HF LT (50-100 Ton) Operator's Manual X40873h (May-2005)

Issue 05/2005

HYDRAULIC PRESS BRAKE

OPERATOR’S MANUAL

X40873H

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

2/10 CONTENTS Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H

Index Issue Updated by Details of revision

D 02/2002 Update to cater for common electric cabinet.

E 12/2002 M. Ahmed - 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.

Ch. 3 pages 6 to 9. Ch. 4 pages 9 to 11. Ch. 6 pages 3 to 7, 9 and 10.

F 09/2003 Ph. Jacquet - Updated, add the “Akas” option, control pannels.and USA machines cycles.

G 09/2004 Ph. Jacquet Updated : - Presentation of page 3 chapter 1. - Label safety chapter 2. - Add note “Switch off operation” ch. 3 & 6. - Pages 19 to 23 ch.5 “expert clamp. - Add paragraph 5.6. chapter 5.

H 05/2005 Ph. Jacquet Updated, - Ch.2 , safety label position.

Modifications of Fig.2.4 & 2.5. - Ch.5 add paragraph for joined mounting

of standard distance pieces. Modification paragraph 5.5.3 & 5.5.4..

- Ch.7 add oil caracteristics.

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.

CONTENTS 3/10 HF LOW TONNAGE OPERATOR’S MANUAL – X40873G Issue 05/2005

LIST OF ADDENDA

Modification coming from Reason Destination Application


HYDRAULIC PRESS BRAKE OPERATOR’S 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


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 .......... 8 2.2.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED..................... 9

2.3. MACHINE RECEPTION ............................................................................................. 10

2.4. RECEPTION & HANDLING....................................................................................... 11

2.4.1. LIFTING ................................................................................................................ 11 2.4.2. BASIC PRINCIPLES............................................................................................. 13 2.4.3. EQUIPMENT......................................................................................................... 19 2.4.4. SPECIAL PARTS FOR TRANSPORT ................................................................. 20

2.5. ELECTRICAL CONNECTIONS ................................................................................. 21

2.5.1. GENERAL CHARACTERISTICS OF THE MAINS SUPPLY ........................... 21 2.5.2. EARTH................................................................................................................... 21 2.5.3. MAINS-RELATED AND ENVIRONMENT-RELATED INTERFERENCE ..... 22 2.5.4. POWER SUPPLY CABLE CHARACTERISTICS .............................................. 25

2.6. WORKSTATION LIGHTING ..................................................................................... 26


2.7. SAFETY PRECAUTIONS ........................................................................................... 27

2.7.1. GENERAL POINTS .............................................................................................. 27 2.7.2. REGULAR INSPECTION AND SAFETY POLICY ........................................... 32 2.7.3. ARRANGEMENT OF WORKSTATIONS .......................................................... 33 2.7.4. CONTROL DEVICES ........................................................................................... 35 2.7.5. RULES FOR SAFE OPERATION........................................................................ 37

2.8. MACHINE OPERATING AND STORAGE CONDITIONS ...................................... 44

2.9. MACHINE CHARACTERISTICS............................................................................... 45

2.9.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED ........ 45 2.9.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED................... 46

2.10. INFORMATION ON NOISE ..................................................................................... 47

2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS ...................................... 48

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 SYSTEM 5

4.3.1. ELIMINATING SOURCES OF ERROR................................................................ 7 4.3.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY 7 4.3.3. PRECISE CENTRING OF THE BEAMS............................................................... 8


4.4. LOCATION OF CONTROL AND SIGNALLING DEVICES...................................... 9

4.5. PRESS BRAKE OPERATING LIMITS IN OFF-CENTRE WORK........................... 10

4.6. PRESSURE GAUGE .................................................................................................... 10

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

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 (OPTION)................................... 15 5.5.3. « EXPERT » CLAMPING SYSTEM – MANUAL VERSION (OPTION).......... 20 5.5.4. « EXPERT » PNEUMATIC CLAMPING SYSTEM – AUTOMATIC VERSION (OPTION)............................................................................................................... 24 5.5.5. PROCEDURE TO BE OBSERVED FOR TOOL INSTALLATION................... 28 5.5.6. CHANGING TOOLS (WITH AMNC NUMERICAL CONTROL)..................... 33

5.6. SPECIAL ACCESSORIES AND OPTIONS ............................................................... 39

5.7. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES............................ 39

5.8. PUNCHING .................................................................................................................. 44

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 MACHINE (WITHOUT LIGHT GUARD) ........................... 13 6.2.4. MACHINE EQUIPPED WITH SICK LIGHT GUARD OPTION ....................... 16 6.2.5. MACHINE EQUIPPED WITH LASER BEAM OPTION ................................... 16

6.3. MOBILE EMERGENCY STOP................................................................................... 19

6.4. START-UP.................................................................................................................... 19


6.5. DESCRIPTION OF CYCLES ...................................................................................... 20

6.5.1. LAYOUT OF CONTROLS PANELS ................................................................... 21 6.5.2. BASIC VERSION MACHINE (WITHOUT LIGHT GUARD) ........................... 23 6.5.3. MACHINE VERSION WITH LIGHT GUARD ................................................... 24 6.5.4. MACHINE VERSION WITH TWO HAND CONTROL OPTION ONLY ......... 25

6.6. PLC MESSAGES LIST ................................................................................................ 28

6.6.1. MACHINE FAULT MESSAGES ......................................................................... 28 6.6.2. MACHINE STATUS MESSAGES ....................................................................... 47 6.6.3. OPERATOR MESSAGES..................................................................................... 51

7. MAINTENANCE ................................................................................................................. 1

7.1. INTRODUCTION........................................................................................................... 2

7.2. MACHINE PERIODIC MAINTENANCE .................................................................... 5

7.2.1. MAINTENANCE OF 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


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.

GENERAL DESCRIPTION Chapter 1 1/6 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H Issue 05/2005

1. GENERAL DESCRIPTION

2/6 Chapter 1 GENERAL DESCRIPTION Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H

Figure 1.1


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: - HF 50-12 (50 tons / 1.2 meter) - HFx 50-20 (50 tons / 2 meters) - HFx 80-25 (80 tons / 2.5 meters) - HFx 100-3 (100 tons / 3 meters) X is added to specify the level of equipment provided on your machine (T, E or P).

----------- NUMERICAL CONTROL T CD2000 E OP2000 P AMNC

All models are delivered:

� In a basic version without light curtain, � Equipped with a “A”, “B” or “C”-type back gauge � In option: - light curtain, which is used as front protection and as an operation

cycle control device or

- laser safety system used as front protection only. Note : In this manual, “tons” is very often used instead of international measurement unit

“kN”. We remind you that 9.81 kN is equivalent to one ton.


Figure 1.2

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


1.2. PRINCIPLE The machine is a manual load/unload hydraulic press brake. HF hydraulic press brakes are down stroking machines equipped with an 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 various options (back gauge, front gauge, etc.), all Amada 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 center than at the ends (Fig. 1.2).


AMADA SYSTEM: Slotted beam (for 35- to 100-ton press brakes). The lower beam is a slotted plate. The arrangement, size, and shape of the slots are designed to allow the lower beam to deform in the same direction and with the same deformation as the upper beam under the action of the bending force. The lower beam is welded to the flanges (Fig. 1.3). 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.

Fig. 1.3

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

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES Chapter 2 1/48 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H Issue 05/2005

2. ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

2/48 Chapter 2 ACCEPTANCE, INSTALLATION AND SAFETY MEASURES Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H


2.1. GENERAL INFORMATION 2.1.1. MARKING

The marking on your press-brake corresponds to the following specifications : a) Name and address of the manufacturer. b) Type of machine. c) Serial number. d) Date machine is manufactured. e) Weight of the press-brake without any tooling or sub-equipment. f) If needed, weight of the main parts and sub-equipment to be removed with lifting devices.

A specific marking will then be afixed on these items. g) Maximum tonnage. h) Data concerning the electric, hydraulic and pneumatic supplies. A specific marking will

then be attached to the optional equipments. i) 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.


j) Warning on residual risks. On HFT

On HFE

j

j


On HFP

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

j

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

i


Plate for a machine with laser beam protection “LazerSafe” model.

Plate for a machine with laser beam protection “Akas” model.

m) Warning related to high speed operation (only concerns high speed machines).


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, allow clearance of approximately 1 metre to allow various maintenance operations and backgauge adjustment to be performed, the same goes to the electrical cabinet side.

- 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.

Figure 2.1

Length

Hei

ght

Wid

th


2.2.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED

DESCRIPTION UNITS MODELS

Standard speed HF 50-12 HF 50-20 HF 80-25 HF 100-3

High speed HF 50-12 S HF 50-20 S HF 80-25 S HF 100-3 S

With CD 2000 (HFT) mm 1 850 2 950 3 410 3 990

With OP 2000 (4) (HFE) mm 2 165 3 161 3 621 4 201

Mac

hine

le

ngth

(1)

With AMNC (5) (HFP) mm n/a 3 458 3 918 4 498

With CD 2000 (3) (HFT) mm 1 610 1 820 1 800 1 940

With OP 2000 (4) (HFE) mm 2 165 2 450 2 450 2 450

Mac

hine

w

idth

(2)


Machine height mm 2 300 2 450 2 550 2 700

GENERAL net weight (6) kg 3 350 4 600 5 600 6 600

Distance between uprights mm 1 035 1 665 2 125 2 705

Thickness of the uprights mm 35 35 35 35

Centre distance between upright axis mm 1 070 1 700 2 160 2 740 (1) The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed.

(2) The dimensions are with the arm and the NC maximum extended in front, and all doors closed. (3) With light guard, add 140mm to this dimension. With a laser beam protection, add 100mm to this

dimension. For transport, reduce by 140mm.

