Operating manual
Press brake
System:
Serial No.:
Version:
Translation of the original instructions
B3.135-3000
MB_0791
1.0
(c) Salvagnini 2018
Document version: 1.0
Machine number: MB_0791, last saving on: 5/22/2018
language: en
15391933195
Italy: SALVAGNINI ROBOTICA S.R.L., Via Pacinotti 44, I-36040 Brendola, Vicenza
T. +39 0444 72 5111, F. +39 0444 43 6404, E. after-sales@salvagninigroup.com
www.salvagnini.com
Index
1 General information ............................................................................................................. 7
1.1
Content of this chapter .................................................................................................. 9
1.2
Target audience of this manual ..................................................................................... 9
1.3
Overview of the documentation..................................................................................... 9
1.3.1
Machine manual............................................................................................. 9
1.3.2
Circuit diagrams ............................................................................................. 9
1.4
Provisioning of this manual ......................................................................................... 10
1.5
Updating of this manual............................................................................................... 10
1.6
Typographical conventions for this manual ................................................................. 11
1.6.1
Safety warning structure .............................................................................. 12
1.6.2
References to screens ................................................................................. 13
1.7
Machine manufacturer................................................................................................. 14
1.8
Qualification and training of the personnel ..................................................................
1.8.1
Qualification and training of the operating personnel...................................
1.8.2
Qualification and training of the maintenance personnel .............................
1.8.3
Qualification and training of the programmer ...............................................
1.8.4
Salvagnini Technician ..................................................................................
1.9
Warranty...................................................................................................................... 19
14
14
15
17
18
1.10 Legal notes.................................................................................................................. 19
1.11 EC declaration of conformity ....................................................................................... 21
1.12 Contact addresses ......................................................................................................
1.12.1 Machine manufacturer .................................................................................
1.12.2 Customer service points - Europe................................................................
1.12.3 Customer service points - America ..............................................................
1.12.4 Customer service points - Asia ....................................................................
1.12.5 Customer service points - Australia and Oceania ........................................
1.12.6 Customer service points - Africa ..................................................................
22
22
22
24
25
26
27
2 Safety instructions............................................................................................................. 29
2.1
Purpose of the chapter ................................................................................................ 31
2.2
Intended use of the machine ....................................................................................... 31
2.2.1
Press-brake.................................................................................................. 31
2.3
Reasonably predictable improper use......................................................................... 31
2.4
Safety signs.................................................................................................................
2.4.1
Hazard symbols ...........................................................................................
2.4.2
Prohibition symbols ......................................................................................
2.4.3
Obligations symbols .....................................................................................
2.4.4
Other symbols ..............................................................................................
Index
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34
35
37
38
40
-3-
2.4.5
Points of application of safety sign............................................................... 41
2.5
Deployment and qualification of personnel ................................................................. 48
2.6
Personal Protection ..................................................................................................... 49
2.7
Work in safe conditions ............................................................................................... 50
2.8
Safety instructions for special dangers........................................................................
2.8.1
Electric energy .............................................................................................
2.8.2
Hydraulic and pneumatic equipment............................................................
2.8.3
Gas, dust, steam and smoke .......................................................................
2.8.4
Oil, grease and other chemical substances .................................................
2.8.5
Noise ............................................................................................................
51
52
53
54
54
55
2.9
Safety instructions for working on the machine...........................................................
2.9.1
Safeguarding measures ...............................................................................
2.9.2
Information about equipment and spare parts .............................................
2.9.3
Information on disposal ................................................................................
56
56
57
57
2.10 Safety devices .............................................................................................................
2.10.1 Fixed guards ................................................................................................
2.10.2 interlocking guards .......................................................................................
2.10.3 Optical barriers.............................................................................................
2.10.4 Guard for the movable parts of the machine................................................
2.10.5 Hydraulic system guard................................................................................
2.10.6 Electrical safety devices...............................................................................
2.10.7 Emergency stop buttons ..............................................................................
2.10.8 Ram imbalance control device .....................................................................
58
58
59
61
64
65
66
67
68
2.11 Lockout and release procedure (Lockout/Tagout).......................................................
2.11.1 Lock-out procedure ......................................................................................
2.11.2 Cutting off the power sources ......................................................................
2.11.3 Restoring machine operation .......................................................................
69
69
70
71
2.12 Operator position......................................................................................................... 72
2.12.1 Manual operation ......................................................................................... 72
3 Description of the machine ............................................................................................... 73
3.1
Machine identification plate ......................................................................................... 75
3.2
Machine structure........................................................................................................
3.2.1
Press-brake..................................................................................................
3.2.2
Ram..............................................................................................................
3.2.3
Pedal control device.....................................................................................
3.2.4
AOPD Laser safety device ...........................................................................
3.2.5
Backgauges .................................................................................................
3.2.6
Smart Tool Locator® ....................................................................................
3.2.7
Bend Angle Measurement Device................................................................
76
76
77
78
79
80
83
84
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3.2.8
Sheet support............................................................................................... 85
3.3
Specifications ..............................................................................................................
3.3.1
Specifications ...............................................................................................
3.3.2
Metal sheet requirements.............................................................................
3.3.3
Ambient conditions.......................................................................................
86
86
87
87
3.4
Component serial number identification ......................................................................
Hydraulic unit ...............................................................................................
Tool-holders .................................................................................................
Backgauges .................................................................................................
AOPD Laser safety device ...........................................................................
Crowning control device...............................................................................
89
89
89
90
91
91
4 Instructions for use............................................................................................................ 93
4.1
Control interface .......................................................................................................... 95
4.1.1
Introduction .................................................................................................. 97
4.1.2
Starting up the application............................................................................ 98
4.1.3
Settings ........................................................................................................ 99
4.1.4
Reference system ...................................................................................... 100
4.1.5
User interface............................................................................................. 101
4.1.6
Using the application.................................................................................. 195
4.1.7
Troubleshooting ......................................................................................... 211
4.2
Control and signaling devices ...................................................................................
4.2.1
Machine console ........................................................................................
4.2.2
Backgauge reset console...........................................................................
4.2.3
Pedal control device console .....................................................................
214
214
216
217
4.3
Operating modes.......................................................................................................
4.3.1
Machine Operation.....................................................................................
4.3.2
Hold-to-run control device ..........................................................................
4.3.3
AOPD Laser safety device .........................................................................
218
218
223
225
4.4
Switching on the machine ......................................................................................... 229
4.4.1
Procedure................................................................................................... 229
4.5
Production ................................................................................................................. 230
4.5.1
Starting production ..................................................................................... 230
4.6
Resetting the machine...............................................................................................
4.6.1
After activating the emergency stop button................................................
4.6.2
After opening the rear guard ......................................................................
4.6.3
After opening the side guards (both)..........................................................
4.6.4
After a ram imbalance ................................................................................
4.7
Shutting off the machine............................................................................................ 232
4.8
Setting up the machine.............................................................................................. 233
Index
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231
231
231
231
231
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4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
4.8.6
4.9
Machine resetting.......................................................................................
Bend angle measuring device reset...........................................................
Tests on the AOPD laser safety device .....................................................
Tool Set-Up Procedure ..............................................................................
Bending Techniques ..................................................................................
Factors influencing the precision of bends.................................................
233
233
234
235
239
242
Troubleshooting.........................................................................................................
4.9.1
Machine stop..............................................................................................
4.9.2
AOPD Laser safety device .........................................................................
4.9.3
Procedure for freeing any parts trapped between tools .............................
4.9.4
Troubleshooting .........................................................................................
245
245
245
257
257
5 Maintenance ..................................................................................................................... 259
5.1
General information................................................................................................... 261
5.2
Organizing maintenance interventions ...................................................................... 263
5.2.1
Contents of the maintenance sheet ........................................................... 265
5.3
Using Salvagnini Maintenance Manager................................................................... 266
5.4
Access procedure...................................................................................................... 266
5.5
Maintenance task ...................................................................................................... 266
5.5.1
Accessing high areas ................................................................................. 267
5.6
Weekly maintenance ................................................................................................. 270
Cleaning the bend angle measuring device ............................................... 270
5.7
Monthly maintenance ................................................................................................
Check the oil level in the toolholder hydraulic unit .....................................
Clean the electrical cabinet filters ..............................................................
Clean the AOPD laser safety device..........................................................
5.8
Three-monthly maintenance...................................................................................... 278
Lubricating the backgauges ....................................................................... 278
5.9
Maintenance every 100 hours of operation ............................................................... 283
Replacing the cartridge of the oil filter on the hydraulic unit....................... 283
272
272
274
276
5.10 Maintenance every 500 hours of operation ............................................................... 286
Replacing the cartridge of the oil filter on the hydraulic unit....................... 286
5.11 Maintenance every 6000 hours of operation ............................................................. 289
Change the hydraulic fluid.......................................................................... 289
5.12 Non-scheduled maintenance..................................................................................... 292
Top up the oil in the toolholder hydraulic unit............................................. 292
5.13 Special maintenance ................................................................................................. 295
Replacing the cartridges of the hydraulic unit's pump protection filters ..... 295
5.14 Conclusion of maintenance task ............................................................................... 297
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Operating manual
1. General information
1. General information
1.1
1.2
1.3
1.3.1
1.3.2
1.4
1.5
1.6
1.6.1
1.6.2
1.7
1.8
1.8.1
1.8.2
1.8.3
1.8.4
1.9
1.10
1.11
1.12
1.12.1
1.12.2
1.12.3
1.12.4
1.12.5
1.12.6
Content of this chapter .................................................................................................. 9
Target audience of this manual ..................................................................................... 9
Overview of the documentation..................................................................................... 9
Machine manual ............................................................................................................ 9
Circuit diagrams ............................................................................................................ 9
Provisioning of this manual ......................................................................................... 10
Updating of this manual............................................................................................... 10
Typographical conventions for this manual ................................................................. 11
Safety warning structure.............................................................................................. 12
References to screens ................................................................................................ 13
Machine manufacturer................................................................................................. 14
Qualification and training of the personnel .................................................................. 14
Qualification and training of the operating personnel .................................................. 14
Qualification and training of the maintenance personnel ............................................ 15
Qualification and training of the programmer .............................................................. 17
Salvagnini Technician ................................................................................................. 18
Warranty...................................................................................................................... 19
Legal notes.................................................................................................................. 19
EC declaration of conformity ....................................................................................... 21
Contact addresses ...................................................................................................... 22
Machine manufacturer................................................................................................. 22
Customer service points - Europe ............................................................................... 22
Customer service points - America ............................................................................. 24
Customer service points - Asia.................................................................................... 25
Customer service points - Australia and Oceania ....................................................... 26
Customer service points - Africa ................................................................................. 27
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Operating manual
1. General information
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B3.135-3000 - MB_0791 - 1.0 - en
Operating manual
1. General information
1.1. Content of this chapter
This chapter contains general information about your Salvagnini
machine and about available technical documentation.
1.2. Target audience of this manual
This manual is intended for the following people:
• The operating personnel of the machine
• The maintenance personnel of the machine
• The programmer of the machine
This includes all persons who are responsible for the installation,
operation, setting up, programming, servicing (maintenance, cleaning,
etc.), repair or transport of the machine.
1.3. Overview of the documentation
Your Salvagnini system includes comprehensive technical
documentation. In this chapter, you can find an overview of the
individual manuals and the respective content.
1.3.1. Machine manual
The machine manual consists of the following three volumes:
1. [Operating manual]
– [OEM Documentation – Appendix]
2. [Software and programming manual]
3. [Installation requirements]
1.3.2. Circuit diagrams
All circuit diagrams of your Salvagnini machine are available in
EasyData, a convenient online information system. The circuit diagrams
are linked together and also linked to the list of devices. This allows you
to trace signals and localize devices in the machine via mouse click.
EasyData can be opened on the machine directly or on an office PC via
CD/DVD. For more information about using EasyData, please refer to
the "User manual Volume 2 Programming and Software".
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Operating manual
1. General information
1.4. Provisioning of this manual
This manual contains important information and instructions about the
safe operation of the machine. It must therefore always be available at
the place of use of the machine and accessible to the personnel at all
times.
This includes all persons who are responsible for the installation,
operation, setting up, programming, servicing (maintenance, cleaning,
etc.), repair or transport of the machine.
1.5. Updating of this manual
Parts of this manual may be updated due to technical changes and new
knowledge about your machine. In this case, you will be sent the
updated pages as print out and a new version of the manual in
electronic form from the machine manufacturer.
The operator of the machine must replace the updated pages at the
corresponding location in the printed operating manual. Moreover, the
operator of the machine must also update the online helps on the
machine computer and all office PCs which contain this manual in
electronic form. The manufacturer supplies precise instructions about
performing this update. If you encounter problems and have additional
questions, please contact your Salvagnini customer service point.
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Operating manual
1. General information
1.6. Typographical conventions for this manual
This manual uses typographical conventions for the different types of
information so as to make it easier to identify and understand this
information. The following table summarizes the conventions used and
what they mean:
Intended use
References.
• Command elements
(buttons, selectors).
Typographica
l convention
[▶ 68]
Example
See the chapter on Qualification and
training of the personnel [} 14].
RESET
SAFETY
DEVICE
CIRCUIT
Press the blue illuminating RESET
SAFETY DEVICE CIRCUIT pushbutton
Monitor
Use the Monitor application to enable
and reset the axis.
Text in target
language [Text
in English]
See the example described in the
chapter on References to screens [} 13].
References to
elements shown in the
image.
(1)
Turn the control knob (1) to shut off the
compressed air supply.
Programming
instructions/syntax.
DIM
The DIM instruction contains information
about the sheet to be processed.
Program code.
DIM
DIM: E X1250 Y720.5 S1.5 P2.6
F2.5 K35 M37 DB "FePOL"
• Switch status (e.g.
ON, OFF).
• Names of software
applications.
• Mathematical
formulas.
• Menu items, input
boxes.
• References to texts
contained in the
image
Maintenance tasks.
[Mxxx]
[Mxxx] - Cleaning the power cabinet
filters
Table 1: Typographical conventions for this manual
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Operating manual
1. General information
1.6.1. Safety warning structure
The safety warnings in the instruction manual are structured as shown
in the following figure:
(1)
Icon indicating the type of
hazard with a symbol.
(2)
Safety symbol only present if
there is a risk of injury to
people.
(3)
Signal word.
(4)
Type and source of hazard.
(5)
Description of hazard.
(6)
Preventative measures to be
adopted.
Figure 1: Safety warning structure
The signal word (3) indicates the severity of hazard:
Signal
word
Warning
color
Description
Hazard
Red
Failure to observe the respective safety measures will
certainly cause death or serious injury to people.
Warning
Orange
Failure to observe the respective safety measures
may cause death or serious injury to people.
Caution
Yellow
Failure to observe the respective safety measures
may cause minor injury to people.
Note
Blue
Failure to observe the respective safety measures
may result in material damage.
Suggestions (tips)
In addition to the safety warnings, there are some suggestions, as
shown below:
Useful suggestions and notes for the operation.
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Operating manual
1. General information
1.6.2. References to screens
The screens in this manual, which reproduce the interface of an
application, display the English version of the application.
The parameters, commands, functions and/or buttons which refer to the
screen are indicated with the names in English in square brackets. This
is to help the reader identify the positions of the commands in the
screen and thus in the application interface.
Example
The reference to the "Parameter groups editor enabled" parameter will
be indicated as follows:
Parameter groups editor enabled [Parameters group editor enabled].
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Operating manual
1. General information
1.7. Machine manufacturer
Salvagnini Robotica S.r.l.
