apply all possible measures to protect the press brake from all factors liable to hinder its smooth operation.

CAUTION: Amada Metrecs engineer will put your machine into operation. Please provide a supply of test sheets for this purpose. Select the material and sheet thickness 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 liability (Labour Law L 233-5-1) as well as the operator's liability (Labour Law L 230-3). These labour laws applies to France only.

NOTE: 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 5C, 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 Para. 3.7).

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2.9. MACHINE CHARACTERISTICS 2.9.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED
DESCRIPTION Standard speed High speed Nominal force Minimum Table length Table width Work surface height Open height without tools Cylinder stroke Throat depth Distance between uprights Max. pressure Number of cycles Oil capacity2 With CD2000 (HFT) Length (overall) With OP2000 (HFE) With AMNC (HFP) With CD2000 (HFT) Width (overall) With OP2000 (HFE) 4 With AMNC (HFP) Height (overall)
3

UNITS HF130-3 HF130-3S 1 300 150 3 140 90 960 470 200 420 2 700 300 5 150 / 180 3 995 4 206 4 503 2 020 2 576 2 715 2 820 8 150 15/21 mm 120 4 7 kW cm 3/T kW cm 3/T mm/s mm/s mm/s 11 / 22 20.7 / 2x30.02 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200 HF130-4 HF130-4S 1 300 150 4 200 180 960 470 200 420 3 760 300 5 150 / 180 5 055 5 266 5 563 2 020 3 576 2 715 2 820 11 300 21/28 120 5 10 11 / 22 20.7 / 2x30.02 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200 HF170-3 HF170-3S 1 700 210 3 170 180 960 470 200 420 2 700 300 5 235 / 280 4 025 4 236 4 533 2 020 2 581 2 720 2 900 11 600 16/21 120 4 7 15 / 30 32.6 / 2x32.6 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200

force1

KN KN mm mm mm mm mm mm mm Bar Litres mm mm mm mm mm mm mm Kg

MODELS HF170-4 HF170-4S 1 700 210 4 230 180 960 470 200 420 3 760 300 5 235 / 280 5 085 5 296 5 593 2 020 2 581 2 720 2 900 13 900 21/28 120 5 10 15 / 30 32.6 / 2x32.6 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200

HF170-4.5 1 700 210 4 520 180 960 470 200 420 4 050 300 5 235 5 375 5 586 5 883 2 020 2 581 2 720 2 920 14 800 22/30 120 5 10 15 32.6 100 1 to 10 1 to 100

HF220-3 HF220-3S 2 200 260 3 220 180 960 470 200 420 2 700 300 5 295 / 350 4 055 4 266 4 563 2 020 2 586 2 725 2 920 13 750 16/21 120 4 7 18.5 / 37 41 / 2x41 100 / 170 1 to 10 / 1 to 20 1 to 100 / 1 to 200

HF220-4 HF220-4S 2 200 260 4 280 180 960 470 200 420 3 760 300 5 295 / 350 5 115 5 326 5 623 2 020 2 586 2 725 2 940 17 100 21/28 120 5 10 18.5 / 37 41 / 2x41 100 / 170 1 to 10 / 1 to 20 1 to 100 / 1 to 200

Machine weight (overall)5 Number of adj. dist. Height of distance pieces Number of lg 835 mm tools lg 415 mm Motor power (Europe)7 Pump capacity (Europe)2 Motor power (USA) 7 Pump capacity (USA) Max. approach speed2 Max. work speed2 & 8 Max. return speed2 pieces6

AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to alter their characteristics at any time.

1 2

Value affecting the smallest allowable length of tools (Para. 5.5). Standard speed / High speed. 3 The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. 4 The dimensions are with the arm and the NC maximum extended in front, and all doors closed. For HFT models, add 140mm to this dimension for the light guard option, and add 100mm for a laser beam protection option. 5 Weights are approximate and correspond to basic machines, for optional equipment, see 2.2.1. 6 Standard distance pieces / Abutting distance pieces. 7 Machine power = Motor power + 3 kW. 8 20mm/s work speed is incompatible with the Akas system.

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2.9.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED

DESCRIPTION Standard speed High speed Nominal force Minimum force Table length Table width Work surface height Open height without tools Cylinder stroke Throat depth Distance between uprights Max. pressure Number of cycles Oil capacity With CD2000 Length With OP2000 (overall) With AMNC With CD2000 Width With OP2000 (overall)4 With AMNC
3

UNITS HF130-3L HF130-3LS KN 1 300 150 3 140 90 960 620 350 420 2 700 300 5 Litres
(HFT) (HFE) (HFP) (HFT) (HFE) (HFP)

HF130-4L HF130-4LS 1 300 150 4 200 180 960 620 350 420 3 760 300 5 150 / 180 5 055 5 266 5 563 2 020 3 576 2 715 3 120 12 000 21/28 120 5 10 11/22 20.7 / 2x30.02 21 41 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200

HF170-3L HF170-3LS 1 700 210 3 170 180 960 620 350 420 2 700 300 5 235 / 280 4 025 4 236 4 533 2 020 2 581 2 720 3 140 12 400 16/21 120 4 7 15/30 32.6/ 2x32.6 25 50.3 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200

MODELS HF170-4L HF170-4LS 1 700 210 4 230 180 960 620 350 420 3 760 300 5 235 / 280 5 085 5 296 5 593 2 020 2 581 2 720 3 150 14 500 21/28 120 5 10 15/30 32.6 / 2x32.6 25 50.3 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200

HF220-3L HF220-3LS 2 200 260 3 220 180 960 620 350 420 2 700 300 5 295 / 350 4 055 4 266 4 563 2 020 2 586 2 725 3 150 14 800 16/21 120 4 7 18.5/37 41 / 2x41 34 64.1 100 / 170 1 to 10 / 1 to 20 1 to 100 / 1 to 200

HF220-4L HF220-4LS 2 200 260 4 280 180 960 620 350 420 3 760 300 5 295 / 350 5 115 5 326 5 623 2 020 2 586 2 725 3 270 18 000 21/28 120 5 10 18.5/37 41 / 2x41 34 64.1 100 / 170 1 to 10 / 1 to 20 1 to 100 / 1 to 200

HF220-6L HF220-6LS 2 200 350 6 100 350 975 620 350 420 5 210 300 5 295 6 776 7 073 2 741 2 880 3 840 30 000 30/40 120 7 14 18.5 41 34 64.1 100 1 to 10 1 to 70

KN mm mm mm mm mm mm mm Bar

mm mm mm mm mm mm mm Kg

150 / 180 3 995 4 206 4 503 2 020 2 576 2 715 3 140 9 000 15/21 120 4 7

Height (overall) Machine weight (overall) Height of distance pieces Number of tools lg 835 mm lg 415 mm
7 2 5 6

Number of adj. dist. pieces

mm

Motor power (Europe)

kW cm 3/T kW cm 3/T mm/s mm/s mm/s

11/22 20.7 / 2x30.02 21 41 100 / 200 1 to 10 / 1 to 20 1 to 100 / 1 to 200

Pump capacity (Europe) Motor power (USA) 7 Pump capacity (USA) Max. approach speed2 Max. work speed
2&8

Max. return speed2

AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to alter their characteristics at any time.

1 2

Value affecting the smallest allowable length of tools (Para. 5.5). Standard speed / High speed. 3 The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. 4 The dimensions are with the arm and the NC maximum extended in front, and all doors closed. For HFT models, add 140mm to this dimension for the light guard option, and add 100mm for a laser beam protection option. 5 Weights are approximate and correspond to basic machines, for optional equipment, see 2.2.2. 6 Standard distance pieces / Abutting distance pieces. 7 Machine power = Motor power + 3 kW. 8 20mm/s work speed is incompatible with the Akas system.

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2.9.3. LONG STROKE WITH STANDARD SPEED

MODELS Description Nominal force Minimum force Table length Table width Work surface height Admission Cylinder stroke Throat depth Distance between uprights Max. pressure Number of cycles Oil capacity With CD2000 (HFT) Machine With OP2000 (HFE) length With AMNC (HFP) With CD2000 (HFT) Machine With OP2000 (HFE) width With AMNC (HFP) Height machine H (overall) Machine weight Number of adj. Dist. pieces Height of distance pieces Number of lg 835mm tools lg 415mm Motor power (Europe) Pump capacity (Europe) Motor power (USA) Pump capacity (USA) Max approach speed machine CE without / with a front protection Max. work speed Max. return speed
1 2 3 4 5 6

Units HF 320-4 kN kN mm mm mm mm mm mm mm bar litre mm mm mm mm mm mm mm kg mm 3 200 400 4 100 250 960 620 350 420 3 230 240 6 350 4 590 4 980 5 150 2 100 2 690 2 810 3 410 24 000 20 120 5 10 37 80.7 N/C N/C 10 / 100 10 100 HF 400-4 4 000 400 4 100 250 960 620 350 420 3 230 240 6 350 4 590 4 980 5 150 2 100 2 690 2 810 3 410 24 000 20 120 5 10 37 80.7 N/C N/C 10 / 100 10 100 HF 320-6 3 200 400 6 100 250 960 620 350 420 5 230 240 6 350 6 590 6 980 7 150 2 100 2 690 2 810 4 035 36 000 30 120 8 15 37 80.7 N/C N/C 10 / 100 10 100 HF 400-6 4 000 400 6 100 250 960 620 350 420 5 230 240 6 350 6 590 6 980 7 150 2 100 2 690 2 810 4 035 36 000 30 120 8 15 37 80.7 N/C N/C 10 / 100 10 100

kW cm3/tr kW cm3/tr mm/s mm/s mm/s

AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to alter their characteristics at any time.

1 2 3

4 5 6

Value affecting the smallest allowable length of tools ( 5.5) The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed. The dimensions are with the arm and the NC maximum extended in front, and all doors closed. For HFT models, add 140mm to this dimension for the light guard option, and add 100mm for a laser beam protection option. Weights are approximate and correspond to basic machines, for optional equipment, see 2.2.3. Machine power = Motor power + 3 kW. Speed for machines skipped to non-EC countries without a front protection = Speed for machines dedicated to EC countries equipped with a front protection.