(4) For transport, reduce length by 256mm and width by 380mm. (5) For transport, reduce length by 553mm and width by 580mm. (6) Add to the machine weight, depending on the options, corresponding weight from the following table :

HF BT

Material Description Units 1,20 m 2 m 2,50 m 3 m AMACLIP sectionalised distance pieces kg 5 8 10 13 Sick light guard system kg 250 250 250 250 LazerSafe system kg 90 90 90 90 Akas system kg 40 40 40 40 Fixed front table/support kg 14 14 14 14 Single manual finger stop assembly kg 12 12 12 12 Programmable front table kg n/a 200 220 240 Work follower – Single arm kg n/a 440 460 480 Work follower – Twin arms kg n/a 640 660 680 Work follower – Single arm + Parking kg n/a 620 640 660 Work follower – Twin arms + Parking kg n/a 820 840 860 Sick light guard system for Parking kg 280 280 280 280 WILA hydraulic clamping kg n/a 120 140 160 n/a : not available


2.2.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED


Vitesse standard HF 50-12 L HF 50-20 L HF 80-25 L HF 100-3 L

Vitesse rapide HF 50-12 LS HF 50-20 LS HF 80-25 LS HF 100-3 LS

With CD 2000 (HFT) mm n/a 2 955 3 415 3 995

With OP 2000 (4) (HFE) mm n/a 3 166 3 626 4 206

Mac

hine

le

ngth

(1)


With CD 2000 (3) (HFT) mm n/a 1 952 1 952 2 052

With OP 2000 (4) (HFE) mm n/a 2 450 2 450 2 450

Mac

hine

w

idth

(2)


Machine height mm n/a 2 770 2 770 2 860

GENERAL net weight (6) kg n/a 5 000 5 750 7 000

Distance between uprights mm n/a 1 660 2 120 2 700

Thickness of the uprights mm n/a 40 40 40

Centre distance between upright axis mm n/a 1 700 2 160 2 740 (1) The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed.

(2) The dimensions are with the arm and the NC maximum extended in front, and all doors closed. (3) With light guard, add 140mm to this dimension. With a laser beam protection, add 100mm to this

dimension. For transport, reduce by 140mm.

(4) For transport, reduce length by 256mm and width by 380mm. (5) For transport, reduce length by 553mm and width by 580mm. (6) Add to the machine weight, depending on the options, corresponding weight from the following table :

HF BT

Material Description Units 1,20 m 2 m 2,50 m 3 m AMACLIP sectionalised distance pieces kg 5 8 10 13 Sick light guard system kg 250 250 250 250 LazerSafe system kg 90 90 90 90 Akas system kg 40 40 40 40 Fixed front table/support kg 14 14 14 14 Single manual finger stop assembly kg n/a n/a 12 12 Programmable front table kg n/a 200 220 240 Work follower – Single arm kg n/a 440 460 480 Work follower – Twin arms kg n/a 640 660 680 Work follower – Single arm + Parking kg n/a 620 640 660 Work follower – Twin arms + Parking kg n/a 820 840 860 Sick light guard system for Parking kg 280 280 280 280 WILA hydraulic clamping kg n/a 120 140 160 n/a : not available


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 pendent arm,* - Mechanical guards, - “C” frame (Goose necks), - 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 2.2 * With NC type : “OPERATEUR 2000” and “AMNC”.


2.4. RECEPTION & HANDLING 2.4.1. LIFTING Before the vehicle arrives, provide a crane with sufficient capacity to unload the press brake from the vehicle. 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. 2.3).

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.

� To direct the machine during handling, press on the frame or its packaging only; 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 procedures. 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.


Figure 2.3

LIFTING BEAM

Only use these holes for anchoring lifting slings

Center of gravity

Only use these holes for anchoring lifting slings


2.4.2. BASIC PRINCIPLES Lifting forces must only be applied to the anchoring points provided for this purpose and a lifting beam or sling should be used for machine handling.

Center of gravity

Distance between uprights

Machine weight

∅ anchoring

holes Press-brake X Y Z mm kg mm

50-12 807.5 ≅ 1 400 500 35 3 350 65

50-20 870 ≅ 1 400 770 35 4 600 65

80-25 926 ≅ 1 400 950 35 5 600 65

100-3 1 026 ≅ 1 400 1 150 35 6 600 65

50-20 L 908 ≅ 1 600 770 40 5 000 65

80-25 L 960 ≅ 1 600 950 40 5 750 65

100-3 L 1 068 ≅ 1 600 1 150 40 7 000 65

NOTE For options, see § 2.2.1. & 2.2.2.


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.

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°.

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

Press-brake Distance in mm between uprights

Minimum length of the slings in mm

50-12 1 035 2 000

50-20 1 665 2 400

80-25 2 125 3 100

100-3 2 705 4 000

50-20 L 1 660 2 400

80-25 L 2 120 3 100

100-3 L 2 700 4 000


Figure 2.4

CAUTION: The choice of footing or anchoring points other than those specified in Fig. 2.3 and Fig. 2.4, is prohibited. Incidents resulting from a failure to comply with these instructions may lead to the suspension of your guarantee.

The following table gives the load distribution on the footing

LOAD PER FOOT (kg) Machine Type Front: 420 x 300 Rear: 150 x 150

50-12 50-20 80-25 100-3

920

1 400 1 850 2 270

630 900 950

1 030

Mandatory ground footing areas for installation or for moving on skates.

Prohibited areas

Areas authorised for shipping/transport


ANCHORING THE MACHINE TO THE GROUND :

Figure 2.5

NOTE All dimensions are given in mm.

Machine type A (mm) B (mm) E (mm)

50-12 1 200 1 236,5 894

50-12 S 1 200 1 236,5 894

50-20 1 840 1 305 1 535

80-25 2 320 1 305 2 015

100-3 2 900 1 405 2 595


Figure 2.6

Figure 2.7


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. 2.5 and 2.6).

CAUTION: Strictly observe the authorised support areas as shown in Fig. 2.4.


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 backgauge cross member is immobilised using two brackets (Item 2), each C-frame side door is blocked using a bracket (Item 3) and a red coloured spacer is mounted in between the motor and it’s mounting plate (Item 4). These accessories are removed by the Amada technician during commissioning, before starting up the machine. They should be kept in a safe place for future use (if the machine is moved to another location in the future).

Only on 80 and 100 Tons machines

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

2 1

4 3


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 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 should be drawn for the EXCLUSIVE use

of the system from the main LOW VOLTAGE panel. The entire system is powered by a single three-phase + earth cable.

2.5.2. EARTH This equipment lacks double insulation hence requires an earthing connection. This is also important for machine operation and to drain electrical noise to the ground. 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.


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 devices.

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


• Medium- or High-Frequency Electromagnetic Radiation This type of interference can cause many problems in systems (operational amplifiers, computer memory, etc.). In general, the extent of the disturbance depends on the duration and intensity of the radiation. It may be caused by nearby radar systems or radio transmitters (military, police, FM radio station, etc.), or even by poorly filtered cathode ray tubes. 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). Although the machine has passed tests to European Standards EN 50140 and 50141, we recommend that you install the press brake in an environment that is free of the above-mentioned types of interference.


Figure 2.8

NOTE Component layout, not binding.

Example of wire attachments for the customer supply cable to QS1

Earth terminal


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 (mm²) are given for a line less than 20 m long. They are different for the three 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

Europe 400 V / 50 Hz

≤ 7,5 kW

10,5 kW

18 kW

4 mm²

4 mm²

6 mm²

See Figure 2.8 as well 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 cutoff device to protect it from short circuits and overcurrents (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 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 Department Services 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.


2.6. WORKSTATION LIGHTING

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


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 inside the safety device covered area nor in the hazardous zone. • Daily inspect the machine before starting work to ensure that :

- All protective devices are in place. - There is no obstruction in between the tools. - There is a free access to command devices. - 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. • 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 start the cycle. We supply on request, special equipment, to allow working on 2 stations or plus, with or without light guard.

• 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). Applies to France only.


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: Ø the name or the trade mark of the manufacturer, Ø identified either by commercial name or the reference of the PPE, Ø the size, if implies, Ø 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.


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

The operation and maintenance of this machine are strictly reserved for qualified professional personnel. For this purpose, Amada Department Services provides training for operators, fitters, 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. Even through,

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 :

- A set of two footswitches (closing/opening), - Cycle selector key switch, - Self controlled side and rear guards, - Self-controlled electrohydraulic circuit.

Options:

1) Light guard to protect the front area. 2) Another control unit for assistant operator, including 2 footswitches

(opening/closing). 3) A laser beam, to protect the front area.


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 :


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. 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 non-

experienced benders or temporary workers.


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

1 Electrical cabinet 2 Backgauge adjustment 3 Start-up and Programming* 4 Production 5 Assistant Operator in the event when production is carried out by two operators

(Caution : the assistant operator should be provided with similar equipment as for the main operator. See § 2.7.1).

* When equipped with “OPERATEUR 2000” controller or “AMNC” controller

* When equipped with « CD2000 » controller

NOTE Visuals, not binding.

1

2

3 4 5

1

2

4 5 3


Figure 2.11

Figure 2.9 Figure 2.10

1 2


2.7.4. CONTROL DEVICES The press brake is supplied with a control device composed of one opening footswitch 1 and one closing footswitch 2 (Fig. 2.10). When the press brake is controlled by two operators, a second unit (option), identical to the first, is required. A selector key switch (option) 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 side of the machine is strictly forbidden.


Figure 2.12

Figure 2.13


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 (§ 5.5 Fig. 2.13) in strict compliance with the procedure described in the Operator Manual and/or the recommendations specific to your tooling.

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 parameters correspond to the tooling

mounted on the machine, the mute point is 6 mm above sheet pinch point and the end of bend is correct.

• 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 Amada supplies. They must be installed for risk-free use in accordance with ergonomic principles.


Figure 2.14

Figure 2.15

Figure 2.16


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

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

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

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


Figure 2.17

Figure 2.18


� Beware of sudden movements of the worksheet during bending (Fig.

2.17).

� Observe the allowable tool loads (Fig. 2.18 and Para. 5.5). For example: - 1.2 T/cm for standard punches, except: - 1.5 T/cm for heavy punches, - 0.5 T/cm for punches with extra thin blades.

(1 T = 10 kN) The specific value for each tool type is marked on the side of the tool and is also shown in the special Tool catalogue.


Figure 2.19

Figure 2.20


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

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


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

Ambient machine storage temp. ............................. -10°C ................................... +50°C Ambient operating temp. ..........................................+5°C ................................... +35°C Oil temp. ...................................................................+5°C ................................... +80°C Relative humidity ......................................................20% .................................... 75%

For temperatures below 5°C, the NC unit must remain powered to keep the components and circuit at a normal temperature. No equipment that produces swarf, dust, paint flakes, etc. must be installed in the immediate vicinity of the machine. If this is not possible, apply all possible measures to protect the press brake from all factors liable to hinder its smooth operation.

CAUTION: Amada engineer will put your machine into operation. Please provide a supply of test sheets for this purpose. Select the material and sheet thicknesses you use most often.

CAUTION : 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.

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). 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 5°C, there is a risk of the machine operating incorrectly. To prevent this, press the STOP button, and then press the opening footswitch for 5 to 10 minutes (see §. 3.7).