Via A. Pacinotti, 44 36040 Brendola (Vicenza)
1.8. Qualification and training of the personnel
The personnel must have special knowledge in order to be able to
operate the machine safely and efficiently. The different areas of
activity, such as operation and maintenance place different qualification
requirements and training on the personnel. You can find a detailed
description of these requirements in the following chapter.
1.8.1. Qualification and training of the operating personnel
The operating personnel is responsible for the preparation and
execution of the production operation. In addition, the operating
personnel must rectify all production-related malfunctions such as
centering errors or removing a production piece from the machine. The
operating personnel is not responsible for the rectification of technical
malfunctions.
WARNING
Injuries if unqualified staff perform this task!
The staff assigned to production must be trained and qualified to run
production.
The personnel must have the following abilities and knowledge for
performing the production operation:
• All safety measures and sources of danger
• Functioning of the machine in production operation
• Rectifying production-related malfunctions
• Intervention options on the machine
• Starting/stopping automatic mode or safe removal of production
parts from the machine
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Operating manual
1. General information
The operating personnel must be trained to acquire these abilities. The
operator training must include at least the following topics:
• Purpose of the machine and its components
• Overview of the structure of the machine including all operating and
control elements
• Operation of the machine and all its components
• Special sources of danger of the machine
• Safety measures
• Preparing the machine for production operation (conversion)
• Operating the machine
• Rectifying production-related malfunctions
Training options
Salvagnini offers comprehensive training to give your personnel the
skills they require. You can obtain detailed information about our
training program at every Salvagnini customer service point. You can
find an overview of all Salvagnini customer service points in chapter
Contact addresses [} 22].
1.8.2. Qualification and training of the maintenance
personnel
The maintenance includes all measures for maintaining or restoring the
functioning state of the machine (repairs, regular maintenance,
cleaning, etc.). These special activities require specific knowledge about
the machine, the intervention options, all safety measures and sources
of danger.
WARNING
Injuries if unqualified staff perform this task!
The staff assigned to production must be trained and qualified to run
production.
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Operating manual
1. General information
The personnel must have the following abilities and knowledge for
performing the maintenance:
• All safety measures and sources of danger
• Functioning of the machine during the maintenance
• Special safety measures and regulations for working with electrical
energy, hydraulic and pneumatic systems
• All safety regulations for the handling of oils, greases and other
chemical substances that are used
• Intervention options on the machine
The maintenance personnel must be trained to acquire these abilities.
These special trainings can be divided into a required occupational
training, a general basic training, and product training.
Required occupational training
The maintenance personnel must have training as a technical
specialized worker in the area of electrical systems, mechanical
engineering or mechatronics.
Content of the general basic training
The essential skills are taught to the specialist workers in the course of
occupational training for electrical systems, mechanical engineering or
mechatronics. If the maintenance personnel have not received a
qualification in one or more of the list of topics during occupational
training, they must be trained accordingly.
The basic training must include at least the following topics:
• Safety measures and regulations for handling electrical energy,
hydraulic and pneumatic systems
• Safe handling of gases, steam, smoke and heat
• National legal regulations about the performing of maintenance
work which apply for the location of the machine.
• Professional execution of general work on mechanical, electrical,
hydraulic, pneumatic systems (example: replacement of general
components such as hydraulic hoses or electric drives).
Content of the product training
In addition to the essential qualification, the maintenance personnel
must also have knowledge about the machine and all intervention
options.
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Operating manual
1. General information
The product training must include at least the following topics:
• Purpose of the machine and its components
• Structure of the machine and its components
• Safety-relevant components of the machine
• Interactions of the subsystems and components of the machine
• Detailed knowledge about the functioning principle of the machine
and all components (technician level)
• Special sources of danger of the machine
• Machine-specific safety measures
• Diagnostics and test procedures
• Safe replacement of components and modules
• Intervention options (e.g. controlling variables, adjustments, etc.)
Training options
Salvagnini offers comprehensive training to give your personnel the
skills they require. You can obtain detailed information about our
training program at every Salvagnini customer service point. You can
find an overview of all Salvagnini customer service points in chapter
Contact addresses [} 22].
1.8.3. Qualification and training of the programmer
The programmer is responsible for the creation and modification of
application programs for the manufacturing of production parts. For the
independent execution of tests on the machine, the programmer must
also be proficient in the safe operation of the machine.
WARNING
Injuries if unqualified staff perform this task!
The staff assigned to production must be trained and qualified to run
production.
The programmer must have the following abilities and knowledge for
creating application programs:
• Professional experience working with the Microsoft Windows©
operating system
• An overview of the machine structure and the functioning principle
of the machine
• Proper structure of an application program
• Correct application of the commands
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Operating manual
1. General information
For the independent execution of tests on the machine, the programmer
must also possess the following knowledge and abilities:
• All safety measures and sources of danger
• Functioning of the machine in production operation and during the
rectification of production-related malfunctions
• Intervention options on the machine
• Starting/stopping automatic mode and safe removal of production
parts from the machine.
The programmer must be trained to acquire these abilities. The
programming training must include at least the following topics:
• Purpose of the machine and its components
• Overview of the structure of the machine
• Overview about the functioning principle of the machine and all
components
• Structure of an application program
• Programming conventions
• Use of the programming commands
If the programmer performs independent tests on the machine,
additionally required skills can be acquired through an operator training
(see chapter Qualification and training of the operating personnel
[} 14]).
Training options
Salvagnini offers comprehensive training to give your personnel the
skills they require. You can obtain detailed information about our
training program at every Salvagnini customer service point. You can
find an overview of all Salvagnini customer service points in chapter
Contact addresses [} 22].
1.8.4. Salvagnini Technician
A highly qualified technician provided by Salvagnini to perform complex
and demanding operations, in special situations and in agreement with
the user.
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Operating manual
1. General information
1.9. Warranty
The machine is supplied with a warranty, as provided for by the general
conditions of sale. If, during the period of validity, defective operation or
malfunctions of machine components should occur which fall within the
provisions of the warranty, Salvagnini shall repair or replace the
defective components after performing the appropriate checks on the
machine.
Any modifications performed by the user without the express written
authorization of Salvagnini shall void the warranty and relieve the
manufacturer, Salvagnini, of any and all responsibility for damage
caused by the defective product. This applies in particular to
modifications made to the safety components.
The same considerations apply when using spare parts which are not
original spare parts or are not those explicitly specified by Salvagnini, as
for the safety components indicated either in this manual or the spare
parts manual. For all other matters, please contact the Salvagnini
Customer Service Department.
Failure to comply with the provisions in this section shall cause the
warranty to lapse.
1.10. Legal notes
This instruction manual provides detailed information about the machine
and allows you to take full advantage of the possibilities of use for the
purposes for which it was built. It contains important information for
safe, proper and economical operation. Observance of the information
in the instruction manual is the basis for avoiding risks, reducing repair
costs and downtimes and increasing the reliability and durability of the
machine.
In addition to the instructions and safety precautions in the instruction
manual, the following must be observed:
• The national provisions on the use of machines.
• The national regulations on accident prevention and the provisions
on the protection of personnel.
• The general technical rules for safe work.
• The national provisions on protection of the environment.
The instruction manual must always be available and accessible to
operators in the place where the machine is used.
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Operating manual
1. General information
The instructions contained in this manual must be read and applied by
all personnel responsible for carrying out operations with the machine
and on the machine itself, such as:
• Activities related to the operation.
– Troubleshooting during the processing.
– Removal of production waste.
– Machine care.
– Disposal of working and auxiliary materials.
• Activities related to preventive maintenance.
– Inspection.
– Maintenance.
The instruction manual and the software supplied can only be used for
their specific purposes.
No part of this instruction manual may be photocopied, reproduced in
any form or by any means or translated into another language, in whole
or in part, without the prior written consent of Salvagnini.
The data given only serves to describe the product and should not be
regarded as legally guaranteed characteristics. Any claims for
compensation from us are excluded, regardless of the legal reason,
unless it concerns gross negligence or premeditation. Subject to errors
and omissions and with reservation to make modifications aimed at
technological progress.
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Operating manual
1. General information
1.11. EC declaration of conformity
Figure 2: EC declaration of conformity (the image shown is indicative only and may differ from the original).
If required, the EC declaration of conformity is issued to the purchaser
on completion of installation and after the technicians appointed by the
manufacturer have verified the correct:
• Positioning of the guards.
• Operation of the safety devices.
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Operating manual
1. General information
1.12. Contact addresses
1.12.1. Machine manufacturer
Salvagnini Robotica S.r.l.
Via A. Pacinotti, 44 36040 Brendola (Vicenza)
1.12.2. Customer service points - Europe
AUSTRIA, CZECH REPUBLIC, SLOVAKIA, ROMANIA,
BULGARIA, HUNGARY,
SERBIA, GREECE, SLOVENIA
SALVAGNINI MASCHINENBAU GMBH
Dr. Guido Salvagnini-Strasse 1
A-4482 Ennsdorf
T. +43 (0) 7223 8850
F. +43 (0) 7223 885299
E. service@salvagnini.at
GERMANY, NETHERLANDS, SWITZERLAND
SALVAGNINI DEUTSCHLAND GMBH
Am Surbach 1
D-35625
Hüttenberg
ITALY, GREECE, SLOVENIA,
MONTENEGRO, SERBIA,
MAZEDONIA, CROATIA,
BOZNIA & HERZEGOVINA, ALBANIA
T. +49 6441 870670
F. +49 6441 8706750
E. service@salvagnini.de
SALVAGNINI ITALIA SPA
Via Guido Salvagnini, 51
T. +39 0444 72 5111
I-36040 Sarego
F. +39 0444 43 6404
Vicenza
E. service@salvagninigroup.com
SALVAGNINI INDUSTRIALE SPA
Via Arcella, 122
T. +39 0825 688711
I-83030 Montefredane
F. +39 0825 688799
Avellino
- 22 -
E. industriale@salvagninigroup.com
B3.135-3000 - MB_0791 - 1.0 - en
Operating manual
1. General information
SWEDEN, NORWAY, FINLAND, DENMARK, ESTLAND, LETTLAND, LITAUEN
SALVAGNINI SCANDINAVIA AB
Bredastensvägen 14
S-331 44
T. +46 370 20730
E. info@salvagnini.se
Värnamo
UNITED KINGDOM, IRELAND
SALVAGNINI UK & IRELAND LTD
Alton Business Park, Alton Road
T. +44 1989 767032
Ross-on-Wye - Herefordshire HR9 5BP
F. +44 1989 563829
Great Britain
FRANCE, BELGIUM
SALVAGNINI FRANCE SARL
Parc Sud Galaxie
T. +33 4 76333258
Rue des Tropiques
F. +33 4 76403728
F-38130 Echirolles/Grenoble
SPAIN, PORTUGAL
E. commercialfrance@salvagninigroup.com
SALVAGNINI IBÉRICA SL
Plaza Julio Gonzales, 6 local 2
E-08005
Barcelona
POLAND
E. web@salvagninigroup.com
T. +34 93 2259125
F. +34 93 2218253
E. asistencia@salvagninigroup.com
SALVAGNINI POLSKA Sp. z o.o.
ul. Graniczna 62
T. +48 42 2089745
Łódz 93-428
Poland
TURKEY
E. radoslaw.pajek@salvagninigroup.com
SIMTED MAKINE SAN.
Ve Mamülleri Tic, Ltd. Sti
Perpa Ticaret Merkezi
A-Blok Kat 11 No: 1377
TR-34384 Okmeydani Istanbul
B3.135-3000 - MB_0791 - 1.0 - en
T. +90 212 222 6112
F. +90 212 222 2166
E. simted@simted.com
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Operating manual
1. General information
RUSSIA, UKRAINE, BELARUS, AZERBAIJAN
SALVAGNINI CIS LLC
Ul. Koplakova 44a
T. +7 495 730 90 42
141008 Mytishchi - Moscow Region
F. +7 495 730 90 47
Russia
E. cis@salvagninigroup.com
1.12.3. Customer service points - America
UNITED STATES
SALVAGNINI AMERICA INC
27 Bicentennial Court
T. +1 513 874 8284
Hamilton, OH 45015
F. +1 513 874 2229
USA
CANADA
E. customercarecanada@salvagnini.com
SALVAGNINI CANADA ULC
44-4181 Sladeview Crescent
Mississauga Ontario L5L 5R2
Canada
MEXICO, ARGENTINIA,
VENEZUELA, COLUMBIA,
CHILE, PERU
F. +1 905 997 7734
E. customer-care@salvagnini.com
SALVAGNINI MEXICO S DE RL DE CV
Privada Artemio Elizondo 1022
T. +52 81 8386 4060
Apocada, Nuevo Leon 66600
F. +52 81 8386 4070
Mexico
BRAZIL
T. +1 905 361 8709
E. informacion@salvagnini.com
SALVAGNINI DO BRASIL COM. MAN. MÁQ. LTDA.
Rua José Sierra, 71
Eldorado - Centro Industrial e
Empresarial
São José dos Campos– SP
T. +55 54 229 5812
F. +55 54 9975 5912
E. contato@salvagninigroup.com
12238-571 São Paulo
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B3.135-3000 - MB_0791 - 1.0 - en
Operating manual
1. General information
1.12.4. Customer service points - Asia
CHINA, TAIWAN
SALVAGNINI INT'L TRADING (SHANGHAI) CO LTD
Room 612, Huana Business Ctr.
1733 Lian Hua Rd, Minhang DC
T. +86 21 52400342
Shanghai 201103
F. +86 21 32121217
PR China
JAPAN
SALVAGNINI JAPAN CO LTD
1-3-13, Techno-stage
T. +81 725 54 3911
J-594-1144 Izumi City
F. +81 725 54 3912
Osaka
KOREA
E. info@salvagnini.com.cn
E. info@salvagnini.co.jp
SALVAGNINI KOREA CO LTD
RM901, B bldg. Indeokwon IT valley,
40,Imi-ro (Poil-dong)
Gyeonggi-do
T. +82 31 4224822
F. +82 31 4224821
E. service@salvagnini.co.kr
Uiwang-si 16006
THAILAND
SALVAGNINI THAILAND CO LTD
No. 98 Akanat Plaza Building
Room Number 12A, 1st Floor
Soi Sukhumvit 66/1, Sukhumvit Road,
Bangna, Bangkok 10260
INDIA
E.
piyahong.khamai@salvagninigroup.com
E.
arthaphol.klinlaor@salvagninigroup.com
SALVAGNINI MACHINERY INDIA
2nd Floor, No. 26, R V M 2nd stage,
New BEL road, Sadashivnagar
Bangalore 560 054
B3.135-3000 - MB_0791 - 1.0 - en
T. +66 27447991
T. +91 80 3221 4123
E.
riddhish.jalnapurkar@salvagninigroup.co
m
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Operating manual
1. General information
MALAYSIA, PHILIPPINES,
THAILAND, INDONESIA,
VIETNAM
SALVAGNINI SOUTH ASIA SDN. BHD.
