C I N C I N N A T I I N C O R P O R A T E D

C I N C I N N A T I , O H I O 4 5 2 1 1

OPERATION, SAFETY AND MAINTENANCE MANUAL

90 – 350 AUTOFORMCNC FORMING CENTERVME II CONTROL

EM-444 (N-09/99)

COPYRIGHT 1999CINCINNATI INCORPORATED

FOR MACHINES BUILTBEFORE OCTOBER, 1992

INTRODUCTION

SECTION 1 IDENTIFICATION

SECTION 2 INSTALLATIONUNLOADING 2-1LIFTING AND MOVING 2-1FOUNDATION 2-1ERECTION 2-2ELECTRICAL ENCLOSURE INSTALLATION 2-3CLEANING 2-3LEVELING 2-3GAGE INSTALLATION 2-4HYDRAULIC RESERVOIR 2-5LUBRICATION 2-5ELECTRICAL CONNECTION 2-5

SECTION 3 SAFETYSAFETY RECOMMENDATIONS 3-1SAFE OPERATION 3-1OPERATING RULES 3-2INSTALLING / REMOVING TOOLING GUIDELINES 3-3SAFETY SIGNS 3-3SAFETY GUIDELINES 3-5SAFETY MAINTENANCE CHECK 3-5

SECTION 4 SPECIFICATIONSPERFORMANCE AND RATINGS 4-1SPECIFICATIONS CHART 4-2PRINCIPLE OF OPERATION 4-2DEFINITION OF TERMS 4-2CAPACITIES 4-4

PUNCHING CAPACITY 4-4STRIPPING CAPACITY 4-4ECCENTRIC LOAD CAPACITY (F-B) 4-4OFF-CENTER LOAD CAPACITY (L-R) 4-5

SECTION 5 SET-UP & USETOOL INSTALLATION - SET-UP MENU 5-1TYPES OF DIES 5-1

TOP OF DIE CALIBRATION FOR UNMEASURED TOOLS 5-5GAGING - STANDARD BACKGAGES 5-5

CAPACITY 5-5SELECT GAGE SURFACE 5-6ADJUST GAGE FINGER POSITION 5-7GAGE BAR CALIBRATION 5-8PROGRAM GAGE POSITION(S) 5-8GAGE FINGER ADJUSTMENT 5-8WORK SUPPORTS 5-9

OPERATING TECHNIQUES 5-9TOOLING AND SET-UP 5-9RUNNING 5-10SPEED CHANGE/FORMING SPEED 5-10GAGES 5-10

REMOVING TOOLING 5-10

AUTOFORM® CNC FORMING CENTER CONTENTS

EM-444 (N-09/99)

SECTION 6 MACHINE CONTROLSMACHINE CONTROLS STATION 6-1AUTOFORM CONTROL STATION 6-3OPERATOR STATION 6-4AUTOFORM ELECTRICAL ENCLOSURE 6-5FOOTSWITCH 6-5FLOPPY DISK DRIVE 6-5RS-232/422 COMMUNICATION INTERFACE 6-6CONTROLS - AUTOFORM OPTIONS 6-6

ADDITIONAL OPERATOR CONTROLS 6-6DATA CARTRIDGE STORAGE 6-6RS-232/422 CONVENIENCE PORT 6-6POWER CLAMP 6-6CNC BACKGAGES 6-6CNC FRONTGAGE 6-7

SECTION 7 OPERATIONINTRODUCTION TO CNC MACHINE CONTROLS 7-1SCREEN LAYOUT 7-1DAILY START-UP 7-9MACHINE CALIBRATION 7-9SET-UP MENU 7-10GAGE BAR CALIBRATION 7-10TOOLING LIBRARY MENU 7-11ENTERING A NEW PROGRAM 7-22

JOB DATA MENU 7-22RAM DATA MENU 7-24GAGE DATA MENU 7-30PROGRAM STORAGE MENU 7-37

RUNNING THE MACHINE 7-39RUN MODE MENU 7-39QUICK BEND MENU 7-43MANAGEMENT DATA MENU 7-45MACHINE CONFIGURATION MENU 7-48

DIAGNOSTICS 7-49MEMORY DIAGNOSTICS 7-49DISPLAY CONTROLLER TESTS 7-50INPUT / OUTPUT TESTS 7-50FILE SYSTEM 7-51SYSTEM ERRORS 7-51STROKE DIAGNOSTICS 7-52FAULT HISTORY 7-52LOAD / UPDATE APPLICATION 7-53TERMINAL MODE 7-53STATUS AND DIAGNOSTIC LEDS 7-54STATUS DISPLAY FUNCTIONS 7-54SUMMARY 7-56

FILE MENU 7-57FILE TRANSFER MENU 7-57FILE UTILITY MENU 7-60FILE PREFERENCES MENU 7-63COMMUNICATIONS SET-UP MENU 7-64

CAD MENU 7-67INTRODUCTION TO CAD MENU FEATURES 7-67PART STORAGE MENU 7-67PART DESIGN MENU 7-68SHAPE LIBRARY 7-76

SECTION 8 OPTIONSADDITIONAL OPERATOR CONTROLS 8-1AUTO CROWN 8-1AUTOFORM ADAPTIVE BENDING 8-1BACKGAGES 8-1

GAGE ASSEMBLIES 8-1GAGE FINGERS 8-2PROGRAM GAGE POSITION(S) 8-3R-AXIS / Z-AXIS DISABLE 8-3HEAVY DUTY BACKGAGE 8-4SIX-AXIS BACKGAGE 8-5SPECIAL STEP PROGRAMMING 8-6

CONTINUOUS RUN MODE 8-7DATA CARTRIDGE STORAGE 8-7CNC FRONTGAGE 8-8

CNC FRONTGAGE SET-UP 8-8CNC FRONTGAGE OPERATION 8-9PROGRAMMING 8-10

CNC FRONTGAGE SAFETY SIGNS 8-11GRAPHICS SOFTWARE 8-11OFFLINE PROGRAMMING 8-12MANUAL FRONTGAGES 8-12POWER CLAMP 8-12PRESENCE SENSING SAFEGUARDING INTERFACE 8-13PROGRAMMABLE FOOTSWITCH 8-13OPERATION IN RUN MODE 8-14

SECTION 9 MAINTENANCE & ADJUSTMENTSLUBRICATION 9-1HYDRAULIC OIL 9-2OIL FILTERS 9-3CHECKING AND SETTING HYDRAULIC PRESSURES 9-3AIR FILTER / BREATHER 9-5OIL LEVEL / TEMPERATURE SWITCH 9-5HYDRAULIC UNIT OPTIONS 9-6

OIL COOLER 9-6OIL HEATERS 9-6

CYLINDERS 9-6MOTOR / PUMP 9-6VALVES 9-6TILT LIMIT SWITCHES 9-6SWIVEL END-GUIDE BEARING 9-7ENCODER ADJUSTMENT 9-7RELEVEL RAM 9-8

USING SPECIAL CONTROL FUNCTION 9-8MECHANICALLY 9-9

CLOSED HEIGHT ADJUSTMENT 9-9CARRIAGE ADJUSTMENT 9-9

STANDARD DUAL DRIVE BACKGAGE 9-9SIX-AXIS BACKGAGE (Optional) 9-10HEAVY DUTY BACKGAGE (Optional) 9-10TAPERED BACKGAGE (Optional) 9-10

MACHINE LEVEL 9-10ELECTRICAL 9-10MAINTENANCE CHECKLIST 9-10TROUBLESHOOTING 9-11

CRT DISPLAY ERROR MESSAGES 9-11OTHER PROBLEMS 9-33

SECTION 10 SERVICE AND PARTSORDERING REPAIR PARTS 10-1RETURNING PARTS FOR CREDIT 10-1SERVICE 10-1TECHNICAL TRAINING 10-1

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AUTOFORM is a registered trademarkof CINCINNATI INCORPORATED

COPYRIGHT 1999CINCINNATI INCORPORATED

INTRODUCTION

CINCINNATI AUTOFORM

The AUTOFORM is a hydraulically driven, servo-controlled press brake. Linearencoders constantly monitor the bed-to-ram position, feeding this information to theControl. The Control is a programmable microcomputer, interfaced by the operatorthrough a keyboard using a conversational program display on a color monitor. Theprogram controls the vertical movement of the ram and movement of the backgage.After a program is entered either the machine can be run or the program stored ininternal memory. The AUTOFORM Control allows an individual job to be quickly set-up and run as well as complicated, multi-bend parts or long run jobs. After a programis run, the program and related set-up information can be saved for future use.

PART QUALITY

The following factors affect part quality:

✦ Press Brake condition and repeatability✦ Operator ability✦ Condition of tooling✦ Quality of material

CINCINNATI machines are designed to be rugged and durable. However, improperadjustment or lack of maintenance can reduce the quality of parts produced on thatmachine. These factors may also affect the repeatability of the machine. A machinethat will not consistently reverse at the same point or will drift out-of-level will notproduce uniform parts.

Operator ability obviously affects part quality and production rate. CINCINNATIINCORPORATED provides many design features in the machine and optional acces-sories to aid even the most experienced operator to produce consistent parts. Theoperator or set-up person must select the best tooling from those available. The typeof gaging, material supports or other special equipment will affect how the part isproduced. Selecting the proper bend sequence is important to obtain quality partsand for operator safety. CINCINNATI offers both Operator and Maintenance trainingprograms at our factory to address these problems. This training may cover subjectsfrom the basics of forming to the use of the machines microcomputer controls.

Worn, damaged or poor quality dies or filler blocks can directly affect part quality.Using good tooling, selecting the correct tooling for the job and setting them upproperly can produce good part quality.

Quality of material can affect angular tolerances of the bend. This is due to normalmaterial thickness variations found in commercial steels as well as hard and softspots in the metal. Using a good grade of material and the proper tooling set-up willminimize the variations.

EM-444 (N-09/99) 1-1

SECTION 1 IDENTIFICATION

AUTOFORM CNC FORMING CENTER

FIGURE 1-1 – Front View

1. LEFT HOUSING2. CYLINDER MANIFOLD & VALVES (2)3. COUNTERBALANCE MANIFOLD

AND VALVES (2)4. RAM5. RIGHT HOUSING6. RIGHT CYLINDER7. PENDANT ARM

8. AUTOFORM CONTROL PENDANT9. MAIN DISCONNECT SWITCH

10. FLOPPY DISK DRIVE11. ELECTRICAL ENCLOSURE12. LINEAR ENCODER (2)13. CAPACITY PLATE14. FILLER BRACKET15. BED SHOE (2)16. DIE CLAMPS

17. STANDARD GAGE BAR18. PALMBUTTON OPERATOR STATION19. FOOTSWITCH20. AUTO CROWN AUXILIARY CROSS

MEMBER (Optional)21. AUTO CROWN CYLINDER (Optional)22. BED23. LEFT CYLINDER

1 2 3 4 3 2 5 6 7 8

23

11

14

13

12

9

10

12

15

20

21

22

19 18 17 16 15

1-2

FIGURE 1-2 – Rear View

1. HOUSING BRACE / HYDRAULIC RESERVOIR2. DRIVE MOTOR AND PUMP3. HYDRAULIC MANIFOLD AND VALVES4. HYDRAULIC FLUID SPECIFICATION PLATE5. OIL SIGHT GAGE & THERMOMETER6. LEFT RAM CLAMP (Behind Encoder Bracket)

7. ENCODER BRACKET8. OPERATOR’S MANUAL POCKET9. LEVELING SCREW (4)

10. RESERVOIR DRAIN VALVE11. BACKGAGE ARM ASSEMBLY12. TILT LIMIT SWITCHES

1 2 3 4 5 6

7

8

9

1011

12

AUTOFORM CNC FORMING CENTER

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UNLOADINGAfter receiving your CINCINNATI AUTOFORM, care-fully remove the contents of the one or more boxesshipped with the machine. All of the machine’soptional accessories and small parts are in theseboxes, such as wrenches and leveling shims. Checkall of these parts with the packing list. Claims forshortages should be made within ten days.

Most machines are shipped assembled on skids.Some of the longer length machines are shippedwith the bed removed and bolted to the rear of thehousings and some are shipped disassembled.

Remove all shipping paper from the wrapped partsof the machine. Leave the shipping skids, bed andram bracing and electrical enclosure attached tothe machine until it has been moved to its finallocation.

LIFTING AND MOVINGThe machine can be handled by a crane(s) of suffi-cient capacity with chains or cables of adequatesize (refer to American National Standards InstituteB30.9). Shipping weight of the machine is listed onthe Bill of Lading for the shipment. Check thisweight carefully before lifting or handling. Usechains or cables adjusted to the proper length foreven lifting. The chains or cables should be longenough to minimize the side loading on the hous-ings. If short cables are used, fit a spreader beambetween the housings near the lifting holes. A typi-cal hitch is shown in Figure 2-1.

If your crane does not have sufficient capacity, orno crane is available, rig the machine into finallocation. Leave the bed attached to the back of thehousing when rigging the longer length machinesinto position.

CINCINNATI INCORPORATED recommends thatprofessional riggers be employed to handle themachine. This is to guard against injury to person-nel and prevent damage to the machine. If jacks areused to lower the machine onto the foundationbolts, care should be taken to prevent twisting ofthe machine.

FIGURE 2-1 – Lifting the machine

FOUNDATION

A CINCINNATI AUTOFORM must be provided witha rigid foundation to ensure that alignment of thehousings and cross framing members is main-tained. The foundation must support the weight ofthe machine without cracking or settling out-of-level.

For details of the foundation recommended for yourmachine refer to the certified Foundation Plandrawing. It is advisable, particularly in localitieswhere unusual soil conditions may exist, to haveyour Foundation Plan approved by a local regis-tered civil engineer.

As a final check before locating the AUTOFORM onthe foundation, see that the anchor bolts in yourfoundation match the bolt hole spacing in thehousing feet. Check the width of the bed pit (whenrequired) and the distance from the centerline ofthe front foundation bolts to the front edge of thebed pit. They should agree with the dimensionsshown on the certified Foundation Plan drawing.

CAUTIONBE EXTREMELY CAREFUL TO KEEP THEMACHINE SUPPORTED EVENLY AND TOGUARD AGAINST TIPPING.

EM-444 (N-09/99) 2-1

SECTION 2 INSTALLATION

ERECTIONOpen the shim packages shipped with the machineand remove the thickest shim from each package.Place one shim at each foundation bolt location.The top surfaces of the shims must be about level.Thinner shims can be used to obtain this level con-dition. Then place a 1/8” (3.2mm) thick shim at thefront feet locations to deliberately make the front ofmachine high. It is easier to raise the rear housingfeet to obtain final leveling when the AUTOFORM isin position. As an option, it is recommended that atransit is used to establish that all four pads are inthe same plane.

Lift the machine with a crane to remove skids. If nocrane is available, secure against tipping as soonas the skidded machine is placed on the foundationand before skids are removed. To secure againsttipping use a block and tackle. Run one from thehousing lifting hole to the rear of the machine andsecure to a solid anchor in the building. Run anoth-er block and tackle from the other housing liftinghole to the front and secure. To remove skids, raisethe machine in about 2” (51mm) steps with the aidof blocking and jacks of sufficient capacity. Thejacks should be placed under the front and rear ofhousings. Use leveling screws in housing feet forinserting and removing jacks. Block up housings,about 2" (51mm) at a time, until there is enoughclearance to remove skids. Lower machine byremoving the blocking about 2" (51mm) at a timefrom alternate housings. Temporarily bolt themachine in place on the foundation. Remove theblock and tackle used to secure machine againsttipping. Remove shipping blocks from between bedand ram.

IMPORTANT: The electrical enclosure mounting feetare on the same level as machine's feet. Careshould be taken not to allow these feet to carryany load of the machine during installation.This could damage the electrical enclosure.

MACHINES SHIPPED WITH BED REMOVED

Remove the “X” type shipping braces bolted to thefront of housings and thoroughly clean the protec-tive grease from the front faces of the housings.Remove the grease with a clean rag soaked in sol-

vent, such as mineral spirits. Wipe with clean rags.A stiff brush will get into the corners. Do not use anair hose because the pressure could drive grit anddirt into the bearing surfaces.

The front vertical bed mounting faces of the hous-ings must be plumb. This can be checked with thelevel in squaring head of an ordinary machinist’ssquare or with any level that can be used on a ver-tical surface. If the housings are not plumb, loosenthe nuts on foundation bolts. Use leveling screws inhousing feet to raise or lower machine. Do not allowmachine to permanently rest on these screws.Insert flat steel shims under the housing feet asrequired. Lower housings and retighten foundationbolt nuts. Recheck the plumb on housing faces andrepeat above procedure if necessary until the hous-ings are plumb.

Remove the bed from rear of housings using achain or cable of adequate capacity. DO NOT USEHOUSING SLOT IN THE BED TO LIFT THE BED.Remove the bed shoes and bed bolts from shippingbox. Clean the bearing surfaces of the housingsand the matching bed surfaces, and the bed shoesand bolts. Carefully lubricate all finished surfacesof the housings where the bed fits. Also lubricatetop and bottom surfaces of bed shoes. Use EP #2Lithium grease (C.I. grease H-2EP). Place bed shoesinto position on the housings. Match the markingson housings and bed shoes. Place the bed into posi-tion on housings and insert bed bolts into bed.Loosen all foundation bolt nuts and tighten bedbolts securely. Retighten the foundation bolt nutssecurely. See the following chart for bed bolt andfoundation nut seating torques.

Check your work with feeler gages. There should beno clearance between the bearing surfaces of thehousings and bed. If there is clearance, either thebed bolts are not tight or there is grit between thebearing surfaces. There should also be no clear-ance between the bed shoes and the bed.

BOLTDIAMETER

SEATING TORQUES Ft.-Lbs. (Nm)

BED BOLT FOUNDATION NUT

3/4

1"

1-1/4

1-1/2

297

(403)

734

(995)1189

(1612)

2033

(2757)

–

–

295

(400)530

(719)

–

–

! ! DANGER ! !! ! DANGER ! !THE MACHINE IS TOP HEAVY TO THE REAR ONSOME MODELS WITH BED ATTACHED TO REAROF HOUSINGS. USE EXTREME CAUTION ANDENSURE MACHINE IS SECURED AGAINST TIPPINGBEFORE REMOVING SHIPPING SKIDS.

2-2

The encoder lower mounting brackets wereremoved for shipment. A Service Representativefrom CINCINNATI INCORPORATED will install andadjust the encoders at start-up.

ELECTRICAL ENCLOSUREINSTALLATIONRemove the bolts and nuts that secure the electri-cal enclosure to the filler brackets attached to themachine’s housing. Be careful to guard againsttipping, because the pendant makes the unit topheavy. Move the electrical enclosure at least 1/8”(3mm) away from the filler brackets to isolate itfrom the machine. Locate the anchor bolt holesfrom the electrical enclosure feet. Install four 1/2”bolts to anchor the enclosure to the floor.

Level the electrical enclosure front-to-back byadding or removing shims under the feet. See Fig-ure 2-2 for dimensions of these shims. Securelytighten the four 1/2” bolts.

Install rubber grommets in the electrical enclosureshipping bracket bolt holes. These grommetsshould be installed from the inside of the electricalenclosure.

FIGURE 2-2 – Electrical Enclosure shims

CLEANING

Thoroughly clean protective grease from all otherparts of the machine. Remove the grease with a ragsaturated in cleaning solvent and wipe with cleanrags. A stiff brush will get into the corners. Do notuse an air hose. The pressure could drive grit anddirt into bearing surfaces. After cleaning themachine thoroughly, wipe dry. Make sure no dirt orgrit is left, then lightly oil the bed and ram finishedsurfaces. Periodic cleaning of the machine afterinstallation is recommended.

LEVELINGCINCINNATI AUTOFORM is leveled by placing flatsteel shims (supplied with machine) of properthickness under the housing feet as required. Use aprecision level – not a carpenter's or machinist'slevel. Always wipe the level and bed surface cleanand remove burrs before positioning the level.

The machine can be raised or lowered by using lev-eling screws in the housing feet. Use at least a twofoot length of pipe on the wrench. The foundationbolt nuts must be loosened, not removed, beforejacking the machine. Before checking the level ofthe machine, foundation bolt nuts must be secure-ly tightened to the previously specified torque.

Start leveling by checking the setting of machinelengthwise. Place level in the center of bed parallelto edges of the bed. Level the machine lengthwiseby placing the required metal shim under the lowhousing feet, both front and back. Lower themachine and recheck level. Repeat until machine islevel lengthwise.

Level the AUTOFORM front-to-back with levelcrosswise on the bed as shown in Figure 2-3. Checkfirst with the level at the right end of the machineand then at the left end. Add or remove shimsunder the front or back housing feet as required.Level readings on both ends of bed must be alikewithin .001" (.025mm). Recheck lengthwise leveland repeat above procedure until machine is levelin all directions.

FIGURE 2-3 – Leveling the machine

Check the ram guide and slide alignment to makesure there is no twist in the machine. This is doneby loosening the ram clamp bolts until the ram

1.25(32mm)

4.0(102mm)

2.5(63.5mm)

.75

(19m

m)

1"(2

5mm

)

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MATERIAL –MILD STEEL

2-3

hangs free of the guides. Use clamp bolt heads topush against the back of the encoder mounting barto pull clamps away from the guides. Measure witha feeler gage the clearance between the ram slideliner and the ram guide at the top and bottom. SeeFigure 2-4. Measure at both left and right guide.The top measurement is always given a plus (+)value and the bottom is always given a minus (-)value.

EXAMPLE #1:Left RightClearance Clearance

At top +.005” (.127mm) +.000”At bottom -.020” (.508mm) -.015” (.381mm)Then total -.015” (.381mm) -.015” (.381mm)

Since the values are equal, the guides are in thesame plane and there is no twist in the machine.

EXAMPLE #2:Left RightClearance Clearance

At top +.005” (.127mm) +.020” (.508mm)At bottom -.015” (.381mm) -.000”Then total -.010” (.254mm) +.020” (.508mm)

FIGURE 2-4 – Ram slide and guide alignment

The amount of clearance is not important. Howev-er, the difference between the clearance of the leftand right guide/slide indicates the amount of mis-alignment. The maximum allowable difference is.004" (.102mm). In Example #2, the difference is.030" (.762mm), which indicates there is twist inthe machine.

This condition is corrected by adding or removingshims under one of the rear housing feet. In Exam-ple #2 the excessive clearance was at the rightguide and slide. Since this measurement was plus,the clearance was at the top. To bring the align-ment into tolerance, shims could be added underthe right rear housing foot, or removed from the leftrear housing foot. The alignment must be correctedeven if it causes the bed to be out-of-level.

After the machine is level retighten foundation boltnuts securely. Recheck guide and slide alignment.

IMPORTANT: Before running the machine,tighten the guide clamp bolts to 60 ft.-lbs.(81.4Nm) and properly lubricate slide linerswith light hydraulic oil. Use tool shown inFigure 2-5.

FIGURE 2-5 – Tool for guide clamp bolts

Alignment may not be permanent. Recheck level in afew weeks. Do not use any grouting around themachine. For machines where the bed goes belowfloor level, leave the bed pit empty and cover exposedpit opening with steel plate.

GAGE INSTALLATIONThe CINCINNATI INCORPORATED AUTOFORMgages are usually shipped assembled to themachine and require no installation.

IMPORTANT: Do not make any electrical con-nections or final adjustments until aCINCINNATI INCORPORATED Service Repre-sentative is present.

In the event that the gage is not already assembledto the machine, remove the gage assemblies fromtheir packing containers. Remove any protectivewrapping and clean the parts.

IMPORTANT: Do not install the gage, rear guardor make electrical connections until aCINCINNATI INCORPORATED Service Repre-sentative is present.

For the final adjustments and installation of thegages, see MAINTENANCE & ADJUSTMENTS,SECTION 9, of this manual.

60 FT. LBS.HERE

EQUALS 100 FT.LBS. ON GUIDECLAMP BOLTS

SPECIAL TOOLTORQUE WRENCH -1/2" DRIVE

2-4

HYDRAULIC RESERVOIR

The hydraulic reservoir is equipped with a drainvalve. See Figure 1-2. Before starting machine,crack this valve open. Water may have collected inthe tank during shipment. If no water comes out, orwhen oil starts coming out, close the valve secure-ly. Repeat this check monthly.

LUBRICATION

Proper lubrication is of extreme importance to yourmachine. Carefully following all lubrication instruc-tions will pay dividends in lower maintenance costsfor your CINCINNATI AUTOFORM.

The following lubrication points should be checkedbefore start-up and at regular intervals thereafter.

1. Hydraulic Reservoir: Before starting machinecheck for proper fluid level at the oil sight gage.See Figure 1-2.

2. Cylinder Clevis Pins: Lubricate while cyclingram under load, such as obtained with a bump-ing die. Lubricate once a month. Use a #2 lithi-um base grease with “moly” additive (C.I. greaseH-2M). This must be done after electrical con-nections are made and the machine is running.

3. Ram Guides and Slide Liners: Wipe clean andflush with light hydraulic oil.

4. Gages: Clean and lubricate all exposed guiderails with a light coating of spray lubricant or#10 oil. The X-Axis, R-Axis (optional) and Z-Axis

(optional) ballscrews should also be lubricatedwith a light coating of spray lubricant or #10 oil.These ballscrews are easily accessed by remov-ing the protective covers. See MAINTENANCE &ADJUSTMENTS, SECTION 9 for more specificdetails.

5. Auto Crown (Optional): There is a grease fit-ting at each of the pins through the bed andauxiliary plate. These grease fittings are on thefront end of the pins in a hole through the pinretaining plates. The pins should be lubricatedmonthly. Use a No. 2 lithium base grease with a"moly" additive (C. I. grease H-2M).

ELECTRICAL CONNECTIONSuitable electrical leads must be brought to themachine as shown on certified Foundation Plandrawing. These leads are connected to the incomingside of electrical disconnect switch in the main elec-trical enclosure. Be certain that leads are of suffi-cient capacity and that proper voltage is fed to themachine. CINCINNATI INCORPORATED equipmentrequires that the incoming line supply at themachine does not vary more than plus or minus10% from the nominal. Some installations mayrequire additional line conditioning, other thansupplied with the machine controls. ContactCINCINNATI INCORPORATED Service Departmentfor further information.

Machine must be connected to a good earthground. A ground lug on the line side of themachine main disconnect is provided for this pur-pose. Refer to local and state codes for acceptablegrounding methods.

Note: If a CINCINNATI INCORPORATED ServiceRepresentative is not present, call beforeproceeding any further or startingmachine. He will complete all electrical con-nections and check motor rotation.

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! W! WARNING !ARNING !KEEP CLEAR OF THE MOVING RAM.

CAUTIONStandard machines are designed for and shippedwith petroleum based hydraulic fluid, which isflammable. Check applicable fire codes for spe-cial precautions.

2-5

SAFETY RECOMMENDATIONSFOR HYDRAULIC PRESS BRAKEOPERATION:Press brakes manufactured by CINCINNATIINCORPORATED comply with the constructionrequirements of the Occupational Safety andHealth Act and the National Safety Standards of theAmerican National Standards Institute.

The AUTOFORM is essentially a hydraulic pressbrake with advanced microprocessor controls andautomatic backgage. The press brake is a versatileand multi-purpose machine. We recommend evalu-ating each press brake operation in order to deter-mine the method of point-of-operation safeguardingwhich best meets that operation. The press brake,tooling, piece part and method of feed and removalmust be evaluated for each job before deciding onthe safeguarding to be used.

CINCINNATI INCORPORATED recommends youread and understand the safeguarding, use andcare requirements of the American National Stan-dard for Press Brakes, ANSI B11.3. This is availablefrom the American National Standards Institute, 11West 42nd Street, New York, New York 10036 andis included with this manual.

For additional safety information we recommend:

✦ securing applicable safety data sheets from theNational Safety Council, 1121 Spring LakeDrive, Itasca, Illinois 60143-3201

✦ determining your responsibilities under yourstate and local safety codes

✦ requesting assistance from the loss preventiondepartment of your workmen’s compensationcarrier

Personnel responsible for your press brake operatortraining program, tooling set-up, maintenance, andoperations must read and understand this Opera-tion, Safety and Maintenance manual. No oneshould set-up, operate or maintain this press brakeuntil they thoroughly understand it and know howto do their job safely. Read this manual in itsentirety. This safety information is not intended asa substitute for the Operation and Maintenancesections of this manual.

FOR SAFE OPERATION OF YOURCINCINNATI PRESS BRAKEKEEP CLEAR OF THE POINT-OF-OPERATION

The purpose of a press brake is to bend metal, andit is obvious that this same capacity will severarms, hands, fingers or any other part of the bodythat is in the point-of-operation when the ram isactivated.

During operation, all parts of your body must becompletely clear of the work area. NEVER PLACEANY PART OF YOUR BODY IN THE POINT-OF-OPERATION (Die area).

If operation by more than one person is required,operator controls must be furnished for each per-son. If foot controls are used, and your evaluationof that specific operation indicates safeguarding isnecessary, provide the necessary safeguardingbefore any work is performed. (See ANSI B11.3.)

If you use two-hand operator control station(s) aspoint-of-operation safeguarding, be certain thatthey comply with ANSI B11.3.

If operation by more than one person is required,one person should be responsible to see that notonly his own body is clear of the point-of-operationand all moving parts, but also that his co-workersare clear and entirely visible in a safe location,before the press brake is operated.

During set-up, maintenance or other work on themachine which necessitates manipulation withinthe point-of-operation, either the ram should be atthe bottom of the stroke or it should be blocked sothe dies cannot close. The power supply should bedisconnected and locked OFF.

CONCENTRATE ON YOUR JOB

Improper operation of a machine, whether causedby daydreaming or worrying about other problems,could cripple you for life. Operating a press brakerequires your complete attention. Talking, joking orparticipating in or watching horseplay could resultin physical injury to you . . . and that is nothing tojoke about. So watch what you are doing and con-centrate on your job.

NEATNESS IS IMPORTANT

Keep the floor of your work area clear of scrap andtrash that could cause you to stumble. Put scrap in

EM-444 (N-09/99) 3-1

SECTION 3 SAFETY

the proper containers and keep stock and finishedwork neatly arranged. Be sure slippery surfaces arecleaned up properly. Stumbling and slipping canresult in painful and perhaps even fatal injuries.

Put all tools and equipment away when you are notusing them. Only the part you are working withshould be on the machine when it is operating.Even a screwdriver can be deadly if left on the pressbrake or lower die.

PROPER TOOLS ARE IMPORTANT

Use proper tools when working on the press brake.An improper tool might slip and cause lacerations.When making repairs on the machine, disconnectthe power source and lock it out. Be sure the ramis at the bottom of the stroke or blocked in place.

ELIMINATE LOOSE AND FLOWING CLOTHING

Loose or flowing clothes may be comfortable, but ifthey are caught on the machine, it could result inan injury to you. Keep jewelry to a minimum. Thatlink I.D. bracelet you got for Christmas could costyou your hand or finger.

LOOK THINGS OVER CAREFULLY

Before operating your CINCINNATI AUTOFORM,look to see if your machine is in proper condition.Are the dies worn? Are the machine’s covers andguards securely in place? Is the machine securelyanchored to the floor? Are all nuts, bolts andscrews tight? Is everything in proper operating con-dition? If not, report any unsafe condition or need-ed repair to your supervisor and be sure the prob-lem is corrected before beginning operations. TheCINCINNATI AUTOFORM you are operating will notproduce a tonnage greater than the maximum ratedmachine capacity (see capacity plate). However,when using short or small area dies, the tonnagemust be reduced to avoid damage to the tooling orthe bed and ram of the machine. Too much tonnagemay also cause a die to rupture and cause injury.Consult the Press Brake Capacities bulletin for theload required to do the job. If this is less than max-imum machine capacity, program the control not toexceed the required force by more than 10%.

FOR THE SAFE OPERATION OFYOUR CINCINNATI AUTOFORM

FOLLOW THESE RULES:1. Never place any part of your body in the

point-of-operation (Die area). Placing yourhands or any part of your body in the point-of-operation may result in serious injury oramputation.

2. Evaluate each operation to determine the point-of-operation safeguarding to be used.

3. Use the point-of-operation safeguarding select-ed, or method of operation selected to minimizethe exposure to potential hazards at the point-of-operation.

4. For small part insertion and removal, use ahand tool. DO NOT place your hands in thepoint-of-operation.

5. Know how to safely operate and adjust yourCINCINNATI AUTOFORM. Review the Operationand Maintenance sections of this manual.

6. Maintain proper lighting levels and eliminatelight glare to prevent eye strain and eye fatigue.

7. Protect your eyes from flying pieces of metal byalways wearing your safety glasses.

8. Always wear safety shoes. A heavy or pointedpiece of stock could fall and cause seriousinjury to your foot.

9. Wear snug fitting hand and arm protectionwhen handling rough or sharp edged stock.

10. Keep the die area free of loose tools and materi-als. When placing stock in the machine forforming, be certain the gages and stops are cor-rectly set and the edge of the stock is againstthe gages.

11. Stand clear of the workpiece with your armsslightly extended to avoid being hit if the stockwhips up or down as the bend is made. Be sureyou know how the workpiece will react to thebend being made. If the workpiece whips-up,place your thumbs and fingers below the mate-

3-2

rial. If the workpiece whips-down, use theclamp/stop feature of the machine control soyour hands can be removed from the workpiecewhen the bend is made. Set the forming speedto avoid excessive part “whip”.

12. When you leave the machine, place the ram atthe bottom of the stroke or place safety blocks inposition under the ram. Turn OPERATOR CON-TROL selector to “OFF” and remove the key,even if you will be away for only a few minutes.

13. Have the routine scheduled maintenance andadjustments performed as shown on the Main-tenance Checklist in SECTION 9.

14. Check the alignment of the dies before operat-ing the machine after the dies have beenchanged or if the machine has been idleovernight. Improper alignment could causechipping and flying chips can cause lacerationsand eye injuries.

15. Report any cuts, bruises and all other injuriesto your supervisor or the medical departmentimmediately. They are the best judges of theseriousness of your injury.

GENERAL GUIDELINES FORINSTALLING, REMOVING ANDTRANSFERRING TOOLING (DIES)Installing, removing and transferring tooling can behazardous and should be done with proper super-vision by experienced set-up men. Improper han-dling techniques can cause muscle strains, herniasor serious disabling injuries.

1. Transfer dies using the proper techniques forthe weight of the die(s) being handled:

a. Very light dies, up to 50 pounds (23kg), canbe carried manually or transferred on a dietruck.

b. Dies weighing over 50 pounds (23kg), orthose that are awkward to move, should behandled by a hoist.

If the punch or die has tapped holes for liftingattachments, be sure the proper size bolts areused. A bolt smaller in diameter than thetapped hole will slip out and cause seriousinjury. If no lifting attachments are provided,use only approved rope slings so the dies willnot be nicked or scratched.

Lift the dies high enough to clear any obstruc-tions, but no higher.

2. When installing and setting-up dies:

a. Clean machine and filler block surfaces towhich the dies will be fastened. Always turnthe machine OFF when working in this area.

b. Inspect the dies for chips, cracks or otherhazardous conditions. Wipe them off with aclean cloth.

c. Always place the machine control MODEselector in the “SET-UP” position so the ramcan only be moved by the use of palmbut-tons, RAM UP button or softkeys.

d. Never reach into or through the die areawhen aligning the dies or setting the gaging.

3. When removing dies from the press brake:

a. Clear the work areas of all stock, containers,tools and other equipment.

b. After placing safety blocks between the diesand turning OFF the machine, clean bothupper and lower dies using a bench brushand finally wipe clean with a cloth.

c. Place machine control MODE selector in the“SET-UP” position so the ram can only bemoved by use of the palmbuttons, RAM UPbutton or softkeys.

d. Never loosen the ram clamp bolts or select“UNCLAMPED”on the optional Power Clampcontrol unless the dies are in a closed posi-tion and the OPERATOR CONTROL selectoris in the “OFF” position.

Detailed step-by-step instructions for installing andremoving tooling are provided in the SET-UP ANDUSE section of this manual. These instructionsshould be followed for safe installation and removalof tooling from your CINCINNATI Press Brake.

Also included in the SET-UP AND USE section ofthis manual are instructions for making bends,gaging, blank development and use of the machinecontrols.

SAFETY SIGNSIn order that press brake operators and mainte-nance personnel may be warned of certain potentialhazards that may exist - unless specified proce-

! ! DANGER ! !! ! DANGER ! !STAY CLEAR OF DIES WHILE THEY ARE BEINGTRANSFERRED, PARTICULARLY WHEN THEYARE BEING LIFTED. IF A DIE SHOULD SLIP, SERI-OUS INJURY, INCLUDING LOSS OF HAND, AFOOT OR EVEN YOUR LIFE, COULD RESULT.

3-3

dures are followed – a number of warning signs areattached to CINCINNATI Hydraulic Press Brakes.Warning signs are not intended to be a substitutefor reading and understanding this Safety sectionand machine Operation and Maintenance manual.

The warning signs are placed at strategic points onthe press brake for the most effective use. It isintended that they become a permanent part of theequipment and, therefore, must not be removed,covered, hidden or defaced. All signs installed onthe machine by CINCINNATI INCORPORATED areidentified by a small six digit part number inthe lower right corner. If any of these platesbecome damaged or defaced, new ones shouldbe ordered by contacting the factory or thenearest CINCINNATI Sales and Service Office.

The following illustrations are of the warning signsmost commonly used on the hydraulic pressbrakes. Some other signs may be furnished to coverpossible hazards due to special equipment ormachine features. The user management shouldalso include additional warning signs to cover anyhazards that may be presented by customer-addedauxiliary equipment.

HAZARDOUS AREA (232913)

This sign warns of a hazardous area between themachine housings at the rear of the press brake.The sign is attached to a steel restraining cablewhich spans the space between the housings. Noone should enter this area while the machine drivemotor is running or the control is energized.

DIE AREA (153725)

This DANGER sign warns the operator to keep hishands out of the die area (point-of-operation). Thesign is usually attached to one end of CINCINNATI

dies and not on the press brake. These adhesivebacked signs have been furnished in safety updatepackages and are available from CINCINNATIINCORPORATED.

DANGER (240008)

This warning sign is attached to the press brakeram, which is the most visible location on themachine. The sign is a reminder to operators ormaintenance personnel that certain proceduresmust be followed to prevent serious bodily injury.

SAFETY GUIDELINES (240003)

This sign is also attached to the ram adjacent to theDANGER sign. It provides a checklist of safety con-siderations which should be observed before, dur-ing and after operation of the press brake.

● READ AND UNDERSTAND THE OPERATION AND SAFETY MANUAL● KNOW HOW TO USE THE OPERATOR CONTROLS AND MODES OF OPERATION

● POSITION RAM AT BOTTOM OF WORKING STROKE● TURN OPERATOR CONTROLS "OFF" (key lock) WHEN WORKING IN DIE AREA● USE "INCH" MODE AND TWO HAND CONTROL● TO AVOID SPLITTING DIE, MAKE CERTAIN TONNAGE CAPACITY OF DIE IS NOT EXCEEDED● PROVIDE POINT OF OPERATION SAFEGUARDING● TEST ALL THE REQUIRED OPERATION CONTROL STATIONS, MODES OF OPERATION AND SAFEGUARDING● INSTRUCT OPERATORS IN PROPER USE OF SET-UP● REMOVE ALL KEYS UNDER SUPERVISORY CONTROL

● USE POINT OF OPERATION SAFEGUARDING● KNOW THE SET-UP AND PROPER METHOD OF OPERATION● TEST ALL THE REQUIRED OPERATOR CONTROL STATIONS AND MODES OF OPERATION BEFORE EACH SHIFT, EACH JOB RUN, AND AFTER EACH BREAK● KEEP HANDS OUT OF DIE AREA (point of operation)● DO NOT POSITION ANY PART OF YOUR BODY WHERE IT MAY BE STRUCK OR CRUSHED BY PART MOVEMENT● USE HAND TOOLS FOR SMALL OR NARROW PIECE PARTS● MAKE CERTAIN EVERYONE IS CLEAR OF PRESS BRAKE, DIES AND MATERIAL BEFORE OPERATING● TURN OFF OR LOCKOUT OPERATOR CONTROLS WHEN NOT OPERATING PRESS BRAKE● WHEN YOU LEAVE THIS PRESS BRAKE: ● POSITION RAM AT BOTTOM OF WORKING STROKE ● TURN OFF OR LOCKOUT OPERATOR CONTROLS ● TURN POWER OFF

DO NOT REMOVE THIS SIGN FROM THIS PRESS BRAKE 240003

SET-UP

OPERATION

SAFETY GUIDELINESHYDRAULIC PRESS BRAKE

240007

DANGERTO REDUCE THE POSSIBILITY OF INJURY . . .

DO NOT

DO NOT

ALWAYS

PLACE YOUR HANDSIN THE DIE AREA

POSITION ANY PART OF YOURBODY WHERE IT MAY BE STRUCKOR CRUSHED BY PART MOVEMENT

READ AND UNDERSTAND THEOPERATION, MAINTENANCE ANDSAFETY MANUAL BEFOREINSTALLING DIES, OPERATING ORSERVICING THE PRESS BRAKE

DO NOT REMOVE THIS SIGN FROM THIS PRESS BRAKE

DANGERKEEP HANDS OUT OF DIE AREA

➧

1537

25

DANGERKEEP OUT OF THISAREA WHILE THEMACHINE DRIVE

MOTOR IS RUNNINGDO NOT REMOVE THIS SIGN FROM THIS MACHINE 232913

3-4

GUARD AGAINST TIPPING (416875)

The design of hydraulic press brakes is such thatmuch of the weight is concentrated to the front ofthe machine. This sign cautions that the machineshould be guarded against tipping when moving orinstalling until it is anchored to the floor. The signrefers to the Operator’s manual for complete instal-lation instructions.

SAFETY GUIDELINES✦ Be sure you know your press brake - capacity,

controls, operating modes, safeguarding

✦ Know and understand the job you are about toperform - material placement, feeding, movementof material being formed

✦ Never place your hands in the die area

✦ Make sure no one is in backgage area at rear ofmachine

✦ Tooling, press brake and gaging properly set forthe job

✦ Always cycle the press brake at least twice with-out a part in dies before each shift and each job

✦ Keep die area free of all unnecessary materialand tools

✦ Do not hang tools on the ram

✦ Adequate safeguarding available and used

✦ Keep your body clear of workpiece

✦ Keep work area clean and orderly

✦ Keep alert - Keep your mind on the job

✦ Hand tools - personal protective devices avail-able and used

✦ Make certain all persons are clear of machine andmaterial before operating

✦ When you leave your press brake:

✧ Place ram at bottom of stroke or block

✧ Turn OPERATOR CONTROL to “OFF” andremove key

✧ Turn MAIN DRIVE to “OFF”

SAFETY MAINTENANCE CHECK✦ SAFEGUARDING at point-of-operation in proper

adjustment and operating properly

✦ PINCH POINT guarding properly installed

✦ OPERATOR CONTROLS working O.K.

✦ OPERATING MODES functioning properly

✦ RAM starting and stopping properly

✦ WARNING PLATES clean and easily read

✦ ELECTRICAL WIRING in good condition

✦ CAUTION PAINTING in good condition

✦ AUXILIARY EQUIPMENT checked - working properly

✦ HAND TOOLS and personal protective equipmentin good order - readily available

✦ SAFETY MANUALS and OPERATOR MANUALSattached to machine

✦ SCHEDULED NORMAL MAINTENANCE workcompleted

❦

SAFETY IS PART OF YOUR JOB . . .THE MORE ATTENTION YOU PAY TO

DEVELOPING SAFE HABITS, THELESS THE CHANCES OF INJURY TO

YOU AND YOUR FELLOW EMPLOYEES.

FAILURE TO FOLLOW SAFE PRESSBRAKE OPERATING PROCEDURESMAY RESULT IN SERIOUS INJURYTO YOU OR ANOTHER EMPLOYEE.

WARNINGTHIS MACHINE IS HEAVY IN FRONT –

GUARD AGAINST TIPPING UNTILANCHOR BOLTS ARE SECURED.

COMPLETE INSTALLATION INSTRUCTIONS ARE IN"OPERATORS MANUAL" PACKED IN PLASTIC POUCHON SIDE OF MACHINE.

BEFORE STARTING - LEVEL, CLEAN, LUBRICATE ANDCHECK RAM SLIDES FOR PROPER CLEARANCE ASDESCRIBED IN "OPERATORS MANUAL"

DO NOT REMOVE THIS SIGN FROM THIS MACHINE 416875

3-5

PERFORMANCE AND RATINGS

EM-444 (N-09/99) 4-1

SECTION 4 SPECIFICATIONS

6(1.8)

8(2.4)10

(3.1)12

(3.7)6

(1.8)8

(2.4)10

(3.1)12

(3.7)14

(4.3)16

(4.9)6

(1.8)8

(2.4)10

(3.1)12

(3.7)14

(4.3)16

(4.9)6

(1.8)8

(2.4)10

(3.1)12

(3.7)14

(4.3)16

(4.9)18

(5.5)20

(6.1)8

(2.4)10

(3.1)12

(3.7)14

(4.3)16

(4.9)18

(5.5)20

(6.1)

SERIESLENGTHFt.-Nominal

(m)

CLEARDISTANCEBETWEENHOUSINGS

Ft.-In.(m)

TOTALOVERALL

DIESURFACE

Ft.-In.(m)

STD.TYPE

BACK-GAGE

AUTOFORM(WITH STD.BACKGAGE)

Lbs.(kg)

AUTO CROWNADDITIONAL

WEIGHTLbs.(kg)

SHIPPING WEIGHT

PITREQD.

BED TOPABOVEFLOOR

In.(mm)

BEDTOP

WIDTHIn.

(mm)

BENDING CAPACITY(Mild Steel)

GA. x FT.(Ga. x m)

VEEIn.

(mm)

MOTORH.P.(kw)

90AF

135AF

175AF

350AF

6'-6-1/2"(2)

8'-6-1/2"(2.6)

10'-6-1/2"(3.2)

12'-6-1/2"(3.8)

6'-6-1/4"(2)

8'-6-1/4"(2.6)

10'-6-1/4"(3.2)

12'-6-1/4"(3.8)

14'-6-1/4"(4.4)

16'-6-1/4"(5)

6'-6-3/4"(2)

8'-6-3/4"(2.6)

10'-6-3/4"(3.2)

12'-6-3/4"(3.8)

14'-6-3/4"(4.4)

16'-6-3/4"(5)

6'-6-1/2"(2)

8'-6-1/2"(2.6)

10'-6-1/2"(3.2)

12'-6-1/2"(3.8)

14'-6-1/2"(4.4)

16'-6-1/2"(5)

18'-6-1/2"(5.6)

20'-6-1/2"(6.2)8'-6"(2.6)10'-6"(3.2)12'-6"(3.8)14'-6"(4.4)16'-6"

(5)18'-6"(5.6)20'-6"(6.2)

8'-0"(2.4)10'-0"(3.0)12'-0"(3.6)14'-0"(4.2)8'-0"(2.4)10'-0"(3.0)12'-0"(3.6)14'-0"(4.2)16'-0"(4.8)18'-0"(5.4)8'-0"(2.4)10'-0"(3.0)12'-0"(3.6)14'-0"(4.2)16'-0"(4.8)18'-0"(5.4)8'-0"(2.4)10'-0"(3.0)12'-0"(3.6)14'-0"(4.2)16'-0"(4.8)18'-0"(5.4)20'-0"(6.1)22'-0"(6.7)10'-0"(3.0)12'-0"(3.6)14'-0"(4.2)16'-0"(4.8)18'-0"(5.4)20'-0"(6.1)22'-0"(6.7)

14,300(6486.5)16,800

(7620.5)19,300

(8754.5)23,500(10660)15,800(7167)18,000(8165)20,800(9435)24,800(11249)30,000(13608)39,000(17690)19,500(8845)22,000(9979)25,500(11567)30,000(13608)35,000(15876)43,500(19732)23,500(10660)26,300(11930)30,200(13699)34,500(15649)40,500(18371)51,000(23134)

––

68,200(30940)35,300(16012)39,600(17963)45,000(20412)51,500(23360)59,400(26944)

––

71,500(32400)

1,150(522)2,175(987)3,000(1361)4,200(1905)2,058(930)3,050(1384)4,150(1880)6,325(2870)

––

6,900(3130)2,250(1021)4,525(2053)6,550(2971)7,775(3527)11,500(5220)12,500(5670)4,100(1860)5,700(2590)7,625(3459)8,900(4037)11,500(5220)12,900(5850)

––––

7,525(3413)9,700(4400)12,400(5625)16,000(7260)24,300(11020)

––

33,000(14970)

NO

YES

NO

YES

NO

YES

NO

YES

YES36

(914)

36(914)

34(864)

34(864)

34(864)

3-1/2(89)

3-1/2(89)

4-1/2(114)

4-1/2(114)

5-1/2(140)

5-1/2(140)

230 AF

25(19)

25(19)

25(19)

25(19)

25(19)

12 Ga. x 12'(12 Ga. x 4)10 Ga. x 9'(10 Ga. x 3)

1/4 X 5'(1/4 x 1.5)

7/8(22)1-1/8(29)

2(51)

10 Ga. x 12'(10 Ga. x 4)3/16 x 10'-3"

(3/16 x 3)1/4 X 7'-6"(1/4 x 2)

1/2 x 4'-8"(1/2 x 1)

1-1/8(29)1-1/2(38)

2(51)

5(127)

3/16 x 13'-4"(3/16 x 4)

1/4 x 10'-0"(1/4 x 3)

3/8 x 6'-3"(3/8 x 2)

1/2 x 6'-1"(1/2 x 2)

1-1/2(38)

2(51)

3(76)

5(127)

3/16 x 17'-6"(3/16 x 5)

1/4 x 12'-9"(1/4 x 4)

3/8 x 8'-2"(3/8 x 2.5)1/2 x 8'-0"(1/2 x 2)

1-1/2(38)

2(51)

3(76)

5(127)

1/4 x 19'-4"(1/4 x 6)

3/8 x 12'-5"(3/8 x 4)1/2 x 12'(1/2 x 4)

3/4 x 8'-6"(3/4 x 2.5)

2(51)

3(76)

5(127)

8(203)

(1)

(2)

CNCBACK-GAGE

GCNC

HEAVYDUTY

DCNC

BACK-GAGE

21C

CNCHEAVYDUTY

414

CNCBACK-GAGE

2C

BACK-CNC

HEAVYDUTY4.27

18'-0"4.888'-0"1.83

10'-0"2.44

CNCHEAVYDUTY3.66

16'-0"4.27

18'-0"4.88

10'-0"2.44

12'-0"3.05

14'-0"

CNCHEAVYDUTY

SPECIFICATIONS CHART

PRINCIPLE OF OPERATIONThe AUTOFORM CNC Forming Center is ahydraulically driven, servo-controlled machine. Asimplified diagram, Figure 4-1, shows the basicoperating logic and components.

FIGURE 4 - 1 – Simplified machine diagram

PUMP: A motor driven, variable volume, hydraulicpiston pump provides the flow and pressure foradvancing, retracting and loading the powercylinders. This pump is equipped with a “loadsensing” control which precisely matches pumpflow and pressure to load demands. This precisematch provides maximum system efficiency.

SERVO VALVES: These are variable orifice valveswith spool position feedback. The valves controlboth the direction and amount of flow from thepump to the cylinders. They provide preciseflow/speed control of the cylinders.

LINEAR ENCODERS: Each end of the machine isequipped with a bed referenced, high resolution.0001” (.00254mm) linear encoder. Theseencoders continually monitor ram-to-bed posi-tion and speed at each cylinder and feed thisinformation to the control. The encoders areshock-resistant and allow normal punchingcapacity on these machines.

CONTROL: The machine control provides the highspeed processing logic for the servo-controlledram position loop. The control consists of multi-ple 32-bit processors residing on the industrystandard VME buss. Operator interface is accom-plished by means of conversational programmingthrough a membrane style keypad and a highresolution 14” (356mm) color monitor.

DEFINITION OF TERMSRAM STROKE: Hydraulic pressure from the motor

driven pump forces the cylinder pistons down orup to move the ram. The stroke length isadjustable. The maximum standard strokelength for each series machine is shown in thepreceding Specifications chart.

TONNAGE CAPACITY: The tonnage on AUTO-FORM CNC Forming Centers is adjustable fromapproximately 1% of full tonnage (dependingupon ram speed selected) to full tonnage. Themaximum full tonnage is determined by thecylinders, pistons and the limits of the frame

4-2

(1) SHIPPING WEIGHTS DO NOT INCLUDE SPECIAL OPTIONS, SUCH AS AUTO CROWN, SIX-AXIS BACKGAGE, POWER CLAMPS, ETC.

(2) BENDING CAPACITIES ALLOW FOR 15% RESERVE OF RATED TONNAGE TO COVER POSSIBLE INCREASES IN MATERIAL THICKNESS, TENSILE STRENGTH AND YIELD STRENGTH.

(3) STROKE ADJUSTS TO ANY LENGTH UP TO MAXIMUM SHOWN.

(4) RAM SPEEDS ARE APPROXIMATE AND BASED ON 1800 RPM MOTOR.

SERIESMAX. SPEED

AT FULLTONNAGEInches/Min.(mm/Sec.)

MAX. TONNAGEAT FULL

FORM. SPEEDTons(kN)

STD.STROKELENGTH

Inches(mm)

THROATCLEARANCE

FROM CENTEROF DIES

Inches(mm)

OPENHEIGHT

CLOSEDHEIGHT

HIGHAPPROACH

VARIABLEFORMING RETURN

OVERALLHEIGHTABOVEFLOOR

Inches(mm)

MACHINE CAPACITY DIE SPACEInches(mm)

RAM SPEEDInches/Min.(mm/Sec.)

90

135

175

230

350

94(39)64

(27)49

(20)37

(15)25

(10)

70(623)105

(934)130

(1157)190

(1690)285

(2535)

8(203)

8(203)

10(254)

10(254)

10(254)

7(178)

7(178)

8(203)

8(203)

10(254)

15(381)

15(381)

17(432)

17(432)

18(457)

7(178)

7(178)

7(178)

7(178)

8(203)

380(161)290

(123)260

(110)230(97)155(66)

1 to 120(1 to 51)1 to 80(1 to 34)1 to 65(1 to 28)1 to 45(1 to 19)1 to 30(1 to 13)

405(171)270(114)290(123)250(106)135(57)

110(2794)

111(2819)

124(3150)

127(3226)

134(3404)

(3) (4)

design. The machine capacity plate and the pre-ceding chart show the maximum tonnage capac-ity. Also see the PRESS BRAKE CAPACITIESbooklet included with this manual.

DIE SPACE: Each size machine has a fixed amountof die space to accommodate the dies or toolingand filler block. OPEN HEIGHT is the maximumdie space available. It is the distance from thebed top to the ram nose when the ram is at max-imum UP stroke position. CLOSED HEIGHT isthe minimum die space available. It is the dis-tance from bed top to ram nose when ram is atbottom of the stroke. See Figure 4-2.

FIGURE 4-2 – Die space

THROAT: Most forming on press brakes is donebetween the housings. However, when longmaterials or forming at one end of the machineis required, the housing throat provides spacefor the material. This space is limited by thedepth of throat. Details of the throat are foundon the throat layout drawing.

CLOSED POSITION: This is the overall height ofthe dies when ram is at the bottom of the strokeand is adjusted to make the proper bend. SeeFigure 4-3.

FIGURE 4-3 – Closed position

DIE PENETRATION: This is the distance the upperdie penetrates the lower die. For a 90° air benddie the penetration is about 0.4 of the vee dieopening.

The combined height of the dies and filler blockwhen in the closed position must be more thanthe closed height, but less than the open heightdimensions. The difference between this com-bined height and the open height is the maximumamount of stroke which can be used for a partic-ular set-up.

FILLER BLOCKS: Various types of filler blocks areavailable to hold the lower die. They provide ameans of adjusting and clamping the lower die inposition. Filler blocks are optional and should beselected to suit the machine tooling and type ofbending.

MICROCROWNING: A crown is machined into thebed of each CINCINNATI Press Brake. It isdesigned so the bed and ram will be parallel at1/2 to 2/3 of machine capacity with a load uni-formly distributed over the nominal length of themachine. This feature improves bend accuracy

4-3

under normal forming loads and minimizesshimming of the dies. Machines furnished withthe optional AUTO CROWN system do not havemicrocrowned beds.

CAPACITIESPUNCHING CAPACITY

CINCINNATI Hydraulic Press Brakes are rated toperform punching loads up to 66% of the maximummachine capacity at the center of the machinewhen punching mild steel using self-containedunits on an occasional basis. When punching is tobe performed on a continuous production basis,with dedicated die sets or high tensile - 70,000 PSI(482636kPa) - material is to be processed, thepunching capacity is reduced to 50% of the maxi-mum machine capacity, Figure 4-4. Additionalpunching capacity can be obtained by stepping thepunches (Figure 4-5) on multiple levels. For specialpunching applications, where die sets or specialmachine features (for example, wide bed, deepthroat, etc.) are required, consult CINCINNATIINCORPORATED.

When punching, the POSITION mode of operationmust be used. See SECTION 6, MACHINE CONTROLS.

FIGURE 4-4 – Maximum punching capacity

FIGURE 4-5 – Multiple level punching

STRIPPING CAPACITYA stripping load is a force which occurs on the UPstroke of the ram. The direction of this type of loadis down on the ram and up on the bed (the reverseof forming and punching loads). Figure 4-6 showsthe maximum stripping load available at the centerof the machine. See PRESS BRAKE CAPACITIES, PI-50691, for more information on controlling strip-ping load.

FIGURE 4-6 – Stripping load

ECCENTRIC LOAD CAPACITY(FRONT-TO-BACK)Occasionally special forming or punching set-upsare made which do not have their load centerslocated on the bed and ram centerlines. When thiscondition exists, care must be taken not to exceedthe maximum eccentric (front-to-back) load capac-ity of the machine. See Figure 4-7.

FIGURE 4-7 – Eccentric load capacity

d x L MUST BE EQUAL TO OR LESS THANMAXIMUM ECCENTRIC LOAD CAPACITY

C - CENTERLINE

L - LOAD (FORMING OR PUNCHING) - TONS (kN)

d - DISTANCE BETWEEN MACHINE C & LOAD C - INCHES (mm)

AUTO-FORM

SERIES

90 AF

135 AF

175 AF

230 AF

350 AF

MAXIMUM ECCENTRICLOAD CAPACITY

INCH-TONS(mm-kN)

100(35)100(35)200(70)200(70)300

(105)

AUTO-FORM

SERIES

90 AF

135 AF

175 AF

230 AF

350 AF

MAXIMUMSTRIPPING LOAD

TONS(kN)

9.0(80)13.5(120)17.5(156)23.0(205)35.0(311)

AUTO-FORM

SERIES

90 AF

135 AF

175 AF

230 AF

350 AF

MAXIMUM PUNCHING CAPACITYTONS/LEVEL(kN/LEVEL)

MILD HI-

60(534)

90(801)115

(1023)150

(1334.5)230

(2046)

45(400)67.5

(600.5)87.5(778)115

(1023)175

(1557)

4-4

OFF-CENTER LOAD CAPACITY(LEFT-TO-RIGHT)

Most forming and punching jobs are located on thecenterline of the machine where the full ratedmachine capacity is available. When the load is notlocated at center of machine, only a portion of thetotal capacity is available as shown in Figure 4-8.

FIGURE 4-8 – Off-center load capacity

For example, a 135 AUTOFORM has 100% - 135tons (1201kN) of its rating available for bending atthe centerline of the machine. At either housing,regardless of length, only 50% of the tonnage - 67.5tons (600.5kN) is available.

To determine the available tonnage at a pointbetween the centerline and either housing, theratios shown in Figure 4-8 can be used. For exam-ple, a 135AF x 10' machine is approximately 128”(3251mm) from housing to housing (L). A point of .3of this length is 38.4” (975mm) (.3 x128”/3251mm). Then at 38.4” (975mm) from thecenterline of the machine 62% (83.7 tons/745kN) ofthe tonnage is available.

❦

! ! DANGER ! !! ! DANGER ! !EXCEEDING THE ECCENTRIC LOAD CAPACITYCOULD OVERSTRESS UPPER BED AND DIECLAMP BOLTS CAUSING THEM TO SHATTER ANDPOSSIBLY CAUSE SERIOUS INJURY TO PERSON-NEL. DAMAGE COULD ALSO OCCUR TO THESLIDES AND GUIDES AND SINK UPPER BEDBOLTS INTO THEIR COUNTERBORES CAUSINGTHE BED TO BECOME LOOSE.

4-5

TOOL INSTALLATION - SET-UP MENUA hydraulic press brake is a very versatile bendingmachine. It is capable of exerting high forcesbetween its bed and ram. These forces are appliedand directed into the material to be formed by theuse of tooling (dies).

The type and shape of the dies are the principle fac-tors in establishing the shape of the part to beformed. There are many different types and shapesof press brake dies. Some have a very special andunique shape. However, most dies are members of afamily of tooling called Vee Dies. See Figure 5-1.

FIGURE 5-1 – Vee Dies

These dies, being the most common and widely used,will be referred to in the following instructions.

TYPES OF DIES

AIR BEND DIES: These dies are made with sharp-er angles than the angle to be formed. The metalbeing formed contacts only the nose of the upperdie and the two radii of the lower vee die open-ing. See Figure 5-2. Thus, all of the ram force isused in forming and none in squeezing themetal. Any greater angle than the die angle canbe formed by adjusting the stroke reversal posi-tion upward as required. See the PRESS BRAKECAPACITIES booklet included with this manualfor further air bending information.

FIGURE 5-2 – Air bend dies

BOTTOMING DIES: The primary purpose of bot-toming dies is to provide greater part accuracyand special shapes. They can also be used toobtain a relatively sharp inside corner. They aremade in matched pairs, according to the thick-ness of the stock to be formed and radiusrequired. See Figure 5-3. These dies require threeto ten times as much force as air bend dies.Other types of bottoming dies are coining dies(used to obtain a sharp inside radius), multiplebend and channel dies and radius bend dies. Donot use ANGLE mode when bottoming. Use POSI-TION or TONNAGE mode. See SECTION 6 for adescription of the available mode selections.

FIGURE 5-3 – Bottoming dies

EM-444 (N-09/99) 5-1

SECTION 5 SET-UP & USE

CINCINNATI INCORPORATED can provide manyother types of standard and special dies, some ofwhich are shown in Figure 5-4.

FIGURE 5-4 – Types of dies

DIE SETS: Special care and precautions should betaken when operating die sets with guide pinsand bushings. The AUTOFORM Control on thismachine is designed to make a full up strokewhen the machine is first turned on and ram iscalibrated, or whenever ram recalibration isrequired.

Depending on the working height of the die set,this full stroke return may cause the die setguide pins and bushings to separate. Re-entry ofthe guide pins into the bushings may be difficult,if not impossible. Each die set application shouldbe reviewed for this condition.

CINCINNATI INCORPORATED recommends thatthe working height of all die sets be such that thebushings never leave the guide pins when theram makes a full up stroke.

TOOL INSTALLATION

To install the tooling, use the following procedure:

◆ Turn “ON” the main disconnect switch. The fol-lowing display will appear:

◆ Depress MAIN DRIVE - START pushbutton onAUTOFORM Control Station (Figure 6-1). Holduntil motor starts.