2.9. MACHINE CHARACTERISTICS 2.9.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED

DESCRIPTION UNITS MODELS Standard speed HF 50-12 HF 50-20 HF 80-25 HF 100-3

High speed HF 50-12 S HF 50-20 S HF 80-25 S HF 100-3 S Nominal force kN 500 500 800 1 000

Minimum force 1 kN 40 40 70 75

Table length mm 1 270 2 090 2 570 3 110 Table width mm 60 60 60 90 Work surface height mm 960 960 960 960 Open height without tools mm 370 470 470 470 Cylinder stroke mm 150 200 200 200 Throat depth mm 100 420 420 420 Distance between uprights mm 1 035 1 665 2 125 2 705 Max. pressure bar 270 270 275 280 Number of cycles 4 4 4 4 Oil capacity 2 litres 55 55 / 110 90 / 185 110 / 225

With CD2000 (HFT) mm 1 850 2 950 3 410 3 990 With OP2000 (HFE) mm 2 165 3 161 3 621 4 201

Machine length 3

With AMNC (HFP) mm n/a 3 458 3 918 4 498 With CD2000 (HFT) mm 1 610 1 820 1 800 1.940 With OP2000 (HFE) mm 2 165 2 450 2 450 2 450

Machine width 4

With AMNC (HFP) mm n/a 2 450 2 450 2 450 Machine height mm 2 300 2 450 2 450 2 700

GENERAL net weight 5 kg 3 350 4 600 5 600 6 600

Number of adj. dist. Pieces 6 6/8 10/13 13/17 15/21

Height of distance pieces mm 120 120 120 120 lg 835 mm 1 2 3 4 Number of

tools lg 415 mm 3 5 6 7

Motor power (Europe) 7 kW 4 4 / 7,5 7,5 / 15 7,5 / 15

Pump capacity (Europe) 2 cm3/T 8,2 8,2 / 16,4 13,3 / 26,6 15,8 / 31,6 Motor power (USA) 7 kW - 4 / 9 7,5 / 12,5 7,5 / 17 Pump capacity (USA) cm3/T - 6,4 / 12,8 10, 2/ 20,4 13,3 / 26,6

Max. approach speed 2 mm/s 100 100 / 200 100 / 200 100 / 200

Max. work speed 2 et 8 mm/s 10 10 / 20 10 / 20 10 / 20 Max. return speed 2 mm/s 100 100 / 200 100 / 200 100 / 200

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

1 Value affecting the smallest allowable length of tools (Para. 5.5). 2 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


2.9.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED


Standard speed HF 50-20L HF 80-25L HF 100-3L

High speed HF 50-20LS HF 80-25L HF 100-3LS

Nominal force kN 500 800 1 000

Minimum force 1 kN 40 70 75

Table length mm 2 090 2 570 3 110

Table width mm 60 60 90

Work surface height mm 960 960 960

Open height without tools mm 620 620 620

Cylinder stroke mm 350 350 350

Throat depth mm 420 420 420

Distance between uprights mm 1 660 2 120 2 700

Max. pressure bar 270 275 280

Number of cycles 4 4 4

Oil capacity 2 litres 55 / 110 90 / 185 110 / 225

With CD2000 (HFT) mm 2 955 3 415 3 995

With OP2000 (HFE) mm 3 166 3 626 4 206 Machine length 3

With AMNC (HFP) mm 3 463 3 923 4 503

With CD2000 (HFT) mm 1 952 1 952 2 052

With OP2000 (HFE) mm 2 450 2 450 2 450 Machine width 4

With AMNC (HFP) mm 2 450 2 450 2 450

Machine height 3 mm 2 770 2 770 2 860

GENERAL net weight 5 kg 5 000 5 750 7 000

Number of adj. dist. Pieces 6 10/13 13/17 15/21

Height of distance pieces mm 120 120 120

lg 835 mm 2 3 4 Number of tools lg 415 mm 5 6 7

Motor power (Europe) 7 kW 4 / 7,5 7,5 / 15 7,5 / 15

Pump capacity (Europe) 2 Cm3/T 8,2 / 16,4 13,3 / 26,6 15,8 / 31,6

Motor power (USA) 7 kW - 7,5 / 12,5 7,5 / 17

Pump capacity (USA) Cm3/T - 10, 2/ 20,4 13,3 / 26,6

Max. approach speed 2 mm/s 100 / 200 100 / 200 100 / 200

Max. work speed 2 et 8 mm/s 10 / 20 10 / 20 10 / 20

Max. return speed 2 mm/s 100 / 200 100 / 200 100 / 200

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

1 Value affecting the smallest allowable length of tools (Para. 5.5). 2 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.


2.10. INFORMATION ON NOISE The measurements methods and the operating conditions used 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.


2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS Normal Use Bending and forming of sheet metals of various types of material and thicknesses 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 by 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.

COMMISSIONING Chapter 3 1/6 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H Issue 05/2005

3. COMMISSIONING

2/6 Chapter 3 COMMISSIONING Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H

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.


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

Figure 3.1

Levelling screw


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. 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.

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 Amada Technical Department.


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 key 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 key

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

supply terminals.

NOTE Switch off operation. First step : turn the motor start up key switch to the 0 fix position. Second step : turn the handle of the main circuit breaker to position 0.


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 backgauge axes or the guide

rails. � Check that the cables are secure in the stuffing boxes (electrical power supply cable), and

check the cable grip at the bottom of the electrical cabinet (footswitch). In the electrical cabinet, check that the earthing wires are properly connected to the terminal blocks.

� Check that the limit switches are operating correctly. � Check that no cover is liable to be caught during movement. � Check that all the indicator lights, machine stops and key switches are operating correctly. � Check that the light guard (if any) is operating correctly. Refer to the specific Appendix

concerning the light guard. 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.

TECHNICAL DESCRIPTION Chapter 4 1/10 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H Issue 05/2005

4. TECHNICAL DESCRIPTION

2/10 Chapter 4 TECHNICAL DESCRIPTION Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H

Figure 4.1


4.1. MECHANICAL STRUCTURE 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) - One lower beam (Item 6)

2) Removable mechanical components:

- One moving upper beam (Item 5)


4.2. MECHANICAL CONNECTIONS 1) The upper beam is supported by the uprights via the two hydraulic cylinders. Four sets of

track-eccentric roller assemblies ensures the perfect guiding of the upper beam, and at the same time provide the means for 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 positioning accuracy to within 1/100th mm.

The piston rods press on the upper beam via spherical supports. This linkage ensures that the piston is perfectly aligned in the cylinder by maintaining the reaction due to the thrust effects in the axis of the uprights.

3) The lower beam is welded to the machine uprights at each end. 4) A uniquely designed external “C” frame that remains rigid under all bending conditions

insures that accurate ram positioning is maintained even with the side frame deflection. The reference of the moving beam is taken completely independently of the side frame to avoid introducing any error resulting from side frame deflection.


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-µ 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

Photo-electrics cells


To B’ B

From Y2

Reference

Y1


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, risk of error introduction, which is 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 A of the 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. On HFP, adding some pressure sensors will improve the accuracy of the results.


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.


4.4. LOCATION OF CONTROL AND SIGNALLING DEVICES • EITHER ON NUMERICAL CONTROL OR ON CONTROL PANEL

- SEE CHAPTER 6 OPERATION


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 left upright. 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.

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

Pressure gauge

FORMING TECHNIQUE & TOOLING Chapter 5 1/46 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H Issue 05/2005

5. FORMING TECHNIQUE & TOOLING

2/46 Chapter 5 FORMING TECHNIQUE & TOOLING Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H

Figure 5.1

Figure 5.2

Figure 5.3

Figure 5.4


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.


Figure 5.5

Figure 5.6

Figure 5.7


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.


Figure 5.8

Figure 5.9

• Distance of penetration

Sheet contact

t = thickness

Die = 8 to 10 t.


5.2. AIR BENDING During air bending, the sheet metal retains certain amount of elasticity in the plastic region. An acute angle, higher than the desired angle, is generally performed to compensate for the opening due to spring back effect. The NC unit is designed to take into account all these parameters required for air bending. Our standard air bending tools too are designed accordingly. The bending chart located in the press brake’s electrical cabinet indicates the required force and internal radius which can be obtained in relation with the other characteristics (thickness, die opening, etc.). During air bending, the sheet is in contact with the tools at three points (A, B1, B2) as shown in Figure 5.8. To obtain quality bend using air bending, it is necessary that the die opening is 8 to 10 times the sheet thickness. (For angles ≥ 135°, it is preferable to use a die opening 10 to 12 times the sheet thickness). In this way, sheet deformation is interrupted before it reaches the bottom of the die. NOTE If there is a specific requirement for bending, e.g. 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.


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 for coining, because it determines the inside radius of the bend (stamping of the punch in the sheet). Coining can only be performed with a punch and die of the same angular value. 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 (§ 5.5).


5.4. LIST OF STANDARD TOOLS

(Refer to “Amada’s Press Brake Tooling” catalogue) Qualitative characteristics common to the whole range: � Easy to store. � Easy for one person to handle. � Hardened working surfaces. � Standardised mounting systems. � Special profiles suited to different sheet

thicknesses. � Wide range of profiles suited to all

applications. � Special custom-designed profiles for

sufficiently large production runs. � Groove in the heel preventing the tool from

dropping when tool clamp plates are unfastened.

Our tools comes in two standard lengths: 835 mm and 415 mm.

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


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

The “Amada’s Press Brake Tooling” catalogue gives you the complete list of available punches and dies. During commissioning, our technician will enter a list of all your tools in your NC unit, and will show you how to input new tools yourself. You will then have the complete list of your punches and dies stored in the NC memory. You must then identify them very carefully when using them to allow the NC unit to calculate the penetration from exact values. If for any reason, the numbers 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.


Only trained and qualified operators are entitled to work on press-brakes.

5.5. TOOL INSTALLATION 5.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM Amada’s standard fast punch clamping system allows an easy and fast mounting of the punches. The use and possibilities are described here after:

Lateral mounting of the punch (short punch lengths)

Punch is clamped


Punch is released

Lateral extraction of the punch

The procedure remains the same for longer punch lengths:

Lateral mounting of the punch (longer punch lengths)


Punch is clamped

Punch is released



Standard clamping system for joined mounting (option). The standard clamping system exist in a special model, for joined mounting of distance pieces. With the joined mounting, the installation of a short tool is possible at any position of a line of joined clamps. To join clamps, from an initial position with space between them : - Untighten by about one turn the two M10 screws of each upper clamp plate, that fix the

clamp unit to the upper beam.. The clamp unit is then maintained in place by heel of the clamp plate, that goes into the groove of the clamp unit.

- Slide laterally one or more untightend clamp units until contact between them. - Push the clamp unit upwards, while tightning the two M10 screws of each clamp plate. To move the clamp units aprat, from a joined position, follow the procedure above in the opposite order. NOTE : Do never separate the clamp units by more than 50 mm between them. In case of too high distance, the clamp unit might be overcharged.