Bangunan A, Peremba Square
Saujana Resort, Seksyen U2
T. +60 3 7842 5233
40150 Shah Alam
E. info@salvagnini.com.my
Selangor Darul Ehsan, Malaysia
JORDAN, OMAN, ISRAEL,
IRAN, UNITED ARAB
EMIRATES
SALVAGNINI MASCHINENBAU GMBH
Dr. Guido Salvagnini-Strasse 1
T. +43 (0) 7223 8850
A-4482 Ennsdorf
F. +43 (0) 7223 885299
E. service@salvagnini.at
ISRAEL, SAUDI ARABIA
SALVAGNINI ITALIA SPA
Via Guido Salvagnini, 51
T. +39 0444 72 5111
I-36040 Sarego
F. +39 0444 43 6404
Vicenza
E. service@salvagninigroup.com
SALVAGNINI INDUSTRIALE SPA
Via Arcella, 122
T. +39 0825 688711
I-83030 Montefredane
Avellino
F. +39 0825 688799
E. industriale@salvagninigroup.com
1.12.5. Customer service points - Australia and Oceania
AUSTRALIA, NEW ZEALAND
MACHINERY FORUM (N.S.W.) PTY LTD
P.O. Box 229
T. +61 2 9638 9600
43 Brodie Street
F. +61 2 9638 0438
AUS-Rydalmere NSW 2116
- 26 -
E. machinery@mafosyd.com.au
B3.135-3000 - MB_0791 - 1.0 - en
Operating manual
1. General information
1.12.6. Customer service points - Africa
SOUTH AFRICA
SALVAGNINI MASCHINENBAU GMBH
Dr. Guido Salvagnini-Strasse 1
A-4482 Ennsdorf
T. +43 (0) 7223 8850
F. +43 (0) 7223 885299
E. service@salvagnini.at
MOROCCO, TUNISIA
SALVAGNINI FRANCE SARL
Parc Sud Galaxie
T. +33 4 76333258
Rue des Tropiques
F. +33 4 76403728
F-38130 Echirolles/Grenoble
EGYPT, SOUTH AFRICA
E. commercialfrance@salvagninigroup.com
SALVAGNINI ITALIA SPA
Via Guido Salvagnini, 51
T. +39 0444 72 5111
I-36040 Sarego
F. +39 0444 43 6404
Vicenza
E. service@salvagninigroup.com
SALVAGNINI INDUSTRIALE SPA
Via Arcella, 122
I-83030 Montefredane
Avellino
B3.135-3000 - MB_0791 - 1.0 - en
T. +39 0825 688711
F. +39 0825 688799
E. industriale@salvagninigroup.com
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Operating manual
1. General information
- 28 -
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Operating manual
2. Safety instructions
2. Safety instructions
2.1
2.2
2.2.1
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.5
2.6
2.7
2.8
2.8.1
2.8.2
2.8.3
2.8.4
2.8.5
2.9
2.9.1
2.9.2
2.9.3
2.10
2.10.1
2.10.2
2.10.3
2.10.4
2.10.5
2.10.6
2.10.7
2.10.8
2.11
2.11.1
2.11.2
2.11.3
2.12
2.12.1
Purpose of the chapter ................................................................................................
Intended use of the machine .......................................................................................
Press-brake .................................................................................................................
Reasonably predictable improper use.........................................................................
Safety signs.................................................................................................................
Hazard symbols...........................................................................................................
Prohibition symbols .....................................................................................................
Obligations symbols ....................................................................................................
Other symbols .............................................................................................................
Points of application of safety sign ..............................................................................
Deployment and qualification of personnel .................................................................
Personal Protection .....................................................................................................
Work in safe conditions ...............................................................................................
Safety instructions for special dangers........................................................................
Electric energy.............................................................................................................
Hydraulic and pneumatic equipment ...........................................................................
Gas, dust, steam and smoke.......................................................................................
Oil, grease and other chemical substances ................................................................
Noise ...........................................................................................................................
Safety instructions for working on the machine...........................................................
Safeguarding measures ..............................................................................................
Information about equipment and spare parts.............................................................
Information on disposal ...............................................................................................
Safety devices .............................................................................................................
Fixed guards................................................................................................................
interlocking guards ......................................................................................................
Optical barriers ............................................................................................................
Guard for the movable parts of the machine ...............................................................
Hydraulic system guard...............................................................................................
Electrical safety devices ..............................................................................................
Emergency stop buttons..............................................................................................
Ram imbalance control device ....................................................................................
Lockout and release procedure (Lockout/Tagout).......................................................
Lock-out procedure .....................................................................................................
Cutting off the power sources......................................................................................
Restoring machine operation ......................................................................................
Operator position.........................................................................................................
Manual operation.........................................................................................................
B3.135-3000 - MB_0791 - 1.0 - en
31
31
31
31
34
35
37
38
40
41
48
49
50
51
52
53
54
54
55
56
56
57
57
58
58
59
61
64
65
66
67
68
69
69
70
71
72
72
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Operating manual
2. Safety instructions
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B3.135-3000 - MB_0791 - 1.0 - en
Operating manual
2. Safety instructions
2.1. Purpose of the chapter
This chapter includes all rules and safety instructions which are required
for working safely with the machine.
Please read through this operating manual carefully before you begin
working on the machine!
Please also observe the valid national and other binding rules for the
prevention of accidents and environmental protection.
Please also inform yourself about supplemental operating instructions
on work organization, work processes and the use of personnel.
2.2. Intended use of the machine
2.2.1. Press-brake
The bending press must be used only for the cold bending of flat sheets
in sizes and thicknesses that are compatible with the maximum force of
the machine.
The sheets must comply with the specifications indicated in chapter
Metal sheet requirements [} 87].
2.3. Reasonably predictable improper use
WARNING
Risk of life to the user or third parties and damage to the machine
or other items due to improper use.
Precautions:
- The machine must only be used in a technically perfect condition, in
accordance with its designated use and the instructions set out in the
operating manual, and only by safety-conscious persons who are fully
aware of the risks involved in operating the machine.
- Any functional issues, especially those affecting the safety of the
machine, should therefore be rectified immediately.
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
2. Safety instructions
It is forbidden to:
• Use the machine for any uses other than those specified in the
Intended use of the machine [} 31] chapter.
• Use the machine to process any materials other than those listed
and with any features other than those indicated in the
Specifications [} 86] chapter.
• Use the machine to process pipes, glass, wood, ceramics or bricks.
• Bypass and/or tamper with the safety devices.
• Modify and/or tamper with the electrical circuits or control devices.
• Switch on the machine if there are any people inside the work area.
• Modify and/or tamper with the mechanical and/or software part of
the machine.
• Use spare parts that have not been authorized by the machine's
manufacturer.
• Use the machine without maintenance.
• Use the machine without personal protective equipment.
• Use the machine without having received adequate technical
training from the manufacturer or from your employer.
• Use the machine under the influence of alcohol, drugs or
medication that can reduce your attention.
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Operating manual
2. Safety instructions
During manual use of the machine
It is forbidden to:
• Remain in the vicinity of the machine if it is not equipped with a
pedal control device.
• Hold the sheet to bend while another operator is acting on the
pedal to command the ram movement.
• Place the sheet on the die before placing the backgauges.
• Bend very small pieces by the operator moving their hands near
the tools. Fingers could get crushed between the part being bent
and the side of the tool.
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
2. Safety instructions
2.4. Safety signs
Safety signs are applied on the machine to signal hazards and residual
risks, using the following symbols:
• Hazard symbols [} 35]
• Prohibition symbols [} 37]
• Obligations symbols [} 38]
Failure to observe symbols and warning texts that appear at the side
may result in injury or material damage, for which Salvagnini disclaims
any liability. For your own safety and the safety of others, you should
therefore observe the safety signs.
CAUTION
Injury hazard.
Safety signage which is difficult to read may mean it is harder to avoid
hazardous situations.
Precautions: clean the safety signage regularly.
If a metal plate deteriorates or is no longer legible, a new one must be
requested from the manufacturer (quoting the code given at the bottom
of the plate or, if it is no longer legible, see the Points of application of
safety sign [} 41] chapter) and affixed in place of the damaged one.
- 34 -
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Operating manual
2. Safety instructions
2.4.1. Hazard symbols
Title
General hazard
Symbol
Risk/hazard
Risk for people specified by the
additional description.
This hazard symbol cannot be used
alone and requires an additional
description to provide additional
information about the hazard.
Laser beam hazard
Laser beam
Magnetic field hazard
Strong magnetic field
Floor-level obstacle
Obstacle on the floor
Falling hazard with height
difference
Fall
Slippery surface hazard/caution
Slippery surface
Electrical hazard
Electricity
The graphic symbol is also
standardized and registered as IEC
60417-5036 "Dangerous Voltage".
Suspended loads hazard
Suspended load
Hot surface hazard
Hot surface
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Operating manual
2. Safety instructions
Title
Symbol
Risk/hazard
Hand crushing hazard
Crushing
Rotating rollers / drawing-in hazard
Drawing-in
Optical radiation hazard
Optical radiations (such as UVvisible radiation, IR)
If necessary, an additional symbol
is used to provide more information
about the type of optical radiation
(e.g. UV-visible radiation, IR)
Falling objects hazard
Falling objects
Press-brake
The following hazard symbols are specific to the bending press.
Title
Symbol
Hazard
Crushing of upper limbs between
the tools of the bending press
Descent of the ram
Crushing of upper limbs between
the bending press and the material
being processed
Movements of the bending press
and the material being processed
Fast movement of the material
being processed
Movement/flexing of protruding
workpiece
- 36 -
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Operating manual
2. Safety instructions
2.4.2. Prohibition symbols
Title
General prohibition
Symbol
Risk/hazard
Risk for people specified by the
additional description.
This prohibition symbol cannot be
used alone and requires an
additional description to provide
additional information about the
prohibited action.
No pedestrians
Impact with vehicles or machines
Do not climb
Object not safe for climbing and
dangerous place/area
Do not touch or perform maneuvers
Slippery surfaces
Do not rest heavy loads
Breakage due to heavy loads
Do not climb
Surface not suitable for people
Do not walk or stand in this area
It is not safe for people to walk or
stand in these areas
Access to unauthorized persons
prohibited
Indicates that it is forbidden to
enter an area unless authorized to
do so
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
2. Safety instructions
2.4.3. Obligations symbols
Title
Symbol
General obligation
Risk/hazard
Risk for people who do not follow
the mandatory action specified in
the additional description.
This obligation symbol cannot be
used alone and requires an
additional description to provide
additional information about the
action to take.
It is obligatory to read the
instructions
Failure to read the instruction
manual before starting work or
before using machinery or
equipment may result in hazardous
situations.
It is obligatory to wear hearing
protection
Noise
It is obligatory to wear eye
protection
Objects/particles in the air, oil
splashes.
It is obligatory to wear glasses with
opaque lenses
Visible or invisible rays
It is obligatory to wear safety
footwear
Feet that hit or are hit by objects or
are in contact with thermal or
chemical materials.
Both symbols have the same
meaning and validity.
or
- 38 -
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Operating manual
2. Safety instructions
Title
Symbol
It is obligatory to wear protective
gloves
Risk/hazard
Hands that hit or are hit by objects
or are in contact with thermal or
chemical materials.
Both symbols have the same
meaning and validity.
or
It is obligatory to wear protective
clothing
Chemical products, heat or cold
It is obligatory to wear a protective
helmet
Objects that fall on the head or
head that hits against something
It is obligatory to wear safety
harness
Falling from height
It is obligatory to check the
safeguarding
Moving machine
It is obligatory to wear a mask
Inhalation of dust
It is obligatory to wear the welding
mask
Splashes of melted metal and
radiations
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
2. Safety instructions
Title
Symbol
Function/description
Safety key
When entering the work area, after
requesting entry, bring the safety
key with you.
Maintenance
Maintenance tasks should only be
performed by trained personnel to
prevent injuries to persons who
have not been trained for specific
operations.
2.4.4. Other symbols
Title
Protective earth ground
Symbol
Function/description
Identifies any component intended
for external connection for
protection against electric shocks in
the event of a fault or terminal of a
ground connection.
Affix to indicate the connection
point of the protective earthing
conductor.
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Operating manual
2. Safety instructions
2.4.5. Points of application of safety sign
Press-brake
Figure 3: Front view of the press-brake
Reference
B3.135-3000 - MB_0791 - 1.0 - en
Plate
Code
(1)
3137010110
(2)
3137xx0105
- 41 -
Operating manual
2. Safety instructions
Reference
- 42 -
Plate
Code
(3)
3137010040
(4)
3137010074
(5)
3137010125
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Operating manual
2. Safety instructions
Figure 4: Motor of the crowning control device
Reference
(1)
B3.135-3000 - MB_0791 - 1.0 - en
Plate
Code
3137010075
- 43 -
Operating manual
2. Safety instructions
Hydraulic unit
Figure 5: Hydraulic unit
Reference
(1)
- 44 -
Plate
Code
3137010075
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Operating manual
2. Safety instructions
Press-brake power cabinet
Figure 6: Press-brake power cabinet (interior)
Reference
Plate
Code
(1)
3137xx0017
(2)
3137010031
Affixed near to the connection point of the
protective earthing conductor.
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
2. Safety instructions
Pneumatic unit
Figure 7: Pneumatic unit
Reference
(1)
- 46 -
Plate
Code
3137xx0018
B3.135-3000 - MB_0791 - 1.0 - en
Operating manual
2. Safety instructions
Bend angle control (AMS)
Figure 8: Bend angle control (AMS)
Reference
B3.135-3000 - MB_0791 - 1.0 - en
Plate
Code
(1)
/
(2)
/
(3)
3137010075
- 47 -
Operating manual
2. Safety instructions
2.5. Deployment and qualification of personnel
• Only staff who have been trained or instructed by Salvagnini
technicians may perform work on the machine.
• The individual responsibilities of the personnel for operation, setup, maintenance and repair must be clearly specified.
• Any work on and with the machine may only be executed by
reliable personnel who have been instructed to do so.
• The statutory minimum age limits must be observed.
• Specify the machine operator and his area of responsibility. And
give him the authority to refuse instructions by third parties that are
contrary to safety.
Information about the required qualification: See chapter
Qualification and training of the personnel [} 14].
• Personnel tasked with activities on the machine must know and
comply, implement and apply the instructions and conditions listed
in the operating manual.
• Personnel who only occasionally work with the machine must
rectify any gaps in knowledge before beginning work
• Do not allow persons to be trained or instructed or take part in a
general training course to operate or work on the machine without
being permanently supervised by an experienced person.
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Operating manual
2. Safety instructions
2.6. Personal Protection
WARNING
Entanglement/dragging hazard by machine parts.
Operatives and maintenance technicians must:
- Tie back long hair with a net.
- Remove any loose-fitting clothing and use work wear.
- Remove jewelery (rings, chains etc.).
Personal Protective Equipment
To guarantee personal safety, personnel must use the following PPE:
Cut-proof gloves
Cut-proof work wear
Safety footwear
Hearing protection
Protective equipment for maintenance work
To perform machine maintenance, it is necessary to wear the devices
indicated in the specific maintenance operation sheet (see
chapterContents of the maintenance sheet [} 265]).
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
2. Safety instructions
2.7. Work in safe conditions
WARNING
Hazard due to faulty safety devices.
Safety devices can only perform their functions if their operation has
not been tampered with by means of unauthorized manipulations.
It is strictly forbidden to make any changes to the safety devices or to
exclude any control devices.
Any intervention on the electrical or electronic part of the machine is
strictly prohibited too.
Precautions: strictly comply with the safety indications listed in this
manual and in all provided manuals.
Checks to perform before starting production
• Maintenance personnel must check that the production personnel
comply with safety and accident prevention regulations, according
to the instruction manual.
• Before each start-up, ensure that the machine is in the intended
state of maintenance.
• All safety devices must be present and operational.
• Switch the machine on and off only as described in the instruction
manual.
Safe working mode during production
• Observe all signaling devices as described in the instruction
manual.
• In the machine's manual feeding stage (if envisaged), always lift
and place only one sheet.
• Safely store all keys of the interlocking devices supplied with the
machine.