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2.10. INFORMATION ON NOISE

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

1 EQUIVALENT ACOUSTIC PRESSURE LEVEL AT WORKSTATION LAeq: The equivalent continuous acoustic pressure level at the workstation, LAeq, is less than 75 dB(A).

2 PEAK ACOUSTIC PRESSURE LEVEL AT WORKSTATION Lpc: The peak acoustic pressure level at the workstation, Lpc, is less than 130 dB

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

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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. COMMISSIONING

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3.1. 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.

3.2. INSTALLATION OF CONTROL DEVICES The footswitch 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

Levelling screw Figure 3.1 Valid for 320 and 400 tons

Levelling screw

Figure 3.1
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3.3. 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). 3.4. 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 at the rear of the machine (Fig. 3.1). 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 at the rear of the machine (Fig. 3.1). 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.

IMPORTANT NOTE THE MACHINE MUST NOT REST ON SUPPORTS OTHER THAN THOSE DEFINED IN FIG. 2.4 (CHAPTER 2) OF THIS MANUAL. For specific installation conditions, contact Amadas Technical Department.

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3.5. PUTTING THE MACHINE INTO OPERATION START-UP .SEE CHAPTER 6.1.

DIRECTION OF ROTATION Check the direction of rotation of the hydraulic unit. To do this: - Start the pump by turning the selector to the right.

-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 turning the to Position 0. -After switching off the main circuit breaker of the machine swap 2 phases at the supply terminals. selector

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3.6. OVERALL CHECK Check the mountings of all covers and casings. Check that no foreign body is present on the ball screws of the back gauge 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 all the indicator lights and check that all 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.

WARM-UP In the event of a low ambient temperature, it may be necessary to warm up the hydraulic circuit. To do the warm up, apply power to the machine, start up the hydraulic unit, and lets climb up the temperature for 5 to 10 minutes.

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4. TECHNICAL DESCRIPTION

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Up to 220 tons

Figure 4.1 Valid for 320 and 400 tons

Figure 4.1
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4.1. MECHANICAL STRUCTURE Up to 220 tons Comprising : (Fig. 4.1) 1) A welded frame, including: -Two uprights (Items 1 and 1) -Two groundplates (Items 2 and 2) -One connecting beam (Item 3) -2 cheeks on the lower beam (Items 4 and 4) 2) Removable mechanical components: -One moving upper beam (Item 5) -One fixed lower beam (Item 6)

Valid for 320 and 400 tons Comprising: (Fig. 4.1) -Two uprights (Items 1 and 1) -Two groundplates (Items 2 and 2) -One connecting beam (Item 3) -2 cheeks on the lower beam (Items 4 and 4) -One moving upper beam (Item 5) -One fixed lower beam (Item 6)

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4.2. 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 mounted in between the two fixed side plates. These side plates are welded for machines up to 220 tons and assembled for 320 and 400 tons to the machine side frames. The lower beam is supported by two large steel shafts located at each side of the press brake axis.

Up 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. 4) 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 insures that accurate ram positioning is maintained even with side frame deflection.

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4.3. 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)

Line grid

Reference mark

Photoelectrics cells

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TECHNICAL DESCRIPTION Chapter 4 HF MEDIUM TONNAGE OPERATORS MANUAL X40882E

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To B

From Y2 Y1

Reference

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4.3.1. ELIMINATING SOURCES OF ERROR Under normal conditions of press brake use, 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 are introduced, which are liable to affect the bending quality. A new technique allows Amada to eliminate these risks completely. 4.3.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY This extremely sophisticated electronic regulating technique guarantees perfect balancing of the parallelism by making it independent of factors liable to alter it. Two incremental linear sensors Y1 and Y2 are mounted at each end of the upper beam. The sensors are directly connected to the electronics of the NC controller for Machine. This controls the oil flow to each cylinder via proportional valves B and B. When the upper beam is lowered, the sensors continuously record the changing positions very accurately. These signals are immediately sent to the NC controller, 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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4.3.3. 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 spread 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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4.4. LOCATION OF CONTROL AND SIGNALLING DEVICES EITHER ON NUMERICAL CONTROL OR ON CONTROL PANEL - SEE CHAPTER 6. OPERATION

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4.5. 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 controller, which calculates the force required according to the user-programmed part position. 4.6. PRESSURE GAUGE A pressure gauge is placed on the outer side of the lateral left cover. By comparing the displayed pressure (in bars) to the maximum pressure given in the machine characteristic table 2.9 in Chapter 2, you can see if the machine is reaching its operating limits.

Pressure gauge

The NC unit lets you limit the force according to the tool (refer to limit values in tool catalogues).

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5. FORMING TECHNIQUE & TOOLING

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Figure 5.1

Figure 5.2

Figure 5.3

Figure 5.4
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5.1. 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. 5.1: Punch and die. Press brake.

Fig. 5.2: Gripper plate and punch. Press. Tangent bending. Hole cut off edge.

Fig. 5.3: Fixed gripper plate, rotating beam. Folding press.

Fig. 5.4: Rotating grippers plates.

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Figure 5.5

Figure 5.6

Figure 5.7

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Fig. 5.5: Fixed guide and rotating gripper plate. Manufacture of shrouds.

Fig. 5.6: Three rollers. Roll bending machine.

Fig. 5.7: 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. 5.1). 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

Sheet contact

Distance of penetration

Die = 8 to 10 t. Figure 5.8

Figure 5.9

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5.2. 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 on 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. 5.9) 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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5.3. 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 5.9 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. 5.5).

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5.4. LIST OF STANDARD TOOLS (Refer to Amadas 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 Amadas 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 Amadas 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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5.5. TOOL INSTALLATION 5.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM Amadas 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

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The procedure remains the same for longer punch lengths:

Lateral mounting of the punch (longer punch lengths)

Punch is clamped

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Punch is released

Lateral extraction of the punch

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5.5.2. 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 Amadas 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 doesnt 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 load punch laterally (in this configuration, AMACLIP doesnt 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 doesnt 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.
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5.5.3. EXPERT CLAMPING SYSTEM MANUAL VERSION (OPTION) 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, up to a 835 mm length. 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 Amadas 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 EXPERT punch clamping system under different condition is explained here after:

Lateral loading of the punch (medium-sized in the above example) For 835 mm long punches, the lateral insertion should be carried out as follows : NOTE The 835 mm long tool should be supported by 3 distance pieces minimum before any release by the operator.

Front loading of the punch

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In order to make the front insertion of the punch easier, the operator may tilt it as shown below. First start with operation then . Also valid for short punches.

Punch is clamped

Punch is released

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Lateral extraction of the punch

Front extraction of the punch

NOTE In case of the front extraction of a 835 mm long punch, a remarkable force should be applied downwards by the operator. The front extraction of the 835 mm long tools is possible, but it is not recommended because the operator may be disturbed by the important weight of the punch.

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5.5.4. EXPERT PNEUMATIC CLAMPING SYSTEM AUTOMATIC VERSION (OPTION) For the extraction of the punches, refer to the procedure used on a manual version. The clamping and extraction operations are carried out by a centralised control system which may be monitored by a push-button.

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DIE HOLDER 2 V DIE FRONT FACE SPACER CLAMP PLATE REAR FACE

LOWER BEAM

Figure 5.10

Figure 5.11

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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 / meter must always be taken into consideration. 5.5.5. TOOLING INSTALLATION PROCEDURE Tool Installation (Fig. 5.10 and 5.11) 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. 5.10). 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 Appendix A: Operators Programming Manual 1.12 Teaching mode). 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 footswitch and rotate the remote hand wheel in a clockwise direction 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.
2 1

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7) Release the Closing footswitch. 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 footswitch. 13) Turn the remote hand wheel on the control clockwise until the displayed value of the sheet pinch point ends 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 .
1 2

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 footswitch. 15) Press the Opening footswitch 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. Example: 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. 2 2.9. 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 up to 1910 mm (due to tool sections) In this example, a 800 mm sectionalised tool cannot be used to set the tools as the minimum tool length required is greater than 800 mm.

All press brakes are designed to take a maximum authorised tool length. This value is given in Para. 2.9, Chap. 2 (Table Length), and 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 need the adjuster 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 END key : FIN 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 footswitch 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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5.6. OPTIONS AND ACCESSORIES See Appendix E.

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5.7. 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 5.12

Figure 5.13

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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. 5.12). 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 5.14

The distance pieces are set to zero in the factory for the entire HF range except for HF 103-3 and HF 220-6 machines. Position of standard distance pieces on these machines are as follows:

Figure 5.15

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Adjust dimension E using travel dial indicator: Select the lowest distance piece, i.e. the one with the smallest distance E (Fig. 5.14). Immobilise its wedge using the 6-mm (hex socket wrench screw) (Fig. 5.12). 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. 5.15). 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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5.8. PUNCHING Your machine cannot be used for punching, notching, etc.

BENDING CHART This chart was drawn up for mild steel with a shearing strength of 40 to 45 daN/mm. 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 Pour 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/ mm steel, gives a force of 500 kN for a given bend, the force is 250 kN for the same bend on a 20 daN/mm aluminium sheet. BENDING CHART LEGEND PLATE
orange

V width
grey

Internal Radius
green

Minimum Flange length

red

Bending Force kN/M

blue

Sheet Thickness

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6. OPERATION

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6.1. START-UP 1. Turn the handle of the main circuit breaker to position 1.

2. Turn the motor start-up selector switch starts running. 3. Press the green luminous reset push button 4. The green indicator light lights up.

to the right unstable position. The motor

. (see NOTE)

5. At a low ambient temperature, the oil becomes less fluid and the amber filter clogging alarm light may light up. The alarm light goes off as soon as the oil temperature rises. If the alarm light remains lit, the filter is clogged.

The NC unit lights up and is ready to be initialised.

NOTE Machine is equipped with LazerSafe light beam, see appendix E1.4 et E1.5. Machine is equipped with Akas light beam, see appendix E1.6.