◆ Turn OPERATOR CONTROL selector (on AUTO-FORM Control Station) to “ON” position.

◆ Turn OPERATOR STATION RIGHT selector to“ON” position and FOOTSWITCH RIGHT selec-tor to “ON” position. If the machine is equippedwith either LEFT footswitch or operator stationcontrols, they should be turned “OFF”. Thesecontrols are on the Machine Control Station(Figure 6-1).

OPERATORCONTROL

OFF ON

MAIN DRIVEON

START

PROGRAM:ABC123

STATUS: Select a menu using the softkeys.

MAIN MENU

ENTER NEW PROGRAMJOB DATARAM DATAGAGE DATARUN MODEQUICK BENDSET-UP MODETOOLING LIBRARYPROGRAM STORAGE

EnterNewProgram

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

6 AUG 8912:00 PM

5-2

◆ Select the "Set-Up Mode" softkey from the MAINMENU screen. The MAIN MENU will be erasedand the SET-UP screen will appear. The SET-UPscreen is used to move the ram up and down inslow speed. Machine tonnage in this mode is lim-ited to 10% of machine’s capacity. Also shown onthe SET-UP mode screen is the actual position ofthe ram and gage (if installed). Shown below is alayout of the SET-UP mode. (This example is fora machine with a CNC Six-Axis backgage.)

◆ Turn the STROKE MODE selector switch to the“SET-UP” position. The selector must be in thisposition to operate the ram or gages in the SET-UP mode.

SET-UP mode is used to run the ram downusing the palmbutton Operator Station and upusing the RAM UP button. In addition, soft-keys allow incremental ram movement up anddown in .0100 (.254mm) or .0010 (.0254mm)inch increments. Each time a softkey ispressed and the footswitch is depressed, the

ram will move the incremental amount. It isnecessary to depress and hold down on thefootswitch as you press on the softkeys to getthe ram to move. These keys are to be usedonly for positioning the ram under no-loadconditions. Do not use the incremental rammovement softkeys to seat dies.

The position of the axis selected is displayed atthe top of the SET-UP screen in large text.

The backgage, X-axis only, may be moved byentering the desired position. The optional “R”and "Z" axis will be displayed, but they can notbe positioned from this screen. A hand-heldpendant is furnished for positioning all axes.

If the ram has not been calibrated when theSET-UP screen is entered, a softkey will appearto start the calibration cycle. The first time thegage is moved, if it has not been calibrated, asoftkey will appear to start the calibration cycle.See MACHINE CALIBRATION, SECTION 7, formore information.

◆ Depress RAM UP button on the palmbuttonOperator Station to raise ram. The ram will moveto the maximum up position and stop. When theram stops, continue with the next step.

◆ Depress the palmbuttons and lower the ram toits maximum down position and stop.

◆ Press "Calibrate Gage" softkey to move the gageaway from die area to the calibrate position.

CAUTIONMAKE SURE THE AREA BEHIND THE MACHINEIS CLEAR BEFORE CALIBRATING THE GAGE.

PROGRAM:ABC123

STATUS: Enter new value using keypad. MAX 24.000 MIN 0.010

SET-UP MENU

RAM POSRAM LEFTRAM RIGHTRAM TILTX AXISX-leftX-rightZ-leftZ-right

Up+0.0100

Down-0.0100

Up+0.0010

Down-0.0010

CalibGage

12.453712.453712.4537

0.000012.00012.00012.000-5.502 5.502

R-AXISR-leftR-rightFR-leftFR-right

TOP OF DIE

4.9854.9854.985

0.0000

RAM IS NOW UNDER OPERATOR CONTROL

X-AXIS 12.000

6 AUG 8912:00 PM

FOOTSWITCH ONLY - ON DOWN STROKE, RELEASING FOOTSWITCH TOCENTER POSITION STOPS RAM. RELEASING TO UP POSITION MAKES RAMGO BACK UP TO TOP OF STROKE. AFTER PASSING BOTTOM OF STROKERAM AUTOMATICALLY RETURNS TO TOP OF STROKE AND STOPS.

PALMBUTTONS OR FOOTSWITCH - CONTROLS RAM ON DOWNAND UP STROKE. AUTOMATIC STOP AT TOP OF STROKE.

AUTO. RETURN - PALMBUTTONS OR FOOTSWITCH CONTROLS RAM ON DOWNSTROKE. AFTER PASSING BOTTOM OF STROKE RAM AUTOMATICALLYRETURNS TO TOP OF STROKE AND STOPS.

SINGLESTROKE

MODE SELECT

OFF

SET-UPSINGLESTROKE

PROGRAM:ABC123

STATUS: Change the position using the keypads.

SET-UP MENU

RAM POSRAM LEFTRAM RIGHTRAM TILTX AXISX-leftX-rightZ-leftZ-right

Up+0.0100

Down-0.0100

Up+0.0010

Down-0.0010

CalibGage

12.453712.453712.4537

0.000012.00012.00012.000-5.502 5.502

R-AXISR-leftR-rightFR-leftFR-right

TOP OF DIE

4.9854.9854.985

0.0000

RAM IS NOW UNDER OPERATOR CONTROL

RAM POS 12.4537

6 AUG 8912:00 PM

CAUTIONREAD GUIDELINES IN SAFETY SECTION FORINSTALLING TOOLING BEFORE PROCEEDING.

MACHINE CONTROLS

OFF ON OFF ON OFF ON OFF ON

OPERATORSTATION LEFT

OPERATORSTATION RIGHT

FOOTSWITCHLEFT

FOOTSWITCHRIGHT

5-3

◆ Turn the OPERATOR CONTROL selector onAUTOFORM Control Station to “OFF” positionand remove the key to prevent ram movement.

◆ If the filler block has not already been installed,deburr, clean and lightly oil bed top. Place nutsfor filler block screws in proper bed cross slots.Place filler block (die holder) on bed and lightlybolt in place. At this time, also install die align-ers (3 front and 3 back) to the front and back ofthe bed. In some cases a filler block may not berequired and die may be placed directly on thebed. Deburr, clean and lightly oil the top of fillerblock. Loosen all of the filler block set screws. Ifmachine is equipped with optional PowerClamps, turn LOWER selector switch to“UNCLAMP” position. See Figure 5-5.

If additional die space is required to install thefiller block or lower die, turn the OPERATORCONTROL selector to “ON”, use the RAM UPbutton to raise the ram so there is just enoughspace, turn the OPERATOR CONTROL selectorto “OFF” and remove the key.

FIGURE 5-5 – CLAMP/UNCLAMP Switch

◆ Insert lower die on the filler block. Leave itextended past end of bed several inches. Visu-ally center filler block so lower die is alignedwith slot in the ram nose.

◆ Loosen all ram die clamps nuts about .125”(3.2mm). If the machine is equipped with option-al Power Clamps for the upper die, useCLAMP/UNCLAMP selector switch located onmain electrical enclosure (Figure 5-5) to openupper die clamp. Depress pushbutton whileturning key to the “UNCLAMP” position. A redlight will indicate the unclamped position. Turnthe OPERATOR CONTROL selector to “ON”.

◆ Move ram as necessary so there is just enoughspace for the upper die. Use palmbuttons tomove ram down or the RAM UP button to moveram up.

◆ Rest the upper die on extended portion of lowerdie. Make sure tongue of upper die is in the ramnose slot and that the upper die is trapped bythe lower die and ram die slot. See Figure 5-6.Then slide upper die into lengthwise positionwith the lower die. Slide the set of dies into acentered position on the machine. Tighten thefiller block set screws or clamp the lower powerdie clamp to lock the lower die.

Note: Short, lightweight dies may be installedas a set and slid into position.

FIGURE 5-6 – Die Positioning

◆ Moderately tighten ram die clamp nuts or clampoptional upper power clamp to prevent theupper die from falling when the ram is raised.Turn OPERATOR CONTROL selector to “ON”.

◆ Use the RAM UP button to raise the ram .125”to .25” (3.2 to 6.4mm). Turn the OPERATORCONTROL selector to “OFF” and remove key.

◆ Visually align the upper and lower dies. Shiftthe filler block front-to-back using die alignersto obtain rough die alignment.

◆ Turn OPERATOR CONTROL selector to “ON”.

OPERATORCONTROL

OFF ON

5-4

◆ Inch the ram down using palmbuttons until theupper die is seated. When seating dies, machinetonnage is limited to 10% of the machine’s capac-ity. For example, for a 350 ton (3114kN) AUTO-FORM the tonnage is limited to 35 tons (311kN).

IMPORTANT: When seating dies it may be advis-able to place wood blocks or soft metalbetween the dies to prevent damage to thedies. Short dies must have sufficient shoul-der area to prevent sinking into the ram, bedor filler block.

The hydraulic components and machineframe members are safeguarded againstoverload by both load cells and a relief valvein the hydraulic circuit. However, care mustbe taken to provide enough area under upperand lower dies to prevent them from sinkinginto the ram nose or bed top due to highlyconcentrated loads. This is the shaded areashown in Figure 5-7. The minimum area (sq.in.) for each die to prevent sinking may becalculated by this formula:

Die Area = MAXIMUM TONNAGE / 15

An example for a 350 ton machine, the mini-mum die area for a capacity load is 350divided by 15, or 23.3 square inches.

FIGURE 5-7 – Seating Dies

◆ Fully tighten the die clamp nuts after seatingthe upper die. Check the shoulders of the diewith a .002” (.05mm) feeler gage to make sure itis seated tightly.

◆ Run the ram upwards to provide clearancebetween dies. This clearance should be equal toat least the metal thickness. Check the front-to-

back die alignment over the full length of thedies. Realign if necessary by moving the fillerblock with die aligners. For Adaptive Bending orother precision bending requirements, a moreaccurate alignment is required. Feeler gagesshould be used to measure front-to-back dieclearances between the upper and lower dies atboth ends and at the center of the dies.

◆ Tighten the filler block to the bed.

TOP OF DIE CALIBRATION FORUNMEASURED TOOLS

When using unmeasured tools in JOB DATA it isrequired to calibrate the top of die position for theram. Select the Top of Die field using the field keysin the SET-UP MENU. Inch the ram up to provideclearance for the one inch calibration block. Placethe calibration block on the lower die. Inch the ramdown until the block is lightly “pinched” betweenthe dies. Press the “Calib Top of Dies” softkey torecord this position as the Top of Die. Inch the ramup, remove the calibration block, and inch the ramdown to bring the dies together. Turn the OPERA-TOR CONTROL selector to “OFF” and remove key.

This calibration is required again whenever themachine is powered-off or the “Enter New Program”softkey is used to erase the current program.

GAGING - STANDARD BACKGAGESThere are two types of Standard Backgages, theSingle Drive Backgage (the CNC Backgage in theControl) and the Dual Drive Backgage (the CNCHeavy Duty Backgage in the control). These stan-dard backgages have a 24" powered X-axis and an8" manual R-Axis adjustment. The Single DriveBackgage is furnished on all 6' and 8' (1.8m and2.4m) length 90AF, 135AF and 175AF machines.The Dual Drive Backgage is standard on all otherAUTOFORMs.

CAPACITYThe Standard Backgages are designed for sheets,3/16" (4.8mm) maximum thickness, that weighless than 100 lbs. (45.4 Kg). The Six Axis Backgageis also designed for sheets 3/16" (4.8mm) maxi-mum thickness that weigh less than 100 lbs. (45.4Kg). The Heavy Duty Backgage (the CNC PlateBackgage in the control) is designed for plates witha weight less than 500 lbs. (227Kg). Reasonablecare should be used when positioning heavy sheetsagainst these gages.

CalibTop ofDie

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

5-5

IMPORTANT: Heavy shock loads could damageparts of the gage.

Gaging surfaces are adjusted manually in the verti-cal direction within the limits shown in Figure 5-8.The standard horizontal (front-to-back) travel is 24"(610mm). It is power-driven at 800 in/min.(339mm/sec.) and is positioned and sequenced bythe program entry in the AUTOFORM control. Thegage can be manually positioned by use of the gagependant control.

FIGURE 5-8 – Adjusting gage surfaces

SELECT GAGE SURFACE

Standard gaging surfaces furnished with theAUTOFORM include the gage bar, two gageassemblies and four gage fingers. The fingers aremanually positioned along the length of the gagebar using a special positioning tool. These gagingsurfaces are shown in Figure 5-9.

FIGURE 5-9 – Standard gaging surfaces

The standard 1/4" (6.4mm) gage fingers can berotated in the gage assembly to provide either a oneinch or a one-quarter inch high surface for shortflanges. See Figure 5-11 for minimum flangedimensions. An optional 1/8" (3.2mm) gage fingercan be furnished for smaller flanges. The one inchsquare finger should be used wherever possible, asit provides the largest gage target and contact area.

FIGURE 5-10 – Two-point Gaging

➛➛

➛➛

➛➛

➛

➛

.25

4.03.0

1.0

1.0

➛➛1.0

➛

➛

➛➛

➛➛

➛

➛

4.03.0

1.0

➛➛1.0

GAGE ASSEMBLY – 1" FINGER

GAGE ASSEMBLY – 1/4" FINGER

1.5

GAGE BAR

➛

➛

➛

7.75"

1.75"

TO24"➛ ➛

➛

➛.25"

1.5"

2"

7.75"

TO 24" ➛➛

➛

➛

➛

➛

MANUALADJUSTMENT

GAGE FINGERS

GAGE BAR

5-6

FIGURE 5-11 – Minimum flange size

IMPORTANT: The selected gage surface shouldbe analyzed carefully to avoid interferencewith the tooling and yet provide a largeenough target to ensure part contact.

The 1/4" (6.4mm) gage finger can also be used as asheet support as shown in Figure 5-12, for light-weight sheets.

FIGURE 5-12 – Gage finger used as sheet support

ADJUST GAGE FINGER POSITIONVertical position of the gage surfaces with manual"R" are adjusted by turning the hand cranks oneach gage carriage (Figure 5-13).

FIGURE 5-13 – Adjusting vertical gage position

Vertical position of the gage surfaces on the SixAxis Backgage and the Heavy Duty Backgage (CNCPlate Gage in the control) with power "R" axis areadjusted with the program or they can be adjustedwith pendant control. The best height for the gageswill depend upon the shape of the part beingformed.

The gage finger assemblies should be positionedleft-to-right to contact the part being formed at thedesired gage points. Normally the two gage finger

CAUTIONIf gage bar or fingers are to be positioned over thetop of the lower die, care should be taken to makethis height adjustment before moving the gageforward. This will avoid a collision between thegage and the tooling.

! ! DANGER ! !! ! DANGER ! !NEVER ADJUST VERTICAL POSITION OF THEGAGE SURFACE BY REACHING BETWEENTHE DIES. MAKE THIS ADJUSTMENT FROMTHE REAR OF THE MACHINE.

Note: If the assembly is used as a sheet support, the flange dimension must be offset in the program.

.25(6.4).375(9.5)

.5(12.7).625

(15.9).75(19).875

(22.2)1"

(25.4)1.125(28.6)

1.125(28.6)1.188(30.2)1.25

(31.8)1.313(33.3)1.375(35)

1.438(36.5)

1.5(38.1)1.563(39.7)

.438(11.1)

.5(12.7).563

(14.3).625

(15.9).688

(17.5).75(19).813

(20.6).875

(22.2)

.313(8)

.375(9.5).438

(11.1).5

(12.7).563

(14.3).625

(15.9).688

(17.5).75(19)

VEE

FINGER SIZE1"

(25.4mm).25

(6.4mm).125

(3.2mm)

5-7

assemblies should be spread as wide as possible toprovide the most accurate gaging. The gage fingerassemblies are moved along the gage bar by usingthe finger assembly positioning tool (Figure 5-14).This tool releases the gage assembly clamp andholds the assembly while it is being moved.

FIGURE 5-14 – Finger assembly positioning tool

GAGE BAR CALIBRATIONIt is advisable to make this calibration wheneverthe dies are changed, the gage fingers are changedor the gage fingers are repositioned a significantamount (12” or more) left-to-right. This calibrationmust be made whenever changing from finger gag-ing to bar gaging or to other special gage blocks orfingers. See SECTION 7, “MACHINE CALIBRATION”.

PROGRAM GAGE POSITION(S)The actual position of the gage in relation to thetooling is selected when entering a program into theControl. This procedure is described in SECTION 7,“GAGE DATA MENU”. The actual gage dimensionfrom the centerline of the tooling to the gage sur-face is determined by three program inputs, flangedimension, bend allowance and finger offset. SeeFigure 5-15.

FIGURE 5-15 – Figuring actual gage dimension

GAGE FINGER ADJUSTMENT

Minor part flange differences (end-to-end) can becorrected by adjusting individual gage fingers for-ward (to shorten flange). First remove the gageassembly from the backgage bar with the position-ing tool. Loosen the finger by pulling out the lock-ing knob (Figure 5-16) and turning knob counter-clockwise. The adjusting collar has a total range of.060" (1.5mm) adjustment.

Adjust the collar forward the desired amount.Reseat finger shoulder tightly against adjusting col-lar and tighten the locking knob. The locking knobspins freely unless it is pulled out. This allows theknob to rest against the backgage face, thus pre-venting the finger from being unlocked while theassembly is in place on the gage bar. All gages areshipped from the factory zeroed from the centerlineof the ram with the gage assembly at .00” position.

CAUTIONThe following gage finger adjustments should neverbe made while the gage assembly is in place on thegage bar. Always use the finger assembly position-ing tool to remove gage assembly.

– BEND ALLOWANCE AND – FINGER OFFSETWILL MOVE THE GAGE FORWARD TOWARDTHE TOOLING.

+ BEND ALLOWANCE AND + FINGER OFFSETWILL MOVE THE GAGE BACKWARDS AWAYFROM THE TOOLING.

➛ ➛

➛ ➛

+–

A

"A" (ACTUAL GAGE DIMENSION) =X-AXIS DIM. ± BEND ALLOWANCEAND ± FINGER OFFSET.

! ! DANGER ! !! ! DANGER ! !NEVER ADJUST GAGE FINGER POSITIONSBY REACHING BETWEEN THE DIES. USE THETOOL PROVIDED.

5-8

FIGURE 5-16 – Gage assembly

WORK SUPPORTSTwo work supports for light gauge material are fur-nished with the Standard Backgage. They areintended to be used in the rear of the bed when longbackpieces (which droop away from the gage sur-face) are formed. These supports attach to reardovetail slots in the bed and should be positionedat same height as top of lower die. Figure 5-17shows a typical work support set-up.

FIGURE 5-17 – Typical work support set-up

Note: 1. If the power "R" option is installed itshould be disabled (see SECTION 8, Page8-3) after the fingers are at the properheight and the work supports areinstalled.

2. These supports will not mount to the rearside of the bed in the area of the SingleDrive Backgage housing.

3. Work supports are not recommended to beused in the rear with a Six-Axis Backgageunless both the "Z" and "R" axis are dis-abled.

OPERATING TECHNIQUESThe following guidelines will help the individualavoid operating problems, producing bad parts,causing injury to himself or damage to the toolingor machine.

TOOLING AND SET-UP

◆ DO inspect the tooling carefully before startingany job. It may be impossible to compensate forbadly worn dies and they could create a safetyhazard.

◆ DO select tooling which is correct for the joband compatible with machine capacity. It isespecially important to have the exact toolingwhen recalling a previously run program fromstorage.

◆ DO ensure that tooling shoulders are tightlyseated against ram and filler block, and thatupper and lower dies are aligned front-to-back.

◆ DO NOT attempt to bend a part to the sameangle as the die when using ANGLE or ADAP-TIVE modes of operation. Dies must have suffi-cient allowance for springback so the part doesnot bottom in the dies. It may be necessary touse 75° (or less) dies when 90° air bending forcertain materials with large “springback”. SeeFigure 5-18 and the PRESS BRAKE CAPACITIESbooklet for more information on springback.

FIGURE 5-18 – Air bend

◆ DO NOT attempt to air bend a part when TON-NAGE reversal has been selected. Bottomingdies must be used when reversing on tonnage.See Figure 5-19.

WORK SUPPORT

➛

5-9

Note: Either air bend or bottoming dies can beused when POSITION reversal has beenselected. However, sufficient clearance inthe dies is necessary to avoid excessivetonnage build-up.

FIGURE 5-19 – Bottoming

◆ DO NOT use ANGLE or TONNAGE reversalwhen punching. POSITION reversal should beselected for punching.

◆ DO use as large a vee die opening as possiblewhen air bending. Larger vee openings are lesssensitive to material thickness variations,deflections and tooling height variations.

◆ DO make ram tilt and die shimming adjust-ments as soon as possible when setting-up aprogram as they may affect program inputs.

RUNNING

◆ DO NOT start running a job until the propermethods and safeguards to protect the operatorand others from injury are understood and arein place.

◆ DO NOT jog through the bend. Once ram hasreached speed change position, motion shouldbe continued through the bottom of the stroke.

◆ DO remove burrs or keep burrs up on materialfor more consistent bends.

◆ DO run production in same speed in which theset-up part was made.

◆ DO NOT make angle corrections in the middleof a production run unless two or more consec-utive bends are out-of-tolerance.

◆ DO store the changes which are made to a newor old program. The latest program must bestored to save the changes.

◆ ALWAYS block the ram or position the ram atbottom of the stroke and turn “OFF” STROKECONTROL switch and remove the key wheneverleaving the machine.

SPEED CHANGE/FORMING SPEED

◆ DO ensure that the forming speed selected isappropriate for the part being formed. Too highof a speed may cause "whip-up", which could behazardous to the operator or cause part damage.

◆ DO ensure that the speed change position iscompatible with the forming speed selected. If ahigh forming speed is programmed and thespeed change point is close to the material (lessthan .25"/6.4mm), then inconsistent part form-ing motion and bend angle may occur.

When using high forming speeds and shortapproach strokes, it is advisable to eliminatespeed change by raising the speed change pointabove the top stop. In many instances this willprovide more strokes per minute and smoothermotion.

GAGES

◆ DO ensure that gaging surfaces will not inter-fere with the tooling or ram when setting-up orrunning a job.

◆ DO use the gaging surface which provides thelargest possible gaging target.

◆ DO spread gage fingers as far as possible toachieve the best gaging accuracy.

◆ DO support workpiece in the gaging position,both in front and rear of the bed.

REMOVING TOOLING

◆ Set the controls on the Machine Control Station.Turn the MODE SELECT switch to "SET-UP"position and the OPERATOR STATION - RIGHTto "ON". The FOOTSWITCH - RIGHT selectormust be in "ON" position if the incremental rammovement softkeys are to be used. PositionLEFT footswitch and operator station to “OFF”.

◆ Select the "Set-up Mode" softkey from the MAINMENU. The SET-UP mode screen also showsthe actual position of the ram.

The SET-UP mode is used to run the ram downusing the palmbuttons and up using the RAMUP button. In addition, the softkeys on theSET-UP MENU allow incremental up or downram movement.

CAUTIONSee SECTION 3 - SAFETY for proper removal of dies.

5-10

◆ Lower the ram, using palmbuttons, to a positionwhere there is .06" to .12" (1.5mm to 3.1mm)clearance between the upper and lower dies.

◆ Turn the OPERATOR CONTROL switch to"OFF" and remove the key.

◆ Loosen the ram die clamp nuts or unclamp theUpper Power Clamps to release the upper die.Loosen the filler block set screws or unclampthe Lower Power Clamp to release the lower die.

IMPORTANT: When loosening the clamps forupper die, be sure upper die will remaintrapped between the lower die and the slotin ram nose. See Figure 5-20.

◆ The dies can now be removed from the end ofthe machine. They may be removed eithertogether or individually.

FIGURE 5-20 – Removing tooling

❦

➛

➛

.063" - .125"

PROGRAM:ABC123

STATUS: Enter new value using keypad. MAX 24.000 MIN 0.010

SET-UP MENU

RAM POSRAM LEFTRAM RIGHTRAM TILTX AXISX-leftX-rightZ-leftZ-right

Up+0.0100

Down-0.0100

Up+0.0010

Down-0.0010

CalibGage

12.453712.453712.4537

0.000012.00012.00012.000-5.502 5.502

R-AXISR-leftR-rightFR-leftFR-right

TOP OF DIE

4.9854.9854.985

0.0000

RAM IS NOW UNDER OPERATOR CONTROL

X-AXIS 12.000

6 AUG 8912:00 PM

5-11

The standard AUTOFORM is a microcomputer con-trolled programmable system. Once a program hasbeen generated on the AUTOFORM Control, the usercan run the machine and/or store the program ininternal memory. Standard internal memory con-tains 96K bytes of storage for programs, tools andoptional Adaptive and/or CAD graphics files. TheAUTOFORM also has a 3.5" 1.44 megabyte floppydisk drive which can be used to store all file types.Files are stored in DOS compatible format and canbe transferred to and from the internal file storageeither individually or in groups of multiple files. TheAUTOFORM Control Station (Figure 6-2) is locatedon the front of a movable pendant enclosure.

The Machine Control Station (Figure 6-1) is locat-ed on the side of the AUTOFORM Control pendant.The controls are used to set the mode of machineoperation and settings are generally determined bythe part(s) being formed and tooling used. Keylockselector switches are provided for use by superviso-ry or set-up personnel to maintain settings.

The Operator Station (Figure 6-3) for a standardmachine is located on the front of the ram. Thepalmbutton controls will actuate ram movement.The RAM UP button will move the ram up on eitherthe DOWN or UP stroke. Lights are provided toindicate the direction of the next ram movement(except RAM UP button).

A cable connected Footswitch control (Figure 6-4)is provided to actuate ram movement. Thefootswitch ON-OFF selector is located on theMachine Control Station.

MACHINE CONTROLS STATION

FIGURE 6-1 – Machine Controls Station

FOOTSWITCH RIGHT (or LEFT) Selector: Onefootswitch is furnished as standard equipmentand is usually connected to FOOTSWITCH RIGHTselector. In the “OFF” position the ram cannot becycled by the footswitch. Turning the switch “ON”permits the ram to be cycled by the footswitch inSINGLE STROKE mode-of-operation. The switch-es are keylock type to permit supervisory controlof the footswitch operation.

If two operators are required, an optional secondfootswitch is connected to the FOOTSWITCHLEFT selector. The operation of multiplefootswitches is explained in the various SINGLESTROKE modes-of-operation.

OPERATOR STATION RIGHT (or LEFT) Selector:One Operator Station is furnished as standardequipment and is usually connected to the OPER-ATOR STATION RIGHT selector. In the “OFF”position the ram cannot be cycled by the palm-buttons. These switches are also keylocked topermit supervisory control of the Operator Sta-tion. Turning the switch “ON” activates the Oper-ator Station and permits the ram to be cycled bythe palmbuttons.

If two operators or set-up men are required, anoptional second Operator Station is connected tothe OPERATOR STATION LEFT selector. The ramwill move when all active palmbuttons arepressed at about the same time. It will stop oneither the down or up stroke when any one palm-button is released. Before ram will resume thedown stroke, all palmbuttons must be releasedand depressed again. For the ram to resume theup stroke, only the released palmbutton(s) mustbe depressed again.

MODE SELECT Switches: Two keylock switchesare used to select the stroking mode. The first 4-position switch has “OFF”, “SET-UP”, “SINGLESTROKE” and optional “RUN” mode positions. Inthe “SINGLE STROKE” position, control is passedon to the second 3-position switch. This switchprovides for the selection of hand and/orfootswitch controls in the SINGLE STROKE mode.The function of these modes are:

“OFF” - The machine cannot be cycled.

“SET-UP” - A set-up mode that can be operatedby the palmbuttons or RAM UP button on theOperator Station or softkeys on the AUTOFORMControl station. The ram will move when the con-trol is pressed. It will stop when the control isreleased on either the DOWN or UP stroke.

EM-444 (N-09/99) 6-1

SECTION 6 MACHINE CONTROLS

“SINGLE STROKE - FOOTSWITCH ONLY” - Thisis a special purpose mode used for straighteningor bumping and should not be used for normalproduction. It can only be operated by thefootswitch (Figure 6-4). Depressing the footswitchwill cause the ram to move. Releasing thefootswitch to the middle position on the DOWNstroke will stop the ram. Releasing footswitch tothe up position on DOWN stroke will cause theram to reverse direction and go back up to the topof the stroke. Releasing the footswitch on UPstroke will not stop the ram - it will continue totop of stroke and automatically stop. Holding thefootswitch depressed will allow ram to move untilit reaches top of the stroke, where it automatical-ly stops. Footswitch must be released beforeanother stroke can be made.

IMPORTANT: If the footswitch is released to the upposition while forming and before stroke rever-sal, the ram will go back up to the top of stroke.This will cause an incomplete bend and produceunacceptable parts.

Multiple footswitches can be used in this mode.When multiple footswitches are used, all activefootswitches must be depressed for the ram tostart a cycle. Releasing any one footswitch willstop the ram. If released footswitch is depressed,the ram will continue the cycle. If all footswitch-es are released to up position, the ram will go upto top of the stroke and stop. At this position, allfootswitches must be released and depressedagain to start another ram cycle.

“SINGLE STROKE - PALMBUTTONS ORFOOTSWITCH” - This is a production mode thatcan be operated by the palmbuttons, footswitchor a combination of palmbuttons and footswitch.To use only the palmbuttons, the OPERATORSTATION (LEFT or RIGHT) selector switch on theMachine Control Station (Figure 6-1) must beturned “ON” and the FOOTSWITCH (LEFT orRIGHT) selector switch must be turned “OFF”. Touse only the footswitch, the FOOTSWITCH selec-tor switch must be “ON” and the OPERATORSTATION selector switch turned “OFF”.

When using either of these controls the ram willmove when the control is depressed. It will stopon either the down or up stroke when the controlis released. The ram will automatically stop attop of the stroke. To make another cycle, theoperator’s control must be released and thendepressed.

To use a combination of palmbutton andfootswitch controls, the OPERATOR STATIONswitch, FOOTSWITCH selector switch andSTROKE STOP-DOWN selection in the AUTO-

FORM program must be “ON” for all steps in theprogram. The HAND/FOOT SEQUENCE willthen be “ON”. In this mode the ram is moved tothe stroke stop position by using the palmbut-tons. The footswitch then controls the ram forthe remainder of the cycle. Depressing the activeoperator control will move the ram. Releasing theactive control will stop the ram on either thedown or up stroke. The ram will automaticallystop at top of the stroke.

Note: This combination mode-of-operation on certainset-ups could provide the point-of-operationsafeguarding required by OSHA. However, thiswould only be true if all unused portions of diesare guarded or eliminated by design. Operatorsmust also use proper handling methods to keepfrom being injured by workpiece movement.

Multiple Operator Stations or multiplefootswitches can be used in this productionmode. When multiple operator controls are inuse all active controls must be depressed to runthe ram. The ram will stop on either down or upstroke when any one operator’s control isreleased. Before the ram will resume downstroke, all operator’s controls must be releasedand depressed again. For the ram to resume upstroke, only the released operator’s control mustbe depressed again.

“SINGLE STROKE - AUTO RETURN” - This isalso a production mode that can be operated bypalmbuttons, footswitch, or a combination ofpalmbuttons and footswitch. To use only palm-buttons the OPERATOR STATION selectorswitch on Machine Control Station (Figure 6-1)must be turned “ON” and the FOOTSWITCHselector switch must be turned “OFF”. To useonly the footswitch, the FOOTSWITCH selectorswitch must be “ON” and the OPERATOR STA-TION selector switch turned “OFF”.

When using either of these controls the ram willmove when the control is depressed. If the con-trol is held depressed, the ram will continue tomove until it reaches the top stop position, whereit automatically stops. Releasing the palmbut-tons on the down stroke will stop the ram.Depressing the palmbuttons will restart rammotion. Releasing the footswitch on the downstroke will stop the ram. The footswitch must bereleased to the “UP” position and depressed againto continue ram motion. The ram will not stopduring the up stroke if either the palmbuttons orfootswitch control is released.

To use a combination of palmbuttons andfootswitch controls OPERATOR STATION switch,FOOTSWITCH selector switch and the STROKE

6-2

STOP - DOWN selection in the AUTOFORM pro-gram must be “ON” for all steps in the program.The HAND/FOOT SEQUENCE will then be “ON”.In this mode the ram is moved to the stroke stopposition by using the palmbuttons. Thefootswitch then controls the ram for the remain-der of the cycle. The ram can be stopped on thedown stroke as described above. However, it can-not be stopped on the up stroke. After the rampasses the stroke reversal position, it automati-cally returns to top of the stroke and stops.

Multiple Operator Stations or multiplefootswitches can be used in this productionmode. All active controls must be depressed torun the ram.

Note: This combination mode-of-operation on cer-tain set-ups could provide the point-of-operation safeguarding required by OSHA.However, this would only be true if allunused portions of dies are guarded oreliminated by design. Operators must alsouse proper handling methods to keep frombeing injured by the workpiece movement.

AUTOFORM CONTROL STATIONMAIN DRIVE - START and STOP Pushbuttons:

To start the main drive motor the “START” push-button is held depressed. If the internal checkindicates all components are operating properly,the motor will start. The yellow “ON” light willilluminate to indicate the drive motor is running.When the “STOP” pushbutton is depressed, allpower to main drive motor and operator controls(palmbuttons or footswitch), is turned off. Themain drive motor and hydraulic pumps will stop.

Note: If a machine fault should occur during operation,it is recommended that power is turned off bypressing the EMERGENCY STOP button on theOperator Station (Figure 6-3).

OPERATOR CONTROL Selector Switch: Thiskeylock switch must be turned “ON” to make theOPERATOR STATION and FOOTSWITCH con-trols on the Machine Control Station (Figure 6-1)active. In the “OFF” position those controls aredeactivated and the ram cannot be cycled, eventhough the main drive motors are running. Theram cannot be moved with the RAM UP buttonon the Palmbutton Operator Station.

6-3

FIGURE 6-2 – AUTOFORM Control Station

CRT Display: The CRT (Cathode Ray Tube) visual-ly displays program information and instruc-tions to the operator.

Softkeys: There are nine “softkeys” located belowthe CRT display which are used for selectingmenu and program functions. The lower part ofthe CRT is reserved for nine information blocks,each block corresponds to the softkey locatedimmediately below the CRT display. Each soft-key label contains a command message to theControl. When the corresponding softkey ispressed, the Control will execute that command.The command message inside each softkey labelwill change, depending on the mode of operation.The two lines just above the softkey label arereserved for operator and status information.

CURSOR CONTROL Keys: The left ( ← ) and right( → ) cursor keys are used to move the cursor onthe CRT display when editing a numeric value. Asingle digit in the value can be changed by mov-ing the cursor to the digit and re-typing the num-ber. Up and down cursor keys are used to editspecial instructions in the JOB DATA MENU.

DISPLAY MAIN MENU Softkey: Pressing this keywill recall the MAIN MENU regardless of whatprogram is now being displayed.

FIELD CONTROL Keys: The up ( ↑ ), down ( ↓ ),left (←), right ( → ) and HOME keys select theactive field in the data area of the CRT display.The field is highlighted with a gray or flashingbackground. HOME key always selects the lefttop field in the data area.

PROGRAM/LOCK Switch: This keylock switch isused to restrict programming on the AUTOFORMControl. In the “LOCK” position no values can be

changed or added to existing programs, no newprogram can be written or recalled and manage-ment data cannot be changed. In the “PRO-GRAM” position all changes, additions and newprogramming can be made.

ALPHANUMERIC Keys: These keys allow the oper-ator to enter names for programs, tools and partsinto the Control. The numeric keys provide thedigital input, using the decimal point key whererequired, for entering program information.

CLR (CLEAR) Key: If numerical inputs have beenmade in error, depressing the “CLR” key willerase the entry line only and new data must beentered. This key must also be depressed toclear diagnostic errors.

YES / + (plus) and NO / - (minus) Keys: The“YES” and “NO” keys are used to respond to pro-gram commands. Plus and minus keys are usedfor numerical entry of signed values. They arealso used to add or subtract a numerical valuefrom the number displayed on the status line.See “Calculator Mode” in SECTION 7 for moreinformation).

ENT (ENTER) Key: After the correct alpha ornumeric input has been made and appears cor-rect on the CRT display, depressing the “ENT”key will place the displayed information into theControl’s active memory.

OPERATOR STATIONPALMBUTTON Switches: Two guarded palmbut-

tons are located on either end of the OperatorStation (Figure 6-3). As a safety feature theymust be pressed about the same time to startram motion. The palmbuttons will cycle the ramin all modes of operation except “SINGLESTROKE - FOOTSWITCH ONLY”. Releasingeither palmbutton will stop the ram. If thisoccurs on the DOWN stroke, both palmbuttonsmust be released and then depressed again tostart ram motion. On the UP stroke, only thereleased palmbutton must be depressed to startthe ram.

CAUTIONThe operator should lock this switch “OFF” andremove the key when away from the machine orwhen performing adjustments to prevent any-one from cycling the machine.

6-4

FIGURE 6-3 – Operator Station

OPERATOR STATION Lights: The Operator Sta-tion is controlled by the OPERATOR STATIONRIGHT (or LEFT) selector located on the MachineControl Station (Figure 6-1). When this switch isturned “ON”, the Control Station is made activeand the amber “ON” light is illuminated. The ramcan be cycled with the palmbuttons. When theOPERATOR STATION switch is turned to “OFF”,the red “OFF” light on the Operator station isilluminated and the ram cannot be cycled withthe palmbuttons.

RAM UP Button: Depressing this pushbutton willcause the ram to go up, regardless of the motionor position of the ram. As long as the button isdepressed the ram will go up until it reaches fulltop of the stroke position. The ram will stop if theRAM UP button is released. The operator’s con-trol must be released and depressed again toresume ram motion.

EMERGENCY STOP Button: When this red buttonis pressed the ram, main drive motor and gageswill stop. The ram will stop on either the DOWNor UP stroke.

NEXT RAM MOVEMENT Lights: These lights indi-cate the direction of movement that the ram ismoving, or will move when an operator control isdepressed. Red indicates down movement andgreen indicates up movement, except RAM UPbutton which overrides these lights.

AUTOFORM ELECTRICALENCLOSUREGROUND CONNECTED LIGHT: The low voltage

circuit is a grounded circuit. The illuminatedlight indicates that the ground is connected. Thisis an internal chassis ground - it does not indi-cate that the machine is grounded.

MAIN DISCONNECT Switch: This switch controlsthe incoming electrical supply to the machine.When turning the main disconnect switch from“ON” to “OFF” and then back to “ON”, wait 10-15seconds before switching back to “ON”.

IMPORTANT: This 10-15 second delay is required toallow machine functions to reset properly.

POWER SUPPLIES OPERATIONAL Light: Indi-cates all internal power supplies are operatingcorrectly.

FOOTSWITCHThis is a guarded, three-position operator controlwhich controls ram motion. It can be used in all“SINGLE STROKE” modes-of-operation. The ramwill move when the footswitch is held depressed. It

will continue to move until it reaches top stop posi-tion. When the STROKE STOP - DOWN or UP selec-tions are ON, the ram automatically stops at thesepositions. To restart ram motion, the footswitchmust be fully released to the UP position anddepressed again.

The footswitch is made active by turning “ON” theFOOTSWITCH RIGHT (or LEFT) selector switch onthe Machine Control Station (Figure 6-1). With theselector in the “ON” position, the ram can be cycledwith the footswitch. In the “OFF” position the ramcannot be cycled with the footswitch. A red indica-tor light on the footswitch indicates the selectorswitch is turned “OFF” and an amber light indi-cates the switch is turned “ON”.

FIGURE 6-4 – Footswitch (Handle removed for clarity)

FLOPPY DISK DRIVEThe AUTOFORM control has one 3.5" floppy diskdrive as standard with provisions to allow a second3.5" floppy disk drive as an option to double thefloppy disk based file storage. The floppy disk driveis capable of reading and writing both 720 Kilobyte(DD) and 1.44 Megabyte (HD) MS-DOS compatible3.5" floppy disks. A cover is provided to protect thefloppy disk drive(s) from contamination. This covershould be kept closed except for changing floppydisks. Failure to keep the cover closed could resultin damage to the drive assembly.

The floppy disk system can be accessed for storingand retrieving files in any of the various storagemenus (programs, tools, etc.) or in the FILE TRANS-FER screen. The floppy disk system supports threedifferent DOS-compatible filename formats. Thor-oughly read and understand the information on filestorage and filename formats in SECTION 7 – OPER-ATION before changing the filename format fromthe recommended default setting.

6-5

An additional floppy disk drive can be added to theAUTOFORM control which will double the availablefloppy disk based storage from 1.44 megabytes to2.88 megabytes for High Density Floppy disks, orfrom 720 kilobytes to 1.44 megabytes for DoubleDensity floppy disks. The additional floppy diskdrive will read/write either HD or DD floppy diskswhich have been formatted for the MS-DOS file sys-tem. The standard floppy drive is referred to aslocal drive "A" and the additional floppy drive aslocal drive "B".

RS-232/422 COMMUNICATIONINTERFACEThe AUTOFORM communications package is ahardware/software function that allows programsto be transferred to and from a remote computer.The file transfer protocol used on the AUTOFORMis based on the familiar "KERMIT" file transferprotocol developed by Frank DaCruz at ColumbiaUniversity. "KERMIT" is a packet-based (data isbroken up into chunks or packets) protocol thatprovides excellent error rejection and recovery.This allows error-free file transfer in the noisyshop floor environment. The press brake controlimplements both CLIENT and SERVER modes ofoperation, allowing file transfers to initiate at thecontrol or the host computer. This allows tremen-dous flexibility when setting up communicationswith the press brake. Care should be exercisedwhen choosing how to label program files, toolfiles, etc. to ensure that these filenames will becompatible with restrictions that exists for filenames on the host computer system.

Note: For more information or to obtain a copy of "KER-MIT" for your host computer, contact KERMITDISTRIBUTION, COLUMBIA UNIVERSITY CEN-TER FOR COMPUTING ACTIVITIES, 612 West115th Street, New York, NY 10025, or visit theirwebsite at www.columbia.edu.

CONTROLS - AUTOFORMOPTIONSFor other available AUTOFORM options and moreinformation on the options whose controls are list-ed here, see SECTION 8 - OPTIONS.

ADDITIONAL OPERATOR CONTROLS

One additional Operator Station (ram mounted orpedestal mounted) and/or footswitch can beinstalled on the machine. There are provisions onthe Machine Control Station for selection of twooperator controls of each type. Their operation isdescribed earlier in this section.

DATA CARTRIDGE STORAGE

The optional external Data Cartridge Storage unit islocated on the side of the main enclosure. (See Fig-ure 8-10.) The cartridge is used to make a copy ofinformation stored in the internal memory of theAUTOFORM Control. It is used to back-up informa-tion stored in this Control.

RS-232/422 CONVENIENCE PORT

The RS-232/422 Convenience Port is a hardwareoption that provides a prewired DB-25 RS-232/422connector in a covered box on the outside of themain electrical enclosure. See the RS-232/422Communications document EM-372 for cable con-nections and protocol.

POWER CLAMP

Power clamps provide means to rapidly install orremove tooling. They are available for the ram, bedor both. The POWER CLAMP control is mounted onfront of the electrical enclosure. It has keylockselector and an indicator light for the UPPERclamps and a selector switch for the LOWERclamps. See Figure 6-5.

FIGURE 6-5 – Power Clamps

CNC BACKGAGES

A hand-held gage pendant control (Figure 6-6)allows the R-axis of the backgage bar to be manu-ally positioned using pushbuttons on the HeavyDuty Backgage (CNC Plate Gage in the control). Onthe Six Axis Backgage, a hand-held gage pendantcontrol allows the R-axis and the Z-axis to be man-ually positioned.

6-6

FIGURE 6-6 – Hand-held operator control

CNC FRONTGAGE

The CNC Frontgage is an optional feature whichprovides programmable frontgage positioning to theAUTOFORM CNC Forming Center. Before the firstcycle of the ram and if the gage needs to be moved,the control display prompts the operator to initiatefrontgage movement. This is done by pressing thesoftkey on the screen.

❦

6-7

HEAVY DUTY BACKGAGE(CNC PLATE GAGE in control)

(Optional)

825144

UP

LEFT ARM

RIGHT ARM

DOWN

UP

DOWN

SIX AXIS BACKGAGE(Optional)

INTRODUCTION TO CNCMACHINE CONTROLSSCREEN LAYOUT

Every screen displayed on the AUTOFORM Controlwill be divided into four areas. The first area at thetop of the screen is called the menu area. It con-tains the name of the current menu and page num-ber. In the upper left corner of the menu area is theprogram name. The next large area of the screen isthe data area. It contains specific information ondata the operator has entered. Just below that isthe status area. All messages to the operator andvalues entered by the operator are displayed here.The last area is reserved for softkey labels. Thereare nine softkeys divided into groups of three. Eachscreen area uses colors to provide the same appear-ance for all menus. The following screen displayshows the different screen areas.

The basic screen displays, called menus, aredescribed in the following pages. To provide a con-venient reference, the AUTOFORM MENU INDEXdiagram shown below lists these menus. In addi-tion, the page number next to each block indicateswhere the description for that menu begins.

MOVING THROUGH MENUS

Operation of the control is divided into menus.Each menu is used to program a different functionof the machine or to store and retrieve tools andprograms. Menus are selected by pressing thedesired softkey on the MAIN MENU screens. Thereare two pages of the MAIN MENU. By pressing theDISPLAY MAIN MENU key, the control will switchbetween page one and two. Figures below show theMAIN MENU screens. The DISPLAY MAIN MENUkey will immediately stop and cancel the currentoperation or machine cycle and display the MAINMENU Page 1.

PROGRAM:ABC123

STATUS:

EM-444 (N-09/99) 7-1

SECTION 7 OPERATION

MAIN MENUPAGE 1

MAIN MENUPAGE 2SET-UP MENU

ENTERINGNEW PROG.

TOOLINGLIBRARY JOB DATA

RAM DATA

GAGE DATA

RUN MODEPROGRAMSTORAGE QUICK BEND

MANAGEMENTDATA MENU

MACHINECONFIG.

DIAGNOSTICS

FILEMENU

ADAPTIVEMENU

CAD MENU

SEE SECTION 5and PAGE 7-10

PAGE 7-11

PAGE 7-22

PAGE 7-22

PAGE 7-24

PAGE 7-30

PAGE 7-37 PAGE 7-39 PAGE 7-41

PAGE 7-45

PAGE 7-48

PAGE 7-67

PAGE 7-49

PAGE 7-57

SEE SECTION 8 (PAGE 8-1)

ENTERING LABELS AND NUMBERS

Figure 7-1 shows the keys used by the operator toenter data into the Control. Each of these controlswas described in SECTION 6 - MACHINE CONTROLS.

DATE AND TIME

The date and time are always displayed in theupper right corner of the screen. To set, see the sec-tion "MACHINE CONFIGURATION MENU".

FIELD KEYS

When a menu softkey is chosen, the MAIN MENUscreen is erased and the new screen is shown. Thedata area of the screen will now be divided into“fields”. Each field on the screen contains twoparts: a name and a value. The field name is a fixedmessage which identifies what the value is used for.

Fields can be selected by using the five field selectkeys:

FIELD CONTROL

HOME

PROGRAM:ABC123

STATUS: Select a menu using the softkeys.

MAIN MENU

MANAGEMENT DATAMACHINE CONFIGURATIONDIAGNOSTICSFILE MENUAUTOFORM CAD MENUPROGRAMMABLE OUTPUTSADAPTIVE MENU

ManageData

MachineConfig

Diag-nostics

FileMenu

CadMenu

6 AUG 8912:00 PM

ProgOutputs

AdaptiveMenu

PROGRAM:ABC123

STATUS: Select a menu using the softkeys.

MAIN MENU

ENTER NEW PROGRAMJOB DATARAM DATAGAGE DATARUN MODEQUICK BENDSET-UP MODETOOLING LIBRARYPROGRAM STORAGE

EnterNewProgram

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

6 AUG 8912:00 PM

7-2

FIGURE 7-1 – AUTOFORM Control Station

These keys allow the operator to move up, down,right and left on the screen relative to the currentfield. There is also a “home” field key which selectsthe top left field in the data area. The current fieldis always made to stand out by using flashing text.Field values which may not be changed by the oper-ator are skipped over when moving around thescreen with the field keys.

CHANGING A FIELD

The “value” in a field may contain a decimal num-ber or a string of characters. The control uses twomethods of editing a value. Many value fields havea fixed set of possible entries. For example, REVER-SAL mode has Position, Tonnage, Angle, Adaptive(optional) or Absolute. In these cases the softkeyswill show all the choices and the operator will beinstructed to make a selection by pressing one ofthe softkeys. When a value field can have manypossible entries (decimal number, text string), thekeypad is used to enter the value one letter or digitat a time.

The status line will display the value in the rightcorner. If the operator does not want to change thevalue shown in the status line, he can use the fieldkeys to skip to another field. To enter a new valueor change a value, the operator can use the keypadto type it in. A flashing underline will move to theright as each letter or number is typed. The CLR keycan be used to erase the entire value to start over.

To change one digit in a number value, the left andright cursor keys can be used to move the cursorover to the digit to be changed. Pressing a numberkey will type over the digit under the cursor.

When the operator has completed a value, pressingthe ENTER key will transfer the value into the field.The field value is not changed until the ENTER keyis pressed.

DEFAULT VALUES

Some fields will already show a value for the entry,and are called default values. These are a normalvalue for the particular function and may either beused or changed to suit the job requirements.

CALCULATOR MODE

When a numeric value is first shown in the statusline and the cursor is under the left most digit, thecalculator mode may be used. CALCULATOR modeallows the operator to add or subtract a fixed num-ber to the value. By first pressing a number andthen a sign key (+/-), the operator selects the fixednumber. Each time a sign key is pressed the fixednumber is added or subtracted to the originalvalue. When the desired value has been reached,pressing the ENTER key will transfer the value intothe field. CALCULATOR mode is handy for fine tun-ing a number. The following example shows this.

STATUS: Enter value using the keypad12.0005

STATUS: Enter value using the keypad12.0006

LIMIT CHECKING

Whenever the operator specifies a field to edit, thesecond line of the status area will show minimumand maximum values which can be entered for anumeric value. The operator will not be allowed totransfer the value into the field if it is outside thisrange. An error message is displayed in the statusarea that tells the operator to re-enter the valuewithin range.

STATUS: Enter value using the keypad8.0000

MAX: 12.0000 MIN: 0.0100

ALTERNATE UNITS / LANGUAGE

The AUTOFORM Control can be used in either Met-ric or English units. A program can be enteredusing one unit type and converted to the other. Tochange units the operator must select the "ChangeUnits" softkey in the MACHINE CONFIGURATIONMENU. This causes all displays to use the new unittype. When using ENGLISH units all values are dis-played in green, while using the METRIC mode theyare displayed in yellow.

Alternate languages are available as an option onthe AUTOFORM Control. To switch between lan-guages the operator must select a language type inthe MACHINE CONFIGURATION MENU. For addi-tional information, see the instructions on thatmenu later in this section.

SCREEN SAVER MODE

The AUTOFORM Control has a special functionwhich blanks the screen after a period of time haselapsed with no keyboard activity. As long as the

. 0 0 0 1 YES+ ENTER

CURSOR CONTROL

7-3

machine is not in a cycle active mode or set-upmode, the Screen Saver Mode will engage afterapproximately ten minutes. Screen Saver Mode isshown by a small flashing block in the lower rightcorner of the screen. Pressing any key will re-drawthe screen and continue the previous menu. ScreenSaver Mode helps prolong the life of the CRT.

INTERNAL / EXTERNAL MEMORY

The storage for the AUTOFORM Control is dividedinto two sections, internal and external memory.Internal memory contains 98,106 bytes of storagespace which holds the tool library, program storageand optional Adaptive and CAD file storage. Notapes or cartridges are needed for internal storage.The internal memory information is maintainedwhen the main disconnect is turned off by a dualbattery back-up circuit which monitors the DCsupply and battery voltages and automaticallyswitches to the highest source.

The external memory consists of one or more diskdrive(s) which function in a similar way to the cur-rent internal memory storage. However, the diskdrive may contain up to 1.44 Megabytes of storagespace. The Operator may load and store files ondisk from each STORAGE MENU, i.e. PROGRAMSTORAGE, TOOLING LIBRARY, PART STORAGE,ADAPTIVE STORAGE, SHAPE LIBRARY. Each ofthese storage screens uses the VOLUME field tospecify either internal memory or a local drive. Thisfield is stored in active memory so the last selectionis always retained. A separate screen (FILE PREF-ERENCES) under the FILE MENU will allow editingthe disk pathname associated with each volumeand file type. The Path is displayed on each storagescreen if the Volume is a disk.

The BYTES remaining field will indicate the freespace on the Volume. If the Volume is internal, thefree space will be displayed in bytes, if the Volumeis a disk, the value displayed is in kilobytes, or “k”(thousands of bytes).

To select between the directory of Internal memoryand a disk, the “Change Volume” softkey can beused. When pressed, the softkeys will change asshown below to indicate the possible choices forvolumes currently available on the control.

STATUS: Select a Storage Volume using thesoftkeys.

Note: Local Drive A is standard. If the option isinstalled, the "Local Drive B" softkey selec-tion will be displayed.

After making the selection, the directory is updated.When switching to a local drive volume there is asmall delay while the directory is read from thedrive. Operations on the local drive take longer thanoperations on internal memory. The status line willindicate when a disk operation is taking place.

When storing a file to a disk volume, the status linedisplays the actual name of the file which is beingstored on the disk as shown below.

STATUS: Storing File < ABCDEFGH.IJK >to disk, please wait.

The “Delete File” softkey will erase the specified filefrom the current volume. In the case of a local drivevolume, the disk must not be write protected for thefile to be deleted. An error message will be displayedif the square write protection hole on the disk isopen.

There is no recoverable directory for files whichhave been deleted from a disk. It may be possible torecover deleted files from disk by using one of thestandard DOS utility packages, such as NORTONUtilities, on an Offline PC. The “Recover File” soft-key on each storage screen will be erased when thevolume is set to local drive. The only exception is onthe TOOL LIBRARY MENU where the “Recover Tool”softkey will appear if either the Upper Tool or LowerTool Volume is set to Internal.

If an attempt is made to store a file that alreadyexists the operator will be prompted to overwritethe file or cancel. The status line and softkeys willbe displayed as shown below.

STATUS: Filename already exists, Overwritefile or Cancel operation.

In a Storage screen with the Volume set to LocalDrive A or B, if the disk is ejected from the drive thedirectory listing will be blanked. When a disk isinserted, the directory listing will automatically bedisplayed. This ensures that if a different disk isinserted, the correct directory is displayed.

Over-WriteFile

CancelLocalDrive B

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

CAUTIONNever remove a disk from the drive while the DiskAccess light is ON. This will result in loss of data onthe disk. Always maintain proper back-up copies ofimportant data. There are no safeguards which pre-vent ejection of the disk while it is being accessed.Keep the disk cover closed when not removing disks.

InternalStorage

LocalDrive A

LocalDrive B

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

7-4

To eject a disk from the drive press the button onthe front of the drive. If the Volume selected on thestorage screen is a local drive, the status line willchange as shown below to indicate the disk hasbeen ejected.

STATUS: Disk has been ejected, insert diskto restore directory.

FILENAME FORMATS

The disk file format used on the control is MS-DOScompatible. This allows a PC or compatible to beused to copy and store files. Three filename formatsare supported when using the local drives. Eachone has a purpose which involves name length,alphabetical directory listings and readability whenusing a PC to view the directories. All three are DOScompatible and can be used with the Off-Line Pro-gramming Software. All three will allow a 16 char-acter name to be entered and will store the fulllength name inside the file. Decide which one ofthese formats is most suitable for the installationand stay with it. Switching from one to the otherwill cause confusion.

Note: The feature that allowed the operator to use ablank name when storing a file to internal memo-ry is not available on the local drive volume. Anerror message will be displayed if a blank file-name copy is attempted to a local drive volume.

DOS FILENAME CHARACTERISTICS

DOS filenames are limited to 11 characters, con-sisting of an 8 character base with a three charac-ter extension. The base and extension are separat-ed by an implied period which is not actually partof the name. A DOS filename cannot consist only ofthe extension. DOS filenames can contain the char-acters 0-9 A-Z _ - ! @ # $ % ^ ( ) and ‘ .Lower case letters are converted to uppercase. Thecharacters | \ , . < > ? / : ; “ [ ] * + =and space are not allowed in the base or the exten-sion. The control can generate 0-9 A-Z . and +and the space character which is converted to anunderscore. The + character should not be usedfor filenames.

Refer to the FILE PREFERENCES MENU section fordetails on selecting the Filename Format.

Listed below is a description of each filename format.

16 CHARACTER NAMES SORTED

This is the default filename format unless changedby the operator in the FILE PREFERENCES MENU.It will support full 16 character filenames andalphabetical directory listings identical to the

method used by internal memory on the AUTO-FORM and is transparent to the operator. It allowsmultiple periods, underscores and dashes in thefilename. To be able to store this format to disk it isnecessary to convert the 16 character filename to aDOS compatible filename. The conversion codingscheme steps are:

1. If the first character of the filename is aperiod, replace it with an underscore.

2. Use the first 8 characters of the 16 char-acter filename, or up to the first period ifless than 8 characters, as the base.

3. Use the next 3 characters of the filenameas an extension.

4. Compare this filename to others alreadystored on the disk.

5. If the filename is unique, store the fileusing the first 11 characters.

6. If not, generate a unique extension usingthe following sequence: AAA, AAB,AAC...ZZZ.

Using the example shown, File 1 has been enteredon the control with the 16 character filenameshown. When stored on the disk it is stored as an11 character name.

Example: File 1 ABCDEFGHIJKLMNOP Stored ondisk as ABCDEFGH.IJK

File 2 has been entered on the control with the 16character name shown. It has the same first 15characters as File 1. When stored on the disk, it isstored with a different name according to the cod-ing scheme so it is unique.

Example: File 2 ABCDEFGHIJKLMNOX Stored ondisk as ABCDEFGH.AAA

This scheme allows all filenames on the disk to beunique because there will be 17,576 possible com-binations per directory using the three letter exten-sion. An alphabetical index file will be created inevery sub-directory on the disk to cross-referencethe 16 character name to the coded 8 characterbase with 3 character extension.

When a directory of the disk is displayed on thecontrol, the operator will not see the coded file-name, but instead, the full 16 character name asoriginally entered. A directory display will showsequence number, 16 character name sorted alpha-betically, and date in two, fifteen name columns.The date shown will be the date the file was lastmodified.

7-5

Any operations performed on the control such ascopying or deleting files, will automatically updatethe index file. In the above example, if File 1 is edit-ed at some point and then stored, it will overwritethe same file (ABCDEFGH.IJK).

If a disk is inserted which does not have an indexfile in the desired directory, an error will be dis-played as follows:

ERROR: Index File not found.

The directory screen will be blanked. If the disk isremoved from the control and a PC is used to copyfiles directly to the disk, these files will not beincluded in a directory listing when the disk isinserted into the control, because the PC does notupdate the index file. To recover from both of thesesituations, in the FILE UTILITY MENU, use the"Change Path" softkey to change the CURRENTPATH to the desired directory, e.g. \PROGRAM forprogram files, then press "Rebuild Index" softkey.

If the operator is attempting to save a file to a localdrive volume and the index file is not found, thecontrol will prompt the operator to re-build theindex file and continue saving the file.

If the "Rebuild Index" softkey is pressed and theCURRENT PATH is set to \ , the following errormessage will be displayed:

ERROR: Disk: File or Directory not Found.

11 CHARACTER NAMES SORTED

The only difference between this format and 16character sorted is that the filename coding schemeis not used. This filename format will shorten 16character names to 11 characters and then checkexisting filenames of the current file type on thedisk for a match. If no match is found, the file willbe stored to the disk, if a match is found, the oper-ator will be notified with a warning message asshown below and given the choice of overwriting thefile or cancelling the operation. Given the sameexample of File 1 and File 2 as shown before, File 2would generate the warning message whenattempting to store.

WARNING: This operation will overwrite anexisting 11 character filename.

When a directory of the disk is displayed on thecontrol, the operator will still see the full 16 char-acter name as originally entered. A directory dis-play will show sequence number, 16 charactername sorted alphabetically and date last modifiedin two, fifteen name columns.

If the disk is removed from the control and a PC isused to copy files directly to the disk, these fileswill not be indicated in a directory once the disk isre-inserted on the control. To correct the situa-tion, the index file can be re-built using the"Rebuild Index" softkey in the FILE UTILITYMENU. If this is a common practice, it is recom-mended that the sorted file formats not be usedand filenames are limited to 11 characters. Usingthis file format allows a standard DOS directory tobe displayed in a more recognizable form thanwith the coded filenames of the 16 characterindexed format.

If a disk is inserted which does not have an indexfile in the desired directory, an error will be dis-played as follows:

ERROR: Index File not found.

The directory screen will be blanked. If the disk isremoved from the control and a PC is used to copyfiles directly to the disk, these files will not beincluded in a directory listing when the disk isinserted into the control, because the PC does notupdate the index file. To recover from both situa-tions, in the FILE UTILITY MENU, use the "ChangePath" softkey to change the CURRENT PATH to thedesired directory, e.g. \PROGRAM for programfiles, then press the "Rebuild Index" softkey.

If the operator is attempting to save a file to a localdrive volume and the index file is not found, thecontrol will prompt the operator to rebuild theindex file and continue saving the file.

11 CHARACTER NAMES UNSORTED

This file format differs from the previous formatsbecause the index file is not used. This filenameformat will shorten 16 character names to 11characters, and then check existing files for aname match. If no match is found, the file will bestored to the disk; and if a match is found, theoperator will be prompted to overwrite the file orcancel the operation.

No index file will be used. A directory display willshow the sequence number, 11 character nameunsorted and date last modified in two, fifteenname columns. This is the standard method DOSuses to display a directory. This format should beused if the files are going to be routinely copied toa PC, edited and uploaded to the control usingthe disk. It is up to the users to maintain distinctfilename convention using the maximum of 11characters for a filename.

7-6

Note: A directory listing of a disk using 16 or 11character sorted filename format viewed on anoffline PC or on the control using 11 characterunsorted format will show the file INDEX.DIR.DO NOT delete or attempt to copy this file.

FILENAME STRATEGIES

The 16 character sorted filename format is thedefault format and uses all sixteen characters todetermine the actual filename stored on the localdrive. If the current part or job naming system inuse has names with the same first eleven char-acters or multiple periods in the name then thisis the format to chose. The only drawback to thisformat is that when the filenames are displayedoff-line on a PC using the DOS DIR command, itwill sometimes be difficult to identify a particularfile because of the .AAA, .AAB .AAC etc. namingalgorithm. When files are added or deleted by anoff-line PC using DOS, the Rebuild Index opera-tion must be performed on each directory modi-fied, for the changes to appear in the directorylistings on the control.

If being able to identify, move and copy files off-lineon a PC is necessary, alphabetical directory listingsare desirable and file naming requirements are flex-ible enough, the 11 character sorted format is agood choice because it does not use the .AAA, .AAB.AAC etc. naming scheme and will display a warn-ing message if a file with the same first eleven char-acters exists on the local drive. When files areadded or deleted by an off-line PC using DOS, theRebuild Index operation must be performed oneach directory modified, for the changes to appearin the directory listings on the control.