Safe working mode during maintenance
• When entering the work area, after requesting entry, bring the
safety key with you.
• Only the maintenance personnel can keep the keys of the
interlocking devices.
• Only the maintenance personnel can keep the keys of the power
cabinets.
- 50 -
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Operating manual
2. Safety instructions
2.8. Safety instructions for special dangers
In this chapter you will find safety information about preventing risks that
are caused by special sources of danger. These special sources of
danger include:
• Electric energy
• Hydraulic and pneumatic equipment (high pressures and
temperatures)
• Emissions (gas, dust, steam, and smoke)
• Hazardous working materials (oils, greases, chemical substances)
• Sound emission (noise)
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
2. Safety instructions
2.8.1. Electric energy
DANGER
Danger of death due to electric shock!
Even when the main switch is turned off, there are still control circuits
that still have dangerous voltage. The circuits are supplied by an
uninterruptible power supply which must be switched off separately.
• A second person must be present who can actuate the emergency
stop or main power switch in case of danger.
• Secure the working area with red-and-white safety chain and a
warning sign.
• Only use voltage-isolating tools.
• Switch off the machine immediately if trouble occurs in the
electrical system!
• Work on the electrical system or equipment may only be carried out
by a skilled electrician himself or by specially instructed personnel
under the control and supervision of such electrician and in
accordance with applicable electrical engineering rules.
• Machines and system components on which inspection,
maintenance and repair work is being carried out must be
disconnected from the voltage supply.
• Check the disconnected components to ensure that they are
voltage-free.
• Secure the switched-off system parts against being switched on
again. The main switch can be locked using a conventional
padlock.
• Use only original fuses with the specified current rating.
• Inspect/check the electrical equipment of the machine regularly.
• Rectify defects such as loose connections, worn-out cables (e.g.
cables in the energy supply chain) immediately.
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2. Safety instructions
2.8.2. Hydraulic and pneumatic equipment
WARNING
Splashed oil may cause injury and fire! During all work on the
hydraulic unit, one must reckon with hot oil escaping.
When working in and around hydraulic units it is forbidden to smoke,
work with flames or anything which could make sparks fly!
• Make sure that a collecting pan, vacuum equipment and material to
soak up the oil are available.
• Regularly check all lines, hoses and screwed connections for leaks
and obvious damage, and rectify this immediately.
• Work on hydraulic equipment may be carried out only by persons
having special knowledge and experience in hydraulic systems.
• When executing the work, everything has to be clean. Thoroughly
clean the outer surrounding area before unscrewing flanges and
screwed connections. When cleaning the oil tanks or valve
connections and clamping surfaces, use only lint-free cloths.
• Close all openings with security covers so that no dirt can get into
the pipe system.
• Make sure that all system sections and pressure pipes to be
opened have been depressurized before commencing with repair
work by moving to the tool change position or turn-off position.
Before maintenance work on pressurized devices, the trapped
pressure must be released via the respective measuring
connection.
• Run and install hydraulic and compressed air lines properly.
• Observe the exact names and types when replacing fittings and
components. The fittings, lengths and quality of the hydraulic hoses
must be in accordance with the technical requirements.
• Do not mix up the connections.
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Operating manual
2. Safety instructions
2.8.3. Gas, dust, steam and smoke
WARNING
Risk of fire and explosion!
Only perform welding, flame-cutting and grinding work on the machine
if this has been expressly authorized, as there may be a risk of fire and
explosion.
• Observe any existing national regulations if work is to be carried
out in small rooms.
• Before carrying out welding, flame-cutting and grinding operations,
clean the machine and its surroundings from dust and other
inflammable substances.
• Make sure that the premises are adequately ventilated.
• Protect plastic lines and cables from flying sparks.
2.8.4. Oil, grease and other chemical substances
WARNING
Risk of burning or scalding!
Be careful when handling hot consumables.
• When handling oil, grease and other chemical substances, observe
the product-related safety regulations.
• The quality of the oil and all lubricants (oils, greases) must be in
accordance with the description in the Inspection, Maintenance and
Repair chapter and under no circumstances have an inferior quality
to those stated.
NOTICE
Oils and liquid which could pollute water must not get into the
earth, water or drains.
Dispose of oils using safe and environmentally friendly methods.
Observe the relevant country requirements for groundwater protection
and the disposal of used oils and waste.
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2. Safety instructions
2.8.5. Noise
CAUTION
Risk of permanent hearing impairment!
Always where the prescribed hearing protection!
During operation, all sound insulation equipment at the machine must
be in the safety position.
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Operating manual
2. Safety instructions
2.9. Safety instructions for working on the machine
2.9.1. Safeguarding measures
WARNING
Hazard due to safety-compromising additions and conversions to
the machine!
Never make any modifications, additions or conversions to the
machine which might affect safety without the approval of Salvagnini.
This also applies to the installation and adjustment of safety devices
and valves as well as to welding work on load-bearing elements!
• Always consult with Salvagnini before making changes, additions
and conversions.
Entering and leaving danger zones
• Observe all indicators at and on the machine.
• Ensure that the maintenance area is adequately secured.
• Only acknowledge the light barriers after ensuring that nobody is
still in the danger area.
Working with lifting equipment
• To avoid the risk of accidents, individual parts and large
assemblies being moved for replacement purposes should be
carefully attached to lifting tackle and secured.
• Use only suitable and technically perfect lifting gear and
suspension systems with adequate lifting capacity.
• Do not go or work under suspended loads.
• Only experienced operators should be permitted to fasten loads
and direct crane operators. The director must be within sight or in
voice range of the operator.
Using climbing aids
• Never use machine parts as a climbing aid! For carrying out
overhead assembly work always use specially designed or
otherwise safe ladders and working platforms.
• Keep all handles, steps, handrails, platforms, landings and ladders
free from parts and dirt.
• Wear a safety harness when carrying out maintenance work at
greater heights.
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2. Safety instructions
2.9.2. Information about equipment and spare parts
• Make the location and operation of fire-warning and fire-fighting
procedures known.
• For the execution of maintenance work, tools and workshop
equipment adapted to the task on hand are absolutely
indispensable.
• Spare parts must comply with the technical requirements specified
by the manufacturer. Spare parts from the original equipment
manufacturers do comply with these requirements.
• The interim storage of machine and system components must be in
a closed room. The ambient temperature should lie in the range
between +10°C and +60°C.
2.9.3. Information on disposal
• Ensure that all consumables and replaced parts are disposed of
safely and with minimum environmental impact.
• Pay attention to the relevant country requirements about
contamination to groundwater, old oil and waste.
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2. Safety instructions
2.10. Safety devices
2.10.1. Fixed guards
A protection that is kept in position (i.e. closed) either permanently or by means of
fastening systems which mean that it can only be removed and opened using tools
(spanners, screwdrivers or Allen keys).
The fixed guards must not be removed for any routine maintenance work.
Cylinder protection
The area of movement of the cylinder rods is protected by fixed guards
(1).
Figure 9: Cylinder protection
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2. Safety instructions
2.10.2. interlocking guards
Guards which, if opened or removed, stop the movement of the machine before the
danger zones can be accessed.
Side guard
Figure 10: Side guard
Opening of a side guard
WARNING
Crushing hazard.
The AOPD safety laser device is not active.
Precautions: take special care when performing operations, even
though the descent speed is slow.
The opening of a side guard (1) permits ram movement only at a slow
speed (<=10 mm/s).
To re-enable movement in fast mode, close the side guard (1) and
press the DOWN pedal (see chapter) Hold-to-run control device
[} 223]).
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2. Safety instructions
Opening of both side guards
The opening of both side guards (1) causes the machine to stop
immediately.
To restore machine operation, close the side guards (1) and proceed as
described in chapter After opening the side guards (both) [} 231].
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2. Safety instructions
2.10.3. Optical barriers
They are electro sensitive devices composed of rays that create a controlled optical
area. They are used in the event that the operator needs frequent access to
hazardous zones.
Refer to the attached layout to identify the position of the optical
barriers and the safety distance from the moving parts. It is prohibited
to reduce the distance between the optical barriers and moving parts.
Optical barriers
Interrupting the beam of the optical barriers (1) causes the machine to
stop immediately.
To restore machine operation, exit from the beam of the optical barrier
and proceed as described in chapter After opening the rear guard
[} 231].
Figure 11: Optical barriers
DANGER
Upper limb crushing and/or shearing hazard.
Precautions: recover sheet parts which have fallen into the bending
press by accessing from the rear.
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2. Safety instructions
AOPD Laser safety device
Interrupting the laser beam during the fast descent phase cuts off the
signal enabling the actuators, and as a result immediately stops ram
movement.
The system is automatically disabled on reaching the zone (2) where
only descent at slow speed (10 mm/s) is permitted, enabled by the
DOWN pedal control (see chapter Hold-to-run control device [} 223]).
(1)
Fast descent zone
(2)
Slow descent zone
(3)
Top Dead Center (TDC)
(4)
Speed change point (mute
point)
(5)
Bottom Dead Center (BDC)
Figure 12: Ram descent
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2. Safety instructions
DANGER
Upper limb crushing and/or shearing hazard
The AOPD safety laser device has been installed in such a way as to
leave sufficient free space for hands not to be crushed. The descent of
the ram can, in any case, lead to the hazards indicated above in the
tools area.
Precautions:
- Avoid rapid, irregular movements during tool closing.
- Use only V dies for bending sheets.
- Do not install accessories or dies that could reduce the clearance
between the AOPD Laser safety device and the lower tool-holder.
WARNING
Eye damage
The emitter device emits a CLASS 1 laser beam.
Precautions:
- Avoid direct eye exposure to the laser beam.
- Do not dismantle the emitter device because this could cause
exposure to the laser beam (removal would void the product warranty).
Every time you perform Tool Set-Up Procedure [} 235] longer than those
previously installed, you must:
• Perform the alignment procedure for the AOPD Laser safety
device, as indicated in the specific chapter of OEM
Documentation – Appendix.
• Perform the Tests on the AOPD laser safety device [} 234].
Automatic test
DANGER
Upper limb crushing and/or shearing hazard
During the automatic test phase, the descent of the ram can lead to
the hazards indicated above.
Precautions: Do not insert body parts between the tools during the
automatic test phase.
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2. Safety instructions
After the Procedure [} 229] procedure, the safety PLC performs an
automatic test to check that the stop times of the ram are within
permissible limits if the following occur:
• Interruption of the laser beam.
• Emergency stop.
• Releasing the descent pedal.
Any error detected by the safety PLC can be reset by pressing the blue
button on the pedal control devices (see chapter Pedal control device
console [} 217]).
2.10.4. Guard for the movable parts of the machine
The machine is equipped with a control system that activates
mechanical and electrical measures to avoid collisions of the moving
parts. The duration of the work cycles is determined by the control
devices (limit switch and position). In the event of wrong values, the
movement stops and an error message appears. The diagnostics
function informs you about the exact cause of the error.
NOTICE
Modification of the machine's work cycle may only be performed by
Salvagnini staff.
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2. Safety instructions
2.10.5. Hydraulic system guard
Protection from
Safety measure
Oil leak
The level switch disables the hydraulic system
Excessive oil temperature
The thermostat disables the hydraulic system
Impurities in the oil
Filter contamination indicators do not allow
automatic cycle restart (error message).
Excessive working pressure
Impediment through:
• Pressure regulators.
• Pressure relief and pressure reducing valves
(approved).
NOTICE
Damage to the hydraulic system due to incorrect valve
adjustment.
Pre-adjusted valves and sealed by Salvagnini should only be replaced
with sealed valves.
Only in this way can the new valve adjustments be complied with.
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2. Safety instructions
2.10.6. Electrical safety devices
If there is a power failure or the Emergency Stop has been activated, all
movement is stopped.
Safety measures in the electric system
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Safety for
Safety precaution by
Motors
Overload and short circuit protection
Servo drives
Overload/short circuit protection,
temperature monitoring
Switch cabinet
Min./max. Temperature monitoring
Encoder
Transmission voltage control
Rotator clamp
Contact ring
Other machine parts
Various electrical locking devices
Output modules, sensors, servo
valves
Electronic overload, short-circuit
protection and single-point information
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2. Safety instructions
2.10.7. Emergency stop buttons
NOTICE
The emergency stop button is only to be used in dangerous situations
to stop the movement of the moving parts of the machine in the
shortest time possible to ensure the safety of people and prevent
damage to the machine.
The emergency stop button is operated manually and remains activated
until manually released. Manual release is done by turning the button
(or key) clockwise.
If the emergency pushbutton has been pressed, it is not possible to
open the interlocking guards with the normal access procedures. Refer
to the chapter on Resetting the machine [} 231].
Figure 13: Emergency stop buttons
The number and position of the emergency stop buttons depend on
the machine configuration (consult the chapter on Control and
signaling devices [} 214]).
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Operating manual
2. Safety instructions
2.10.8. Ram imbalance control device
Figure 14: Ram imbalance control device
A device detects when the ram is unbalanced in order to protect the
machine. It is activated when there is a difference in level of between
15-20 mm, depending on the dimensions of the machine, and causes
the backgauges and ram movement to stop immediately.
To restore the machine operation, see the specific procedure described
in the chapter on Resetting the machine [} 231].
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2. Safety instructions
2.11. Lockout and release procedure (Lockout/Tagout)
2.11.1. Lock-out procedure
WARNING
Danger of injury to the operator.
Accidental machine start-up during maintenance tasks.
Precautions: cut off all energy sources and use padlock to lock the
relating feeding devices in place OFF.
The padlocks and signage used during the lock-out procedure are not
supplied by Salvagnini.
Perform the lock-out procedure before all maintenance operations
which must be performed with the machine switched off.
1. Isolate all machine energy sources.
2. Dissipate any residual or stored energy to prevent unexpected
movement of moving parts, or in any case to eliminate any risk to
people:
– Bring the machine parts to rest on the electromechanical
system to eliminate any potential energy.
– On the hydraulic and/or pneumatic circuits, make sure that
there is no fluid under pressure.
3. Perform the lock-out procedure: lock each power supply device of
the energy sources with a padlock.
4. Perform Tagout: place a warning sign on each padlock with the
name of the maintenance operator and a sign that warns others that the
machine is out of service for maintenance reasons.
5. At the end of maintenance task, perform the Restoring machine
operation [} 71] procedure.
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Operating manual
2. Safety instructions
All operators must be:
• Inform yourself of the importance, for safety reasons, of the lockout procedure.
• instructed on the methods and procedures for locking out the
machines and for working under safe conditions.
• respect the restrictions and limitations imposed during lock-out
procedures. If an operator realizes that a Salvagnini machine has
been locked out for servicing or maintenance purposes, they must
not attempt to start it up or to use it.
2.11.2. Cutting off the power sources
WARNING
Crushing and/or shearing hazard for the upper limbs.
If the machine is not used for a long time, the top-beam may drop.
Precautions: position two blocks above the lower toolholder so as to
prevent the top-beam from dropping.
Locking out the electricity supply device
(master switch)
Figure 15: Locking out the electricity supply device (master switch)
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2. Safety instructions
2.11.3. Restoring machine operation
After performing the maintenance operations, the machine's normal
operating conditions must be restored. Perform the following operations:
1. Check the machine and the area around it, ensuring that the
devices used for maintenance (tools, cleaning products) have been
removed and that the machine components are functionally intact.
2. Check the work area to ensure that all employees are in a safe
area and that they are not performing maintenance operations on
the machine.
3. Declare aloud your intention to start up the machine and wait for
any replies while also carrying out a visual inspection of the area.
4. Remove all the padlocks placed during the Lockout and release
procedure (Lockout/Tagout) [} 69] and place them in order in their
assigned location.