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


5.5.2. “AMACLIP” PUNCH CLAMPING SYSTEM (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. This solution reduces considerably the tool change time when it comes to frequent punch changes, at the same time remaining totally compatible with standard Amada range of tooling available in Amada’s Press Brake Tooling catalogue. All existing possibilities of the standard fast punch clamping system is conserved, e.g. stacking of the distance pieces for bending deep boxes, etc. The use of “AMACLIP” punch clamping system under different condition is explained here after: - Short length of punches (less than 200 mm)

Front-loading of the punch

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


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).


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



- Punches having lengths equal or higher than 200 mm

Front-loading of the punch



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.


5.5.3. « EXPERT » CLAMPING SYSTEM – MANUAL VERSION (OPTION) In order to increase both safety and flexibility in addition to well-founded functions proper to the standard fast punch clamping system, Amada has implemented a fast clamping distance piece-based system allowing what fallows :

Tools

< ou = à 200mm 415mm 835mm

Front loading valid valid not valid Lateral loading valid valid valid Front unloading valid not valid not valid Lateral unloading valid valid valid

This is a remarkable time-saving solution when it comes to frequent tool loading/unloading operations, while remaining in full agreement with Amada standard range of tooling available in Amada’s Press Brake Tooling catalogue. The two models of standard tool fixation compatibles with Expert are :

Standard punch Inclined punch The so-called “plating” function is also ensured by this device, only with Amada standard range of tools. All already existing functions associated to the standard fast punch clamping system are maintained, for instance the slave distance piece usually used on RG-type press brakes due to be clamped beneath the “expert” clamping system.


Depending upon the below-described operating modes, use the “EXPERT” punch clamping system as follows : Lateral loading of the punch Every punches can be laterally inserted The lateral insertion should be carried out as described below.

NOTE A 835-mm long tool should be totally supported by 3 distance pieces minimum before the operator can release it .

Important : remember that the tool should be firmly held in your hands throughout the entire process.

Front loading of the punch The front insertion should be carried out as follows (415-mm long punch given as an example). For safety reasons, the front loading of 835-mm long punches is not valid.

In order to make the front insertion of the punch easier, the operator should tilt it (see above). First start with operation � then �. Also valid for short punches.


Clamping With the palm of your hand, move the lever upwards.

Releasing Move the lever downwards

Anti-fall process push-button



Lateral removal of the punch : Check that the distance pieces are unclamped, slightly slide the punch towards the outer machine. The anti-fall devices can therefore ensure a safe mouvement . Important : remember that the tool should be firmly held in your hands throughout the entire process.

Front removal of the punch

Front removal of the punch: (see table 0.01). 200-long punch given as an example. Distance piece unclamped,

- hold the tool in your hands. - Use your thumb as a means of pressure onto the anti-fall push button ; the tool should

be extracted. - Tilt the punch downwards from one side, then extract it out.

Important : remember that the tool should be firmly held in your hands throughout the entire process.


5.5.4. « EXPERT » PNEUMATIC CLAMPING SYSTEM – AUTOMATIC VERSION (OPTION) The Expert automatic clamping system allows for an instant clamping and unclamping of an entire line of bending tools.

The insertion and removal principles are similar to the manual version

The clamping/unclamping operation is ensured by a 2-position « Clamping & Unclamping » switch located on a magnetic panel likely to be positionned for instance on the lower beam cover.

The clamping process is operated through pneumatic actuators located on the rear side of the upper beam. Several « clamping modules » have also been provided as equipement. A clamping module is basically composed of both a control bar and one, or more generally, two actuators. A magnetic sensor has been integrated on each module in order to allow for the “clamping” position of the system. When the distance pieces are positionned in an « unclamping » position, any movement of the beam is prohibited by a safety device. The design of the control bar allows for a lateral sliding of the clamp units, to put them in a joined position. Factory mount installation. Expert Automatic version can be delivered from factory, equipped onto a new pressbrake. In this case, only a 5-7 bar pneumatic air supply must be provided.. Use a ½” male threaded pneumatic connector (not supplied), to be fitted to the Filter-Regulator unit on the rear of the press brake. After sales mounting. It is possible to equip an Amada pressbrake already in operation, by the Expert Automatic version. This only concerns pressbrakes produced since september 2003 ; also pressbrakes with the Long Stroke option (350 mm) are excluded.. On each pressbrake, even delivered without the Expert Automatic option, machined surfaces and holes are made. Threads are not made, and can be done with a M8 thread tap delivered with the Expert Automatic option kit for after sales mounting. Then install the clamping modules and make pneumatic and electric installations, necessary for the options function. It is recommended to contact your local AMADA Services Department to make any after sales installation.


Switching the distance pieces from manual to automatic version. For press-brakes equipped with the EXPERT manual version, it is now possible to replace it by the automatic version. In this case, manual levers should be replaced by controlled ones. As a matter of consequence, a mechanical modification – consisting in changing the position of two pins used as stoppers - should be applied onto distance pieces. Please remember that on the manual version, pins are positionned downwards and upwards in the automative one. On every machine, even when supplied without the «controlled clamping system » option , machinings and piercings have been operated. Tappings are not provided and may be done through an optional M8 tap (second installation). Clamping modules should then be installed as well as pneumatic and electrical connections, necessary for the option to be operative. Please contact AMADA Services Department for each second installation.

NOTE In order to enable detecting possible interferences with the « EXPERT » clamping system whenever bending, the NC should be familiar with the « machine profile » suitable for this option. In that respect, in second installation, a floppy disk is supplied with options for the updating of the « machine profile » in the press-brake NC. Please contact AMADA Services Department.


EXPERT in standard manual and automatic versions has been designed for joined mounting. NOTE : Do never separate the clamp units by more than 50 mm between them. In case of too high distance, the clamp unit might be overcharged.

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


Figure 5.10

Figure 5.11

DIE HOLDER

CLAMP PLATES

REAR FACE FRONT FACE

2 V DIE 1 V DIE

SPACER

LOWER BEAM


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, and taking into consideration the maximum load and minimum tool length restrictions.

5.5.5. PROCEDURE TO BE OBSERVED FOR TOOL INSTALLATION Tool Installation (Fig. 5.10 and 5.11) 1) Place the lower part of the tooling in position, according to case: - Spacer, - Single V die with die holder - Two V die plate with die holder, which is slid onto the table of the lower beam. 2) Immobilise 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 dies require an alignment, make sure that the locking screws (Hm8) on the die holders are loosened (13-mm flat spanner). 3) Select a program on the NC unit. 4) Go into sheet contact point TEACH mode (see Appendix A: Operator’s Programming

Manual). The use of this mode guarantees machine operation at minimum pressure. 5) Define the stacking value Y consisting of: lower tools + punch length + 3 mm (Fig. 5.11). 6) Issue an upper beam lowering order using the Closing footswitch and a clockwise rotation

of the remote control hand wheel or push buttons (depending on the NC equipping the machine) together until the S.P.P. (Sheet Pinch Point) value corresponding to Y is obtained.


7) Release the Closing footswitch. 8) Press the machine stop push button. 9) Introduce punch tip in the V groove of the die then slide the lengths of the punches on the

dies, and clamp them. 10) Reset the machine stop. 11) Press the green START button on the NC unit. 12) Press the Closing footswitch. 13) Turn the hand wheel on the remote control clockwise until change in 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.

14) If using dies that require centring on the 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. 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 sales catalogues as well as marked on the side of each tool.

Sectionalised 4 mm gooseneck punch: - Maximum load withstood by this tool: 11 T/M i.e. 110 kN - Total length of sectionalised tool: 800 mm

In this case, the maximum force that this tool can withstand is:

- Max. load withstood by tool (kN) x total tool length/1000

110 x 800/1000 = 88 kN. If you exceed this value it will create “DANGER”.


Minimum force values for each type of machine:

HF 50-12 : 50 kN HF 50-20 : 50 kN HF 80-25 : 70 kN HF 100-3 : 90 kN

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 80.25 (80 T, 2.5 m) - Minimum force applied by this machine: 70 kN - Minimum tool length: 70 x 1000 /110 = 636.36 rounded up to 640 mm (due to tool

sections) But for an HF 100.3, a 800 mm sectionalised tool cannot be used to set the tools as the minimum tool length required is greater than 800 mm.

- The lateral guarding (size & position) on your press brake is designed to take in to account the maximum authorised tool length. This value is given in Para. 2.9, Chap. 2 (Bending Length), and reminded at the bottom of the Table under Number of Tools.

- Do not exceed these limits.


Note It is technically in-correct to centre a long length of dies 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 As the rest of the procedure requires the setter to place his hands in between the tools, it is essential to ensure his safety by turning OFF the hydraulic unit using SA1 (hydraulic unit ON / OFF selector switch) and removing the key from the selector switch.

� 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.


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 beams. - 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 locker (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.).


5.5.6. CHANGING TOOLS (WITH AMNC NUMERICAL CONTROL)

• Unless a proper pressure is applied to the tools, the tools may break in a dangerous manner.

• Pay full attention to the allowable tonnage of the tools. (Refer to the pressure table attached hereto).

• It is dangerous if you have your hands caught between the punch and die. Do not put your hand or hands between the punch and die when you lower the upper beam. (Refer to “Safety Rules”).

Installing tools (When the tools are not installed)

Install the tools as described below.

1. Calculate the P value from the tool installation length and tool allowable tonnage by the following equation:

P = L x T where,

L = tool installation length (m) T = allowable tonnage marked on tool (tons/m)

2. Select SETUP mode and press the ON/OFF

button on the teaching handwheel, Y1 and Y2 will be displayed red (see opposite).

The tonnage applied to tools

will be displayed


3. With the DOWN foot pedal pressed and held, slowly turn the handwheel clockwise to lower the upper beam. When the punch is apart from the die, touch the X5 button to turn on its light and to bring the punch close to the die at a high speed (×5). Slowdown when the punch gets close to the die and before the punch engages the die, release the footswitch and press the X5 button again to turn off the light and to bring the punch into the die at a low speed (×1) whenever turning the handwheel clockwise.

Stop the handwheel rotation when the opposite position is reached (3 to 5 mm).

4. Release the CLOSING foot pedal. 5. Press the emergency stop button. 6. Install the dies and the die holders on the upper beam and tighten their clamping bolts. 7. Install the punches as described below.

1) Insert the fall prevention tongue of the punch into the groove of the punch holder as shown below and slide the punch into position.

2) Tighten the punch holder levers to prevent the punches from falling.

NOTE The punches and dies should be staggered as shown above to prevent the worksheet from being scratched.