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6.2. DESCRIPTION OF CYCLES (OUT OF US MARKET) NOTE The machine cycle depends on: The programming mode selection on the NC unit. The mute point. Presence or absence of a light guard, LazerSafe (appendix E1.4 & E1.5) or Akas (appendix E1.6).

The Opening footswitch always overrides any other controls.

Above

Sheet pinch point

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. If the footswitch is depressed once more, it will take the beam from the programmed opening dead centre to the mechanical opening dead centre.

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6.2.1.LAYOUT OF CONTROLS PANELS

OPERATEUR 2000 NC with or without Light Guard option

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OPERATEUR 2000 NC with LAZERSAFE option

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OPERATEUR 2000 NC with Akas option

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CD 2000 control panel with or without Light Guard option

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CD 2000 control panel with LAZERSAFE option

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CD 2000 control panel with AKAS option

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AMNC control panel with or without Light Guard option

AMNC control panel with LAZERSAFE option

AMNC control panel with AKAS option

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6.2.2. DESCRIPTION OF CONTROL AND SIGNALLING DEVICES EITHER ON NUMERICAL CONTROL OR ON CONTROL PANEL

: Two-position + one unstable position Hydraulic Unit On/Off selector switch -0, Hydraulic unit off -1, Hydraulic unit on , Hydraulic unit start-up (unstable position)

: Machine is equipped with Sick Light Guard (see Appendix E1.3): Seven-position CYCLE selector key switch: -Manual mode for tool setting or adjustment. -Selectors 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.

: Machine is equipped with laser beam (see E1.5 for LazerSafe and E1.6 for Akas):

Appendix

E1.4 or

Three-position mode selector key switch: -Manual mode for tool setting or adjustment. -Selectors OFF position, Machine out of operation. -Machines normal operating mode with LazerSafe or Akas beam protection.

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: LazerSafe test / confirm push-button with blue indicator light (see Appendix E1.4 & E1.5).

: Machines reset push-button with green indicator light.

: Write protection key switch (On Oprateur 2000). - 0, keyboard disabled - 1, keyboard enabled

: Machine stop

: Second Operator Option: With two-position key selector switch: -Single-operator cycle control -Two-operator cycle control

: Light guard or Two hand push-button control key switch selector (Only on HFE / HFT machines exported to countries outside European Union)

: FREE : Hole no more used for mute selector. Selection on or off at mute point, is to select on the NC.

: SPARE

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6.2.3. BASIC VERSION OF MACHINE (WITHOUT LIGHT GUARD OR LAZERSAFE OPTION) CYCLE 1 : ADJUSTMENT CYCLE WITH MOBILE BEAM STOPPING AT MUTE POINT Control: Closing footswitch. Program auxiliary function F5 to 1 to stop the beam at the mute position. This can be programmed on each bend if need be.

Switch SA4 on position BREAKDOWN OF CYCLE: Over entire stroke: working speed 10 mm/s. Outside the mute position, pressing the Closing footswitch closes the press brake as far as 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 footswitch. To pass through the mute point with out beam stoppage, program auxiliary function F5 to 0. This can be programmed bend by bend if required.

Switch SA4 on 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 unit: Closing footswitch. Program auxiliary function F5 to 1 to stop the beam at the mute position. This can be programmed on each bend if need be.

Switch SA4 on position BREAKDOWN OF CYCLE: Above mute position, pressing the Closing footswitch closes the press brake beam at low speed until the mute point is reached ( 10 mm/s). Stop at mute point. Release the Closing footswitch. Press the Closing footswitch to continue the cycle at working speed (< 10 mm/s). CYCLE 2 MOBILE BEAM NOT STOPPING AT MUTE POINT Control: Closing footswitch. To pass through the mute point with out beam stoppage, program auxiliary function F5 to 0. This can 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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THESE CYCLES ARE INOPERATIVE WITHOUT SICK LIGHT GUARD OPTION

See appendix E1.3 Light Guard.

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6.2.4. MACHINE EQUIPPED WITH SICK LIGHT GUARD OPTION THIS CYCLE IS IDENTICAL TO THE ONE DESCRIBED IN BASIC VERSION OF MACHINE

(See 6.2.1, CYCLE 1).

See appendix E1.3 Light Guard.

6.2.5. MACHINE EQUIPPED WITH LASER BEAM OPTION THIS CYCLE IS IDENTICAL TO THE ONE DESCRIBED IN BASIC VERSION OF MACHINE

(See 6.2.1, CYCLE 1).

See appendix E1.4 et E1.5 LazerSafe. or E1.6 Akas

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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, following should be observed for safe use of this option : Select 2 operators mode using key selector.

The operator or fitter should remove the key and keep it by himself so as to prevent anyone else changing the keyswitch position while operators are bending parts. 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. NOTA Same procedure whenever using the two-hand control.

Bending with one operator and 2 control stations (multi staging or multiple bending) Machines equipped with Safety PLC unit allows a single operator to use two independent control stations. Select one operator mode using key selector switch.

Program auxiliary function F (see Appendix A) corresponding to the workstation you intend to use in each bend.

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, no motion will occur ; an alarm will be generated and displayed on the CNC screen.

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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 with key selector switch, 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).

Out of US market machines

US market machines

Press green reset push button, the light will come on confirming the new mode of operation. Open only the required side gate. Opening both of them will generate a machine stop, because operators visibility is poor for the far end. NOTE 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 the optional second operator control panel (footswitch control), it is possible to operate the machine with both side gates open only if machine is operated by two operators. two operator position. In that case, turn the 2nd operator work switch to 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 footswitches and re-initiate a new cycle.

NOTE If the machine is equipped with a laser beam protection, for the bending at the extremityof the beam, see also the appendix E1.4 and E1.5 LazerSafe and appendix E1.6 Akas.

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6.1. MOBILE EMERGENCY STOP This machine is equipped with a supplementary emergency stop. It has a magnetic rear-plate who allows to fixed it near the operator, at any bending position.

6.2. START-UP 6. Turn the handle of the main circuit breaker to Position 1.

7. Turn the motor start-up key switch starts running. 8. Press the green luminous reset push button 9. The green indicator light lights up.

to the right unstable position. The motor

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

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6.3. DESCRIPTION OF CYCLES NOTE The machine cycle depends on: The programming mode selection on the NC unit. The mute point. Presence or absence of a light guard (see Appendix E1).

The Opening footswitch always overrides any other controls.

Above

Sheet pinch point

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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6.2.6. LAYOUT OF CONTROLS PANELS OPERATEUR 2000 NC for standard machine and machine with option Light Guard protection

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CD 2000 control panel for standard machine and machine with option Light Guard option.

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6.3.1. BASIC VERSION MACHINE (WITHOUT LIGHT GUARD) Cycle 1 : so called adjustment cycle with mobile beam stopping at mute point Control: Closing footswitch. Program auxiliary function F5 to 1 to stop the beam at the mute position. Switch SA4 on position :

Breakdown of cycle : Over entire stroke: working speed 20 mm/s. Outside the mute position, pressing the Closing footswitch closes the press brake as far as 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 footswitch . Program auxiliary function F5 to 0 to stop the beam at the mute position.

Switch SA4 on position :

Breakdown of cycle : Over entire stroke: working speed 20 mm/s. No stop at mute point.

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BASIC VERSION MACHINE (WITHOUT LIGHT GUARD) No movement. 6.3.2. MACHINE VERSION WITH LIGHT GUARD Cycle 2 with mobile beam stopping at mute point Control unit: Closing footswitch. Program auxiliary function F5 to 1 to stop the beam at the mute position.

Switch SA4 on position :

Breakdown of cycle : Above mute position, pressing the Closing footswitch closes the press brake at high speed until the mute point is reached (200 mm/s) if light curtain is free. During high speed closing if light guard is covered , the press brake stops Release the Closing footswitch. If light guard stays covered , no movement. If light guard is free , press the Closing footswitch to continue the cycle at high speed. Stop at mute point. Release the Closing footswitch. Press the Closing footswitch to continue the cycle at working speed. Cycle 2 mobile beam stopping at mute point Control: Closing footswitch. Program auxiliary function F5 to 0 to stop the beam at the mute position. Switch SA4 on position :

Breakdown of cycle : Above the mute point, lowering at high speed During high closing (high speed) if light guard is covered , the press brake stops Release the Closing footswitch. If light guard stays covered , no movement If light guard is free , press the Closing footswitch to continue the cycle at high speed. No stop at mute point. Working stroke continues below the mute point in working speed.

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6.3.3. MACHINE VERSION WITH TWO HAND CONTROL OPTION ONLY Cycle 3 Control unit: Two hand control above the mute point. Closing footswitch Working stroke continues below the mute point in working speed.

Switch SA4 on position :

Breakdown of cycle : Press two hand control Above the mute point, lowering at high speed During high speed closing if two hand control is released , the press brake stop Press two hand control Stop at mute point. Release two hand control Press the Closing footswitch. Working stroke continues below the mute point in working speed.

VERSION MACHINE (WITH TWO HAND CONTROL OPTION ONLY) Cycle 4 with mobile beam stopping at mute point Control unit: TWO hand control Program auxiliary function F5 to 1 to stop the beam at the mute position. Switch SA4 on position :

Breakdown of cycle : Press two hand control Above the mute point, lowering at high speed Stop at mute point. Release two hand control Press two hand control Working stroke continues below the mute point in working speed.

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MACHINE VERSION WITH TWO HAND CONTROL OPTION ONLY Cycle4 with mobile beam not stopping at mute point Control unit: TWO hand control Program auxiliary function F5 to 0 to stop the beam at the mute position.

Switch SA4 on position :

Breakdown of cycle : Press two hand control Above the mute point, lowering at high speed No stop at mute point. Working stroke continues below the mute point in working speed.

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Cycle 6 : cycle without safety With mobile beam stopping at mute pointT Control: Closing footswitch. Program auxiliary function F5 to 1 to stop the beam at the mute position.