5. Make sure that the number of padlocks removed coincides with the
number of padlocks present before the Lockout and release
procedure (Lockout/Tagout) [} 69].
6. Inform the personnel involved that maintenance operations have
been completed and that the machine is ready for use.
7. Perform the production start-up procedure (see chapter Production
[} 230]).
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2. Safety instructions
2.12. Operator position
2.12.1. Manual operation
During manual operation of the machine, the correct location of the
operator is at the front of the machine.
Figure 16: Operator station
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3. Description of the machine
3. Description of the machine
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.3
3.3.1
3.3.2
3.3.3
3.4
Machine identification plate .........................................................................................
Machine structure........................................................................................................
Press-brake .................................................................................................................
Ram.............................................................................................................................
Pedal control device ....................................................................................................
AOPD Laser safety device ..........................................................................................
Backgauges.................................................................................................................
Smart Tool Locator® ...................................................................................................
Bend Angle Measurement Device...............................................................................
Sheet support ..............................................................................................................
Specifications ..............................................................................................................
Specifications ..............................................................................................................
Metal sheet requirements............................................................................................
Ambient conditions ......................................................................................................
Component serial number identification ......................................................................
Hydraulic unit...............................................................................................................
Tool-holders ................................................................................................................
Backgauges.................................................................................................................
AOPD Laser safety device ..........................................................................................
Crowning control device ..............................................................................................
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75
76
76
77
78
79
80
83
84
85
86
86
87
87
89
89
89
90
91
91
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3. Description of the machine
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3. Description of the machine
3.1. Machine identification plate
The machine is marked by a serial number shown on the following
plate:
(1)
Type
(2)
Serial number
(3)
Model
(4)
Year of construction
(5)
VAT registration number
(6)
Country of origin
(7)
Weight
Figure 17: Machine identification plate with CE marking
If the country of destination of the machine does not envisage CE
marking, the CE marking does not appear on the identification plate.
To identify the point of application of the machine’s identification plate,
see the chapter on Points of application of safety sign [} 41].
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3. Description of the machine
3.2. Machine structure
3.2.1. Press-brake
The press-brake cylinders (8) impart a downward force on the ram (1).
As the punch (2) approaches the die (3), it bends the sheet of metal
along a straight line.
(1)
Ram
(2)
Punch
(3)
Die
(4)
Upper toolholder
(5)
Control unit (the position of
installation may vary)
(6)
Lower toolholder
(7)
Bed
(8)
Cylinder
(9)
Pedal control device
(10)
AOPD laser safety device
Figure 18: Press-brake
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3. Description of the machine
3.2.2. Ram
DANGER
Upper limb crushing and/or shearing hazard.
The descent of the ram can lead to the hazards indicated above in the
tools area.
Precautions: use the safety devices provided for.
Ram AXES of movement
Ram movement is generated by the AXES (1) and (2).
(1)
AXIS that performs a
translation of the left vertical
bending cylinder
(2)
AXIS that performs a
translation of the right vertical
bending cylinder
Figure 19: Ram axes of movement
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3. Description of the machine
3.2.3. Pedal control device
The machine is equipped with a pedal control device, which the
operator uses to enable the upward or downward movement of the ram.
(1)
Pedal control device console
[} 217]
(2)
Pedal control area (see Holdto-run control device [} 223])
Figure 20: Pedal control device
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3. Description of the machine
3.2.4. AOPD Laser safety device
The AOPD laser safety device is a protection system which uses a laser
beam to create a safety barrier inside the danger area of a tool. If the
laser beam is only partially broken, the safety controller immediately
stops the machine.
Figure 21: AOPD Laser safety device
The laser beam is generated by a laser emitter, which is aligned with
the danger zone of the bending press and emits the light in a welldefined pattern. The receiver device detects the laser beam with a video
camera and determines whether the danger area is free of obstructions.
The safety controller allows the normal operation of the machine only
when the danger zone is clear of obstructions.
The AOPD laser safety device is equipped with a safety PLC known as
PCSS (this is installed in the electrical cabinet). It is a programmable
monitoring and safety system which communicates directly with the
machine control system. The control interface displays the messages
and status codes transmitted by the PCSS (see PCSS messages and
status codes [} 245]).
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3. Description of the machine
3.2.5. Backgauges
The backgauges permit precise positioning of the sheets.
Figure 22: Backgauges
CAUTION
Hazard from impact and cutting against the sheet.
Only position the sheet for bending once the backgauges have
stopped.
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3. Description of the machine
Backgauge movement AXES
The system for moving the backgauges is composed of the following
AXES:
• AXIS R (1): vertical movement of the bar (6).
• AXIS X1 (2): horizontal movement of the bar (6).
• X2 AXIS (4): relative movement of the backgauge (8) of ±100 mm
with respect to the bar (6).
• Z1 AXIS (3), Z2 AXIS (5): independent movement of the
backgauges (7) and (8).
(1)
R AXIS
(2)
X1 AXIS
(3)
Z1 AXIS
(4)
X2 AXIS
(5)
Z2 AXIS
(6)
Bar
(7)
Backgauge number 1
(8)
Backgauge number 2
Figure 23: Backgauge movement AXES
Backgauges (7) and (8) are motorized backgauges (see Motorized
backgauges [} 82]).
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3. Description of the machine
Motorized backgauges
WARNING
Danger of impact with, falling on and/or crushing of the operator.
During sheet bending, an uncontrolled movement of the backgauge
could push the sheet against the operator.
Precautions: pay particular attention to the movement of the
backgauges.
WARNING
Danger of impact with and/or crushing of the lower limbs.
During sheet bending, an uncontrolled movement of the backgauges
could impact the die and cause it to fall.
Precautions: wear safety footwear (see chapter Clothing and
protective equipment).
The motorized backgauges are actuated automatically on the basis of
the bending cycle.
(1)
Motorized backgauge
(2)
Motor for moving the
backgauge
Figure 24: Motorized backgauges (the image may vary according to the model)
The immediate stopping of motorized backgauges can be caused by:
• Opening the rear guard.
• Opening the side guards.
• Activating one of the emergency stop buttons.
The backgauge movement speed in the zone approaching the ram is
limited to 2 m/min.
If there is no power, the backgauges are supported by automatically
engaging the motor brake and transmission reduction gear.
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3. Description of the machine
3.2.6. Smart Tool Locator®
The Smart Tool Locator® option is an intelligent scale with incorporated
LEDs installed in the upper tool holder. It guides the operator during the
set-up and production phases and offers benefits in terms of speed,
precision and convenience.
The Smart Tool Locator® emits two types of light signals:
• The continuous light signal (1) shows where to position the tool (2)
in the upper tool holder during set-up.
• The intermittent light signal (3) shows which tool to position the
sheet (4) under before ordering descent of the ram.
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3. Description of the machine
3.2.7. Bend Angle Measurement Device
The bend angle measurement device (1) is a laser device which:
• Measures the bend angle in real time (calculating the angle
effectively obtained at the conclusion of bending.
• Allows and guarantees that the programmed bend angle is
achieved.
• Calculates the springback, whether or not material parameters are
entered in the machine program.
The bend angle measurement device is installed on the lower toolholder
and can move all the way along it.
The device operates independently of the dimension of the die and uses
a number of laser beams to obtain precise measurements, even in the
presence of holes and cavities.
WARNING
Burn and/or blinding hazard.
During measurement of the bend angle, a laser beam is emitted.
Precautions: wear protective gloves and goggles with opaque lenses
(see chapter Clothing and protective equipment).
CAUTION
Danger of impact with upper limbs.
Precautions: pay particular attention to the movement of the bend
angle measurement device during measurement of the bend angle
during sheet bending.
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3. Description of the machine
3.2.8. Sheet support
The sheet support device is made up of two front arms (1) that perform
a movement parallel to the bend line along a linear guide (2) placed on
the machine bed by means of the operator's manual movement. Each
arm is equipped with:
• Locking lever (3) to lock the movement parallel to the bend line.
• Adjustment device (4) for the alignment in height with the die.
Figure 25: Sheet support
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3. Description of the machine
3.3. Specifications
3.3.1. Specifications
Description
Unit of
measure
ment
Value
mm
3060
Speed (up/down movement)
mm/s
250
Bending speed (100% force)
mm/s
10
Opening (3)
mm
600
Throat depth (2)
mm
435
Hydraulic fluid
liters
70
bar
6
dB(A)
< 70
Bend length (1)
Compressed air supply
Noise Leq
(Acoustic pressure level in the control
position, measured in line with the
conditions foreseen under current
legislation)
(1)
Bend length
(2)
Throat depth
(3)
Opening
Figure 26: Specifications
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Operating manual
3. Description of the machine
3.3.2. Metal sheet requirements
Characteristics
WARNING
Cutting hazard.
The cutting edges of the tools and metal sheet may cause cutting
injuries.
Precautions:
- Wear protective gloves (see the chapter on Clothing and protective
equipment).
- Take special care when performing the operations.
- Respect the general safety rules.
WARNING
Impact and/or crushing hazard for the lower limbs.
The tools and metal sheet may cause impact and/or crushing injuries if
they fall.
Precautions:
- Wear safety shoes (see the chapter on Clothing and protective
equipment).
- Take special care when performing the operations.
- Respect the general safety rules.
The blanks must not be damaged or with planarity and dimensions
outside the tolerance range.
3.3.3. Ambient conditions
Storage temperature
Storage relative humidity
Work ambient temperature
Work ambient relative humidity
Altitude above the sea level
Electromagnetic fields
B3.135-3000 - MB_0791 - 1.0 - en
Minimum
Maximum
-10°C
60°C
0%
95%
+10°C
40°C
0%
90%
-
1000m
Below the immunity limits laid down for
industrial environments.
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Operating manual
3. Description of the machine
Minimum
Work ambient lighting
Maximum
All work equipment must be properly visible.
Avoid direct light in the eyes.
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3. Description of the machine
3.4. Component serial number identification
Hydraulic unit
Hydraulic unit.
Tool-holders
Upper and lower tool-holders
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Operating manual
3. Description of the machine
Hydraulic unit
Backgauges
Backgauges
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Operating manual
3. Description of the machine
AOPD Laser safety device
AOPD Laser safety device
Crowning control device
Crowning control device motor.
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3. Description of the machine
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4. Instructions for use
4. Instructions for use
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.2
4.2.1
4.2.2
4.2.3
4.3
4.3.1
4.3.2
4.3.3
4.4
4.4.1
4.5
4.5.1
4.6
4.6.1
4.6.2
4.6.3
4.6.4
4.7
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
4.8.6
4.9
4.9.1
4.9.2
4.9.3
4.9.4
Control interface .......................................................................................................... 95
Introduction.................................................................................................................. 97
Starting up the application........................................................................................... 98
Settings ....................................................................................................................... 99
Reference system ..................................................................................................... 100
User interface ............................................................................................................ 101
Using the application ................................................................................................. 195
Troubleshooting......................................................................................................... 211
Control and signaling devices ................................................................................... 214
Machine console ....................................................................................................... 214
Backgauge reset console .......................................................................................... 216
Pedal control device console..................................................................................... 217
Operating modes....................................................................................................... 218
Machine Operation .................................................................................................... 218
Hold-to-run control device ......................................................................................... 223
AOPD Laser safety device ........................................................................................ 225
Switching on the machine ......................................................................................... 229
Procedure.................................................................................................................. 229
Production ................................................................................................................. 230
Starting production .................................................................................................... 230
Resetting the machine............................................................................................... 231
After activating the emergency stop button ............................................................... 231
After opening the rear guard ..................................................................................... 231
After opening the side guards (both) ......................................................................... 231
After a ram imbalance ............................................................................................... 231
Shutting off the machine............................................................................................ 232
Setting up the machine.............................................................................................. 233
Machine resetting ...................................................................................................... 233
Bend angle measuring device reset .......................................................................... 233
Tests on the AOPD laser safety device..................................................................... 234
Tool Set-Up Procedure.............................................................................................. 235
Bending Techniques.................................................................................................. 239
Factors influencing the precision of bends ................................................................ 242
Troubleshooting......................................................................................................... 245
Machine stop ............................................................................................................. 245
AOPD Laser safety device ........................................................................................ 245
Procedure for freeing any parts trapped between tools ............................................ 257
Troubleshooting......................................................................................................... 257
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4. Instructions for use
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Operating manual
4. Instructions for use
4.1. Control interface
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
Introduction.................................................................................................................. 97
Starting up the application........................................................................................... 98
Settings ....................................................................................................................... 99
Reference system ..................................................................................................... 100
User interface ............................................................................................................ 101
Using the application ................................................................................................. 195
Troubleshooting......................................................................................................... 211
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4. Instructions for use
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Operating manual
4. Instructions for use
4.1.1. Introduction
All the information contained in this manual is available online, under
the Help topics function of the Toolbar [} 110].
Instructions for using the optional applications can be found in the
specific manuals in the Software and programming manual volume of
the documentation.
Function
The present manual for using the control interface describes:
• The commands and functions of the application.
• The operations that the machine user can perform, check and
modify.
The control interface is accessed via a touch-screen. The Touch-screen
commands [} 101] can be selected using a finger or a special pen.
User
NOTICE
The user must respect the machine safety instructions.
All operations on the machine must be performed in safe conditions:
please consult the Safety instructions [} 29] chapter.
The predefined users are:
• GUEST with access to functions linked to production.
• ADMIN with exclusive access to all functions (reserved solely for
Salvagnini technicians).
To log in as a different user, refer to the Logging in as another user
[} 195] procedure.
Version of the application
The version of the application described in this Operating Manual is
8.0.0.0.
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Operating manual
4. Instructions for use
4.1.2. Starting up the application
Preliminary checks
Before turning the control unit on, it is necessary to:
• Check that no maintenance is being performed on the machine.
• Check that the power cabinet is under power.
Turning the control unit on
1. Turn the machine’s power switch to the ON position and wait for
the login request.
2. Select the user syscon.
3. Type the password Enterprise.
4. When the operating system has been loaded, the control interface
start-up window appears on the screen.
5. If you need to log in as a different user, please refer to the chapter.
6. A message advising that the machine must be reset appears in the
Message scroll bar [} 105].
7. A message asking you to confirm that the machine has been reset
appears in the User message display area [} 112].
8. Reset the machine and confirm the message.
9. The machine is now ready for the required program to be loaded.
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Operating manual
4. Instructions for use
4.1.3. Settings
The user can modify the way in which the functions are displayed, the
language of the control interface, the message notifications themselves
and so on. To modify the control interface settings, refer to the Settings
[} 178] chapter.
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Operating manual
4. Instructions for use
4.1.4. Reference system
The control interface manages the position of the panel using
coordinates and orientations with respect to:
• The machine reference system.
• The backgauge reference system (see the chapter on Backgauges
[} 80]).
Figure 27: Machine reference system
The origin of the AXES of the machine is the point furthest to the left of
the press-brake set-up.
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Operating manual
4. Instructions for use
4.1.5. User interface
Touch-screen commands
This chapter describes the basic actions for using the touch-screen.
Symbol
Action
Command
Briefly touch the screen with
your finger.
Tap (click).
Press your finger on the
screen and keep it there until
the new icon is activated,
then remove your finger.
Press and hold (equivalent to
the right mouse button).
Move your finger across the
screen without losing contact
with it.
Drag.
Move two fingers across the
screen without losing contact
with it.
Two-finger drag (only in the
Graphical display area
[} 107]).
Touch the screen with two
fingers:
- bring them together to
zoom out.
- move them apart to zoom
in.