If alphabetical directory listings are not necessary,the 11 character unsorted format will allow files tobe copied, moved, and deleted off-line on a PC andbecause an index file is not used, the Rebuild Indexprocess is not necessary and disk operations aresomewhat faster.

FILENAME OPTIMIZATION FOR DOS

Eliminating the use of periods or replacing themwith underscores is the best way to make more file-name characters significant when the filename isstored to the local drive volume. The followingexamples show how filenames are converted toDOS format by the 11 character sorted and unsort-ed selections:

File 5825712LEFT Stored on disk as5825712L.EFT.

File .825712LEFT Stored on disk as_825712L.EFT.

File 8.25712LEFT Stored on disk as 8.257

File 8_25712LEFT Stored on disk as8_25712L.EFT.

3.5" DISK HANDLING

The 3.5” disks used for the System and Data filesare reasonably rugged and can be safely sentthrough the mail and carried around in a briefcaseor shirt pocket. They can be left partially insertedinto the drive on the AUTOFORM control as longas the external access door is closed and latched.When the disk is fully inserted into the drive, themetal cover on the disk is slid open and theread/write heads are lowered into contact with themagnetic media. For this reason, it is not recom-mended to leave the disk fully inserted intothe drive for long periods of time, whether themachine is operating or idle. The disk should beejected from the drive whenever power to machineis cycled off or on. The disk should not be exposedto direct sunlight, water, extreme temperatures, orstrong magnetic fields. Never slide the metal coveropen or touch the magnetic media disk throughthe opening.

FILE SYSTEM BACK-UPS

Back-ups of program, tool, etc. files should be per-formed at regular intervals. There are three devicesthat can be used for file back-up:

1. The Data Cartridge.

2. The REMOTE volume.

3. The Local Drive volume.

The first device is an option which consists of aData Cartridge and cable. The cartridge can beused as a back-up for the entire internal memory ofthe machine. The data cartridge may be discon-nected from the Control and its memory will beretained by an internal battery. Each time theinternal memory of the control is copied to the datacartridge, the existing data in the cartridge is over-written. Individual files can not be retrieved fromthe cartridge, so if an internal memory fault occursand the last cartridge save was four days earlier, allof the changes that occurred to the files since thesave will be lost when the cartridge data is loadedinto internal memory.

The second device requires an off-line computerrunning a kermit server with an RS-232/422 con-nection to the communication port of the control.Although care must be taken in choosing filenamesto ensure that files are not overwritten, individualfiles or groups of files can be uploaded to and down-loaded from the kermit server using the "Copy" soft-key in the FILE TRANSFER screen.

7-7

The third device requires the built-in local driveand can be used to back-up individual files as theyare changed to 3.5” disk.

The file system back-up utility can be used to haveavailable changes to all files which occurred duringthe most recent four week time period by using thefollowing method:

Format a high density disk and once each day dur-ing the week press the "Back-up/Restore Internal"softkey in the FILE UTILITY screen, then press the"Intern To Disk" softkey and the "Default ArchiveName" softkey. This will store all of internal memo-ry to a file named FILESARC.001. Follow the samesequence each day using the same disk. Each daythe extension of the archive filename will automat-ically be incremented e.g. .002, .003, etc. At theend of the week, format another disk and continuethe procedure. At the end of four weeks, set onedisk aside as a permanent back-up, format anadditional disk and continue. Using this methodwill make available a monthly snapshot of the filesand changes to all files which occurred during themost recent four week time period.

External memory is an option which consists of aData Cartridge. This cartridge can be used as aback-up for the machine if a memory failure shouldpossibly occur. It may also be used to store addi-tional programs which cannot fit into the internalmemory. The operator may copy internal memory tothe external data cartridge and vice versa. The datacartridge may be disconnected from the Control andits memory will be retained by an internal battery.

ACTIVE MEMORY

The AUTOFORM Control contains memory storagefor one program, an upper and lower tool, oneAdaptive file (optional), one CAD file (optional) andone QUICK BEND MENU. This means that whenthe machine is powered OFF and back ON, the pro-gram being used before the power-down will still be“active” on the AUTOFORM Control. Therefore, it isnot necessary to reload the program from storage(Internal Memory). This is the same for the toolslast used, QUICK BEND MENU values last entered,and the Adaptive file (optional) last used.

WHAT IS A PROGRAM

A Program is defined as a set of entered valuesrequired to form a part on the machine. These val-ues are entered in JOB DATA, RAM DATA andGAGE DATA MENUs. Once a program has beenprogrammed into the Control, it can be stored forlater use. A separate menu called PROGRAM STOR-AGE is used to store and recall these programs.

Each program is referred to by a program name.The Control can only contain one program in activememory at a given time. There may be many suchprograms stored in internal memory which can beloaded at a later time. The current program name isalways displayed in the upper left corner of theMAIN MENU. For more information see the sectionJOB DATA MENU, RAM DATA, GAGE DATA andPROGRAM STORAGE MENU.

FILE DATE STAMP

When a file appears in the corresponding Storagescreen, the date and time which the file was storedappears to the right of the filename. This date isonly modified if the file is stored. Be sure the dateand time displayed on the menu bar are accurateso files are stored with the correct information.

LOADING / DELETING FILES

On all File Storage screens, i.e. Program Storage,Tooling Library, Part Storage, etc., a file may beloaded into/deleted from active memory by eithertyping the filename or the sequence number. Thedefault is by sequence number. If it is desired toload/delete a file by filename, press the "By Name"softkey first.

RECOVER DIRECTORY

When a file is deleted from INTERNAL memory acopy is saved in a special area called the "RecoverDirectory". The recover directory is limited in sizeso as more files are deleted, older files in the recov-er directory are erased to provide room. On eachstorage screen there is a "Recover File" softkeywhich, when pressed, will show a directory of thedeleted files. The filenames are shown in yellow todistinguish them from the normal storage screen.When a file is selected from the recover directory itis put back into internal memory and appears inthe File Storage screen. The files in the recoverdirectory are lost when the control is powered off.This feature is not available for the local drive vol-ume. The “Recover File” softkey on each storagescreen will be erased when the volume is set tolocal drive. The only exception is on the TOOLLIBRARY MENU where the “Recover Tool” softkeywill appear if either the Upper Tool or Lower ToolVolume is set to Internal.

FILE SYSTEM REPAIR

The file system in internal memory ischecked/repaired on power-up. If a corrupt file orother problem is encountered, it is deleted and the

ByName Cancel

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

7-8

name of the file is displayed on the file system infor-mation screen. If any errors are found on power-up,the file system information screen will remain untilthe "Main Menu" key is pressed to allow specificerror information to be written down. The file mem-ory fault error will no longer occur because file sys-tem errors are repaired on power-up. When files arecopied from an external data cartridge to internalmemory, the file system repair utilitychecks/repairs the files.

DAILY START-UPAt the beginning of a new shift, after every break, atthe start of a new job, or when machine is startedafter an extended off-period (several hours orlonger), the following procedure is recommended.

1. Check reservoir oil level.

2. Let the pumps idle for a few minutes.

3. Check controls for proper operation.

4. Check that all required safety devices and pro-cedures are operating properly and are beingused.

5. Check that all controls are correctly positionedfor the set-up or job to be run.

6. Check for tools, loose material or persons in thepoint-of-operation or at rear of machine.

7. BE SAFETY CONSCIOUS. Always follow thesafety precautions outlined in this manual. Beparticularly careful never to place any part ofyour body in the die area.

8. Select proper tooling for the job. Make sure thedies are in good condition.

MACHINE CALIBRATIONThe AUTOFORM Control requires that the ram andgage be calibrated before programmed ram or gagemovement can be started. Calibration of raminvolves moving the ram up until it contacts thelimit switches. Gage calibration is the same, withthe gage moving to its home limit switch locations.Once the ram and gage are calibrated, it is not nec-essary to re-calibrate unless the main disconnect isturned OFF or a fault occurs.

IMPORTANT: There is no menu or function on thecontrol that can be selected to calibrate the ram.Calibration is only required after the main dis-connect has been turned ON. When the operatorattempts to move the ram or gage, the AUTO-FORM Control will display a calibration messagein the status area.

The AUTOFORM Control will display a message onthe CRT if it requires calibration. A special softkeywill appear in the first position (extreme left) whenram movement is attempted. Pressing the softkeywill activate the calibration cycle for the ram orgage. There is also a softkey in the extreme rightposition of the screen to abort the calibration cycle.The "Calibration" softkey will appear in any of themenus where ram movement is allowed (RUNMODE, SET-UP MODE, QUICK BEND, ADAPTIVE,TEACH DIE SET-BEND).

To calibrate the ram, press the “Calibrate Ram”softkey. The status line will now display the follow-ing message:

CALIBRATING MODE ! ! !

STROKE MODE selector (Figure 7-2) must be in the“SINGLE STROKE” or “SET-UP” position. In SIN-GLE STROKE, either the OPERATOR STATION orFOOTSWITCH can be used to calibrate the ram ifits selector is “ON”. In SET-UP, the OPERATORSTATION selector must be “ON” and the OPERA-TOR STATION must be used to calibrate the ram.

FIGURE 7-2 – Machine Controls Station

Activate the ram motion using the palmbuttons orfootswitch. The ram will move up to the top of thestroke limit switches, will move down off the limitswitches, will move up to the limit switches andpause, and then will move up to zero the encoders.Do not release the palmbuttons or footswitch untilthe status line is cleared and the softkeys are re-displayed.

If the machine is equipped with a backgage, the“Calibrate Gage” softkey will appear in the samemanner as before. The operator may use the “Abort”softkey to cancel the calibration cycle. Normal soft-keys for the current menu will now return.

7-9

To calibrate gage, press “Calibrate Gage” softkey.

At this time the gage will move to its extreme posi-tion until the limit switches are contacted. The fol-lowing message will appear on the status line.

CALIBRATING THE GAGES!

After calibration of gage is complete the normalsoftkeys will return to the menu the operator wasusing before.

SET-UP MENU

The SET-UP MENU is used to install dies in themachine. Refer to “TOOL INSTALLATION” in SEC-TION 5 - SET-UP & USE for further information.

TOP OF DIE CALIBRATION FORUNMEASURED TOOLS

When using unmeasured tools in JOB DATA it isrequired to calibrate the top of die position for theram. Select the TOP OF DIE field using the fieldkeys in SET-UP MENU. Insert the one inch calibra-tion block on the die. Inch the ram down until theblock is “pinched” between the dies. Press the“Calib Top of Die” softkey to record this position asthe Top of Die.

This calibration is required again whenever themachine is powered-off or the “Enter New Program”softkey is used to erase the current program.

GAGE BAR CALIBRATION(Dual Drive Backgage Only)It is advisable to make this calibration wheneverthe dies are changed, the gage fingers are changedor the gage fingers are repositioned a significantamount (12” or more) left-to-right. This calibrationmust be made whenever changing from finger gag-ing to bar gaging or to other special gage blocks orfingers.

Aluminum/urethane calibration blocks (see Figure7-3) are used for calibrating the gage bar to thedies. Even though the blocks allow for a slightamount of “pinch” between the dies, care must betaken to avoid damaging the blocks or the tooling.These gage blocks are designed to be used with themajority of vee dies used for sheet metal bending.

FIGURE 7-3 – Calibrating gage bar

◆ Select the SETUP mode and cycle the ram tothe maximum up position. SETUP mode isused to position the ram and gages to calibratethe gage bar.

◆ Select the X-axis field of the SETUP mode usingthe field keys. Move the X-axis to the extremerear position by entering the maximum gagedistance. (For the standard Dual Drive Back-gage, this position is 24”.)

The gage should now move to the extreme rearposition for a 24” gage. If the gage is not cali-brated, a message will instruct the operator tocalibrate the backgage at this time.

◆ When the gage is in position, turn the OPERA-TOR CONTROL selector to “OFF”.

◆ Loosen both horizontal gage adjustmentclamps, manually move the gage bar to itsextreme rear position and retighten clamps. SeeFigure 7-4. If gage fingers are to be used in the

ENTER2 4

CAUTIONNever hold these blocks in the die area whilethe ram is being lowered to a position to clampcalibration blocks.

CalibTop ofDie

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

CalibrateGage

HighStrengthSteel

Stain-lessSteel

SoftAlum

HardAlum

SoftCopper

HardCopper

ToolingLibrary

ProgramStorage

7-10

forming operation, they should be installed atthis time. For best accuracy, it is advisable toplace the gage fingers and calibration blocks atthe positions where the part is to be gaged.

◆ Turn the OPERATOR CONTROL selector to the“ON” position.

◆ Enter a 3.000” position for the X-axis.

FIGURE 7-4 – Moving the gage bar

◆ After the ENTER key is pressed, the gage willmove forward to the 3” position. Place both cal-ibration blocks on the lower die with the slot ofthe blocks centered under the upper die and inline with the gage fingers.

◆ Inch the ram down with the palmbuttons untilcalibration blocks are clamped in positionbetween the dies (Figure 7-3).

IMPORTANT: Blocks should be slightly pinched– excessive clamping pressure by toolingmay damage calibration blocks.

◆ Turn OPERATOR CONTROL selector to “OFF”.

◆ Adjust the vertical position of gage bar. Turnboth vertical adjustment handwheels located atthe rear of the machine to obtain proper work-

ing height. This height will depend upon thetooling and configuration of the part beingformed.

IMPORTANT: Make sure workpiece will contactgaging surface at all bend positions. Gagesurface or gage fingers must not contactany part of tooling to prevent possible dam-age to gage surfaces or tooling.

◆ Loosen both horizontal gage adjustment clampsand push horizontal gage bar or gage fingersagainst tooling calibration blocks. Securelytighten both clamps.

◆ Turn the OPERATOR STATION selector to the“ON” position. Raise ram using RAM UP buttonon OPERATOR STATION high enough to removeboth calibration blocks.

Gage Bar Calibration is now complete.

TOOLING LIBRARY MENU

The TOOLING LIBRARY MENU is selected by press-ing the "Tool Library" softkey from the MAIN MENUor JOB DATA screens. The TOOL LIBRARY con-tains the dimensions of all upper and lower dieswhich have been stored. Before running a programit is usually necessary to enter the tooling informa-tion for the dies being used. The upper and lowerdies entered in the JOB DATA MENU must bestored in the TOOLING LIBRARY. Shown below is adiagram of this menu screen.

The top line indicates the storage volume. The nextline indicates the directory path if the storage is adisk. The last line shows the bytes remaining inmemory for additional storage. Note that the stor-age space is shared by the TOOLING LIBRARY,PROGRAM STORAGE and optional ADAPTIVE FILESTORAGE. The TOOLING LIBRARY MENU lists a

DATE

29APRIL91 11:5828APRIL91 10:58

PROGRAMTEST000

STATUS: Select a function using the softkeys.

TOOLING LIBRARY

EditTool

LoadTool

LoadLowerTool

ChangeVolume

LastMenu

Use up and down field keys for more directory entries.

UPPER TOOL VOL: LOCAL DISK APATH: \UTOOLBYTES REMAINING: 737k

LOWER TOOL VOL: LOCAL DISK APATH: \LTOOLBYTES REMAINING: 737k

StoreTool

StoreLowerTool

DeleteTool

30 APRIL 9112:00 AM

SEQ

12

UPPER TOOLS

47U135U

SEQ

12

LOWER TOOLS

47L135L

DATE

29APRIL91 11:5928APRIL91 10:59

DeleteTool

ENTER3

7-11

HORIZONTALADJUSTMENTCLAMP

column of UPPER TOOLS and LOWER TOOLS.Each type is specified by a name supplied by theoperator to identify his tooling. The name may haveany combination of letters, numbers and symbolsup to 16 characters. Each tool is also identified bya sequence number on the left side of the column.The sequence numbers are a shorthand method ofreferring to tools without typing the full name.Sequence numbers begin at 1 and count up asadditional tools are stored.

If there are more tools stored on the volume thancan be displayed on the TOOLING LIBRARY screen,the up and down field keys may be used to “page”through the tools not shown. Each time an up ordown field key is pressed, the previous or next pagewill be displayed.

The AUTOFORM Control will always have one toolset in active memory. If additional tools arerequired to run a program, the control will loadthem from the TOOLING LIBRARY as needed. Toenter tools into the library or edit existing tools, thetool set in active memory is used. It is modified andthen can be stored to internal memory.

UPPER and LOWER tools are modified indepen-dently of each other. The following paragraphs willexplain how to add new tools to the TOOLINGLIBRARY and edit existing tools in the library.

ENTERING AN UPPER TOOL

◆ Turn the PROGRAM/LOCK key selector to the“PROGRAM” position.

◆ Press the "Change Volume" softkey as shownbelow.

◆ Press the "Upper Tool" softkey as shown below.

◆ Press "Internal Storage" softkey as shown below.

◆ Press the "Edit Tool" softkey as shown below.

◆ Press the "Upper Tool" softkey as shown below.

The TOOLING LIBRARY screen will now change tosomething similar to the following. The tool dimen-sions now in active memory will be shown.

There will be a column of fields listed on the left sideof the screen and a three-dimensional graphic of thetool on the right. There may be values previouslyentered in the fields listed. These are values for theUPPER TOOL in active memory. Since a new tool isbeing entered, these values are not important forthis discussion and will be changed shortly.

◆ The highlighted field should now be TOOLNAME. Using the keypad, enter the followingTOOL NAME.

◆ Use the down field key to select the TOOL TYPEfield. The softkeys will change as shown below.

◆ The TOOL TYPE field is used to select the gen-eral shape of the UPPER DIE. When the tool isrecalled from the TOOL LIBRARY it can be usedby the operator to help identify the tool.

◆ Each time one of the "Tool Type" softkeys ispressed, the three-dimensional graphic of thedie will change. Take time to view each type tobecome familiar with the various tool types.Note that the VEE tool type has four variations.When the "Vee" softkey is pressed, the screenwill show four two-dimensional outlines of thevee die variations. The softkeys will change asshown below.

1 2 3 4RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

Vee Offset RadiusFlatt-ening

Goose-neck Other

Set-upMode

ToolingLibrary

ProgramStorage

ENTER4 7 U

PROGRAM:TEST001

STATUS: Enter new label using keypad.

UPPER TOOL

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING

ToolingMenu

1AVEE

0.125080.002.50024.001.0000.031

30.0 tons/ft.

6 AUG 8912:00 PM

UpperTool

LowerTool

LocalDrive B

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

EditTool

LoadTool

StoreTool

GageData

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary

LastMenu

InternalStorage

LocalDrive A

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

UpperTool

LowerTool

LocalDrive B

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

EditTool

LoadTool

StoreTool

GageData

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary

LastMenu

7-12

◆ Choose the desired version by pressing the soft-key. The control will then draw the graphic andreturn softkeys to the TOOL TYPES.

There is a TOOL TYPE selection called OTHER. Thisis used when none of the types available match thedie being used. In this case no graphic is drawn.The applicable fields such as HEIGHT, MAXIMUMLOADING and LENGTH must be completed. Thiscan be used to record dies, such as channel, rib,punching and many others.

See the end of this section for drawings of the vari-ous tool types. These drawings are almost identicalto the CRT displays and provide blank spaces toenter data. Full size copies are included with thismanual. They can be copied and used to record diedimensions/information prior to entry into theTOOL LIBRARY. They can be kept as a hard copyreference or for a back-up record.

◆ Press the "Vee" tool type softkey, then press theversion number "1" softkey for this example.

The RADIUS is used in angle reversal mode calcu-lations. This is the radius of the upper die nose. Theradius should be measured with a radius gage tothe nearest .015” (1/64”)/.381mm.

Note that if the FLATTENING tool type has beenselected, the RADIUS field is automatically set tozero and cannot be changed by the operator.

◆ Use the down field key to select the RADIUSfield. Notice that the radius dimension on thegraphic is being highlighted by a flashing “R”.

◆ Using the keypad, enter the following for theRADIUS dimension.

The ANGLE is a reference dimension only, and isused to identify the upper die. The included angle ismeasured with a protractor type gage to the near-est degree. See Figure 7-5.

Note that if the FLATTENING tool type has beenselected, the ANGLE is automatically set to 180.0and cannot be changed by the operator.

◆ Use the down field key to select the ANGLEfield. Notice that the angle dimension on thegraphic is being highlighted by a flashing “A”.

FIGURE 7-5 – Measuring included angle

◆ Using the keypad, enter the following for theANGLE dimension.

The HEIGHT dimension is the distance from thenose of upper die to the shoulder. It is importantto measure this dimension carefully for anaccurate initial bend and less corrections later.This dimension should be measured to within.002”. See Figure 7-6 below for the method to mea-sure HEIGHT (H). Use a micrometer or dial caliper.

FIGURE 7-6 – Measuring height dimension

◆ Use the down field key to select the HEIGHTfield. Notice that the height dimension on thegraphic is being highlighted by a flashing “H”.

8 0 ENTER

. 1 2 5 ENTER

1 2 3 4RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

Vee Offset RadiusFlatt-ening

Goose-neck Other

Set-upMode

ToolingLibrary

ProgramStorage

7-13

◆ Using the keypad, enter the following for theHEIGHT dimension.

LENGTH dimension is the length of the tool (left-to-right). It is used with the MAXIMUM LOADING fieldto calculate the maximum safe tonnage that thetool will accept. Make sure this value matches thetools used, so the built-in safeguards will functionproperly. This dimension is measured in inches andshould be to the nearest .25” (1/4")/6.4mm.

◆ Use the down field key to select the LENGTHfield. Notice that the dimension on the graphicis being highlighted by a flashing “L”.

◆ Using the keypad, enter the following for theLENGTH dimension.

The CLEARANCE dimension “C” is the distancebetween the centerline of the mounting tongue andthe back side of the die for all tool types. Thisdimension is used to check for gage clearance oftools. It is usually half the width of the die. Thisdimension is in inches and should be within .030”(1/32")/.762mm.

◆ Use the down field key to select the CLEAR-ANCE field. Notice that the CLEARANCE dimen-sion on the graphic is being highlighted by aflashing “C”.

◆ Using the keypad, enter the following for theCLEARANCE dimension.

The OFFSET dimension is the difference betweenthe centerline of the mounting tongue and the cen-terline of the nose. This entry is used to compen-sate for the offset. Positive offsets indicate that thenose is to the rear of the tongue. Negative offsetsindicate the nose is in front of the tongue. Thedefault value is zero. See Figure 7-7.

◆ Use the down field key to select the OFFSETfield. Notice that the OFFSET dimension on thegraphic is being highlighted by a flashing “O”.

◆ Use the default value by pressing the down fieldkey for this example.

FIGURE 7-7 – Offset dimensions

The MAXIMUM LOADING is the maximum numberof tons per foot that the tool can accept safely. Thisis used in combination with the die length and thebend length to calculate the maximum safe tonnagethat the machine can exert on the tools. Make surethis matches the tools used so the built-in safe-guards can function properly. Guidelines for maxi-mum load capacities of various types of dies areshown in charts next to the tooling drawings at theend of this section.

◆ Use the down field key to select the MAXIMUMLOADING field.

◆ Using the keypad, enter the following for theMAXIMUM LOADING field.

This completes the tool information for theUPPER DIE. The screen should appear as shownbelow.

4 0 ENTER

. 7 5 ENTER

➛

➛

C

FRO

NT

RE

AR

4 8 ENTER

3 . 1 2 5 ENTER

7-14

◆ Press the following softkey to return to theTOOLING LIBRARY screen.

◆ To save the UPPER TOOL in the TOOLINGLIBRARY, press the "Store Tool" softkey asshown below.

◆ Press the "Upper Tool" softkey as shown below:

If it is necessary to go back and edit the tool infor-mation to correct an entry, select the "Edit Tool"softkey, then "Upper Tool", and modify the requiredfields. Then return to the TOOLING LIBRARYscreen and again save the UPPER TOOL into theTOOLING LIBRARY using the "Store Tool" softkey.

ENTERING A LOWER TOOL

◆ Press "Change Volume" softkey as shown below.

◆ Press the "Lower Tool" softkey as shown below.

◆ Press "Internal Storage" softkey as shown below.

◆ Press the "Edit Tool" softkey as shown below.

◆ Press the "Lower Tool" softkey as shown below.

The TOOLING LIBRARY screen will now change tosomething similar to the following. The tool dimen-sions loaded into the control will be shown.

There will be a column of fields listed on the leftside of the screen and a three-dimensional graphicof the tool on the right. There may be values previ-ously entered in the fields listed. These are valuesfor the current LOWER TOOL in active memory.Since a new tool is being entered, these values arenot important for this discussion and will bechanged shortly.

◆ The highlighted field should now be TOOLNAME. Using the keypad, enter the following forthe TOOL NAME.

◆ Use the down field key to select the TOOL TYPEfield. The softkeys will change as shown below.

The TOOL TYPE field is used to select the generalshape of the LOWER DIE. When the tool is recalledfrom the TOOL LIBRARY it can then be used by theoperator to identify the tool.

VeeSpecialRelief

Four-Way

Flatt-ening Offset Other

Set-upMode

ToolingLibrary

ProgramStorage

ENTER4 7 L

PROGRAM:TEST001

STATUS: Enter new value using keypad.

LOWER TOOL

TOOL NAMETOOL TYPEVEE OPENINGRADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

ToolingMenu

47LVee1.0

0.12580.003.000

48.00.7540.0 tons/ft.

6 AUG 8912:00 PM

UpperTool

LowerTool

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

EditTool

Left Right GageData

RunMode

NextStep

EndNewPgm

GageData

Page2

InternalStorage

LocalDrive A

Tonn Adapt Absol-ute

NextStep

EndNewPgm

GageData Abort

UpperTool

LowerTool

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

ChangeVolume

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

UpperTool

LowerTool

LocalDrive B

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

EditTool

LoadTool

StoreTool

GageData

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary

LastMenu

CalibrateGage

HighStrengthSteel

Stain-lessSteel

SoftAlum

HardAlum

SoftCopper

HardCopper

ToolingLibrary

ToolingMenu

PROGRAM:TEST001

STATUS: Enter new label using keypad. MAX: MIN:

UPPER TOOL

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING

ToolingMenu

47UVEE

0.12580.003.125

48.00.75

0.00040.0 tons/ft.

6 AUG 8912:00 PM

7-15

Each time one of the "Tool Type" softkeys ispressed, the three-dimensional graphic of the diewill change. Take time to view each type to becomefamiliar with the various tool types. Note that theVEE tool type has three variations. When the "Vee"softkey is pressed, the screen will show three two-dimensional outlines of the vee die variations. Thesoftkeys will change as shown below.

The SPECIAL RELIEF tool type has three variations.When the softkey is pressed, the screen will showthree two-dimensional outlines of special relief dievariations. The softkeys will change as shown below.

There is a TOOL TYPE selection called OTHER. Thisis used when none of the types available match thedie being used. In this case no graphic is drawn.The applicable fields such as HEIGHT, MAXIMUMLOADING and LENGTH must be completed.

Choose the correct version by pressing the softkey.The control will then draw the graphic and returnsoftkeys to the TOOL TYPES.

See the end of this section for drawings of the vari-ous tool types. These drawings are almost identicalto the CRT displays and provide blank spaces toenter data. Full size copies are included with thismanual. They can be copied and used to record diedimensions/information prior to entry in the TOOLLIBRARY.

◆ Press the "Vee" tool type softkey, then press theversion number "1" softkey for this example.

The VEE OPENING is used in angle reversal modecalculations. This is the actual width of the veeopening. See Figure 7-8 for correct interpretationand method of measuring the vee opening. Thisdimension should be measured to the nearest .010”(1/100)/.254mm.

FIGURE 7-8 – Measuring the Vee opening

Note that if the FLATTENING tool type is selected,the VEE OPENING dimension will automatically beset to 0.000 and cannot be changed by the operator.

◆ Use the down field key to select the VEE OPEN-ING field. Notice that the field dimension on thegraphic is being highlighted by a flashing “V”.

◆ Using the keypad, enter the following for theVEE OPENING dimension.

The RADIUS is used in angle reversal mode calcu-lations. This is the radius of the corners of the veeopening. These should be measured with a radiusgage to the nearest .015” (1/64”)/.4mm.

Note that if the FLATTENING tool type is selectedthe RADIUS dimension will automatically be set to0.000 and cannot be changed by the operator.

◆ Use the down field key to select the RADIUSfield. Notice that the radius dimension on thegraphic is being highlighted by a flashing “R”.

1 ENTER

1 2 3 4RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

VeeSpecialRelief

Four-Way

Flatt-ening Offset Other

Set-upMode

ToolingLibrary

ProgramStorage

1 2 3 4RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

1 2 3 4RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

7-16

◆ Using the keypad, enter the following for theRADIUS dimension.

The ANGLE is used in angle reversal mode calcula-tions. This angle is measured to the nearest degreewith a protractor at the end of die. See Figure 7-9.

FIGURE 7-9 – Measuring the angle

Note that if the FLATTENING tool type is selectedthe ANGLE dimension will automatically be set to180.0 and cannot be changed by the operator. Fora channel type die shown previously, this angleshould be set to 0.1.

◆ Use the down field key to select the ANGLEfield. Notice that the angle dimension on thegraphic is being highlighted by a flashing “A”.

◆ Using the keypad, enter the following for theANGLE dimension.

The HEIGHT dimension is the distance from the topof the die to the shoulder (where the die rests on thebed or filler block). It is important to measure thisdimension carefully for an accurate initial bend andless corrections later. This dimension should bemeasured within .002” (.05mm). See Figure 7-10for method to measure HEIGHT (H).

FIGURE 7-10 – Measuring the height dimension

◆ Use the down field key to select the HEIGHTfield. Notice that the height dimension on thegraphic is being highlighted by a flashing “H”.

◆ Using the keypad, enter the following for theHEIGHT dimension.

The LENGTH dimension is the length of the tool(left-to-right). It is used with the MAXIMUM LOAD-ING field to calculate the maximum safe tonnagethe tool will accept. Make sure this value matchesthe tools used, so the built in safeguards will func-tion properly. This dimension is measured in inch-es and should be to the nearest .25” (1/4”)/6.4mm.

◆ Use the down field key to select the LENGTHfield. Notice that the length dimension on thegraphic is being highlighted by a flashing “L”.

◆ Using the keypad, enter the following for theLENGTH dimension.

The CLEARANCE dimension is the distancebetween the centerline of the mounting tongue andthe back side of the die for all tool types. Thisdimension is used to check for gage clearance oftools. It is usually half the width of the die. Thisdimension is in inches and should be within .030”(1/32")/.762mm.

◆ Use the down field key to select the CLEAR-ANCE field. Notice that the CLEARANCE dimen-sion on the graphic is being highlighted by aflashing “C”.

4 8 ENTER

3 ENTER

8 0 ENTER

. 1 2 5 ENTER

7-17

◆ Using the keypad, enter the following for theCLEARANCE dimension.

The MAXIMUM LOADING is the maximum numberof tons per foot that the tool can accept safely. Thisis used in combination with the die length and thebend length to calculate the maximum safe tonnagethat the machine can exert on the tools. Make surethat this matches the tools used so the built-insafeguards can function properly. Guidelines formaximum load capacities of various types of diesare shown in charts next to the tooling drawings atthe end of this section.

◆ Use the down field key to select the MAXIMUMLOADING field.

◆ Using the keypad, enter the following for theMAXIMUM LOADING field.

This completes the tool information for theLOWER DIE. The screen should appear as shownbelow.

◆ Press the following softkey to return to theTOOLING LIBRARY screen.

◆ To save the LOWER TOOL in the TOOLINGLIBRARY, press the "Store Tool" softkey asshown below.

◆ Press the "Lower Tool" softkey as shown below:

If it is necessary to go back and edit the tool infor-mation to correct an entry, select the "Edit Tool"softkey and "Lower Tool" softkey and modify therequired fields. Then return to the TOOLINGLIBRARY screen and again save the LOWER TOOLinto the TOOLING LIBRARY using the "Store Tool"and "Lower Tool" softkeys.

LOADING A TOOL IN ACTIVE MEMORY

If tooling data is found to be incorrect, tooling hasworn or has been re-machined, the data stored canbe corrected. To edit a tool stored in TOOLINGLIBRARY, it must first be loaded into active memory.

First select proper volume (Internal or Local DiskA). The following softkeys on the TOOLINGLIBRARY screen will load in the desired tool, thusreplacing current UPPER or LOWER tool in activememory.

Pressing the above sequence of softkeys allows theoperator to choose the tool to load by either itssequence number or by the actual tool name. Thefollowing softkey will appear.

The status line will change to:

STATUS: Enter sequence number of the file to be loaded.

The default method for loading tools is by sequencenumber.

Simply enter the sequence number of the UPPER orLOWER tool to be loaded and press ENTER.

If the "Tool Name" softkey is pressed, the status linewill change to the following:

STATUS: Enter name of tool to be LOADED.

Enter the tool name exactly as it appears in thestorage list on the TOOLING LIBRARY screen andpress ENTER.

UpperTool

EnterByName

Top ofDie

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

UpperTool

LowerTool

LocalDrive B

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

EditTool

LoadTool

StoreTool

GageData

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary

LastMenu

UpperTool

LowerTool

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

EditTool

LoadTool

StoreTool

GageData

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary

LastMenu

CalibrateGage

HighStrengthSteel

Stain-lessSteel

SoftAlum

HardAlum

SoftCopper

HardCopper

ToolingLibrary

ToolingMenu

PROGRAM:TEST001

STATUS: Enter new value using keypad. MAX: MIN:

LOWER TOOL

TOOL NAMETOOL TYPEVEE OPENINGRADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

ToolingMenu

47LVee1.0

0.12580.003.000

48.00.7540.0 tons/ft.

6 AUG 8912:00 PM

4 0 ENTER

. 7 5 ENTER

7-18

DELETING A TOOL FROM TOOL LIBRARY

UPPER and LOWER tools can be deleted from theTOOL LIBRARY by using the "Delete Tool" softkeyshown in the following.

When this softkey is pressed, the softkeys willchange as shown below so the operator may chooseto delete either an UPPER or a LOWER tool.

After making the choice, the status line will changeas shown below.

STATUS: Enter sequence number of toolto be DELETED.

Enter the sequence number of the tool to be deletedusing the keypad and press ENTER. To delete byname, press the "Delete By Name" softkey, enter thetool name and press enter. The TOOLING LIBRARYMENU will now update to show that the deleted toolis no longer in storage.

The remaining softkey on the TOOL LIBRARYscreen is the "Job Data" softkey. This will switchdirectly to the JOB DATA MENU from the TOOLLIBRARY. This completes the discussion of theTOOL LIBRARY MENU.

TYPICAL MAXIMUM LOAD CAPACITY: The valuesthat are shown superimposed in the following tool-ing drawings are for general information only. Thecapacity will vary according to the dimension of thetooling and their condition.

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

OFFSET

tons/ft.

TOOLING MENU

DIEWIDTH

(2 x C)

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

1.12

1.50

2.50

40

5080

85

4.00 100

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

VEE

tons/ft.

TOOLING MENU

DIEWIDTH

(2 x C)

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

2.50

3.50

4.00

60

707075

5.00

6.00

80

90

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

VEE

tons/ft.

TOOLING MENU

DIEWIDTH

(2 x C)

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

1.12

1.25

1.50

10

1014

30

1.12

1.25

1.50

40

5060

75

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING tons/ft.

4-WAY

TOOLING MENU

DIEWIDTH

(2 x C)

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

3.25

3.62

5.25

31

3540

80

UpperTool

LowerTool

LocalDrive B

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

EditTool

LoadTool

StoreTool

GageData

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary

LastMenu

7-19

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENUSET-UP #

VEE

MAX.DIE

WIDTH

MAX.LOAD

(TONS/FT)

1.12

1.25

1.50

40

5060

2.25 100

NOTE: If offset "0" exceeds.050", the above load doesnot apply.

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENU

VEE

*

* THIS HEIGHT IS DETERMINED BY SUBTRACTING THE PENETRATION DISTANCE INTO THE RAM NOSE FROM THE OVERALL HEIGHT OF THE DIE.

MAX.DIE

WIDTH

MAX.LOAD

(TONS/FT)

.50 40

NOTE: If offset "0" exceeds.050", the above load doesnot apply.

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

OTHER

tons/ft.

TOOLING MENU

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

SPECIAL RELIEF

tons/ft.

TOOLING MENU

.5"

DIEWIDTH

(2 x C)

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

2.50

3.50

4.00

40

454575

5.00

6.00

50

60

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

SPECIAL RELIEF

tons/ft.

TOOLING MENU

DIEWIDTH

(2 x C)

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

1.12

1.25

1.50

10

1014

30

1.12

1.25

1.50

12

1616

75

SET-UP #

TOOL NAMETOOL TYPEVEE OPENING (V)RADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)MAXIMUM LOADING

SPECIAL RELIEF

tons/ft.

TOOLING MENU

DIEWIDTH

(2 x C)

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

1.12

1.25

1.50

10

1014

30

1.12

1.25

1.50

20

2540

75

2.25

2.50

6070

7-20

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENUSET-UP #

OTHER

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENUSET-UP #

GOOSENECK

MAX.DIE

WIDTH

OFF-SET"O"

MAX.LOAD

(TONS/FT)

1.12

1.50

2.25

12

1624

2.75 40

.06

.25

.50

.50NOTE: If offset "0" exceeds .050", the aboveload does not apply. Rated loads are noted tokeep from damaging ram and tooling wherepossible. Gooseneck loading assumes reliefangle in die allows "RATED LOAD" withoutbending nose area of die.

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENUSET-UP #

FLATTENING0.0000180.00

MAX.DIE

WIDTH

MAX.LOAD

(TONS/FT)

1.12

1.50

2.25

60

60100

2.50 100

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENUSET-UP #

OFFSET

MAX.DIE

WIDTH

MIN.ANGLE

"A"

MAX.LOAD

(TONS/FT)

1.12

1.50

2.50

40

5080

85

4.00 100

NOTE: If offset "0" exceeds .050",the above load does not apply.

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENUSET-UP #

RADIUS

MAX.DIE

WIDTH

MAX.LOAD

(TONS/FT)

1.12

1.25

1.50

40

5060

2.25 100

NOTE: If offset "0" exceeds.050", the above load doesnot apply.

TOOL NAMETOOL TYPERADIUS (R)ANGLE (A)HEIGHT (H)LENGTH (L)CLEARANCE (C)OFFSET (O)MAXIMUM LOADING tons/ft.

TOOLING MENU

VEE

SET-UP #

MAX.DIE

WIDTH

MAX.LOAD

(TONS/FT)

1.12

1.25

1.50

40

5060

2.25 90

NOTE: If offset "0" exceeds .050", the aboveload does not apply. Also, two times "C" mustbe at least .50".

7-21

ENTERING A NEW PROGRAMA program on the AUTOFORM Control is made byentering data into the JOB DATA, RAM DATA andGAGE DATA MENUs. A program consists of one ormore steps and a common data section for jobinformation. Each step of the program containsdata about the ram cycle and gage positioning. Thecommon job data section contains part numberinformation, tooling selections, material thicknessand other miscellaneous information.

◆ To enter a new program, select the “Enter NewProgram” softkey from the MAIN MENU screen(shown below). The PROGRAM/LOCK selectormust be in the “PROGRAM” position.

The ENTER NEW PROGRAM MENU will appear andthe softkey will change as shown below and theSTATUS line will show the following statement:

STATUS: Current Program will be DELETED! Do you wish to continue?

◆ Pressing the "Yes" softkey will delete the currentprogram from the active memory. This erasesthe information in the JOB DATA, RAM DATAand GAGE DATA screens in the active memory.Note that the program is not erased from thePROGRAM STORAGE MENU (internal memory)if it had been stored. Pressing the "No" softkeywill keep the current program and display theMAIN MENU screen. Proceed by pressing the"Yes" softkey for this example.

The softkeys will be cleared and the status linewill change as shown.

STATUS: Enter set-up name using the keypad.

◆ Using the keypad the operator may enter up to16 characters (a combination of alpha, numericor symbols) for the program name. The programname is used to identify the program that willbe entered. Enter the following as a sample pro-gram name.

The backspace key (left cursor arrow) can be usedto correct the program name before the ENTER keyis pressed. Pressing the ENTER key transfers theprogram name into the upper left corner of the

screen. After pressing the ENTER key, the screenwill now go directly to the JOB DATA MENU. Con-tinue entering the example program described inthe next section.

JOB DATA MENU

The JOB DATA MENU is selected by pressing the"Job Data" softkey or it is automatic after enteringthe program name from ENTER NEW PROGRAMMENU. Below is a diagram of the JOB DATA screenbefore a program has been entered. Notice thatsome fields contain default values and others areleft blank. The program name previously entered isdisplayed in the upper left corner. The first field inthe data area, “PART NUMBER”, is highlighted.

◆ Become familiar with how the field keys areused to select fields by pressing the left, right,up and down field keys. Notice that the high-lighted field moves around the data area as thefield keys are pressed. Return the highlightedfield to “PART NUMBER” with the HOME fieldkey. The PART NUMBER is an optional fieldwhich allows the operator to link a part to theprogram name. The status line should displaythe following:

STATUS: Enter New Part Number:

◆ Enter the following as a sample part number:

The part number can be changed with the leftcursor key before pressing ENTER. Index to theleft to the incorrect character and enter propercharacter. Then press the ENTER key to trans-fer the changes into the field. The entered partnumber now appears in the data area next tothe Part Number label. Once the ENTER key ispressed, the part number will be transferred

1 5 6 ENTER0 1

PROGRAM:TEST001

STATUS: Enter new part number using keypad.

JOB DATA

PART NUMBERMATERIAL THICKNESSCLAMP POS ADJMATERIAL TYPEK-Forming Factor

LastMenu

156010.130 in.

0.000 in.Mild Steel

AUTO

RamData

RunMode

ChangeProgramName

RETURN SPEEDGUARD MUTE PTR, Z AXISFRONTGAGE

20.0 in/mintop of mat + 1/4

ONBOTH ON

TOOL SETSUPPER LOWER SPECIAL INSTRUCTIONS

A:B:C:D:E:

6 AUG 8912:00 PM

T E S T 0 0 1 ENTER

Yes NoRamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

EnterNewProgram

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

7-22

into the field and the MATERIAL THICKNESSfield will now become highlighted and displayedin the status line.

The next step is to enter the nominal material thick-ness of the part. The status line should now show:

STATUS: Enter new value using keypad .060

Note that the default value of .060 inches willalways appear for a new program.

◆ Enter a new material thickness as shown below:

The next step is to enter the Clamp Position Adjust-ment. This allows minor adjustments to the ramposition at which the material is clamped. (Negativemeans clamping harder.) Enter:

The control will now select the MATERIAL TYPEfield. The softkeys will change as shown below toallow the operator to choose the type of materialwhich is being used.

The material type is used to help the operator iden-tify the part with the set-up.

◆ Select Mild Steel for this example and advanceto the next field:

The next field is the K-Forming Factor, leave atAUTO. The K-Forming Factor is related to GageAllowance calculations. For more details, see sec-tion about Gage Allowance in GAGE DATA MENU.

The next field in the JOB DATA screen is the TOOLSETS section. The tool sets may contain up to fivesets of upper and lower die names. These namesmust match with those entered in the TOOLLIBRARY MENU. Refer to the description of thismenu for more information. To the left of the nameare the letters “A” thru “E”. Once the upper andlower tools are entered, they are referenced by theletters “A” thru “E” in the RAM DATA MENU. It isusually required that both the upper and lower toolnames be entered for a tool set unless AbsolutePosition Reversal mode is selected. At least one toolset is required, and up to five may be used in thesame program.

When entering tool sets in the JOB DATA screen,tools can be selected by name or by the sequencenumber in the Tool Library. The default is bysequence number. Type the number correspondingto the desired upper or lower tool and press ENTER.The tool name will be inserted in the Tool Sets field.To enter a tool by typing its name, press the "ByName" softkey and then enter the tool name.

The control has moved the highlighted area toUPPER TOOL set “A”. Press the "Enter By Name"softkey. The status line will show the following:

STATUS: Enter new name using the keypad.

◆ Enter the following example for the upper toolname “A”:

◆ The Control will move the highlighted field cur-sor to the lower tool name field for “A”. Enter thefollowing example for lower tool name “A”.

If additional tool sets are required for this set-up, the operator must select the tool field forthese sets.

◆ Use the field keys to move to the upper toolname “B” and enter the following example:

◆ Move the highlighted area to the lower toolname “B” and enter the following example:

There should now be two tool sets entered in theTOOL SET fields of the screen.

UNMEASURED TOOLS

To instruct the Control not to look for tools in theTOOL LIBRARY, press the “Set Tool Unmeas” softkeyfor each field (“A” - “F”) used. When using unmea-sured tools, the reversal modes in the RUN MODEare limited to Absolute, Position and Tonnage.

SetToolUnmeas

EnterByName

Tonn Adapt Absol-ute

ChangeProgName

RunMode

RamData

ToolLibrary

2 2 2 B D ENTER

B 1 ENTER1 1

ENTER4 7 L

ENTER4 7 U

UpperTool

EnterByName

Top ofDie

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Abort

MildSteel

HighStrengthSteel

Stain-lessSteel

SoftAlum

HardAlum

SoftCopper

HardCopper

ToolingLibrary

ProgramStorage

0. ENTER0

. 1 ENTER3 0

7-23

The remaining fields on the JOB DATA screen to beedited are SPECIAL INSTRUCTIONS, RETURNSPEED, GUARD MUTE POINT and OPTIONALGAGE OPERATION. These fields can be edited inany order.

◆ Select the SPECIAL INSTRUCTIONS field andthe status line will change as shown:

STATUS: Edit the special instructions.

This field allows reference notes entered by theoperator to be saved with the program. Up tofive lines of text may be entered into the field. Aseach key is pressed the cursor will move to theright until it reaches the end of that line. Tomove around in the field use the cursor up,down, left and right keys to change positions.

◆ Enter the following as an example:

◆ Use the cursor keys (down and left) to move tothe start of the next line. Enter the second lineof text as follows.

To leave the SPECIAL INSTRUCTIONS field usethe field keys.

◆ Select the LOW RETURN SPEED field at the topright of the screen using the field keys. The lowreturn speed starts after reversal at bottom ofthe stroke and continues up to the UP SPEEDCHANGE point. This portion of the up stroke isprogrammable for both speed and distance.(The UP SPEED CHANGE position is pro-grammed in RAM DATA (2) MENU.) The lowreturn speed for all steps of the program is sethere. A default value of 20.0 is used. For thisexample the default value will not be changed.

◆ Use the cursor keys to move to the GUARDMUTE POINT field:

GUARD MUTE POINT is used with an optionalpresence sensing device. This field specifies theposition in the down ram stroke at which tomute the presence sensing device. The operatorshould select the mute point most suitable forthe job being run. The default mute point is

"Top of Material + 1/4 inch". When the device ismuted, the operator can enter the guarded areato position or hold the workpiece.

◆ If this device is not installed, leave default valueas is and skip to the next paragraph. If presencesensing option is installed, select the guardmute point using the softkeys shown below:

The optional "R", "Z" and frontgage axes may bedisabled in the JOB DATA screen if desired.Select the desired field and use the softkeys toenable or disable operation.

At this point the JOB DATA screen should look likethe following:

If the JOB DATA screen does not have the same val-ues as above, go back and find which field(s) needto be corrected. The program name (TEST001) mayalso be changed at this time by selecting the"Change Program Name" softkey. If the screenmatches exactly, then all job data information hasbeen entered correctly.

The next step in writing the program is to enter theRAM DATA MENU by selecting the "Ram Data" soft-key. Continue with the next section.

RAM DATA MENU

The RAM DATA MENU is selected by pressing the"Ram Data" softkey from the MAIN MENU or JOBDATA screens. This menu is used to enter stepinformation for the program. It can be used to enternew steps, edit steps or delete steps in a program.Below is a diagram of the RAM DATA screen beforea new program is entered. Note that all of the fieldshave a default value.

PROGRAM:TEST001

STATUS: Enter new part number using keypad.

JOB DATA

PART NUMBERMATERIAL THICKNESSCLAMP POS ADJMATERIAL TYPEK-Forming Factor

LastMenu

156010.130 in.

0.000 in.Mild Steel

AUTO

RamData

RunMode

ChangeProgramName

RETURN SPEEDGUARD MUTE PTR, Z AXISFRONTGAGE

20.0 in/mintop of mat + 1/4

ONBOTH ON

TOOL SETSUPPER LOWER SPECIAL INSTRUCTIONS

A: 47U 47L USE BLANK BLZB: B111 222BD SEND TO AREA 5C:D:E:

6 AUG 8912:00 PM

Top ofMat +1/4 inch

ReversalPos

Top ofDie

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

SPACE

U S E SPACE B L A N K

ZB L NO–

SPACE

U S E SPACE B L A N K

ZB L NO–

7-24

One step with default values is listed in the dataarea. To add steps to the program use the "NextStep" softkey. Each time the softkey is pressed aduplicate step of the previous step values will beadded. Up to 99 steps can be programmed. The fol-lowing example of a two-step program will be usedto explain each field in the RAM DATA MENU.

REPEAT: This field specifies the number of timesthe control will perform the step before advanc-ing to the next step.

◆ Press ENTER or field key right to keep therepeat count set to one. The control will move tothe REVERSAL MODE field. This specifies howthe ram will reverse at the bottom of the strokefor the step. The following softkeys and statusline will appear:

STATUS: Select a mode using the softkeys.

The following is an explanation of these reversalmodes:

ANGLE: The operator specifies a given angle indegrees for the AUTOFORM to bend. The con-trol will automatically calculate the ram rever-sal position based on entries for material thick-ness, tool sets and filler blocks. Angle modemust only be used for air bending. The angleof the bend is the included angle.

POSITION: This mode is used for air bending,punching or special tooling applications. Theram reversal position is selected by the opera-tor. The position is relative to the top of materi-al with negative values representing penetrationinto the material and positive values above thematerial.

TONNAGE: This mode is used for bottoming typeof forming. The ram will reverse when theselected tonnage is reached. The tonnage select-ed must be less than the maximum loading forthe tool set used.

ADAPTIVE: This optional mode is similar toANGLE where the operator specifies a givenangle to bend. ADAPTIVE reversal moderequires that the control be taught about airbending on a given die set using a strictsequence of bends before ADAPTIVE reversalmode can be used in RUN MODE. The advan-tages of ADAPTIVE reversal mode are more con-sistent air bent parts, bend-to-bend, andincreased accuracy on first bend parts. Formore information on ADAPTIVE BENDING seeseparate supplement manual (EM-327).

ABSOLUTE: This mode is used for air bending,punching or special tooling applications. Theram reversal position is selected by the opera-tor. The position is an absolute value, whichrelates the ram nose to the bed top. This valueis the same ram position as shown in theQUICK BEND MENU.

Note: It is possible to use the TONNAGE, POSI-TION or ABSOLUTE reversal modes with-out entering tools in the JOB DATAMENU. Select the "Unmeasured Tools"softkey in the JOB DATA for the “A” - “F”tool sets. It is also necessary to calibratethe Top of Die position using the 1"(25.4mm) calibration block when usingUnmeasured Tools. See JOB DATA andSET-UP MENU for details on UnmeasuredTools.

◆ For this example select the "Angle" reversalmode softkey:

The VALUE field will now be highlighted. VALUE isrelated to the reversal mode field. For the ANGLE orADAPTIVE mode, enter a desired angle (includedangle). For the TONNAGE mode, enter the reversaltonnage. For the POSITION mode, enter the rampenetration. For ABSOLUTE mode enter the ramreversal position.

◆ Press the ENTER key or field right key to usethe default value of 90:

The next highlighted field will be BEND POSITION.This entry indicates to the AUTOFORM Controlwhere the workpiece will be placed on the lower die.The default is the CENTER of the machine. Theentry for off-center bends are LEFT or RIGHT.

Angle Posit Tonn Adapt Absol-ute

NextStep

EndNewPgm

GageData

PagePage 2

PROGRAM:TEST001

STATUS: Enter new value using keypad.

RAM DATA (1)

Page 2GageData

EndNewPgm

NextStep

REVERSAL BEND BEND RAM FORMINGSTEP REPEAT MODE VALUE POSITION LENGTH OPENING SPEED

1 1 Angle 90.0 Center 12.0 10.0 20.0

6 AUG 8912:00 PM

7-25

When making air bends, it is important to properlyspecify the bend position to obtain accurate parts.The following status line and softkeys will appear:

STATUS: Select a mode using the softkeys.

◆ Press the ENTER or field right key to use thedefault value of CENTER:

The next highlighted field will be BEND LENGTH.This is the actual length of the bend in inches. It isused to calculate a maximum loading factor for thedies and deflection compensation for the bend. Ifthe length of the part is not acceptable for the diesused, the bend will not be allowed. An error mes-sage will appear in the STATUS area when the AUT-OFORM Control is turned to the RUN MENU and a"Start Cycle" softkey is pressed.

◆ Enter 24 inches for this example:

The next field will now be RAM OPENING. This isdefined as the distance between the upper die noseand top of lower die when the ram is at top stopposition. It should be enough to permit the work-piece to be positioned for the next bend (step) butnot excessively large. Unnecessarily large openingsincrease cycle time and therefore reduce productiv-ity. For the last step in a program, the RAM OPEN-ING should be large enough to remove the work-piece from the dies.

◆ Enter one inch for this example:

The next highlighted field will be FORMING SPEED.This is the speed of the ram during contact with theworkpiece. The forming speed does not affect accu-racy of the reversal position. However, it does affectADAPTIVE (See ADAPTIVE bending in AUTOFORMOPTIONS section). The forming speed can be pro-grammed from a minimum value of one inch perminute to the maximum available.

◆ Press ENTER to keep the default of 20 for thisexample.

This completes the first step information for page 1of the RAM DATA screen. However, the step infor-mation is not complete until page 2 information isentered for the step.

◆ Use the last softkey to change screen pages:

The following is a diagram of the second page ofRAM DATA. Again the fields have default values.

The TOOL field should be highlighted and shouldcontain the default value “A”. The first five softkeyswill change as shown above.

Each letter corresponds to a tool set which was pre-viously entered in the JOB DATA MENU. Up to fivedifferent tool sets may be used on one program.Each step may contain one of five possible tool sets.

◆ Press the “A” softkey or field right softkey to usethe default value for this example:

The next two fields specify the SPEED CHANGEDOWN and SPEED CHANGE UP points in the ramstroke. The value entered for the SPEED CHANGEDOWN is the distance away from the workpiecewhere the ram will change its speed from highapproach to the forming speed. The value enteredfor SPEED CHANGE UP is the distance above rever-sal position where the ram changes from a lowreturn speed to high return speed. A default of 0.25inch is used for each field.

Note: The low return speed value was selected inthe JOB DATA screen.

◆ Press ENTER twice or field key right twice tokeep both default values for this example:

The highlighted field will now be TILT. This specifiesthe position of the left side of the ram in referenceto the right side. Changing the tilt will not affect theposition of the ram at the center of the machine.Tilt is used to vary the bend angle along the lengthof the workpiece. Enter a positive value to make theleft side higher than the right (clockwise tilt), or a

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

RAM DATA (2)

Page 3GageData

EndNewPgm

NextStep

SPEED SPEED BOTTOM MATERIAL UP DOWNSTEP TOOL CHG. DWN CHG. UP TILT DWELL CLAMP STOP STOP

1 A 00.25 00.25 0.0000 0.0 OFF OFF OFF

E D C B A

6 AUG 8912:00 PM

Page2

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary Page 2

1 ENTER

2 4 ENTER

Center Left Right GageData

RunMode

NextStep

EndNewPgm

GageData

PagePage 2

7-26

negative value to make the left side lower than theright (counterclockwise tilt). Maximum tilt of 1.000”(25mm) is allowed with default value being zero tilt.

◆ Press ENTER or field key right to use zero tilt forthis example:

BOTTOM DWELL: This field specifies the numberof seconds for the ram to hold at the reversalposition before starting the up stroke while theoperator control (palmbutton or footswitch) isdepressed. Releasing the control will suspendram dwell: depressing again continues thedwell. The dwell could be used to allow theoperator to hold or support the workpiecebefore the upper die releases it. A value from 0to 9.9 seconds is allowed, with the default beingzero. If ADAPTIVE reversal mode option is used,BOTTOM DWELL is not allowed.

◆ Press ENTER or field key right to keep thedefault for this example:

MATERIAL CLAMP: This field can either be set ONor OFF. When clamp is ON, the control will stopthe ram on the down stroke .010” (.254mm) intomaterial which clamps the workpiece in thedies. Once the material is clamped, the operatormust release the palmbuttons or footswitch andre-activate to continue the bend. This is oftenused in conjunction with the backgages so thegages can be retracted away from the workpiecebefore bending. See GAGE DATA MENU formore information.

If ADAPTIVE reversal mode is selected, MATER-IAL CLAMP does not function. See SECTION 6 -MACHINE CONTROLS.

The first two softkeys will show the following:

◆ Press the “ON” softkey for this example:

UP STOP: This field can be ON or OFF only. WhenUP STOP is “ON”, the ram will stop .025” (.635mm) after reversal position. This feature is usedto hold the formed workpiece in the dies, thuspreventing it from dropping rapidly and possi-bly injuring the operator. With the workpieceheld in the dies, it can be secured manually orwith crane assistance. To restart the rammotion the palmbuttons or footswitch must bereleased and re-activated.

◆ Press the “On” softkey for UP STOP for thisexample:

DOWN STOP: This field can be ON or OFF only.When DOWN STOP is “ON” the ram will auto-matically stop on the down stroke at the SPEEDCHANGE DOWN position. This is used whenthe operator must align material just beforebending or when using the HAND/FOOT com-bination of control. To restart ram motion thepalmbuttons or footswitch must be releasedand re-activated. When using HAND/FOOTmode, palmbuttons must be released at speedchange position and footswitch activated tocomplete the cycle.

◆ Press the “Off” or "Enter" softkey for DOWNSTOP for this example.

This completes the RAM DATA information for thefirst step. Use the "Page 1" and "Page 2" softkeys toview both pages. If other options are furnished onthe machine, such as Programmable Footswitch,page 3 may require programming. See SECTION 8 –OPTIONS.

To add additional steps to the program, use the"Next Step" softkey from either page 1 or 2 of theRAM DATA MENU. Each time the softkey is presseda step will be added on the end of the list. This newstep will be a copy of the previous step.

There are two methods of programming additionalsteps. One is to enter all the required steps in theRAM DATA MENU. This will automatically enter thesame number of steps in the GAGE DATA MENU,each step having the default values. The othermethod is to enter only Step 1 in RAM DATA andthen enter desired values for Step 1 in GAGE DATA.Return to RAM DATA to enter Step 2. When Step 2is automatically entered in GAGE DATA, the copiedvalues (from Step 1) for Step 2 will more likely becorrect than the default values.

◆ For this example, add a second step to the pro-gram by pressing the softkey below:

◆ Display page one of the RAM DATA MENU.There should now be two steps displayed on thescreen:

◆ For this example, modify the values in Step 2 tothe following:

REPEAT = 2REVERSAL MODE = TONNAGEVALUE = 50.0RAM OPENING = 2.0

◆ Switch to page 2 and modify the values in step2 to the following:

NextStep

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

ON OFFRamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

7-27

TOOL = BDWELL = 1.0CLAMP = OFFUP STOP = OFF

After completing the above changes to the programthe screens should now be exactly as follows:

This concludes the RAM DATA MENU portion ofentering a NEW program. The next step in spec-ifying an AUTOFORM program is to enter theGAGE DATA MENU by selecting the "Gage Data"softkey. Continue with GAGE DATA MENUdescribed in the next section if entering a newprogram.

Before going to the GAGE DATA MENU, the RAMDATA MENU just entered can be changed by select-ing the desired field using the field keys. Additionalsteps can also be added. However, in order to insertor delete a program step, the "End New Program"softkey must be pressed.

◆ Press the following softkey to END the program.

The softkeys should now be exactly as shownbelow.

EDITING THE RAM DATA

To change any item in the RAM DATA MENU, thefield keys can be used to move to any field on thedata area and modify the value in that field. Thestatus line and softkeys will change for the appro-priate field. To quickly index between the first andlast step of a program, use the following softkeys.

Pressing one of the above softkeys will position thecurrent field to either the first or last step of theprogram.

It is also possible to enter the number of the desiredstep. Use the field keys to select the STEP field. Thestatus line will change to the following.

STATUS: Enter new value using the keypad

◆ Simply enter the number of the desired stepand press ENTER:

The current field position will now change to stepnumber 2.

The step switching feature is useful for large pro-grams where all steps cannot fit on one screen. Thescreen is used as a window to display a fixed num-ber of total steps. By using the up and down fieldkeys, the window will “scroll”. Steps will appear onthe bottom and roll-off the top of the step list.

Steps may be inserted or deleted anywhere in thestep list.

◆ To insert a step between one and two, firstmake Step 1 the current step by pressing the"First Step" softkey:

◆ Now press the "Insert Step" softkey:

The following softkeys will appear which ask theoperator if the step should be inserted BEFORE orAFTER the current step.

BeforeCurrentStep

AfterCurrentStep

Top ofDie

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

InsertStep

JobData

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

2 ENTER

FirstStep

LastStep

FirstStep

LastStep

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

InsertStep

DeleteStep

FirstStep

LastStep

CopySteps

JobData

RunMode

GageData Page 2

EndNewPgm

NoRamData

GageData

RunMode

QuickBend

EndNewProgram

ToolingLibrary

ProgramStorage

PROGRAM:TEST001

STATUS: Select tool type using softkeys.

RAM DATA (2)

Page 3GageData

EndNewPgm

NextStep

SPEED SPEED BOTTOM MATERIAL UP DOWNSTEP TOOL CHG. DWN CHG. UP TILT DWELL CLAMP STOP STOP

1 A 00.25 00.25 0.0000 0.0 ON ON ON 2 B

E D C B A

00.25 00.25 0.0000 1.0 OFF OFF ON

6 AUG 8912:00 PM

PROGRAM:TEST001

STATUS: Enter new value using keypad.

RAM DATA (1)

Page 2GageData

EndNewPgm

NextStep

REVERSAL BEND BEND RAM FORMINGSTEP REPEAT MODE VALUE POSITION LENGTH OPENING SPEED

1 1 Angle 90.0 Center 24.0 1.0 20.0 2 2 Tonnage 50.0 Center 24.0 2.0 20.0

6 AUG 8912:00 PM

7-28

◆ Press "After Current Step" softkey and the page1 and 2 display will now change to the followingscreen. Notice that a copy of the current stephas been created between what were originallysteps one and two. There are now three steps inthe program. The inserted step number auto-matically has the next larger number and allfollowing numbers will also be increased by one:

The values in this step may be changed using thefield keys as before.

To delete a step, the "Delete Step" softkey is used toerase the current step from the program.

◆ For this example select the first step of the listas current by using the field keys to select afield in the first step ( or press the "First Step"softkey). Now press the "Delete Step" softkeyand the step will disappear. The following stepnumbers will automatically be reduced by oneafter the "Delete Step" softkey is pressed. Thescreen will return to its original state as shownin the following. Page 2 (not shown) is similar:

COPY STEPS

This function allows the user to copy a block ofsteps and insert them anywhere in the program. Itis available in either the RAM DATA screen or theGAGE DATA screen when the user edits the stepnumber field. For example, if a user has an existingprogram to form a channel on one side of a blankand a new program needs to be generated whichrequires channels on two sides of the blank. Thisfunction can be used to copy the original steps (1and 2) to make the two additional steps required toform the new part.