8. Release the emergency stop button and reset the machine. Press the ON/OFF button on

the teaching handwheel. 9. Press the DOWN foot pedal. Use the teaching handwheel to move the beam down into the

tools (if X5 light is on, press it to turn it off). Check on the NC tonnage display that the pre-set values are not exceeded.

10. Calculate the P value from the tool installation length and tool allowable tonnage by the

following equation: P = L x T where,

L = tool installation length (m) T = allowable tonnage marked on tool (tons/m)

NOTA In this operating mode, the tonnage limitation operated by the NC is equivalent to the load deduction on the relief valve. Although it is inferior to the controlled machine minimum tonnage, it should be taken into consideration (see table per machine type). This load deduction directly linked to the hydraulic component is about 7 bars on HFP Low Tonnage and 15 bars on HFP Medium Tonnage.

The table below will specify the maximum tonnage applicable to the tool if the stroke required through the handwheel is greater than the tool bottom position. LT MT

Machine type 50 T 80 T 100 T 130 T 170 T 220 T

Tonnage applied on tools

1,2 T 1,8 T 2 T 7,5 T 10 T 13 T

NOTE When the result obtained from the above equation is inferior to the minimum machine tonnage (see machine chart) - it is highly recommended not to use X5 key - press the DOWN (closing) foot pedal, turn the handwheel with great care so that an excessive tonnage is not applied to the tools, while checking P tonnage value as displayed on the screen.

NOTE Dies and punches are available in various V angles, punch tip radiuses, V bottom radiuses and other types. The tools may be misaligned when their angle is not the same or when the punch tip radius is smaller than the V bottom radius. In such a case, place a thin material or newspaper between the punch and die and engage them.

12. Raise the upper beam.


Installing 2V-dies Install the 2V-dies as described below. 1. Install the die holders at the top of the upper beam and fix them with the clamps of the

upper beam. Since the dies and die holders differ in length as shown in the table below, separate the die holders by about 5 mm as shown in the figure below.

L-type length S-type length

Die holder 830 mm 410 mm

Die 835 mm 415 mm

NOTICE Set the die holders for the 2V-dies so that their step and the V-groove of the die to be used face the rear as shown in the figure above. This orientation is termed “front”. This is to prevent the die from flying toward the operator when it breaks.

2. Loosen the die clamping bolts, slide the die from the operator’s side (the front of the

machine) onto the die holder top with the V-groove to be used facing the rear and approximately center the die.


Installing 1V-dies Install the 1V-dies as described below. 1. Loosen the die clamping bolts, slide the die from the operator’s side (the front of the

machine) onto the die holder top and approximately center the die.

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

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


Dismantling the tools Remove the tools as described below. When tool origin is not set 1. Select ON/OFF teach button on the remote handwheel control. 2. Press (hold) down CLOSING footpedal, turn the remote handwheel and lower the upper

beam until the distance between the punch tip and the bottom of the V-groove becomes 2 to 3 mm.

3. Release CLOSING footpedal and press an emergency stop button. 4. Loosen the punch holder clamps and slide the punch sideways to remove it. 5. Remove the die. 6. Release the emergency stop button. Reset the machine. Turn the teach button to OFF

position. 7. Press the OPENING footpedal to raise the upper beam.


5.6. SPECIAL ACCESSORIES AND OPTIONS See Appendix E. 5.7. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES A) Purpose To allow fine adjustment of the tools to obtain minimum angular variation over the bending length 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 & its 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 on Amada machines is factory-adjusted according to average values, and checked by the Amada technician during commissioning on the customer site.


Figure 5.12

Figure 5.13


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 punch and die, or use two special devices which are to be manufactured according to Figure 5.13. These devices are moved simultaneously and symmetrically for the settling of each pair of distance pieces working from outwards in. - Set press brake force to 20 tonnes (200 kN). - Settle the two end distance pieces (simultaneously) first and then the next two, and so on.

At the end, if you are left with only one in the centre of the press brake, it should be settled using a force of 10 tons (100 kN).


Figure 5.14 The distance pieces are set to zero at the factory for the entire range (HF 50-12, 50-20, 80-25 and 100-3) when machines are shipped. Position of standard distance pieces.

0 0 0

0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

Position of abutting distance pieces.

0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0

Figure 5.15

HF 50-20

HF 80-25

HF 100-3

HF 50-12

HF 50-20

HF 80-25

HF 100-3

HF 50-12


Adjusting the dimension “E” using sliding 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 screw (Fig. 5.12). Place the sliding dial indicator on the lower beam, at the centre of the distance piece, and set the pointer to zero. Adjust the remaining distance pieces: - Adjust each distance piece in accordance with the values indicated in the distance piece

curve (Fig. 5.15) which are average values for your machine. - Or by customising the adjustments according to the operating conditions and the results to

be obtained.


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/mm². Using the chart, you can normally find the following information if the sheet thickness e and inside bending radius ri are known:

� Force (kN) per metre of bent length f � Size of the smallest possible edge b � Opening of the die to be used, V

Recommended die openings are shown in shaded boxes.

This opening, V, is related to the thickness e of the sheet to be bent. The recommended values are as follows: For e ≤ 10 mm V = 8 e 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 close to the recommended value, shown in the light boxes of the chart. This chart remains valid for bending other materials (e.g. stainless steel or aluminium); in which case you will be required to apply a correction factor to the given values in accordance with the ratio of their mechanical strengths.

Example: If the chart, based on 40 daN/ mm² mild steel gives a force of 500 kN for a given bend then, to perform the same bend in an aluminium sheet, having a tensile strength of 20 daN/mm² will be 250 kN. BENDING CHART LEGEND PLATE

V width

Internal Radius

Minimum Flange Length

Sheet Thickness

Bending Force kN/M

orange

grey

green

red

blue

OPERATION Chapter 6 1/56 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H Issue 05/2005

6. OPERATION

2/56 Chapter 6 OPERATION Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H

Only trained and qualified operators are entitled to work on press-brakes.

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

2. Turn the motor start-up key switch to the right unstable position. The motor starts

running.

3. Press the luminous reset push button . (see NOTE)

4. The green indicator light lights up.

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.



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 or laser safety system.

The Opening footswitch always overrides any other controls.

⊕

− 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.

Sheet pinch point 0

Above


6.2.1.LAYOUT OF CONTROLS PANELS

“OPERATEUR 2000” NC with or without Light Guard option


“OPERATEUR 2000” NC with “LAZERSAFE” option


“OPERATEUR 2000” NC with “Akas” option


“CD 2000” control panel with or without Light Guard option


“CD 2000” control panel with “LAZERSAFE” option


“CD 2000” control panel with “AKAS” option


“AMNC” control panel with or without Light Guard option

“AMNC” control panel with “LAZERSAFE” option

“AMNC” control panel with “AKAS” option


0

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. - Selector’s 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 safety system (see Appendix E1.4 or E1.5 for “LazerSafe” and E1.6 for “Akas”):

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


: 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 Opérateur 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)

: SPARE



6.2.3. 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 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. � 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 10 mm/s. � No stop at mute point.


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 slow 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. CYCLE 2 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: � Above the mute point, lowering at slow speed (< 10 mm/s). � No stop at mute point. � Working stroke continues below the mute point in working speed.


THESE CYCLES ARE INOPERATIVE WITHOUT SICK LIGHT GUARD OPTION See appendix E1.3 “Light Guard”.


6.2.4. MACHINE EQUIPPED WITH SICK LIGHT GUARD OPTION

THIS CYCLE IS IDENTICAL TO THE ONE DESCRIBED IN BASIC VERSION OF MACHINE (See § 6.2.3, 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 § 6.2.3, CYCLE 1).

See appendix E1.4 & E1.5 “LazerSafe” or E1.6 “Akas”.


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

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

Bending with one operator and 2 control stations (multi staging or multiple bending) 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.


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).

• 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 operator’s 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. In that case, turn the 2nd operator work switch to two operator position.

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”.

Out of US market US market machines machines


6.3. 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. 6.4. START-UP 6. Turn the handle of the main circuit breaker to Position 1.

7. Turn the motor start-up key switch to the right unstable position. The motor

starts running.

8. Press the green luminous reset push button .

9. The green indicator light lights up.

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.



6.5. 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.

⊕

− 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.

Sheet pinch point 0

Above


6.5.1. LAYOUT OF CONTROLS PANELS

“OPERATEUR 2000” NC for standard machine and machine with option Light Guard protection


“CD 2000” control panel

for standard machine and machine with option Light Guard option.


6.5.2. 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.


BASIC VERSION MACHINE (WITHOUT LIGHT GUARD) � No movement. 6.5.3. 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.


6.5.4. 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.


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. Cycle 5 laser protection Not yet available for USA.

Switch SA4 on position :


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.


6.6.PLC MESSAGES LIST 6.6.1.MACHINE FAULT MESSAGES

Message Troubleshooting (red colour) Problem Solution

1 PLC error. The PLC is in hold.. Change CPU board.

2 Start the PLC (Programmable Logic Controller)

Fail safe program is stopped.

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

3 E0.08 or A0.24 input error

The input Ex.xx is faulty or the output of the forced opening relays KAY1 or KAY2 is in short-circuit.

Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics, to check the relay wiring and replace the faulty relay.


The input Ex.xx is faulty or the output for KM1, KM2 or KM3 circuit breakers is in short-circuit.

Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics, to check the circuit breaker wiring and replace the faulty circuit breaker.


The input Ex.xx is faulty or the non-connected light guard terminal is in short-circuit. This output is used by the programmable front support table and sheet-follower options.

Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to to identify short circuit and replace the faulty component.


The input Ex.xx is faulty or 10 mm/s working speed output (input to NC) is in short-circuit.

Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component.


The input Ex.xx is faulty or the machine ready light HL2 (SLB5) or back gauge relay KA4 is in short-circuit.



The input Ex.xx is faulty or high speed output (input to NC) is in short-circuit.





The input Ex.xx is faulty or press-brake opening output (input to NC) is in short-circuit.



The input Ex.xx is faulty or slow speed output for press-brake closing in (input to NC) is in short-circuit.


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

On 35 to 100 T machines : the input Ex.xx is faulty or YV1.1 solenoid valve (left hand side) is disconnected or in short-circuit.



On 130 to 220 T machines: the input Ex.xx is faulty or YV1 solenoid valve is disconnected or in short-circuit.

Check the wiring at input Ex.xx or use an ohmmeter and the electric schematics to identify short circuit and replace the faulty component..


On 35 to 100 T machines: the input Ex.xx is faulty or YV1.2 solenoid valve (right hand side) is disconnected or in short-circuit.



On 130 to 220 T machines: the input Ex.xx is faulty or YV3.1 solenoid valve (left hand side) is disconnected or in short-circuit.