Pinch/stretch.
Touch the screen with two
fingers and move them
clockwise or anti-clockwise.
Rotate (only in the Graphical
display area [} 107]).
Rotate (only in the Graphical
display area [} 107]).
Typographical conventions for this manual.
Titles like Touch-screen shortcut indicate the commands, with their
symbols, that can be activated in the screen shown.
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Operating manual
4. Instructions for use
Dialog boxes
The control interface contains boxes where the user can enter values.
The table below shows what appears when you select different entry
boxes in order to enter values in them.
- 102 -
Dialog box:
Values entered via:
Text
Virtual keypad
Date
Virtual calendar
Numbers
Virtual calculator
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Operating manual
4. Instructions for use
General description
(1)
Navigation bar [} 104]
(2)
Secondary navigation bar (varies according to the object selected in the
navigation bar).
(3)
Toolbar [} 110]
(4)
Message scroll bar [} 105]
(5)
Page [} 106]
(6)
User message display area [} 112]
User privileges.
Some parts of the interface may be enabled/disabled depending on
user privileges.
NOTICE
The predefined unit of measurement is the millimeter.
The predefined unit of measurement is the millimeter and it is not
shown next to the values in the control interface. If the unit of
measurement is not the predefined one, the symbol for it is shown next
to the value.
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Operating manual
4. Instructions for use
Navigation bar
The navigation bar contains tabs that can, in turn, enable a secondary
navigation bar; the composition of this bar depends on the configuration
of the machine.
- 104 -
(1)
Displays production and allows you to manage it in real time.
See the chapter on Production [} 113].
(2)
Defines a new program.
See the chapter on New program [} 145].
(3)
Allows you to manage the machine’s set-up.
See the chapter on Tools [} 146].
(4)
Allows you to activate the manual commands.
See the chapter on Actions [} 169].
(5)
Displays machine messages.
See the chapter on Messages [} 170].
(6)
Displays the applications used while the machine is running.
See the chapter on Operator [} 173].
(7)
Display and management settings.
See the chapter on Settings [} 178].
(8)
Information useful for support.
See the chapter on Service [} 191].
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Operating manual
4. Instructions for use
Message scroll bar
The message scroll bar (1) displays messages informing the operator
about the status of the machine (the operator is not required to
intervene to proceed with production).
To view the messages displayed in the message scroll bar, tap the
Messages [} 170] tab and then tap Information [Informations] (2).
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
4. Instructions for use
Page
The contents of the page vary according to the tab selected in the
Navigation bar [} 104]. The page is divided into the following areas:
• Parameters area (1).
• Graphical display area (2).
- 106 -
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Operating manual
4. Instructions for use
Graphical display area
(1)
Expands/reduces the graphical display area.
/
(2)
Displays the next/previous bend.
(3)
Starts/stops production.
/
(4)
Pie menu [} 109]
Touch-screen shortcut
The following commands can be activated in the graphical display area:
Zooms in/out of the image shown.
Opens the pie menu (4).
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Operating manual
4. Instructions for use
Rotates the image shown.
Translates the image shown.
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Operating manual
4. Instructions for use
Pie menu
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Allows you to select the parts of the machine that you want to display in the
graphical display area.
(2)
Allows you to simulate the program, activating the relative buttons.
(3)
Displays the whole image.
(4)
Closes the pie menu.
(5)
Changes the view.
- 109 -
Operating manual
4. Instructions for use
Toolbar
- 110 -
(1)
Name of the application.
(2)
Help topics [} 111].
(3)
Locks/unlocks the screen.
(4)
Work mode (load or no-load).
(5)
Name of the group containing the program selected.
(6)
Name of the program selected.
(7)
Icon and user connected.
(8)
Current time.
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Operating manual
4. Instructions for use
Help topics
The icon on the left opens the page on the desired topic in the manual.
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Operating manual
4. Instructions for use
User message display area
The Messages [Messages] that require operator intervention appear in
the user message display area (1).
To modify this setting, use the Message notification [} 185] section.
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Operating manual
4. Instructions for use
Production
The Production [Production] tab displays the groups of programs and
is used to run a program. It shows the production status in real time and
is used to modify some of the program’s parameters.
(1)
Area in which the groups of programs are displayed.
(2)
Searches for the group by name.
(3)
Defines the order in which the groups of programs are displayed (by name
or by date).
(4)
Enables the groups of programs to be displayed in the following ways:
• List.
• Thumbnails.
B3.135-3000 - MB_0791 - 1.0 - en
(5)
Adds a new group of programs.
(6)
Reloads the current screen.
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Operating manual
4. Instructions for use
Touch-screen shortcut
Pressing your finger on a group of programs activates the pop-up menu
(7):
- 114 -
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Operating manual
4. Instructions for use
Selecting a program
When a program is selected, the following information is displayed:
(1)
Returns to the display of the groups of programs.
(2)
Name of the group selected.
(3)
Searches for the program in the group selected.
(4)
Defines the order in which the programs are displayed (by name or by
date).
(5)
Displays all the programs.
(6)
Enables the programs to be displayed in the following ways:
• List.
• Thumbnails.
B3.135-3000 - MB_0791 - 1.0 - en
(7)
Reloads the current screen.
(8)
Previews the panel for the program selected.
(9)
Number of panels to be produced.
(10)
Information about the program selected.
(11)
Button for starting to elaborate the program selected.
(12)
Renames the program.
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Operating manual
4. Instructions for use
Touch-screen shortcut
Pressing your finger on a program activates the pop-up menu (13):
- 116 -
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Operating manual
4. Instructions for use
Elaborating a program
The button on the left is used to run and/or edit the program.
At the end of the elaboration, the following screen appears:
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Secondary navigation bar used to edit the program.
(2)
Area for Editing the program [} 118].
(3)
Graphical display area [} 107].
- 117 -
Operating manual
4. Instructions for use
Editing the program
NOTICE
Automatic compilation.
The validity of all the values entered/edited is checked
instantaneously. If the value is correct, the program is compiled
automatically and it is not possible to return to the previous situation.
Sequence
The Sequence [Sequence] section displays the bend sequence for the
program.
(1) Editing the bend sequence [} 119]
(2) Adding a bend [} 120]
(3)
(4)
Adding multiple bends [} 126]
Editing a bend [} 127]
(5) Deleting a bend [} 128]
- 118 -
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Operating manual
4. Instructions for use
Editing the bend sequence
1. Drag the bend to the position you want to move it to.
B3.135-3000 - MB_0791 - 1.0 - en
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Operating manual
4. Instructions for use
Adding a bend
1. Tap the button on the left.
2. The following screen appears:
(1)
Data specific to the bend, that changes depending on the type of bend
selected:
• Adding a normal bend [} 121]
• Adding a radius bend [} 122]
• Adding a flattened bend [} 123]
- 120 -
(2)
Configures a new set-up (see the Configuring a new set-up [} 124]
procedure).
(3)
Copies the set-up for the previous bend.
(4)
Displays the current set-up for the machine.
(5)
Displays the name and characteristics of the segment selected.
(6)
Displays the drawing of the current machine set-up, highlighting the
segment selected.
(7)
Deletes the changes.
(8)
Applies the changes.
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Operating manual
4. Instructions for use
Adding a normal bend
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Bend type.
(2)
Bend angle.
(3)
Bend height.
(4)
Enables/disables the inner measurement. If enabled, the value of the
Height [Height] parameter indicates the bend height measurement in the
flat model (4).
(5)
Bend length.
(6)
Right-hand bend height, if the bend is conical.
(7)
Bend unfolding.
(8)
Central position of the bend with respect to the origin of the AXES of the
machine.
(9)
Bend radius.
- 121 -
Operating manual
4. Instructions for use
Adding a radius bend
- 122 -
(1)
Bend type.
(2)
Bend angle.
(3)
Bend height.
(4)
Bend length.
(5)
Right-hand bend height.
(6)
Bend unfolding.
(7)
Central position of the bend with respect to the origin of the AXES of the
machine.
(8)
Bend radius.
(9)
Length of a single step for making the radius bend.
(10)
Number of steps needed to obtain the value of the radius for the radius
bend.
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Operating manual
4. Instructions for use
Adding a flattened bend
NOTICE
Flattening tool
To be able to add a flattened bend, you must have the appropriate
flattening tool.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Bend type.
(2)
Distance between the outer surfaces of the flat bend.
(3)
Bend length.
(4)
Central position of the bend line.
(5)
Enables/disables the data for creating the preparatory bend for the flattened
bend, also known as the preliminary bend.
(6)
Bend angle.
(7)
Bend height.
(8)
Enables/disables the inner measurement. If enabled, the value of the
Height [Height] parameter indicates the bend height measurement in the
flat model.
(9)
Right-hand bend height, if the bend is conical.
(10)
Bend radius.
(11)
Central position of the bend with respect to the origin of the AXES of the
machine.
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Operating manual
4. Instructions for use
Configuring a new set-up
1. Tap the button on the left. The screen that appears is used to
select the configuration most suitable for the total bend length
indicated.
2. Set the search parameters (2) described in the following table.
3. Select Calculate [Calculate].
4. Tap (5) to apply the modifications and use the new set-up.
(1)
List of the tools in the current set-up. The way in which the list is displayed
can be modified as follows:
• Punches. Only the punches will be shown.
• Dies. Only the dies will be shown.
• Split. Divides the window into two parts, showing both the dies and the
punches.
• Aligned. Cancels the effect of the Split command.
- 124 -
(2)
Search parameters.
(3)
Displays the possible combinations of segments calculated.
(4)
Deletes the changes.
(5)
Applies the changes.
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Operating manual
4. Instructions for use
(6)
Total bend length.
(7)
Maximum spacing between the tools.
(8)
Minimum length of the desired bend line.
(9)
Maximum length of the desired bend line.
(10)
Minimum spacing desired on the left. If the value is set at AUTO, the
spacing is calculated automatically.
(11)
Minimum spacing desired on the right. If the value is set at AUTO, the
spacing is calculated automatically.
(12)
Used to rearrange the tools list according to the distance between the
center of the configuration and the:
• Left-hand side of the machine.
• Right-hand side of the machine.
• Center of the machine.
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(13)
Punch code.
(14)
Die code.
(15)
Codes of the right- and left-hand horns.
(16)
Calculates the possible combinations of segments available for the total
bend length defined.
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Operating manual
4. Instructions for use
Adding multiple bends
1. Select the bend you want to add.
2. Tap the button on the left.
3. The following screen appears:
(1)
Copies the bend selected, by adding it to the list.
(2)
Deletes the bend selected.
(3)
Cancels the changes and returns to the previous screen.
(4)
Applies the changes and returns to the previous screen.
Touch-screen shortcut
Select the bend parameter values in order to edit them.
- 126 -
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Operating manual
4. Instructions for use
Editing a bend
1. Select the bend you want to edit.
2. Tap the button on the left.
3. The following screen appears:
(1)
Data specific to the bend, that changes depending on the type of bend
selected:
• Adding a normal bend [} 121]
• Adding a radius bend [} 122]
• Adding a flattened bend [} 123]
B3.135-3000 - MB_0791 - 1.0 - en
(2)
Configures a new set-up (see the Configuring a new set-up [} 124]
procedure).
(3)
Copies the set-up for the previous bend.
(4)
Parameters that can be recalculated.
(5)
Displays the set-up for the machine.
(6)
Displays the name and characteristics of the tools in the segment selected.
(7)
Displays the drawing of the current machine set-up, highlighting the
segment selected.
(8)
Deletes the changes.
(9)
Applies the changes.
- 127 -
Operating manual
4. Instructions for use
Deleting a bend
1. Select the bend you want to delete.
2. Tap the button on the left to delete the bend selected.
- 128 -
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Operating manual
4. Instructions for use
Corrections
The Corrections [Corrections] section is used to edit some of the bend
execution parameters.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Selection of the bend you want to edit.
(2)
Enables/disables the second correction point.
(3)
New value for the bend angle if the desired angle is not reached.
(4)
Correction value that is added to/subtracted from the real value of the X
AXIS of the backgauges.
(5)
Correction value that is added to/subtracted from the real value of the R
AXIS of the backgauges.
(6)
Indicates the value for optimizing (reducing or increasing) the stroke of the
cylinder when extracting the material.
(7)
Height of the speed change point.
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Operating manual
4. Instructions for use
- 130 -
(8)
Displays the type of bend.
(9)
Value of the bending force that is calculated automatically. The value
indicated is that calculated automatically but a new value can be entered if
the material code and/or thickness have changed.
(10)
Position of the left-hand cylinder. The value indicated in the box is the
expected position. The Real [Actual] value is the actual position.
(11)
Position of the right-hand cylinder. The value indicated in the box is the
expected position. The Real [Actual] value is the actual position.
(12)
Compensation to be given to the crowning (flexing) before the end of the
bend. The value indicated is that calculated automatically but a new value
can be entered if the material code and/or thickness have changed.
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Operating manual
4. Instructions for use
Backgauges
The Backgauges [Backgauges] section displays the backgauge
parameters for the bend selected.
Backgauge axes.
The number of axes varies according to the model of backgauge used.
For this reason, the screen below may vary.
(1)
Type of support for the left-hand backgauge. Defines which point of the
backgauge the panel must be positioned on.
(2)
Type of support for the middle backgauge. Defines which point of the
backgauge the panel must be positioned on.
(3)
Type of support for the right-hand backgauge. Defines which point of the
backgauge the panel must be positioned on.
(4)
Graphically displays the position of the backgauges:
• During [During]: displays the position of the backgauges during the
bend.
• After [After]: displays the position of the backgauges after the bend.
(5)
Used to select the type of backgauge movement:
• Default movement.
• Movement of the R AXIS first.
• Movement of the X AXIS first.
• Movement above the die.
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4. Instructions for use
(6)
Enables/disables the wait for the backgauges to move away before the
bend is made.
(7)
Backgauge reference positions.
The values indicated in the boxes are the expected positions of the
backgauges for making the bend (they can be modified).
The Real [Actual] values are the actual positions of the backgauges (they
cannot be edited).
(8)
- 132 -
Used to acquire the real values of the backgauge positions, after they have
been repositioned manually.
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4. Instructions for use
Bend options
The Bend options [Bend options] section displays the options for the
bend selected.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Enables/disables Tray mode [} 226]. If this option is enabled, the movement
of the top-beam is not interrupted during the fast descent (despite the bent
side of the box being detected).
(2)
Height of the box.
(3)
Enables/disables the function that omits the backgauge gripping phase.
The top-beam descends without interruptions until the bend has been
completed. If this option is enabled, the backgauges cannot move to the
After position.
(4)
Position of the backgauges on X after the gripping phase.
(5)
Enables/disables the top-beam stopping at the speed change point. If this
option is enabled, the operator must press the down pedal to be able to
continue with the bend.
(6)
Enables the first pedal control device.
(7)
Enables the second pedal control device.
(8)
Time for which the top-beam waits in the bending position at the height
indicated.
(9)
Bending speed when the top-beam reaches the speed change point. The
maximum value is 10 mm/s, but this can be reduced.
(10)
Enables/disables dynamic reading of the flexing of the bed and calculates
in real time the compensation to be applied to the crowning (flexing) before
the end of the bend. See Automatic crowning (flexing) correction [} 243].
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4. Instructions for use
- 134 -
(11)
Enables/disables the reascent of the top-beam at controlled speed (Soft
return). During this phase, the backgauges are positioned ready for the
next bend.
(12)
Distance from the bend forming position.
(13)
Enables/disables deactivation of the reascent of the top-beam at controlled
speed, using the down pedal. If this option is enabled, the top-beam
continues to reascend at the default speed when the operator presses the
down pedal.