Switch SA4 on position :

Breakdown of cycle : Press the Closing footswitch. Above the mute point, lowering at high speed Stop at mute point. Release the Closing footswitch. Press the Closing footswitch again to continue the cycle at slow speed . Cycle 6 : without safety protection With mobile beam not stopping at mute point Control: Closing footswitch. Program auxiliary function F5 to 0 to stop the beam at the mute position.

Switch SA4 on position :

Breakdown of cycle : Press the Closing footswitch. Above the mute point, lowering at high speed No stop at mute point. Working stroke continues below the mute point in working speed.

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6.3. LISTE DES MESSAGES AUTOMATE 6.3.1. MACHINE FAULT MESSAGES Message 1 2 Troubleshooting (red colour) PLC error. Start the PLC (Programmable Logic Controller) Problem The PLC is in hold.. Solution

E0.08 or A0.24 input error

E0.09 or A0.25 input error

E0.10 or A0.26 input error

E0.11 or A0.27 input error

E0.12 or A0.28 input error

E0.13 or A0.29 input error

Change CPU board. Turn off and restart ; if the Fail safe program is problem persists, check that stopped. the switch on the controller is in RUN mode. Check the wiring at input The input Ex.xx is faulty or Ex.xx or use an ohmmeter and the output of the forced the electric schematics, to opening relays KAY1 or check the relay wiring and KAY2 is in short-circuit. replace the faulty relay. Check the wiring at input The input Ex.xx is faulty or Ex.xx or use an ohmmeter and the output for KM1, KM2 the electric schematics, to or KM3 circuit breakers is check the circuit breaker in short-circuit. wiring and replace the faulty circuit breaker. The input Ex.xx is faulty or the non-connected light Check the wiring at input guard terminal is in short- Ex.xx or use an ohmmeter and circuit. This output is used the electric schematics to to by the programmable front identify short circuit and support table and sheetreplace the faulty component. follower options. Check the wiring at input The input Ex.xx is faulty or Ex.xx or use an ohmmeter and 10 mm/s working speed the electric schematics to output (input to NC) is in identify short circuit and short-circuit. replace the faulty component. The input Ex.xx is faulty or Check the wiring at input the machine ready light Ex.xx or use an ohmmeter and HL2 (SLB5) or back gauge the electric schematics to relay KA4 is in shortidentify short circuit and circuit. replace the faulty component. Check the wiring at input The input Ex.xx is faulty or Ex.xx or use an ohmmeter and high speed output (input to the electric schematics to NC) is in short-circuit. identify short circuit and replace the faulty component.

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Message

Troubleshooting (red colour) E0.14 or A0.30 input error

Problem

Solution

10

E0.15 or A0.31 input error

11

E1.00 or E1.08 or A1.16 input error

12

E1.00 or E1.08 or A1.16 input error

13

E1.01 or E1.09 or A1.17 input error

14

E1.01 or E1.09 or A1.17 input error

15

E1.02 or E1.10 or A1.18 input error

Check the wiring at input The input Ex.xx is faulty or Ex.xx or use an ohmmeter and press-brake opening output the electric schematics to (input to NC) is in shortidentify short circuit and circuit. replace the faulty component. The input Ex.xx is faulty or Check the wiring at input slow speed output for Ex.xx or use an ohmmeter and press-brake closing in the electric schematics to (input to NC) is in shortidentify short circuit and circuit. replace the faulty component. On 35 to 100 T machines : Check the wiring at input the input Ex.xx is faulty or Ex.xx or use an ohmmeter and YV1.1 solenoid valve (left the electric schematics to hand side) is disconnected identify short circuit and or in short-circuit. replace the faulty component. On 130 to 220 T machines: Check the wiring at input the input Ex.xx is faulty or Ex.xx or use an ohmmeter and YV1 solenoid valve is the electric schematics to disconnected or in shortidentify short circuit and circuit. replace the faulty component.. On 35 to 100 T machines: Check the wiring at input the input Ex.xx is faulty or Ex.xx or use an ohmmeter and YV1.2 solenoid valve (right the electric schematics to hand side) is disconnected identify short circuit and or in short-circuit. replace the faulty component. On 130 to 220 T machines: Check the wiring at input the input Ex.xx is faulty or Ex.xx or use an ohmmeter and YV3.1 solenoid valve (left the electric schematics to hand side) is disconnected identify short circuit and or in short-circuit. replace the faulty component. On 35 to 100 T machines: Check the wiring at input the input Ex.xx is faulty or Ex.xx or use an ohmmeter and YV3 solenoid valve is the electric schematics to disconnected or in shortidentify short circuit and circuit. replace the faulty component.

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Message

Troubleshooting (red colour) E1.02 or E1.10 or A1.18 input error

Problem On 130 to 220 T machines: the input Ex.xx is faulty or YV3.2 solenoid valve (right hand side) is disconnected or in short-circuit. On 35 to 100 T machines: the input Ex.xx is faulty or YV5.1 solenoid valve (left hand side) is disconnected or in short-circuit. On 130 to 220 T machines: the input Ex.xx is faulty or YV5.1 solenoid valve (left hand side) is disconnected or in short-circuit. On 35 to 100 T machines: the input Ex.xx is faulty or YV5.2 solenoid valve (right hand side) is disconnected or in short-circuit. On 130 to 220 T machines: the input Ex.xx is faulty or YV5.2 solenoid valve (right hand side) is disconnected or in short-circuit. On 35 to220 T machines: the input Ex.xx is faulty or YV6 solenoid valve is disconnected or in shortcircuit. The input Ex.xx is faulty or HL5 output : GUARD OFF lamp is disconnected (blown) or in short-circuit.

Solution Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component. Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component. Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component. Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component. Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component. Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component. Check the wiring at input Ex.xx or change the guard off lamp or check any shortcircuit in the wiring.

16

17

E1.03 or E1.11 or A1.19 input error

18

E1.03 or E1.11 or A1.19 input error

19

E1.04 or E1.12 or A1.20 input error

20

E1.04 or E1.12 or A1.20 input error

21

E1.05 or E1.13 or A1.21 input error

22

E1.06 or E1.14 or A1.22 input error

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Message

Troubleshooting (red colour) E1.07 or E1.15 or A1.23 input error The LazerSafe detect excessive environmental light. Reserved Reserved Faulty PV out put from LazerSafe

Problem

Solution

23

Check the wiring at input The input Ex.xx is faulty or Ex.xx or use an ohmmeter and the output is disconnected the electric schematics to from its load or is in shortidentify short circuit and circuit. replace the faulty component.

24 25 26

27

The input E0.08 does not receive slow speed output from LazerSafe controller.

28

One of the two channels of Fault in the machine stop the machine stop stayed in line. close state. The operation of KA4A Faulty KA4A (Closing relay is defective. The authorisation for YV2 commuting time of the solenoid valve). relay from 0 to 1 exceed 100 ms. Stopping distance too large. The stopping distance measured by LazerSafe unit is greater than 8.5 mm. The input Ex.xx is faulty or the pulse output is abnormally connected to a voltage source or is in short-circuit with 0 volt or short-circuited with another pulse output. Similar to A0.16.

29

30

31

E0.00 or A0.16 input error

Check the cable connection at E0.08 or use ohm meter and electric schematics and identify and replace the faulty component. 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. Using an ohmmeter and the electrical schematics, check the breakage in the circuit or the short-circuit, replace the faulty component if necessary. Switch off the machine and restart. If the fault persist, YV2 solenoid valves should be checked. Check the wiring at input Ex.xx or check that no voltage is applied to this output (after this type of fault, normally this output should not have any voltage). Using an ohmmeter, ensure that this output is not short-circuited with 0 volt nor with another pulse outputs. Similar to A0.16.

32

E0.01 or A0.17 input error

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Message 33 34 35 36 37 38 39

Troubleshooting (red colour) E0.02 or A0.18 input error E0.03 or A0.19 input error E0.04 or A0.20 input error E0.05 or A0.21 input error E0.06 or A0.22 input error E0.07 or A0.23 input error Error on board 0 (DI2OT)

Problem Similar to A0.16. Similar to A0.16. Similar to A0.16. Similar to A0.16. Similar to A0.16. Similar to A0.16. The board is faulty.

Solution Similar to A0.16. Similar to A0.16. Similar to A0.16 Similar to A0.16 Similar to A0.16 Similar to A0.16 Check if 24 VDC is present on the board connectors. If yes, change the board. Check if 24 VDC is present on the board connectors. If yes, change the board. Check if 24 VDC is present on the board connectors. If yes, change the board.

40

Error on board 1 (DIOZ) The board is faulty.

41 42 43

Error on board 2 Reserved YV1 static fault

The board is faulty.

44

YV1 dynamic fault

45

Static fault on YV1.1 or YV1.2

On 130 to 220 T machines: the piston of the pump relieve solenoid valve (YV1) is not in idle (0) position. On 130 to 220 T machines: the piston of the pump relieve solenoid valve (YV1) is faulty. When switching to status 0 or 1, the displacement time of the piston is > 80 ms or it has returned to 0 position while the solenoid valve is in status 1. On 35 to 100 T machines: the piston of either pump solenoid relieve valves (YV1.1 or YV1.2) is not in idle position.

Check the operation of YV1.

Check the operation of YV1.

Check the operation of YV1.

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Message

Troubleshooting (red colour)

Problem On 35 to 100 T machines: the piston of the pump relieve solenoid valve (left hand side) (YV1.1) is faulty. When switching to status 0 or 1, the displacement time of the piston is > 80 ms or it has returned to 0 position while the solenoid valve is in status 1. On 35 to 100 T machines: the piston of the pump relieve solenoid valve (right hand side) (YV1.2) is faulty. When switching to status 0 or 1, the displacement time of the piston is > 80 ms or it has returned to 0 position while the solenoid valve is in status 1. On 35 to 100 T machines: the piston of slow speed solenoid valve (YV3) is not in idle (0) position. On 35 to 100 T machines: the piston of slow speed solenoid valve (YV3) is faulty. When switching to status 0 or 1, the displacement time of the piston is > 80 ms or it has returned to 0 position while the solenoid valve is in status 1. On 130 to 220 T machines: the piston of the pump relieve solenoid valve (YV1) is not in idle (0) position.