On 35 to 100 T machines: the input Ex.xx is faulty or YV3 solenoid valve 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 short-circuit.



The input Ex.xx is faulty or HL5 output : “GUARD OFF” lamp is disconnected (blown) or in short-circuit.

Check the wiring at input Ex.xx or change the guard off lamp or check any short-circuit in the wiring.




The input Ex.xx is faulty or the output is disconnected from its load or is in short-circuit.


24 The LazerSafe detect excessive environmental light.

25 Reserved 26 Reserved

27 Faulty « PV » out put from LazerSafe

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

Check the cable connection at E0.08 or use ohm meter and electric schematics and identify and replace the faulty component.

28 Fault in the machine stop line.

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

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

29 Faulty KA4A (Closing authorisation for « YV2 » solenoid valve).

The operation of « KA4A » relay is defective. The commuting time of the relay from « 0 » to « 1 » exceed 100 ms.

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

30 Stopping distance too large.

The stopping distance measured by LazerSafe unit is greater than 8.5 mm.

Switch off the machine and restart. If the fault persist, “YV2” solenoid valves should be checked.


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.

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.

32 E0.01 or A0.17 input error Similar to A0.16. Similar to A0.16.





35 E0.04 or A0.20 input error Similar to A0.16. Similar to A0.16




39 Error on board 0 (DI2OT) The board is faulty.

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. Check if 24 VDC is present on the board connectors. If yes, change the board.

41 Error on board 2 The board is faulty. Check if 24 VDC is present on the board connectors. If yes, change the board.

42 Reserved

43 YV1 static fault

On “130 to 220 T” machines: the piston of the pump relieve solenoid valve (YV1) is not in idle (0) position.

Check the operation of YV1.

44 YV1 dynamic fault

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.


45 Static fault on YV1.1 or YV1.2

On 35 to 100 T machines: the piston of either pump solenoid relieve valves (YV1.1 or YV1.2) is not in idle position.




46 YV1,1 dynamic fault

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.


47 YV1.2 static fault

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.

Check the operation of YV1.2.


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.


50 YV1 static fault

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 too long or it has returned to 0 position while the solenoid valve is in status 1.


52 Faulty CLP1 check valve (left hand)

On 130 to 220 T machines: the retaining check valve is not in position.

Check the operation of the valve.

53 YV6 static fault

On 35 to 220 T machines: the piston of slow speed 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 displacement time of the piston is > 80 ms or it has returned to 0 position while the solenoid valve is in status 1.


55 Faulty CLP2 check valve (right hand)

On 130 to 220 T machines: the retaining check valve is not in position.

Check the operation of the valve.

56 Reserved

57 Faulty KA51 & 2 (closing of YV2 valve authorized)

Relay KA51 & KA52 is faulty. When switching to status 0 or 1, the response time of the relay is > 100 ms.

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

58 Slow Speed NC output faulty

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

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



59 NC Safety Relay output fault

See fault 58 (NC slow output speed fault).

See fault 58 (NC slow speed output fault).

60 NC axis in position See fault 58 (NC slow output speed fault).


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


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


63 All NC outputs are in short-circuit.

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

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

64 NC not ready When turned on, the NC ODC output remains at 0 (transistor not commuting).

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

65 SA5 push-button fault at power on.

The normally closed contact of the reset push button is closed when the NC controller is turned on.

Check the wiring ; replace the push button if necessary.

66 SA4 mode selector key switch (000) fault at power on

The mode selector key switch is faulty, all contacts are at 0.

Check the wiring ; replace the key switch if necessary.

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

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

Check the wiring ; replace the contact if necessary.

68 Footswitch 2 fault (n.o to 1) at power on.

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

Check the wiring ; replace the contact if necessary.

69 Footswitch selection faulty (NC output) at power on

The machine auxiliary function (NC output is short-circuited to 0 volt when the PLC unit is turned on.

Check the wiring, replace the output board of the NC if necessary.



70 Footswitch 1faulty (n.o to 1) at power on

The normally open contact of the closing footswitch 1 is abnormally closed when the PLC unit is turned on.

Check the wiring, replace the contact if necessary.

71 Footswitch 1 faulty (n.c to 0) at power on

The normally closed contact of the closing footswitch 1 is abnormally open when the PLC unit is turned on.


72 Opening footswitch 1 or 2 faulty at power on.

One of the opening footswitch is pressed or a contact is faulty when the PLC unit is turned on.


73 KM1 contact faulty when at power on.

The contact of KM1 circuit breaker is abnormally closed or the circuit breaker stayed close when the PLC unit is turned on.

Check the wiring, replace the circuit breaker if necessary.

74 Closing footswitch 1 is active at power on.

Closing footswitch 1 is pressed.

Release the footswitch and reset the fault.

75 Closing footswitch 2 is active at power on.

Closing footswitch 2 is pressed.

Release the footswitch, reset the fault.

76 Awaiting ODC signal after end of bend.

Reserved for running in mode for factory.

77 KPVR1 or 2 faulty (arm rotation)

The contacts of the relay KPVR1&2 are defective. When switching to status 0 or 1, the response time of the relay is > 100 ms.

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

78 E2.00 or A2.16 output error

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

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.





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










































94 LazerSafe is incompatible with two hand push button control.

LazerSafe is incompatible with two hand push button control.

Check the configuration of the machine.

95 Faulty mute output from LazerSafe

The mute output signal from LazerSafe controller is connected to input E1.07 of the PLC unit does not function in each bending cycle.

Check the connection of this output cable.

96 Upper beam is closing with out closing command signal.

LazerSafe has detected closing beam movement without closing foot pedal being activated.

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



600 PLC error F06 Defective PLC unit. Remplace PLC unit.

601 I0.xx input error Many errors at input I0.xx Check the input cables at I0.xx or use ohm meter and electric schematics to trace the fault.

602 I0.00 to I0.15 input error Many errors at the inputs I0.00 to I0.15

Check the input cables at I0.xx or use ohm meter and electric schematics to trace the fault.

603 I0.16 to I0.31 input error Many errors at the inputs I0.16 to I0.31


604 I1.xx or O1.xx input error Many errors at the inputs I1.xx or outputs O1.xx

Check the input cables at I0.xx or outputs at O1.xx or use ohm meter and electric schematics to trace the fault.

605 I1.xx input error Many errors at the inputs I1.x


606 I0.16 to I0.31 input error Many errors at the outputs O1.xx

Check the outputs O1.xx or use ohm meter and electric schematics to trace the fault.

607 Tx or O2.xx output error Many errors at the outputs Tx or O2.xx

Check the outputs Tx or O2.xx or use ohm meter and electric schematics to trace the fault.

608 Tx or O2.8 to O2.15 output error

Many errors at the outputs Tx or O2.8 to O2.15

Check the outputs Tx or O2.8 to O2.15 or use ohm meter and electric schematics to trace the fault.

609 O.16 or O2.17 output error Many errors at the outputs O1.6 or O1.7

Check the outputs O1.6 or O1.7 or use ohm meter and electric schematics to trace the fault.

610 I3.x input error Many errors at the inputs I3.x

Check the input cables at I3.x or use ohm meter and electric schematics to trace the fault.

611 O4.x output error Many errors at the outputs O4.x

Check the outputs O4.x or use ohm meter and electric schematics to trace the fault.

612 I0.0 (//X, Y) input error Input error I0.0 Check the input cables at I0.0 or use ohm meter and electric schematics to trace the fault.

613 I0.1 (SQ12) input error Input error I0.1 Check the input cables at I0.1 or use ohm meter and electric schematics to trace the fault.



614 I0.2 (ctrl KA51&52) input error I0.2 input error

Check the input at I0.2 or use ohm meter and electric schematics to trace the fault.

615 I0.3 (Motor / Pump unit ON) input error I0.3 input error

Check the input wiring at I0.3 or use ohm meter and electric schematics to trace the fault.

616 I0.4 (NC running) input error I0.4 input error


617 I0.5 (Clamping On) input error I0.5 input error


618 I0.6 (HF BT / MT) input error I0.6 input error


619 I0.7 (axes init OK) input error I0.7 input error


620 I0.8 (FGSE OUT1) input error I0.8 input error

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

621 I0.9 (FGSE OUT2) input error I0.9 input error


622 I0.10 (NC axe in pos.) input error 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 decompression) input error I0.13 input error


626 I0.14 (NC RS) input error I0.14 input error




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


628 I0.16 (SA4 bit0) input error I0.16 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




638 I0.26 (NC pedal select) input error 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 Check the input wiring at I1.0 or use ohm meter and electric schematics to trace the fault.










652 I1.8 (SA12) input error I1.8 input error Check the input wiring at I1.8 or use ohm meter and electric schematics to trace the fault.

653 I1.9 (set LS) input error I1.9 input error Check the input wiring at I1.9 or use ohm meter and electric schematics to trace the fault.

654 O1.16+ (YV1.1) output error

Error at output O1.16 + (YV1.1) : wiring or impedance problem.

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

655 O1.16+ (YV1) output error Error at output O1.16 + (YV1) : : wiring or impedance problem.



Error at output O1.17+ (YV1.2) : : wiring or impedance problem.





658 O1.18+ (YV3) output error Error at output O1.18+ (YV3) : : 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.


662 O1.21+ (YV6) output error Error at output O1.21+ (YV6) : wiring or impedance problem.


663 O1.16- (YV1.1) output error

Error at output O1.16- (YV1.1) : wiring or impedance problem.


664 O1.16- (YV1) output error Error at output O1.16- (YV1) : wiring or impedance problem.























672 O/T 2.0 impulsive output error

Pulse output error : wiring or impedance problem.











676 O2.8 (KAY1&2) output error

Single channel output error : wiring or impedance problem.


677 O2.9 (Pump motor unit ON) output error



678 O2.10 (command KA51) output error



679 O2.11 (HL2, KA4) output error



680 O2.12 (FGV to CN) output error





681 O2.13 (Opening to NC) output error



682 O2.14 (FPV to CN) output error



683 O2.15 (n.c) output error Single channel output error : wiring or impedance problem.


684 O2.16 + (HL5 or HL7) output error

Double channel output error: wiring or impedance problem.


685 O2.17 + (n.c) output error Double channel output error: wiring or impedance problem.


686 O2.16 - (HL5 or HL7) output error

Double channel output error: wiring or impedance problem.


687 O2.17 - (nc) output error Double channel output error: wiring or impedance problem.


688 I3.0 (test sec LS) input error I3.0 input error.

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

689 I3.1 (test LED) input error I3.1 input error. Check the input wiring using ohm meter and electric schematics to trace the fault.

690 I3.2 (nc) input error I3.2 input error. Check the input wiring using ohm meter and electric schematics to trace the fault.