A softkey, "Copy Steps", is available when the cur-rent field is "ON" the step number. The softkeys willappear as follows:

After pressing the "Copy Steps" softkey, the soft-keys and the status line will show:

STATUS: Enter starting number of copiedsteps.

Only existing step numbers are valid. After the userenters the beginning step number of the block ofsteps to copy, the softkeys and status line show:

STATUS: Enter ending step number of copiedsteps.

Only step numbers beginning with the step numberspecified as the beginning of the block through theend of the program are valid. After entering theending step number of the block to be copied, the

AbortCopySteps

Left Right GageData

RunMode

NextStep

EndNewPgm

GageData

Page2

AbortCopySteps

Left Right GageData

RunMode

NextStep

EndNewPgm

GageData

Page2

InsertStep

DeleteStep

FirstStep

LastStep

CopySteps

NextStep

EndNewPgm

GageData

Page2

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

RAM DATA (1)

Page 2GageData

RunMode

JobData

REVERSAL BEND BEND RAM FORMINGSTEP REPEAT MODE VALUE POSITION LENGTH OPENING SPEED

1 1 Angle 90.0 Center 24.0 1.0 20.0 2 2 Tonnage 50.0 Center 24.0 2.0 20.0

InsertStep

DeleteStep

FirstStep

LastStep

6 AUG 8912:00 PM

CopySteps

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

RAM DATA (2)

Page 3GageData

RunMode

JobData

SPEED SPEED BOTTOM MATERIAL UP DOWNSTEP TOOL CHG. DWN CHG. UP TILT DWELL CLAMP STOP STOP

1 A 00.25 00.25 0.0000 0.0 ON ON ON 2 A 3 B

LastStep

FirstStep

DeleteStep

InsertStep

00.25 00.25 0.0000 0.0 ON ON ON00.25 00.25 0.0000 1.0 OFF OFF ON

6 AUG 8912:00 PM

CopySteps

PROGRAM:TEST001

STATUS: Select a function using the softkeys..

RAM DATA (1)

Page 2GageData

RunMode

JobData

REVERSAL BEND BEND RAM FORMINGSTEP REPEAT MODE VALUE POSITION LENGTH OPENING SPEED

1 1 Angle 90.0 Center 24.0 1.0 20.0 2 1 Angle 3 2 Tonnage

90.0 Center 24.0 1.0 20.050.0 Center 24.0 2.0 20.0

InsertStep

DeleteStep

FirstStep

LastStep

6 AUG 8912:00 PM

CopySteps

7-29

user must select the destination of the copied blockof steps. This includes a "target" step number andwhether the copied block of steps should be insert-ed before or after the "target" step. The softkeys andstatus line show:

STATUS: Select destination for copied steps.

Note the destination step number cannot bebetween the start and end step numbers, i.e. it isnot possible to copy within the block of selectedsteps.

If the user selects the "After Step #" or "Before Step#" softkeys, the "target" step must be entered. Thestatus line and the softkeys will appear as follows:

STATUS: Enter number of step to copy stepsbefore or after.

Once all data has been entered correctly by theuser, the step data (Ram Data or Gage Data) will beupdated immediately to show the user's changes.The control will move all current steps (if any) afterthe target step to higher step numbers to allowroom for the new block of steps. The block of stepswill then be copied to the desired position.

An "Abort" softkey will be present during all theabove steps to allow the user to quit the "copysteps" process.

This concludes the RAM DATA MENU portion ofediting a program. The next step in specifyingan AUTOFORM program is to enter the GAGEDATA MENU by selecting the "Gage Data" soft-key. Continue with the next section.

GAGE DATA MENU

The GAGE DATA MENU is selected by pressing the"Gage Data" softkey from the MAIN MENU or RAMDATA screens. This menu will appear whether ornot the machine is equipped with a backgage. Thismenu is used to enter the step information forbackgages installed on the machine. This menuoperation is very similar to RAM DATA. After theprogram is ended, steps may be modified, added,inserted or deleted. Following is the diagram of theGAGE DATA screen, page 1. There will be the samenumber of steps, with default values, as pro-grammed in the RAM DATA MENU.

The GAGE MODE field will be highlighted and thefollowing softkeys will appear.

GAGE MODE specifies the gaging method used onthe "X" axis (front-to-rear):

STANDARD: Only a LEFT FLANGE dimension isused to position the backgages. The gage bar isparallel to the bed.

INDEPENDENT: Allows both a LEFT and RIGHTFLANGE dimension to be used. Both left andright backgages may be positioned to a differentposition. Not available for Standard CNCBackgage (Single Drive Backgage).

TAPERED: This option provides the capability toposition the gage bar at an angle to the bendline. The LEFT FLANGE dimension is used forthe flange dimension. An angle is entered tospecify the FLANGE ANGLE. Not available forStandard and Six-Axis CNC Backgage.

◆ Press the "Standard" softkey to select the STAN-DARD gage mode:

◆ Use the field control key to move the highlight-ed field to LEFT FLANGE. Enter a flange dimen-sion for the part. The default value is the maxi-mum gage position. For example, 24" (610mm)on a machine with 24" (610mm) backgage.

◆ For this example enter a 3” (76.2 mm) flange:

◆ After pressing ENTER, move the highlightedfield to the GAGE ALLOWANCE. The GAGEALLOWANCE is a value which is added to the X-Axis Flange Dimension and is then passed to the

3 ENTER

Stand-ard

Indep-endent

Taper GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

PROGRAM:TEST001

STATUS: Select a mode using the softkeys.

GAGE DATA (1)

Page 2JobData

EndNewPgm

NextStep

LEFT RIGHT GAGE RETRACT PAUSESTEP GAGE MODE FLANGE FLANGE ANGLE ALLOW DIST TIME

1 Standard 24.000 0.000 0.0 0.1 2 Standard 24.000 0.000 0.0 0.1

Stand-ard

Indep-endent

Taper

6 AUG 8912:00 PM

AbortCopySteps

OFFRamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

AfterCurrentStep

BeforeCurrentStep

AfterStep #

BeforeStep #

AbortCopySteps

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

7-30

backgage as the gage position. If gage allowanceis necessary to obtain proper flange dimension,enter the desired amount. Gage allowances canbe obtained from your reference tables or calcu-lated. Bend allowance can be entered as a nega-tive (-) value, which moves the backgage towardthe tooling, or as a positive (+) value, whichmoves the backgage away from tooling.

The "Transfer" softkey can be used to transfer thecurrent gage position into the flange dimensionfield.

Automatic gage allowance calculations for theAUTOFORM Press Brake:

The softkey shown above is provided in the GAGEDATA MENU when the current field is GAGEALLOWANCE. Pressing this softkey will set the gageallowance for the current step to a value calculatedby the AUTOFORM.

The AUTOFORM can calculate a GAGEALLOWANCE based on the material thickness, partradius, die information and what type of dimensionis being used. This is a theoretical value based onformulas which will be described below. Typically itis necessary to bend a part, then measure theflanges and adjust the GAGE ALLOWANCE value sothe exact flange dimension is achieved.

The following must be maintained if the automat-ic GAGE ALLOWANCE calculation is to be usedproperly.

1. The formed part must have an inside bendradius equal to or greater than the materialthickness.

2. The formed part must have an inside bendradius equal to the actual entered value for thebend radius.

3. The calculation is dependent on the ability topredict the position of the neutral bending axis(K-factor) of the material. Any distortion of theneutral axis (i.e. such occurs when coining orpenetrating the material with the upper die)will result in error in the GAGE ALLOWANCEcalculation.

The operator has the choice of having the controluse a K-factor or entering a value of their choicebased on past experience with a particular material.

The following will explain the operation of the con-trol and the calculations involved in GAGEALLOWANCE. The K-Forming Factor field appearson the JOB DATA and PART DESIGN MENU.

K-FORMING FACTOR

Use the cursor keys to move to the K-Forming Fac-tor field, when in the JOB DATA screen.

This field is used in the Auto Gage Allowance cal-culation previously described. The K-Forming Fac-tor specifies what constant is going to be used inthe Gage Allowance equation. The following soft-keys will now be shown:

The "Auto" softkey specifies that the default con-stants supplied by CINCINNATI will be used. The"Fixed" softkey specifies the operator will supply aconstant to be used. Selecting "Fixed" will cause thefollowing prompt to be displayed.

STATUS: Please enter K-Forming Factor for GageAllowance.

0.000 MIN: 0.100 MAX: 0.900

Enter the desired value using the keypad and pressENTER. The value entered will now be displayed inthe K-Forming Factor field.

K-Forming Factor FIXED 0.330

The K-Forming Factor is only used if the operatorused the Automatic Gage Allowance feature.

AUTO GAGE ALLOWANCE

Use the field keys and cursor over to the GAGEALLOW field on the GAGE DATA MENU. The "AutoGage Allow" softkey will now appear and the opera-tor has the option of either entering their own valueor pressing the softkey to calculate the value auto-matically.

If the softkey is pressed, the operator will be firstprompted to enter what type of dimension is beingused for the flange (inside, outside or radius). Thisis critical because the Gage Allow value changesdramatically depending on the type of dimensionused.

After entering the dimension type by selecting oneof the three softkey choices the operator will thenbe prompted to enter the bend radius of the part.Note that the default value listed on the prompt linewill be 5/32 times the vee die opening. When airbending, the bend radius will typically be equal tothis value.

Either use the default bend radius or enter a valueof your choice and press ENTER. The GageAllowance value will now be calculated and insert-ed into the current program step.

Auto FixedFirstStep

LastStep

CopySteps

JobData

RunMode

GageData

Page 2

AutoGageAllow

NoRamData

GageData

RunMode

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7-31

CAD MENU

When using the CAD MENU on the AUTOFORM toautomatically generate part programs, the GAGEALLOW value is calculated automatically when aprogram is generated.

The operator enters the Part Bend Radius on thePART DESIGN MENU as well as each flange dimen-sion type. The K-Factor field is also included on thePART DESIGN MENU to allow the option of enter-ing the desired K-factor by the operator.

EXPLANATION OF FORMULAS USED

One formula used is the equation to calculate theBend Allowance (BA) or arc length of the bend.

BA = [ (K x t) + r) ] x [ 2∏ x (180 - ANG) / 360 ]

where:

t = Material Thicknessr = Inside Bend RadiusANG = Bend AngleK = % location of neutral axis of material =

Neutral Axis / tBA is the arc length of the bend.

This formula has been proven over the years to pro-vide the best approximation of the length of the arc.However, it is dependent on how well the location ofthe neutral axis can be predicted. Currently we areusing the following factors for the K value.

K-FORMING FACTOR CONSTANT

The K used in the equation is dependent on theselection made in Job Data for the K-Forming Fac-tor. If the AUTO selection is made, K will be as fol-lows using the step values shown:

K = 0.40 for 14 Ga. or thicker0.33 for thinner than 14 Ga.0.50 when Bend Radius (r) is greater thanor equal to 3 times (t)

If the FIXED selection is made in Job Data, K willbe equal to the value entered by the operator.

The definition of K-factor is the location of the neu-tral bending axis of the material. If the K-factor is0.500, the neutral axis is located at the center ofthe material. A typical value will be in the range0.30 - 0.50. However, the operator may enter avalue in the range of 0.10 - 0.90.

The Bend Allowance formula has been found toprovide a good approximation. However, it is depen-dent on the location of the neutral bending axis.The ability to change this factor has been includedto allow the operator to approximate this valuemore accurately if they are knowledgeable abouttheir material.

FIGURE 7-11 – Neutral bending axis of material

After pressing "Auto Gage Allow" softkey the soft-keys will change as follows. The PART DESIGNMENU will display these softkeys when the currentfield is "FLANGE DIM".

Select the type of dimensioning used for the FlangeDimension. Note the diagrams shown below whichindicate the proper way of defining the flange.

Shown below is a diagram of a single 90° bend indi-cating three methods of specifying a flange dimen-sion (Outside or Vertex, Inside, Radius). For thecase of a 90° angle all of the dimensions can be con-verted by the following formulas.

FIGURE 7-12 – Three methods of specifying a flange

Note: For 90° angles Outside and Vertex dimensions areequal.

➛

➛

t

➛

➛

➛

➛

➛➛

➛

➛

➛

r

r Radius

Inside

Outside / Vertex

➛

➛

ang

t = Material Thicknessr = Bend Radiusang = included Angle

Inside Outside Radius VertexRunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

➛

➛

NEUTRAL AXIS

t

BA

➛

➛

➛

➛

➛

7-32

Radius Dimension = Inside Dimension - rRadius Dimension = Outside Dimension - ( r + t )

Using the equations above the final Gage Allowanceis calculated as shown below.

GA (Outside) = 1/2 BA - ( r + t )GA (Inside) = 1/2 BA - rGA (Radius) = 1/2 BA

Typically when and Outside or Vertex dimensionhas been specified, the GA value will be negative.When a Radius dimension has been specified, theGA will be positive. For an Inside dimension, it canbe either positive or negative.

It is important when specifying the type of dimen-sion that it matches those indicated in the abovedrawing. The above formulas apply only to anglesequal to 90°. Shown in Figure 7-13 is a diagram ofan acute angle where different formulas apply.

Radius Dimension = Inside Dimension - rRadius Dimension = Outside Dimension - ( r + t )Radius Dimension = Vertex Dimension - TAN

( ( 180 - ANG )/2 ) * ( r + t )

Using the equations above, the final GageAllowance is calculated as shown:

GA (Outside) = 1/2 BA - ( r + t )GA (Vertex) = 1/2 BA - TAN ( ( 180 - ANG )/2 ) *

( r + t )GA (Inside) = 1/2 BA - rGA (Radius) = 1/2 BA

FIGURE 7-13 – Acute angle with different formulas

Typically when an Outside or Vertex dimension hasbeen specified, the GA value will be negative. Whena Radius dimension has been specified, the GA willbe positive. For an Inside dimension, it can beeither positive or negative.

It is important when specifying the type of dimen-sion that it matches those indicated in the abovedrawing. When the included angle is greater than90° the dimensions shown above become muchharder to specify as shown in Figure 7-14 for anobtuse angle.

FIGURE 7-14 – Obtuse angle

Note that the dimensions labeled "x" and "y" aremeasured from the radius to the theoretical inter-section point of the two flanges and is no longerequal to the bend radius. Thus, the required for-mulas are shown below for angles greater than 90°.

The Gage Position, to achieve the desired flange, isfound by adding half of the BA value to the RadiusDimension. Therefore, the following formulas definethe Gage Allowance (GA) value shown in the GAGEDATA MENU on the AUTOFORM for the dimensiontypes.

GA (Outside) = 1/2 BA -[TAN ( (180 - ang )/2 ) * ( r + t )]

GA (Inside) = 1/2 BA -[TAN ( ( 180 - ang )/2 ) * r]

GA (Radius) = 1/2 BA

Once flange type has been selected using softkeys,a prompt is displayed to enter desired bend radiusor use the default 5/32" x vee die opening. PressENTER to keep the default or enter desired radius.After completing this prompt, the Gage Allowancefield will be calculated.

It is important that all of the values used in theequation (including tool specification and defini-tion) are programmed before the "Auto Gage Allow"softkey is pressed, otherwise erroneous valuescould be calculated. Error message will be dis-played if you attempt to use AUTO GAGE

➛➛

➛➛ ➛

➛ ➛

➛

➛ ➛Radius

Inside

Outside / Vertex

yx

r➛

➛

➛t

➛

➛

t

➛

➛

➛

➛

➛➛

➛

➛

➛

r

r Radius

Inside

Outside

➛Vertex

➛

7-33

ALLOWANCE with *UNMEASURED TOOLING*. Thebend allowance can be re-calculated at any time oradjusted by entering a value using the keypad.

◆ For this example enter a gage allowance of -.06”(-1.5mm):

If no GAGE ALLOWANCE is necessary, press theENTER key which will advance to the next field.

The RETRACT DISTANCE field will now be high-lighted.

RETRACT DISTANCE is the amount the backgagewill move backwards (away from the part and dies)after ram reaches the clamp point during the downstroke. The clamp point is the ram position wherethe upper die nose has penetrated the workpiece.010” (.254mm).

This gage retract feature is used to provide clear-ance during the bend between the workpiece andthe gage surface when the part has a reverse flange.See Figure 7-15. The feature is also used to provideadditional clear space between the dies and thegage when it is necessary to rotate the workpiecewhile it is supported on lower die. GAGE PAUSETIME (see following description) may be used tohold the gage in the retracted position for this typeof part positioning operation.

FIGURE 7-15 – Clamp and Retract

For some parts it may be desirable to stop the rammotion while the gage is retracting. RETRACT canbe used for this sequence in conjunction with theCLAMP function (see RAM DATA). When the CLAMPfunction is ON the ram will automatically stop onthe down stroke when the upper die nose has pen-

etrated the workpiece .010” (.254mm). The back-gage will then move to the programmed RETRACTDISTANCE. The OPERATOR STATION orFOOTSWITCH must be reactivated to continue thebend. If ADAPTIVE reversal mode is selected,RETRACT will still function, although the ram willnot stop at the CLAMP position.

◆ The default value for RETRACT DISTANCE is0.0”. For this example, enter a RETRACT DIS-TANCE of 2.5” (63.5mm):

The next field, PAUSE TIME, will now be highlight-ed. If the next step position is forward, PAUSETIME is the amount of time (in seconds) the back-gage will delay before moving forward. The pausetimer starts after the ram returns to the top of thestroke. The maximum PAUSE TIME is 9.9 seconds.The default value for PAUSE TIME is 0.1 seconds.

If the next programmed step is forward, the back-gage will move to the retracted position when theram reaches the clamp point. If a gage pause timeis programmed, the gage will not move forwarduntil the ram has returned to the top of the strokeand the PAUSE TIME has elapsed. If the gage pausetime is programmed to zero, the gage will move for-ward to the next step programmed position whenthe ram reaches the bottom of the stroke.

If the next programmed step is backward, thePAUSE TIME has no effect on gage movement. Thegage will move backward to the retracted distanceor the next step programmed position, whichever isfurther from the dies, when the ram reaches theclamp point. When the ram reaches the top of thestroke, it will pause until the PAUSE TIME haselapsed.

◆ Enter the following for a 1 second pause time:

After completing the above changes to the programthe display should appear as follows.

1 ENTER

2 . 5 ENTER

NO– . 0 6 ENTER

7-34

◆ Select page 2 of the GAGE DATA MENU bypressing the "Page 2" softkey. For an AUTO-FORM with a standard backgage, the screenshould appear as follows.

The FINGER OFFSET field will be highlighted. Thisvalue is used to offset the gage finger positions fromthe normal programmed positions to correct for fin-ger lengths which are longer or shorter than stan-dard. A positive (+) value will offset the fingers awayfrom dies and a negative (-) value will offset towardthe dies.

The standard gage finger length is 3” (76mm). SeeFigure 7-16. If a longer finger is used, then a posi-tive offset should be entered which is equal to theadditional finger length. The default value for fingeroffset is zero.

For example, if a 6” (152mm) long finger is used,then a +3.000 (76mm) offset should be entered. If a2” (51mm) long finger is used, a -1.000" (-25mm)offset should be entered.

FIGURE 7-16 – Standard gage finger

◆ Press ENTER to keep the default of zero:

This completes the GAGE DATA information for thefirst step of this example.

◆ Press the "Page 1" softkey to switch back to thepage 1 display:

◆ Position the field to GAGE MODE for step 2using field keys:

The following GAGE MODE softkeys will againappear.

Select the INDEPENDENT GAGE MODE by press-ing the softkey.

The INDEPENDENT GAGE mode permits individualpositioning of each gage arm. The difference in gagearm positions may be used for minor compensa-tions to blanks with out-of-parallel sides. This modedoes not apply to the Standard CNC Backgage.

For INDEPENDENT GAGE mode, both a right andleft flange dimension must be entered for the step.

◆ Enter the following for the LEFT FLANGEdimension:

◆ Enter the following for the RIGHT FLANGEdimension:

3 . 3 ENTER0

3 . 2 ENTER5

Stand-ard

Indep-endent

Taper GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

4.0

3.0

1.0

1.0

PROGRAM:TEST001

STATUS: Enter new value using keypad.

GAGE DATA (2)

Page 1JobData

EndNewPgm

NextStep

FINGERSTEP OFFSET

1 0.000 2 0.000

6 AUG 8912:00 PM

PROGRAM:TEST001

STATUS: Enter new value using keypad.

GAGE DATA (1)

Page 2JobData

EndNewPgm

NextStep

LEFT RIGHT GAGE RETRACT PAUSESTEP GAGE MODE FLANGE FLANGE ANGLE ALLOW DIST TIME

1 Standard 3.000 -0.060 2.5 1.0 2 Standard 24.000 0.000 0.0 0.1

6 AUG 8912:00 PM

7-35

For the remaining field entries in Step 2 of the pro-gram, keep the default values. The screen shouldappear as follows:

This concludes the GAGE DATA MENU portion ofentering a new program. It also concludes step-wise information required to run the program.

◆ END the program by pressing the following soft-key:

The softkeys should now be exactly as shownbelow.

EDITING THE GAGE DATA

To change any item in the GAGE DATA MENU, thefield keys can be used to move to any field on thedata area and modify the value in that field. Thestatus line and softkeys will change for the appro-priate field. To quickly index between the first andlast step of a program, use the following softkeys.

Pressing one of the above softkeys will position thecurrent field to either the first or last step of theprogram.

It is also possible to proceed to a particular stepnumber by entering that number. Use the field keysto select the STEP field. The status line will changeto the following with the default being Step 1.

STATUS: Enter new value using the keypad 1

◆ Simply type the desired step number and pressENTER:

The current field position will now change tostep number 2.

The step switching feature is useful for large pro-grams where not all of the steps can fit on onescreen. The screen is used as a window to display afixed number of the total steps. By using the upand down field keys, the window will scroll. Stepswill appear on the bottom and rolled off the top ofthe step list.

Steps may be inserted or deleted anywhere in thestep list.

◆ To insert a step between one and two, first makeStep 1 the current step by pressing the "FirstStep" softkey. Now press "Insert Step" softkey:

The following softkeys will appear which ask theoperator if the step should be inserted BEFORE orAFTER the current step.

◆ Press "After Current Step" softkey and page 1display will now change to the following. Noticethat a copy of the current step has been creat-ed between what were originally steps 1 and 2.There are now three steps in the program:

The values in this step may be changed using thefield keys as before.

To delete a step, the "Delete Step" softkey is used toerase the current step from the program.

PROGRAM:TEST001

STATUS: Enter new value using keypad.

GAGE DATA (1)

Page 2JobData

RunMode

RamData

LEFT RIGHT GAGE RETRACT PAUSESTEP GAGE MODE FLANGE FLANGE ANGLE ALLOW DIST TIME

1 Standard 3.000 -0.060 2.5 1.0 2 Standard 3.000 -0.060 2.5 1.0 3 Independent 3.250 3.300 0.000 0.0 0.1

LastStep

FirstStep

DeleteStep

InsertStep

6 AUG 8912:00 PM

CopySteps

BeforeCurrentStep

AfterCurrentStep

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

InsertStep

BeforeCurrentStep

AfterStep #

BeforeStep #

AbortCopySteps

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

2 ENTER

FirstStep

LastStep

FirstStep

LastStep

RunMode

NextStep

EndNewPgm

GageData

Page2

InsertStep

DeleteStep

FirstStep

LastStep

CopySteps

JobData

RunMode

RamData Page 2

EndNewProgram

AfterCurrentStep

Top ofDie

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

PROGRAM:TEST001

STATUS: Enter new value using keypad.

GAGE DATA (1)

Page 2JobData

EndNewPgm

NextStep

LEFT RIGHT GAGE RETRACT PAUSESTEP GAGE MODE FLANGE FLANGE ANGLE ALLOW DIST TIME

1 Standard 3.000 -0.060 2.5 1.0 2 Independent 3.250 3.300 0.000 0.0 0.1

6 AUG 8912:00 PM

7-36

◆ For this example select the first step of the listas current by using field keys to select a field inthe first step (or press the "First Step" softkey).Now press the "Delete Step" softkey and thestep will disappear. The following step numberswill automatically be reduced by one after the"Delete Step" softkey is pressed. The screen willreturn to its original state as shown below:

COPY STEPS

This function allows the user to copy a block ofsteps and insert them anywhere in the program. Itis available in either the RAM DATA screen or theGAGE DATA screen when the user edits the stepnumber field. For example, a user has an existingprogram to form a channel on one side of a blankand a new program needs to be generated whichrequires channels on two sides of the blank. Thisfunction can be used to copy the original steps (1and 2) to make the two additional steps required toform the new part.

A softkey, "Copy Steps", is available when the cur-rent field is the step number. The softkeys willappear as follows:

After pressing the "Copy Steps" softkey, the soft-keys and the status line will show:

STATUS: Enter starting number of copiedsteps.

Only existing step numbers are valid. After the userenters the beginning step number of the block ofsteps to copy, the softkeys and status line show:

STATUS: Enter ending step number of copiedsteps.

Only step numbers beginning with the step numberspecified as the beginning of the block through theend of the program are valid. After entering theending step number of the block to be copied, theuser must select the destination of the copied blockof steps. This includes a "target" step number andwhether the copied block of steps should be insert-ed before or after the "target" step. The softkeys andstatus line show:

STATUS: Select destination for copied steps.

Note the destination step number cannot bebetween the start and end step numbers. It is notpossible to copy within the block of selected steps.

If the user selects the "After Step #" or "Before Step#" softkeys, the "target" step must be entered. Thestatus line and the softkeys will appear as follows:

STATUS: Enter number of step to copy stepsbefore or after.

Once all data has been entered correctly by theuser, the step data (Ram Data or Gage Data) will beupdated immediately to show the user's changes.The control will move all current steps (if any) afterthe target step to higher step numbers to allowroom for the new block of steps. The block of stepswill then be copied to the desired position.

An "Abort" softkey will be present during all theabove steps to allow the user to quit the "copysteps" process.

This concludes the GAGE DATA MENU portion ofediting a program. Information on the Backgagemay be found in SECTION 8 - OPTIONS.

PROGRAM STORAGE MENU

The PROGRAM STORAGE MENU is selected bypressing the "Program Storage" softkey from theMAIN MENU. This menu is used to save and recallprograms from and to the internal memory. Pro-grams which are no longer needed may be deletedfrom internal memory in the PROGRAM STORAGEMENU. Following is a diagram of the screen.

AbortCopySteps

OFFRamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

AfterCurrentStep

BeforeCurrentStep

AfterStep #

BeforeStep #

AbortCopySteps

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

AbortCopySteps

Left Right GageData

RunMode

NextStep

EndNewPgm

GageData

Page2

AbortCopySteps

Left Right GageData

RunMode

NextStep

EndNewPgm

GageData

Page2

InsertStep

DeleteStep

FirstStep

LastStep

CopySteps

NextStep

EndNewPgm

GageData

Page2

PROGRAM:TEST001

STATUS: Enter new value using keypad.

GAGE DATA (1)

Page 2JobData

RunMode

RamData

LEFT RIGHT GAGE RETRACT PAUSESTEP GAGE MODE FLANGE FLANGE ANGLE ALLOW DIST TIME

1 Standard 3.000 -0.060 2.5 1.0 2 Independent 3.250 3.300

LastStep

FirstStep

DeleteStep

InsertStep

0.000 0.0 0.1

6 AUG 8912:00 PM

CopySteps

7-37

The top line indicates the storage volume is internalmemory and bytes remaining in memory for futurestorage. Note that the storage space is shared by thetooling library, program storage and optional Adap-tive file storage. The PROGRAM STORAGE MENUlists two columns of program names. Each columnmay contain 15 program names. Each program isidentified by a sequence number on the left side ofthe column. Sequence numbers are a shorthandmethod of referring to programs without typing thefull program name. Sequence numbers begin at 1and count up as additional programs are stored.

The current program in active memory is displayedin the upper left corner of the menu area as usual.When a program is stored, all the values currentlyin the JOB DATA, RAM DATA and GAGE DATAMENUs are saved under the program name. If anangle correction has been made in the RUN MODE,it will be stored also with the program. Refer to RUNMODE for information on angle correction.

If there are more programs stored in memory thancan be displayed on the PROGRAM STORAGEscreen, the up and down field keys may be used to“scroll” through the programs not shown.

The three softkeys below are used to load, store anddelete programs from memory.

When the "Store Program" softkey is pressed it willsave the current program in active memory to thestorage area. The program name will then appear inthe list. Programs are stored first by numerical val-ues, then by alphabetical values. The first charac-ter of the program name is used to start the orderof listing, followed by the second, third and so on.Numbers always take precedence over letters in theorder of listing.

◆ Press the "Store Program" softkey to store theTEST001 program currently in memory:

The screen should now appear as follows:

Each program name in PROGRAM STORAGE isunique. There cannot be more than one programwith the same name in storage. If the "Store Pro-gram" softkey is pressed again after the program isalready stored, the original copy in storage will beOVERWRITTEN. It is important to remember thatwhen a program is recalled from storage and mod-ified, it should be saved in PROGRAM STORAGEusing a different program name unless the originalcopy is no longer needed. Refer to the JOB DATAMENU on changing the current program name.

The "Load Program" softkey will replace the currentprogram in active memory with the program fromstorage. After pressing the "Load Program" softkeythe following softkey will appear:

Pressing the above softkey allows the operator tochoose the program to load by the actual programname. If the "Name" softkey is not pressed, the sta-tus line will show the following:

STATUS: Enter sequence number of file to beloaded.

Simply enter the number of the program to beloaded and press ENTER.

If the "Name" softkey is pressed, the status line willchange to the following:

STATUS: Enter program name to be loaded.

Simply enter the program name exactly as itappears in the storage list and press ENTER.

LoadByName

NoRamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

PROGRAM STORAGE

RunMode

ChangeVolume

DeleteProgram

StoreProgram

LoadProgram

SEQ PROGRAM NAME DATE SEQ PROGRAM NAME DATE

Use up and down field keys for more directory entries.

30APRIL9112:00 AM

29APRIL91 11:5928APRIL91 10:59

RecoverFile

JobDate

12

.TEST001

VOLUME: INTERNALPATH:BYTES REMAINING: 96k

LoadProgram

StoreProgram

DeleteProgram

GageData

RunMode

NextStep

EndNewPgm

GageData

Page2

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

PROGRAM STORAGE

RunMode

ChangeVolume

DeleteProgram

StoreProgram

LoadProgram

SEQ PROGRAM NAME DATE SEQ PROGRAM NAME DATE

Use up and down field keys for more directory entries.

30APRIL9112:00 AM

29APRIL91 11:5928APRIL91 10:59

RecoverFile

JobDate

12

.TEST001

VOLUME: INTERNALPATH:BYTES REMAINING: 96k

7-38

The program will be loaded into active memory andthe program name in the menu area of the screenwill show the current program which has just beenloaded.

The "Delete Program" softkey will remove a programfrom the internal storage memory. It does not affectthe current program in active memory. To delete aprogram from storage, press the "Delete Program"softkey and then enter the complete program nameor sequence number to be deleted.

The "Recover File" softkey is provided to allow delet-ed files to be restored to PROGRAM STORAGE. The"RECOVER FILE" is only there until power isturned OFF.

The "Run Mode" softkey is provided to quicklychange to the RUN MODE screen once a programhas been loaded into active memory.

"Copy Storage Units" softkey is used with theoptional DATA CARTRIDGE unit. See SECTION 8 -OPTIONS for information.

RUNNING THE MACHINEThere are two menus on the AUTOFORM Controlwhich allow the ram to be cycled. RUN MODEMENU is used to run a program which has beenentered or loaded from PROGRAM STORAGE.QUICK BEND MENU allows the ram to be cycledwithout entering a program or tool set. It is used forsimple, one step parts and ram reversal is by posi-tion or tonnage only.

RUN MODE MENU

RUN MODE MENU is selected by pressing the "RunMode" softkey from the MAIN MENU. Below is a dia-gram of the RUN MODE screen showing TEST001program, which will be used as an example.

Displayed on the screen are summary data for thefirst step of the program. The first line shows thecurrent step number and the number of steps inthe program. It also shows the number of repeatsfor the step and the current repeat count. The nextline shows the reversal mode and value. For ANGLEreversal mode the value is the desired angle indegrees. The desired angle is the included angle,that is, the angle measured between the legs of thebend. See RAM DATA MENU for more informationon reversal mode.

Flange dimension shows the value entered in theGAGE DATA MENU. If both a LEFT and RIGHTflange are entered for the step they are shown sep-arated by a slash (/). The next line shows the BENDLENGTH and BEND POSITION.

PREVIOUS LOAD

This highlighted area in left center of the RUNMODE screen shows the peak tonnage which wasexerted on the last stroke. The PREVIOUS LOADvalue is cleared when a cycle mode softkey ispressed or when a new stroke is initiated.

PART COUNTER AND BATCH SET

The highlighted area in the right center of the RUNMODE screen shows the current values of thePART COUNTER and BATCH SET. The PARTCOUNTER is increased by one each time all of thesteps in a program have been run. The BATCH SETis the total number of complete parts to be made.See the MANAGEMENT DATA MENU for moreinformation.

The bottom portion of the RUN MODE screen showsthe remaining summary data entered in the RAMand GAGE DATA MENUs. The right bottom side ofthe screen shows programmed values for optionalgage data “R”, "Z" and FRONT gages.

The "Manage Data" softkey is provided on the RUNMODE screen to quickly switch to the MANAGE-MENT DATA MENU for setting PART and BATCHCOUNTERS.

ANGLE CORRECTION

The ACTUAL ANGLE field is used with ANGLE andADAPTIVE reversal modes. After a bend is complet-ed, measure the actual included angle and enter itin the ACTUAL ANGLE field. The first time that abend is made in a new program using angle modeit will normally be under-bent (included angle toolarge). The AUTOFORM Control will make a correc-tion to the ram reversal position each time theACTUAL ANGLE field is modified.

PROGRAM:TEST001

STATUS: Select function using the softkeys.

RUN MODE

Simu-late

LastStep

NextStep

StartAutoSeq

StartSingleStep

PrevStep

FirstStep Edit

ManageData

STEP 1 of 2REV. MODEFLANGE DIM.BEND LENGTH

Angle3.00024.0

ACTUAL ANGLERAM OPENINGTOOL SETTILTUP STOPDOWN STOPDWELL

90.01.0

A0.0000

ONOFF

0.0

FORMING SPEEDGAGE MODEBEND ALLOWANCERETRACT DISTANCECLAMPPAUSE TIMEFINGER OFFSET

20.0Standard

-0.0602.50ON1.0

0.000

Left Right

R

Z

F

PREVIOUS LOAD40.0

REPEAT 1 of 1 90.0

BEND POS Center

PART CT. 0000BATCH SET 0005

6 AUG 8912:00 PM

7-39

IMPORTANT: If a stored program is called intoactive memory and then changed, it must bestored again to save the changes.

LISTING AND EDITING PROGRAM STEPS

The RUN MODE screen shows all important datafor a single step of the program. If there is morethan one step, the softkeys below can be used todisplay the data for other steps.

Data can be edited on the RUN MODE screen with-out switching to the RAM or GAGE DATA MENUs.

◆ Press the "Edit" softkey to change a field on theRUN MODE screen:

The softkeys will now change to the following:

◆ Use the field keys to position the highlightedfield to the desired field to edit. Enter the newvalue and press ENTER:

To edit a value in another step, use the "Next Step"or "Prev Step" softkeys. The current field will stayhighlighted and the data for the next or previousstep will be displayed.

EDIT ALL STEPS

This function allows a user to edit a particular fieldin program data in the RUN MODE screen. Thechange is applied to the same field (i.e. angle cor-rection, reversal mode flange dimension) for all pro-gram steps.

The "Edit All Steps" softkey will appear wheneverthe "Edit" softkey is pressed in the RUN MODEscreen.

The Run Mode edit softkeys will now look like:

Using the field up and down keys, move to thedesired field to edit. Press the "Edit All Steps" soft-key. Next select the type of change to make,whether it is a new value for all steps or an incre-mental change to make to all steps, and theamount of the desired change. Also, an abort soft-key is available to the user to cancel this functionso no changes are made to the program.

When the user selects the "Edit All Steps" softkey,the status line and softkeys will look like:

STATUS: Select a function using the softkeys.

If the user selects "Enter New Value", the status lineprompts:

STATUS: Enter new value using the keypad.

If the user chooses "Enter Incr. Change", then thestatus line reads:

STATUS: Enter incremental change using thekeypad.

All program steps will be changed to the new userspecified data. If the change is a new value for allsteps, then the new value will be inserted into theselected steps. If the change is incremental, thenthe increment will be added to the selected steps.The increment can be a positive or negative value.

The display is now updated to reflect the changesmade to the program by the user and the softkeylabels are changed back to the labels displayedbefore this function was invoked.

◆ Press the "End Edit" softkey to return to thenormal "Run Mode" softkeys:

TRANSFER SOFTKEY

If the reversal mode is POSITION or ABSOLUTE, itis possible to enter the current ram position for thereversal position value. Using the field keys, moveto the reversal VALUE field. A softkey will appear atthe far left labeled “Transfer”. Pressing this softkeywill change the value to the current ram position.

Gage positions may be transferred into the programin the same manner. The current Flange Dimensionand “R” position may be transferred into their valuefields. Whenever editing each of these fields, the"Transfer" softkey will appear. Pressing it will enterthe current gage position into the field being edited.

CYCLE MODE SOFTKEYS

The two softkeys below will signal the AUTOFORMControl to allow a machine cycle(s).

StartSingleStep

StartAutoSeq.

AfterStep #

BeforeStep #

AbortCopySteps

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

Trans-fer

LastStep

Right GageData

RunMode

NextStep

EndNewPgm

GageData

Page2

EnterNewValue

EnterIncr.Change

FirstStep

LastStep

CopySteps

NextStep

PrevStep

AbortEditAll

Abort

EndNewPgm

AfterCurrentStep

Top ofDie

GageData

RunMode

NextStep

PrevStep

EndEdit

EditAllSteps

NextStep

PrevStep

EndEdit

GageData

RunMode

NextStep

PrevStep

EndEdit

EditAllSteps

Edit Outside Radius VertexRunMode

QuickBend

Set-upMode Edit

ProgramStorage

NextStep

PrevStep

NextStep

PrevStep

FirstStep

LastStep

RunMode

GageData

Page 2

7-40

The "Start Single Step" softkey will instruct thecontrol to allow one ram cycle using the currentstep information shown on the RUN MODEscreen. The softkey must be pressed prior to eachram stroke. If the step contains more than onerepeat, only one ram stroke is made. BATCHCOUNT and PARTS COUNTER are not affected. Tocycle the machine through all steps of the pro-gram, use the "Next Step" softkey to advance tothe next step and press the "Start Single Step"softkey to allow a ram stroke. After the ram strokeis completed, repeat this sequence to advancethrough the remaining steps.

The "Start Auto Seq" softkey will instruct the con-trol to allow a cycle for the current step informationshown on the RUN MODE. Once the step is com-pleted the control will automatically sequence tothe next step in the program. This will continueuntil either the operator stops the sequence usingthe "Cycle Stop" softkey or the BATCH COUNTERreaches zero, at which time the Status line willshow BATCH COMPLETE. The BATCH COUNTERis decreased by one each time the last step of theprogram is completed.

Before running a program, observe the following:

◆ List each program step one-by-one using the"Next", "Prev", "First" and "Last" softkeys toensure all information is correct. If changes arerequired either use the "Edit" softkey andchange the appropriate fields or select the JOB,RAM, or GAGE DATA MENU to correct the pro-gram. The PROGRAM/LOCK selector switchmust be in the “PROGRAM” position to changethe program.

◆ Select the correct step number to begin thecycle.

◆ Turn OPERATOR CONTROL selector (on AUTO-FORM Control Station ) to “ON” position.

◆ Turn MODE SELECT switch to SINGLESTROKE and select the appropriate operationmode (Palmbuttons or Footswitch, Footswitchonly, or Auto Return).

◆ Depress MAIN DRIVE - START pushbutton onAUTOFORM Control Station. Hold until motorstarts.

◆ Turn “ON” either OPERATOR STATION orFOOTSWITCH selector on MACHINE CON-TROLS station.

Now press the desired cycle softkey, either "StartSingle Step" or "Start Auto Seq". The status line willchange to indicate the cycle is now active andwhether the FOOTSWITCH, PALMBUTTONS orboth are being used.

STATUS: Cycle Active!!! Single Stroke - Palmbuttons

The softkeys will now be erased and the extremeright softkey will change as shown.

The "Cycle Stop" softkey will cancel the active cycleand return to the RUN MODE softkeys. In AUTOSEQUENCE cycle mode, the "Cycle Stop" softkeymust be pressed to cancel the cycle and return toRUN MODE softkeys. Using SINGLE STEP cyclemode, the softkeys will return after completion ofthe step.

Note: Pressing the "Cycle Stop" softkey does not stop theMAIN DRIVE.

Immediately after pressing a "Cycle Start" softkey,the backgage will move to the displayed flangedimension. The ram may now be cycled using theactive control station (Palmbuttons or Footswitch).

CycleStop

AfterCurrentStep

RamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

CycleStop

MACHINE CONTROLS

OFF ON OFF ON OFF ON OFF ON

OPERATORSTATION LEFT

OPERATORSTATION RIGHT

FOOTSWITCHLEFT

FOOTSWITCHRIGHT

MAIN DRIVEON

START

FOOTSWITCH ONLY - ON DOWN STROKE, RELEASING FOOTSWITCH TOCENTER POSITION STOPS RAM. RELEASING TO UP POSITION MAKES RAMGO BACK UP TO TOP OF STROKE. AFTER PASSING BOTTOM OF STROKERAM AUTOMATICALLY RETURNS TO TOP OF STROKE AND STOPS.

PALMBUTTONS OR FOOTSWITCH - CONTROLS RAM ON DOWNAND UP STROKE. AUTOMATIC STOP AT TOP OF STROKE.

AUTO. RETURN - PALMBUTTONS OR FOOTSWITCH CONTROLS RAM ON DOWNSTROKE. AFTER PASSING BOTTOM OF STROKE RAM AUTOMATICALLYRETURNS TO TOP OF STROKE AND STOPS.

SINGLESTROKE

MODE SELECT

OFF

SET-UPSINGLESTROKE

OPERATORCONTROL

OFF ON

7-41

MAKING CORRECTIONS

Before starting production, it is recommended thatthe ram be cycled through the entire program with-out bending material. This is to ensure all controls,gage motions and ram motions are set and func-tioning properly.

Test bends for each step in a new program must bemade to check the accuracy of the bend and flangelength. SINGLE STEP cycle mode is recommendedto make test bends. Measure test bend on the work-piece and adjust as follows:

ANGLE REVERSAL: Measure included angle oftest bend with protractor gage. See Figure 7-17.If the bend angle is not within the desired toler-ance, press "Edit" softkey. The ACTUAL ANGLEfield will be highlighted. Enter the measuredincluded angle of the workpiece in degrees andpress ENTER. Press the "End Edit" softkey toreturn to normal RUN MODE softkeys.

FIGURE 7-17 – Measuring included angle of testbend with protractor gage

ADAPTIVE REVERSAL (Optional): See SECTION 8- OPTIONS.

POSITION REVERSAL: If the bottom reversal posi-tion does not give desired results, press the"Edit" softkey and select the value field ofREVERSAL MODE using the field keys. Typethe corrected position value and press ENTER.Press the "End Edit" softkey to return to normalRUN MODE softkeys.

TONNAGE REVERSAL: If the tonnage does not givedesired results, press the "Edit" softkey andselect the value field of REVERSAL MODE usingthe field keys. Enter the corrected tonnage valueand press ENTER. Press the "End Edit" softkeyto return to normal RUN MODE softkeys.

ABSOLUTE REVERSAL: If the bottom reversalposition does not give desired results, press the"Edit" softkey and select the value field ofREVERSAL MODE using the field keys. Typethe corrected position value and press ENTER.Press the "End Edit" softkey to return to normalRUN MODE softkeys.

FLANGE DIMENSION/BEND ALLOWANCE: If theflange length of the part does not give thedesired results, press the "Edit" softkey andselect the FLANGE DIMENSION or BENDALLOWANCE field using the field keys. Enterthe corrected value and press ENTER. Press the"End Edit" softkey to return to normal RUNMODE softkeys.

Make corrections for each step of the programusing the above procedure. You may wish to usethe Calculator mode.

To obtain the desired bend angle from one end ofthe bend to the other, it may be necessary to tilt theram to compensate for variations in the dies ormaterial. Some jobs may require shimming underdies to correct for machine deflection or die wear.After changing the tilt value or shimming under thedie it may be necessary to make ANGLE or POSI-TION corrections to the program steps.

When an acceptable part has been made, the pro-gram may be stored so repeat jobs can be set-upagain in minimum time. See the PROGRAM STOR-AGE MENU for information.

SIMULATE CYCLE MODE

The RUN MODE MENU has a special softkey called"Simulate". This activates a mode which does notallow the machine to be cycled. When the softkey ispressed, the RUN MODE screen will be erased andthe SIMULATE screen will appear.

! ! DANGER ! !! ! DANGER ! !BEFORE CYCLING OR MAKING BENDS, MAKESURE THAT ALL SAFETY DEVICES ARE BEINGUSED AND ARE OPERATING PROPERLY. EVALU-ATE EACH JOB FOR PROPER SAFEGUARDING.SEE ANSI B11.3 - SAFETY REQUIREMENTS FORTHE CONSTRUCTION, CARE AND USE OF POWERPRESS BRAKES.

7-42

The SIMULATE screen shows absolute position val-ues for the ram and gages for the current step. Italso shows calculated maximum loading for the toolset and angle correction (adjustment) being used.Data on the SIMULATE screen cannot be changed.

Press the "Run Mode" softkey to return to the RUNMODE screen. The various "Step" softkeys can beused to view the simulation data for any of thesteps in the current program.

QUICK BEND MENU

The QUICK BEND MENU is selected by pressing the"Quick Bend" menu softkey from the MAIN MENU.Below is a diagram of the QUICK BEND screen.

Displayed on the screen are the current settings forQUICK BEND MENU. The field keys can be used toselect any field on the screen and then enter a valueusing the keypad. The following is a description ofeach field on the QUICK BEND screen. Note thatTOP STOP, SPEED CHANGE, REVERSAL POSITIONand RAM LOCATION are measured from the bed topto the ram nose.

TOP STOP: Actual position the ram returns to uponcompletion of the stroke. Note: TOP STOP posi-tion must be greater than or equal to SPEEDCHANGE position.

SPEED CHANGE: Actual position where the ramchanges from high approach speed to FORM-ING SPEED. Note: SPEED CHANGE positionmust be greater than REVERSAL POSITION andequal to or less than the TOP STOP position.

REVERSAL POSITION: Actual position where theram reverses when using POSITION reversalmode. Note: REVERSAL POSITION must be lessthan SPEED CHANGE position.

REVERSAL MODE: Method used to reverse ram,either POSITION or TONNAGE.

REVERSAL TONS: Maximum tonnage value whichis allowed for the stroke.

FORMING SPEED: Speed of ram in inches/minute(mm/second) to form the workpiece.

TILT: Position of the left side of the ram in refer-ence to the right side. Changing the tilt will notaffect the position of the ram at the center of themachine. Tilt is used to vary the bend anglealong the length of the workpiece. A positivenumber will make the left side higher than theright (clockwise tilt). A negative number willmake the left side lower than the right (coun-terclockwise tilt). Maximum tilt is 1.000”(25mm) with the default value being zero tilt.

DWELL: The number of seconds for the ram tohold the reversal position before starting the upstroke. A value from 0 to 9.9 seconds is allowed,with the default being zero.

UP STOP: When UP STOP is “ON” the ram will stopslightly after reversal position. This feature isused to hold the formed workpiece in the dies,thus preventing it from dropping rapidly. Torestart the ram motion the palmbuttons orfootswitch must be released and re-activated.

DOWN STOP: When DOWN STOP is “ON” the ramwill stop on the down stroke at the SPEEDCHANGE position. This is used when the oper-ator must align the material just before bendingor when using the HAND/FOOT combination ofcontrol. To restart ram motion, the palmbut-tons or footswitch must be released and re-acti-vated. When using HAND/FOOT mode, palm-buttons must be released after stopping at thespeed change position and footswitch activatedto complete the cycle.

PROGRAM:TEST001

STATUS: Enter new value using keypads.

QUICK BEND

TOP STOPSPEED CHREV. POS

17.0013.00 10.3800

REV. MODEREV. TONS FORM SPEED

Position125.0 10.0

RAM LOCATION 17.0000PREVIOUS LOAD 40.0

TILTDWELLUP STOPDOWN STOP

0.00000.0 OFF OFF

X 12.000R 7.500Z -20.500F 10.000

12.0007.50018.37510.000

CopyCurrentStep

MoveGage(s)

TransferCycleStart

6 AUG 8912:00 PM

CopyLastStroke

LEFT RIGHT

GageRetract

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

SIMULATE

RunMode

PREVIOUS LOAD40.0

PART CT. 0000BATCH SET 0005

Step NumberTop Stop PositionSpeed Change DownTop of MaterialReversal PositionPenetration DepthSpeed Change Up

10.000011.000010.380010.1300

9.6300-0.500010.3800

Maximum LoadingAngle AdjustmentX-leftX-right

80.00.00

3.0003.000

6 AUG 8912:00 PM

NextStep

Prev-iousStep

FirstStep

LastStep

7-43

The highlighted area at the center of the QUICKBEND screen shows the actual current RAM POSI-TION and the peak tonnage that was reached onthe last bend. The previous load tonnage is clearedwhen the "Cycle Start" softkey is pressed or a newdown stroke is initiated.

Note when using the field select keys to movearound the QUICK BEND screen, the first and sec-ond softkeys will change on the UP STOP andDOWN STOP fields to the following.

When the REVERSAL MODE field is selected, thefirst two softkeys will change to the following.

In these cases, select the desired softkey to updatethe field and then select the next field to edit usingthe field keys.

The "Transfer" softkey can be used to transfer theactual ram position into one of the following fields:TOP STOP, SPEED CHANGE or REVERSAL POSI-TION. When the current field is one of the listedfields, pressing the "Transfer" softkey will transferthe current ram position into that field.

Note: If the ram is not calibrated when the "Transfer" soft-key is pressed, an error message ("Ram not Cali-brated") will be displayed and no transfer of posi-tion will be made.

The "Gage Retract" softkey will move all installedbackgages to the maximum rear positions.

Note: If the MAIN DRIVE motor is off, the "Gage Retract"softkey will not function.

GAGE MOVEMENT

Inputs: The operator enters a value for any gageposition by using the cursor keys to highlight theparticular field (see the QUICK BEND screen). Onlythe axes that are installed and enabled in the con-figuration will be displayed. Disabling an axis in theJOB DATA screen will not prevent moving that axisin the QUICK BEND screen. The "Transfer" softkeywill transfer the current gage position into the high-lighted field (except for the front gage fields). The"Copy Current Step" and "Copy Last Stroke" soft-keys will copy the gage positions as well as the rampositions.

All gage dimensions are absolute dimensions. If the"Copy Current Step" or "Copy Last Stroke" softkeyis pressed, the relative dimensions in the RUN

MODE screen will be converted to absolute dimen-sions and copied into the QUICK BEND screen.

The gages will not automatically move when a newvalue is entered or when the "Cycle Start" softkey ispressed. If gage motion is desired, the "MoveGage(s)" softkey must be pressed. The softkeysshown below will be displayed. A particular gagewill be commanded to move when its correspondingsoftkey is pressed.

The "Gage Retract" softkey will cause the X-Axisgage to move to it's maximum position.

COPY LAST STROKE

When this softkey is pressed in the QUICK BENDscreen, values for the last completed stroke in RunMode will be transferred into the Quick Bend fields.Pressing "Cycle Start" will then allow a bend to usethe reversal position from the last completed strokeof the program. Note that the REV Mode field is lim-ited to POSITION or TONNAGE. However, if an Adap-tive or Angle REV Mode is used in the current pro-gram step in Run Mode, the Actual Position will betransferred and REV Mode will be set to POSITION.

Note: One stroke must be made in the RUN mode forCOPY LAST STROKE to work.

COPY CURRENT STEP

"Copy Current Step" copies values for the ramstroke from the current step in the Run Mode Pro-gram. This function does not require the ram tohave made a stroke, like "Copy Last Stroke".

GUARD MUTE POINT

With an optional presence sensing device installed,GUARD MUTE POINT in QUICK BEND occurs onlyat the speed change position because there is notooling or material thickness information in QUICKBEND. Set speed change .25” (6.35mm) above topof material.

CYCLE START SOFTKEY

The "Cycle Start" softkey will instruct the control touse the data entered in the QUICK BEND MENU toallow ram cycling.

The following describes how the ram will reverse:

If REVERSAL MODE is set to POSITION, the ramwill try to achieve this reversal position. If, howev-er, the tonnage reaches the REVERSAL TONNAGEvalue, it will reverse immediately.

X-AXIS R-AXIS Z-AXIS F-AXISAllAxes

QuickBend

Set-upMode

ToolingLibrary Abort

Posit-ion

TonnageRadius Vertex

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

ON OFFFirstStep

LastStep

CopySteps

JobData

RunMode

GageData

Page 2

7-44

If REVERSAL MODE is set to TONNAGE, the ramwill continue moving down until the tonnage valueis reached. However, if the ram reaches the REVER-SAL POSITION value first, it will reverse before ton-nage is achieved.

To summarize, when POSITION REVERSAL is used,be sure that tonnage value is adequate so as to notreverse early and when TONNAGE REVERSAL isused, be sure that position is set low enough tokeep from reversing early.

Before pressing the "Cycle Start" softkey toallow a ram stroke, observe the following:

◆ Verify entered values for proper tonnage andposition. The PROGRAM/LOCK selector must bein “PROGRAM” position to change the program.

◆ Turn OPERATOR CONTROL selector (on AUTO-FORM Control station) to “ON” position.

◆ Turn MODE SELECT switch to “SINGLESTROKE” and select the appropriate operationmode (Footswitch only, Palmbuttons orFootswitch, or Auto Return).

◆ Depress MAIN DRIVE - START pushbutton onAUTOFORM Control station. Hold until themotors start.

◆ Turn “ON” OPERATOR STATION orFOOTSWITCH on MACHINE CONTROL station.

Now press the "Cycle Start" softkey. The status linewill change to indicate the cycle is now active.

STATUS: Cycle Active!!

The softkeys will now be erased and the extremeright softkey will change as shown.

The "Cycle Stop" softkey will cancel the cycle andreturn to the QUICK BEND softkeys.

Note: Pressing the "Cycle Stop" softkey does not stop theMAIN DRIVE.

The ram may now be cycled using the active controlstation (Palmbuttons or Footswitch).

If an error message appears when the "Cycle Start"softkey is pressed, then an incorrect value hasprobably been entered in one of the QUICK BENDfields. Check all values and correct.

This concludes RUNNING THE MACHINE section.

MANAGEMENT DATA MENU

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

MANAGEMENT DATATOTAL MACHINE STROKESPARTS COUNTERBATCH COUNT SETBATCH COUNT ACTUALTOTAL POWER ON TIMEPOWER CONSERVATION TIME

127123110048449 hours60 minutes

RunMode

SetHoursOn

ServiceCode

SetPartsCount

SetBatchCount

SetPowerConsv

SetStrokeCount

6 AUG 8912:00 PM

ViewMaint.Msgs

SAMPLE SIZEPARTS PER MINUTEAVERAGE PARTS PER MINUTECYCLE TIME PER PARTAVERAGE CYCLE TIME PER PARTTOTAL CYCLE TIMEMAIN DRIVE ON TIME

10011.10.50 minutes0.5369.3225 hours

Maintenance Required – View Messages

SERVICE ACCESS - denied

! ! DANGER ! !! ! DANGER ! !BEFORE CYCLING RAM OR MAKING BENDS,MAKE SURE ALL SAFETY DEVICES ARE BEINGUSED AND ARE OPERATING PROPERLY. EVAL-UATE EACH JOB FOR PROPER SAFEGUARD-ING. SEE ANSI STANDARD B11.3 - SAFETYREQUIREMENTS FOR THE CONSTRUCTION,CARE AND USE OF POWER PRESS BRAKES.

CycleStop

AfterCurrentStep

Top ofDie

GageData

RunMode

NextStep

PrevStep

EndEdit

CycleStop

MACHINE CONTROLS

OFF ON OFF ON OFF ON OFF ON

OPERATORSTATION LEFT

OPERATORSTATION RIGHT

FOOTSWITCHLEFT

FOOTSWITCHRIGHT

MAIN DRIVEON

START

FOOTSWITCH ONLY - ON DOWN STROKE, RELEASING FOOTSWITCH TOCENTER POSITION STOPS RAM. RELEASING TO UP POSITION MAKES RAMGO BACK UP TO TOP OF STROKE. AFTER PASSING BOTTOM OF STROKERAM AUTOMATICALLY RETURNS TO TOP OF STROKE AND STOPS.

PALMBUTTONS OR FOOTSWITCH - CONTROLS RAM ON DOWNAND UP STROKE. AUTOMATIC STOP AT TOP OF STROKE.

AUTO. RETURN - PALMBUTTONS OR FOOTSWITCH CONTROLS RAM ON DOWNSTROKE. AFTER PASSING BOTTOM OF STROKE RAM AUTOMATICALLYRETURNS TO TOP OF STROKE AND STOPS.

SINGLESTROKE

MODE SELECT

OFF

SET-UPSINGLESTROKE

OPERATORCONTROL

OFF ON

7-45

This menu is used for statistical information onparts and the machine.The MANAGEMENT DATAMENU is selected by pressing the "Manage Data"softkey from either MAIN MENU Page 2 or fromthe RUN MODE screen. The previous screen is anexample of a MANAGEMENT DATA screen.

The first field on the MANAGEMENT DATA screenis TOTAL MACHINE STROKES. This is a continu-ous counter which is incremented every time theram is cycled. The operator is not allowed tochange this value. If it is required, a Service Rep-resentative from CINCINNATI INCORPORATEDmay adjust this value.

The next field is PARTS COUNTER, which may bechanged by the operator. PARTS COUNTER isincreased each time a program has been cycledthrough and returns to Step 1, Repeat 1 with AUTOSEQUENCE cycle in the RUN MODE screen. Theoperator may reset this value by using the field con-trol keys to highlight the parts counter field. (ThePROGRAM/LOCK selector must be in the “PRO-GRAM” position.)

Enter the new value and press ENTER key.

BATCH COUNT SET is a counter which can bechanged by the operator. This sets the total numberof complete parts to be made when using the AUTOSEQUENCE cycle mode in the RUN MODE screen.

BATCH COUNT ACTUAL is a counter which showsthe number of complete parts remaining to be madefrom the BATCH COUNT SET. It is decreased by oneeach time an AUTO SEQUENCE is completed in RUNMODE. Once the BATCH COUNT ACTUAL reaches 0,AUTO SEQUENCE will stop and a status messagewill appear indicating the batch is complete.

If the operator sets BATCH COUNT SET to 0, thebatch feature is not used in the AUTO SEQUENCEcycle mode. Note that using SINGLE STEP cyclemode does not affect the PARTS COUNTER orBATCH COUNT ACTUAL. See RUN MODE screenfor more information on BATCH and PART COUNT.

To change the BATCH COUNT SET field, use thefield control key to highlight the batch count setfield. In the following example the values shown arenow displayed:

BATCH COUNT SET 100

BATCH COUNT ACTUAL 48

BATCH COUNT SET 50

BATCH COUNT ACTUAL 50

Notice that BATCH COUNT ACTUAL was alsochanged to the entered value. Once an AUTOSEQUENCE is started, the BATCH COUNT ACTUALwill count down as each part is completed.

TOTAL POWER ON TIME is a field which shows thenumber of hours the AUTOFORM Control (maindisconnect) has been powered-on. It cannot bechanged by the operator. Only a CINCINNATIINCORPORATED Service Representative may alterthis value.

POWER CONSERVATION TIME is a field whichspecifies how many minutes the main drive willstay on if the machine is not cycled. If the CON-SERVATION TIME is set at 30 minutes, the MAINDRIVE motor will turn off after 30 minutes of cycleinactivity. To set POWER CONSERVATION TIME,use the field control keys to highlight the PowerConservation Time field. Enter the new value andpress ENTER key.

TIMING OF PRESS UTILIZATION

The MANAGEMENT DATA screen also displaysParts Per Minute, Cycle Time Per Part, Total CycleTime and Main Drive On Time. Parts Per Minutecan be used to measure process efficiency andCycle Time Per Part can be used to measuremachine performance.

The control monitors the Main Drive, cycle time andram motion. The control will keep track of the fol-lowing items:

Sample Size of parts to be used to calculateaverage times - To select the sample size, use thefield control keys to highlight the sample size fieldand enter the desired value.

Parts Per Minute - Based on the total time elapsedbetween the start of the first step and the end ofthe last step of a program, including the operator

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

MANAGEMENT DATATOTAL MACHINE STROKESPARTS COUNTERBATCH COUNT SETBATCH COUNT ACTUALTOTAL POWER ON TIMEPOWER CONSERVATION TIME

12712315050449 hours60 minutes

RunMode

SetHoursOn

ServiceCode

SetPartsCount

SetBatchCount

SetPowerConsv

SetStrokeCount

6 AUG 8912:00 PM

ViewMaint.Msgs

SAMPLE SIZEPARTS PER MINUTEAVERAGE PARTS PER MINUTECYCLE TIME PER PARTAVERAGE CYCLE TIME PER PARTTOTAL CYCLE TIMEMAIN DRIVE ON TIME

10011.10.50 minutes0.5369.3225 hours

Maintenance Required – View Messages

SERVICE ACCESS - denied

5 ENTER0

7-46

handling time, the time per part will be mea-sured. This time will then be inverted and dis-played as a Parts Per Minute value.

Average Parts Per Minute - Same as above, aver-aged over the customer selected sample size.

Cycle Time Per Part - The time the ram is inmotion between the start of the first step and theend of the last step in a program will be measured.

Average Cycle Time Per Part - Same as above,averaged over the customer selected sample size.

Total Cycle Time - A running total of the CycleTime per Part will be kept. This time can only bemodified by a CINCINNATI INCORPORATED Ser-vice Representative.

Main Drive On Time - The amount of time theMain Drive is ON will be kept. This time can onlybe modified by a CINCINNATI INCORPORATEDService Representative.

PLANNED MAINTENANCE MESSAGES

The MAINTENANCE MESSAGES screen is used todisplay messages when it is time to performplanned maintenance tasks. It is shown under theMANAGEMENT DATA screen.

Softkeys in the MAINTENANCE MESSAGES screenare used to acknowledge the completion of a main-tenance item. The interval for each maintenanceitem and the time of day to report any pendingmaintenance can be edited. Six user-programmabletasks may be entered and given their own intervals.