Solution

46

YV1,1 dynamic fault

Check the operation of YV1.

47

YV1.2 static fault

Check the operation of YV1.2.

48

YV3 dynamic fault

Check the operation of YV3.

49

YV3 dynamic fault

Check the operation of YV3.

50

YV1 static fault

Check the operation of YV1.

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Message

Troubleshooting (red colour)

Problem

Solution

51

52

53

54

55 56

57

On 130 to 220 T machines: the piston of the pump relieve solenoid valve (YV1) is faulty. When switching to status 0 YV1 dynamic fault or 1, the displacement time of the piston is too long or it has returned to 0 position while the solenoid valve is in status 1. On 130 to 220 T machines: Faulty CLP1 check valve the retaining check valve is (left hand) not in position. On 35 to 220 T machines: the piston of slow speed YV6 static fault solenoid valve (YV6) is not in idle (0) position. On 35 to 220 T machines: the piston of 10mm/s slow speed solenoid valve (YV6) is faulty. When switching to status 0 or 1, the YV6 dynamic fault displacement time of the piston is > 80 ms or it has returned to 0 position while the solenoid valve is in status 1. On 130 to 220 T machines: Faulty CLP2 check valve the retaining check valve is (right hand) not in position. Reserved Relay KA51 & KA52 is Faulty KA51 & 2 faulty. When switching to (closing of YV2 valve status 0 or 1, the response authorized) time of the relay is > 100 ms.

Check the operation of YV1.

Check the operation of the valve.

Check the operation of YV6.

Check the operation of YV6.

Check the operation of the valve.

58

Slow Speed NC output faulty

Using an ohmmeter and the electrical schematics, check the disconnection in the circuit or the short-circuit, replace the faulty component if necessary. Check the output connections. This NC output is not If everything is OK, turn off correctly enabled, the the press-brake, then turn it on transistor on the NC output again and reset the Y1 and Y2 is either in short-circuit or axes. If the problem persists, stayed open. replace the I/O board of the NC.

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Message 59 60 61 62

63

64

65

66

67

68

69

See fault 58 (NC slow speed output fault). See fault 58 (NC slow output NC axis in position speed fault). See fault 58 (NC slow output NC ODC output fault speed fault). See fault 58 (NC slow output NC ER output fault speed fault). Check the output connections. If everything is OK, turn the All NC output transistors All NC outputs are in press-brake on and then off are in short-circuit or short-circuit. and reset the Y1 and Y2 axes. abnormally activated. If the problem persists, replace I/O board of the NC. Check the output connections. When turned on, the NC If everything is OK, turn the NC not ready ODC output remains at 0 press-brake off and then on. If (transistor not commuting). the problem persists, replace I/O board of the NC. The normally closed SA5 push-button fault at contact of the reset push Check the wiring ; replace the power on. button is closed when the push button if necessary. NC controller is turned on. SA4 mode selector key The mode selector key Check the wiring ; replace the switch (000) fault at switch is faulty, all contacts key switch if necessary. power on are at 0. The normally closed contact of the closing Footswitch 2 fault (n.c to Check the wiring ; replace the footswitch 2 is abnormally 0) at power on. contact if necessary. open when PLC unit is turned on. The normally open contact Footswitch 2 fault (n.o to of the closing footswitch 2 Check the wiring ; replace the 1) at power on. is abnormally close when contact if necessary. PLC unit is turned on. The machine auxiliary Footswitch selection function (NC output is Check the wiring, replace the faulty (NC output) at short-circuited to 0 volt output board of the NC if power on when the PLC unit is necessary. turned on.

Troubleshooting (red colour) NC Safety Relay output fault

Problem See fault 58 (NC slow output speed 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).

Solution

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Message

Troubleshooting (red colour) Footswitch 1faulty (n.o to 1) at power on

Problem

Solution Check the wiring, replace the contact if necessary.

70

71

72

73

74 75 76

77

The normally open contact of the closing footswitch 1 is abnormally closed when the PLC unit is turned on. The normally closed contact of the closing Footswitch 1 faulty (n.c footswitch 1 is abnormally to 0) at power on open when the PLC unit is turned on. One of the opening Opening footswitch 1 or footswitch is pressed or a 2 faulty at power on. contact is faulty when the PLC unit is turned on. The contact of KM1 circuit breaker is abnormally KM1 contact faulty when closed or the circuit breaker at power on. stayed close 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. Awaiting ODC signal Reserved for running in after end of bend. mode for factory. The contacts of the relay KPVR1&2 are defective. KPVR1 or 2 faulty (arm When switching to status 0 rotation) or 1, the response time of the relay is > 100 ms. E2.00 or A2.16 output error The output is disconnected from the load or in short circuit.

Check the wiring, replace the contact if necessary.

Check the wiring, replace the contact if necessary.

Check the wiring, replace the circuit breaker if necessary. Release the footswitch and reset the fault. Release the footswitch, reset the fault.

78

79

E2.01 or A2.17 output error

The output is disconnected from the load or in short circuit.

Using an ohmmeter and the electrical schematics, check the breakage in the circuit or the short-circuit, replace the faulty component if necessary. Using an ohmmeter and the electric schematics, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric schematics, check any short-circuit or disconnection in the circuit, replace the faulty component if required.

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Message

Troubleshooting (red colour) E2.02 or A2.18 output error

Problem The output is disconnected from the load or in short circuit.

Solution Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required.

80

81

E2.03 or A2.19 output error

The output is disconnected from the load or in short circuit.

82

E2.04 or A2.20 output error

The output is disconnected from the load or in short circuit.

83

E2.05 or A2.21 output error

The output is disconnected from the load or in short circuit.

84

E2.06 or A2.22 output error

The output is disconnected from the load or in short circuit.

85

E2.07 or A2.23 output error

The output is disconnected from the load or in short circuit.

86

E2.08 or A2.24 output error

The output is disconnected from the load or in short circuit.

87

E2.09 or A2.25 output error

The output is disconnected from the load or in short circuit.

88

E2.10 or A2.26 output error

The output is disconnected from the load or in short circuit.

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Message

Troubleshooting (red colour) E2.11 or A2.27 output error

Problem The output is disconnected from the load or in short circuit.

Solution Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Using an ohmmeter and the electric diagram, check any short-circuit or disconnection in the circuit, replace the faulty component if required. Check the configuration of the machine.

89

90

E2.12 or A2.28 output error

The output is disconnected from the load or in short circuit.

91

E2.13 or A2.29 output error

The output is disconnected from the load or in short circuit.

92

E2.14 or A2.30 output error

The output is disconnected from the load or in short circuit.

93

E2.15 or A2.31 output error

The output is disconnected from the load or in short circuit.

94

95

96

LazerSafe is incompatible LazerSafe is incompatible with two hand push button with two hand push control. button control. The mute output signal from LazerSafe controller Faulty mute output from is connected to input LazerSafe E1.07 of the PLC unit does not function in each bending cycle. LazerSafe has detected Upper beam is closing closing beam movement with out closing command without closing foot pedal signal. being activated.

Check the connection of this output cable.

Check the operation of the relay KA6 (command to LazerSafe).

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Message 600 601

Troubleshooting (red colour) PLC error F06 I0.xx input error

Problem Defective PLC unit. Many errors at input I0.xx Many errors at the inputs I0.00 to I0.15 Many errors at the inputs I0.16 to I0.31 Many errors at the inputs I1.xx or outputs O1.xx Many errors at the inputs I1.x Many errors at the outputs O1.xx Many errors at the outputs Tx or O2.xx Many errors at the outputs Tx or O2.8 to O2.15

Solution Remplace PLC unit. Check the input cables at I0.xx or use ohm meter and electric schematics to trace the fault. Check the input cables at I0.xx or use ohm meter and electric schematics to trace the fault. Check the input cables at I0.xx or use ohm meter and electric schematics to trace the fault. Check the input cables at I0.xx or outputs at O1.xx or use ohm meter and electric schematics to trace the fault. Check the input cables at I0.xx or use ohm meter and electric schematics to trace the fault. Check the outputs O1.xx or use ohm meter and electric schematics to trace the fault. Check the outputs Tx or O2.xx or use ohm meter and electric schematics to trace the fault. Check the outputs Tx or O2.8 to O2.15 or use ohm meter and electric schematics to trace the fault. Check the outputs O1.6 or O1.7 or use ohm meter and electric schematics to trace the fault. Check the input cables at I3.x or use ohm meter and electric schematics to trace the fault. Check the outputs O4.x or use ohm meter and electric schematics to trace the fault. Check the input cables at I0.0 or use ohm meter and electric schematics to trace the fault. Check the input cables at I0.1 or use ohm meter and electric schematics to trace the fault.

602

I0.00 to I0.15 input error

603

I0.16 to I0.31 input error

604

I1.xx or O1.xx input error

605

I1.xx input error

606

I0.16 to I0.31 input error

607

Tx or O2.xx output error

608

Tx or O2.8 to O2.15 output error

609

O.16 or O2.17 output error

Many errors at the outputs O1.6 or O1.7 Many errors at the inputs I3.x Many errors at the outputs O4.x Input error I0.0

610

I3.x input error

611

O4.x output error

612

I0.0 (//X, Y) input error

613

I0.1 (SQ12) input error

Input error I0.1

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Message 614

Troubleshooting (red colour)

Problem

Solution Check the input at I0.2 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.3 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.4 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.5 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.6 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.7 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.8 or use ohm meter and electric schematics. 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.