(14)
Top-beam reascent speed.
(15)
Enables/disables the descent of the top-beam only after the down pedal
has been pressed. If this option is enabled, after the bend has been made
and the top-beam reascended, the control system waits for the down pedal
to be pressed before proceeding with the next bend.
(16)
Indicates the delay between one bend and the other for the operator to
extract the panel with ease.
(17)
Enables/disables the early movement of the backgauges. This option is
disabled during the last bend in the program, because the operator must
remove the panel at the end of the program in order to pick up a new blank
for processing.
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Operating manual
4. Instructions for use
CAUTION
Crush hazard if function (17) is enabled.
Great care must be taken when enabling this function. Only the
operator can know whether this operation is safe, or whether the early
movement of the backgauges would cause a collision with the bend
being performed.
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Operating manual
4. Instructions for use
AMS
The parameters of the bend angle measurement system for the bend
selected are displayed in the AMS section.
(1)
Modes of compensating similar bends that you do not want to measure or
that cannot physically be measured:
• Default.
• Do not compensate. No compensation is performed.
• Compensate using positions measured. Compensation is performed
by applying the forming, cylinder inclination and crowning positions
reached on earlier bends.
(2)
Preliminary bend angle to allow the bend angle measurement system to be
inserted in the measuring position.
(3)
Measurement methods:
• Once. A single measurement is taken in the maximum forming position.
• Springback. The correction is calculated automatically according to the
springback of the material.
• Three points. The correction is calculated automatically on three points
of the panel (measurements are taken on the right, in the middle and on
the left).
- 136 -
(4)
Enables/disables measurement of the selected bend by the bend angle
measurement system.
(5)
Position of the bend angle measurement system while the panel is being
inserted.
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4. Instructions for use
B3.135-3000 - MB_0791 - 1.0 - en
(6)
Position of the bend angle measurement system while the panel is being
pre-bent.
(7)
Position of the bend angle measurement system while the panel is being
extracted.
(8)
Position of the bend angle measurement system while the panel is being
bent.
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Operating manual
4. Instructions for use
Panel
The Panel [Panel] section is used to edit the settings for the panel.
(1)
Material.
(2)
Thickness of the material.
(3)
Sheet gripping position.
(4)
Enables/disables the bend angle check by the bend angle measurement
system.
(5)
Calibration position for the bend angle measurement system.
(6)
Modes of operation for the bend angle measurement system.
• Always. All the bends on all the panels are measured.
• First panel. Only the first panel is measured.
• N panels every M. A certain number of panels every M panels are
measured.
- 138 -
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Operating manual
4. Instructions for use
(7)
Modes of compensation for similar bends that you do not want to measure
or that cannot physically be measured.
• Do not compensate. No compensation is performed.
• Compensate using positions measured. Compensation is performed
by applying the forming, cylinder inclination and crowning positions
reached on earlier bends.
• Compensate by measuring the angle. Compensation is performed by
re-measuring the angle but applying the springback, cylinder inclination
and crowning values measured on previous bends.
• Compensate by measuring springback. Compensation is performed
by measuring the springback and angle but applying the cylinder
inclination and crowning values measured on previous bends.
B3.135-3000 - MB_0791 - 1.0 - en
(8)
Position of the bend angle measurement system when not in use (e.g.
during the compensation phase).
(9)
Enables/disables activation of the LEDs indicating the positions in which the
dies are installed.
(10)
Enables/disables activation of the LEDs indicating the positions in which the
punches are installed.
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Operating manual
4. Instructions for use
Set-up
The Set-up [Setup] section is used to edit the set-up for the program.
- 140 -
(1)
Enables/disables the display of the punches.
(2)
Enables/disables the display of the dies.
(3)
Tool type.
(4)
Tool code.
(5)
Tool length.
(6)
Initial position of the tool in the set-up.
(7)
Final position of the tool in the set-up.
(8)
Enables/disables the 180 degree rotation of the tool.
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Operating manual
4. Instructions for use
Info
The Info [Info] section is used to associate files (1) and notes (2) with
the program selected.
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Operating manual
4. Instructions for use
State
Information about the program being run is displayed in the Status
[Status] section.
- 142 -
(1)
Group containing the program being run.
(2)
List containing the program being run.
(3)
Program name.
(4)
Panel dimensions.
(5)
Material used.
(6)
Total number of bends and panels made since the machine was first turned
on (can be reset).
(7)
Status of the panel currently being machined.
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Operating manual
4. Instructions for use
Caution
Messages about possible machine malfunctions that relate to the
program being performed but do not affect its execution are displayed in
the Warnings [Warnings] section.
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Operating manual
4. Instructions for use
Errors
Errors that prevent the program from being run are displayed in the
Errors [Errors] section.
- 144 -
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4. Instructions for use
New program
The New program [New program] tab is used to create:
• A new program.
• A list of programs.
• A group of programs.
To create a new program, see the chapter on Creating a new program
[} 196].
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Operating manual
4. Instructions for use
Tools
The Tools [Tools] tab is used to manage the tool set-ups.
- 146 -
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4. Instructions for use
Set-ups
A list of all the set-ups available is displayed in the Set-up [Setup]
section. It is used to:
• Define a new set-up.
• Edit an existing set-up.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
List of the set-ups present in the database.
(2)
List of the tools used in the set-up selected.
(3)
Code of the set-up selected.
(4)
Additional information associated with the set-up selected.
(5)
Enables/disables use of the default set-up.
(6)
Enables/disables automatic die change.
(7)
Enables/disables automatic punch change.
(8)
Edit sectioning [} 149]
(9)
Segment details [} 148]
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Operating manual
4. Instructions for use
Segment details
- 148 -
(1)
Tool type.
(2)
Code and characteristics of the profile selected.
(3)
Initial position of the tool selected in the set-up.
(4)
Tool length.
(5)
Y correction of the point in which the tool is fixed to the press-brake.
(6)
Z correction of the point in which the tool is fixed to the press-brake.
(7)
Enables/disables automatic correction along the Z AXIS.
(8)
Enables/disables the 180 degree rotation of the tool.
(9)
Enables/disables the definition of a tool as Optional. When necessary, the
control interface issues a message asking for the optional tool to be
installed.
(10)
Choice of the left-hand horn of the punch.
(11)
Choice of the right-hand horn of the punch.
(12)
Defines the composition of the current tool, i.e. the list of the segments to
be used.
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Operating manual
4. Instructions for use
Edit sectioning
The Edit sectioning [Edit sectioning] tab is used to edit the tool
segments.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Total length of the segment.
(2)
Tolerance on the total length of the segment.
(3)
Calculates the sectioning for the values indicated.
(4)
Cancels the calculation of the sectioning.
(5)
Applies the changes.
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Operating manual
4. Instructions for use
Punches
A list of the punches present in the database is displayed in the
Punches [Punches] section. It is used to:
• Delete the punches from the database.
• Edit the characteristics of the punches.
• Define new punches.
If the Show unavailable tools option is enabled in the tab, the tools
that are available will be shown in black whereas those that are not
available will be shown in red.
- 150 -
(1)
List of the punches available.
(2)
Code identifying the tool selected.
(3)
Additional information associated with the tool selected.
(4)
Punch type.
(5)
Maximum load that the punch can withstand.
(6)
Point in which the top-beam exerts its force on the punch.
(7)
Enables/disables automatic punch movement (ATA).
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4. Instructions for use
B3.135-3000 - MB_0791 - 1.0 - en
(8)
Angle of punch tip.
(9)
Distance from the center-line of the machining at which the ATA translation
devices are engaged; this distance is measured along the bend line.
(10)
Distance from the bending edge of the machining at which the ATA
translation devices are engaged; this distance is measured perpendicular to
the bend line.
(11)
Radius of punch tip.
(12)
Punch height.
(13)
Enables/disables availability of the tool. If this function is enabled, the tool
can be added to the set-ups.
(14)
Saves the modifications.
(15)
Imports a new tool from a drawing. See the paragraph on Import [} 168].
(16)
Deletes the tool selected.
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Operating manual
4. Instructions for use
Segments
Displays the status of the tool magazine. This screen is used to:
• Edit the existing segments.
• Delete the segment selected.
• Add new segments.
- 152 -
(1)
Tool width.
(2)
Number of tools available.
(3)
Code of the right-hand horn.
(4)
Code of the left-hand horn.
(5)
X position for inserting the ATA selector in the tool.
(6)
Y position for inserting the ATA selector in the tool.
(7)
Deletes the segment selected.
(8)
Adds a segment with the tool selected.
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Operating manual
4. Instructions for use
Dies
A list of the dies present in the database is displayed in the Dies [Dies]
section. It is used to:
• Delete the dies from the database.
• Edit the characteristics of the dies.
• Define new dies.
If the Show unavailable tools option is enabled in the tab, the tools
that are available will be shown in black whereas those that are not
available will be shown in red.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
List of the dies available.
(2)
General [} 154]
(3)
Variable width die [} 155]
(4)
Special die [} 156]
(5)
Saves the modifications.
(6)
Imports a new tool from a drawing. See the paragraph on Import [} 168].
(7)
Deletes the tool selected.
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Operating manual
4. Instructions for use
General
- 154 -
(1)
Code identifying the tool selected.
(2)
Additional information associated with the tool selected.
(3)
V width.
(4)
Type of die.
(5)
Y correction of the position of the die with respect to the origin of the AXES
of the machine.
(6)
V angle.
(7)
Die width.
(8)
Inside width of the die, i.e. distance between the bend line and the inner
surface of the die (backgauge side).
(9)
Die height.
(10)
V radius.
(11)
Parameter for LVD model dies.
(12)
Maximum load that the die can withstand.
(13)
Fillet radius.
(14)
Enables/disables availability of the tool. If this function is enabled, the tool
can be added to the set-ups.
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4. Instructions for use
Variable width die
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Enables/disables the variable width die.
(2)
Minimum opening of the die.
(3)
Maximum opening of the die.
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Operating manual
4. Instructions for use
Special die
- 156 -
(1)
Enables/disables use of a special die.
(2)
Minimum thickness of the sheet metal.
(3)
Maximum thickness of the sheet metal.
(4)
Force to be exerted when using the special die.
(5)
Rotation (with respect to the origin of the AXES of the machine) of the
reference bend, after forming the bend with the special die.
(6)
Type of bend to be formed.
(7)
Number of bends to be formed.
(8)
Enables/disables execution of the first bend upwards.
(9)
Y position (with respect to the origin of the AXES of the machine) of the
reference bend, before forming the bend with the special die.
(10)
Z position (with respect to the origin of the AXES of the machine) of the
reference bend, before forming the bend with the special die.
(11)
Rotation (with respect to the origin of the AXES of the machine) of the
reference bend, before forming the bend with the special die.
(12)
Y position (with respect to the origin of the AXES of the machine) of the
reference bend, after forming the bend with the special die.
(13)
Z position (with respect to the origin of the AXES of the machine) of the
reference bend, after forming the bend with the special die.
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Operating manual
4. Instructions for use
Segments
Displays the status of the tool magazine. This screen is used to:
• Edit the existing segments.
• Delete the segment selected.
• Add new segments.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Tool width.
(2)
Number of tools available.
(3)
Code of the right-hand horn.
(4)
Code of the left-hand horn.
(5)
X position for inserting the ATA selector in the tool.
(6)
Y position for inserting the ATA selector in the tool.
(7)
Deletes the segment selected.
(8)
Adds a segment with the tool selected.
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Operating manual
4. Instructions for use
Horns
A list of the horn-type tools present in the database is displayed in the
Horns [Horns] section. It is used to:
• Delete the horn-type tool from the database.
• Edit the characteristics of the horn-type tool.
• Define new horn-type tools.
If the Show unavailable tools option is enabled in the tab, the tools
that are available will be shown in black whereas those that are not
available will be shown in red.
- 158 -
(1)
List of the horn-type tools available.
(2)
Code identifying the tool selected.
(3)
Additional information associated with the tool selected.
(4)
Height of the horn-type tool.
(5)
Width of the horn-type tool.
(6)
Enables/disables availability of the tool. If this function is enabled, the tool
can be added to the set-ups.
(7)
Saves the modifications.
(8)
Imports a new tool from a drawing. See the paragraph on Import [} 168].
(9)
Deletes the tool selected.
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Operating manual
4. Instructions for use
Flattening tools
A list of the flattening tools present in the database is displayed in the
Flattening [Flattening] section. These tools are used to form safe-edge
bends. In this section you can:
• Delete the flattening tool from the database.
• Edit the characteristics of the flattening tool.
• Define new flattening tools.
If the Show unavailable tools option is enabled in the tab, the tools
that are available will be shown in black whereas those that are not
available will be shown in red.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
List of the flattening tools available.
(2)
General [} 160]
(3)
Special flattening tool [} 161]
(4)
Saves the modifications.
(5)
Imports a new tool from a drawing. See the paragraph on Import [} 168].
(6)
Deletes the tool selected.
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Operating manual
4. Instructions for use
General
- 160 -
(1)
Code identifying the tool selected.
(2)
Additional information associated with the tool selected.
(3)
Maximum opening of the flattening tool.
(4)
Total height of the flattening tool when closed.
(5)
Position of the point in which the sheet metal rests on the flattening tool.
(6)
Opening between the two mobile parts of the flattening tool.
(7)
Type of flattening tool (whether operated automatically or by spring).
(8)
Code of the die associated with the flattening tool.
(9)
Enables/disables availability of the tool. If this function is enabled, the tool
can be added to the set-ups.
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Operating manual
4. Instructions for use
Special flattening tool
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Enables/disables use of a special flattening tool.
(2)
Enables/disables execution of the first bend upwards.
(3)
Minimum thickness of the sheet metal.
(4)
Maximum thickness of the sheet metal.
(5)
Y position (with respect to the origin of the AXES of the machine) of the
reference bend, before forming the bend with the special flattening tool.
(6)
Z position (with respect to the origin of the AXES of the machine) of the
reference bend, before forming the bend with the special flattening tool.
(7)
Y position (with respect to the origin of the AXES of the machine) of the
reference bend, after forming the bend with the special flattening tool.
(8)
Z position (with respect to the origin of the AXES of the machine) of the
reference bend, after forming the bend with the special flattening tool.
(9)
Rotation (with respect to the origin of the AXES of the machine) of the
reference bend, before forming the bend with the special flattening tool.
(10)
Rotation (with respect to the origin of the AXES of the machine) of the
reference bend, after forming the bend with the special flattening tool.
(11)
Force to be exerted when using the special flattening tool.
(12)
Type of bend to be formed.
(13)
Number of bends to be formed.
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Operating manual
4. Instructions for use
Segments
Displays the status of the tool magazine. This screen is used to:
• Edit the existing segments.
• Delete the segment selected.
• Add new segments.
- 162 -
(1)
Tool width.
(2)
Number of tools available.
(3)
Code of the right-hand horn.
(4)
Code of the left-hand horn.
(5)
X position for inserting the ATA selector in the tool.
(6)
Y position for inserting the ATA selector in the tool.
(7)
Deletes the segment selected.
(8)
Adds a segment with the tool selected.
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Operating manual
4. Instructions for use
Die-holders
The Die-holders [Die-holders] section displays a list of the die-holders
present in the database and allows you to:
• Delete the die-holders from the database.
• Edit the characteristics of the die-holders.
• Define new die-holders.
If the Show unavailable tools option is enabled in the tab, the tools
that are available will be shown in black whereas those that are not
available will be shown in red.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
List of die-holders available.
(2)
Code identifying the tool selected.