The planned maintenance items that are monitoredper calendar day are:

✦ Check machine for loose fasteners - 1 day✦ Wipe machine clean - 30 days✦ Lubricate cylinder head clevis pins - 30 days✦ Clean and flush ram guides with oil- 30 days✦ Check reservoir for water - 30 days✦ Lubricate Autocrown pins (if present - 30 days✦ Check machine levelness - 90 days✦ Check ram guide clearance - 90 days✦ Adjust swivel end-guide bearings - 90 days✦ Drain, clean and refill hydraulic reservoir -

365 days

The planned maintenance items that are monitoredper hours of main drive "on" time are:

✦ Air Filter / Breather - replace every 2000 hours.✦ Replace filter in air-cooled heat exchanger -

1200 hours.✦ Clean, lubricate, adjust gages (200 hours) See

SECTION 9 for more details.

When it is time for a planned maintenance task tobe performed, a message describing that task isdisplayed on the MAINTENANCE MESSAGESscreen. It will remain there until it is acknowledgedby selecting the proper softkey on that screen.

When a maintenance task is pending, a generalwarning message is displayed on the status line ofthe CRT. This message will be removed when theuser presses any key, but will return each time themachine is powered on. The message will alsoappear at 24 hour intervals, if the machine has notbeen powered off in that time. The time of day thatthis message appears is programmable. This mes-sage will continue to appear until all planned main-tenance is acknowledged to be completed. Thismessage can be prevented from appearing by set-ting the Time of Day Report Maintenance to 0:00.

When maintenance is pending, a message will alsoappear at the bottom of the MANAGEMENT DATAscreen to prompt the operator to view the MAINTE-NANCE MESSAGES screen. This message will alsobe disabled if the status line message is preventedfrom appearing.

When a softkey is selected to acknowledge the com-pletion of a maintenance item, the time and datewill be saved. The next time that item comes due,the time and date will be displayed on the screen as"Last Service".

Messages describing pending planned maintenancewill be displayed on the MAINTENANCE MESSAGESscreen, which is accessed by the "View Maint. Msgs"softkey on the MANAGEMENT DATA screen. Soft-keys on the MAINTENANCE MESSAGES screen willbe used to acknowledge the completion of each item.If more than seven tasks are pending, the addition-al tasks will appear on another layer of softkeys.The operator can edit the Maintenance Time Inter-

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

Maintenance Msgs

1 Lubricate Cylinder Head Clevis Pins Last Service: NOV 15 91 13:00

2 Check Hydraulic Oil Level Last Service: NOV 30 91 16:00

3 Lubricate Gage Ball Screws Last Service: NOV 24 91 16:10

ManageData

SetHoursOn

Item 1Done

Item 2Done

Item 3Done

SetStrokeCount

6 AUG 8912:00 PM

EditTimes

7-47

vals and the Time of Day to Report Maintenance onpage two of the MAINTENANCE MESSAGES screen,accessed by the "Edit Times" softkey. Field selectkeys can be used to highlight the time interval to bechanged and then the new value can be entered.The "Change Report Time" softkey must be used tochange the time of day to report that maintenanceis required (if necessary).

A softkey is also provided on the right side of thescreen to return to the RUN MODE screen.

MACHINE CONFIGURATION MENU

This menu contains information about the size ofthe machine and various options installed. Thisdata is set at the factory and cannot be changed bythe customer. There are up to eight fields on thescreen which the customer may change. TheMACHINE CONFIGURATION MENU is selected bypressing the "Machine Config" softkey from MAINMENU, page 2. Shown below is a typical page 1 ofthe MACHINE CONFIGURATION MENU.

The first user-changeable field is LANGUAGE. TheAUTOFORM has the option of being able to displaytext on the CRT screen in several languages. Bypressing the "Change Language" softkey, text willchange from ENGLISH to another language whichis optionally installed. To change back to ENGLISHlanguage, press the softkey again.

The second user-changeable field is UNITS. TheAUTOFORM has the built-in capacity to display val-ues in either ENGLISH or METRIC units. By press-ing the "Change Units" softkey, values will changeto METRIC from ENGLISH. To emphasize the unitchange, METRIC values are shown in yellow text,while ENGLISH values are shown in green text. Pro-grams written in one unit type may be converted tothe other by pressing the "Change Units" softkey.

When the "Change Date" softkey is pressed thescreen will change to show fields for month, day,year, hours and minutes. Use the field keys toselect each field and enter the desired values usingthe keypad.

The third user-changeable field is FractionalAngles, which toggles between minutes or tenths ofdegrees. If fractional degrees are in tenths of adegree, angle entry will use the standard decimalpoint. If fractional degrees are in minutes, the usercan enter the whole degrees and then press thedecimal point which will cause the degree symbol (°)to be displayed. Two additional digits may beentered for the number of minutes.

Page 1 of the Configuration data shows the currentsetting of how the fractional degrees are entered.

When entering or displaying degrees in the "min-utes" mode the decimal will be replaced by thedegree symbol (°).

Example: 90°30' would be equal to 90.5.

The fourth user-changeable field is FILLER BLOCKHEIGHT. This specifies the height of the currentfiller block installed in the machine. If the fillerblock is changed after the initial factory setting, thenew height dimension must be entered. Thisdimension must be measured accurately to plusor minus .002” (.05mm). To change the filler blockheight dimension, press the "Edit" softkey. Enterthe new value and press ENTER key.

The remaining user-changeable fields are for gageenable/disable. Depending on the backgageinstalled the following fields may appear:

X-AXIS ENABLER-AXIS ENABLEZ-AXIS ENABLE

PROGRAM:TEST001

STATUS: Select function using the softkeys.

CONFIGURATION (1)* LANGUAGE* UNITS* FRACTIONAL ANGLES* FILLER BLOCK HEIGHT MAX FORMING SPEED BED CROWN DIMENSIONS X-axis max X-axis min R-axis max R-axis min ZL-axis max ZL-axis min ZR-axis max ZR-axis min FRONT max FRONT min* X-AXIS ENABLE* FRONT-AXIS ENABLE

ConfigPage 2

EditTonnageCal

ServiceCode

ChangeLanguage

ChangeUnits

EnglishEnglishTenths

0.010

MAX RAM UP SPEED MAX RAM DOWN SPEED MAX STROKE LENGTH CLOSED HEIGHT TONNAGE CAPACITY NOMINAL LENGTH GAGE BAR INSTALLED Maximum Hor. bar skew Maximum Vert. bar skew Left-right pivot dim Bar-pivot dimension Z left-right minimum* R-AXIS ENABLE* Z-AXIS ENABLE

INCHES, INCHES/MIN., TONS

SERVICE ACCESS DENIED

6 AUG 8912:00 PM

ChangeDate

ChangeFract.Angles

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

Maint Msgs – Pg 2

Maintenance Time Intervals

Cylinder Head Clevis Pins Ram Guides Autocrown Hydraulic Oil

Air Filter/Breather Gage Ball Screws Gage Guides and Screws Gage Grease Carriage Vee Track

Time of Day to Report Maintenance

ManageData

SetHoursOn

ChangeReportTime

Item 2Done

Item 3Done

SetStrokeCount

6 AUG 8912:00 PM

ViewMaintMsgs

M

30 days 30 30 1

2000 Main Drive On hours 200 600 200

08:00

7-48

If a frontgage is installed, the following will appear:

FRONT AXIS ENABLE

Each of these fields can be 1 = ON or 0 = OFF. If agage is OFF, the control will not attempt to move itif a programmed value has been entered.

Page 2 of the MACHINE CONFIGURATION MENUcan be obtained by pressing the "Config Page 2"softkey. Additional machine constants which thecustomer cannot change are shown. Also shownare the memory kit serial numbers and releasedates. If upgrades are installed, the serial numberand release date will be shown on this page. Shownbelow is a typical page 2 screen.

Configuration Data Page 3 shows the optionsinstalled in the machine. The Configuration DataPage 3 is accessible using the softkey on Configu-ration Data Page 2.

A sample of the Configuration Page 3 is shownbelow.

The softkey labeled "Linear Comp" displays the fol-lowing screen. This can be used to make minor posi-tion corrections to the backgage ballscrew. The cus-tomer cannot alter any information on this screen.

DIAGNOSTICSA series of diagnostics are provided to help trou-bleshoot or set-up the control. All diagnostics areaccessed through the DIAGNOSTICS MENU. Pressthe "Diagnostics" softkey on page 2 of the MAINMENU to display the DIAGNOSTICS MENU. A briefdescription of each diagnostic follows.

MEMORY DIAGNOSTICS

CPU RAM test - Tests the random access memoryon the CPU 030 board and displays a pass/failindication.

CRC (Cyclic Redundancy Check) TEST - Performsa CRC test on the AUTOFORM Control's inter-nal software. CRCs that do not match thestored CRC will be displayed in red.

Editing: MAINSET-UP: Test1 D I A G N O S T I C S

STATUS:

Memory Display FileSystem

Input /Output

01 Sept 9201:30 PM

M E M O R Y

D I S P L A Y C O N T R O L L E R

I N P U T / O U T P U T

F I L E S Y S T E M

S Y S T E M E R R O R S

S T R O K E D I A G N O S T I C S

F A U L T H I S T O R Y

L O A D / U P D A T E A P P L I C A T I O N

T E R M I N A L M O D E

SystemErrors

StrokeDiag-nostics

FaultHistory

Load/UpdateApplic

TerminalMode

PROGRAM:TEST001 LINEAR COMPENSATION

ConfigPage 2

SaveChanges

SERVICE ACCESS DENIED

CORRECTION POINTSPROG. POS. ERROR

1 0.1000 +0.0000 2 3.0000 +0.0000 3 7.5000 –0.0000 4 13.0000 –0.0000 5 17.0000 +0.0000 6 24.0000 +0.0000 7 8 910

AXIS X left UNCOMPENSATED MOVES . . . OFF

SelectAxis

Uncomp-ensatedmoves

ConfigPage 1

10 20 30 40 50

50

30

10

-10

-30

-50

6 AUG 8912:00 PM

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

CONFIGURATION (3)

Software Options Installed:

Heavy-Duty BackgageTaper Backgage CapabilityFrontgagePart Orientation GuideAutoform GraphicsAdaptive FormingLight Guard InterfaceStandard AutocrownProgrammable FootswitchProgrammable Outputs

ConfigPage 1

ConfigPage 1

6 AUG 8912:00 PM

LinearComp

PROGRAM:TEST001

STATUS: Select function using the softkeys.

CONFIGURATION (2)ENCODER

RAMXRZ

FRONT

ConfigPage 3

ConfigPage 1

PULSES/INCH10,000.001,000.00

2000 OR 1778.00200.000

1,000.000

TRANSDUCER COEF. LHTRANSDUCER COEF. RHOVERALL DIE SURFACE

SERVICE ACCESS DENIED

Deflection Coefficients A1 A2 A3 A4

Master Memory Kit #Slave Memory Kit #Boot Rom Version Wed, Jul 29, 1992 2:48:07 PMFPGA version Mon Jul 20 16:21:16 1992

-39.026350.094870.00091

-8.79308

6 AUG 8912:00 PM

LinearComp

7-49

MMU TEST - Verifies that RAM pages, write pro-tected by the Memory Management Unit, can-not be written to by the CPU.

DISPLAY CONTROLLER TESTSSELF TEST - This softkey brings up another menu

of tests:

VRAM test - Tests the video RAM.

ROM test - Performs a checksum test on the EPROMs.

RAM test - Tests the CPU RAM.

ACRTC test - Tests the drawing processor IC.

Cable test - displays four colored sections onthe CRT. Each section is labeled to indicate thecolor. If the displayed color does not match thelabel, then the CRT cable is not connectedproperly. If the green cable is not connected,nothing will be displayed as the composite syncsignals are carried on the green video cable.

Crosshatch test - Used to align the CRT.

Dots test - Used to align the CRT.

Color bars - Used to tune colors on the CRT.

INPUT / OUTPUT TESTSSerial Port Test - This diagnostic allows each RS-

232/422 port to be functionally tested.

At the selected port (on CPU 030 board), thetransmit minus and receive minus lines (pins 3and 4) must be jumpered together and the sig-nal common and receive + lines (pins 5 and 6)must be jumpered together.

When the test is started, a string of characterswill be sent out the selected port. The selectedport watches for that same string of charactersto return.

If the transmitted string of characters isreceived, a successful test is reported. If thetransmitted string of characters is not received,a failed test is reported.

This RS-232/422 Port Diagnostic allows theuser to select which port to test. It also promptsthe user to jumper pins 3 and 4 together andpins 5 and 6 together at the selected port. Thetest results will appear on the screen.

I/O Monitor - This screen allows the operator toview the status of all machine inputs and out-puts which are interfaced to discreet devicesthrough the I/O controller board(s) in the VMEcard cage. If more than one I/O board isinstalled, a separate screen is used to displaythe status for each board. There will be a soft-key at the bottom of the display for each I/Oboard present. To monitor a different board'sI/O status, press the corresponding softkey.

The I/O monitor screen contains two tables,one with 32 inputs and one with 32 outputs.The tables display the current state of each I/O,as seen by the software, and also help identifythe I/O circuits by listing the correspondingLED and screw terminal numbers on the inputand output driver boards.

The large numbers which form the top and lefttable margins are LED numbers. Adding anumber from the left margin to one from the topgives a value equal to one of the numberssilkscreened next to the LED's on the driverboards. The smaller numbers in the center ofthe table correspond to the numbers on thescrew terminal strip to which the I/O wires areconnected. The terminal numbers are backlitaccording to the current state of the associatedI/O circuit as follows.

BACKGROUND INDICATIONCOLOR

Inputs:Green ON (24 volts), no errorBlack OFF (0 volts), no error

Outputs:Green ON (0 volts), no errorBlack OFF (24 volts), no errorRed OFF, error - output should be

OFF, but is actually ONYellow ON, error - output should be

ON, but is actually OFF

Keypad test - Displays a representation of the key-pad/legend plate. Each key and selector switchon front of the pendant can be tested.

Switch test - Displays a representation of thekeyswitches on the side of the pendant. Eachswitch can be tested.

Manual Test of Outputs - The purpose of this diag-nostic is to allow CINCINNATI INCORPORATEDService personnel to turn off all outputs, thenfire only specific outputs for the desired amountof time. The Service Access code must beentered correctly to gain access to the OUTPUTDIAGNOSTIC screen.

9 –

8 –

7 –

6 –

– 5

– 4

– 3

– 2

– 1

7-50

The OUTPUT DIAGNOSTIC screen, under theDIAGNOSTIC MENU, allows the selection ofwhich outputs to turn on. Choices include any ofthe outputs on the output interface boards (digi-tal), and the left and right servo valves (analog).The digital outputs may only be programmed ONor OFF, but the analog outputs may be pro-grammed to turn ON at any percentage from 0 to100. The control watches for the right palmbuttonstation to be pressed. The user may also enter amaximum tonnage limit which, if exceeded, willcause the control to cease all ram motion andturn OFF the selected outputs (as if palmbuttonswere released). An error message is displayedexplaining why the outputs were turned OFF.

The OUTPUT DIAGNOSTIC screens may be edit-ed to select which outputs to turn on. While thepalmbuttons are pressed, those outputs selectedare turned on. The ram tilt limit switches aremonitored while the selected outputs are turnedon, and if either of the switches are tripped, theoutputs are shut off (as if the palmbuttons werereleased). An error message is displayed explain-ing why the outputs were turned off. When exit-ing the OUTPUT DIAGNOSTIC, all outputs willreturn to their previously saved state.

Pressing the palmbuttons will cause the selectedoutputs to turn ON. They will stay ON as long asthe palmbuttons are held down. These outputsmay be any of the outputs on the output inter-face board (digital) and the left and right servovalves (analog).

In the OUTPUT DIAGNOSTIC MENU, there is ascreen for each output interface board present,plus a screen for the servo valves. Each outputhas a label that may be edited. The digital out-puts may be programmed ON or OFF. The ana-log outputs may be programmed to any percent-age between 0 and 100. The screens look likethose shown.

FILE SYSTEMFile System Repair - This tests the contents of the

96K bytes of file system NOV RAM for validinformation. It will remove any corrupt files andrepair any memory segments that have illegalcharacters. This test is performed automatical-ly every time the control powers-up or resets.

Task Stack Check - Tests for Stack overrunsamong the many system tasks.

SYSTEM ERRORS

The above screen accounts for any fatal errors thatoccur during the course of operating the control.This screen may be reached by pressing the "Sys-tem Errors" softkey in the DIAGNOSTIC MENU.

Note: If any of the error counts are non-zero, theSYSTEM ERRORS screen will appear everytime the control is powered-up until clearedby a CINCINNATI INCORPORATED ServiceRepresentative.

SET-UP #ABC123 S Y S T E M E R R O R S

STATUS: Select function using the softkeys.

This diagnostic menu indicates whether any fatal softwareerrors have occurred. These errors should never occur, butif they do, they should be reported to CINCINNATI INCORPORATEDListed below is a count of the number of times each system errorhas occured as well as the pertinent data corresponding to thelast occurrence of each system error. If any of the numbers listedin the column marked 'COUNT' are non-zero, please contact CIService Representative.

Diag-nosticMenu

Clear-Faults

Priv-Violatn

DumpDataRemote

DumpDataDisk

AddrError

ForceFault

EnterServiceCode

ERROR TYPE

Bus ErrorAddress ErrorIllegal InstructionZero DividePrivilege ViolationOthers

COUNT

000000

TASK ID

000000

PROGRAM COUNTER

000000000000000000000000000000000000000000000000

Service Access: denied

PageTwo

Editing: MAINSET-UP: Test1 O U T P U T D I A G N O S T I C

STATUS: Select a function using the softkeys.

EditOutputs

EditLabels

FileSystem

EditTonnage

01 Sept 8801:30 PM

Analog Board

SystemErrors

OutputsReady

Valve 16 3 4

% Off 20 20

LabelRam Up LtsRight Servo ValveLeft Servo Valve

OutputBoard

Diag-nosticMenu

Maximum Tonnage Allowed (%) : 10

Editing: MAINSET-UP: Test1 O U T P U T D I A G N O S T I C

STATUS: Select a function using the softkeys.

EditOutputs

EditLabels

FileSystem

ClearOutputs

01 Sept 8801:30 PM

Output Board 1

SystemErrors

OutputsReady

Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Setting Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off

LabelR Dump ValveL Dump ValvePilot ValveL & R Load SenseClamp PresUp UnclmpLow UnclmpAutocrownProg Out 1Prog Out 2Prog Out 3Prog Out 4Prog Out 5Prog Out 6Prog Out 7Prog Out 8

Output 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Setting Off Off Off Off Off Off On On Off Off Off Off Off Off Off Off

LabelRam Up LtsRam Dn LtsR Op St Off LtR Op St On LtR Fts St Off LtR Fts St On LtOp Cntl - 3CRMain Drv - 1CRL Op St Off LtL Op St On LtPres Sens On LtLt Guard TransPres Sens Off LtL Fts St Off LtL Fts St On LtOil Cooler

AnalogOutputs

Diag-nosticMenu

7-51

In addition to accounting for errors, if the ServiceAccess code is entered, the screen above will allowthe error counts to be cleared and various types oferrors to be induced for diagnostic purposes.

The "Dump Data" softkeys are used to send systemerror data to the RS-232/422 port (remote) or to adisk. If the RS-232/422 port is selected, the datathat is currently being displayed will be sent out theDiagnostic RS-232/422 Port. If a disk is selected,the control will ask for a file name to store the dataunder. The data will then be written to the disk.

Data saved to a disk will be stored under the filename selected. Data to be printed will be sent outPort 1, the Diagnostics Port.

A floppy disk will be needed to store the data or anRS-232/422 printer or a terminal, set at 9600baud, will be needed to print the data.

Pressing the "Page Two" softkey will cause the sec-ond page of the SYSTEM ERRORS screen to appear.This also provides more detailed information aboutthe state of the operating system and the CPU, aswell as access to the data at any memory locationand the current state of the task stacks.

The following screen shows the second page of theSYSTEM ERRORS screen.

On the left side of the screen, information about thestate of MTOS (internal operating system) and thestate of the CPU immediately after a fault willappear. The information will be replaced each timea fault occurs. Also, when the "Clear Faults" softkeyis pressed in the SYSTEM ERRORS screen, thisinformation will reset to zero.

The right side of the screen contains a data windowthat allows the contents of any memory location to

be displayed. The "Change Base Address" softkeyallows a new starting address (the first line of thewindow) to be displayed.

Note: If an odd address is entered, it will be rounded tothe nearest word boundary; an invalid address willcause a bus error to occur.

The "Display Task Stacks" softkey will cause theinformation in the various MTOS stacks to be dis-played. The display will scroll to the next stack eachtime the softkey is pressed in a "round-robin" sortof fashion. To scroll up or down one screen of infor-mation, use the UP and DOWN field keys.

The main SYSTEM ERRORS screen will re-appearwhen the "Page One" softkey is pressed.

If a fatal error occurs, the main drive will shut-offand the screen will show the type of error, the num-ber of times the error has occurred, the number ofthe task that caused the error and the approximateaddress in the program where the fault occurred.

STROKE DIAGNOSTICS

When the Stroke Diagnostic is turned ON, thedesired and actual ram positions for each side aresaved and displayed for the last ten steps. Theactual ram positions for each side, along with atime stamp and the command voltage to each side,may be saved for up to 1024 points sampled at 3milliseconds. This data may be dumped out the RS-232/422 port.

FAULT HISTORY

The purpose of this diagnostic is to keep track ofthe time and date of the last 50 error messages.

The time, date and message for the last 50 errors isdisplayed on a screen in the DIAGNOSTIC MENU.

SET-UP #ABC123 S Y S T E M E R R O R S

STATUS: A FATAL ERROR HAS OCCURED! Use softkeys to reset or examine

This diagnostic menu indicates whether any fatal softwareerrors have occurred. These errors should never occur, butif they do, they should be reported to CINCINNATI INCORPORATEDListed below is a count of the number of times each system errorhas occured as well as the pertinent data corresponding to thelast occurrence of each system error. If any of the numbers listedin the column marked 'COUNT' are non-zero, please contact CIService Representative.

ExamineData

ResetControl

ERROR TYPE

Bus ErrorAddress ErrorIllegal InstructionZero DividePrivilege ViolationOthers

COUNT

000000

TASK ID

000000

PROGRAM COUNTER

000000000E2B400000000000000000000000000000000000

Service Access: denied

SET-UP #ABC123 S Y S T E M E R R O R S

STATUS: Select function using the softkeys.

Diag-nosticMenu

Clear-Faults

DumpDataRemote

DumpDataDisk

DisplaySlaveData

DisplayTaskStacks

ChangeBaseAddress

EnterServiceCode

PageOne

M

: 0: 0: 0000: 0M

: 0000: 00000000: 0000: 0000: 00000000: 0000: 0000: 0000

: 0: 00000000

MTOS TASK DATA

Fault TypeCode FaultException VectorTask ID Number

MC68010 STACK FRAME

Status RegisterProgram CounterVector OffsetSpecial StatusWDFault AddressData OUTPUT bufferData INPUT bufferInstr. INPUT buffer

Tstack OverflowUser Stack Pointer

ADDRESS

00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 < use field keys to scroll up or down >

HEX DATA KEYSTK = 00000000

0000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 00000000 0000 0000 0000 0000

7-52

Press the softkey labeled "Fault History" to view themessages. The UP and DOWN field keys can beused to scroll through the list. The HOME key willalways display the first message in the list. Notethat error messages appear in reverse order withthe first message being the newest error whichoccurred.

LOAD/UPDATE APPLICATION

The presence of the floppy disk drive to the AUTO-FORM control allows the system software to beupdated via floppy disk. It also presents the capa-bility of loading special purpose software into thecontrol for special diagnostics, help menus or train-ing aids, or even demonstration software. The con-trol now takes on some of the traits of a computersystem in which the software loaded into memorydefines what the system does. The user will accessthis function, called "Load/Update Application",under the DIAGNOSTIC MENU.

The user must select this function to load softwarefrom a floppy disk. A floppy disk is also requiredwhich contains a valid bootable file. The user, ifrunning a special application program, will alsoneed to have access to a floppy disk containing theAUTOFORM control software which can bereloaded after the special application program hasbeen run. Before the floppy disk software is loaded,the user can input a command to the control toabort the load sequence.

Once the user has confirmed the software loadsequence, the disk drive is checked to ensure thata floppy is in place and that it contains a valid bootfile. If all checks are correct, the software will beloaded and run. If the software is a special applica-tion program and it terminates, the control willbegin executing the reset software, which will thenprompt the user for the AUTOFORM software onfloppy disk to reload it.

When the user selects this function, a warningmessage will be displayed along with a "Continue"softkey and "Abort" softkey. The following screenwill be displayed.

TERMINAL MODE

The purpose of this diagnostic is to simulate theoperation of a Display Terminal using the pendantCRT and keyboard. Terminal Mode can be used,with the proper connections, to access a remotecomputer or to run diagnostics.

Inputs may come from any of the three RS-232/422serial ports (1 - 3) on the VMEII CPU card (includ-ing the I/O daughter board). All keys pressed on thependant will be output on the designated serial port.

The control softkeys will be assigned the characters:

The “Shift” key will toggle the case between upperand lower. The control key will cause the next char-acter typed to be a control character. The ESC keywill interpret the next two characters typed as aHEX value. The rest of the softkeys will be inter-preted as the characters assigned to them. The "etc"softkey is used to change the softkeys to the vari-ous special characters as shown above.

The "Main Menu" key will clear the screen andreturn to the MAIN MENU.

{ } [ ] ( ) < > etc

% @ colon semi- colon

# | ^ ~ etc

= comma doublequote

` singlequote

! & $ etc

Shift CNTRL n ESC nn \ / * ? – etc

SET-UP #ABC123 L O A D / U P D AT E A P P L I C AT I O N

STATUS: Make a selection using the softkeys.

If the "Continue" softkey is pressed, the machinesoftware may be updated or an application program willbe loaded from the floppy diskette and executed.

CAUTION ! The floppy diskette containing the machineprogram may be required to restore machine operationif special application software is being loaded.

AbortContinue

Editing: MAINSET-UP: Test1 F A U LT H I S T O R Y

STATUS: Select a function using the softkeys.

EditOutputs

EditLabels

FileSystem

EditTonnage

01 Sept 8801:30 PM

1 Right zero pulse error Dec 14 91 08:30

2 Right zero pulse error Dec 14 91 08:20

3 RAM is out of tilt Dec 14 91 08:08

4 Gage is not calibrated ! ! ! Dec 13 91 15:31

5 RAM is not calibrated ! ! ! Dec 13 91 15:31

SystemErrors

OutputsReady

OutputBoard

Diag-nosticMenu

< < use field keys to scroll up or down > >

7-53

Characters processed as described above and anyother characters from the keypad will be passed tothe selected output port. Input from the specifiedinput port will be output to the selected outputport. Input from the specified input port will also beoutput to the Matrox (display controller) card fordisplay to the user.

When entering the command to start TerminalMode, the port and baud rate to use may be select-ed. It will default to the Gage Port (port 3) and 9600baud. Once the terminal mode is started, thescreen will clear, a command prompt will be givenand the following softkeys will appear:

The Main Menu button will clear the screen andreturn with just the command prompt.

STATUS AND DIAGNOSTIC LEDs

The following section describes the function of theLED indicators on the CPU 030, Matrox and DualPort CPU boards of the AUTOFORM Control elec-tronics.

CPU 030 LED Functions:

Load LED - Indicates the field programmable gatearrays are loading information.

Fail LED - Indicates the VME signal SYSFAIL isasserted.

Halt LED - Indicates the 030 CPU is halted.

Reset LED - Indicates reset is asserted.

STATUS DISPLAY FUNCTIONS

LED STATUS DISPLAY:

The following codes may be displayed when themachine is turned "on". Error codes will only bedisplayed if there is an error.

bnnnn Number of Kbytes of non-volatile SRAMthat tested successfully during self-test.

c Running EPROM checksum test.

C Running CRC test.

Cnnn Cancelled self-test number nnn (test wasde-configured).

dn Insert system disk #n and push test switchup.

Ecnn Exception code. An unexpected exceptionhas occurred - nn indicates the vectornumber. Example: E.c.0.2 indicate a BusError exception has occurred.

Enn General Error, nn = error number. Exam-ple: E.0.9 indicate no disk in drive.

Fnnn Failed Self-test, nnn = test number. Exam-ple: F.1.6.7 indicates the fiber optic looptest failed on the Dual Port CPU board

L Loading File from disk.

P Passed Self-test.

U Loading Utility File from disk.

Vector Numbers:

00 Initial Stack Pointer01 Initial Program Counter02 Bus Error03 Address Error04 Illegal Instruction05 Zero Divide06 CHK,CHK2 Instructions07 TRAPcc and TRAPV Instructions08 Privilege Violation09 Trace10 Line 1010 Emulator11 Line 1111 Emulator12 Unassigned, Reserved13 Co-processor Protocol Violation14 Format Error15 Uninitialized Interrupt24 Spurious Interrupt48 FPCP Branch or Set on Unordered Condition49 FPCP Inexact Result50 FPCP Divide by Zero51 FPCP Underflow52 FPCP Operand Error53 FPCP Overflow54 FPCP Signaling NAN55 FPCP Unassigned, Reserved56 MMU Configuration Error

GENERAL ERROR CODES

Note: The decimal point will be flashed betweendigits as a separator.

E01 Error when sending command to floppydisk controller

E02 Timed out waiting for FDC to be readyE03 Improper number of result registers readE04 Invalid command status from FDCE05 CRC error when reading diskE06 No data found when reading diskE07 Data overrun-up not there in timeE08 File name not found on diskE09 No disk in driveE10 Memory map not compatibleE11 CRC error when checking systemE12 Ready changed state (see 8743 data sheet)

Shift CNTRL n ESC nn \ / ? " ' ;

7-54

E13 End of track errorE14 No address markE15 Tried to read deleted dataE16 Desired sector not foundE17 Abnormal command terminationE18 Track zero failed to occur after recalibration

Matrox LED Functions:

1 Red LED - Heartbeat - the LED blinks on andoff to indicate the board is functioning.

2 Red LED - Data Out Register Full - indicatesthere is more than one byte of data in the DataOut Register. The VG640 will cease processinguntil this data is read.

3 Red LED - Input Data FIFO Empty - indicatesthe Input Data FIFO is empty and the board iswaiting for input. Due to a bug in the VG640firmware this LED is not always on when theVG640 is idle.

4 Red LED - Error Register Full - indicates thereis more than one byte of error data in the DataOut Register. The VG640 will cease processinguntil this data is read.

Dual Port CPU LED Functions:

Run - Top Green LED - Indicates reset is notasserted.

Halt - Top Red LED - Indicates the 010 CPU ishalted.

Pass - Bottom Green LED - Off during Reset.Turned on by software and indicates the CPUmade it at least through the operating systeminit section.

Fail - Bottom Red LED - Complement of the Bot-tom Green LED. (On during Reset etc.)

NORMAL LED STATUS

CPU 030

Load LED - Off

Fail LED - Off

Halt LED - Off

Reset LED - Off

Led Status Display - Circular heartbeat display

Note: Any of the single red LEDs on or a stopped heartbeat STATUS display indicates a problem.

Matrox

LED1 (heart beat) flashing.LED2 off.LED3 may be on or off.LED4 off.

Note: LED1 not flashing indicates a hardware orfirmware problem on the Matrox board. LED2 orLED4 on could indicate either a Matrox or ForceCPU software problem.

Dual Port CPU

Both Green LEDs on.Both Red LEDs off.

Note: Either Red LEDs on indicates a Dual Port CPUproblem.

I/O Board

Green Run LED on.

SELF-TEST (CPU030 Board)

The self-test procedure will be activated if the USERswitch (top switch on the CPU030 board) is helddown while the RESET switch (bottom) is pressedup, then released. At the beginning of each test, theleast significant digit of the test number will beflashed on the seven segment LED. The decimalpoint will also be displayed for test numbers in theranges of 10-19, 30-39, 50-59, etc. At the first fail-ure, the letter "F" and the failed test number will berotated continually on the LED display. The decimalpoint will be flashed between digits as a separator.To resume testing at the next test, the USER switchmay be pressed down momentarily. If all of the testscomplete, without failure, then a "P" will be pre-sented on the LED. If any of the tests fail (and test-ing is resumed) the LED display will be blankedwhen all of the tests have been performed. Pressingthe USER switch up, after the self-tests are finished,will display all of the tests that were cancelled asindicated by the letter "C".

Failure of Test 0-6 or 8-13 is usually fatal and willrequire replacement of the CPU, Memory Daughteror I/O Daughter board, or all three boards. Test 7,voltage check failures, should be verified with amulti-meter, and if the voltage is within tolerance,can be ignored. Tests 14-17 deal with other VMEboards in the card cage and provide information forfurther action.

In order of execution:

0. SRAM Board Non-destructive RAM test001) Address line test002) Data line test003) Long work test004) Word test005) Byte test

1. VIC VME Interface Chip test011) All VIC registers did not compare against

default values

2. EEPROM021) Access test - failure occurred during read

of complete range.022) Write test.023) Write protection test024) Boot Rom code CRC025) FPGA code CRC test

7-55

3. SCC - Serial Controller Chip031) Polled mode loop back test on port A032) Polled mode loop back test on port B033) Interrupt test034) Timeout waiting for SCC chip035) Interrupt received before enabled

4. FPGA - Field Programmable Gate Array041) FPGA #1 Data read back test042) FPGA #2 Data read back test

5. PIT - Peripheral Interface / Timer051) Timer interrupt counter not within

tolerance052) Premature interrupt

6. RTC - DS1284 Real time clock and watch dogtimer061) Watch dog timer interrupt failure062) Watchdog timer/counter not within time

tolerance063) Timed out waiting for RTC chip

7. Power supply and temperature check071) Temperature check,

Pass if measured temp is 60 - 80° F (16 -27° C).

Go No-go checks on power supply levels072) 5V073) 15V074) 24V075) Battery076) Ana5V077) -5078) -15

8. Floating point co-processor081) Existence test082) Minimal functional test

9. On board dual port RAM091) Read and write to full range test092) Data line test093) Address line test

OFF-BOARD TESTS

10. EPROM board101) test for existence - warn if no EPROMS

found.102) Position Check EPROM #1103) Position Check EPROM #2104) Position Check EPROM #3105) Position Check EPROM #4106) Checksum test. EPROM #1107) Checksum test. EPROM #2108) Checksum test. EPROM #3109) Checksum test. EPROM #4

11. SCC on I/O daughter board111) Polled mode loop back test on port A112) Polled mode loop back test on port B113) Timeout waiting for SCC chip114) Interrupt test

12. Floppy Disk controller chip on I/O daughterboard121) Invalid command status not set when

invalid command sent122) Interrupt test123) Timed out waiting for FDC

13. SCSI Port

14. Matrox Graphics Card141) Buss error existence check142) ROM test143) RAM test144) VRAM test145) ARTC test146) Display screen test147) Uninitialized interrupt148) Timeout during matrox self-test149) Spurious Interrupt - Occurs when the

Matrox board asserts the interrupt requestline but is not acknowledged. Usuallycaused by a missing jumper between the030 CPU board and the Matrox board.

15. I/O Board Existence Test151) Board #1 - An F143 Matrox failure code fol-

lowed by an F151 can be caused by incor-rect I/O board address switch settings.

152) Board #2153) Board #3154) Board #4155) Board #5156) Board #6

16. Dual Port CPU161) Buss error existence check162) EEPROM CRC test163) Local RAM test164) Dual port RAM test165) System timer test166) Serial I/O -Watchdog167) Fiber optic loop test168) Illegal Dual Port CPU error code169) Timeout

17. Additional Dual Port CPU Tests171) Analog board test172) I/O board output test

SUMMARYThe diagnostics do not test all aspects of eachboard, so it is possible for the STATUS LED to dis-play a “P” and there still be problems. Also, static,thermal or noisy power supply problems will not bedetected unless the problem occurs while the diag-nostics are running.

7-56

FILE MENUThe FILE MENU is shown below. It contains foursub-menus: FILE TRANSFER, FILE UTILITY, FILEPREFERENCES and COMMUNICATION SET-UP.

FILE TRANSFER MENU

The FILE TRANSFER MENU will perform all typesof transfers. See the AUTOFORM File System Orga-nization diagram, Figure 7-18, for the possibleoperations which may be performed. This menuallows the operator to view the directories of theinternal memory or the local drive volumes by filetype and uses a source / destination analogy toindicate file copy direction.

FILE TRANSFER: SELECTING SOURCE / DESTINA-TION VOLUME

The following screen shows the layout of the FILETRANSFER sub-menu. The screen is divided into twoareas with the SOURCE Volume information on theleft and DESTINATION Volume information on theright. All operations will take place on the Active Vol-ume. The Active volume label (SOURCE or DESTINA-TION) is highlighted in blue. To make the SOURCEvolume active, press the Left Field key, and to makethe DESTINATION volume active, press the RightField key. At the top of the screen, File Type andSearch Format displayed affects both volumes. Vol-ume name, Bytes Free, Path, and directory listing isdisplayed for both SOURCE and DESTINATION.

Note: The Source and Destination Volumes should notbe the same. It would not make sense to copyfiles back on to themselves. An error messagewill be displayed if the user proceeds with aCopy Command to the same volume.

The first softkey labeled “Change File Type” whenpressed, will display softkeys for each possible filetype on the control: Program, Upper Tool, LowerTool, Part, Shape, Adaptive and Text. Selecting onechanges the File type listed at the top of the screento the desired selection. This results in a directorylisting of the type selected for both the source anddestination volumes. In the case of a local drive vol-ume, the actual pathname of where these files arestored will be displayed in the Path field. (The defaultpathname of where these files are stored is specifiedin the FILE PREFERENCES sub-menu.)

PROGRAM:TEST0001 F I L E M E N U

STATUS: Select a function using the softkeys.

File Transfer

File Utility

File Preferences

Communication Set-up

AbortFileTrans-fer

30 APRIL 9112:00 AM

FileUtility

FilePrefs

Comm.Set-up

7-57

INTERNALMEMORY

FILE SYSTEM

DATACARTRIDGE

FILE SYSTEM

ACTIVEMEMORY

PROGRAM, TOOL,PART, SHAPE,

ADAPTIVESTORAGE

DISKFILE SYSTEM

(REMOTERS-232/422)➛➛

➛➛ ➛

➛➛

➛

➛

➛

➛

➛

Disk System appearsidentical to the InternalMemory displays currentlyused. DOS compatibleDouble or High Densitydisk formats.

Each storage screen will be used to loadand store the specific file type to and fromeither internal memory or Disk. Disk StoragePath can be changed for each individualstorage menu. Screen will indicate bytesremaining for internal memory or Disk storage.Directory listing will show full 16 characterfilenames, even though they are stored as8.3 on the disk.

Data Cartridge still onlyallows bulk transfer ofinternal memory to andfrom cartridge. It is notpossible to transfer in-dividual files.

FILE TRANSFER MENUallows operator to transferfiles using a SOURCEDEST type designation.Choices include directtransfer from RS-232/422to disk or internal memoryand vice versa, internalmemory to disk and viceversa, displays directoryof disk or internal memory.Also uses wildcard charac-ters to select groups of files.

Uses existing 96K ofstorage for files.

FIGURE 7-18 – AUTOFORM File System Organization

When pressed, the “Change Volume” softkey willshow softkeys for each type of volume available.DRIVE B is an option and may not exist on everycontrol.

Pressing one of these will change the correspondingactive Source or Destination Volume type.

The next softkey labeled "Swap Source / Dest"switches the active Volume between the two sourceand destination windows. This allows the operatorto quickly change the direction in which files are tobe copied.

CHANGE PATH

Pressing the "Change Path" softkey will allow theuser to override the default path associated withthe File type and Volume in File Preferences. Thesoftkeys will change as shown below.

The Source/Destination area will display thenames of the sub-directories located in the currentpath. The status line will now prompt the user toenter a sequence number of the desired path. The“Up One Level” softkey will cause the current pathto go up one directory level (for example, from the"\PROGRAM" directory to the root directory “\”)and display the sub-directories located in the newdirectory. The “Enter by Name” softkey may also bepressed to allow the complete pathname to be typedby the user.

Once the pathname is entered or the "Abort" or"Done" softkeys are pressed, the FILE TRANSFERMENU will return, showing the directories of theSource and Destination volumes. Note that chang-

ing the path for a Volume in this screen does notaffect the pathnames shown in the FILE PREFER-ENCES MENU.

If you are going to copy files from the selected pathto the destination volume, first make sure the filetype corresponds to the path you have selected. Ifnot, the error message, "File Data Corrupt, Bad FileType", will occur and the copy function will abort.As a rule, always set the file type first, then changepath to the desired directory.

If the pathname is changed to a path that does notexist, an error message "File or Directory NotFound!", will be displayed. If an indexed file formatis being used, the error message, "Unable to OpenIndex File", will be generated if the index file doesnot exist in the specified path. See the FILE UTILI-TY MENU section for more information on rebuild-ing an index file.

CHANGE SEARCH FORMAT

Change Search Format will change the directorylisting to allow specific files to be searched for onthe Volume and displayed. The default search pat-tern is * which means show all files. It is possible touse the ? wildcard character to only show files withthe desired characters. The "?" character repre-sents any single character. The following searchpattern could be entered.

PROG?1 - To list all files beginning with the lettersPROG followed by any single character and then a1. Any characters after the one are also consideredwild card characters. Examples of matching filesare PROG11, PROGX1, PROGX1AAA, etc.

????CINC - This would list all files beginning withany four characters followed by the letters CINCand any other characters after. Examples ofmatching files are AAAACINC, ZZZZCINC,ZZZZCINC111, etc.

Search patterns are used when there are a largenumber of files on the disk and it is not desired topage through them all using the field keys. It is pos-sible to select the full name of the file as the searchpattern causing only one file to be displayed in thedirectory.

Note: It is recommended that the Search Format be resetto * (show all files), especially if there are otheroperators that use the control.

SELECTING FILES

The next softkey, "Select Files", is used to selectwhich files in the active directory will be acted on bythe "Copy File" and "Delete File" softkeys.

EnterByName

UpOneLevel

FirstStep

LastStep

CopySteps

JobData

Done GageData

Abort

InternalStorage

LocalDrive A

LocalDrive B F-AXIS Remote

QuickBend

Set-upMode

ToolingLibrary Abort

PROGRAM:PROG1 F I L E T R A N S F E R

STATUS: Select a function using the softkeys.

Volume: Internal FREE: 48238

PATH:

SEQ NAME DATE

1 PROG1 28 APRIL91 10:09 2 PROG2 28 APRIL91 12:55 3 PROG3 28 APRIL91 13:39 4 PROGX 29 APRIL91 13:19

FileMenu

ChangeFileType

30 APRIL 9112:00 AM

ChangeVolume

ChangePath

SwapSource/Dest

DeleteFile(s)

CopyFile(s)

SelectFile(s)

ChangeSearchFormat

SOURCE Filetype: PROGRAM SEARCH FORMAT: * DESTINATION

Volume: LOCAL DRIVE A FREE: 456k

PATH: \PROGRAM

SEQ NAME DATE

1 TSTPROG1 28 APRIL91 10:09 2 TSTPROG2 28 APRIL91 11:05 3 TSTPROG3 28 APRIL91 01:05

7-58

After pressing the "Select Files" softkey, the follow-ing softkeys will appear.

When one of these softkeys is pressed, the resultwill be to highlight one or more files as listed in theactive directory. A file is highlighted by turning on(yellow) the small block directly to the right of thesequence number for the file.

The "Select All" softkey will select all of the files inthe Active Directory which correspond to the cur-rent search pattern. This will highlight all of thefiles in the window and print the message>>>>>>ALL FILES SELECTED<<<<<< at the bot-tom of the window.

The "Select Page" softkey will select only those filesdisplayed on the screen, fifteen at a time.

The “Select Single” softkey allows the user to scrollthrough the directory using the field keys andselect individual files by pressing the “Toggle SelectStatus” softkey. Use the field keys to change pagesand the up and down cursor keys to position ineach page. The small square cursor will move upand down to indicate the current position on thepage. As each file is selected, it will be highlighted.Pressing the “Toggle Select Status” when the cursoris at the position of a highlighted filename will un-select the file.

It is possible using the SELECT PAGE and SELECTSINGLE functions to highlight up to 45 files. If theoperator attempts to select any more, an error mes-sage will be displayed.

The "Un-Select ALL" softkey will clear all previousselections made.

When the “Swap Source/Dest” softkey is pressed,file selection information will follow the directory.When the SOURCE Volume is REMOTE (OfflineCommunications), it is not possible to select files byany other method than by NAME because the direc-tory for a REMOTE device is not available to thecontrol. Up to 15 filenames may be specified. Todelete a name from the list, press the “Un-Select bySeq” softkey and then enter the sequence number.To erase the entire list, press the “Delete AllNames” softkey.

It is not possible to select files in the Destinationwhen the Volume is REMOTE.

COPYING FILES

The "Copy Files" softkey, when pressed, will copy allselected files in the SOURCE Volume and PATH tothe DESTINATION Volume and PATH. It is only pos-sible to copy files from the SOURCE to the DESTI-NATION. The actual transfer process which willtake place depends on the type of Volume. If one ofthe volumes is the REMOTE, then Kermit will beinvoked to transfer the files. If the volume is strict-ly disk or memory, then the files will be transferreddirectly.

When the "Copy Files" softkey is pressed, the statusline and softkeys will change as shown below.

STATUS: Select options if file already existson Destination Volume.

During the copy process, if the file already exists onthe Destination Volume, the softkey selected abovewill determine whether to overwrite the file withoutwarning, or to abort the copy process. Using the"No OverWrite" option protects files on the Destina-tion Volume from being replaced by files on theSource Volume with the same name. If a file on theDestination Volume is found with the same nameas a Source Volume file, an error message will bedisplayed. If this occurs, review the files selected forcopy and determine if they should replace those onthe Destination, if they should be renamed, or ifthey were selected in error.

ERROR: File exists in memory. Requestedfile not saved!

If you are copying a file to internal or remote whichdoes not match the current file type indicated, thefollowing error will occur:

ERROR: File Data Corrupt, Bad File Type

To avoid confusion, it is recommended that you donot mix files of different file types in the same diskdirectory.

RECEIVING FILE FROM THE REMOTE SYSTEM

To receive a file from the remote computer, set theSource Volume to REMOTE and the DestinationVolume to INTERNAL. Press the “Select Files” soft-key. Press the “Select by Name” softkey and enterthe name of the file to be received. Up to 15 filesmay be received at once by repetitively enteringadditional names. To delete a name from the list,press the “Un-Select by Seq” softkey, then enter thesequence number. To erase the entire list, press the“Delete All Names” softkey.

Over-WriteFile(s)

NoOver-Write

Z-AXIS F-AXISAllAxes

QuickBend

Set-upMode

ToolingLibrary Abort

SelectAll

SelectPage

SelectSingle

Un-SelectAll

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

7-59

The filename specified may contain wildcard char-acters supported by the operating system runningon the remote computer. For example, if the remotecomputer is a DOS machine, entering the filenamePROG* would specify all files beginning with PROGto be copied to the control and if *.* is entered, allfiles in the directory on the remote computer wouldbe copied to the control.

When the "Copy" softkey is pressed, the control willbegin receiving the requested files.

SENDING A FILE TO THE REMOTE SYSTEM

Sending files is done by selecting the destinationvolume as REMOTE. The files to be sent to theremote computer will be selected using the normalmethod of selecting files in the FILE TRANSFERscreen. Multiple files can be selected for batchtransfers. After the files have been selected, press-ing the “Copy Files” softkey will start the transferprocess.

To quickly switch back and forth between send andreceive, use the "Swap Source/Dest" softkey.

The command to change directories on the remotecomputer will be sent automatically before eachlocal file send/receive if "Remote Directory Change"is enabled in the COMMUNICATIONS SET-UPscreen. The individual directory names for each filetype are entered in the FILE PREFERENCESSCREEN.

DELETING FILES

The "Delete Files" softkey will delete the selectedfiles from either the SOURCE or DESTINATION Vol-ume, whichever is active at the time. It is not pos-sible to delete files from the REMOTE volume.

When deleting files the operator will be prompted,as shown below, for every file selected before delet-ing the file. This is a safety precaution to preventaccidentally deleting files.

STATUS: Deleting file <123456.789>, Do youwish to continue?

Note: If indexed files are being used, do not use DOS orchange the format to unsorted files to delete filesfrom the directory. Since the files were not deletedfrom the index, they will still be referenced as beingon the disk. It will be necessary to rebuild the indexfile in this case to obtain the proper directory list-ing. When using indexed file format, delete filesusing the control only.

FILE UTILITY MENU

The FILE UTILITY MENU, as shown in the followingscreen display, contains functions for managingdisks, making back-up copies of files and transfer-ring configuration files. It can be used to formatblank disks, rebuild an index file, create directorieson disks, back-up internal memory and copy themachine configuration files to local disk or remoteserver.

FORMATTING DISKS

The disk drives use DOS formatted, 3-1/2"diskettes. It can read and write both the 720k dou-ble density or 1.4 Meg high density formats. Thedisk may be formatted on an offline PC or they maybe directly formatted on the control itself.

Note: If the disk is formatted on an offline PC, it willbe necessary to create default directories. Ifthis is not completed, an error message willbe received.

To format a blank disk, first use the "Change DriveOptions" softkey to select which disk volume to for-mat if there is more than one installed. The softkeyswill change as shown below.

STATUS: Select Drive Volume using thesoftkeys.

After selecting the drive volume, the status line andsoftkeys will change as shown below.

STATUS: Select the type of disk to formatusing the softkeys.

HighDensity

LowDensity double

quote ` single

quote ! & $ etc

LocalDrive A

LocalDrive B ESC nn \ / * ? – etc

PROGRAM:TEST0001 F I L E U T I L I T Y

STATUS: Select a function using the softkeys.

Drive Volume: LOCAL DRIVE A

Disk Format: High Density

Current Path: \

OPERATION STATUS: WAITING

FileMenu

ChangeDriveOptions

30 APRIL 9112:00 AM

ChangePath

FormatLocalDisk

RebuildIndex

DeleteFile(s)

Back-up/RestoreInternal

Back-up/RestoreConfig

MakeNewDIR

DeleteFile

AfterCurrentStep

Top ofDie

GageData

RunMode

NextStep

PrevStep

EndEdit Abort

7-60

The FILE UTILITY screen will now display the cur-rent settings as selected. If these are correct, beginthe format by pressing the "Format Disk" softkey.The screen will now display a status message indi-cating to insert the blank disk in the drive.

The "Abort" softkey can be used to quit the formatoperation if it is not desired. Pressing the "Cont"softkey will begin the formatting process. The for-matting process is shown in the following screen.

Note: Once a format is started it must be completed.

If the format is unsuccessful, the appropriate errormessage will be displayed. If a disk is not found inthe drive specified, the OPERATION STATUS willindicate CANCELLED.

DIRECTORIES

Part of the formatting process involves creating thedefault directories as defined in the FILE PREFER-ENCES MENU. The control also creates the indexfiles in each of the directories required for the 16 or11 character filename cross reference.

Note: It is recommended that when using the indexedfile format, disks be formatted on the controlitself rather than an offline PC. This ensuresthat all default directories and index files arecreated properly. If a disk is formatted on anoffline PC, make sure the default directorieslisted in the FILE PREFERENCES screen arealso created on the disk.

The disk formatting process, including creating thedirectories and index files, takes about four min-utes for a high density disk, slightly less for a dou-ble density disk.

CHANGE PATH

This softkey allows the operator to enter the path-name of a particular directory on the local drive vol-

ume and functions identically to the “Change Path”softkey on the FILE TRANSFER screen. This path isthen used by either the Rebuild Index function orthe Make New Path function. The Current Path isdisplayed on top of the screen.

REBUILDING INDEX FILE

This function is only used whenever the 16 charac-ter or 11 character sorted file format is being used.If files have been copied to a disk using a PC withDOS, they will not be identified in a directory list-ing on the control because the index file has norecord of these files. Rebuilding the index file willdelete the existing index file on a disk and create anew one by scanning all files on the disk and gen-erating the index file. Thus any new files copied tothe disk will now be in the indexed directory.

This feature should also be used if, for some rea-son, a directory listing will not appear for a partic-ular disk, the index file is corrupt, or convertingexisting data disks from 11 character unsorted for-mat to one of the sorted formats.

The Rebuild Index function will only build the indexfile for the directory specified under the currentpath. Make sure the desired path is selected first byusing the Change Path command.

Note: The rebuild process is lengthy because theentire disk must be scanned. It is directlyrelated to the number of files contained in thedirectory on the disk. This process cannot beinterrupted without removing the disk fromthe drive. Therefore, before rebuilding anindex file, be prepared for the time it takes tocomplete. The larger the number of files in thedirectory, the longer it takes. (One hundredfiles will take approximately 3 - 5 minutes.)

After pressing this softkey, the screen will be dis-played as shown.

PROGRAM:TEST0001 F I L E U T I L I T Y

STATUS: Select a function using the softkeys.

Drive Volume: LOCAL DRIVE A

Disk Format: High Density

Current Path: \

OPERATION STATUS: WAITING REBUILDING DONE

AbortChangeDriveOptions

30 APRIL 9112:00 AM

ChangePath

FormatLocalDisk

ContinueDeleteFile(s)

Back-up/RestoreInternal

Back-up/RestoreConfig

MakeNewDIR

Insert Disk into Drive Unit and press the "Continue" softkey to beginrebuilding file index. Operation Status will indicate when rebuilding iscomplete and disk can be removed from drive. Operation cannot be cancelledonce it has started.

PROGRAM:TEST0001 F I L E U T I L I T Y

STATUS: Select a function using the softkeys.

Drive Volume: LOCAL DRIVE A

Disk Format: High Density

Current Path: \

OPERATION STATUS: WAITING FORMATTING CREATING DIRECTORIES DONE

AbortChangeDriveOptions

30 APRIL 9112:00 AM

ChangePath

FormatLocalDisk

ContinueDeleteFile(s)

Back-up/RestoreInternal

Back-up/RestoreConfig

MakeNewDIR

Insert Blank Disk into Drive Unit and press the "Continue" softkey to beginformatting. Operation Status will indicate when formatting is completeand disk can be removed from drive. Formatting cannot be cancelled once ithas started.

7-61

When building the index file the warning messageshown below may occur. This indicates that there areone or more files in the specified path which are notvalid AUTOFORM files. It is not necessary to deletethese files for proper operation. However, you shouldscan the disk directory to determine the cause.

WARNING: Directory contains one ormore invalid data files.

MAKING DIRECTORIES

The "Make New DIR" softkey will create a sub-direc-tory in the current path on the selected drive vol-ume. This feature may be used to create additionaldirectories on the disk for storing files. The defaultdirectories which are listed in the FILE PREFER-ENCES MENU are created when a disk is formattedon the control. Additional directories that the cus-tomer would like to use must be created manually.

Note: This can also be done offline on a PC usingDOS commands.

For example, the sub-directory TST within the PRO-GRAM directory could be created by changing theCurrent Path to \PROGRAM, pressing the "MakeNew DIR" softkey and entering TST as the new path.

After entering the path, the screen will be displayedas shown in the following display. Once the opera-tion is started it cannot be cancelled.

BACK-UP / RESTORE CONFIG

This feature allows the machine configuration val-ues on the control to be saved and recalled to thedisk volume or the Remote volume. The serial num-ber of the machine will be stored in the machineconfiguration files so it can be verified before load-ing back into the control. This prevents accidentalloading of an incorrect configuration into a controland allows for easier servicing.

If for some reason the serial number of themachine does not match the serial number storedin the configuration file, it can only be loaded if theService Access Code has been entered. This opera-tion would only be required for a special case suchas a retrofit or board replacement type service call.This can only be performed by a CINCINNATIINCORPORATED Service Representative.

The "Back-up/Restore Config" softkey is used fortransferring the Machine Configuration. The soft-keys below will appear to show the possible choices.

STATUS: Select option for transferring Machine Configuration.

The “Config to Remote” softkey will transfer theMachine Configuration to the REMOTE deviceusing Kermit. This is typically done once duringmachine set-up so the Offline Programming soft-ware corresponds with the control. Be sure to useunique directory paths on the REMOTE devicewhen backing up the configuration information ofseveral AUTOFORMs to the same REMOTE device.

The "Config to Disk A" softkey will transfer theMachine Configuration to the Disk A Volume. Thiswill be stored in the directory corresponding to theTEXT File Path in FILE PREFERENCES as severalfiles CONFIG.X, CONFIG2.X, etc. This is typicallyused when performing a software update so themachine configuration can be recalled when theupdate is finished.

The "Disk A to Config" softkey will restore theMachine Configuration to the non-volatile memoryof the control from the previously saved file CON-FIG.X on the Disk A Unit. This operation is typical-ly used after a software update is performed.

The process can be cancelled at any time by press-ing the "Abort" softkey.

BACK-UP/RESTORE INTERNAL MEMORY

The next softkey, "Back-up/Restore Internal", isused for transferring all files in the internal memo-ry of the control. This feature allows the internalmemory to be saved or recalled to the data cartridgeof the disk volume. When this softkey is pressed,the following softkeys will appear:

InternToDisk

DiskToIntern

colonInternToCart

CartToIntern

| ^ ~ Abort

ConfigToRemote

ConfigToDISK A

DISK AToConfig

InternToCart

CartToIntern

) < > Abort

PROGRAMTEST000 F I L E U T I L I T Y

STATUS: Select a function using the softkeys.

Drive Volume: LOCAL DRIVE A

Operation Status: WAITING MAKING DIR DONE

Current Path: \PROGRAM

New Path: \PROGRAM\TST

AbortChangeDriveOptions

30 APRIL 9112:00 AM

ChangePath

FormatLocalDisk

ContinueDeleteFile(s)

Back-up/RestoreInternal

Back-up/RestoreConfig

MakeNewDIR

Insert Disk into Drive Unit and press the "Continue" softkey to beginmaking the directory. Operation Status will indicate when directory is completeand disk can be removed from drive. Operation cannot be cancelled once it hasstarted.

7-62

"Intern to Disk" will copy all of the files in internalmemory to the disk volume as one large archive file(approximately 96K bytes). The archive files arealways stored in the TEXT File Type directory.When the "Intern to Disk" softkey is pressed, thefollowing softkeys will appear:

The display will also show a default archive namenear the center of the screen. The control startswith FILESARC.001 as the archive name and if thatname already exists in the TEXT file directory, it willtry FILESARC.002, etc. until it finds a unique name.Pressing the "Default Archive Name" softkey acceptsthis name as the archive name and will continue thearchive process. The "Enter New Name" softkey canbe pressed to override the default archive name.

The "Disk to Intern" softkey is used to restore theentire file system from an archive file. When thissoftkey is pressed, the control will search the TEXTdirectory for all archive files it can find and displaythe archive names and the date and time they werecreated. At this point, the sequence number of thedesired archive file is entered or alternatively, thefilename can be entered by pressing the "Enter ByName" softkey.

Note: It is not possible to restore just one file from anarchive file. When the restore function is per-formed, all of the files stored in internal memory(PROGRAM, TOOLS etc.) will be replaced withthose stored in the archive file.

"Intern to Cart" will transfer all files in internalmemory to the cartridge.

"Cart to Intern" will transfer all files located on thedata cartridge to the internal memory of the controland replace those currently in internal memory.

The "File Menu" softkey will change the menu backto the FILE MENU.

FILE PREFERENCES MENU

This menu is used to define the file pathnameswhich are associated with each file type stored inthe control. It is organized around the Storage Vol-ume. For each storage unit the operator may selectthe default directory where files of a particular typewill be stored. These are the same directories whicheach of the individual storage screens use. Chang-ing the pathname for each file type in this screenwill change where each individual storage screen(i.e., PROGRAM, TOOL LIBRARY, PART STORAGE,etc.) looks for files. The default directories areshown in the following screen.

Unless there is a specific requirement to do so, usethe default pathnames to avoid any confusion onwhere a file is stored.

SELECT STORAGE VOLUME

This softkey will select which volume to display orchange the File Preferences. The current volume isdisplayed on top of the screen.

EDIT FILE PATH

The operator may change the path associated witheach Storage screen by entering a new pathnamefor one or more storage paths. After pressing the"Edit File Path" softkey, the softkeys will change asshown following:

STATUS: Select the type of file to changepathname.

Once again the "Auxiliary Char" softkeys willappear. Enter the desired path and press ENTER.The screen will now update to reflect the pathnameentered for the corresponding file path.

SET DEFAULT PATHNAMES

The softkey labeled "Set Default Pathnames" willreset all of the pathnames of the volume displayedback to those shown in the previous screen display.These default names are the same pathnames usedwith AUTOFORM Offline Programming.

When the storage volume is the REMOTE device,the directories shown on the screen refer to thestorage device of the remote system.

FILENAME FORMAT SELECTION

The Disk Filename Format field is used to let theoperator choose between 16 character filenameswith index, 11 character filenames with index, or

Program UpperTool

LowerTool CAD Shape

TeachData Text

ToolingLibrary Abort

PROGRAMTEST0001 F I L E P R E F E R E N C E S

STATUS: Select a function using the softkeys.

FileMenu

SelectStorageUnit

30 APRIL 9112:00 AM

EditFilePath

ChangeFilenameFormat

ContinueDeleteFile(s)

Back-up/RestoreInternal

Back-up/RestoreConfig

SetDefaultPaths

V

: \PROGRAM: \UTOOL: \LTOOL: \CAD: \SHAPE: \TEACH: \TEXT

Volume: LOCAL DRIVE A

Program File Path Upper Tool File Path Lower Tool File Path CAD Part File Path Shape File Path Adaptive File Path Text File Path

Disk FileName Format: 16 char sorted

DefaultArchiveName

EnterNewName

ESC nn \ / ? " ' ;

7-63

11 character filenames without index. These threefile formats can be identified easier as 16 charactersorted, 11 character sorted or 11 character unsort-ed. Using the softkeys as shown below select thefilename format to be used for storing files on thelocal drive volume.

COMMUNICATIONS SET-UP MENUThis menu is used for setting communication baudrate and other Kermit parameters.

The additional remote directory change entry hasbeen added to allow the operator to specify whethera directory change is made automatically by theAUTOFORM for remote file transfers.

Before a file is sent, or received, the control willcheck the status of the "Remote Directory Change"variable. If it is enabled, the control will send theappropriate directory change command to theremote computer before it does the actual filetransfer. For example, if an Upper Tool file is beingsent to a remote computer and "Remote DirectoryChange" is enabled, the control will first send acommand to the remote computer telling it tochange its current directory to \UTOOL (or whatev-er directory name has been entered in the FILEPREFERENCES screen) and then send the actualUpper Tool file. This will allow the AUTOFORMoperator to store files in several different directorieson a remote computer without having to walk to thecomputer to change directories manually.

BACKGROUND FILE TRANSFER

This feature allows the AUTOFORM to communi-cate with a remote computer using the Kermit filetransfer protocol while the press is performingother tasks such as cycling, program editing, etc.

Five different transactions can take place in thebackground. All transactions must be initiated atthe remote computer. These five transactions are:

✦ Sending files to the AUTOFORM from a remotecomputer

✦ Transferring files to a remote computer fromthe AUTOFORM

✦ Displaying a list of files stored on the AUTO-FORM

✦ Deleting files from the AUTOFORM's internalstorage memory

✦ Changing the current remote file type

All of these transactions can take place with nooperator intervention at the AUTOFORM itself. Allcommands are issued at the remote computer andall responses are displayed on the remote comput-er's screen.