I0.2 (ctrl KA51&52) input I0.2 input error error I0.3 (Motor / Pump unit ON) input error I0.4 (NC running) input error I0.5 (Clamping On) input error I0.6 (HF BT / MT) input error I0.7 (axes init OK) input error I0.8 (FGSE OUT1) input error I0.9 (FGSE OUT2) input error I0.10 (NC axe in pos.) input error I0.3 input error

615

616

I0.4 input error

617

I0.5 input error

618

I0.6 input error

619

I0.7 input error

620

I0.8 input error

621

I0.9 input error

622

I0.10 input error

623

I0.11 (NC PV) input error

I0.11 input error

624

I0.12 (NC ODC) input error

I0.12 input error

625

I0.13 (NC end of I0.13 input error decompression) input error

626

I0.14 (NC RS) input error

I0.14 input error

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Message

Troubleshooting (red colour)

Problem

Solution Check the input wiring at I0.15 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.16 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.17 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.18 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.19 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.20 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.21 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.22 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.23 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.24 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.25 or use ohm meter and electric schematics to trace the fault.

627

I0.15 (ctrl KPV1&2) input I0.15 input error error

628

I0.16 (SA4 bit0) input error

I0.16 input error

629

I0.17 (SA4 bit1) input error

I0.17 input error

630

I0.18 (SA4 bit2) input error

I0.18 input error

631

I0.19 (CN) input error

I0.19 input error

632

I0.20 (select Robot) input error

I0.20 input error

633

I0.21 (SA6) input error

I0.21 input error

634

I0.22 (ped2 n.c) input error I0.22 input error

635

I0.23 (ped2 n.o) input error

I0.23 input error

636

I0.24 (SQ11) input error

I0.24 input error

637

I0.25 (SA9) input error

I0.25 input error

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Message

Troubleshooting (red colour) I0.26 (NC pedal select) input error

Problem

Solution Check the input wiring at I0.26 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.27 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.28 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.29 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.30 or use ohm meter and electric schematics to trace the fault. Check the input wiring at I0.31 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.

638

I0.26 input error

639

I0.27 (AM NF 1) input error

I0.27 input error

640

I0.28 (AM NF 2) input error

I0.28 input error

641

I0.29 (pedal 1 n.c) input error

I0.29 input error

642

I0.30 (pedal 1 n.o) input error

I0.30 input error

643

I0.31 (opening pedal) input error

I0.31 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

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Message 651

Troubleshooting (red colour) I1.7 input error

Problem I1.7 input error

Solution Check the input wiring at I1.7 or use ohm meter and electric schematics to trace the fault. 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.

652

I1.8 (SA12) input error

I1.8 input error

653

I1.9 (set LS) input error O1.16+ (YV1.1) output error O1.16+ (YV1) output error O1.17+ (YV1.2) output error O1.17+ (YV3.1) output error O1.18+ (YV3) output error O1.18+ (YV3.2) output error O1.19+ (YV5.1) output error O1.20+ (YV5.2) output error O1.21+ (YV6) output error O1.16- (YV1.1) output error O1.16- (YV1) output error O1.17- (YV1.2) output error

I1.9 input error Error at output O1.16 + (YV1.1) : wiring or impedance problem. Error at output O1.16 + (YV1) : : wiring or impedance problem. Error at output O1.17+ (YV1.2) : : wiring or impedance problem. Error at output O1.17+ (YV3.1) : : wiring or impedance problem. Error at output O1.18+ (YV3) : : wiring or impedance problem. Error at output O1.18+ (YV3.2) : : wiring or impedance problem. Error at output O1.19+ (YV5.1) : : wiring or impedance problem Error at output O1.20+ (YV5.2) : wiring or impedance problem. Error at output O1.21+ (YV6) : wiring or impedance problem. Error at output O1.16(YV1.1) : wiring or impedance problem. Error at output O1.16(YV1) : wiring or impedance problem. Error at output O1.17(YV1.2) : wiring or impedance problem.

654

655

656

657

658

659

660

661

662

663

664

665

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Message 666

Troubleshooting (red colour) O1.17- (YV3.1) output error

Problem

Solution 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. 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.

667

668

669

670

671

Error at output O1.17(YV3.1) : wiring or impedance problem. Error at output O1.18O1.18- (YV3) output error (YV3) : wiring or impedance problem. Error at output O1.18O1.18- (YV3.2) output (YV3.2) : wiring or error impedance problem. Error at output O1.19O1.19- (YV5.1) output (YV5.1) : wiring or error impedance problem. Error at output O1.20O1.20- (YV5.2) output (YV5.2) : wiring or error impedance problem. Error at output O1.21O1.21- (YV6) output error (YV6) : wiring or impedance problem. O/T 2.0 impulsive output error O/T 2.1 impulsive output error O/T 2.2 impulsive output error O/T 2.3 impulsive output error O2.8 (KAY1&2) output error Pulse output error : wiring or impedance problem. Pulse output error : wiring or impedance problem. Pulse output error : wiring or impedance problem. Pulse output error : wiring or impedance problem.

672

673

674

675

676

677

678

679

680

Single channel output error : wiring or impedance problem. Single channel output O2.9 (Pump motor unit error : wiring or ON) output error impedance problem. Single channel output O2.10 (command KA51) error : wiring or output error impedance problem. Single channel output O2.11 (HL2, KA4) output error : wiring or error impedance problem. Single channel output O2.12 (FGV to CN) output error : wiring or error impedance problem.

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Message 681

Troubleshooting (red colour) O2.13 (Opening to NC) output error

Problem

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

682

683

684

685

686

687

Single channel output error : wiring or impedance problem. Single channel output O2.14 (FPV to CN) output error : wiring or error impedance problem. Single channel output O2.15 (n.c) output error error : wiring or impedance problem. Double channel output O2.16 + (HL5 or HL7) error: wiring or output error impedance problem. Double channel output O2.17 + (n.c) output error error: wiring or impedance problem. Double channel output O2.16 - (HL5 or HL7) error: wiring or output error impedance problem. Double channel output O2.17 - (nc) output error error: wiring or impedance problem. I3.0 (test sec LS) input error I3.0 input error.

688

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.

694

695

Single channel output O4.0 (Aut. Sheet follower) error : wiring or output error impedance problem. Single channel output O4.1 (nc) output error error : wiring or impedance problem.

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Message 696

Troubleshooting (red colour) O4.2 (nc) output error

Problem

Solution Check the output wiring using ohm meter and electric schematicsto trace the fault. Check the output wiring using ohm meter and electric schematicsto trace the fault. Check the output wiring using ohm meter and electric schematicsto trace the fault. Check the output wiring using ohm meter and electric schematicsto trace the fault.

697

698

699

Single channel output error : wiring or impedance problem. Single channel output O4.8 (KA6 laser) output error : wiring or error impedance problem. Single channel output O4.9 (LS ON) output error error : wiring or impedance problem. Single channel output O4.10 (Mute LS) output error : wiring or error impedance problem.

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6.3.2. MACHINE STATUS MESSAGES Message 125 Troubleshooting (white colour) Close the rear door and start the motor Problem Solution Close the rear gate and start the motor (switch located on the NC panel). Select an operating mode, then press reset push-button.

126

127

128

129

130

131

132

The hydraulic unit is stopped. Close the rear gate to start it. The reset push-button is pressed while the operating Select operating mode mode selector key switch is in stop position. Over-travel of the back gauge cross-member (X1 or X2) due to parallelism loss and gone on its safety limit Parallelism lost on X or switch ; over-travel of the Y axes. press brake beam (Y1 and Y2) due to parallelism loss and gone on either (Y1 or Y2) limit switch. When the above fault has Reset machine been corrected, this (parallelism had been lost message specifies that the on X or Y axes). fault has been rectified. One of the machine stop Machine stop pressed. button is engaged. Once the machine stop Reset machine (machine button is released, it stop had been pressed). indicate that the fault has been rectified. The left side gate door is Left hand side gate door open, only adjustment open. mode can be executed. When the above fault has Reset the machine (Side been corrected, this gate doors had been message specifies that all opened). gate doors are now closed.

X axes : manually position the cross-member parallel and restart. Y axes : press the opening footswitch ; the problem should be solved.

Press reset push-button and restart. 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. Press reset push-button and restart.

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Message 133

Troubleshooting (white colour)

Problem

Solution 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.

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.

134

135

136 137 138

139

140

141

142

143

144

Every time tool holder is Tools holder unclamped. unclamped, it will initiate a machine stop. Reset the machine (tool holders had been Clamp the tool holders. unclamped). 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 A new operating mode is mode enabled during activated. beam movement). Reset the machine (robot A 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. It mode enabled) is possible that operator forgot 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.

Press reset push-button. Press reset push-button Press reset push-button

Press reset push-button

Press reset push-button

Select 2 operators mode and reset.

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

Press reset push-button.

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Message

Troubleshooting (white colour)

Problem

Solution

145

146

147

148 149 150 151

152 153 154 155 156 157

158

159

In one of the light guard Reset the machine (light operated modes, during the guard broken during high high speed closing phase, Press reset push-button. speed approach). the light guard has been broken. When the machine is ready Reset the machine. (no fault), but not yet been Press reset push-button. reset. Press the opening footswitch if Enable the opening Either footswitch or the Y axis is out of parallelism or footswitch (forced reset push button is pressed move X axis manually if it is opening) or move X axis while X or Y axis is out of X axis, then press reset push manually. parallelism. button. New working mode is Reset (adjustment mode) Reset with the push-button. enabled. Reset (light guard New working mode is Press reset push-button. protection) enabled. New working mode is Reset (robot control) Press reset push-button. enabled. Reset (single passingNew working mode is through mode + Press reset push-button. enabled. footswitch) Reset (single passingNew working mode is through mode + Press reset push-button. enabled. footswitch) Reset (single passingNew working mode is Press reset push-button. through mode) enabled. Reset (double passingNew working mode is Press reset push-button. through mode) enabled. Reset (robot adjustment New working mode is Press reset push-button. mode) enabled. Reset (adjustment mode New working mode is Press reset push-button. enabled) enabled. Reset (production mode New working mode is Press reset push-button. enabled) enabled. When the two-hand push button control mode is Operating mode non enabled (if option compatible with the two- installed), the modes Change the mode and reset. hand push button control corresponding to 2 passingthrough control with the light curtain are prohibited. Reset the machine (twoWhenever mode is changed hand push button control Press reset push-button machine stop occurs. disabled)

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Message 160

161

162 163 164 165

166

167

168

169

170

171

Troubleshooting Problem Solution (white colour) Reset the machine (twoWhenever mode is changed hand push button control Press reset push-button. machine stop occurs. enabled) Wait for the temperature to Oil temperature gone too drop without stopping the Oil temperature too high high. motor-pump and cooling unit motors. Reset (Two-hand push New working mode is button control + Press reset push-button enabled. footswitch) Reset (Two-hand push New working mode is Press reset push-button button control) enabled. LazerSafe under initialisation or machine Wait for ~ 4 seconds. stop push button active. Reset (stopping test by LazerSafe test is finished. Press reset push-button LazerSafe done) When Laser beam Working mode non protection is installed, only compatible with Laser setting and production Change the mode and reset. beam protection. modes are available at SA4 key selector. When machines are in Working mode non tandem configuration, only compatible with Tandem Change the mode and reset. setting and production machine configuration. modes are available. When machines are in Side gate open. tandem configuration, side Close side gates and reset. gates must remain close. Whenever separator is installed on a tandem Reset machine (SOLO Press reset push-button to start machine, it will initiate a mode enabled) machine in SOLO mode. machine stop and call for a reset. Whenever separator is Reset machine removed on a tandem Press reset push-button to start (TANDEM mode machine, it will initiate a machine in TANDEM mode. enabled) machine stop and call for a reset. When LazerSafe option is Initialisation of axes is installed, initialisation of Choose setting mode to only allowed in setting axes can only be done in initialise the machine axes. mode. setting mode.