694 O4.0 (Aut. Sheet follower) output error



695 O4.1 (nc) output error Single channel output error : wiring or impedance problem.




696 O4.2 (nc) output error Single channel output error : wiring or impedance problem.

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

697 O4.8 (KA6 laser) output error



698 O4.9 (LS ON) output error Single channel output error : wiring or impedance problem.


699 O4.10 (Mute LS) output error




6.6.2.MACHINE STATUS MESSAGES

Message Troubleshooting (white colour) Problem Solution

125 Close the rear door and start the motor

The hydraulic unit is stopped. Close the rear gate to start it.

Close the rear gate and start the motor (switch located on the NC panel).

126 Select operating mode

The reset push-button is pressed while the operating mode selector key switch is in stop position.

Select an operating mode, then press reset push-button.

127 Parallelism lost on X or Y axes.

Over-travel of the back gauge cross-member (X1 or X2) due to parallelism loss and gone on its safety limit switch ; over-travel of the press brake beam (Y1 and Y2) due to parallelism loss and gone on either (Y1 or Y2) limit switch.

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

128 Reset machine (parallelism had been lost on X or Y axes).

When the above fault has been corrected, this message specifies that the fault has been rectified.

Press reset push-button and restart.

129 Machine stop pressed. One of the machine stop button is engaged.

Release the concerned machine stop button.

130 Reset machine (machine stop had been pressed).

Once the machine stop button is released, it indicate that the fault has been rectified.


131 Left hand side gate door open.

The left side gate door is open, only adjustment mode can be executed.

If the selected operating mode is not adjustment mode, close the door then reset.

132 Reset the machine (Side gate doors had been opened).

When the above fault has been corrected, this message specifies that all gate doors are now closed.




133 Right hand side gate door open.

The right side gate door is open, only the adjustment mode can be executed.

If the selected operating mode is not adjustment mode, close the door then reset.

134 Both side gate doors are open.

Both side gate doors are open.

Opening both doors at the same time is prohibited. Close one of the door then reset to operate in adjustment mode.

135 Tools holder unclamped. Every time tool holder is unclamped, it will initiate a machine stop.

Clamp tool holders.

136 Reset the machine (tool holders had been unclamped).

Clamp the tool holders. Press reset push-button.

137 Reset the machine (Two operators mode enabled).

Each change in mode will initiate a machine stop. Press reset push-button

138 Reset the machine (Single operator mode enabled).

A new operating mode is activated. Press reset push-button

139 Reset the machine (robot mode enabled during beam movement).


140 Reset the machine (robot mode disabled during beam movement).


141 Reset the machine (1 operator, 2 footswitches mode enabled)

If the switch is in 1 operator position, it may be dangerous when both footswitches are enabled. It is possible that operator forgot to switch over to 2 operators mode.

Select 2 operators mode and reset.

142 Operating mode non compatible with the robot.

When the robot mode is enabled (if robot option available), the light guard modes are disabled.

Change the operating mode and reset.

143 Reset the machine; pedal operating mode enable.

Pedal operating mode enable Press reset push-button

144

Reset the machine (>30 seconds since the last light guard operated cycle).

In light guard operated mode, the press-brake was inoperative for more than 30 seconds.

Press reset push-button.



145 Reset the machine (light guard broken during high speed approach).

In one of the light guard operated modes, during the high speed closing phase, the light guard has been broken.


146 Reset the machine. When the machine is ready (no fault), but not yet been reset.


147

Enable the opening footswitch (forced opening) or move X axis manually.

Either footswitch or the reset push button is pressed while X or Y axis is out of parallelism.

Press the opening footswitch if Y axis is out of parallelism or move X axis manually if it is X axis, then press reset push button.

148 Reset (adjustment mode) New working mode is enabled. Reset with the push-button.

149 Reset (light guard protection)

New working mode is enabled. Press reset push-button.

150 Reset (robot control) New working mode is enabled. Press reset push-button.

151 Reset (single passing-through mode + footswitch)


152 Reset (single passing-through mode + footswitch)


153 Reset (single passing-through mode)


154 Reset (double passing-through mode)


155 Reset (robot adjustment mode)


156 Reset (adjustment mode enabled)


157 Reset (production mode enabled)


158 Operating mode non compatible with the two-hand push button control

When the two-hand push button control mode is enabled (if option installed), the modes corresponding to 2 passing-through control with the light curtain are prohibited.

Change the mode and reset.

159 Reset the machine (two-hand push button control disabled)

Whenever mode is changed machine stop occurs. Press reset push-button



160 Reset the machine (two-hand push button control enabled)

Whenever mode is changed machine stop occurs. Press reset push-button.

161 Oil temperature too high Oil temperature gone too high.

Wait for the temperature to drop without stopping the motor-pump and cooling unit motors.

162 Reset (Two-hand push button control + footswitch)

New working mode is enabled. Press reset push-button

163 Reset (Two-hand push button control)

New working mode is enabled. Press reset push-button

164 LazerSafe under initialisation or machine stop push button active.

Wait for ~ 4 seconds.

165 Reset (stopping test by LazerSafe done) LazerSafe test is finished. Press reset push-button

166 Working mode non compatible with Laser beam protection.

When laser beam protection is installed, only setting and production modes are available at “SA4” key selector.


167 Working mode non compatible with Tandem machine configuration.

When machines are in tandem configuration, only setting and production modes are available.


168 Side gate open. When machines are in tandem configuration, side gates must remain close.

Close side gates and reset.

169 Reset machine (SOLO mode enabled)

Whenever separator is installed on a tandem machine, it will initiate a machine stop and call for a reset.

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

170 Reset machine (TANDEM mode enabled)

Whenever separator is removed on a tandem machine, it will initiate a machine stop and call for a reset.

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

171 Initialisation of axes is only allowed in setting mode.

When LazerSafe option is installed, initialisation of axes can only be done in setting mode.

Choose setting mode to initialise the machine axes.


6.6.3.OPERATOR MESSAGES

Message Troubleshooting (yellow colour) Problem Solution

249

Break light curtain, then reset the machine ; to authorize high speed approach is.

In « alternate production mode », once the press-brake has been turned on or during the first cycle in this mode, break the light curtain to ensure correct operation of the light guard. If this operation is not performed, the press-brake will operate in working speed.

Break the light guard.

250 Select Mode 1 to 4 to reset the machine.

Once the press-brake is turned on, you must reset the machine. This can only be done by pressing foot pedal 1 (or both foot pedals if 2 operators mode has been selected). Complete cycle with light curtain cannot be used.

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

251 Control device is light guard. Footswitches disabled

If the closing of the press-brake in this mode is authorized by the light guard, pressing either footswitch produces this message.

Close the press-brake by breaking the light guard.

252 Footswitch 1 selected.

This message indicates that only footswitch 1 can close the press-brake. It is displayed when footswitch 2 is pressed.

Release footswitch 2 and press footswitch 1.

253 Footswitch 2 selected.

This message indicates that only footswitch 2 can close the press-brake. It is displayed when footswitch 1 is pressed.

Release footswitch 1 and press footswitch 2.

254 Delay between pressing the two footswitches exceeded.

This message is displayed when de-synchronisation time between the two footswitches is > 4 seconds.

Release both footswitches then press them within 4 seconds at the most.



255 Reset for high speed approach.

In the « alternate production mode », once the light guard has been broken, it should be reset ; if not, the press-brake will only operate in working speed.

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

256 Two operators mode enabled.

Once the press-brake has been turned on, machine reset can only be carried out using both footswitches if the two operators mode has been enabled. This message avoid searches for non-existing faults.

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

257 Footswitch 2 is in stand-by position.

This message appears in 2 operators mode to specify that footswitch 1 has been activated and machine is waiting for 2nd footswitch command to close the press-brake.

Press footswitch 2.

258 Footswitch 1 is in stand-by position.

This message appears in 2 operators mode to specify that footswitch 2 has been activated and machine is waiting for 1st footswitch command to close the press-brake.

Press footswitch 1.

259 Two-hand push button control 1 is selected.

This message specifies that only two-hand push button control 1 can close the press-brake ; it is displayed if two-hand push button control 2 is enabled.

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

260 Two-hand push button control 2 is selected.

This message specifies that only two-hand push button control 2 can close the press-brake ; it is displayed if two-hand push button control 1 is enabled.

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



261 Delay between pressing the two, two hand push button controls exceeded.

This message is displayed when de-synchronisation time between the two, two hand push button controls is > 4 seconds.

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

262 Two-hand control 2 is in stand-by position.

This message appears in 2 operators mode to specify that two hand push button control 1 has been activated and machine is waiting for 2nd two hand push button control command to close the press-brake.

Press two-hand control 2.

263 Two-hand control 1 is in stand-by position.

This message appears in 2 operators mode to specify that two hand push button control 2 has been activated and machine is waiting for 1st two hand push button control command to close the press-brake.

Press two-hand control 1.

264 Press NC Start button to RESET.

Once the press-brake has been turned on, press NC Start button then press the opening footswitch to reset the axes.

Release the footswitch and press NC Start button.

265 Oil filter clogged-up SQ8 filter soiled. Replace the filter cartridge.

266 Light guard in control. Two-hand push button control inoperative.

This message is displayed if two-hand push button control is activated when selected mode only authorize closing of the press-brake through the light guard.

Break the light curtain to close the press-brake.

267 Footswitch control. Two-hand push button control inoperative.

This message is displayed if two-hand push button control is activated when selected mode only authorize closing of the press-brake through the footswitch.

Press the footswitch.

268 Two-hand control. Footswitch inoperative.

This message is displayed if footswitch is activated when selected mode only authorize closing of the press-brake through two-hand push button control.

Press the two-hand control.



269 See message 265. 270 Running in mode active.

271 Motor pump unit auto shut-down off.

Press 5 seconds on START button.

272 Watch out oil temperature too high.

Press brake is used very intensively. Slow down working rate.

273 Press INIT button on LazerSafe.

274 Waiting axis in position signal.

Post NC axes output remain active (at 1) after end of bend when beam reaches ODC and if the closing foot pedal is activated.

See error message 58 (NC output error for slow speed « PV »).

275 LazerSafe : Working mode changed. Press Test button.

The working mode has been changed.

Confirm using Lazersafe Test / confirmation button.

276 LazerSafe : Obstruction during set-up.

The LazerSafe laser beam is obstructed before confirming the mute point

Remove the part or open the pressing beam.

277 LazerSafe : Confirm mute point. Confirm using Lazersafe

Test / confirmation button

278 LazerSafe : Start up time over or encoder error. Check encoder operation.

279 LazerSafe : Work sheet not detected.

After mute point, work sheet is not detected.