The AUTOFORM will be in server mode waiting forbackground transaction requests from the remotecomputer unless a local Kermit request is beingprocessed. Background requests will be ignoredwhen the AUTOFORM is in the FILE TRANSFERscreen or displaying a Recoverable Files directory inone of the storage screens. Background requestsare also ignored momentarily when the operator isprompted to verify deletion of a file from internalmemory. These remote requests are entered at theremote computer's Kermit command line as follows:

SEND <Filespec>Send one or more files to theAUTOFORM<Filespec> can be either one filename or cancontain "wildcard" characters so multiplefiles can be sent. See “CHANGE SEARCHFORMAT” for use of wildcard.

GET <Filespec>Receives one or more files from theAUTOFORM<Filespec> can be either one filename or cancontain "wildcard" characters so multiplefiles can be received. See “CHANGESEARCH FORMAT” for use of wildcard.

REMOTE DIR <Filespec> Displays the files storedon the AUTOFORM<Filespec> is optional and is used with"wildcard" characters so only matching filesare displayed. See “CHANGE SEARCH FOR-MAT” for use of wildcard.

The AUTOFORM will respond to the REMOTE DIRcommand as follows:

File Type: PROGRAM Bytes Free: 78999PART12-34-56 AUG 22 1991 13:12:40PART12-34-57 AUG 22 1991 14:52:33TEST_PROG MAR 18 1991 09:10:21

PROGRAMTEST000 C O M M U N I C AT I O N S - SET-UP

STATUS: Select a function using the softkeys.

EndEdit 300

30 APRIL 9112:00 AM

1200 2400 4800 57600 38400 19200 9600

Communications Port:Baud Rate:Parity:Data Bits:Stop Bits:

Send Init String:Receive Init String:Communications Mode:Translate Upper to Lower:Remote Directory Change:

2 (Lower)9600None82

kermit -rkermit -sServerOffOn

16 charsorted

11 charsorted

11 charun-sorted

LastStep

CopySteps

JobData

Done GageData

Abort

7-64

REMOTE DELETE <Filespec>Deletes a file fromthe AUTOFORM<Filespec> can be only one filename. Multi-ple files cannot be deleted at one time.

REMOTE CWD <Filespec> Changes the remote filetype.<Filespec> can be one of the following:PROGRAM, UTOOL, LTOOL, CAD, SHAPE,TEACH or TEXT. The remote file type isused with the GET, REMOTE DIRECTORYand REMOTE DELETE commands above. Itspecifies what types of files will be used forsubsequent commands.

When any of the above commands are received bythe AUTOFORM, the entire command will be con-verted to all upper case characters making all com-mands case insensitive. The "wildcard" matchingwill be the same as used in the FILE TRANSFERscreen of the AUTOFORM. See “CHANGE SEARCHFORMAT” for use of wildcard.

If a file is sent to the AUTOFORM in the remotemode and a file already exists on the AUTOFORMwith the same name and file type, the existing filewill be deleted and replaced with the new file auto-matically.

When a file is deleted from the AUTOFORM's inter-nal storage memory using the REMOTE DELETEcommand, it will be copied into the recover directo-ry just as if it had been deleted locally at the press.The file can be recovered at a later time using thenormal file recovery procedure.

The output of all remote commands including errormessages will be sent out the Kermit serial port fordisplay on the remote computer. No error messagesresulting from remote commands will be displayedon the AUTOFORM CRT.

The only memory device supported for remote com-mands will be the internal storage memory. It is notpossible to access the AUTOFORM's local disk drivewith remote commands.

To use background communications on the AUTO-FORM, the version of Kermit running on the remotecomputer must support the "client" mode-of-opera-tion. In addition, the version of Kermit must be ableto output "generic commands" to use the RemoteDirectory, Remote Delete, Remote Directory Changefeatures on the AUTOFORM. Most Kermit imple-mentations allow this, including MS Kermit 2.29and MS Kermit 3.0 for MS-DOS computers.

EDITING THE COMMUNICATIONS SET-UP

STEP 1: Choose an operation

✦ Press the "Comm. Set-up" softkey as shownbelow:

STEP 2: Editing the set-up

The screen will now display a list of communica-tions parameters similar to the following screen.

Note: In most cases, it will never be necessary toedit the communications set-up. All parame-ters will default to preset values on power-upand when the MAIN MENU key is pressed.Brief descriptions of parameters are givenbelow.

The first five entries are fixed and cannot bealtered, except for Baud rate. Baud rate defaults to9600, but can be set to other values shown in thechart. A brief description of these parameters isgiven below. For technical information on connec-tivity and file format, refer to the RS-232/422 ref-erence manual (EM-372).

FIELD DESCRIPTION

Communications Port The cable should beS2 connected to (optional)

convenience outlet on the side of the mainenclosure or to the S2port of the CPU 030board inside the mainenclosure.

PROGRAM:ABC123

STATUS: Select function using the softkeys.

COMMUNICATIONS SET-UP

EndEdit

6 AUG 8912:00 PM

Communications Port:Baud Rate:Parity:Data Bits:Stop Bits:

Send Init String:Receive Init String:Communications Mode:Translate Upper to Lower:Remote Directory Change:

2 (Lower)9600None82

kermit -rkermit -sServerOffOn

FileTrans-fer

FileUtility

FilePrefs

Comm.Set-up

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary

LastMenu

7-65

Baud Rate 300, 1200 The speed at which2400, 4800 the data travels9600, 19200 through the RS-38400 232/422 cable.57600

Parity NONE Parity checking is notused.

Data Bits 8 The number of pulsesthat represent onepiece of data.

Stop Bits 1 The number of pulsesused to signal the endof a piece of data andthe beginning of thenext.

Send and Receive Init Strings

✦ Pressing the DOWN field key will cause the nexteditable selection to be highlighted. The high-lighted field should now be "Send Init String".The screen will appear as shown.

The "Send Init String" is used only when remotemode is selected.

✦ Pressing the DOWN field key will cause the nexteditable selection to be highlighted. The high-lighted field should now be "Receive Init String".

The "Receive Init String" is used only whenremote mode is selected.

✦ Pressing the DOWN field key will cause the nexteditable selection to be highlighted. The high-lighted field should now be "CommunicationsMode".

Communications Mode

The Communications Mode defines how the AUTO-FORM will go about establishing a dialog with the

remote computer. The recommended default modeis "server".

The following describes the use of the Remote Com-munications mode for the AUTOFORM Controlusing Kermit. The COMMUNICATIONS SET-UPMENU allows certain parameters to be changedwhich affect how the Communications protocol isdefined. The default operation is to set the Com-munications mode to Server. For this case, theAUTOFORM assumes that a dedicated Kermit serv-er application is running on the computer system(host) which is connected through the RS-232/422interface. Thus, the AUTOFORM will send out theappropriate Kermit initialization packet after theoperator starts the send or receive file operation.The Kermit application on the host will thenrespond with the proper Kermit protocol and per-form the requested operation.

Since it is not always possible to have a dedicatedKermit server always running on the host, there is amethod available to send a command string to thehost computer which first starts the Kermit applica-tion and then proceeds with the normal Kermit pro-tocol communication. When Communications Modeis set to REMOTE, as soon as the operator starts theprocess, the AUTOFORM will first send out a userprogrammable string followed by the filename whichwas requested by the operator. This string is listedon the SET-UP MENU as either the "SEND INITSTRING" or “RECEIVE INIT STRING". Which stringis used depends whether a send or receive operationis being requested. Each string can be edited toallow the correctly formatted command to invokethe Kermit server on the host computer.

The remote protocol format is as follows: The pro-grammable init string may contain a maximum of16 characters. Immediately following the string is aspace character and then the filename selected bythe operator. Filenames may be up to 16 characters.

The default value for the init string is "Kermit-r" or"Kermit-s". This case works with the HP-UX operat-ing system to invoke a Kermit transaction. Thedefault value should be changed to suit your needs.These values are saved in active memory so it is notnecessary to re-enter them after powering down thecontrol.

After the initialization string is sent, the control willwait approximately five seconds before starting theKermit communications transaction. It will thensend out the Kermit initialization packet to beginthe transaction. It is the responsibility of the hostcomputer to start the Kermit application which willrespond to the initialization packet within the five

PROGRAM:ABC123

STATUS: Please select a new value using the keyboard and softkeys.

COMMUNICATIONS SET-UP

EndEdit

6 AUG 8912:00 PM

-etc- | > ? * \ /LowerCase

Communications Port:Baud Rate:Parity:Data Bits:Stop Bits:

Send Init String:Receive Init String:Communications Mode:Translate Upper to Lower:Remote Directory Change:

2 (Lower)9600None82

kermit -rkermit -sServerOffOn

7-66

second period. The AUTOFORM control will re-tryseveral times after the five second period haspassed. If no response is received after all re-trieshave been exhausted, the Kermit transaction willabort with an error message on the control. Refer toRS-232/422 Communications Manual, EM-372.

Translate Upper to Lower

When using the remote mode feature, it is some-times desired to translate an upper case string tolower case. If the "TRANSLATE UPPER TO LOWER"parameter is selected, the init string will be trans-lated to lower case. Note that it is possible to enterthe string as a lower case value using the specialsoftkey which appears when editing either the sendor receive init string. It is also possible to enter spe-cial characters such as /, \, ?, >, <, etc., which arenot available on the keyboard using the softkeysprovided.

CAD MENUThe AUTOFORM CAD MENU is selected from pagetwo of the MAIN MENU. This menu contains func-tions to graphically design a part and to automati-cally create an AUTOFORM program to bend thepart. The following screen is the CAD MENU.

INTRODUCTION TO CAD MENU FEATURES

PART STORAGE MENU

Once the flange information has been enteredusing the PART DESIGN MENU, the part may besaved in internal storage. A directory of enteredparts is shown similar to the PROGRAM STOR-AGE MENU. This allows quick recall of a CADdrawing for the part.

PART DESIGN MENU

This menu allows a part to be graphically designedby entering flange information. A two dimensionalcross section of the part is drawn as it is entered.The flange information is used by the control to cre-ate a program to bend the designed part.

SHAPE LIBRARY

The SHAPE LIBRARY contains a list of genericflange types which can be used as building blockswhen designing a part in the PART DESIGNMENU. The AUTOFORM Control includes a set ofstandard shapes and the customer may designadditional shapes for the library using the PARTDESIGN MENU.

PART STORAGE MENU

The PART STORAGE MENU is selected by pressingthe softkey from the AUTOFORM CAD MENU. Thismenu is used to save and recall parts, designedusing the PART DESIGN MENU, to and from theinternal memory. Parts which are no longerrequired may be deleted from internal memory inthis menu. Following is a diagram of the screenwith no parts stored.

The top line indicates the storage unit is internalmemory and the bytes remaining in memory forfuture storage. The PART STORAGE MENU func-tions in a similar manner to the PROGRAM STOR-AGE MENU. Parts may be loaded by name orsequence number. Each column of the screen showsup to 15 part names. The up and down field keys willdisplay additional pages of parts if there are morethan 30 parts stored in memory.

The "Build Program" softkey allows the operator tocreate an AUTOFORM program from the currentpart just loaded or designed in the PART DESIGN

PART STORAGE MENUPROGRAM:ABC123

STATUS: Make a selection using the softkeys.

LoadPart

SavePart

DeletePart

BuildProgram

PartDesignMenu

CADMenu

<< Use up and down field keys for more directory entries. >>

BYTES REMAINING: 96000

SEQ PART NAME DATE SEQ PART NAME DATE1 DEMO1 Aug 19 88 10:58

VOLUME: INTERNALPATH:

AUTOFORM CAD MENUPROGRAM:ABC123

PART STORAGE MENU

PART DESIGN MENU

SHAPE LIBRARY

STATUS: Select a menu using the softkeys.

PartStorage

PartDesign

ShapeLibrary

7-67

MENU. When pressed, the "Build Program" softkeywill validate the part and calculate the step valuesto bend the part. See the PART DESIGN MENU foradditional information on the BUILD PROGRAMfeature.

The last two softkeys, "Part Design Menu" and"CAD Menu", allow the operator to quickly switch tothe appropriate menu after the desired part hasbeen selected in the PROGRAM STORAGE MENU.

PART DESIGN MENU

The PART DESIGN MENU is selected by pressingthe softkey from the AUTOFORM CAD MENU. TheAUTOFORM control will always have one currentpart in active memory, which will be displayed onthe PART DESIGN MENU screen. The followingPART DESIGN MENU screen does not show a cur-rent part.

The upper portion of the PART DESIGN MENUscreen lists the general part information, such aspart name, material thickness and part bend radius.Blank width is displayed in the lower right corner.

The softkeys allow the operator to either edit thecurrent part displayed and create a program from itor to create a new part, thus deleting the currentpart displayed.

CREATING A NEW PART

A sample part will be presented to instruct theoperator on how a part is designed using thismenu. To delete the current part and begin thedesign, press the softkey below:

After pressing the above softkey, the status line andsoftkeys will appear as shown.

STATUS: Current part will be deleted, Continue?

If the current part is not saved in PART STORAGE,press the "NO" softkey and store before continuing.See PART STORAGE MENU for more information.To continue creating a new part, press the "YES"softkey. The current part will be erased from thescreen and should appear as shown following.

The PART NAME field will be highlighted to indicatethe operator should type in up to 16 characters forthe name of the part. For this example type:

The next field will now be MATERIAL THICKNESS.This value is the nominal thickness of the part. Forthis example, type the following for MATERIALTHICKNESS:

. 85 ENTER0

1D E M O ENTER

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new part using keypad.

NextFlange

EndPart

RotatePart

PART NAME . . . . . . . . . . .MATERIAL THICKNESS . . 0.000K-FORMING FACTOR . . . . AUTO

PART BEND RADIUS . . . . 0.000

. . . . . . .

. . . . . . .

. . . . . . .

FLANGE A

FLG LENGTH 0.000

FLG DIM. Outside

FLG ANGLE 90.0

BND LENGTH 12.0

BND SEQ 1

GAGE PNT. 0 BK

RedrawPart

BLANK WIDTH =

CreateNewPart

SelectPage

SelectSingle

Un-SelectAll

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

CreateNewPart

SelectPage

SelectSingle

Un-SelectAll

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

PROGRAM:ABC123

CADMenu

PART DESIGN MENU

STATUS: Make a selection using the softkeys.

CreateNewPart

EditCurrentPart

BuildProgram

ShapeLibrary

PartStorageMenu

PART NAME . . . . . . . . . . .MATERIAL THICKNESS . . 0.000K-FORMING FACTOR . . . . . AUTO

PART BEND RADIUS . . . . 0.000

. . . . . . .

. . . . . . .

. . . . . . .

BLANK WIDTH =

7-68

! W! WARNING !ARNING !THIS CAD FEATURE DOES NOTCALCULATE INTERFERENCE BE-TWEEN PART AND MACHINE COM-PONENTS. ENSURE PART SHAPE,DIMENSIONS AND MOVEMENT DONOT CREATE PINCH POINTSBETWEEN PART AND MACHINECOMPONENTS AWAY FROM THEPOINT-OF-OPERATION.

The next field will be PART BEND RADIUS. Thisvalue is the desired radius of all bends for the part.

Note: Tooling must be selected by the operator toachieve this desired radius. The value of thisfield defaults to the entered MATERIALTHICKNESS.

For this example, type the following for PART BENDRADIUS:

The general part information has been completedwith the previous three entries and the screenshould appear as shown.

Note that the flat BLANK WIDTH of the part is cre-ated at the lower right corner of the drawing area.This is a theoretical value based on the enteredbend radius. If the actual blank width of the partdiffers from this value, it is due to variances inmaterial and bend radius when the part is formed.

Now the information required for each flange will beentered. The following illustration is a simple draw-ing of the part to be entered showing bend anglesand flange dimensions.

This part is 16" (406.4mm) in length, 16 Gauge or.058" (1.47mm) in thickness, and the bend radiusis .060" (1.52mm).

There are six flanges to be entered with the startingflange of the part at the left. When entering partforming sequences, the operator may start fromeither edge.

The highlighted field will now be FLANGE LENGTH.The drawing indicates the first flange length is0.75" (19.1mm).

For this example, enter the following for FLANGELENGTH:

After entering the FLANGE LENGTH, the Controlwill prompt for the method used to dimension theflange. The current highlighted field will beFLANGE DIMENSION. The four choices for this fieldare RADIUS, INSIDE, VERTEX or OUTSIDE. Thesoftkeys will change to the following for selection ofthis field:

For a diagram of how these dimensions are speci-fied, consult the GAGE DATA MENU section underGAGE ALLOWANCE.

For this example, all flange measurements areOUTSIDE dimensions. Select the "Outside" softkey.

For the K-Forming Factor, see the GAGE DATAMENU section under AUTO GAGE ALLOWANCE.

The next highlighted field will be FLANGE ANGLE.This value specifies the included angle (in degrees)and also the direction of the bend. FLANGE ANGLEis a signed value. A positive value will cause theangle to be bent counterclockwise on the drawingarea, while a negative value will cause the angle tobe bent clockwise.

For this example the FLANGE ANGLE should be a-90°. (Note: The Flange Angle is always associatedwith the previously entered flange length.)

The next highlighted field will be BEND LENGTH.This value is the length of material to be bent. It isimportant to enter the correct bend length of thepart for each flange if they are different.

For this example the BEND LENGTH is the samealong the part for all flanges. Enter the following forBEND LENGTH:

09 ENTER-

Inside Outside Radius VertexRunMode

NextStep

PrevStep

EndEdit Abort

57 ENTER.

90 90

90 135

135

2.0

6.0

1.41

1.0.75

2.01 2

3 4

5O O

OO O

O

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .MIN: 0.001 MAX: 999.900

NextFlange

EndPart

RotatePart

PART NAME . . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-FORMING FACTOR . . . . AUTO

PART BEND RADIUS . . . . 0.060

. . . . . . .

. . . . . . .

. . . . . . .

FLANGE A

FLG LENGTH 0.000

FLG DIM. Outside

FLG ANGLE 90.0

BND LENGTH 12.0

BND SEQ 1

GAGE PNT. 0 BK

RedrawPart

0.000BLANK WIDTH =

. 06 ENTER0

7-69

The next highlighted field is BEND SEQUENCE.This value is a number from one to the number offlanges, minus one, which specifies the order ofbending. The default bend sequence is equal to theorder of entry.

In this example, this is the first bend in thesequence. It is the same as the default value andtherefore can be entered by pressing ENTER key. Ifthe default value is not acceptable, enter thedesired sequence number using the keypad.

The last field for the flange information is GAGEPOINT. This selection is either a flange number, thestart edge or end edge, or a '-' representing no gag-ing. The GAGE POINT for each flange must be spec-ified by the operator so gaging positions can be cal-culated when a program is created. These arebackgage positions (BK).

The softkeys will change as shown below to allowselection of the starting or ending edges of the part,or to select no gaging:

Selecting the "No Gaging" softkey will instruct thecontrol not to calculate a gage position for theflange when the program is created. The defaultgage position will be set to the maximum rear posi-tion so the operator may use an alternate method,such as a frontgage or fixed gaging, to properly gagethe part.

If the GAGE POINT is another previously formedflange of the part, enter the flange number in theGAGE POINT field using the keyboard. Similar toBEND SEQUENCE, the GAGE POINT is typicallyentered after all flanges have been entered and theBEND SEQUENCE has been specified.

The AUTOFORM Control will check for illegal gagepoints whenever a program is created from theentered part. The following rules have been estab-lished to ensure proper gaging of the part. If it isnecessary to violate these rules to bend the part,select the NO GAGING selection and manuallyenter the gage position in the part program. SeeBUILDING PROGRAM for more information.

1. GAGE POINT cannot be a flange with anglegreater than 90 degrees. This does not providea positive gage surface.

2. GAGE POINT cannot be a flange which is notformed. An example is the BEND SEQUENCEhigher than current flange.

3. GAGE POINT cannot be either leg of the currentFLANGE.

4. GAGE POINT cannot be chosen such that thereis a previously bent angle between currentflange and gage point. Gage position wouldinclude angle errors of previous bends.

Since this is the first bend in the example, GAGEPOINT will be either the START or END edge of thesheet, or NO GAGING. Select the "Start Edge" soft-key for this example to leave most of material out infront of the dies which can be supported safely.

This completes the flange information for the firstflange. To view the entered flange, press the"Redraw Part" softkey. The screen should nowappear as shown in the following. Note that the firstflange does not appear until the next flange isentered.

If the screen does not appear as shown above, usethe field keys to move to the incorrect fields andenter the correct value.

If the flange is correct, press the "Next Flange" soft-key to advance to the next flange. The screenshould appear as shown following:

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .MIN: 0.001 MAX: 999.900

NextFlange

EndPart

RotatePart

PART NAME . . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

. . . . . . .

. . . . . .

. . . . . . .

FLANGE A

FLG LENGTH 0.750

FLG DIM. Outside

FLG ANGLE - 90.0

BND LENGTH 16.0

BND SEQ 1

GAGE PNT. 0 BK

RedrawPart

0.750BLANK WIDTH = .632

StartEdge

EndEdge

NoGaging \ / * ? – etc

61 ENTER

7-70

The drawing will now change to show the secondflange, which will appear in a flashing yellow color.The direction and bend sequence number of theprevious angle will also be indicated at this time.The length of the current flange will be the same asthe previous flange until changed.

Note that the line segment flashing indicates thecurrent flange being entered. The part will alsoindicate the flange number, the start edge and thebend sequence.

From this point on, as flanges are added using the"Next Flange" softkey, the previous flange valueswill be defaulted to the next flange.

Enter the FLANGE LENGTH value for the secondflange by typing the following.

The FLANGE ANGLE and DIMENSION values arethe same as the first flange. Press ENTER to keepthe default value.

In this example, the FLANGE ANGLE value for thesecond flange is the same as the first. The angle isagain 90 degrees and in the same downward direc-tion as the previous flange. Press ENTER to keepthe default value (-90).

The BEND LENGTH values are the same as the firstflange. Press ENTER to keep each of these defaultvalues.

The highlighted field should now be the BENDSEQUENCE field. This will be the second bend inthe sequence which is the same as the defaultvalue. Press ENTER to move to the next field GAGEPOINT.

The bend can be successfully gaged from either thefirst flange (A) or the END EDGE of the sheet. Foroperator safety, the first flange is best. Enter thefollowing for the GAGE POINT.

This completes the information for the secondflange. Press the "Redraw" softkey to verify thedesign. The part should appear as follows:

If the screen does not appear as shown, correct theappropriate values and redraw the part.

ROTATION AND SCALING

Note that the part does not look identical to thedrawing at this point. This is because the part isoriented differently from original drawing. The"Rotate Part" softkey can be used to rotate the partin 15 degree increments (either clockwise or coun-terclockwise) to provide the proper orientation withthe original drawing. It can also be used to rotatethe part so the drawing takes advantage of thescreen area available.

The drawing area is limited because of the screensize. Scale is indicated by the white grid of dotswhich represent one inch between dots. As a part isentered, the scale will be reduced to allow the wholepart to be viewed in the drawing window. As thescale reduces, the dot grid becomes more compact.The part itself is scaled down, thus showing lessdetail. Flange labels and Bend Sequence maybecome difficult to read. The "Rotate Part" softkeymay be used to take advantage of the large drawingarea for the horizontal axis. Select the appropriaterotation which gives the best view of the part.

For this example, press the "Rotate Part" softkey sixtimes for a 90 degree rotation to orient the partsimilar to the original drawing.

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .MIN: 0.001 MAX: 999.900

NextFlange

EndPart

RotatePart

PART NAME . . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

. . . . . . .

. . . . . . .

. . . . . . .

FLANGE B

FLG LENGTH 2.000

FLG DIM. Outside

FLG ANGLE - 90.0

BND LENGTH 16.0

BND SEQ 2

GAGE PNT. A BK

RedrawPart

2.000

A

B

BLANK WIDTH = 2.638

ENTERA

0. ENTER2

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .MIN: 0.001 MAX: 999.900

NextFlange

EndPart

RotatePart

PART NAME . . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

. . . . . . .

. . . . . .

. . . . . . .

FLANGE B

FLG LENGTH 0.750

FLG DIM. Outside

FLG ANGLE - 90.0

BND LENGTH 16.0

BND SEQ 1

GAGE PNT. 0 BK

RedrawPart

0.750BLANK WIDTH = 1.388

A

B

7-71

Now that the Part is oriented correctly, press the"Next Flange" softkey to continue.

Enter the following flange information in the samemanner as the previous example:

FLG CFLG.LENGTH 2.0FLG. DIM. OutsideFLG. ANGLE 90BND. LEN 16BND. SEQ 3GAGE PNT. B

Press the "Redraw" softkey after entering the aboveinformation for verification. The screen should nowappear as shown.

If the flange information is correct, press the "NextFlange" softkey to continue. If the screen does notappear as shown, correct the appropriate fields andredraw the part.

Enter the following flange information for the nexttwo flanges in the same manner.

FLG D EFLG. LENGTH 6.0 1.41FLG. DIM. Outside OutsideFLG. ANGLE 135 135BND. LEN 16 16BND. SEQ 4 5GAGE PNT. END EDGE END EDGE

Upon pressing the "Redraw" softkey after enteringinformation for flange 'E', the screen should appearas follows. If correct, press the "Next Flange" soft-key to advance to the last flange.

The only information which needs to be entered forthe last flange is the LENGTH and FLANGE DIMEN-SION. After entering those values the part designwill be complete.

Enter a FLANGE LENGTH of 1.0" (25.4mm) andindicate a FLANGE DIMENSION of Outside.

Press the "End Part" softkey and the part design isnow complete. The screen should appear as shown:

PART INTERFERENCE

When drawing the part, as each flange is enteredthe Control checks for flanges interfering with eachother. If a flange touches or intersects one or moreflanges, a warning message will appear and theflange will be drawn in red. Change the flange infor-mation so the flange does not interfere and redrawthe part. Note that if the flange angle is entered aszero (hemming operation), the warning messagewill appear because the flange is bent back onitself. In this case, ignore the message because ahem is desired.

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .MIN: 0.001 MAX: 999.900

ListAllFlanges

RedrawPart

RotatePart

PART NAME . . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

FLANGE F

FLG LENGTH 1.000

FLG DIM. Outside

FLG ANGLE N/A

BND LENGTH N/A

BND SEQ END

GAGE PNT. N/A

PrevFlange

1.000

. . . . . . . . . . .

. . . . . . . . . . .

...........

A

B

C

D

E

F

BuildProgram

NextFlange

Re-NumberSeq

PartStorageMenu

CADMenu

BLANK WIDTH = 12.713

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .MIN: 0.001 MAX: 999.900

NextFlange

EndPart

RotatePart

PART NAME . . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

FLANGE E

FLG LENGTH 1.410

FLG DIM. Outside

FLG ANGLE 135.0

BND LENGTH 16.0

BND SEQ 5

GAGE PNT. BK

RedrawPart

1.410

. . . . . . . . . . .

. . . . . . . . . . .

...........

A

B

C

D

E

BLANK WIDTH = 11.769

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .MIN: 0.001 MAX: 999.900

NextFlange

EndPart

RotatePart

PART NAME . . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

. . . . . . .

. . . . . . .

. . . . . . .

FLANGE C

FLG LENGTH 2.000

FLG DIM. Outside

FLG ANGLE 90.0

BND LENGTH 16.0

BND SEQ 3

GAGE PNT. B BK

RedrawPart

2.000

A

B

C

BLANK WIDTH = 4.527

7-72

EDITING CURRENT PART

Now that the part is complete it is possible to stepthrough each flange using the "Prev Flange" and"Next Flange" softkeys. Each time one of these ispressed, the flange information will change andallow the operator to edit any field by selecting thefield with the field keys. To see the effect on thedrawn part, press "Redraw Part" or "Rotate Part"softkeys and the part will reflect the change made.

Pressing the "List All Flanges" softkey will erase thepart drawing and show a list of all the flanges forthe part. The up, down, left and right field keys canthen be used to select any field for any flange. Thepart name, material thickness and material radiusfield can be selected by using the up field key. TheHOME key will position the highlighted field to thePART NAME field. Below is the screen after press-ing the "List All Flanges" softkey:

The field keys can be used to move to a specific fieldfor any flange.

Individual flanges can be selected by either the up-down field keys, entering the flange letter, or theuse of "First, Last, Prev or Next Flange" softkeys.

Typing a flange number from the keyboard andpressing ENTER will position the highlighted fieldto the indicated flange.

Pressing the "First Flange" or "Last Flange" softkeywill position the highlighted field to the appropriateflange.

To insert a flange before or after the current high-lighted flange, press the "Insert Flange" softkey. Thesoftkeys will then change to the following:

Pressing one of the previous softkeys will insert acopy of the current flange either before or afteritself. The flange may then be modified. To delete aflange, press the "Delete Flange" softkey and thecurrent flange will be erased.

After making the desired changes to the flanges, thepart can be redrawn by pressing the "Redraw Part"softkey. The list of flanges will be erased and thecurrent flange will be shown at the top of the screenwith the part drawn in the part window.

RENUMBER BEND SEQUENCE

When choosing the BEND SEQUENCE for a flange,it may be convenient to reset the sequence back tothe default when making changes on a large part.The "Renumber Seq" softkey when pressed willrenumber the bend sequence in order.

This completes the section on editing an existingpart. Now that a part is complete, a program maybe generated for the part.

BUILDING A PROGRAM

When the "Build Program" softkey is pressed, thecontrol will check the part to see that all valueshave been entered and that the gage points havebeen correctly chosen. If errors are found, theappropriate error message will be displayed alongwith the incorrect FLANGE NO. If the part is foundto be correct, the following softkeys and statusmessage will be displayed:

STATUS: Choose option for building program using the softkeys.

When one of these softkeys is pressed, the controlwill calculate the values for RAM DATA, GAGEDATA and JOB DATA MENUs. The current programin the AUTOFORM memory will be altered with thecalculated values to bend the designed part.

If the "Append To Program" softkey is pressed, thestep values will be added to the existing programin the AUTOFORM memory. This may be usedwhen a part has flanges which are perpendicularto the two-dimensional view of the PART DESIGNMENU. Two or more parts can be combined to cre-ate a program which will bend the desired part(i.e. box-type parts).

If the "Replace Current Program" softkey is select-ed, the Control will prompt the Operator to decidewhether the current program should be deleted.The following softkeys and status message will bedisplayed:

AppendToProgram

ReplaceCurrentProgram

DISK AToConfig

InternToCart

CartToIntern

) < > Abort

BeforeCurrentFlange

AfterCurrentFlange

doublequote

` singlequote

! & $ etc

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .

InsertFlange

DeleteFlange

LastFlange

PART NAME . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

FLANGE A B C D E F

FLG LENGTH 0.750 2.000 2.000 6.000 1.410 1.000

FLG DIM. Outside Outside Outside Outside Outside Outside

FLG ANGLE - 90.0 - 90.0 90.0 135.0 135.0 N/A

BND LENGTH 16.0 16.0 16.0 16.0 16.0 N/A

BND SEQ 1 2 3 4 5 END

GAGE PNT. 0 BK A BK B BK BK BK N/A

PrevFlange

FirstFlange

NextFlange

Re-NumberSeq

PartStorageMenu

CADMenu

7-73

STATUS: Current program will be DELETED!Do you wish to continue?

Selecting the "Yes" softkey will cause the control toprompt the operator for the new name of the pro-gram. For this example type the following for theProgram name:

The Control will pause briefly to create the programand return to normal PART DESIGN MENU screen.

The following screen shows what happens when aninvalid gage point is selected for the first flange andthe "Build Program" softkey is pressed. Correct theindicated flange and press "Build Program" to cre-ate a program.

The "Build Program" softkey is available when thepart is being edited or when the PART DESIGNMENU is first entered. It is not possible to build aprogram until a part is completed.

To examine the program created for this part, exitthe PART DESIGN MENU by pressing "Display MainMenu" button and select the JOB DATA MENU.

The following shows a diagram of the JOB DATAMENU. When a program is built for a part, only cer-tain fields of the JOB DATA MENU are completed.The remaining fields will contain default values.

The PROGRAM NAME appears in the upper leftcorner of the menu area. The PART NAME fromwhich the program was built is listed in the PARTNAME field. The MATERIAL THICKNESS from thePART DESIGN MENU is listed in the MATERIALTHICKNESS field.

Note that TOOL SETS are left blank. TOOL SETSmust be selected by the operator before the pro-gram can be cycled. TOOL SETS should be chosenwith the proper vee opening and radius so the bendradius of the designed part is achieved.

Select RAM DATA MENU by pressing the softkey.

Shown is Page 1 of the RAM DATA MENU with thecompleted step information for the example part.The values which are calculated by the BUILD PRO-GRAM function are REVERSAL MODE, VALUE andBEND LENGTH. The remaining fields use thedefault values. The calculated reversal mode will bethe ANGLE mode. Since this mode is designed forair bending, any bottoming operations would needto be edited to select POSITION or TONNAGE modewith the appropriate value.

PROGRAM:DEMO1PROG

Page 2

RAM DATA (1)

STATUS: Enter new value using keypad.MIN: 1 MAX: 5

Page 3

1

InsertStep

DeleteStep

FirstStep

LastStep

GageData

STEP REPEATREVERSALMODE VALUE

BENDPOSITION

BENDLENGTH

RAMOPENING

FORMINGSPEED

12345

11111

AngleAngleAngleAngleAngle

90.0 90.0 90.0135.0135.0

CenterCenterCenterCenterCenter

16.016.016.016.016.0

7.07.07.07.07.0

20.020.020.020.020.0

PROGRAM:DEMO1PROG

RamData

JOB DATA

STATUS: Enter new part number using keypad.

ToolLibrary

PART NAME . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058MATERIAL TYPE. . . . . . Mild SteelF-Forming Factor . . . . . . . . . AUTO

RETURN SPEED . . 20.0 in/minGUARD MUTE PT . top of mat. + 1/4 inR,Z-AXIS . . . . . . Off

ChangeProgramName

DEMO1

T O O L S E T SUPPER LOWER SPECIAL INSTRUCTIONS

A:B:C:D:E:

.

.

.

.

.

.

.

.

.

.

PROGRAM:ABC123 PART DESIGN MENU

STATUS: Enter new value using keypad. . .

InsertFlange

DeleteFlange

LastFlange

PART NAME . . . . . . . . . . . DEMO1MATERIAL THICKNESS . . 0.058K-Forming Factor . . . . . . . . . AUTO

PART BEND RADIUS . . . . 0.060

FLANGE A B C D E F

FLG LENGTH 0.750 2.000 2.000 6.000 1.410 1.000

FLG DIM. Outside Outside Outside Outside Outside Outside

FLG ANGLE - 90.0 - 90.0 90.0 135.0 135.0 N/A

BND LENGTH 16.0 16.0 16.0 16.0 16.0 N/A

BND SEQ 1 2 3 4 5 END

GAGE PNT. C BK A BK B BK BK BK N/A

PrevFlange

FirstFlange

NextFlange

Re-NumberSeq

PartStorageMenu

CADMenu

ERROR: Invalid Gage Point, Angle is not formed. Please check the Gage Point for FLANGE No. A

1D E M O P R O G ENTER

YES NO colonInternToCart

CartToIntern

| ^ ~ Abort

7-74

The default value for RAM OPENING is the maxi-mum stroke of the machine. This value should beadjusted by the operator for each flange to optimizebending of the part.

The order of steps in the RAM DATA MENU shouldcorrespond to the BEND SEQUENCE selected inthe PART DESIGN MENU. For this example, thebending sequence was in the order the flanges wereentered.

HEMMING

Note that REVERSAL MODE field is set to ANGLE.If the FLANGE ANGLE of the part in PART DESIGNMENU is zero, this indicates a hemming operationand the REVERSAL MODE field is set to TONNAGE.

For a hemming operation additional steps mayneed to be added before TONNAGE REVERSALMODE step to bend the part using an acute angledie. The operator must also determine the correctVALUE for TONNAGE REVERSAL which will hemthe part.

The operator may include in the design of the partan acute angle bend prior to hemming. Simply adda tonnage reversal step to the program for flatten-ing. QUICK BEND MENU may also be used for thesecondary operation.

TOOL SETS

Page 2 of the RAM DATA MENU contains all defaultvalues. If multiple tool sets are used to bend thepart, the operator must edit the TOOL SET field ofRAM DATA page 2 to use the proper tool for eachstep. The default tool for all steps is "A."

Select the GAGE DATA MENU by pressing softkey.

Shown below is page 1 of the GAGE DATA MENUwith the completed step information for the exam-ple part. The values which are calculated by theBUILD PROGRAM function are LEFT FLANGE andBEND ALLOW. The remaining fields use the defaultvalues. GAGE MODE is set to STANDARD.

The value field of LEFT FLANGE is calculateddirectly from the FLANGE LENGTH fields in thePART DESIGN MENU. The BEND ALLOW value iscalculated based on the FLANGE ANGLE, MATERI-AL RADIUS, and MATERIAL THICKNESS fields ofthe PART DESIGN MENU.

The actual X -AXIS GAGE POSITION is the sum ofthe LEFT FLANGE and BEND ALLOW values. Ifadjustments are necessary to achieve the desiredpart, edit BEND ALLOW value to change the gageposition.

Note that the value calculated for the BEND ALLOWfield is dependent on the FLANGE DIMENSIONTYPE specified in the PART DESIGN MENU. Forthis example flange dimensions are OUTSIDEdimensions. The BEND ALLOW value will change ifthe FLANGE DIMENSION TYPE is changed.

For the example part illustrated, the CLAMP func-tion in RAM DATA must be set ON in step 3because it is a reverse angle bend.

The Operator must enter a retract distance andpause time if required to avoid gage/part interfer-ence. For the example part, a RETRACT DIS-TANCE of about two inches and PAUSE TIME ofone second should be added to step 3 due to thereverse angle bend.

For an AUTOFORM with a standard-type backgage(CNC Backgage or CNC Heavy Duty) having manu-al R-axis, this is the only information for the GAGEDATA MENU. If an optional type backgage (CNC

PROGRAM:DEMO1PROG

Page 2

GAGE DATA (1)

STATUS: Enter new value using keypad.MIN: 1 MAX: 5

1

InsertStep

DeleteStep

FirstStep

LastStep

RamData

STEP GAGE MODELEFTFLANGE

RIGHTFLANGE ANGLE

GAGEALLOW

RETRACT DIST

12345

StandardStandardStandardStandardStandard

0.7502.0002.0002.4101.000

-0.056-0.056-0.056-0.084-0.028

PAUSETIME

0.00.00.00.00.0

0.10.10.10.10.1

JobData

PROGRAM:DEMO1PROG

Page 3

RAM DATA (2)

STATUS: Enter new value using keypad.MIN: 1 MAX: 5

Page 1

1

InsertStep

DeleteStep

FirstStep

LastStep

GageData

STEP TOOLSPEEDCHG.DWN

SPEEDCHG.UP TILT

BOTTOMDWELL

MATERIAL CLAMP

UPSTOP

12345

AAAAA

0.250.250.250.250.25

0.250.250.250.250.25

0.00000.00000.00000.00000.0000

0.00.00.00.00.0

OffOffOffOffOff

DOWNSTOP

OffOffOffOffOff

OffOffOffOffOff

7-75

Six-Axis or CNC Plate) having powered R-axis isinstalled, the following values are calculated onPage 2 of the GAGE DATA MENU.

R-AXIS LEFT and RIGHT (HEAVY DUTY orSIX-AXIS option)

The R-Axis values for Page 2 of the GAGE DATAMENU are calculated based on the MATERIALTHICKNESS entered in the PART DESIGN MENU.The R-AXIS position will be set at .050" (1.3mm)above the top of die if the material is .060" (1.5mm)or greater. If the material is less than .060"(1.5mm), the R-AXIS positions will be .010"(.25mm) less than the MATERIAL THICKNESS.

The screen should appear as shown:

Z-AXIS LEFT AND RIGHT (SIX-AXIS option only)

The Z-AXIS values for Page 2 of the GAGE DATAMENU are calculated based on the BEND LENGTHof the part as entered in the PART DESIGN MENU.Default values are based on the bend occurring atthe center of the bed. The Z-LEFT and Z-RIGHTpositions are one-half the bend length minus 1/2”(12.7mm) on either side of the center of the bed.

It will be necessary to adjust these positions if thepart is not centered about the bed or special mate-rial supports, or multiple die sets are installed inthe machine.

At this point the program may be used to bend thepart. It can be saved in PROGRAM STORAGE forlater recall thus avoiding the BUILD PROGRAM cre-ation sequence. This completes the discussion ofBUILD PROGRAM and the PART DESIGN MENU.

SHAPE LIBRARY

The purpose of the SHAPE LIBRARY is to shortenthe time required to go from a designed part to aformed part. The shape library works in conjunc-tion with the PART DESIGN MENU. A list of gener-ic shapes will be displayed on the screen. The oper-ator or designer may then scan the shapes for aclose approximation to the desired part. Once thecorrect shape has been found, it may be transferredto the PART DESIGN MENU where specific flangedimensions, gaging and bend sequence are added.Thus, the SHAPE LIBRARY, in many cases, willsave one step of the part entry procedure.

The AUTOFORM Control contains a set of generalvee bend shapes in the SHAPE LIBRARY. In addi-tion, optional shape sets may be obtained fromCINCINNATI INCORPORATED for specific fabrica-tion requirements.

The customer may customize their shape library bytransferring parts created in the PART DESIGNMENU into the SHAPE LIBRARY.

The SHAPE LIBRARY is selected by pressing thesoftkey from the AUTOFORM CAD MENU. The con-trol will have one active shape loaded. The name ofthe current shape is listed at the top of the screen.The SHAPE LIBRARY screen will graphically displayup to 16 parts on each screen. The field up anddown keys may be used to display additionalscreens of shapes. Each shape is identified by asequence number and up to a 16 character name.The following is a diagram of the screen with sever-al shapes displayed:

PROGRAM:DEMO1PROG

Page 1

GAGE DATA (2)

STATUS: Enter new value using keypad.MIN: 1 MAX: 5

1

InsertStep

DeleteStep

FirstStep

LastStep

RamData

STEPFINGEROFFSET R-left R-right

12345

0.0000.0000.0000.0000.000

0.0480.0480.0480.0480.048

JobData

0.0480.0480.0480.0480.048

Z-left Z-right

-7.500-7.500-7.500-7.500-7.500

7.5007.5007.5007.5007.500

PROGRAM:DEMO1PROG

Page 1

GAGE DATA (2)

STATUS: Enter new value using keypad.MIN: 1 MAX: 5

1

InsertStep

DeleteStep

FirstStep

LastStep

RamData

STEPFINGEROFFSET R-left R-right

12345

0.0000.0000.0000.0000.000

0.0480.0480.0480.0480.048

JobData

0.0480.0480.0480.0480.048

7-76

The "Select Current Shape" softkey is used tochoose the current shape in the library to be latertransferred into the PART DESIGN MENU. Afterpressing softkey, the following softkeys will appear:

The operator may select a shape by typing thesequence number or the full shape name underwhich it is stored.

The CURRENT SHAPE field will show the name ofthe shape which has been selected.

The "Delete Shape" softkey is used to delete a shapefrom the library. After pressing this softkey, theControl will prompt the Operator for the full nameof the shape to be deleted. When the operator typesthe name and presses ENTER key, the shape will bedeleted and the display will be updated to erase thedeleted shape. Note that the CURRENT SHAPE isnot affected when deleting shapes from the library.The Operator may delete the original copy of theshape in internal memory, and the CURRENTSHAPE will still exist until it is replaced.

TRANSFERRING SHAPES AND PARTS

The "Transfr Shape/Part" softkey is used to trans-fer a shape into the PART DESIGN MENU, or to adda shape to the library by transferring a part into theSHAPE LIBRARY.

After pressing the softkey above, the softkeys willchange to the following and the control will promptthe operator with the following message:

STATUS: Choose direction to transfer PART or SHAPE using the softkeys.

The "Shape to Part Design" softkey will transfer thecurrent shape listed in the SHAPE LIBRARY intothe PART DESIGN MENU. This shape will replacethe current part in the PART DESIGN MENU. Notethat the values transferred to the PART DESIGNMENU are the number of flanges, flange length andflange angle. The other fields are completed withthe default values. The PART NAME is filled in withthe SHAPE NAME. It will be necessary to completethe PART DESIGN information by entering the gagepoint, bend sequence, flange dimension type if notdefault and material thickness and radius.

Before transferring the shape, the Control willprompt the Operator whether the transfer shouldbe continued with the following message:

STATUS: Do you wish to continue the transfer?WARNING: Current Part will be replaced

with current shape.

The "Design to Shape" softkey will transfer the cur-rent part listed in the PART DESIGN MENU into theSHAPE LIBRARY. This shape will be stored in thelibrary and it will also replace the current shapeselected. Note that when a part is transferred as ashape, only the number of flanges, flange lengthand flange angle are saved with the shape. Thename used for the part will be the name used forthe SHAPE NAME. The CURRENT SHAPE field onthe SHAPE LIBRARY screen will display the nameof the shape which was just transferred.

Before transferring the part, the control will promptthe operator to determine whether the transfershould be continued with the following message.

STATUS: Do you wish to continue the transfer?WARNING: Current Shape will be replaced

with current Part.

The softkey labeled "Change Display View" can beused to show the shapes stored in internal memo-ry in a non-graphical format. Pressing the softkeywill cause the softkeys to change as shown below.

DisplayText

DisplayShapes Radius Vertex

RunMode

NextStep

PrevStep

EndEdit Abort

Cont-inue

CancelZ-AXIS F-AXIS

AllAxes

QuickBend

Set-upMode

ToolingLibrary Abort

Cont-inue

Cancel SelectSingle

Un-SelectAll

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

Shapeto PartDesign

DesigntoShape

11 charun-sorted

LastStep

CopySteps

JobData

Done GageData

Abort

TransfrShape/Part

UpperTool

LowerTool CAD Shape

TeachData Text

ToolingLibrary Abort

SeqNumber Name ESC nn \ / ? " ' ;

PROGRAM:DEMO1PROG

CADMenu

SHAPE LIBRARY

STATUS: Make a selection using the softkeys.

SelectCurrentShape

DeleteShape

TransfrShape/Part

PartDesignMenu

ChangeDisplayView

CURRENT SHAPE: KPATH:VOLUME: Internal

BYTES REMAINING: 96000

1 A 2 B 3 C 4 D

5 E 6 F 7 G 8 H

9 I 10 J 11 K

7-77

Selecting the "Display Text" softkey will erase theshapes from the screen and display a list of shapesin text format similar to the PROGRAM STORAGEor PART STORAGE MENUs. All functions discussedabove for transferring, deleting or selecting currentshapes will work the same, except that the shapeswill not be drawn. This feature may by used insome cases to search for a shape quickly withouthaving to page through 16 shapes at a time.

Following is a diagram of the SHAPE LIBRARY inthe all text format.

Selecting the "Display Shape" softkey will changethe display back to the graphical listing if the textformat was previously being used.

Two additional softkeys are displayed which allowthe operator to quickly select the PART DESIGNMENU or go back to the AUTOFORM CAD MENU.

This completes the discussion the the SHAPELIBRARY and the AUTOFORM CAD MENU.

❦

PROGRAM:DEMO1PROG

CADMenu

SHAPE LIBRARY

STATUS: Make a selection using the softkeys.

SelectCurrentShape

DeleteShape

TransfrShape/Part

PartDesignMenu

ChangeDisplayView

CURRENT SHAPE: KPATH:VOLUME:

BYTES REMAINING: 96000

SEQ DATE SEQ SHAPE NAME DATESHAPE NAME

1234567891011

ABCDEFGHIJK

Sep 14 88 10:58Sep 14 88 10:59Aug 16 88 12:36Aug 16 88 12:38Aug 16 88 12:39Aug 16 88 12:40Aug 16 88 12:42Aug 16 88 12:43Sep 14 88 11:01Sep 14 88 11:04Sep 14 88 11:05

7-78

ADDITIONAL OPERATOR CONTROLSOne additional palmbutton Operator Stationand/or footswitch can be installed on the AUTO-FORM. See previous description of MACHINE CON-TROLS STATION in SECTION 6 - MACHINE CON-TROLS for the operation of these controls.

AUTO CROWN

The Auto Crown option is a special bed with avariable proportional crown which automaticallycompensates for both bed and ram deflection for anapplied centered load of any magnitude and lengthup to the nominal machine length. It causes thebed and ram to remain parallel in the loaded con-dition. With this device, the bend angle remainsconstant along the length of the bend.

A machine equipped with Auto Crown does nothave a microcrowned bed. The bed top and ramnose are machined straight.

The bed is sandwiched between two auxiliary crossmembers. All three are pinned together at twoplaces near the end of the bed as shown in Figure8-1. A hydraulic cylinder is mounted in slots in thecenter of these three members. The top of the pis-ton contacts the top of the slot in the bed. The bot-tom of the cylinder contacts the bottom of slots inthe auxiliary cross members.

FIGURE 8-1 – Auto Crown

The force developed by Auto Crown cylinder isproportional to the forming load. This force pushesup on the center of the bed. The cylinder is of sucha size that its force is approximately twice as largeas the forming load. The bed therefore deflects upan amount equal to the deflection of the ram. Theresult is that the bed and ram remain parallel andthe upper die penetration is uniform along the bendlength. Longer machines may have two AutoCrown cylinders.

AUTOFORM ADAPTIVE BENDINGAdaptive bending option allows the AUTOFORM toadapt to a change in material strength and thick-ness by changing the ram reversal position whenair bending parts. The feature includes a TEACHmode, which requires a series of test bends. Fromthese test bends the Control determines the rela-tionship between material strength, material thick-ness, ram position and bend angle. The test bendsare made once for a set of dies, with the informa-tion stored in the Control’s memory.

At the start of the bend the ram reversal point isunknown. The material thickness and materialstrength of the piece being bent are measured dur-ing the bend. The Control uses this informationand the information from its memory, “learned”during the TEACH mode, to calculate a ram rever-sal point. When this point is reached, the ramreverses. All of these calculations occur during theactual bend cycle for every stroke.

It is important to read the Adaptive Bending opera-tion described in a separate manual EM-327.

BACKGAGESSet-up, programming and operating techniques forthe optional backgages are described in the follow-ing procedures. Also described are the gage assem-blies and fingers used with these backgages.

GAGE ASSEMBLIES

! W! WARNING !ARNING !THE FOLLOWING GAGE FINGER ADJUSTMENTSSHOULD NEVER BE MADE WHILE THE GAGEASSEMBLY IS IN PLACE ON THE BACKGAGE.ALWAYS USE THE FINGER ASSEMBLY POSITION-ING TOOL TO REMOVE THE GAGE ASSEMBLY.

EM-444 (N-09/99) 8-1

SECTION 8 OPTIONS

The gage finger assemblies are installed orremounted by using the finger assembly positioningtool (Figure 8-2). This tool releases the gage assem-bly clamp and holds the assembly while it is beingmoved. The finger assembly positioning tool can beused to position the gage assemblies from the frontof the machine.

FIGURE 8-2 – Finger assembly positioning tool

GAGE FINGERS

Several types of gage fingers are available for theAUTOFORM backgages. The 1" (25.4mm), 1/4"6.4mm) and 1/8" (3.2mm) (optional) fingers areinstalled in the standard gage assembly. For gaginglarge or heavy material, the heavy duty gage blockreplaces the standard gage assembly. Refer to Fig-ure 8-3.

The 1/4" (6.4mm) gage fingers can be rotated in thegage assembly to provide either a one inch or a one-quarter inch high surface for short flanges. See Fig-ure 8-4 for minimum flange dimensions. The 1/8"(3.2mm) gage finger (optional) can be used forsmaller flanges. The 1" (25.4mm) square gage fingeror the heavy duty gage block should be used when-ever possible, as these provide the largest gage tar-get and contact area.

IMPORTANT: The selected gage surface shouldbe analyzed carefully to avoid interferencewith the tooling.

The 1/8" (3.2mm) (optional) and 1/4" (6.4mm) gagefingers can also be used as a sheet support, asshown in Figure 8-5.

FIGURE 8-3 – Gage/finger assemblies

➛➛

➛➛

➛➛

➛

➛

.25

4.03.0

1.0

1.0

➛➛1.0

➛

➛

➛➛

➛➛

➛

➛

4.03.0

1.0

➛➛1.0

STD. GAGE ASSEMBLY – 1" FINGER

STD. GAGE ASSEMBLY – 1/8" & 1/4" FINGER

FINGER OFFSET = 0.0"

FINGER OFFSET = 0.0"

HEAVY DUTY GAGE BLOCK

FINGER OFFSET = -3.0"

➛ ➛

➛

➛

1.0

1.5

8-2

FIGURE 8-4 – Minimum flange size

FIGURE 8-5 – Gage finger used as sheet support

PROGRAM GAGE POSITION(S)

The actual position of the gage in relation to thetooling is selected when entering a program into theAUTOFORM Control. This procedure is described in“GAGE DATA MENU”, which appears in SECTION 7.The actual gage dimension from the centerline ofthe tooling to the gage surface is determined byflange dimension, bend allowance and finger offsetprogram inputs. See Figure 8-6.

FIGURE 8-6 – Actual gage dimensions

R-AXIS / Z-AXIS DISABLE

This control feature is provided when either a Six-Axis, Plate Gage or the powered "R" option isinstalled on the AUTOFORM. Its purpose is to pre-vent "R" or "Z" gage motion when a gage bar or rearmaterial supports are used. An "R", and Z-axis fieldwill be displayed in the JOB DATA screen if both anR and a Z-axis are present. If only an R-axis is pre-sent, the display will show the R-axis field. If theseoptions are not installed, this field will not appearon the JOB DATA screen.

The R, Z-axis field allows these axes to be turnedOFF. When OFF, no motion will occur along theseaxes, even if positions have been set in the pro-gram. The default value is ON.

The value of this field is saved with the program.When a program is loaded from Program Storage,the state of the R, Z-axis field is checked. If the fieldis set to ON, the R, Z-axis value may be changedfrom the program being loaded. If the field is set to

– BEND ALLOWANCE AND – FINGER OFFSETWILL MOVE THE GAGE FORWARD TOWARDTHE TOOLING.

+ BEND ALLOWANCE AND + FINGER OFFSETWILL MOVE THE GAGE BACKWARDS AWAYFROM THE TOOLING.

➛ ➛

➛ ➛

+–

A

"A" (ACTUAL GAGE DIMENSION) =X-AXIS DIM. ± BEND ALLOWANCEAND ± FINGER OFFSET.

WORK SUPPORT

➛

FINGER OFFSET = -1.0”WHEN USED AS SHEETSUPPORT

.25(6.4).375(9.5)

.5(12.7).625

(15.9).75(19).875

(22.2)1"

(25.4)1.125(28.6)

1.125(28.6)1.188(30.2)1.25

(31.8)1.313(33.3)1.375(35)

1.438(36.5)

1.5(38.1)1.563(39.7)

.438(11.1)

.5(12.7).563

(14.3).625

(15.9).688

(17.5).75(19).813

(20.6).875

(22.2)

.313(8)

.375(9.5).438

(11.1).5

(12.7).563

(14.3).625

(15.9).688

(17.5).75(19)

VEE

FINGER SIZE1"

(25.4mm).25

(6.4mm).125

(3.2mm)

8-3

OFF, the R, Z-axis value from the program beingloaded is ignored. The only way to change the R, Z-axis field from OFF to ON is to enter the JOB DATAscreen and manually change it.

HEAVY DUTY BACKGAGE(CNC Plate Backgage in the Control)Two types of gaging surfaces are furnished withHeavy Duty Backgages. Heavy duty gage blocks arenon-adjustable hardened steel assemblies, whichare generally recommended for gaging large sheetsor plates (over 100 lbs./45.4kg). Standard gageassemblies consist of an aluminum body with anadjustable finger holder, which can be used tomount a variety of gage fingers. See Figure 8-7.

The gage finger assemblies should be positionedleft-to-right to contact the part being formed at thedesired gage points. Normally, the two gage fingerassemblies should be spread as wide as possible toprovide the most accurate gaging. The gage fingerassemblies are moved along the gage bar by usingthe finger assembly positioning tool (Figure 8-2).This tool releases the gage assembly clamp andholds the assembly while it is moved. The fingerassembly positioning tool can be used to positionthe gage assemblies from the front of the machine.

Minor part flange differences (end-to-end) can becorrected by adjusting the individual gage fingerseither forward (to shorten flange) or backward (tolengthen flange). First remove the gage assemblyfrom the backgage bar. Loosen the finger by pullingout the locking knob (Figure 8-7) and turning knobcounterclockwise. The adjusting collar has a totalrange of .060" (1.5mm).

Adjust the collar forward the desired amount.Reseat finger shoulder tightly against adjusting col-lar and tighten the locking knob.

FIGURE 8-7 – Gage assembly

Note: The locking pin spins freely unless it is pulledout. This allows the knob to rest against thebackgage face, thus preventing the finger frombeing unlocked while the assembly is in posi-tion on the gage bar.

IMPORTANT: Do not use the standard gage fin-ger assemblies when gaging plates orsheets that weigh over 100 lbs. (45.4kg).Damage to adjustable finger holder couldresult. Use Heavy Duty Gage Blocks forthese applications. Never allow the work-piece to contact the aluminum gage bar.Bar damage could result.

Note that finger offset must be entered when usingHeavy Duty Gage Blocks and other gages which arenot 3.000" (76.2mm) long. Procedure for enteringFINGER OFFSET is described below. Examples offinger offset values for some common applicationsappear in Figures 8-3, 8-5 and 8-6.

To enter finger offset for the Heavy Duty Backgage,use the following GAGE DATA (2) MENU.

Normally the control will position the gage barrelative to the ram centerline for a gage surfacethat is 4.000" (102mm) in front of the face of thegage bar. This is correct when using standardgage finger assemblies with 3.000" (76mm) longfingers, along with tooling that is centered onram centerline. Shorter gage assemblies requirenegative offset and longer assemblies requirepositive offset values. Heavy duty gage blocksrequire a -3.000" (-76mm) offset since their gagesurface is 1.000 (25.4mm) in front of the gagebar. See Figure 8-6 for more information.

PROGRAM:TEST001

STATUS: Enter new part number using keypad.

JOB DATA

PART NUMBERMATERIAL THICKNESSCLAMP POS ADJMATERIAL TYPEK-Forming Factor

LastMenu

156010.130 in.

0.000 in.Mild Steel

AUTO

RamData

RunMode

ChangeProgramName

RETURN SPEEDGUARD MUTE PTR, Z AXISFRONTGAGE

20.0 in/mintop of mat + 1/4

ONBOTH ON

TOOL SETSUPPER LOWER SPECIAL INSTRUCTIONS

A:B:C:D:E:

6 AUG 8912:00 PM

8-4

◆ Enter the following for FINGER OFFSET:

Vertical position of the gage bar is controlled byAUTOFORM programs using the R-RIGHT and R-LEFT fields. The procedure for entering Bar Heightinto a program is described below. Sometimes itmay be desirable to position the gage bar manuallyusing the Remote Gage Pendant. Individual UP andDOWN switches on pendant allow control of bothends of the gage bar.

The bar height will depend upon the shape of thepart being formed. Care should be exercised whenthe gage bar is being positioned close to the dies orwork supports to avoid interference.

The R-LEFT and R-RIGHT fields position the verti-cal height of the gage fingers. When the '"R" positionis 0.000", the bottom of the Standard 1" (25.4mm)square finger will be 0.000" above the top of thelower die. If non-standard fingers are used whichare greater than one inch, adjust the "R" positionsby a positive number equal to one-half the differ-ence. If non-standard fingers are used which areless than one inch, adjust the "R" positions by anegative number equal to one-half the difference.For example, if a 1.5" (38.1mm) finger is used,make all "R" positions .25" (6.4mm) higher. If a .5"(12.7mm) finger is used, make all "R" positions .25"(6.4mm) lower.

The default position for both R-LEFT and R-RIGHTis 0.050" (1.27mm) above die.

◆ Enter the following for R-LEFT to position thebottom of the left finger 1.000" (25.4mm) abovethe die:

The R-RIGHT dimension automatically defaults tothe same value as was selected for the left dimen-sion. Either this default value or a new value can beselected.

Press the ENTER key to keep the R-RIGHT dimen-sion the same as the left.

IMPORTANT: Since the gage bar height on theHeavy Duty Backgage is programmable,there is danger of collision between thegage bar and work supports. Special careshould be taken when programming thegage with work supports.

SIX-AXIS BACKGAGE

Gaging surfaces furnished with the Six-Axis Back-gage include two standard gage assemblies, andtwo 1" (25.4mm) and two 1/4" (6.4mm) gage fin-gers. These fingers are shown in Figure 8-3.

The gage assembly adjusting collar is normallynot used for Six-Axis Backgage applications. Thecollar should be adjusted to .00” and left in thisposition. Otherwise the programmed positioncould be off the amount the adjusting collar isturned out. See Figure 8-7. Minor adjustments tothe part flange dimensions can be made to X-axisright and left input dimensions using INDEPEN-DENT GAGE mode.

The Six-Axis Backgage is programmed by X-axis, R-axis and Z-axis inputs.

The actual position of the gage finger in relation tothe tooling in the X-axis direction is determined bythree program inputs. They are the X-axis dimen-sion, bend allowance and finger offset. See Figure8-6. To enter X-axis positions, refer to GAGE DATAMENU described earlier in this section.

An R-axis position is required for each step in aprogram. A dimensional value for each step of theprogram must be selected. The R-axis position isillustrated in Figure 8-8.

1 ENTER

NO– ENTER3

PROGRAM:TEST001

STATUS: Enter new value using keypad.

GAGE DATA (2)

Page 1RamData

JobData

RunMode

FINGERSTEP OFFSET R-left R-right

1 0.000 00.050 00.050

2 0.000 00.050 00.050

Trans-fer

8-5

FIGURE 8-8 – R-axis position

To enter R-axis and Z-axis positions, use the GAGEDATA (2) MENU shown below:

◆ Enter the following for R-LEFT to position thebottom of the left finger 1.000" (25.4mm) abovethe die.

The R-RIGHT dimension automatically defaults tothe same value as was selected for the left dimen-sion while in ENTER NEW PROGRAM. But if youare in EDIT mode, then both must be changed indi-vidually. Either this default value or a new valuecan be selected.

◆ Press the ENTER key to keep the R-RIGHTdimension the same as the left.

The Z-LEFT and Z-RIGHT fields position the gagefingers horizontally left-to-right. The default values

for Z-LEFT and Z-RIGHT are the maximum left andright positions. These depend on the length of themachine.

A Z-axis position is required for each step of a pro-gram. A dimensional value for each step of the pro-gram can either be selected or manually transferredto the program step. At the 0.000 position the cen-ter of the finger is at the center of the machine. Neg-ative (-) numbers are to the left of center and posi-tive (+) numbers are to the right.

For each bend being made the fingers should bespread as far as possible to provide the most accu-rate gaging.