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6.3.3. OPERATOR MESSAGES Message Troubleshooting (yellow colour) Problem Solution

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250

251

252

253

254

In alternate production mode , once the pressbrake has been turned on or Break light curtain, then during the first cycle in this reset the machine ; to mode, break the light curtain authorize high speed to ensure correct operation approach is. of the light guard. If this operation is not performed, the press-brake will operate in working speed. Once the press-brake is turned on, you must reset the machine. This can only be done by pressing foot Select Mode 1 to 4 to reset pedal 1 (or both foot pedals the machine. if 2 operators mode has been selected). Complete cycle with light curtain cannot be used. If the closing of the pressbrake in this mode is Control device is light authorized by the light guard. Footswitches guard, pressing either disabled footswitch produces this message. This message indicates that only footswitch 1 can close Footswitch 1 selected. the press-brake. It is displayed when footswitch 2 is pressed. This message indicates that only footswitch 2 can close Footswitch 2 selected. the press-brake. It is displayed when footswitch 1 is pressed. This message is displayed Delay between pressing the when de-synchronisation two footswitches exceeded. time between the two footswitches is > 4 seconds.

Break the light guard.

Do not select single passing-through complete cycle or double passing-through complete cycle .

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.

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Message

Troubleshooting (yellow colour)

Problem

Solution

255

256

257

258

259

260

In the alternate production mode , once the light guard has been Reset for high speed broken, it should be reset ; approach. if not, the press-brake will only operate in working speed. Once the press-brake has been turned on, machine reset can only be carried out using both Two operators mode footswitches if the two enabled. operators mode has been enabled. This message avoid searches for nonexisting faults. This message appears in 2 operators mode to specify that footswitch 1 has been Footswitch 2 is in stand-by activated and machine is position. waiting for 2nd footswitch command to close the press-brake. This message appears in 2 operators mode to specify that footswitch 2 has been Footswitch 1 is in stand-by activated and machine is position. waiting for 1st footswitch command to close the press-brake. This message specifies that only two-hand push button Two-hand push button control 1 can close the control 1 is selected. press-brake ; it is displayed if two-hand push button control 2 is enabled. This message specifies that only two-hand push button Two-hand push button control 2 can close the control 2 is selected. press-brake ; it is displayed if two-hand push button control 1 is enabled.

Press the reset push-button located on the NC panel.

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

Press footswitch 2.

Press footswitch 1.

Release two-hand push button control 2 and enable two-hand push button control 1.

Release two-hand push button control 1 and enable two-hand push button control 2.

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Message

Troubleshooting (yellow colour)

Problem

Solution Release both two hand push button controls then press them within 4 seconds at the most.

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262

263

264

265

266

267

268

This message is displayed Delay between pressing the when de-synchronisation two, two hand push button time between the two, two controls exceeded. hand push button controls is > 4 seconds. This message appears in 2 operators mode to specify that two hand push button Two-hand control 2 is in control 1 has been activated stand-by position. and machine is waiting for 2nd two hand push button control command to close the press-brake. This message appears in 2 operators mode to specify that two hand push button Two-hand control 1 is in control 2 has been activated stand-by position. and machine is waiting for 1st two hand push button control command to close the press-brake. Once the press-brake has been turned on, press NC Press NC Start button to Start button then press the RESET. opening footswitch to reset the axes. Oil filter clogged-up SQ8 filter soiled. This message is displayed if two-hand push button Light guard in control. control is activated when Two-hand push button selected mode only control inoperative. authorize closing of the press-brake through the light guard. This message is displayed if two-hand push button Footswitch control. Twocontrol is activated when hand push button control selected mode only inoperative. authorize closing of the press-brake through the footswitch. This message is displayed if footswitch is activated when Two-hand control. selected mode only Footswitch inoperative. authorize closing of the press-brake through twohand push button control.

Press two-hand control 2.

Press two-hand control 1.

Release the footswitch and press NC Start button. Replace the filter cartridge.

Break the light curtain to close the press-brake.

Press the footswitch.

Press the two-hand control.

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Message 269 270 271 272 273

Troubleshooting (yellow colour) See message 265. Running in mode active. Motor pump unit auto shut-down off. Watch out oil temperature too high. Press INIT button on LazerSafe. Waiting axis in position signal. LazerSafe : Working mode changed. Press Test button. LazerSafe : Obstruction during set-up. LazerSafe : Confirm mute point. LazerSafe : Start up time over or encoder error. LazerSafe : Work sheet not detected.

Problem

Solution

Press 5 seconds on START button. Press brake is used very intensively.

Slow down working rate.

274

Post NC axes output remain active (at 1) after end of bend when beam reaches ODC and if the closing foot pedal is activated. The working mode has been changed. The LazerSafe laser beam is obstructed before confirming the mute point

See error message 58 (NC output error for slow speed PV ). Confirm using Lazersafe Test / confirmation button. Remove the part or open the pressing beam. Confirm using Lazersafe Test / confirmation button Check encoder operation. Check if the magnetic laser beam blanking plate is correctly installed at the die end or redo teaching of the mute point. Check if the cooling unit is operating correctly. Liberate the zone monitored by LazerSafe. Liberate the zone monitored by LazerSafe. Liberate the zone monitored by LazerSafe. Liberate the zone monitored by LazerSafe. Liberate the zone monitored by LazerSafe. Liberate the zone monitored by LazerSafe.

275

276 277 278

279

After mute point, work sheet is not detected.

280

281 282 283 284

285

286

The temperature in the electric Electric cabinet cabinet exceed the temperature too high. temperature monitored by thermal sensor TH3. LazerSafe : Front beam is The front laser beam of the obstructed. LazerSafe is obstructed. LazerSafe : Rear beam is The rear laser beam of the obstructed.. LazerSafe is obstructed. LazerSafe : Central beam The central laser beam of the is obstructed.. LazerSafe is obstructed. LazerSafe : Central and The central and rear laser rear beams are beams of the LazerSafe are obstructed. obstructed. LazerSafe : Front and The front and central laser central beams are beams of the LazerSafe are obstructed. obstructed. LazerSafe : Front, rear The front, rear and central and central beams are laser beams of the LazerSafe obstructed. are obstructed.

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Message 287

288

289

290 291

292

293

Troubleshooting Problem (yellow colour) LazerSafe : The front and The front laser and rear rear beams of the LazerSafe beams of the LazerSafe are are obstructed obstructed Each time LazerSafe is LazerSafe secondary test in switched on, it checks the progress, please wait. stopping distance of the upper beam. Work sheet detected, The laser beam has detected release the pedal and press presence of the work sheet. TEST button for This position should be confirmation. confirmed. Work sheet detected, The laser beam has detected release foot pedal. presence of the work sheet. Tool height has been Teach new mute position changed, press TEST due to change in tool height button to teach. in the NC program. When LazerSafe is switched Place work sheet to be bent on, it is mandatory to teach and press closing foot pedal the mute position using until sheet is detected. correct work sheet. When LazerSafe is switched Press TEST button. on, you must press TEST button to proceed.

Solution Liberate the zone monitored by LazerSafe. Release the closing foot pedal and wait for the LazerSafe test to end.

Press TEST button.

Release closing foot pedal. Press TEST button.

Press closing foot pedal until work sheet is detected.

Press TEST button.

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7. 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. 2.4.4).

7.1. 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, floppy disk drive, 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 an AMADA supply).

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7.2. MACHINE PERIODIC MAINTENANCE - COMPOSITION 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 H00284** 3 Breather H02160** 4 Oil Shell DS46 or equivalent

** Always check the part list for correct references.

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FREQUENCY Monthly Monthly Quarterly

PERIODIC MAINTENANCE OF THE MACHINE ITEM COMPONENT PRODUCT/REF. 1 2 3 Keyboard/screen Floppy disk drive Linear scale guides Gentle cleaning agent + soft cloths 3 " cleaning diskette + alcohol Lithium grease

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7.2.1. 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

l
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7.2.2. 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 lower 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.

7.2.3. FILLING PROCEDURE Close the drain valve and remove the hose. Reinstall the drain plug. 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. During the filling operation, filter the oil through a 6-micron absolute filter cartridge x = 200. Check the level. It should be between the minimum and maximum marks on the gauge. 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). Remove the bowl feeder (Item 3) from the high pressure filter.

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Replace the oil filter cartridge (for Amada reference see 7.2 and Parts List). Reinstall the filter bowl feeder. 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. Unlock the electrical power supply. CAUTION: The legislation in force prohibits the disposal of oil into the environment. Take care to observe the regulations in force in your region.