Check if the magnetic laser beam blanking plate is correctly installed at the die end or redo teaching of the mute point.

280 Electric cabinet temperature too high.

The temperature in the electric cabinet exceed the temperature monitored by thermal sensor “TH3”.

Check if the cooling unit is operating correctly.

281 LazerSafe : Front beam is obstructed.

The front laser beam of the LazerSafe is obstructed.

Liberate the zone monitored by LazerSafe.

282 LazerSafe : Rear beam is obstructed..

The rear laser beam of the LazerSafe is obstructed.


283 LazerSafe : Central beam is obstructed..

The central laser beam of the LazerSafe is obstructed.


284 LazerSafe : Central and rear beams are obstructed.

The central and rear laser beams of the LazerSafe are obstructed.


285 LazerSafe : Front and central beams are obstructed.

The front and central laser beams of the LazerSafe are obstructed.


286 LazerSafe : Front, rear and central beams are obstructed.

The front, rear and central laser beams of the LazerSafe are obstructed.




287 LazerSafe : The front and rear beams of the LazerSafe are obstructed

The front laser and rear beams of the LazerSafe are obstructed


288 LazerSafe secondary test in progress, please wait.

Each time LazerSafe is switched on, it checks the stopping distance of the upper beam.

Release the closing foot pedal and wait for the LazerSafe test to end.

289

Work sheet detected, release the pedal and press TEST button for confirmation.

The laser beam has detected presence of the work sheet. This position should be confirmed.

Press « TEST » button.

290 Work sheet detected, release foot pedal.

The laser beam has detected presence of the work sheet. Release closing foot pedal.

291 Tool height has been changed, press « TEST » button to teach.

Teach new mute position due to change in tool height in the NC program.


292 Place work sheet to be bent and press closing foot pedal until sheet is detected.

When LazerSafe is switched on, it is mandatory to teach the mute position using correct work sheet.

Press closing foot pedal until work sheet is detected.

293 Press « TEST » button. When LazerSafe is switched on, you must press « TEST » button to proceed.


MAINTENANCE Chapter 7 1/34 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H Issue 05/2005

7. MAINTENANCE

2/34 Chapter 7 MAINTENANCE Issue 05/2005 HF LOW TONNAGE OPERATOR’S MANUAL – X40873H

CAUTION: Any maintenance operation on components which are liable to cause upper beam movement (hydraulic circuit, cylinder, etc.) must be performed with the beam in lower 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. On the other-hand, 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 two or three shifts production (16 to 24 hours per day), and it does not eliminate the need for punctual maintenance according to conditions such as frequent use of oiled or galvanised sheets in large production runs.


IMPORTANT If necessary, use this type of ladder whenever accessing the top of the machine (not an AMADA supply).


7.2. MACHINE PERIODIC MAINTENANCE - COMPOSITION – List of components subject to periodic maintenance

Item 1 - NC UNIT 2 - ELECTRICAL CABINET 3 - EXTERNAL “C” FRAME 4 - UPPER / LOWER TOOLS 5 - LOWER BEAM 6 - PROTECTIVE SIDE GATES 7 - BACKGAUGE (see corresponding appendix) 8 - ROLLER GUIDE PLATE 9 - HYDRAULIC UNIT (MOTOR PUMP) 10 - OIL TANK


PERIODIC MAINTENANCE OF THE MACHINE FREQUENCY ITEM APPLIES TO PRODUCT

Monthly 1 Beam + dist. piece Fine oil Fortnightly 5 Roller guide « TARP S » grease 2000 hours 2 Filtering element H02343 or H02528* / ** 2000 hours 3 Breather H15147** 2000 hours 4 Oil Shell DS46 or equivalent *** * High speed machine ** Always check the part list for correct reference *** ISO VG 46

DIN 51524/2 1st part HL 2nd part HLP AFNOR NF-E 60-200 category HM ISO 11158


PERIODIC MAINTENANCE OF THE MACHINE FREQUENCY ITEM COMPONENT PRODUCT/REF.

Monthly 1 Keyboard/screen Gentle cleaning agent + soft cloths

Monthly 2 Floppy disk drive 3 ½ " cleaning diskette + alcohol

Quarterly 3 Linear scale guides Lithium grease


7.2.1. MAINTENANCE OF THE HYDRAULIC INSTALLATION The hydraulic installation of your press brake has proportional hydraulic directional control valves and the reliability of these components depends above all on the cleanliness of the oil. Remember these fundamental facts: � 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 which is supposed to

be clean. Basic rules: � Because of this, you are advised not to top up or perform oil changes too often. � Well-filtered oil degrades very slowly. � Always filter the oil before topping up or carry out oil change. � Unfiltered oil increases the contamination level.

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 should never run without oil.

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


2

3

1

Hydraulic circuit drain handle


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 upper beam is in its top position. Remove the drain plug (Item 1) and replace it with a hose. Swing the drain handle to open the valve and completely drain the reservoir. 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 *. For reservoir capacity: see Chapter 2, Characteristics. During the filling operation, filter the oil through a 6-micron absolute filter cartridge βx = 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. * ISO VG 46

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


Replace the oil filter cartridge, for Amada reference see Ch. 7, page 6 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 as option.


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)


PERIODIC INSPECTION AND CLEANING LIST FOR THE VARIOUS COMPONENTS

WARNING

THIS PERIODIC MAINTENANCE SCHEDULE IS RELATED TO MACHINE SAFETY.


For HFE, HFT

Upper beam guiding

Main power supply circuit breaker

Floppy drive

3

1 2

Lower beam Tooling


For HFP

Main power supply circuit breaker

3

Floppy drive

2

1


ASSEMBLY SUBASSEMBLY ITEM FREQ. INSPECTION/METHOD TIME

General items Safety switches

Item 1 Item 2 Item 4

Weekly

Weekly

- Clean the carbon deposits

and dust from the following, using a shop vacuum cleaner: - The various parts of the

back gauge (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


Fig. 7.2

UPPER BEAM GUIDING

Fig. 7.1

Fig. 7.1

Upper beam guiding

Lower beam Tooling



Upper beam guiding Filtering elements Light guard interlock (option) Laser beam protection (option)

Fig. 7.1 Fig. 7.2

Fortnightly

Fortnightly

- 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.

- Remove and clean using

compressed air: - Electrical cabinet filters

- See Appendix E1.3 - See Appendix E1.4 ,E1.5

or E1.6.


Sectionalised distance pieces

Lower beam bearing surface

Upper beam bearing surface

Fig. 7.3

Fig. 7.4



Mechanical

NC cabinet Tools

Fig. 7.3

Fig. 7.4

Monthly

Monthly

- Clean using a cloth soaked

in dilute ammonia solution - Screen - Keyboard

- 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


Upper beam guide rail

Breather

Oil tank

Filter

Linear scale guide rail



Upper beam External “C” frame Hydraulic

3 months

3 months

2000 hours

After cleaning use lithium grease to grease the following: - Guide rail - Linear scale guide rail

(remove cylinder covers) - Replace oil filters and

breathers - Drain oil tank


Fig. 7.5

Fig. 7.6

Silent block mountings



Mechanical

Frame Motor Hydraulic/pneu-matic pipework (see Maintenance of the Hydraulic Installation) Electric cabinet Machine stop Rear grid Side protections Opening footswitch Closing footswitch

Fig. 7.5

Fig. 7.6

6 months

6 months

6 months

6 months

Quaterly

Quaterly

Quaterly

Quaterly

Quaterly

- Check machine levelling

(see Ch. 3.3) - Check securing of motor

to its plates and silent blocks

- Check connections - Detect leaks - Check fan operation - Check machine stop

operation (safety devices) - Visual control + door

opening trial - Visual control + opening

trial - Check the operation - Check the operation


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 Department Services (telephone and fax numbers given at the beginning of manual).

PROBLEM SOLUTION

Keyboard does not operate. � Check position of keyboard interlock key. Position 0: Keyboard inactive Position 1: Keyboard active.

The backgauge is not parallel to the tools � If the backgauge is outside the tolerance for parallelism with the tools, it goes into interlock mode (pump’s green indicator light goes off). Push or pull the backgauge to reset the pump.

For the pump to reset, (X1 – X2) must be within axes off-set limit.

Green indicator light does not light up. � Check the Left, Right, and NC unit machine stops.

Refer to the Incidents table in the machine electrical drawing.

TO CONTINUE OPERATING IN COMPLETE SAFETY, USE ONLY ORIGINAL

REPLACEMENT PARTS


7.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL POINTS (APPLICABLE TO 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 in advance, any fault liable to cause an accident, so that such faults can be rectified. These checks are limited to the visible parts and components accessible by removing the covers and cowlings include the following: � 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 debris 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 the settings and clearances

- Fluid levels, - Air and oil pressure, - Limit switch adjustment.

� Check the state of indicators:

- Condition of measuring devices: pressure gauges, - Condition of signalling devices: indicator lights and inscriptions.


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.


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 during use. - Spray in short bursts only. - Air thoroughly the area 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 micro-mechanisms, charged rails, and precision tools. Description:

2 lubricant aerosols: For the ball screws and guides, micro-mechanisms and notched pulleys.

1 cleaning and anti-seizing aerosol: To correct any maintenance and cleaning deficiency, for guide, ball screw, and

precision mechanisms.

1 greasing aerosol: For guides (rails and rollers) of the beams and punch 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 short bursts, 30 cm distance away from the part to be treated.


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 irritations 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. � Dispose any soiled packaging materials via 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.


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: localise and remove the spilled oil using physical means (e.g. absorbent materials), degrease surfaces, dispose the used items in accordance with Section 6. Do not use dispersing agents whenever there is a risk of polluting the environment.

3 - INFLAMMATION AND EXPLOSION 3.1 - FLASH POINT: > 190°C in accordance with AFNOR NF M 07 019 3.2 - SELF-IGNITION TEMPERATURE

> 250°C 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: Foam, carbon dioxide, powder � TO BE AVOIDED: Water jet and water spray extinguisher


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 grams 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 DL50: > 5 ml/kg ACUTE PERCUTANEOUS TOXICITY DL 50: > 4 ml/kg

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.


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:

INGESTION: No special treatment is normally required. Do not induce vomiting to

avoid the risk of debris being sucked into the respiratory passages. INHALATION: 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.

ASPIRATION: 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.

EYES: Wash eyes with copious water, and consult a specialist. SPECIFIC CASE: In the event of contamination via the skin by a high-pressure jet, there is

a risk of contaminant introduction into the patient’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 88-1261 dated 30-12-88.

HF LT (50-100 Ton) Operator's Manual X40873h (May-2005)

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Transcript of HF LT (50-100 Ton) Operator's Manual X40873h (May-2005)