◆ Enter the following for Z-LEFT gage finger 24"(610mm) to the left of center:

The Z-RIGHT dimension automatically defaults tothe same value as was selected for the left dimensionwhile in ENTER NEW PROGRAM, except that thesign becomes positive. But if in EDIT mode, thenboth must be changed individually. Either thisdefault value or a new value can be selected. Alwaysmaintain a minimum of 3" (76.2mm) clearancebetween Z-LEFT and Z-RIGHT dimension to avoidinterference.

◆ Press the ENTER key to keep the Z-RIGHTdimension the same as the left and the gage fin-gers symmetrical about the center of themachine.

SPECIAL STEP PROGRAMMING

IMPORTANT: In some special machine set-ups whenmultiple dies or special die sets (i.e. punching diewith guide pins) are used, it is necessary to takespecial precautions when programming to pre-vent gage finger interference with the tooling.

When direct line movement of gage finger(s) alongthe Z or R-axis would cause a collision between thegage and tooling (Figure 8-9), a "dummy" (extra)step(s) should be added to provide a motion patharound obstacles for the gage finger to follow. Extrasteps can be added by setting the REPEAT at "0" forthat step. This will allow the gage to cycle throughthe extra step without cycling the ram.

As shown in Figure 8-9, when moving from position"A" to position "B" along the Z-axis, possible inter-ference could occur at the step between the diesunless an extra (dummy) step(s) is added. The extrastep would first move the fingers backward andupward away from the dies. The bending step wouldthen move the gage sideways and finally back intoposition over the higher die. This step would elimi-nate the gage/tooling interference.

2 4 ENTERNO–

1 ENTER

PROGRAM:TEST001

Page 1

GAGE DATA (2)

STATUS: Select function using softkeys.

NextStep

JobData

STEPFINGEROFFSET R-left R-right

12

0.0000.000

00.05000.050

RamData

00.05000.050

Z-left Z-right

-46.630-46.630

46.63046.630

EndNewPgm

Trans-fer

➛

➛

➛

8"

2"

TRAVEL LIMIT

0.0000"R" POSITION

8-6

FIGURE 8-9 – Special step programming

CONTINUOUS RUN MODEThe MODE SELECT switch may have an optionalfourth position - “RUN”. This is a production modethat will continue to cycle through the program aslong as the active control is depressed. The opera-tor is not required to release the control betweenstrokes.

DATA CARTRIDGE STORAGEThe external DATA CARTRIDGE STORAGE unit islocated on the side of the main electrical enclosure.Behind the flip-up cover is a receptacle into whicha data cartridge can be inserted. Figure 8-10 showsthe enclosure and the DATA CARTRIDGE.

The flip-up cover should always be kept closedwhen not accessing the cartridge inside. The car-tridge is used to make a copy of the informationstored in the internal memory of the AUTOFORMControl. This consists of the TOOLING LIBRARY,PROGRAM STORAGE and optional ADAPTIVE FILESTORAGE. Once the internal memory of the controlhas been copied to a data cartridge, it can be re-loaded back into the control at a later date.

There are two reasons for using a data cartridge.One is simply to back-up the information stored inthe Control. If for some reason the AUTOFORMControl internal memory is erased, it can be recov-ered from the cartridge.

The other reason for using a data cartridge is toprovide additional storage for programs and toolsand optional Adaptive files. Once the internal mem-ory of the Control is filled, no additional programs,etc., can be stored there. Using data cartridges, the

internal memory can be stored on a cartridge. Theinternal memory can then be erased and filled withnew files.

When it is necessary to recall a file which wasstored on the data cartridge, transfer the data car-tridge memory back into the AUTOFORM Controlinternal memory. Note that whenever the data car-tridge is loaded into the AUTOFORM Control, allfiles previously stored in the internal memory areerased. Therefore, if the operator is using the datacartridges to gain additional storage, at least twocartridges are required to swap internal memory toand from the cartridge.

The data cartridge contains non-volatile memory,which means it can be disconnected from the Con-trol without losing any data. The cartridge will holdthe information stored on it for many years. Thecartridge also has a “Write Protect” switch whichselects whether data can be stored. If the Write Pro-tect switch is “ON”, then no information can bestored on the cartridge. Turning the switch to the“OFF” position will allow the cartridge to be used forstoring data.

FIGURE 8-10 – Panel for Data Cartridge Storage

The AUTOFORM menu used to access the data car-tridge is the FILE UTILITY MENU. "Back-up/Restore Internal" softkey is used.

8-7

Press one of the following softkey to access the datacartridge:

Pressing the "Intern To Cart" softkey will cause allthe internal memory to be transferred to the datacartridge currently inserted in the panel. A warningmessage will appear and allow the operator to can-cel as shown below:

STATUS: Copy all internal memory to Data cartridge?

IMPORTANT: All the data in the cartridge will beoverwritten!

At this time the operator may cancel the transfer bypressing the "Cancel" softkey. If the "Yes" softkey ispressed, the status line will change as follows:

STATUS: Change name of Cartridge?

If you select the "Yes" softkey, the operator isallowed to enter up to sixteen characters for a car-tridge name. Pressing the "Cancel" softkey will con-tinue with the transfer process.

Once the transfer is complete, the PROGRAMSTORAGE softkeys will return.

Pressing the "Cart To Intern" softkey will cause allthe internal memory to be replaced with that storedon the data cartridge. A warning message willappear and allow the operator to cancel as shownbelow.

STATUS: Copy all cartridge data to internal memory?

IMPORTANT: All data in internal memory will beoverwritten!

At this time, the operator may cancel the transfer bypressing the "Cancel" softkey. If the "Yes" softkey ispressed, the transfer will begin and, when complete,the PROGRAM STORAGE softkeys will return.

CNC FRONTGAGEThe CNC Frontgage is designed to gage sheets up to3/16"/4.8mm maximum thickness that weigh lessthan 400 lbs. (181.4kg) or 200 lbs. (90.7kg) perunit. Heavier sheets may be gaged if additionalwork supports are used. Reasonable care should beused when positioning heavy sheets.

IMPORTANT: Heavy shock load could damage partsof the frontgage.

Each gage unit has a programmable gage range of40" (1016mm). The absolute maximum and mini-mum programmable gage positions vary dependingon the press brake bed width.

The carriage travel is limited to 10" (254mm) andthe operator must select the proper finger to useduring gaging.

The gage bar vertical range is 6" (152.4mm) andshould accommodate most die heights.

The gage units can be positioned anywhere alongthe bed of the press brake. The maximum distancebetween gage fingers is the actual bed length minus29" (736.6mm). The minimum distance betweengage fingers is 5" (127mm). For example: A 135 x 10Ft. AUTOFORM Press Brake has an actual bedlength of 144" (3657.6mm). This means the maxi-mum distance between fingers is 144" - 29" = 115"(3657.6 - 736.6 = 2921mm) and the minimum is 5"(127mm).

CNC FRONTGAGE SET-UPBased on the workpiece, determine where the gageunits will be positioned along the press brake bed.The gage units should be positioned such that theyadequately support the workpiece and are posi-tioned as far apart as possible to provide accurategaging. If a single gage unit with the squaring armis to be used, the other unit should be positionedout of the way, near the end of the press brake withdisabled command in the control.

To move the gage units, loosen the housing clamphandles (1/2 turn). Move the gage units to thedesired positions along the front of the press brake.Tighten the housing clamp handles.

Yes CancelStain-lessSteel

SoftAlum

HardAlum

SoftCopper

HardCopper

ToolingLibrary

ProgramStorage

Yes CancelStain-lessSteel

SoftAlum

HardAlum

SoftCopper

HardCopper

ToolingLibrary

ProgramStorage

Yes CancelStain-lessSteel

SoftAlum

HardAlum

SoftCopper

HardCopper

ToolingLibrary

ProgramStorage

InternToDisk

DiskToIntern

colonInternToCart

CartToIntern

| ^ ~ Abort

PROGRAM:TEST0001 F I L E U T I L I T Y

STATUS: Select a function using the softkeys.

Drive Volume: LOCAL DRIVE A

Disk Format: High Density

Current Path: \

OPERATION STATUS: WAITING

FileMenu

ChangeDriveOptions

30 APRIL 9112:00 AM

ChangePath

FormatLocalDisk

RebuildIndex

DeleteFile(s)

Back-up/RestoreInternal

Back-up/RestoreConfig

MakeNewDIR

8-8

Note: Failing to tighten the housing clamp handlescould result in damage to the gage unitmounting track.

To set the gage bar height, turn the vertical adjust-ing handles until the top of the gage bars are flushto 1/32" (.793mm) above the lower die.

After the gage units have been positioned andclamped, select which units are to be enabled. Toenable the frontgage, select the JOB DATA screen.If a frontgage is present, the display will show afrontgage field. If this optional feature has not beeninstalled, this field will not appear on the JOBDATA screen. Move the cursor to the frontgage fieldand enable the desired gage unit(s) by pressing oneof the four softkeys. The options are BOTH OFF,LEFT ON, RIGHT ON, OR BOTH ON.

The frontgage has now been set-up and is ready toprogram.

CNC FRONTGAGE OPERATION

Before operating the frontgage, read and under-stand the safety guidelines on Page 8-11.

Note: Frontgage mounting position and adjustmentmay interfere with point-of-operation safe-guarding. Ensure safeguarding is not compro-mised and operator protection is maintained.

The operation of the CNC Forming Center with afrontgage enabled is the same as without, exceptthe operator now has the ability to frontgage partsthat may have been difficult or inaccurate to gagewhen backgaging.

Before the first cycle of the ram and if the gage barneeds repositioning, the operator will be promptedto initiate the frontgage movement. The status lineon the control display will read: "Initiate FrontgageMovement with Softkey or Pushbutton". The opera-

tor should now press the softkey display on thescreen. This will cause the frontgage to reposition.

Based on the following criterion, the frontgage mayor may not automatically reposition during thebend for the remaining program steps:

◆ If the next frontgage movement is away from thedie, the frontgage will automatically repositionat the workpiece clamp point.

◆ If the next frontgage movement is towards thedie, the frontgage will not reposition until theram gets to a predetermined position below theclamp point, thus allowing front edge of theworkpiece to clear the gage fingers.

◆ If the desired bend angle is shallow and theworkpiece edge will not clear the gage finger, thefrontgage will not reposition and the operatorwill be prompted to initiate the gage movementthe same as before.

The operator must select the proper gage finger touse during gaging since there is a 40" (1016mm)gage range, but only a 10" (254mm) carriage travel.

The proper finger to use during gaging will be dis-played on the RUN MODE screen under the front-gage data fields. The fingers are numbered (1), (2),(3) and (4), with number (1) being closest to the die.

The following is a list of finger ranges for each pressbrake bed width:

3.50" Wide Bed

Finger #1 3.500" to 13.500"Finger #2 13.501" to 23.500"Finger #3 23.501" to 33.500"Finger #4 33.501" to 43.500"

4.50" Wide Bed

Finger #1 4.000" to 14.000"Finger #2 14.001" to 24.000"Finger #3 24.001" to 34.000"Finger #4 34.001" to 44.000"

5.50" Wide Bed

Finger #1 4.500" to 14.500"Finger #2 14.501" to 24.500"Finger #3 24.501" to 34.500"Finger #4 34.501" to 44.500"

! ! DANGER ! !! ! DANGER ! !MAKE SURE YOU KNOW WHEN AND WHERETHE GAGE WILL MOVE BEFORE YOU PLACETHE FRONTGAGE IN OPERATION.

PROGRAM:TEST001

STATUS: Enter new part number using keypad.

JOB DATA

PART NUMBERMATERIAL THICKNESSCLAMP POS ADJMATERIAL TYPEK-Forming Factor

LastMenu

156010.130 in.

0.000 in.Mild Steel

AUTO

RamData

RunMode

ChangeProgramName

RETURN SPEEDGUARD MUTE PTR, Z AXISFRONTGAGE

20.0 in/mintop of mat + 1/4

ONBOTH ON

TOOL SETSUPPER LOWER SPECIAL INSTRUCTIONS

A:B:C:D:E:

6 AUG 8912:00 PM

8-9

For example, if a 25.500" (647.7mm) frontgagebend was required on a 350AF (5.50" wide bed), theoperator should use Finger #3 since 25.500"(647.7mm) is within the 24.501" to 34.500"(622.3mm to 876.3mm) finger range.

Note: Be sure to retract the unused gage fingers to helpreduce the possibility of injury as well as incorrectgaging.

PROGRAMMINGThe frontgage can be programmed in either RUNMODE or QUICK BEND mode-of-operation. In theRUN MODE, the gage can be programmed from theRUN MODE screen or the GAGE DATA (2) screen.

Note: All gage distances are from the centerline of theupper die slot.

RUN MODE PROGRAMMING

To program from the RUN MODE screen, press the"Edit" softkey, then select proper program step andmove the cursor to the F-left and/or F-right fieldand enter the desired gage position(s). The left andright gage units are independently programmableand can have the same or different gage positions.Continue editing each step of your program andpress the "End Edit" softkey when complete.

The Control displays below each frontgage dimen-sion the number of the corresponding gage finger tobe used to obtain the desired flange length. Gagefinger number 1 is the finger closest to the ram. Theremaining fingers are numbered sequentially goingaway from the ram.

To program from the GAGE DATA (2) screen, movethe cursor to the F-left and/or F-right field underthe desired step and enter the desired gage posi-tion(s). Continue entering steps to your program ina similar manner. Press the "End New Program"softkey when complete.

QUICK BEND PROGRAMMING

The QUICK BEND MENU is selected by pressing the"Quick Bend Menu" softkey from the MAIN MENU.

The "Move Gage(s)" softkey is used to enter anabsolute position for the frontgage. Pressing thissoftkey will cause the status line to change to:

STATUS: Enter New Value Using Keypad.

To change the position of the frontgage, enter avalue and press ENTER. The frontgages will thenmove to the requested position. During the QUICKBEND mode, the left and right gage units are notindependently programmable.

Note: If the main drive motor is off, the frontgagewill not move.

PROGRAM:TEST001

STATUS: Enter new value using keypads.

QUICK BEND

TOP STOPSPEED CHREV. POS

17.0013.00 10.3800

REV. MODEREV. TONS FORM SPEED

Position125.0 10.0

RAM LOCATION 17.0000PREVIOUS LOAD 40.0

TILTDWELLUP STOPDOWN STOP

0.00000.0 OFF OFF

X 12.000R 7.500Z -20.500F 10.000

12.0007.50018.37510.000

CopyCurrentStop

MoveGage(s)

TransferCycleStart

6 AUG 8912:00 PM

CopyLastStroke

LEFT RIGHT

GageRetract

PROGRAM:TEST001

STATUS: Select function using softkeys.

GAGE DATA (2)

Page 1JobData

RamData

EndNewPgm

FINGER LEFT RIGHT GAGE RETRACT PAUSESTEP OFFSET R-left R-right Z-left Z-right F-left F-right

1 0.000 00.050 00.050 -46.630 46.630 2 0.000 00.050 00.050 -46.630 46.630

Stand-ard

Indep-endent

Taper

6 AUG 8912:00 PM

NextStep

PROGRAM:TEST001

STATUS: Select function using the softkeys.

RUN MODE

Simu-late

LastStep

NextStep

StartAutoSeq

StartSingleStep

PrevStep

FirstStep Edit

ManageData

STEP 1 of 2REV. MODEFLANGE DIM.BEND LENGTH

Angle3.00024.0

ACTUAL ANGLERAM OPENINGTOOL SETTILTUP STOPDOWN STOPDWELL

90.01.0

A0.0000

ONOFF

0.0

FORMING SPEEDGAGE MODEBEND ALLOWANCERETRACT DISTANCECLAMPPAUSE TIMEFINGER OFFSET

20.0Standard

-0.0602.50ON1.0

0.000

Left Right

R 4.000 4.000

Z -24.000 24.000

F 18.000 18.000

2 2

PREVIOUS LOAD40.0

REPEAT 1 of 1 90.0

BEND POS Center

PART CT. 0000BATCH SET 0005

6 AUG 8912:00 PM

8-10

CNC FRONTGAGE SAFETY SIGNS

WEIGHT LIMIT CAUTION (424448)

This caution sign is attached to the frontgage hous-ing. It provides a reminder to the operator not toexceed the maximum sheet weight limit of 200 lbs.(90.7kg) per gage unit.

DANGER (424447)

This warning sign is attached to the most visiblelocation on the frontgage housings. The sign is areminder to operators or maintenance personnelthat certain procedures must be followed to preventserious bodily injury.

SAFETY GUIDELINES (424444)This sign is also attached to the frontgage housingnear the Danger sign. It provides a checklist of safe-ty considerations which should be observed beforeand during operation of the frontgage.

GRAPHICS SOFTWARE2D GRAPHICS

The 2D Graphics Software option adds the follow-ing features:

✦ Automatic Bend Sequence selection to avoidmachine interference.

✦ Graphic Bend Simulation of selected sequence.

✦ Generation of program from sequence.

✦ Parts Orientation Guide.

The operation of this option is explained in a sepa-rate supplement manual (EM-339).

The 2D Graphics Software may also be used in con-junction with the Offline Programming System(Optional). See supplement manual (EM-399) forfurther information.

3D GRAPHICS

The 3D Graphics Software option adds the follow-ing features:

✦ Ability to convert 3D wireframe and 2D flat pat-tern drawings from CAD systems supportingthe DXF file format.

✦ Ability to design a 3D part directly on themachine control or offline PC.

SAFETY GUIDELINESF R O N T G A G E

READ AND UNDERSTAND THE OPERATION, SAFETY AND MAINTENANCE MANUAL.KNOW HOW TO USE THE OPERATOR CONTROLS AND MODES OF OPERATION.

SET-UPTIGHTEN HOUSING CLAMPS BEFORE PLACING SHEET ON GAGE BAR.POSITION TOP OF GAGE BAR JUST ABOVE TOP OF LOWER DIE.RETRACT GAGE FINGERS WHICH ARE NOT USED.ADEQUATE MATERIAL SUPPORTS SHOULD BE USED.

OPERATIONUSE POINT-OF-OPERATION SAFEGUARDING.KNOW THE SET-UP AND PROPER METHOD OF OPERATION.KEEP HANDS AND OTHER PARTS OF YOUR BODY AWAY FROM GAGE WHILE IT ISBEING POSITIONED.NEVER PLACE HANDS BETWEEN GAGE BAR AND TOOLING.DO NOT STAND BEHIND GAGE BAR.USE HAND TOOLS FOR SMALL OR NARROW PIECE PARTS.MAKE CERTAIN EVERYONE IS CLEAR OF GAGE UNIT AND MATERIAL BEFOREOPERATING.DISABLE UNUSED GAGE UNIT WHEN USING SINGLE GAGE WITH SQUARING ARM.DO NOT POSITION ANY PART OF YOUR BODY WHERE IT MAY BE STRUCK ORCRUSHED BY PART MOVEMENT.

DO NOT REMOVE THIS SIGN FROM THIS FRONTGAGE 424444

●●

●

●

●

●

●

●

●

●

●

●

●

●

●

DANGERTO REDUCE THE POSSIBILITY OF SERIOUS INJURY . ..DO NOT

DO NOT

ALWAYS

POSITION ANY PART OF YOURBODY WHERE IT MAY BE CAUGHTBETWEEN THE GAGE BAR ANDTHE MATERIAL BEING GAGED

ALLOW THE MATERIAL BEING GAGEDTO BECOME TRAPPED BETWEEN THEGAGE BAR AND LOWER TOOLING

READ AND UNDERSTAND THEOPERATION, SAFETY ANDMAINTENANCE MANUAL BEFOREOPERATING OR SERVICING

424447DO NOT REMOVE THIS SIGN FROM THIS FRONTGAGE

CAUTIONMAXIMUM SHEET WEIGHT

200 LB. PER UNIT

DO NOT REMOVE THIS SIGN FROM THIS FRONTGAGE 424448

CAUTIONWhen programming front and backgage, theprogrammer should guard against workpiecebeing trapped between the frontgage and back-gage. It is recommended the operator retract allfrontgage fingers when using the backgage,and program backgage to its maximum valuewhen using frontgage.

8-11

✦ Automatic fold/unfold of flat pattern and wire-frame part.

✦ Bend simulation and machine interferencechecking in 3D.

✦ Automatic creation of bending program.

✦ Ability to export wireframe or flat pattern as aDXF file.

✦ Pointing device for selecting geometry and editfields.

✦ Internal file storage is now double the capacity(192k).

✦ Support for European tooling.

✦ Ability to import tools using DXF files.

✦ Graphic display of tool layout in SETUP screen.

✦ Support for segmented tooling.

The operation of this option is explained in a sepa-rate supplement manual (EM-448).

The 3D Graphics Software may also be used in con-junction with the Offline Programming System(Optional). See the same supplement manual (EM-448) for further information.

OFFLINE PROGRAMMINGThe Offline Programmer is a software package thatwill allow creating (or revising) AUTOFORM partprograms, adding new tools to the tooling library,and graphical part design and simulation on a per-sonal computer totally independent of the AUTO-FORM control.

The Offline Programmer user interface is nearlyidentical to the AUTOFORM control user interface.Personnel familiar with the AUTOFORM control canoperate the Offline Programmer with a minimum ofadditional training. Program files, tooling files,CAD/graphics files, etc. can then be transferred tothe AUTOFORM by either the RS-232/422 serialcommunications link or by duplicating the desiredfiles to an MS-DOS floppy disk and then taking thefloppy disk to the AUTOFORM control which canthen use these files.

MANUAL FRONT GAGESFixed front gaging and material supports are avail-able for the AUTOFORM. Gage brackets and gagestops are manually set to position material for form-ing. Front gage brackets without gage stops can alsobe used to support material. See Figure 8-11.

FIGURE 8-11 – Frontgage supports

POWER CLAMPPower Clamp eliminates the need to loosen andretighten die clamp nuts when changing dies.Hydraulic power is used to unclamp the die hold-ers. Once the dies are installed and POWER CLAMPis deactivated, powerful springs hold the dies inplace. Power Clamps are available for the ram, bedor on both. See Figure 8-12. Operation is describedin SECTION 5 - SET-UP & USE.

8-12

FIGURE 8-12 – Ram Power Clamp

PRESENCE SENSING SAFE-GUARDING INTERFACEThis is a hardware/software package to interfacethe AUTOFORM control with a customer suppliedpresence sensing device. When installed, this safe-ty device will prevent ram operation when a personor an object is detected in the protected area.

Interface provisions for presence sensing deviceincludes pedestal mounting of the standard palm-button operator station and mute indicator light.See Figure 8-13.

Some presence sensing devices are programmableand allow a blanking window of variable size to beprogrammed from step-to-step. The AUTOFORMhas an output available which can be configured asa step advance output to a programmable presencesensing device to take advantage of this feature.

FIGURE 8-13 – Mute Indicator Light forPresence Sensing Device

PROGRAMMABLE FOOTSWITCHProgrammable Footswitch is an available option onthe AUTOFORM Control. It may be used to selectwhich footswitch (left, right or both) must be pressedto cycle the ram when two footswitches are installed.Each step of the program can be programmed torequire either the left, right or both footswitches.When the “BOTH” selection is made, bothfootswitches must be pressed to cycle the ram. When“LEFT” or “RIGHT” selection is made, only the select-ed footswitch must be pressed to cycle the ram.

To use this option, the FOOTSWITCH selectorslocated on the MACHINE CONTROL station mustboth be “ON”.

To turn the option ON and program the footswitchselection for each step, first select the RAM DATA(3) MENU. The following RAM DATA (3) screen hasthis option installed with typical entries shown.

PROGRAM:TEST001

STATUS: Select a function using the softkeys.

RAM DATA (3)

Page 1GageData

RunMenu

Page 2

PROG-On-

STEP FOOTSWITCH

1 LEFT 2 RIGHT

6 AUG 8912:00 PM

LastStep

FirstStep

DeleteStep

InsertStep

8-13

POWER CLAMPS

Use the field keys to select the PROG ONFOOTSWITCH field. The softkeys will now changeas shown below to allow the operator to turn theoption ON or OFF.

When the "OFF" softkey is pressed, all field valuesunder PROG-ON-FOOTSWITCH field label areblanked-out. This indicates the ProgrammableFootswitch option is turned OFF for this program.

When the "ON" softkey is pressed, the field valuesfor the steps are displayed. The softkeys will alsochange to the following:

Pressing the desired softkey will change the pro-grammable footswitch field of the highlighted step.

OPERATION IN RUN MODE

When a cycle is started (Start Auto Seq, Start Sin-gle Step) in the RUN MODE, the operator will bewarned that the PROGRAMMABLE FOOTSWITCHoption is ON for the set-up about to be run. The fol-lowing status line message and softkeys willappear.

STATUS: WARNING: Footswitches are Programmable, Review Operation Manual

At this point, if the operator is unsure whichfootswitch(es) is active for the set-up, he can reviewthe set-up and programmed footswitch values bypressing the "Review Set-up" softkey. The RAMDATA (3) screen will appear. To continue the bendcycle, press the "Cont Cycle" softkey.

❦

ContCycle

ReviewSet-up

Top ofDie

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

LEFT RIGHT BOTHGageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

ON OFFRamData

GageData

RunMode

QuickBend

Set-upMode

ToolingLibrary

ProgramStorage

8-14

To maintain the accurate performance of yourCINCINNATI AUTOFORM CNC FORMING CENTER,there are maintenance practices that should be fol-lowed. This section deals with the maintenance andadjustments of the Press Brake.

LUBRICATIONRefer to Figure 9-1 for machine lube point locations.Lube points for the Standard and optional back-gages are shown in other figures as noted below.

FIGURE 9-1 – Lubrication points(Machine shown with optional Auto Crown )

1. Cylinder Head Clevis Pins: Lubricate greasefittings while cycling the ram under load, suchas obtained with a bumping die. Use No. 2Lithium base grease with “moly” additive (C.I.grease H-2M). Lubricate once a month.

2. Ram Guides: Wipe clean and flush with lighthydraulic oil once a month.

3. Auto Crown (Optional): There is a grease fit-ting at each of the pins through the bed andauxiliary plate. These grease fittings are on thefront end of the pins in a hole through the pinretaining plates. The pins should be lubricatedmonthly. Use a No. 2 lithium base grease witha "moly" additive (C. I. grease H-2M).

4. Standard Backgage Single Drive: See Figure9-2. Lube the X-axis screw located inside themain housing with a thin coating of No. 1 EPgrease (C. I. grease H-1EP) once a month. Thescrew may be accessed through a slot in thebottom of the main housing or it may beaccessed from the top by removing the screwsand top cover. Clean and apply SAE #10 oilspray lubricant to the pair of X-axis guide rodson the sides of the main gage housing.

FIGURE 9-2 – Standard Single Drive backgage

Standard Backgage Dual Drive: Clean gageand lubricate backgage ballscrews with a thincoating of No. 1 EP grease (C. I. grease H-1EP)once a month. Lubricate vertical and horizontalguides and vertical adjusting screws by spray-ing with SAE #10 oil every three months. SeeFigure 9-3. Apply a thin coating of No. 1 EPgrease to carriage vee track contact surfacesevery month.

Six-Axis Backgage (Optional): The Z and X-axis ball bushing guide rails should be cleanedand lubricated monthly with light coating ofSAE #10 oil. See Figure 9-4.

EM-444 (N-09/99) 9-1

SECTION 9 MAINTENANCE & ADJUSTMENTS

1

3

2

FIGURE 9-3 – Standard Dual Drive backgage lube points

FIGURE 9-4 – Six-Axis backgage lube points

Heavy Duty Backgage (Optional): Clean gageand lubricate horizontal guide rails with a thincoating of SAE #10 oil once a month. Removelarge cover plate on backgage arm housing andclean horizontal ballscrew every three months.Lubricate screw with a thin coating of #1 EPgrease (C. I. grease H-1EP). Grease verticalguide bushings using fitting on back of castingas required. Horizontal guides on right end ofgage bar should be kept clean and lubricatedwith a thin coating of oil. See Figure 9-5.

Tapered Backgage (Optional): The gage barpivot pins and the gage bar sliding joint on theleft end of the gage bar should be lightly oiledwith an SAE #10 oil once a month. All othermaintenance is the same as described for theStandard Backgage.

FIGURE 9-5 – Heavy Duty backgage lube points

HYDRAULIC OILThe hydraulic reservoir should be filled to the centerof the oil sight gage located at the rear of the reser-voir. The filler cap is located on the motor/pumpmounting plate. The ram should be at the top of itsstroke. Use a light hydraulic oil, viscosity 150 sec-onds at 100°F (37.8°C) with anti-rust, anti-oxidationand anti-wear additives (C. I. oil B-150).

The Lubrication Recommendation chart includedwith this manual lists brand names and numberswhich meet CINCINNATI specifications. Extremeshop temperatures may require lighter or heavier oilthan shipped with the machine and normally rec-ommended. The allowable range of oil temperaturesfor different viscosity oils are shown in the followingchart. Whenever the ambient room temperature isbelow 40°F (4.4°C), we recommend installing an oilheater in the reservoir.

VISCOSITYGRADE

AT 100°F (38°C)

150 SUS (32 cSt)

215 SUS (46 cSt)

315 SUS (68 cSt)

START-UP4000 SUS(860 cST)

11°F (-12°C)

22°F (-6°C)

32°F (0°C)

RUNNING250 SUS

(54 cST) MAX.

80°F (27°C)

94°F (34°C)

108°F (42°C)

RUNNING70 SUS

(13 cST) MIN.

143°F (62°C)

159°F (71°C)

177°F (81°C)

! W! WARNING !ARNING !STANDARD PRESS BRAKES ARE DESIGNEDFOR AND SHIPPED WITH A PETROLEUM BASEDHYDRAULIC FLUID. THIS IS FLAMMABLE.CHECK APPLICABLE FIRE CODES FOR SPE-CIAL PRECAUTIONS.

9-2

GREASE VERTICALGUIDE BUSHING FITTING

HORIZONTALBALLSCREW

VERTICAL GUIDE &ADJUSTING SCREW

HORIZONTAL GUIDE

VEE TRACK

BACKGAGEBALLSCREW

X-AXISGUIDERAILS

Z-AXISGUIDERAILS

The following chart shows the reservoir capacity ofCINCINNATI AUTOFORM CNC Forming Center.

It is very important to keep the oil clean. All pre-cautions must be taken to keep the oil clean, free ofchips, grit, water, sludge, etc. The oil should bedrained and replaced after one year of service.Replace the oil sooner if sludge or other contami-nation is present. The drain valve is located in thebottom of the reservoir. This valve should becracked once a month to remove any accumulatedmoisture. Check the oil level daily.

New oil stored in drums is usually not as clean asthe filtered oil shipped with the machine. Oil shouldbe pumped through a 10 micron filter. After the oilis changed the CRT should be checked periodicallyto see if a dirty filter error message appears in thestatus area. Change the filter element if required.

OIL FILTERSThere are two types of filters on this hydraulic pressbrake – a low pressure (return line) and a highpressure filter. The low pressure filter is mountedon an auxiliary cover plate located on top of themain reservoir. See Figure 9-6. The hydraulic oil iscirculated by the auxiliary pump to this filter.

The high pressure filter is located on the motor/pump mounting plate on top of the main reservoir.See Figure 9-7. When the ram is moving, oil flowsfrom the variable volume pump through the highpressure filter.

When either filter has reached its dirt holdingcapacity, an error message will appear in the sta-tus area of the CRT display. The flashing messagewill remain until the dirty element is replaced.Both filters use the same 10 micron (absolute) dis-posable element. To replace either filter, turn OFFthe main drive motor and the disconnect switch onthe main electrical enclosure and install a safetylockout. Remove the top cap on the filter and thedirty filter element. Install a new element andreplace the top cap.

FIGURE 9-6 – Low pressure filter

FIGURE 9-7 – High pressure filter

CHECKING & SETTINGHYDRAULIC PRESSURESThe hydraulic system is equipped with male quick-disconnect fittings at the most frequently checkedpressure test ports. Identification of the hydraulicsystem components is shown on Figure 9-8.

MAIN RELIEF PRESSURE

This pressure is preset at the factory and shouldnot require adjustment under normal operatingconditions. Special tooling is required to check and

MACHINELENGTH

RESERVOIR CAPACITYGALLONS (LITERS)

6 FT.

8 FT.

10 FT.

12 FT.

14 FT.

16 FT.

125 (473)

170 (643)

215 (814)

260 (984)

305 (1154)

260 (984)

9-3

LOW PRESSURE FILTER

HIGH PRESSURE FILTER

adjust main relief pressure. Contact a CINCINNATIINCORPORATED Service Representative to havethis pressure checked or adjusted.

COUNTERBALANCE PRESSURE

Two test ports (#3) are provided in the circuit forchecking counterbalance pressure. See Figure 9-9.No dies should be installed in the machine for thischeck.

1. Install 0-600 PSI range pressure gage with afemale quick-disconnect into either test port#3. Both must be checked.

2. Set the machine controls:

OPERATOR STATION RIGHT ONOPERATOR STATION LEFT OFFFOOTSWITCH RIGHT OFFFOOTSWITCH LEFT OFFMODE SELECT Selector SINGLE STROKESINGLE STROKE Selector PALMBUTTONS

OR FOOTSWITCHOPERATOR CONTROL Selector ONPROGRAM/LOCK Selector PROGRAM

3. Start machine by turning main disconnect ONand pressing MAIN DRIVE “START” button.

4. Select QUICK BEND MENU from the MAINMENU by pressing the "Quick Bend" softkey.

FIGURE 9-9 – Counterbalance pressure check

9-4

FIGURE 9-8 – Hydraulic reservoir components

OIL SIGHT GAGE /THERMOMETER

MOTOR / PUMP MAIN MANIFOLDTEST PORTS #5 & #6REDUNDANT VALVERELIEF VALVEPILOT VALVE

HIGHPRESSUREFILTER

AUTO CROWN VALVE MANIFOLD (Optional)

OIL LEVELSWITCH

RESERVOIROIL FILLER

AIR FILTER / BREATHER

LOWPRESSUREFILTER

AIR BREATHER /FILTER

CYLINDERAREA VALVE

PREFILL VALVE

TESTPORT #1

#4 SOL.PROPORTIONALVALVE

#6 SOL. LOADSENSE VALVE

TEST PORT #3

COUNTER-BALANCEMANIFOLD

COUNTERBALANCE VALVE

RIGHTCYLINDERMANIFOLD

TESTPORT #2

NEEDLEBLEEDVALVE

5. Enter a program in QUICK BEND as follows:

TOP STOP max. valueSPEED CHANGE max. valueREVERSAL POS. min. valueREVERSAL MODE POSITIONREVERSAL TONS 5.0FORMING SPEED 15TILT 0.0000DWELL 0.0UP STOP OFFDOWN STOP OFF

6. To start a cycle, press the “Cycle Start” softkey.“RAM MUST BE CALIBRATED” will be dis-played on the CRT.

7. To calibrate the ram, press the “Calibrate Ram”softkey and the calibrate mode will be dis-played on the CRT.

8. Cycle the ram upwards with the PalmbuttonOperator Station to calibrate the ram.

9. To cycle the machine, press the “Cycle Start”softkey. “CYCLE ACTIVE !!! SINGLE STROKEPALMBUTTONS” will be displayed on the CRT.

10. The counterbalance pressure is checked whilerunning the ram down. The proper pressurecan be found in Figure 9-10 or on the metaltag located near the counterbalance valves. Ifthe machine has a wide ram, extension(s) orvery heavy upper dies, consult CINCINNATIINCORPORATED for information to set thecounterbalance pressure.

11. To adjust the pressure, loosen the locknut andturn adjusting screw on counterbalance valve.Turn adjusting screw clockwise to increase andcounterclockwise to decrease pressure. Tightenthe locknut.

12. After setting the pressure, cycle ram a numberof strokes and then recheck both counterbal-ance pressures.

13. Turn OFF motor/pump and remove pressuregage.

FIGURE 9-10 – Counterbalance pressure

AIR FILTER / BREATHERThere are two air filter / breathers, one on eachend of the hydraulic reservoir. See Figure 9-8. Thedisposable, canister-type filter / breather shouldbe replaced about every 2000 hours of machineoperation.

OIL LEVEL / TEMPERATURESWITCHIf the oil drops to the minimum allowable level,an error message appears in the status area ofthe CRT display. This will turn OFF the maindrive motor. The cause for the low oil level shouldbe found and corrected. Fill reservoir to the prop-er level.

If the operating temperature reaches the maxi-mum level, an error message appears in the sta-tus portion of the CRT display. Stop machineoperation as soon as possible and locate thecause of the excessive heat.

MACHINESIZE

COUNTERBALANCEPRESSURE

90 x 6

90 x 8

90 x 10

135 x 6

135 x 8

135 x 10

135 x 12

175 x 6

175 x 8

175 x 10

175 x 12

230 x 6

230 x 8

230 x 10

230 x 12

350 x 8

350 x 10

350 x 12

350 x 16

234 PSI (1613kPa)

285 PSI (1965kPa)

380 PSI (2620kPa)

215 PSI (1482kPa)

245 PSI (1689kPa)

285 PSI (1965kPa)

335 PSI (2310kPa)

215 PSI (1482kPa)

260 PSI (1793kPa)

290 PSI (2000kPa)

365 PSI (2517kPa)

210 PSI (1448kPa)

250 PSI (1724kPa)

305 PSI (2103kPa)

350 PSI (2413kPa)

215 PSI (1482kPa)

250 PSI (1724kPa)

300 PSI (2068kPa)

385 PSI (2655kPa)

CAUTIONDO NOT LEAVE THE GAGE PERMANENTLYATTACHED TO THE TEST PORT.

CAUTIONAll dies must be removed from the press brake.

9-5

HYDRAULIC UNIT OPTIONSOIL COOLER

The oil cooler is an air-type heat exchanger. Theheat exchanger is equipped with a thermostatical-ly controlled electric fan which is operable onlywhen the motor/pump is running. The thermostatis set to start the heat exchanger motor at approx-imately 135°F (57°C). A furnace-type air filter isinstalled between the fan and the core of theexchanger. The filter should be changed asrequired. See Figure 9-11.

FIGURE 9-11 – Oil cooler

OIL HEATERS

Oil heaters are recommended for cold start-ups andcold running conditions (see temperature chart in“HYDRAULIC OIL” section). They are immersion-type, thermostatically controlled, and may be usedindependently of the motor drive.

CYLINDERS

Cylinders on the CINCINNATI AUTOFORM PressBrake have an inner and outer piston. See Figure9-12. The inner piston is attached to the fixedupper cylinder head and does not move. Theouter piston is attached to the ram, moving inthe cylinder and in relation to the inner piston.For information to replace piston rod seals, con-tact CINCINNATI INCORPORATED ServiceDepartment.

FIGURE 9-12 – Cylinder assembly

MOTOR / PUMPThe motor/pump combination is vertically mount-ed on the reservoir top with the pump submergedin the hydraulic oil. The pump is a variable volume,pressure compensated piston pump with a loadsensor control. The compensating and load sensepressures are factory-set and no adjustments arerequired.

VALVESThe hydraulic control valves are manifold mountedon the reservoir (Figure 9-8) and on both cylinders(Figure 9-9). The valves can be easily removed forservice or replacement.

IMPORTANT: Whenever servicing these valves,the ram should be blocked, all power to themachine turned OFF and the electrical dis-connect locked.

9-6

TILT LIMIT SWITCHESTwo limit switches shown in Figure 9-13 aremounted on the right ram slide (back side of ram)for limiting the maximum ram tilt. Should the ramexceed its allowable tilt, these switches will shut offthe drive motor. To set the tilt limit switches, thebed and ram should be parallel (plus or minus1/16" / 1.6mm) to one another. The tripping pointof the switches is measured by passing a feeler gagepast the rollers and holding it against the side ofthe ram guide.

FIGURE 9-13 – Limit switches & end-guide bearing

The limit switches should be set with feeler gages asshown in the following chart:

SWIVEL END-GUIDE BEARINGTo adjust for wear in the swivel end-guide bearings,loosen the locking screws. Adjust ram shoe clampby tightening the adjusting screws evenly until theyare snug. Backoff to obtain a .003" (.076mm) clear-ance between the bearing and the ram guide. Thentighten the locknuts and the locking screws. SeeFigure 9-13.

ENCODER ADJUSTMENT1. Set a dial indicator to read “0” (with a .020”

touch) at a height of 12.0000”. To obtain thisheight, use a precision height gage or job blocks.

2. Set machine controls:

OPERATOR STATION RIGHT ONOPERATOR STATION LEFT OFFFOOTSWITCH RIGHT OFFFOOTSWITCH LEFT OFFMODE SELECT Selector SINGLE

STROKESINGLE STROKE Selector PALMBUTTONS

OR FOOT-SWITCH

OPERATOR CONTROL Selector ONPROGRAM/LOCK Selector PROGRAM

3. Start machine by turning the main disconnectswitch ON and press the MAIN DRIVE - STARTbutton.

4. Select QUICK BEND menu from MAIN MENU bypressing the "Quick Bend" softkey.

5. Enter a program in QUICK BEND as follows:

TOP STOP max. valueSPEED CHANGE max. valueREVERSAL POSITION 12.0000REVERSAL MODE POSITIONREVERSAL TONS 5.0FORMING SPEED 15TILT 0.0000DWELL 9.9UP STOP OFFDOWN STOP OFF

6. To start a cycle, press the “Cycle Start” softkey.“RAM MUST BE CALIBRATED” will be displayedon the CRT.

7. To calibrate the ram, press the “Calibrate Ram”softkey and the calibrate mode will be displayedon the CRT.

8. Cycle the ram upwards with the PalmbuttonOperator Station to calibrate the ram.

TILT SWITCH SETTINGSMACHINENOMINALLENGTH

6 FT.

8 FT.

10 FT.

12 FT.

14 FT. & UP

BELOW THISAMOUNT WILL

NOT TRIP SWITCH

.040"

.032"

.026"

.022"

.020"

THIS AMOUNTMUST TRIP

SWITCH

.044"

.036"

.030"

.026"

.024"

9-7

CLEARANCE(SEE CHARTBELOW)

RAM GUIDE

LOCKINGSCREWS

SWIVEL ENDGUIDE BEARING

END GUIDEADJUSTINGSCREWS

TILT LIMIT SWITCH

TILT LIMIT SWITCH

9. Clean bed top and place the dial indicator (setat 12.0000” in Step 1) between the bed andram, in-line with the encoder rods. Do not indi-cate from ram die clamp. Both ends must bechecked.

10. To cycle the machine, press the “Cycle Start”softkey. “CYCLE ACTIVE !!! SINGLE STROKEPALMBUTTONS” will be displayed on the CRT.

11. Cycle the ram with the Palmbutton OperatorStation until the ram will dwell at the preset12.0000” position. The dial indicator should beat the zero position within plus or minus .0005”.

12. If adjustment is required, remove the linearencoder guard and loosen the adjusting screwlocknuts. See Figure 9-14. Adjust the threadedstud up or down until the ram will dwell at thepreset position in Step 11.

Note: As the encoder rod is moved, the ram willfollow it up or down.

13. Tighten the adjusting screw locknuts andrepeat Step 11.

FIGURE 9-14 – Linear encoder

14. Turn “OFF” main drive and then main discon-nect switch. Repeat Steps 3 through 11. Adjustif necessary.

15. Re-install the guard removed in Step 12.

16. Repeat above procedure for encoder at otherend of machine.

Note: It is important that both ends are the same.

RELEVEL RAMIf the ram goes out-of-level enough to actuate thetilt limit switches, the main drive motor will turnOFF or cannot be started and an error messageappears on the status line of the CRT display. Themain drive cannot be started until the ram level iscorrected or the relevel control sequence is used.

IMPORTANT: The Tilt Limit Switches must notbe bypassed or readjusted to restore elec-trical circuits. If machine is operated withexcessive tilt, the slides and guides may bedamaged.

There are two methods to relevel the ram. One is byusing a special function contained in the AUTO-FORM Control and the other is to relevel the rammechanically using jacks and bleed valves.

RELEVELING RAM USING SPECIALCONTROL FUNCTIONSelect one of the menus which actually operate theram, i.e. SETUP MENU, QUICK BEND MENU orRUN mode. Attempt ram movement with one of thenormal cycle start or ram movement softkeys. If theram is out-of-level, the following softkey will appear:

Press the “Relevel Ram” softkey. The status lineshould change to “Releveling the Ram”.

It should now be possible to start the main drivemotor. Press the MAIN DRIVE - START pushbutton.

Go to the Palmbutton Operator Station and pressthe RAM UP button. Continue to hold the buttondepressed until the ram moves to a level position.At this point the status line and softkey displaysshould return to normal menu functions.

If the error message “Ram Tilt Limit Switch Fault”should appear after pressing the “Relevel Ram”softkey, the main drive motor cannot be started.

RelevelRam

FileUtility

FilePrefs

Comm.Set-up

ChangeVolume

QuickBend

DeleteTool

ToolingLibrary Abort

CAUTIONAll tooling, including filler block and lowerpower clamp (if equipped), must be removedfrom the press brake.

9-8

ENCODERBODY

ENCODERHEAD

ENCODERROD

SPRINGBLOCK BED

ENCODERBRACKET

NOTE:ENCODERGUARDNOT SHOWN

RAMENCODERBRACKET

The ram must then be releveled mechanically toenergize the electrical circuits so the cause for out-of-level condition can be found and corrected.

The high end of the ram must be lowered to relevelthe ram. It is not possible to raise the low end of theram unless special tooling is used. If it is necessaryto raise the low end of the ram, consult CINCIN-NATI INCORPORATED’s Service Department forspecial instructions.

IMPORTANT: Do not try to raise low end of ramwith a jack or hoist. Damage could resultto bed, ram or hydraulic system.

RELEVELING RAM MECHANICALLY

1. Turn OFF all power to machine and lock dis-connect switch on main electrical enclosure.

2. Place a jack between bed and ram at each hous-ing. Protect bed and ram nose with wood or softmetal. Do not place jack under ram die clamps.Apply enough pressure to support weight ofram, ram slides and pistons.

3. Lower the high side of the ram by gradually low-ering its respective jack and opening the coun-terbalance bleeder valve. See Figure 9-9 forappropriate valve location. When ram is parallelto the bed, close valve. The tilt limit switcheswill no longer deactivate the electrical circuitsand the main drive motor can be started. DONOT remove jacks. The cause for out-of-levelcondition may allow ram to continue to drop.

Note: Special care must be taken to ensure thatthe bleed valve is completely closed beforethe jam locknut is tight.

4. Find cause for machine going out-of-level. Pos-sible causes are incorrect counterbalance pres-sure, damaged or broken linear encoder(s).Make necessary repairs or adjustments. Whentroubleshooting, it may be necessary to relevelram several times.

CLOSED HEIGHT ADJUSTMENTClosed height, which is the distance from the bedtop to the ram nose at the maximum down positionof the stroke, is controlled by two adjustments. Thereference limit switches provide coarse adjustmentand the linear encoder provides fine adjustment.

The closed height can be measured by program-ming a stroke reversal position of 12.0000” inQUICK BEND mode. Cycle the ram for one complete

stroke with a forming speed of 15 inches perminute and maximum dwell at reversal point. Thismeasurement should be within plus or minus.0005”. See linear encoder adjustment for proce-dure to measure and adjust.

CARRIAGE ADJUSTMENT

STANDARD DUAL DRIVE BACKGAGEEach backgage carriage assembly is guided by a veetrack wheel system. The adjustment of this guidingshould be checked at six month intervals or asrequired by usage. To adjust (refer to Figure 9-15):

1. Turn OFF main disconnect switch and lock.

2. Clean and lubricate both carriage assemblies.

3. Remove gage bar.

FIGURE 9-15 – Standard backgage carriage

4. Free carriage from ballscrew drive by removingbracket bolts “A”.

5. No “play” or looseness should be felt when firm-ly rocking carriage back and forth (as shown inFigure 9-15) at each end.

6. Loosen the cam wheel locking nuts. Tighten thecam wheel eccentric bushing nut and lockingnut to remove “play” in the guiding system.Care must be taken not to over-tighten thesecam wheels. It should require no more than fivepounds pull to move the detached carriage theentire track length.

7. After adjusting and checking both carriages, re-attach carriages to ballscrew drive with bracketbolts “A” and replace gage bar.

9-9

SIX-AXIS BACKGAGE (Optional)

The X-axis and Z-axis carriage ball bushingsshould be checked periodically for looseness. Eachball bushing has a preload adjusting screw (Figure9-16). These screws should be snug, never tight.

FIGURE 9-16 – Backgage carriage ball bushing

HEAVY DUTY BACKGAGE (Optional)

No adjustments are necessary.

TAPERED BACKGAGE (Optional)

Adjust the backgage carriage assemblies in a simi-lar manner described for the Standard Dual DriveBackage. No other adjustments.

MACHINE LEVELThe level of the machine should be checked everythree months and adjusted if necessary. See SEC-TION 2 for details of this adjustment.

ELECTRICALThere are no customer serviceable parts in themain electrical enclosure. Contact a CINCINNATIINCORPORATED Service Representative fordetailed information.

9-10

MAINTENANCE CHECKLIST – AUTOFORM CNC FORMING CENTER

Check entire machine for loose fasteners – tighten if necessary.

Wipe entire machine clean.

Check machine levelness.

Check ram guide clearance – relevel if necessary.

Adjust swivel end-guide bearings.

Replace oil return line or pressure line filter element.

Clean strainer in water line to heat exchanger (if so equipped).

Check backgage guide clearance.

Replace filter in air-cooled heat exchanger (optional).

Replace reservoir air filter – breather.

1

2

3

4

5

6

7

8

9

10

DA

ILY

WE

EK

LY

MO

NT

HLY

3 M

ON

TH

S

6 M

ON

TH

S

YE

AR

LY

LUBRICATION SCHEDULE

ABOVE INTERVALS ARE BASED ON ONE SHIFT AND NORMAL PRESS BRAKE OPERATION.DETAILED INSTRUCTIONS FOR SERVICING THE MACHINE CAN BE FOUND IN THIS MANUAL.

XXXXXX

X

X

X

XXXX

XX

1

2

3

4

5

6

7

8

Check reservoir oil level.

Lubricate cylinder clevis pin.

Clean and flush ram guides with oil.

Check for water in reservoir.

Lubricate backgage guide rails and adjusting screws.

Lubricate Auto Crown pins (optional).

Clean and lubricate backgage ballscrews and vee tracks.

Drain, clean and refill hydraulic reservoir.

CHECK OR ADJUSTMENT

X

WHEN INDICATED

X

ADJUSTINGSCREW

TROUBLESHOOTINGEffective troubleshooting is usually acquired with experience and by a thorough knowledge of yourmachine and its operation. The assembly drawings, including hydraulic and electrical schematics (includ-ed with this manual), should be used as troubleshooting aids. Most problems, however, can be more effi-ciently diagnosed by contacting your local CINCINNATI Field Service Representative or through telephonesupport with a Technical Service Specialist. Having the following information ready before making contactwith a CINCINNATI Representative will help to diagnose the problem faster.

✦ Company Name✦ Machine Model✦ Machine Serial Number✦ All error messages (exactly as displayed)✦ Have this manual and prints available for reference✦ Describe the symptoms of the problem from the following list. Problem diagnosis will go quick-

ly if you can answer the questions associated with each symptom.

CRT DISPLAY ERROR MESSAGES

A special feature of the AUTOFORM control system is the display of error messages to indicate a fault inthe program or machine function. The following chart will provide a guide to identify the problem andsuggest possible corrections. The error messages are listed in alphabetical order.

A System failure has occurred. Call Maintenance.Software or hardware problem. Clear and repeat operation. If the error messagerecurs, contact CINCINNATI Service.

Adaptive data invalid !!!Error was set during TEACH mode bend. Repeat operation. If error message recurs,use the ADAPTIVE GUIDELINES & LIMITATIONS, OS-136, to check your work.

Adaptive data not loaded , please check!Adaptive reversal selected but correct Teach File not loaded for ADAPTIVE MENUfor the tooling in JOB DATA. Repeat operation.

Adaptive parameters are not valid.Repeat operation. If the error message recurs, use the ADAPTIVE GUIDELINES &LIMITATIONS, OS-136, to check your work.

All footswitches must be ‘on’ for prog. footswitch mode.All footswitches not turned"ON". Turn ON footswitches.

All steps MUST have same rev. mode to enter new rev. value !Attempted to edit all steps with different reversal modes. Change values manuallyon each step required.

All steps MUST have same rev. angle to enter new actual angle!Edit all steps attempted on actual angle field with different desired angles. Changevalues manually on each step required.

Analog Board Failure!Hardware problem, order new or remanufactured analog/servo board.

Angle and width dimensions for lower tool in error.Check tooling and repeat operation. If the error message recurs, contactCINCINNATI Service.

Angle and width dimensions for upper tool in error.Check tooling and repeat operation. If the error message recurs, contactCINCINNATI Service.

9-11

Angle too small for lower die.Angle cannot be achieved with tool. Check angle input, check angle for vee die intooling library and material thickness.

Angle too small for upper die.Angle cannot be achieved with tool. Check angle input, check angle for vee die intooling library and material thickness.

Archive file is corrupt.Back-up of the file system on disk was damaged when attempting to restore. Repeatoperation. Try another archive disk.

Bad command or mode.Bad command or mode, check program inputs. If the error message recurs, contactCINCINNATI Service.

Bad Data Detected, Please Repeat Incorrect Bend!!!!Adaptive verify failed on this bend. Repeat the bend. If the error message recurs,use ADAPTIVE GUIDELINES & LIMITATIONS, OS-136, as a checklist.

Bad error message number.Repeat operation. If the error message recurs, contact CINCINNATI Service.

Busy, Please repeat command !!!Control was performing last command. Repeat operation. If the error messagerecurs, contact CINCINNATI Service.

Cannot copy files to same Volume as SOURCE.Attempting to copy files back to original source. Change destination volume orreview operation.

Cannot copy files to the same path.Attempting to copy files back to original source. Change destination volume orreview operation.

Cannot load application, invalid address in bootrom.Attempt to load new software update failed. Contact CINCINNATI Service.

Cannot use this mode with unmeasured tools.REVERSAL mode must have tools from tooling library, select tools. If tools areselected in JOB DATA, check name.

Clamp Position is higher than Speed Change Down.User adjustable clamp position offset is greater than ram data speed change value.Adjust clamp position in Job Data to lower value, or raise speed change value inRam Data.

Clamps were on and they should not have been.Clamps should only be used in SET-UP mode. Repeat operation. If the error mes-sage recurs, check the I/O display to see if there is a problem.

Clogged pressure filter.Clogged pressure filter - install new filter. If the error message recurs, order a filterswitch.

Continuous Run Disabled!CYCLE mode not available - use SINGLE STROKE mode.

Control relay fault ! Reset control to clear.Reset control and repeat operation. If the error message recurs, contactCINCINNATI Service.

9-12

Control system fault ! Reset control to clear.Reset control and repeat operation. If the error message recurs, contactCINCINNATI Service.

Could not find all cad parts used in program.Could not find program. Check programs and repeat operation.

Current teach bend is in error, please recheck.ADAPTIVE verify failed on this bend, repeat the bend. If the error message recurs,use ADAPTIVE GUIDELINES & LIMITATIONS, OS-136, as a checklist.

Note: These errors should not occur. If any of these do occur, reset control and repeat operation.If the error message recurs, contact CINCINNATI Service.

Cycle stop while finding actual rev point.Cycle stop while in keystroke loop.Cycle stop while ramping down.Cycle stop while scanning for reversal.Cycle stop while waiting to finish stroke.Cycle stop while waiting to read Stroke_dataData collection exceeded for down stroke.Data collection exceeded for up stroke.

Data write to cartridge did not verify.Bad data cartridge. Retry. If the error message recurs, replace cartridge #827311.

Diagnostic output not enabled - press Outputs Ready softkey.Press "Outputs Ready" softkey to enable outputs.

Dietop not in range, check and repeat.Measured dietop was not in range with previous bend. Check tooling size (height),thickness entered, filler block height and encoder settings.

Dietop was not calculated, repeat bend.Error occurred in data, repeat bend.

Directory contains one or more invalid data files.When rebuilding index file, non-AUTOFORM files were located on disk. Take thedisk to a remote computer and use DOS to delete any non-AUTOFORM related files.

Directory Error - Rebuild Directory!Error in directory, repeat operation. If the error message recurs, contactCINCINNATI Service.

Directory Full!Delete some programs or install RS-232/422 per EM-372.

Disk:Directory Full, root directory is fullRoot directory can only contain a limited number of files. Delete files or store inanother sub-directory.

Disk:Disk Full, delete files or use another diskNo free bytes remaining on disk. Delete files or use another disk.

Disk:Diskette inserted in drive is write protectedCannot store files on write protected disk. Eject disk, switch write protect tab.

Disk:File or Directory Already ExistsAn attempt was made to create a path which already exists. Review the requestedoperation.

9-13

Disk:File or Directory not FoundPart or file does not exist on disk. Either create the specified directory or locate thespecified file.

Disk:Invalid Filename, check lengthAttempt was made to store a blank filename to disk. Check for blank filename ininternal storage and change name.

Disk:No address marks on diskette. Is diskette formatted ?An unformatted disk was inserted in the drive. Format the disk first using FILEUTILITY, or choose another disk.

Disk:No data found on diskette. Is diskette formatted ?An unformatted disk was inserted in the drive. Format the disk first using FILEUTILITY, or choose another disk.

Disk:Write Protect switch is selected on disketteDisk write protect is ON. Check disk.

Note: These should not occur. If they do, reset the control and repeat operation. If the problemstill exists, contact CINCINNATI Service.

Disk:Allocate-De-allocate ErrorDisk:CRC error occurred during diskette accessDisk:Diskette is not inserted in requested driveDisk:Diskette was ejected. Is proper diskette inserted ?Disk:End of File UnexpectedDisk:End of File with partial recordDisk:Error in Physical readDisk:Error in Physical writeDisk:Error in Volume access, check volume specifierDisk:Error occurred in floppy disk controller initializeDisk:Error occurred in physical address calculationDisk:Error occurred in processing result phase errorsDisk:Fatal ErrorDisk:File already openDisk:File Locked, cannot open fileDisk:Files open on directory, cannot closeDisk:Format data did not verify. Is proper density selected?Disk:Handshake error occurred during FDC transferDisk:Initialization interrupt from FDC did not occurDisk:Invalid Attribute(s) , File attributes do not matchDisk:Invalid Configuration, examine msfs configurationDisk:Invalid Function Option, check option valueDisk:Invalid Opcode, bad function request blockDisk:Invalid Parameter(s), check RPBDisk:Invalid status register read from floppy controllerDisk:Overrun error occurred during diskette accessDisk:Queue Empty, check FCB and CCB blocks allocatedDisk:Request terminated due to timeoutDisk:Seek did not complete because of an error

DOWN STOP must be on when Palm and Foot stations are on.DOWN STOP not turned ON – turn ON. If it is ON, check the I/O display.

Down stroke data not correct, Bend Terminated.Material was not at expected position or machine was cycled without material -repeat operation. If the error message recurs, check tooling size (height) , thicknessentered, filler block height and encoder settings.

9-14

<Emergency Stop> was pressed or gage <Safety Gate> is open!Restart machine / close safety gate and restart machine.

Error in loading file!!!Error occurred trying to load file from internal storage volume. Repeat operation. Iferror persists, run File System Repair and / or contact CINCINNATI Service.

Error occurred during rise data calculation.TEACH mode bend in error. Repeat bend. If the error recurs, run the Force BugTest. If there is still a problem, Use ADAPTIVE GUIDELINES AND LIMITATIONS,OS-136, as a checklist.

Error occurred while Loading Machine ConfigurationRestore configuration from disk was unable to locate desired files. Verify files existin "\ Text" directory on disk.

Error occurred while scanning for reversal.Error occurred on initial contact with material. Repeat operation. If the error mes-sage recurs, check tooling size (height), thickness entered, filler block height andencoder settings. If the error message recurs, use ADAPTIVE GUIDELINES & LIMI-TATIONS, OS-136, as a checklist.

Error occurred while scanning for material, check thickness.Error occurred near reversal point. Repeat operation. If the problem still exist,check tooling size (height), thickness entered, filler block height and encoder set-tings. If the error message recurs, use ADAPTIVE GUIDELINES & LIMITATIONS,OS-136, as a checklist.

Error occurred while setting reversal pos, restart cycle.Reset control and repeat operation. If the error message recurs, contactCINCINNATI Service.

Error occurred while trying to read the requested fileThe disk being used is corrupted - use a different disk. If the error message recurs,contact CINCINNATI Service.

[F -AXIS] Amplifier resetting !Reset control and repeat operation. If the error message recurs, contactCINCINNATI Service.

[F -AXIS] Calibration failure !What did the faulty axis do when attempting to calibrate? Move to its maximumposition? Did it move slightly in the other direction?If so, check the encoder outputs "A", "B" and "Z". If it did not move slightly back, isthe axis hitting an obstruction?

[F -AXIS] Calibration is required before use !Gage is not calibrated. Calibrate the gage.

[F -AXIS] Communication fault !Repeat operation. If the error message recurs, check the fiber optic cable connec-tions at the VME Slave CPU.

[F -AXIS] Did not position properly !Repeat operation. If the error message recurs, check to see if the axis is hittingsome physical obstruction.

[F -AXIS] Dimension is not within travel limits !F-axis dimension too large or small. Check F-axis gage configuration settings andprogrammed value.

9-15

[F -AXIS] Horizontal bar skew exceeded !Repeat operation. If the error message recurs, check the configuration data to see ifthe maximum horizontal bar skew is the same as the maximum travel limit. If it is,contact CINCINNATI Service.

[F -AXIS] Timed out before completing move !Gage did not achieve position. Check to see if the axis is hitting some physicalobstruction. Repeat, and if the problem still exists, contact CINCINNATI Service.

Fiber Optic Loop Failure!Error in fiber optic loop. Reset control and repeat operation. If the error messagerecurs, remove the TX cable from the keypad interface board. The connector on theboard should flash when a key is pressed. If it does, replace the cable and removethe RX cable from the slave CPU board. When a key is pressed, it should flash. If itdoes, replace the cable and remove the TX cable. When a key is pressed, the boardshould flash. If it does, replace the cable and remove the RX cable from the AGMBoard. Reset the control and the cable should flash once. If it does, replace thecable and remove the TX cable. Reset the control again. The connector on theCPU332 board should flash once. Replace the cable and remove the RX cable fromthe keypad interface board. Reset the control and it should flash once. If the errormessage recurs, contact CINCINNATI Service.

File Already Exists - Delete or Re-name File.Attempted to recover a file which already exists in internal memory. Rename theoriginal or recheck desired operation.

File already exists! Delete file in memory first.File previously saved, change name or delete original first.

File already exists, Replace old version?This is a CAUTION.

File data corrupt. Bad File Type !File received from offline is not compatible. Reset control and repeat operation.Does the file type listed on the FILE TRANSFER screen match the file type of thefile(s) selected to copy? Repeat, if the problem still exists, contact CINCINNATIService.

File data corrupt. Date string bad !File received from offline is not compatible. Reset control and repeat operation. Ifthe problem still exits, contact CINCINNATI Service.