7.3. 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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7.3.1. SPECIFIC DAILY TEST PROCEDURE 1- Light guard (see option, appendix E1.3) 2- LazerSafe system (see option, appendix E1.4 et E1.5) 3- Akas system (see options, Appendix E1.6)

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PERIODIC INSPECTION AND CLEANING LIST FOR THE VARIOUS COMPONENTS

WARNING THIS PERIODIC MAINTENANCE SCHEDULE IS RELATED TO MACHINE SAFETY.

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On HFE, HFT
Upper beam guiding

Tooling

Lower beam

Floppy drive

Main power supply circuit breaker

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On HFP

Main power supply circuit breaker

k
Floppy drive

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

TIME

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

Safety switches

Weekly -

Item 1 Item 2 Item 3

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UPPER BEAM GUIDING

Upper beam guiding

Fig. 7.2

Tooling

Lower beam

Fig. 7.1

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

TIME

Upper beam guiding

Fig. 7.1 Fig. 7.2

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. See Appendix E1.3

Light guard interlock (option)

Laser beam protection (option)

See Appendix E1.4 ,E1.5 or E1.6.

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Fig. 7.3

Upper beam bearing surface Sectionalised distance pieces

Upper beam bearing surface

Fig. 7.4

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

TIME

NC cabinet

Fig. 7.3

Monthly -

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

Mechanical Tools Fig. 7.4 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

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Breather

Upper beam guide rail

Oil tank

Linear scale guide rail

High pressure filter

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

TIME

After cleaning use lithium grease to grease the following: Upper beam Measurement C frame Hydraulic 3 months 3 months Guide rail Linear scale guide rail (remove cylinder covers) Replace oil filters and breathers Drain oil tank

2000 hours

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Fig. 7.5

Mountings

Fig. 7.6

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ASSEMBLY

SUBASSEMBLY

ITEM

FREQ.

INSPECTION/METHOD

TIME

Mechanical Frame Fig. 7.5 6 months Check machine levelling (see Ch. 3.3) Check securing of motor to its plates and silent blocks Check connections Detect leaks

Motor

Fig. 7.6

6 months -

Hydraulic/pneumatic pipework (see Checks Specific to the Hydraulic Installation)

6 months -

Electrical cabinet Machine stop

6 months Quarterly -

Check fan operation Check machine stop operation (safety devices) Visual control + door opening trial Visual control + opening trial Check the operation

Rear grid

Quarterly -

Side protections Opening footswitch Closing footswitch

Quarterly -

Quarterly -

Quarterly -

Check the operation

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7.4. TROUBLESHOOTING 7.4.1. 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 Metrecs Service Department (telephone and fax numbers given at the beginning of manual). PROBLEM Keyboard does not operate. SOLUTION Check position of keyboard interlock key. Position 0: Keyboard inactive Position 1: Keyboard active. 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. Check the machine stops.

The back gauge is out of parallel with the tools

Green indicator light does not light up.

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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7.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL POINTS (FRANCE ONLY) Article R233.11 of the labour law and the Act dated 5 March 1993, modified by the Act dated 4 June 1993, require preventive maintenance to be performed on a quarterly basis. 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. 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.

Operating tests to check functional components involved in the work: Presence and operation of protective devices in all operating modes, Abnormal operating characteristics: noise, vibration, temperature, impact, Operation of manual stopping devices, Operation of stopping devices associated with a protective function, Electrical operation under manual force of false parallelism sensor SQ1 and SQ2 contacts located on the upper beam.

Check of settings and clearances Fluid levels, Air and oil pressure, Limit switch adjustment.

Check on condition of indicators: Condition of measuring devices: pressure gauges, 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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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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APPENDIX TO CHAPTER 7 SAFETY DATA SHEET DRAWN UP ACCORDING TO NF T.01.100 IN COMPLIANCE WITH THE ACT DATED 5 JAN. 1993

1 - IDENTIFICATION Product concerned: SHELL TELLUS 46 oil Supplier: Shell Oil Company Responsible body: M.K.L.U. Use: Hydraulic oil Ingredient subject to health and safety regulations: Zinc dithiophosphate Maximum content: 0.4% 2 - STORAGE AND HANDLING 2.1 - SPECIAL PRECAUTIONS FOR STORAGE AND HANDLING Keep away from combustible materials; keep away from foodstuffs and drinks. Prolonged and repeated contact with the skin can cause skin conditions which are aggravated by minor injuries or rubbing against soiled clothing. Avoid splashing. After contact with the skin, wash immediately with copious water and approved detergents. Do not use irritant products or solvents. Do not wipe hands with cloths that were used for cleaning. Immediately remove any soiled or splashed clothing. Do not inhale the vapours, fumes, or spray. Do not eat, drink, or smoke during use.

2.2 - PACKING OR BOTTLING MATERIALS Use only containers, seals, pipes, etc. that are resistant to hydrocarbons. Hand any soiled packaging materials to an approved waste processing organisation.

2.3 - HAZARDOUS REACTIONS WITH: oxidant products PREVENTIVE MEASURES: Store in a cool, clean, dry location with appropriate ventilation. Keep away from heat and oxidising agents.

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2.4 - HAZARDOUS DECOMPOSITION PRODUCTS During combustion, unidentified organic or inorganic compounds can be formed, as well as sulphured hydrogen and short-chain alkylmercaptans. 2.5 - INDIVIDUAL PREVENTIVE MEASURES Barrier cream (on medical advice) or gloves, Goggles in the event of splashing, Avoid inhaling oil droplets, Avoid repeated or prolonged contact, When handling drums, wear safety shoes. 2.6 - SPECIAL PROTECTIVE MEASURES: not applicable 2.7 - MEASURES FOLLOWING A LEAK OR SPILLAGE Eliminate or destroy the product: contain and recover using physical means (e.g. absorbent materials), degrease surfaces, eliminate scrap in accordance with Section 6. Do not use dispersing agents in the event of a risk of polluting the environment. 3 - INFLAMMATION AND EXPLOSION 3.1 - FLASH POINT: > 190C in accordance with AFNOR NF M 07 019 3.2 - SELF-IGNITION TEMPERATURE > 250C according to ASTM E 659 standards. This value can be significantly reduced under particular conditions (slow oxidation in strongly divided media). 3.3 - SPECIFIC FIRE OR EXPLOSION HAZARDS Explosivity limit in air at ambient temperature = 1 to 10% vapour volume. The vapour pressure of this product is too low at ambient temperature for the lower explosivity limit to be reached. 3.4 - EXTINGUISHING EQUIPMENT RECOMMENDED: TO BE AVOIDED: Foam, carbon dioxide, powder Water jet and water spray extinguisher

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3.5 - SPECIAL PROTECTIVE MEASURES FOR FIREFIGHTING Wear breathing apparatus if required due to copious fumes. 3.6 - OTHER RECOMMENDATIONS Arrange your installation to avoid accidental oil splashes (e.g. seal failure) on hot covers and cowlings and electrical contacts. Hydraulic oil leaks in a circuit under pressure result in jets of a fine spray that can reach very high speeds. Under these conditions, the lower ignition limit of the oil spray is reached for concentrations in the region of 45 grammes per cubic metre.

4 - TOXICOLOGICAL DATA Maximum allowable concentration of oil spray in air: approximately 5 mg/m3. Under normal conditions of use, the mineral oils and other components of this product do not present an acute intoxication hazard. SPECIFIC TOXICOLOGICAL DATA: In the absence of toxicological data specific to SHELL TELLUS 46, we are able to provide the following indicative information by analogy with similar mineral oils: ACUTE ORAL TOXICITY ACUTE PERCUTANEOUS TOXICITY IRRITATION: - Skin: Considered to be a mild irritant - Eyes: Considered to be a mild irritant SENSITISATION: Unlikely to sensitise the skin. CHRONIC TOXICITY: SHELL TELLUS products are formulated from severely refined mineral oils which are considered to be non-cancer causing following toxicological tests performed on the skin of mice using the same types of oil. SUMMARY: SHELL TELLUS oils are considered to be of a low level of acute systemic toxicity. In normal use, they are unlikely to irritate the skin or eyes, or to sensitise the skin. No long-term toxic effect is likely. Users are nonetheless advised to avoid repeated and/or prolonged contact with mineral oils such as SHELL TELLUS, which could lead to irritation or even dermatitis in the event of conditions of poor personal hygiene. DL50: > 5 ml/kg DL 50: > 4 ml/kg

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USED OILS:

Used oils may contain impurities that are health hazards. They must be handled with care, and contact with the skin must be avoided whenever possible. Collection and disposal must be carried out in accordance with the regulations in force (see Section 6).

5 - FIRST AID Call a doctor Whilst waiting for the doctor to arrive, refer to the following guidelines: No special treatment is normally required. Do not induce vomiting to avoid the risk of debris being sucked into the respiratory passages. This risk exists only for oils that contain a high proportion of very light distillates. If inhalation occurs, the mouth and gastro-intestinal tract may become irritated. In the event of exposure to a high vapour concentration, move the patient to a location with fresh air. Keep the patient warm and relaxed. The risk of aspiration depends on the viscosity, which determines the ability of materials to be sucked into the respiratory system. In the event of suspected aspiration (e.g. during vomiting), transport the patient to hospital for emergency treatment. Wash eyes with copious water, and consult a specialist.

INGESTION:

INHALATION:

ASPIRATION:

EYES:

SPECIFIC CASE: In the event of contamination via the skin by a high-pressure jet, there is a risk of contaminant introduction into the patients's system. The patient must be taken to hospital even if there is no obvious injury. 6 - ENVIRONMENTAL PROTECTION Regulations concerning the disposal of oils and lubricants in surface, underground, and sea water: Acts 73-218 dated 23-02-73 and 77-254 dated 8-03-77, information notes dated 14-01-77 and 4-11-80. Regulations concerning waste: Law 75-633 dated 15-07-75 and Act 77-974 dated 19-08-77 and Act 79-981 dated 21-11-79, modified by Acts 85-387 dated 29-03-85 and 89-192 dated 24-03-89 applying to the regulations concerning the recovery of used oil: Law 881261 dated 30-12-88.

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