File data corrupt. ETX char not found !File received from offline is not compatible. Reset control and repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

File data corrupt. Filename missing !File received from offline is not compatible. Reset control and repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

File data corrupt. Filename missing start null char !File received from offline is not compatible. Reset control and repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

File data corrupt. Incoming file not saved !The file sent is not compatible or has been damaged. Check to make sure that youcan save a file. If so, retry. If not, check the PC and cable per EM-325.

File data corrupt. STX char not found !File received from offline is not compatible. Reset control and repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

9-16

File exists in memory. Requested file not saved !A file with the same name as the one sent to the control has been found. Firstdelete the original, then retry.

File name exists ... File not saved !!A file with the same name as the one sent to the control has been found. Firstdelete the original, then retry.

File not foundUnable to find file. Check input and repeat operation.

File not found, please try again.Unable to find file. Check input and repeat operation.

File Prefix must be at least one character.Attempted to store blank filename on disk volume. Change file to a valid name.

File Store ErrorCould not store file. Repeat operation. If the error message recurs, run the FileSystem repair. If there is still a problem, contact CINCINNATI Service.

File System Access ABORTED - CORRUPT FILE!The file sent was not the correct format or has been damaged. Re-examine desiredoperation.

File System Access ABORTED - file length error!The file sent was not of the correct format or has been damaged. Run File Systemrepair. Check to make sure that you can save a file, and if you can, retry. If not,check the PC and cable per EM-372, RS-232/422 COMMUNICATIONS.

File System Access ABORTED - move memory error!The file sent was not the correct format or has been damaged. Run the File Systemrepair diagnostic. Check to make sure that you can save a file, and if you can, retry.If not, check the PC and cable per EM-372, RS-232/422 COMMUNICATIONS.

File System Access ABORTED - set partition error!The file sent was not the correct format or has been damaged. Run the File Systemrepair. Check to make sure that you can save a file, and if you can, retry. If not,check the PC and cable per EM-372, RS-232/422 COMMUNICATIONS.

File system is busy, try again later.A background remote access is in progress. Wait and try operation again, or haveremote user stop accessing.

[FL-AXIS] Amplifier fault !Check to make sure gage will move by hand. If over 15 seconds, power downmachine and repeat operation. Contact CINCINNATI Service.

[FL-AXIS] Calculated dimension exceeds travel limits !FL-axis dimension too large or small. Check FL-axis gage input.

[FL-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z. (See drawing.)

[FL-AXIS] Front limit switch fault !Repeat operation. If the error message recurs, contact CINCINNATI Service.

[FL-AXIS] Motion error !Repeat operation. If the error message recurs, check the encoder output A, B and Z.

9-17

[FL-AXIS] No-motion error !Did the gage move at all or did it start to move then stop? Repeat operation. If theerror message recurs, contact CINCINNATI Service.

[FL-AXIS] Rear limit switch fault !Repeat operation. If the error message recurs, contact CINCINNATI Service.

Flange in red is interfering with another flange!Red flange is interfering with another flange. Remove erroneous step.

Flange length less than half of vee opening, check tooling.Check the die tooling and the part size.

Footswitch (es) MUST be turned OFFFootswitch is turned ON, turn footswitch OFF. If it is "off", check the I/O diagnosticdisplay.

Footswitch (es) MUST be turned ONFootswitch is turned OFF, turn footswitch ON. If it is "on", check the I/O diagnosticdisplay.

Footswitch I/OSlave processor error. Repeat operation. If the error message recurs, order slaveboard.

Footswitch Only Mode not allowed in Adaptive !Change to another mode.

Footswitch only not permitted in Tandem Operation.Cannot use this mode with tandem operation. Change Stroke Selector Switch toPALMSTATION or FOOTSWITCH mode.

[FR-AXIS] Amplifier fault !Check to make sure gage will move by hand. If over 15 seconds, power downmachine and repeat operation. Look at the SRV332 board. Contact CINCINNATIService.

[FR-AXIS] Calculated dimension exceeds travel limits !FR-axis dimension too large or small. Check FR-axis gage input.

[FR-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z. (See drawing.)

[FR-AXIS] Front limit switch fault !Repeat operation. If the error message recurs, contact CINCINNATI Service.

[FR-AXIS] Motion error !Repeat operation. If the error message recurs, check the encoder output A, B and Z.

[FR-AXIS] No-motion error !Did the gage move at all or did it start to move and then stop? Repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

[FR-AXIS] Rear limit switch fault !Repeat operation. If the error message recurs, contact CINCINNATI Service.

Gage is within tool clearance, Retract will be usedInformation only.

Height dimensions for lower tool in errorProblem with height of lower tool. Verify height dimension for tool in Tool Library.

Height dimensions for upper tool in errorProblem with height of upper tool. Verify height dimension for tool in Tool Library.

9-18

Impossible block check typeInvalid configuration parameter sent by remote computer. Check communicationlink and software running on remote computer per EM-372.

Incremental change results in bad value on current step !Value for field would be out of range if increment is added. Check value being inputfor Edit All Steps.

Index File does not exist or is corrupt, rebuild indexUsing 11 or 16 character sorted filenames and could not find index file. UseREBUILD INDEX function in FILE UTILITY.

Input buffer overflow. Transfer aborted!File sent to control was not one of the valid file-types. Check offline file per EM-372.

Invalid dataSpeed change, DOWN STOP or REVERSAL out of range. Check program inputs.

Invalid Flange, please check!Problem with the flange. Check input.

Invalid Gage Point, Angle is not formed.Problem with the gage point. Recheck input.

Invalid Gage Point, Bent Angle between bend and gage pointProblem with the gage point. Recheck input.

Invalid Gage Point, Cannot Gage Bend from itselfProblem with the gage point. Recheck input.

Invalid Gage Point, Gage Angle is Greater than 90Problem with the gage point. Recheck input.

Left dump valve spool failed closedWhen the dump valve is energized, the spool sensor input must be “ON” (+24 VDC).This can also be checked on input board #1, input LED #25.

Left transducer is malfunctioningTransducer problem. Switch the cables on the analog/servo board. If the problemswitches, order new transducer. If the problem did not switch, order new or reman-ufactured analog/servo board.

Left zero pulse errorError in the encoder output or slave board processor. Recalibrate the ram and repeatoperation. If the problem returns, switch the encoder cables and the servo cables onthe analog/servo board. If the problem moves to the other side, order a new orremanufactured encoder. If the problem did not switch sides, order a new or reman-ufactured analog/servo board. If you still have a problem, install the slave board.

Light curtain must be on to operate in this modeGuard must be "on". Turn guard ON. If it is "on", check the I/O diagnostic display.

Light guard was not interrupted!The guard was not interrupted before a stroke was started. Check to see if theguard has the self-check feature. If so, check the output board LED #27. This LEDshould go off at the bottom and turn on before the top of the stroke. Repair theguard if necessary to restore proper operation.

Lower Tool file not found, Please try again.Did not find lower tool. Check tool name in JOB DATA and TOOLING LIBRARY.

Machine fault(s) - diagnostic output disabledControl selections are not properly set. Check that Stroke Selector is in SET-UP.

9-19

Main drive is offMain drive not running. Turn ON the main drive.

Main Drive Must be On for 15 seconds before starting Cycle !Pressed "Start Cycle" softkey too quickly after starting main drive. Wait 15 secondsand repeat.

Maintenance Required - View Messages under Management DataTime to perform a planned maintenance item. Go to REVIEW MANAGEMENT DATAscreen. Press "Maint Msg" softkey for specific item to perform.

Material bottomed in die, increase minimum angle.Increase minimum angle or select different tooling.

Material Radius is zero, check part.Radius for bend is zero. Recheck input.

Material Thickness is zero, check part.Thickness for material is zero. Recheck input.

Max of three footswitches can be active in Tandem ModeMore than the allowed number of operator controls turned "on". Disable one of theoperator controls.

Max of two PalmStations can be active in Tandem ModeMore than the allowed number of operator controls turned "on". Disable one of theoperator controls.

Maximum number of flanges allowed for partNumber of flanges too large. Remove one or more flanges.

Maximum tonnage exceededExceeded safety tonnage for tools. Part not in center of the machine or ram tilted.Center the part in the machine. Check the ram tilt, check the encoder settings.Check tooling, part width and tonnage limits in the TOOLING LIBRARY (upper andlower).

Maximum tonnage exceeded on left sidePart not in center of the machine or ram tilted. Center the part in the machine.Check the ram tilt, check the encoder settings. Check if the part is within themachine tonnage capacity.

Maximum tonnage exceeded on right sidePart not in center of the machine or ram tilted. Center the part in the machine.Check the ram tilt, check the encoder settings. Check if the part is within themachine tonnage capacity.

Measured angle is zero for bend, please repeat.Angle is zero for bend. Check input.

Measured dietop out of tolerance, repeat all bends noted.Dietop out of tolerance. Check tooling in TOOLING LIBRARY, filler block, materialthickness and encoder adjustments.

Measured dietop out of tolerance, repeat bend.Dietop out of tolerance. Check tooling in TOOLING LIBRARY, filler block, materialthickness and encoder adjustments.

Minimum Teach Angle not entered, please checkMinimum angle was not entered. Check and repeat operation.

9-20

Motion errorRepeat operation. If the error message recurs, check the encoder output A, B and Z.

No Files Selected to COPY."Copy Files" softkey was pressed with no files selected. Use "Select Files" first, thenrepeat.

No motionRam failed to move when instructed. Repeat operation. If the error message recurs,contact CINCINNATI Service.

No reply received ! Timed out...Communication link does not have proper connections to the remote computer.Check the PC and cable. Perform the PC RS-232/422 self test per EM-372.

No Serial Number in file, Service Access required to loadAttempted to load machine configuration file for another machine. Locate correctconfiguration disk for machine. Repeat operation. If the error message recurs, con-tact CINCINNATI Service.

No valid bend sequences were foundDid not find any valid bend sequence. Recheck inputs. (Pinch point under ram inConfiguration). Refer to Graphics Manual, EM-339.

Not enough memory !!!Internal memory full. Delete some programs or use RS-232/422 Communicationsper EM-372.

Oil level too lowOil level too low or bad switch. Check and add oil. If oil level is normal, install newswitch.

Oil temp too highOil temperature too high. Turn OFF machine. This error will come on at 175°. If themachine has only been on for a short time, check TP#5. It should be 300 to 500PSI. If not, contact CINCINNATI Service. If the machine has power clamps, checkTP#7. It should be about 1425 to 2000 PSI with the power clamp open. With powerclamp closed, it should be about 25 PSI or less. If not, order SOL #7.

Only 10 parts allowed using append Function.Remove some of the parts.

Only 99 steps allowed in program.Remove some steps or use multiple programs.

Only one tool set allowed for Adaptive Reversal Mode.Remove other tool sets in JOB DATA or change tool in RAM DATA for all steps.

Only the keys A - Z are allowedNumber keys are not allowed.

Operator Abort.Operator cancelled the transfer (RS-232/422) by pressing the "Abort" softkey.

Operator controls must be on !Control is "off" – turn operator control ON. If it is on, check the I/O display.

Operator controls not onOperator control not on – turn operator control ON. If it is on, check the I/O dis-play.

9-21

Output Board Fault !Check the I/O display and chips U1 and U2 on output board. If there is an error onthe I/O display, remove the short and replace chips U1 or U2 E-01565. If U1 andU2 are not replaceable, order new or remanufactured output board.

Palm and Foot stations cannot be on in AUTO RETURNPalm and Foot Station both on. Turn one OFF or use Single Stroke. If it's okay,check the I/O display.

Palm Station (s) Must be turned OFFStation is turned on – turn station OFF. If it's off, check the I/O display.

Palm Station (s) Must be turned ONStation is turned off – turn station ON. If it's on, check the I/O display.

Palm station or Hand/Foot seq must be used when guard is off!Turn ON Palmstation or use Hand/Foot Sequence.

Parameter 1 not calculated, repeat bend.Repeat operation. If the error message recurs, contact CINCINNATI Service.

Parameter 2 not calculated, repeat bend.Repeat operation. If the error message recurs, contact CINCINNATI Service.

Part does not meet minimum tonnage, Bend Rejected!Repeat operation. Teach Bend requires minimum tonnage. Either bend a longerpiece or use thicker material.

Part is below minimum tonnage, Angle may be in error!Adaptive Bend requires minimum tonnage. Angle may be inaccurate. Bend longerpart, use thicker material, or switch to ANGLE mode.

Part is Incomplete, Please enter more than one flange.Repeat operation. If the error message recurs, contact CINCINNATI Service.

Part was hit in high speed !Speed change position set too low. Change Speed Change position. Check tooling,material thickness and encoder settings.

Password not entered, cannot edit values!Enter password. If forgotten, contact CINCINNATI Service.

Pathname too longPath chosen for make directory is longer than 8 characters. Choose another namewith 8 characters or less.

Please check the Gage Point for FLANGE NO:Recheck gage point. Entered invalid flange for this part.

Please check tilt for correct valueTilt value is greater than 1.0". This is a warning only. Verify that you have correcttilt.

Please support part in back of ram to prevent fallingInformation only.

Position reversalTonnage reversal desired but position achieved first. Lower reversal position. Checktool load setting in TOOL LIBRARY.

Power Conservation Timed OutMain drive shut off because of machine inactivity. Press main drive ON, reviewtimer setting in MANAGEMENT DATA.

9-22

Pressure is not building in Clamp CircuitPower clamp is not functioning properly. Check the I/O diagnostic display. ContactCINCINNATI Service.

Pressure is not building in Left Clamp CircuitPower clamp is not functioning properly. Check the I/O diagnostic display. ContactCINCINNATI Service.

Pressure is not building in Right Clamp CircuitPower clamp is not functioning properly. Check the I/O diagnostic display. ContactCINCINNATI Service.

Program Lock selector switch must be off!Cannot edit Program when in locked position. Turn Program/Lock Selector to "PRO-GRAM". If it's in "PROGRAM", check the I/O display.

Program steps were added or deleted, Simulation invalid!Add or delete flanges in part design. Repeat the part simulation.

[R & Z-AXIS] On/Off conflict with program value !Attempted to run program with different R and Z-axis status settings than thoselast selected in JOB DATA.

[R -AXIS] All steps MUST have same <rev. mode> to enter new VALUE!Attempted to edit all steps with absolute position reversal on some steps. Changevalues manually on each step required.

[R -AXIS] Calculated vertical bar skew is too large !Difference between R-left and R-right positions is too large. Check R-axis inputs.

[R -AXIS] Calibration is required before use !Gage is not calibrated. Calibrate the gage.

[R -AXIS] On/Off conflict with program value !Attempted to run program with different R-axis status setting.

Ram completed stroke prior to material contactThe default reversal position was reached in ADAPTIVE mode prior to sensing mate-rial contact. Check material thickness, die and filler block dimensions. Repeat.

Ram completed stroke while scanning for final reversalRepeat operation. If the error message recurs, contact CINCINNATI Service.

Ram completed stroke while waiting for Ramp DownRepeat operation. If the error message recurs, contact CINCINNATI Service.

RAM is not calibrated !!!Ram is not calibrated because control was powered "off". Calibrate ram.

RAM is out of tiltRam is out of tilt (>1"). Relevel ram per instructions in SECTION 9 of this manual. Ifthe machine is not out of level >1", check adjustment on the Tilt Limit Switches.

Ram tilt limit switch fault !Both tilt switches are activated. Check adjustment on the switches.

Ram too low, raise ram above speed change and restart cycle.Raise ram using RAM UP button and restart cycle.

Rear guard fault ! Check behind machine and resetCheck to see that the guard is clear and reset using button provided.

9-23

Recover directory not available for disk storage VolumeAttempted to recover a file when volume set to Local Drive. Operation not available.Once deleted, a file on disk cannot be recovered on control.

Recovery Aborted - FILE CORRUPT!File requested is corrupt. Turn the machine OFF and back ON to clear out therecover buffer. Try to delete and recover another file. If the error message recurs,contact CINCINNATI Service.

Recovery Error - Recovery Aborted!File requested is corrupt. Turn the machine OFF and back ON to clear out therecover buffer. Try to delete and recover another file. If the error message recurs,contact CINCINNATI Service.

Retract too large for entered flange value.Retract distance added to flange dimension exceeds the maximum travel limit forthe gage. Change retract distance value to a smaller number.

Rev. mode is not valid for changing rev. value on all steps!Attempted to edit all steps with different reversal modes on some steps. Change val-ues manually on each step as required.

Reversal error while waiting to finish strokeRepeat operation. If the error message recurs, contact CINCINNATI Service.

Reversal Position is higher than Speed Change DownProgrammed values are not realistic. Check tooling, material thickness and encodersettings.

Reversal position is too highReversal position is above the open height of machine. Check program input forreversal position. Check tooling, material thickness and encoder settings.

Reversal position is too lowReversal position is below the closed height of machine. Check program inputs forreversal position. Check tooling, material thickness and encoder settings.

Reversal Tonnage reached before clamp positionClamp position set too low. Adjust to higher value in JOB DATA.

Reversal tonnage too high for diesTonnage has exceeded maximum loading value set for tooling. Check programinputs or select different tooling.

Right transducer is malfunctioningTransducer problem. Switch the cables on the analog/servo board. If the problemswitches to the left side, order new transducer. If the problem did not switch, ordernew or remanufactured analog/servo board.

Right zero pulse errorError in the encoder output or slave board processor. Recalibrate the ram andrepeat operation. If the problem recurs, switch the encoder cables and the servocables on the analog/servo board. If the problem moves to the other side, order anew or remanufactured encoder. If the problem did not switch, order a new orremanufactured analog/servo board. If you still have trouble, install the slaveboard.

[RL-AXIS] Actual position is out of tolerance !Check to see if the axis is hitting an obstruction. Did the gage move at all or did itstart to move and then stop? Repeat operation. If the error message recurs, contactCINCINNATI Service.

9-24

[RL-AXIS] Calculated dimension exceeds travel limits !R-axis position not realistic. Check R-axis inputs.

[RL-AXIS] Calibration failure !Axis did not calibrate. Did the axis move to its maximum position? Did it moveslightly in the other direction? If so, check the encoder outputs A, B and Z. If it didnot move slightly back, before the axis reached its maximum travel. Started to movebut stopped or did not move at all? Is the axis hitting a physical obstruction?

[RL-AXIS] Communication fault !Repeat operation. If the error message recurs, check the fiber optic cable connec-tions at the VME slave CPU332 Communications controller. Check that there isinput and output from each board.

[RL-AXIS] Did not position properly !Repeat operation. If the error message recurs, check to see if the axis is hittingsome physical obstruction.

[RL-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z. (See drawing.)

[RL-AXIS] No-motion error !Did the gage move at all or did it start to move then stop? Repeat operation. If theerror message recurs, contact CINCINNATI Service.

[RL-AXIS] Not responding properly to commands !Axis did not achieve position. Turn the machine OFF for 40 seconds. Turn back ON.Repeat operation. If the error message recurs, contact CINCINNATI Service.

[RR-AXIS] Actual position is out of tolerance !Check to see if the axis is hitting an obstruction. Did the gage move at all or did itstart to move and then stop? Repeat operation. If the error message recurs, contactCINCINNATI Service.

[RR-AXIS] Calculated dimension exceeds travel limits !R-axis position not realistic. Check R-axis inputs.

[RR-AXIS] Calibration failure !Axis did not calibrate. Did the axis move to its maximum position? Did it moveslightly in the other direction? If so, check the encoder outputs A, B and Z. If it didnot move slightly back, is the axis hitting a physical obstruction?

[RR-AXIS] Communication fault !Repeat operation. If the error message recurs, check the fiber optic cable connec-tions at the VME slave CPU and the CPU332 Communications Controller. Checkthat there is input and output from each board.

[RR-AXIS] Did not position properly !Repeat operation. If the error message recurs, check to see if the axis is hitting aphysical obstruction.

[RR-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z.

[RR-AXIS] No-motion error !Did the gage move at all or did it start to move and then stop? Repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

9-25

[RR-AXIS] Not responding properly to commands !Axis did not achieve position. Turn the machine OFF for 40 seconds, then back ON.Repeat, and if the problem still exists, contact CINCINNATI Service.

Run display edit value is undefined,has Run display changed?Software problem. Contact CINCINNATI Service.

Safety blocks are disconnected !Safety blocks disconnected – reconnect. If they are connected, check the I/O dis-play.

Select setup mode using mode selector switch!Mode switch not in SET-UP mode position. Turn switch to SET-UP MODE position.

Selected sequence has interference, please reviewReview inputs for interference and repeat operation.

Serial Number stored, does not match, use Service AccessAttempting to load configuration from another machine. Locate correct configura-tion for this machine or contact CINCINNATI Service to override.

Service access not permitted! Enter service code.Operator not allowed to change value. Contact CINCINNATI Service.

Service access required to enter this diagnosticOperator not allowed to change value. Contact CINCINNATI Service.

Simulation must be generated before viewingGenerate simulation.

Simulation was not stored before entering Run ModeStore simulation before going to RUN mode.

Slave Machine Control has an error, check and correctCheck other machine pendant for proper operating mode.

Slave received bad command from masterSoftware problem. Repeat / Contact CINCINNATI Service.

Slave reset while in keystroke loopRepeat operation. If the error message recurs, contact CINCINNATI Service.

Slave reset while in priority loopRepeat operation. If the error message recurs, contact CINCINNATI Service.

Slave reset while ramping downRepeat operation. If the error message recurs, contact CINCINNATI Service.

Slave reset while scanning for reversalRepeat operation. If the error message recurs, contact CINCINNATI Service.

Slave reset while waiting to finish strokeRepeat operation. If the error message recurs, contact CINCINNATI Service.

Slave reset while waiting to read Stroke_dataRepeat operation. If the error message recurs, contact CINCINNATI Service.

Speed Chg Down cannot be less than .25 for Adaptive ModeUse the ADAPTIVE GUIDELINES & LIMITATIONS, OS-136, to check.

Stroke complete while in priority loopRepeat operation. If the error message recurs, contact CINCINNATI Service.

Stroke Control must be in SET-UP modeReset control to "SET-UP". If already in SET-UP, check I/O display.

9-26

Stroke Control must be in SINGLE STROKE or RUN modeIf not in SINGLE STROKE or RUN mode, turn to SINGLE STROKE or RUN mode. Ifit is, check the I/O display.

Stroke did not complete, angle may be incorrectCheck part and repeat operation.

Tandem Data Link is malfunctioningPossible hardware problem. Contact CINCINNATI Service.

Tandem operation not permitted in SETUP ModeCannot use in SET-UP mode. Change Stroke Selector to SINGLE STROKE mode.

Tandem Selector switch must be in DUAL positionAttempt was made to operate machines in a mode different from Tandem SelectorSwitch setting. Review operating mode and check switches.

Tandem Selector switch must be in SINGLE positionAttempt was made to operate machines in a mode different from Tandem SelectorSwitch setting. Review operating mode and check switches.

Target step cannot be within start, end copy range !Attempted to copy a group of steps to a step within the group. Select a target stepoutside the selected copy range or insert new step.

Teach Bend Length not entered, please checkBend length was not entered. Check and repeat operation.

The gage (s) are already in motion !A new position was requested while the gages were in motion. The new position wasignored. Repeat operation.

The gage(s) have not moved successfully !Repeat operation. If the error message recurs, contact CINCINNATI Service.

The gage(s) must be calibrated before use !Gage is not calibrated because control was powered OFF. Calibrate gage.

THE RAM is moving !Information only.

There are no more extension pointers, delete some filesThe maximum number of files in internal memory has been reached. Deleteunwanted files or transfer to a disk.

Thickness is out of tolerance for bend, please check.Part thickness was not within thickness range taught during Adaptive Set-up.Verify material and repeat.

This feature is not available for INTERNAL VolumeSelected operation does not apply to this source/destination choice. Review thedesired operation. See SECTION 7 of this manual.

This feature is not available for REMOTE VolumeSelected operation does not apply to this source/destination choice. Review thedesired operation. See SECTION 7 of this manual.

This feature is ONLY available for a DISK VolumeSelected operation does not apply to this source/destination choice. Review thedesired operation. See SECTION 7 of this manual.

9-27

This operation will overwrite an existing 11 char filenameUsing 11 character sorted filename mode and filename already exists. Determine ifthis is desired or choose another name.

This output cannot be changed by this diagnostic utilityCertain outputs cannot be changed in this function. Review your selection.

To calibrate Palm and Foot stations cannot both be onBoth operator controls turned "on"; turn one control OFF. If only one is on, checkthe I/O display.

To calibrate STATION SELECT must be in PALM OR FTS modeNot in PALM or FOOTSWITCH mode. Select PALM or FOOTSWITCH mode. If alreadythere, check the I/O diagnostic display.

To calibrate STROKE CONTROL must be in SINGLE STROKE modeNot in SINGLE STROKE mode. Select SINGLE STROKE mode. If already there,check the I/O diagnostic display.

Tool file not found, Please try againCould not find tool file. Repeat operation.

Tool not specified for one or more stepsSpecify tools and repeat operation.

Tool set not definedNo tool found in library matching Job Data information. Check TOOL LIBRARY andJOB DATA.

Top of dies not calibratedTo use unmeasured tools, top of dies must be calibrated in the SET-UP MENU.Calibrate top of dies in SET-UP MENU.

Transfer ABORTED: Cartridge data corruptData cartridge removed or faulty. Retry. If problem persists, replace cartridge.

Two flanges have the same bend sequence numberCheck inputs on PART DESIGN screen and change the offending flange entry.

Unable to achieve reversalRepeat operation. If the error message recurs, contact CINCINNATI Service.

Unable to completely sort directoryRepeat operation. If the error message recurs, contact CINCINNATI Service.

Unable to find specified directoryDirectory does not exist on the disk volume. Create directory first or review desiredoperation.

Unable to insert record into index fileThe disk inserted in local Drive "A" is corrupt. Use a different disk or reformat.

Unable to Load in Cad Configuration filesRepeat operation. If the error message recurs, contact CINCINNATI Service.

Unable to load Management DataRestore configuration from disk was unable to locate desired files. Verify files existin "\Text" directory on disk.

Unable to make the specified directoryRepeat operation. If the error message recurs, contact CINCINNATI Service.

9-28

Unable to open the index file, rebuild indexUsing 11 or 16 character sorted filenames, the index file was corrupt or lost.Rebuild the index file by using the "Rebuild Index" function in FILE UTILITY.

Unable to open the requested fileThe disk inserted in Local Drive "A" is corrupt. Use a different disk or reformat.

Unable to select file - Maximum number already selected.Exceeded maximum selections allowed. Unselect some files or use the "Select All"function.

Unable to store Diagnostic Data to fileRepeat operation. If the error message recurs, contact CINCINNATI Service.

Unable to read or write to cartridgeCartridge not inserted – insert cartridge. If it is inserted, order cartridge.

Unable to write to cartridgeCartridge not inserted or write protected – insert cartridge or change write protectswitch. If it is inserted, order cartridge.

Unable to write to the requested fileThe disk inserted in Local Drive "A" is corrupt. Use a different disk.

Undefined calculation error #An undefined error number occurred. Repeat operation. If the error message recurs,contact CINCINNATI Service.

Undefined error number received from slave !Software problem. Repeat operation. If the problem still exists, contact CINCINNATIService.

Undefined value for modeSoftware problem. Repeat operation. If the problem still exists, contact CINCINNATIService.

Undefined value for STATION SELECTSoftware problem. Repeat operation. If the problem still exists, contact CINCINNATIService.

Unexpected file type. Incoming file not saved !File sent (RS-232/422) to control is not of the currently selected file type. Check thefile being sent.

Unexpected file type.File sent (RS-232/422) to control is not of the currently selected file type. Check thefile being sent.

Unexpected packet typePacket received (RS-232/422) from the remote device was not the type theAUTOFORM expected. Check communication link and software running on remotedevice. Run the RS-232/422 Self Test per EM-372.

Up stroke data not correct, Bend terminated.Repeat operation. If the error message recurs, contact CINCINNATI Service.

Upper Tool file not found, Please try again.Did not find upper tool. Check tool name in Job Data and Tooling Library.

Value entered exceeds the maximumNumber entered is too large. Check input value.

Value entered is less than the minimumNumber entered is too small. Check input value.

9-29

Valve supply is offHardware failure. Check operator control switch. If the problem still exists, ContactCINCINNATI Service.

Vee opening less than 6 times material thick, check tooling.Check the tooling in the Tooling Library. If necessary, select more appropriate tooling.

Vertical bar skew would be too large !R-axis position not realistic. Check R-axis inputs.

VME Input/output board failure !Order new or remanufactured I/O board.

[X -AXIS] Amplifier resetting !Check to make sure gage will move by hand. Power down machine, restart, repeat.

[X -AXIS] Calculated horizontal bar skew is too large !Difference between X-left and X-right positions is too large. Check X-axis input.

[X -AXIS] Calibration failure !Axis did not calibrate. Did it move to its maximum position? Did it move slightly inthe other direction? If so, check the encoder outputs A, B and Z. If it did not moveslightly back, is the axis hitting an obstruction?

[X -AXIS] Calibration is required before use !Gage is not calibrated. Calibrate the gage.

[X -AXIS] Communication fault !Repeat operation. If the error message recurs, check the fiber optic cable connec-tions at the VME slave CPU.

[X -AXIS] Did not position properly !Is the axis hitting an obstruction? Did the gage move at all or did it start to moveand then stop? Repeat operation. If the error message recurs, contact CINCINNATIService.

[X -AXIS] Dimension is not within travel limits !Out of range. Check X-axis input.

[X -AXIS] Horizontal bar skew exceeded !Repeat operation. If the error message recurs, check the configuration data to see ifthe maximum horizontal bar skew is the same as the maximum travel limit. If it is,contact CINCINNATI Service.

[X -AXIS] Timed out before completing move !Gage did not achieve position. Check to see if the axis is hitting an obstruction.Repeat operation. If the error message recurs, contact CINCINNATI Service.

[XL-AXIS] Amplifier fault !Check to make sure gage will move by hand. If over 15 seconds, power downmachine and repeat operation. Contact CINCINNATI Service.

[XL-AXIS] Calculated dimension is too large !X-axis position is not realistic for machine. Check program input for X-axis.

[XL-AXIS] Calculated dimension is too small !X-axis position is not realistic for machine. Check program input for X-axis.

[XL-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z.

[XL-AXIS] Front limit switch fault !Repeat operation. If the error message recurs, contact CINCINNATI Service.

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[XL-AXIS] Motion error !Repeat operation. If the error message recurs, check the encoder output A, B and Z.

[XL-AXIS] No-motion error !Did the gage move at all or did it start to move and then stop? Repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

[XL-AXIS] Rear limit switch fault !Repeat operation. If the error message recurs, contact CINCINNATI Service.

[XR-AXIS] All steps MUST have same <gage mode> to enter newAttempted to edit all steps with different gage modes. Change values manually oneach step required.

[XR-AXIS] Amplifier fault !Check to make sure gage will move by hand. If over 15 seconds, power down themachine and repeat operation. Contact CINCINNATI Service.

[XR-AXIS] Calculated dimension is too small !X-axis position is not realistic for machine. Check program input for X-axis.

[XR-AXIS] Calculated dimension is too large !X-axis position is not realistic for machine. Check program input for X-axis.

[XR-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z.

[XR-AXIS] Front limit switch fault !Repeat operation. If the error message recurs, check SRV332 Board to see if LS1 orLS3 are "on".

[XR-AXIS] Motion error !Repeat operation. If the error message recurs, check the encoder output A, B and Z.

[XR-AXIS] No-motion error !Did the gage move at all or did it start to move and then stop? Repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

[XR-AXIS] Rear limit switch fault !Repeat operation. If the error message recurs, contact CINCINNATI Service.

[Z -AXIS] Calibration is required before use !Gage is not calibrated. Calibrate the gage.

[Z -AXIS] Conflict ! Left and Right arms would collide !Both axes cross center of bed - not possible. Check Z-axis inputs.

[Z -AXIS] Distance between Left & Right arms is too small !Programmed Z-axis positions will cause a collision. Check Z-axis inputs.

[ZL-AXIS] Actual position is out of tolerance !Check to see if the axis is hitting an obstruction. Did the gage move at all or did itstart to move and then stop? Repeat operation. If the error message recurs, ContactCINCINNATI Service.

[ZL-AXIS] Calculated dimension exceeds travel limits !Z-axis position is not realistic. Check Z-axis inputs.

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[ZL-AXIS] Calibration failure !Axis did not calibrate. Did it move to its maximum position? Did it move slightly inthe other direction? If so check the encoder outputs A, B and Z. If it did not moveslightly back, is the axis hitting an obstruction?

[ZL-AXIS] Communication fault !Repeat operation. If the error message recurs, check the fiber optic cable connec-tions at the VME slave CPU.

[ZL-AXIS] Did not position properly !Repeat operation. If the error message recurs, see if the axis is hitting some physi-cal obstruction.

[ZL-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z.

[ZL-AXIS] No-motion error!Did the gage move at all or did it start to move and then stop? Repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

[ZL-AXIS] Not responding properly to commands !Axis did not achieve position. Turn OFF the machine for 40 seconds. Turn back ON.Repeat operation. If the error message recurs, check the ribbon cable between theCPU332 Communications Controller Board and the INFC332 Interface Board. If theerror message recurs, contact CINCINNATI Service.

[ZR-AXIS] Actual position is out of tolerance !Check to see if the axis is hitting some obstruction. Did the gage move at all or didit start to move and the stop? Repeat operation. If the error message recurs, contactCINCINNATI Service.

[ZR-AXIS] Calculated dimension exceeds travel limits !Z-axis position is not realistic. Check Z-axis inputs.

[ZR-AXIS] Calibration failure !Axis did not calibrate. Did it move to its maximum position? Did it move slightly inthe other direction? If so, check the encoder outputs A, B and Z. If it did not moveslightly back,is the axis hitting an obstruction?

[ZR-AXIS] Communication fault !Repeat operation. If the error message recurs, check the fiber optic cable connec-tions at the VME slave CPU.

[ZR-AXIS] Did not position properly !Repeat operation. If the error message recurs, check to see if the axis is hitting anobstruction.

[ZR-AXIS] Encoder fault !Repeat operation. If the error message recurs, check the output from the encoder A,B and Z in left gage control enclosure on Z-axis carriage. (See drawing.)

[ZR-AXIS] No-motion error!Did the gage move at all or did it start to move and then stop? Repeat operation. Ifthe error message recurs, contact CINCINNATI Service.

[ZR-AXIS] Not responding properly to commands !Axis did not achieve position. Turn machine OFF for 40 seconds, and then turnpower back ON. Repeat operation. If the error message recurs, contact CINCINNATIService.

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OTHER PROBLEMS

Certain machine problems pertaining to ram motion or control operation may be intermittent or prohibitthe machine from displaying an error. By providing the information below prior to scheduling a service callor consulting with a Technical Service Specialist, the Troubleshooting process can be significantly reduced.

RAM / MOTION (Select the current problem.)

✦ NO RAM MOTION: The ram did not move when you used the footswitch or operator station tooperate the machine.

Switch bend position to the other side. If the current bend position is "right" or "center", switch to theleft. If the current bend position is "left", switch to the right. Is the ram moving now?

✧ RAM IS MOVING OR WENT OUT-OF-LEVEL

1. Refer to the electrical schematic and check the 5VDC input voltage to the encoders.

– If above 4.6VDC, proceed to the next step.– If it is less then 4.5VDC, replace the Analog/Servo board.

2. Refer to the electrical schematic and check the output of the encoder signals. A, A NOT, B, BNOT, Z and Z NOT. The A's and B's should occur every .0001 (.0025mm). The Z's shouldoccur every inch. These signals will change from 0 volts to 5 volts when a pulse occurs. Doyou have all signals on both encoders?

– If you have all signals, proceed to the next step.– If you do not have all signals, order a new ram encoder.

Note: Signals may be checked using a digital logic probe.

3. Check the hydraulic idle pressure at TP #4. Use a 600 PSI (4137 kPa) or 1000 PSI (6895 kPa)gage. Is there 300 to 500 PSI (2068 to 3447 kPa) there? (Refer to hydraulic schematic.)

– If you have 300 to 500 PSI (2068 to 3447 kPa), proceed to the next step.– If you do not have 300 to 500 PSI (2068 to 3447 kPa), contact CINCINNATI Service.

4. Switch the cables on the Analog/Servo board. Both servo outputs and encoder inputs cablesmust be switched as pairs. How does the ram move now?

– Ram not moving. BLOCK THE RAM and switch the proportional valves. Set bend positionback to original side. Remove the block and press the RAM UP button. What does the ramdo now?

a.) If ram went out-of-level, replace the proportional valve on the side that is notmoving.

b.) If the ram did not move, contact CINCINNATI Service.

– Ram went out-of-level. Replace the Analog/Servo board.

✧ RAM IS NOT MOVING

1. Are you using the footswitch(es), palmbutton(s) or both? Check the I/O MONITOR DIAGNOS-TICS screen to verify they are working. (Refer to DIAGNOSTICS in SECTION 7.)

– If the I/O monitor confirms that they are working, proceed to the next step.– If the I/O monitor does not confirm that they are working, check the wiring to the

footswitch(s) or palmbutton(s). Also check the switches and buttons.

2. Does the machine have a light guard?

– If it does not, proceed to the next step.– If it does, check the I/O MONITOR DIAGNOSTICS screen to verify it is working. (Refer to

electrical schematic.)

3. Check the hydraulic idle pressure at TP #4. Use a 600 PSI (4137 kPa) or 1000 PSI (6895 kPa)gage. Is there 300 to 500 PSI (2068 to 3447 kPa) there? (Refer to hydraulic schematic.)

– If you do have 300 to 500 PSI (2068 to 3447 kPa), proceed to the next step.– If you do not have 300 to 500 PSI (2068 to 3447 kPa), contact CINCINNATI Service.

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4. Check the LEDs on the valve plugs of the load sense valves while trying to move the ram up.(Refer to the electrical schematic.) Do both LEDs come “on”?

– If they are "on", proceed to the next step.– If not, check the I/O MONITOR DIAGNOSTICS screen to verify they are both turned “on”.

a.) If the LEDs are turned “on” check the wiring to the valve. (Refer to the electricalschematic.)

b.) If the LEDs are “off”, check the I/O board run LED (green) and the cable to theoutput board.

5. Manually fire the load sense valves, Solenoids #5 and #6, while using the footswitch or palm-buttons to command motion. If the ram starts to move, try moving the ram without firing thevalves manually. How does the ram move now?

– Ram moving now. Manually fire the load sense valves (Solenoids #5 and #6) a couple moretimes to ensure that they are no longer stuck.

– Still no ram motion. Replace the load sense valves.

✦ RAM WILL NOT CALIBRATE: The ram would move but would not calibrate.

1. Are you using the footswitch(es), palmbutton(s) or both? Check the I/O MONITOR DIAGNOS-TICS screen to verify they are working. (Refer to DIAGNOSTICS in SECTION 7.)

– If the I/O monitor confirms that they are working, proceed to the next step.– If the I/O monitor does not confirm that they are working, check the wiring to the

footswitch (s) or palmbutton (s). Also check the switches and buttons.

2. Does the machine have a light guard?

– If it does not, proceed to the next step– If it does, check the I/O MONITOR DIAGNOSTICS screen to verify it is working. (Refer to

electrical schematic.)

3. Check the hydraulic idle pressure at TP #4. Use a 600 PSI (4137 kPa) or 1000 PSI (6895 kPa)gage. Is there 300 to 500 PSI (2068 to 3447 kPa) there? (Refer to hydraulic schematic.)

– If you do have 300 to 500 PSI (2068 to 3447 kPa), proceed to the next step.– If you do not have 300 to 500 PSI (2068 to 3447 kPa), contact CINCINNATI Service.

4. Check the LEDs on the valve plugs of the load sense valves while trying to move the ram up.(Refer to the electrical schematic.) Do both LEDs come “on”?– If they are "on", proceed to the next step.– If not, check the I/O MONITOR DIAGNOSTICS screen to verify they are both turned “on”.

a.) If LEDs are turned “on” check wiring to the valve. (Refer to electrical schematic.)b.) If the LEDs are “off”, check the I/O board run LED (green) and the cable to the

output board.

5. Manually fire the load sense valves, Solenoids #5 and #6, while using the footswitch or palm-buttons to command motion. If the ram starts to move, try moving the ram without firing thevalves manually. How does the ram move now?

– Ram moving now. Manually fire the load sense valves (Solenoids #5 and #6) a couple moretimes to ensure that they are no longer stuck.

– Still no ram motion. Replace the load sense valves.

✦ ONLY ONE SIDE MOVES: When the ram moves, only one side moves.

Switch bend position to the other side. If the current bend position is "right" or "center", switch to theleft. If the current bend position is "left", switch to the right. Is the ram moving now?

✧ RAM IS MOVING OUT-OF-LEVEL

1. Refer to the electrical schematic and check the 5VDC input voltage to the encoders.

– If above 4.6VDC, proceed to the next step.– If it is less then 4.5VDC, replace the Analog/Servo board.

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2. Refer to the electrical schematic and check the output of the encoder signals. A, A NOT, B, BNOT, Z and Z NOT. The A's and B's should occur every .0001 (.0025mm). The Z's shouldoccur every inch. These signals will change from 0 volts to 5 volts as a pulse occurs. Do youhave all signals on both encoders?

– If you have all signals, proceed to the next step.– If you do not have all signals, order a new ram encoder.

3. Check the hydraulic idle pressure at TP #5. Use a 600 PSI (4137 kPa) or 1000 PSI (6895 kPa)gage. Is there 300 to 500 PSI (2068 to 3447 kPa) there? (Refer to hydraulic schematic.)

– If you have 300 to 500 PSI (2068 to 3447 kPa), proceed to the next step.– If you do not have 300 to 500 PSI (2068 to 3447 kPa), contact CINCINNATI Service.

4. Switch the cables on the Analog/Servo board. Both servo outputs and encoder inputs cablesmust be switched as pairs. How does the ram move now?

– Ram not moving. BLOCK THE RAM and switch the proportional valves. Set bend positionback to original side. Remove the block and press the RAM UP button. What does the ramdo now?

a.) If ram went out-of-level, replace the proportional valve on the side that is notmoving.

b.) If the ram did not move, contact CINCINNATI Service.

– Ram went out-of-level. Replace the Analog/Servo board.

✧ RAM IS NOT MOVING

1. Are you using the footswitch(es), palmbutton(s) or both? Check the I/O MONITOR DIAGNOS-TICS screen to verify they are working. (Refer to DIAGNOSTICS in SECTION 7.)

– If the I/O monitor confirms that they are working, proceed to the next step.– If the I/O monitor does not confirm that they are working, check the wiring to the

footswitch (s) or palmbutton (s). Also check the switches and buttons.

2. Does the machine have a light guard?

– If it does not, proceed to the next step– If it does, check the I/O MONITOR DIAGNOSTICS screen to verify it is working. (Refer to

electrical schematic.)

3. Check the hydraulic idle pressure at TP #4. Use a 600 PSI (4137 kPa) or 1000 PSI (6895 kPa)gage. Is there 300 to 500 PSI (2068 to 3447 kPa) there? (Refer to hydraulic schematic.)

– If you do have 300 to 500 PSI (2068 to 3447 kPa), proceed to the next step.– If you do not have 300 to 500 PSI (2068 to 3447 kPa), contact CINCINNATI Service.

4. Check the LEDs on the valve plugs of the load sense valves while trying to move the ram up.(Refer to the electrical schematic.) Do both LEDs come “on”?– If they are "on", proceed to the next step.– If not, check the I/O MONITOR DIAGNOSTICS screen to verify they are both turned “on”.

a.) If the LEDs are turned “on” check the wiring to the valve. (Refer to the electricalschematic.)

b.) If the LEDs are “off”, check the I/O board run LED (green) and the cable to theoutput board.

5. Manually fire the load sense valves, Solenoids #5 and #6, while using the footswitch or palm-buttons to command motion. If the ram starts to move, try moving the ram without firing thevalves manually. How does the ram move now?

– Ram moving now. Manually fire the load sense valves (Solenoids #5 and #6) a couple moretimes to ensure that they are no longer stuck.

– Still no ram motion. Replace the load sense valves.

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✦ RAM MOVING SLOW / RAM MOVING SLOW ON RETURN STROKE: Ram appears to be movingslower than normal.

Put the machine in Quick Bend. For the 2” (51mm) stroke test, set the Top Stop at 1” (51mm) from themaximum "up" position. Set the Speed Change at 1-1/2” (38mm) down from Top Stop. Set the ReversalPoint at 1/2” (13mm) down from Speed Change point. Example: Top Stop 16” (406mm), SpeedChange 14.5” (368mm), Reversal 14” (356mm). Count the number of strokes made in one minute. Forthe 3” 76mm) stroke test, lower the Speed Change and the Reversal Point by 1” (25.4mm). Example:Top Stop 16” (406mm), Speed Change 13.5” (343mm), Reversal 13” (330mm). (Note: Do not use CON-TINUOUS RUN mode for these tests.) Contact CINCINNATI Service with both count numbers.

✦ UNEVEN RAM MOTION: Ram appears to be moving uneven at the start of the stroke.

Switch the bend position to the other side. If the current bend position is right or center, switch to theleft. If the current bend position is left, switch to the right. How does the ram move now?

– Moves smoothly. Tilt the ram +/- 0.5” (1.3mm) so the side that was originally the master islower than the other side. Enter a positive tilt to make the right side lower or a negative tiltto make the left side lower. Does the ram achieve the tilt?

YES. Switch the bend position back and retest the machine.NO. Is there pressure at the inner cylinder (TP#1). (Refer to hydraulic schematic.)Contact CINCINNATI Service after you have checked the pressure.

Moves unevenly. Contact CINCINNATI Service.

✦ MOTION FAULT AT SPEED CHANGE: The ram stopped or had a very uneven speed change.

1. Does the machine have the AUTO CROWN option?– If the machine has AUTO CROWN, manually turn "OFF" the AUTO CROWN valve. Does the

problem still exist?Yes. Check the prefill valve and pipes for damage or air leaks. If there are no airleaks, switch the right and left prefill valves.a.) If the problem switches sides, install a new prefill valve.b.) If it did not switch, contact CINCINNATI Service.

No. Remove the air from the AUTO CROWN cylinder. Remove the plug on top of theAUTO CROWN cylinder and install a test stand with a line going back to the tankfill. Open the test stand a little and cycle the machine. Use both left and right bendpositions. This may take 200 strokes or more. Note: If the test stand is opened toomuch, the machine will stall.

– If the machine does not have AUTO CROWN, check the prefill valve and pipes for damageor air leaks. If there are no air leaks, switch the right and left prefill valves.

a.) If the problem switches sides, install a new prefill valve.b.) If it did not switch, contact CINCINNATI Service.

✦ REVERSAL / REPEATABILITY / ANGLE PROBLEMS: The ram appears to have a reversal,repeatability or angle problem (part not within tolerance).

1. Turn stroke diagnostic “on” and cycle machine for 11 strokes with the same reversal position.Is each side’s command position within +/- .0004” (.0102mm) of it’s desired position on allstrokes displayed?

– If it is within +/- .0004" (.0102mm), contact CINCINNATI Service.– If it is not within +/- .0004" (.0102mm), switch the bend position to the other side. If the

current bend position is right or center, switch to the left. If the current bend position isleft, switch to the right. Did the problem switch?

Yes. Refer to DIAGNOSTICS in SECTION 7 and check or adjust the counterbalancepressure to within 10 PSI.No. Proceed to the next step.

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2. Refer to the electrical schematic and check the 5VDC input voltage to the encoders.a.) If it is above 4.6VDC, proceed to the next step.b.) If it is less than 4.5VDC, replace the Analog/Servo board.

3. Refer to the electrical schematic and check the output of the encoder signals. A, A NOT, B, BNOT, Z and Z NOT. The A’s and B’s should occur every .0001 (.0025mm). The Z’s shouldoccur every inch. These signals will change from 0 volts to 5 volts as a pulse occurs. Do youhave all signals on both encoders?

Yes. Order a new Analog/Servo board.No. Order a new ram encoder.

✦ RAM OSCILLATES AT REVERSAL: Ram appears to oscillate at reversal or has a rough reversal.

1. Does the machine have the AUTO CROWN option?

– If the machine has AUTO CROWN, manually turn "OFF" the AUTO CROWN valve. Does theproblem still exist?

Yes. Check the prefill valve and pipes for damage or air leaks. If there are no airleaks, switch the right and left prefill valves.a.) If the problem switches sides, install a new prefill valve.b.) If it did not switch, contact CINCINNATI Service.

No. Remove the air from the AUTO CROWN cylinder. Remove the plug on top of theAUTO CROWN cylinder and install a test stand with a line going back to the tankfill. Open the test stand a little and cycle the machine. Use both left and right bendpositions. This may take 200 strokes or more. Note: If the test stand is opened toomuch, the machine will stall.

– If the machine does not have AUTO CROWN, check the prefill valve and pipes for damageor air leaks. If there are no air leaks, switch the right and left prefill valves.

a.) If the problem switches sides, install a new prefill valve.b.) If it did not switch, proceed to the next step.

2. Turn the stroke diagnostic “on” and cycle the machine for 11 strokes with the same reversalposition. Is each side’s command position within +/- .0004” (.0102mm) of it’s desired positionon all strokes displayed?

– If it is within +/- .0004" (.0102mm), contact CINCINNATI Service.– If it is not within +/- .0004" (.0102mm), switch the bend position to the other side. If the

current bend position is right or center, switch to the left. If the current bend position isleft, switch to the right. Did the problem switch?

Yes. Refer to DIAGNOSTICS in SECTION 7 and check or adjust the counterbalancepressure to within 10 PSI.No. Proceed to the next step.

3. Refer to the electrical schematic and check the 5VDC input voltage to the encoders.a.) If it is more than 4.6VDC, proceed to the next step.b.) If it is less than 4.5VDC, replace the Analog/Servo board.

4. Refer to the electrical schematic and check the output of the encoder signals. A, A NOT, B, BNOT, Z and Z NOT. The A’s and B’s should occur every .0001 (.0025mm). The Z’s shouldoccur every inch. These signals will change from 0 volts to 5 volts as a pulse occurs. Do youhave all signals on both encoders?

Yes. Order a new Analog/Servo board.No. Order a new ram encoder.

✦ RAM LEVEL PROBLEM: The ram does not stay level on the down stroke.

1. Turn the stroke diagnostic “on” and cycle the machine for 11 strokes with the same reversalposition. Is each side’s command position within +/- .0004” (.0102mm) of it’s desired positionon all strokes displayed?

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– If it is within +/- .0004" (.0102mm), contact CINCINNATI Service.– If it is not within +/- .0004" (.0102mm), switch the bend position to the other side. If the

current bend position is right or center, switch to the left. If the current bend position isleft, switch to the right. Did the problem switch?

✧ RAM IS MOVING OR WENT OUT-OF-LEVEL

1. Refer to the electrical schematic and check the 5VDC input voltage to the encoders.

– If it is less then 4.5VDC, replace the Analog/Servo board.– If above 4.6VDC, proceed to the next step.

2. Refer to the electrical schematic and check the output of the encoder signals. A, A NOT, B, BNOT, Z and Z NOT. The A's and B's should occur every .0001 (.0025mm). The Z's shouldoccur every inch. These signals will change from 0 volts to 5 volts as a pulse occurs. Do youhave all signals on both encoders?

– If you have all signals, proceed to the next step.– If you do not have all signals, order a new ram encoder.

3. Check the hydraulic idle pressure at TP #4. Use a 600 PSI (4137 kPa) or 1000 PSI (6895 kPa)gage. Is there 300 to 500 PSI (2068 to 3447 kPa) there? (Refer to hydraulic schematic.)– If you have 300 to 500 PSI (2068 to 3447 kPa), proceed to the next step.– If you do not have 300 to 500 PSI (2068 to 3447 kPa), contact CINCINNATI Service.

4. Switch the cables on the Analog/Servo board. Both servo outputs and encoder inputs cablesmust be switched as pairs. How does the ram move now?

– Ram not moving. BLOCK THE RAM and switch proportional valves. Set bend position backto original side. Remove the block and press the RAM UP button. What does the ram donow?

a.) If ram went out-of-level, replace proportional valve on the side that is not moving.b.) If the ram did not move, contact CINCINNATI Service.

– Ram went out-of-level. Replace the Analog/Servo board.

✧ RAM IS NOT MOVING

1. Check the hydraulic idle pressure at TP #4. Use a 600 PSI (4137 kPa) or 1000 PSI (6895 kPa)gage. Is there 300 to 500 PSI (2068 to 3447 kPa) there? (Refer to hydraulic schematic.)– If you have 300 to 500 PSI (2068 to 3447 kPa), proceed to the next step.– If you do not have 300 to 500 PSI (2068 to 3447 kPa), contact CINCINNATI Service.

2. Check the level limit switch settings. Are they set per the manual?– If yes, proceed to the next step.– If no, adjust switches per the manual.

3. Check the machine closed height per the manual. Are the encoders set correctly?– If yes, contact CINCINNATI Service.– If no, adjust the closed height per the manual.

✦ RAM DRIFT PROBLEM: The ram appears to be drifting down when the machine is at idle.

1. Refer to this section and check or adjust the counterbalance pressure to within 10 PSI (69kPa).– If it is within 10 PSI (69 kPa), proceed to the next step.

2. Check to ensure that the bleeder valve is closed.– If it is closed, proceed to the next step.– If not, close the bleeder valve.

Note: Ram must be blocked before valves are removed.

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Check the following with the operator control switch turned “off”.

3. Switch the counterbalance valves from side-to-side. Did the problem switch sides?– If yes, order new counterbalance valve.– If no, proceed to the next step.

4. Switch the counterbalance check valves from side-to-side. Did the problem switch sides?– If yes, order new counterbalance check valve.– If no, order new cylinder seals.

✦ TONNAGE PROBLEM: Machine does not reverse, a tonnage error occurs, or the ram stalls dur-ing the bend sequence.

1. Are the Reversal Position, Reversal Tonnage and the Reversal Mode entered correctly?– If yes, proceed to the next step.– If no, reset the Reversal Position, Reversal Tonnage and Reversal Mode.

2. Check the tilt information in the program. Is it correct?– If yes, proceed to the next step.– If no, reset the tilt information.

3. Check the machine closed height. See this Section, "CLOSED HEIGHT ADJUSTMENT". Arethe encoders set correctly?– If yes, proceed to the next step.– If no, reset the closed height.

4. Check the tilt when the machine has the problem. Is the machine out-of-tilt? Refer to theelectrical schematic and check the 5VDC input voltage to the encoders.– If above 4.6VDC, proceed to the next step.– If it is less then 4.5VDC, replace the Analog/Servo board.

5. Refer to the electrical schematic and check the output of the encoder signals. A, A NOT, B, BNOT, Z and Z NOT. The A’s and B’s should occur every .0001 (.0025mm). The Z’s shouldoccur every inch. These signals will change from 0 volts to 5 volts as a pulse occurs. Do youhave all signals on both encoders?– If yes, order a new Analog/Servo board.– If no, order a new ram encoder.– If the problem still exists, proceed to the next step.

6. Check the configuration data. Does it match the configuration sheets?– If yes, proceed to the next step.– If no, contact CINCINNATI Service.

7. Switch the cables for the strain gages on the Analog/Servo board. Did the problem changefrom side-to-side?– If yes, check the wiring from the questionable strain gage to the plug at the Analog/Servo

board. (Refer to electrical schematic.) Is the wiring good?

– If no, check the 10 VDC terminal in the junction boxes inside the right and left housings.(Refer to electrical schematic.)

a.) Check voltage between the + sig to com and the - sig to com. It should be 5 +/-.250VDC. Is voltage present? Contact CINCINNATI Service with this information.

b.) Check the wiring to the plug on the Analog/Servo board. Is the wiring good?Yes. Order new Analog/Servo board.No. Order or repair the cable.

✦ ADAPTIVE PROBLEM

Refer to the Adaptive Manual Supplement EM-327.

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CRT DISPLAY PROBLEMS (Select the current problem.)

✦ NO CRT DISPLAY: No display on the CRT.

1. Is the Ground Connected Light “on”?– If it is "on", proceed to the next step.– If it is not "on", push in on the Ground Connected Light. Does it come “on”? If it does not,

check the light, socket or wiring. If it does come on, check the wiring to the socket.

2. Is the Power Supplies Operational Light “on”?– If it is "on", proceed to the next step.– If it is not "on", push in on the Power Supplies Operational Light. Does it come “on”? If not,

check the light, socket or wiring. If it does come on, check the LED’s on the power supplymonitor board. If the following LEDs are “on”, check these:

• 5 VDC LED, check and adjust the 5 VDC power supply.• 15 VDC LED, check and adjust the 15 VDC power supply.• -15 VDC LED, check and adjust the -15 VDC power supply.• 12 VDC LED, check and adjust the 12 VDC power supply.• -12 VDC LED, check and adjust the -12 VDC power supply.• 120 vac LED, check the 120 vac power line.

3. Check the slave CPU board, both green LED’s should be “on”.– If it is "on", proceed to the next step.– If not, how many times does the red halt light flash (at power up)?

• Flashed one time: replace the Analog/Servo board.• Flashed two times: replace the I/O board.• Flashed three times: remove the RX cable from the slave CPU board. The

connector on the RX cable should flash when a key is pressed. If it does,replace the cable and remove the TX cable from the slave CPU board. Theconnector on the slave board should flash when a key is pressed. If it doesnot, replace the slave CPU board.

4. The green LED on the I/O board should be “on”. If not, check the I/O monitor under theDIAGNOSTICS in SECTION 7. Are any “lights” red or yellow?– If they are not red or yellow, proceed to the next step.– If they are red or yellow, it is because of a short. With the electrical print, check the wiring

for the short. This could be in the footswitch or hand control.

5. The matrox board LED #1 should be blinking.– If it is, proceed to the next step.– If not, replace matrox board.

6. Check the 120VAC power to the CRT at the terminal strip in the pendant control.– If 120VAC is present, proceed to the next step.– If 120VAC is not present, check the fuses and wiring.

7. Does the CRT have the red LED “on”?– If it is "on", proceed to the next step.– If it is not “on”, replace the fuse in the CRT or replace the CRT.

8. Switch the red, green, blue color cables on the CRT. Is the CRT still blank?– Check the plugs on the end of the cable. If good, replace cable.– If the CRT still does not have a display, contact CINCINNATI Service.

✦ CRT DISPLAY WILL NOT CHANGE: Cannot change from display to display.

1. Check the slave CPU board, both green LED’s should be on.– If it is "on", proceed to the next step.– If they are not, how many times does the red halt light flash?

9-40

• Flashed one time, replace the Analog/Servo board.• Flashed two times, replace the I/O board.• Flashed three times, remove the RX cable from the slave CPU board. The

connector on the RX cable should flash when a key is pressed. If it does,replace the cable and remove the TX cable from the slave CPU board. Theconnector on the slave board should flash when a key is pressed. If it doesnot, replace the slave CPU board.

2. Check the 24VDC at the keypad interface board in the pendant control terminals #6 and #7.Is voltage present?– If yes, proceed to the next step.– If not, check the 24VDC wiring to the keypad interface.

3. Check the 5VDC into the keypad interface board. This should between terminals #3 and #4.Is voltage present?– If yes, proceed to the next step.– If not, check the 5VDC out of the DC to DC power supply.

4. Check the 24VDC into the DC to DC power supply.– If there is, replace the DC to DC power supply.– If not, check the wiring, then contact CINCINNATI Service.

✦ MACHINE WILL NOT START: Machine will not start when you push the START pushbutton.

1. Is the Ground Connected Light “on”?– If it is "on", proceed to the next step.– If it is not "on", push in on the Ground Connected Light. Does it come “on”?If it does not,

check the light, socket or wiring. If it does come on, check the wiring to the socket.

2. Is the Power Supplies Operational Light “on”?– If it is "on", proceed to the next step.– If it is not "on", push in on the Power Supplies Operational Light. Does it come “on”?If it

does not, check the light, socket or wiring. If it does come on, check the LED’s on thepower supply monitor board. If the following LEDs are “on”, check these:

• 5 VDC LED, check and adjust the 5 VDC power supply.• 15 VDC LED, check and adjust the 15 VDC power supply.• -15 VDC LED, check and adjust the -15 VDC power supply.• 12 VDC LED, check and adjust the 12 VDC power supply.• -12 VDC LED, check and adjust the -12 VDC power supply.• 120 vac LED, check the 120 vac power line.

3. Check the slave CPU board, both green LED’s should be “on”.– If both are "on", proceed to the next step.– If not, how many times does the red halt light flash?

• Flashed one time: replace the Analog/Servo board.• Flashed two times: replace the I/O board.• Flashed three times: remove the RX cable from the slave CPU board. The

connector on the RX cable should flash when a key is pressed. If it does,replace the cable and remove the TX cable from the slave CPU board. Theconnector on the slave board should flash when a key is pressed. If it doesnot, replace the slave CPU board.

4. The green LED on the I/O board should be “on”. If not, check the I/O monitor under theDIAGNOSTICS in SECTION 7. Are any “lights” red or yellow?– If they are not red or yellow, contact CINCINNATI Service.– If they are red or yellow, it is because of a short. With the electrical print, check the wiring

for the short. This could be in the footswitch or hand control.

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9-41

ORDERING REPAIR PARTS

When ordering repair parts be sure to give thisinformation:

1. Serial number of the AUTOFORM Press Brake.This is located on the machine’s capacity plateand on the right end of the bed.

2. The part number and part name, obtained fromassembly drawings included with this manual.

3. As complete a description of the part as pos-sible.

4. Delivery required.

5. It is sometimes necessary to furnish sub-assemblies instead of single parts. In suchcases, we reserve the right to ship and toinvoice accordingly.

RETURNING PARTS FOR CREDIT

1. No item is to be returned without prior autho-rization. Please write or call (513-367-7100) thefactory for instructions and the returned goodsauthorization number.

2. Returned goods authorization number must beshown on the outside of the package beingreturned. Unauthorized shipments will bereturned to the sender freight collect.

SERVICE

CINCINNATI INCORPORATED Service includes:

1. Established field service having numerous localoffices for prompt service assistance. Factorytrained servicemen are available to assist youwith any service problems you might be having.This includes service ranging from minorrepairs and adjustments to major recondition-ing jobs.

2. Planned Maintenance Service (PMS). This is aprogram designed to give you comprehensiveinspections and recommendations concerningthe condition of your equipment. PMS is specif-ically tailored to your needs to give you timelyinspections, qualified recommendations andexpert field assistance with repairs to yourequipment.

TECHNICAL TRAINING

CINCINNATI INCORPORATED offers a variety ofOperator and Maintenance Training Programs toour customers to assist in obtaining maximumvalue from your investment in metal fabricatingequipment. With today's sophisticated CNC con-trols, operator knowledge and proficiency have asignificant effect on overall productivity. Thesetraining programs also review many of the basics ofmetal fabricating, which may enhance the abilitiesof your newer employees.

The Operator Training Program is offered at no-charge for two customer employees with thepurchase of a new AUTOFORM CNC PressBrake. Training for additional employees, forMaintenance Training Program and other sub-jects are available at an additional cost. Pleasecontact our Customer Technical TrainingDepartment for further information.

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EM-444 (N-09/99) 10-1

SECTION 10 SERVICE & PARTS

C I N C I N N A T I I N C O R P O R A T E D

COPYRIGHT 1999CINCINNATI INCORPORATED