(3)
Additional information associated with the tool selected.
(4)
Height of the die-holder.
(5)
Total height dimension of the die-holder.
(6)
Enables/disables availability of the tool. If this function is enabled, the tool
can be added to the set-ups.
(7)
Saves the modifications.
(8)
Imports a new tool from a drawing. See the paragraph on Import [} 168].
(9)
Deletes the tool selected.
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Operating manual
4. Instructions for use
Segments
Displays the status of the tool magazine. This screen is used to:
• Edit the existing segments.
• Delete the segment selected.
• Add new segments.
- 164 -
(1)
Tool width.
(2)
Number of tools available.
(3)
Code of the right-hand horn.
(4)
Code of the left-hand horn.
(5)
X position for inserting the ATA selector in the tool.
(6)
Y position for inserting the ATA selector in the tool.
(7)
Deletes the segment selected.
(8)
Adds a segment with the tool selected.
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Operating manual
4. Instructions for use
Punch-holders
The Punch-holders [Punch-holders] section displays a list of the
punch-holders present in the database and allows you to:
• Delete the punch-holders from the database.
• Edit the characteristics of the punch-holders.
• Define new punch-holders.
If the Show unavailable tools option is enabled in the tab, the tools
that are available will be shown in black whereas those that are not
available will be shown in red.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
List of the punch-holders available.
(2)
Code identifying the tool selected.
(3)
Additional information associated with the tool selected.
(4)
Point in which the top-beam applies its force to the tool.
(5)
Distance between the top of the punch-holder and the point in which it is
clamped to the machine.
(6)
Actual height of the punch-holder when using a punch where the force is
applied to the head.
(7)
Actual height of the punch-holder when using a punch where the force is
applied to the side.
(8)
Total height dimension of the punch-holder.
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Operating manual
4. Instructions for use
- 166 -
(9)
Enables/disables availability of the tool. If this function is enabled, the tool
can be added to the set-ups.
(10)
Saves the modifications.
(11)
Imports a new tool from a drawing. See the paragraph on Import [} 168].
(12)
Deletes the tool selected.
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Operating manual
4. Instructions for use
Segments
Displays the status of the tool magazine. This screen is used to:
• Edit the existing segments.
• Delete the segment selected.
• Add new segments.
B3.135-3000 - MB_0791 - 1.0 - en
(1)
Tool width.
(2)
Number of tools available.
(3)
Code of the right-hand horn.
(4)
Code of the left-hand horn.
(5)
X position for inserting the ATA selector in the tool.
(6)
Y position for inserting the ATA selector in the tool.
(7)
Deletes the segment selected.
(8)
Adds a segment with the tool selected.
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Operating manual
4. Instructions for use
Import
The Import [Import] section is used to import a new tool from a drawing
(file with the .dxf or .dwg extension).
To import a new tool, see the chapter on Importing a tool from a
drawing [} 205].
- 168 -
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Operating manual
4. Instructions for use
Actions
The Actions [Actions] tab displays:
• A list of the manual commands for activating special cycles and
moving the machine's AXES.
• A simulation of the movement of the manual command selected.
The composition of the following screen depends on the configuration of
the machine:
(1)
Functional group.
(2)
Movable organ.
(3)
Manual commands.
(4)
Runs the manual command selected.
(5)
Simulates the manual command selected.
(6)
Enables/disables the lights in the work area of the machine.
(7)
Enables/disables the closing of the tools (optional).
Enables/disables the release of the upper tools (optional).
Enables/disables the release of the lower tools (optional).
When a manual command is being run, all other commands are
disabled.
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Operating manual
4. Instructions for use
Messages
The Messages [Messages] tab displays the messages issued by the
control system to inform the user about the status of the machine and/or
ask him to intervene in order to continue with production.
Depending on what has been set in the Message notification
[Message Notification] section of the Settings [Settings] tab, the
messages can appear either in new windows or in a list in the previous
window.
All the messages are permanently memorized in dedicated files.
Each message is characterized by:
• Type of message (1). In area (4), select the types of message you
want to display.
– Errors [Errors]. Irrecoverable errors that usually require the
application to be restarted or Timeout errors [} 172].
– Warnings [Warnings]. An event commanded by a machine
automation cycle that did not occur within the expected time
frame.
– Messages [Messages]. Information about the status of the
machine that requires the user to intervene in order to continue.
– Information [Informations]. Information about the status of the
machine that does not require the user to intervene in order to
continue with production.
• Date and time of occurrence (2).
• Description (3).
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To sort the table according to a given characteristic, select the heading
of the column with that particular characteristic.
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4. Instructions for use
Timeout errors
The following screen appears when a timeout error occurs, i.e. when a
condition has either not occurred at all or when it has not occurred
within a given time limit.
- 172 -
(1)
Displays a list of the signals that have generated the timeout error.
(2)
Displays the code of the automation cycle, highlighting the lines where the
logical conditions expected did not occur.
(3)
If the cause of the problem has been removed, the automation cycle can
restart from the exact point in which it was suspended and production can
be continued.
(4)
Opens the wiring diagram at the page for the signal selected via the
EasyData application.
(5)
Activates a notepad on which you can write any notes about the date and
time when the problem occurred and the procedures that were used to
solve it.
(6)
Only available to ADMIN users.
(7)
Only available to ADMIN users.
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4. Instructions for use
Operator
The Operator [Operator] tab allows you to access the machine
documentation and other applications useful for managing production.
Touch-screen shortcut
Pressing your finger on an application in the Operator [Operator] tab
activates edit mode and displays the following icons:
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(1)
Closes the edit application mode.
(2)
Changes the application’s parameters.
(3)
Deletes the application from the tab.
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4. Instructions for use
User manuals
Displays the machine documentation, published in EasyData:
• Operating manual.
• Software and programming manual.
• Installation requirements.
Oil temperature
The Oil temperature [Oil temperature] function opens the application
for weekly management of the heating of the oil in the power packs.
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4. Instructions for use
File transfer
The File transfer [File Transfer] function is used to transfer production
programs and specific data between the machine workstation and other
workstations (typically those in the programming office).
NOTICE
The File transfer function must not be used to transfer generic files
between the workstations in the network. The commands offered by
the operating system must be used directly for this purpose.
(1)
List of the source computers.
(2)
Used to add a new computer.
(3)
Reloads the current screen.
(4)
Area for dragging the programs and/or groups of programs that you want to
transfer.
(5)
Starts transferring the objects selected, from the source computer to the
target computer.
(6)
Used to select the target computer.
To transfer files between two computers, follow the procedure described
in the chapter on Transferring programs between computers [} 207].
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4. Instructions for use
Adding a new host
The following screen is used to add a new computer to those already
connected to the local data network.
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(1)
Name of the computer.
(2)
Network path for the computer.
(3)
List of the machines managed by the computer.
(4)
Closes the screen without saving the changes.
(5)
Saves the changes and closes the screen.
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4. Instructions for use
Load/no-load operation
Used to define the mode of operation:
Load operation (with a sheet).
No-load operation (without a sheet).
EasyData
Please refer to the appropriate manual in the Software and
programing manual volume of the documentation.
PressStudio
Please refer to the appropriate manual in the Software and
programing manual volume of the documentation.
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4. Instructions for use
Settings
The Settings [Settings] tab is used to configure:
• Machine parameters.
• Option parameters.
• Interface display options.
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Backgauges
The Backgauges [Backgauges] tab defines the type of backgauge tip
to be used.
The following screen varies according to the model of backgauge used.
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4. Instructions for use
Barcode
The Barcode [Barcode] section defines the parameters for the barcode
scanner.
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(1)
Enables/disables use of the barcode scanner.
(2)
Number of characters that identify the name of the group.
(3)
Number of characters that identify the name of the program.
(4)
Number of characters that identify the quantity of panels to be produced.
(5)
Number of characters to be ignored.
(6)
Parameters for configuring the communication port for the barcode
scanner.
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(7)
Displays an example string.
(8)
Displays the string read by the barcode scanner.
(9)
Enables/disables the reading of the name of the program.
(10)
Enables/disables the reading of a given string.
(11)
Enables/disables the reading of a string that has not been defined but is
delimited by special characters.
(12)
Enables/disables the search for the program in the groups. Loads and
elaborates the first program found.
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4. Instructions for use
General
The General [General] section is used to set the language of the
interface and the system of measurement.
- 182 -
(1)
Customer’s name.
(2)
Only available to ADMIN users.
(3)
Sets the language in which the application and the messages are
displayed. Close and restart the control interface to make the language
selected effective.
(4)
Enables/disables use of the imperial system.
(5)
Enables/disables use of the metric system.
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4. Instructions for use
Line manager
The Line manager [Line manager] section is used to configure the
management of programs from a machine upstream.
(1)
Enables/disables in-line operation.
(2)
Number of the local server port.
(3)
Enables/disables the opening and starting of production of the program
from the machine upstream, in automatic mode.
Restart the control interface to make the enabling of the function (1)
effective. When production is next restarted, the Production
[Production] tab appears as the following screen:
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- 184 -
(4)
List of the programs received from the machine upstream.
(5)
Deletes the program selected in the list (4).
(6)
Deletes all the programs in the list (4).
(7)
Puts the program selected in the list (4) on standby.
(8)
Previews the panel selected.
(9)
List of the programs that have been run and are running.
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4. Instructions for use
Message notification
The Message notification [Message notification] section is used to
define the way in which the different types of message are displayed.
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(1)
Messages enabled as Popup notifications [Popup notifications] are
displayed on the screen in a separate window.
(2)
Messages enabled as Scrolling notifications [Scrolling notifications] are
displayed in the Message scroll bar [} 105].
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4. Instructions for use
Remote notification
The Remote notification [Remote notification] section is used to
manage notifications of messages generated by the control system.
- 186 -
(1)
Disables message notification.
(2)
Enables message notification.
(3)
Enables message notification only within a given time-frame.
(4)
The time-frame within which message notifications are received.
(5)
Enables message notification only if a signal has a given value.
(6)
Name of the signal, the value of which generates the message notification.
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4. Instructions for use
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(7)
Enables/disables message notification (11) when production has finished.
(8)
Enables/disables message notification (12) when a timeout error occurs.
(9)
Enables/disables message notification (13) when the machine needs to be
reset.
(10)
Enables/disables message notification (14) when a cycle message occurs.
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4. Instructions for use
Preferences
The Preferences [Preferences] section is used to edit the settings
shown in the following table.
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(1)
Enables/disables the display of the tools that are not available.
(2)
Enables/disables the display of the values of the angles as decimals.
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4. Instructions for use
Reset
The Reset [Reset] section is used to edit some of the functions relating
to resetting the machine.
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(1)
Enables/disables the request for confirmation before the reset is
performed.
(2)
Enables/disables the deletion of the messages when the reset is
performed.
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4. Instructions for use
Simulation
The Simulation [Simulation] section is used to manage the parameters
for the simulation.
- 190 -
(1)
Enables/disables the display of the parts of the machine while the program
is being simulated.
(2)
Enables/disables the display of the simulation centered on the panel.
(3)
If option (2) is enabled, indicates the free space around the panel.
(4)
Enables/disables full-screen display when the simulation starts.
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4. Instructions for use
Service
The Service [Service] tab contains information and functions useful for
customer service.
User access
The User access function is used to access the control interface as
another user.
User management
Only available to ADMIN users.
Service log
Only available to ADMIN users.
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4. Instructions for use
Close application
The Close application [Close application] function is used to close the
control interface.
(1)
Goes back to the previous page.
(2)
Closes the control interface.
(3)
Shuts down and restarts the control interface.
Applications at start-up
Only available to ADMIN users.
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4. Instructions for use
Events list
The Events list [Events List] function displays a list of all the events
that occur after the machine is turned on. Each event is characterized
by:
• Type of event (1).
• Date and time of occurrence (2).
• Description of the event (3).
• Answer from the user (4).
To sort the table according to a given characteristic, select the heading
of the column with that particular characteristic.
Minimize
The Minimize function iconizes the control interface window.
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4. Instructions for use
Restart shutdown
The Restart shutdown [Restart shutdown] function is used to shut
down or restart the computer of the control unit.
- 194 -
(1)
Goes back to the previous page.
(2)
Restarts the computer of the control unit.
(3)
Turns off the computer of the control unit.
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4. Instructions for use
4.1.6. Using the application
Logging in as another user
To access the control interface as another user, you must:
1. Tap the SERVICE [SERVICE] tab.
2. Tap the USER LOGIN [USER LOGIN] function.
3. Enter the user and the password.
If the data entered is correct, the control interface will open
automatically. Depending on the type of user, certain areas and
functions will be enabled/disabled.
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4. Instructions for use
Creating a new program
1. Select the NEW PROGRAM [NEW PROGRAM] tab. The following
screen appears:
2. Select the group containing the program.
3. Enter the name of the new program.
4. Tap button (1).
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4. Instructions for use
5. Enter the material of the sheet metal to be processed (2).
6. Enter the thickness of the sheet metal to be processed (3).
7. Enable/disable (4) the display of only those set-ups that can be
used with the thickness indicated, from among the existing set-ups.
8. Tap the existing set-up (5) or create a New set-up [} 198] (6).
9. Tap button (7) to continue creating the program via the control
interface (see ).
10. Tap button (8) to create the program with the Press Studio
application (please refer to the specific manual in the Software
and programming manual volume of the documentation). All of
the data just entered will be preloaded and, once it has been
configured, the program will be loaded in the control interface.
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4. Instructions for use
New set-up
When creating a new program, it is possible to create a new set-up.
1. Tap tab (1).
2. Tap the punch in section (2). You can filter the display by typing the
following values:
• A – Angle at the tip.
• R – Radius at the tip.
• H – Height.
3. Tap the die in section (3). You can filter the display by typing the
following values:
• V – V width.
• A – V angle.
• H – Height.
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4. Instructions for use
Loading and elaborating a program
1. Tap the group (1) containing the program to be elaborated.
2. Tap the program (2) to be elaborated.
3. Tap button (3) to elaborate the program.
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4. Instructions for use
4. The following screen appears:
5. The program has been elaborated successfully and is ready to be
run.
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4. Instructions for use
Editing a program
The modifications that can be made to a program are indicated in the
chapter on Editing the program [} 118].
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4. Instructions for use
Running a program
1. Loading and elaborating a program [} 199].
2. Tap button (1).
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4. Instructions for use
3. On the machine, form the bend highlighted in the parameters area
(2). The bend selected is simulated in the graphical display area
(3).
4. Form all the bends in the program sequence.
Button (4) is used:
To repeat the forming of the entire bend sequence for the program.
Not to repeat the forming of the bend selected.
To repeat the forming of the bend selected.
5. The program has been completed.
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4. Instructions for use
Simulating a program
1. Loading and elaborating a program [} 199].
2. Tap the graphical display area (1) to activate the Pie menu [} 109].
3. Tap Simulate [Simulation] in the pie menu to start simulating the
program.
Goes to the previous step in the simulation.
Starts the simulation in continuous mode (animated).
Interrupts the simulation.
Exits from simulation mode.
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4. Instructions for use
Importing a tool from a drawing
1. Tap the TOOLS [TOOLS] tab.
2. Tap the Import [Import] section.
3. Tap the input field (1) and select the file to be imported.
4. Tap Open [Open] to load the drawing.
5. Set the type of tool (2) that you want to import (die, punch, etc.). In
this way, the other information for the tool added will be displayed
too.
6. Fill in all the information for the tool added.
7. Tap Save [Save].
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4. Instructions for use
Changing the language of the application
interface
1. Tap the SETTINGS [SETTINGS] tab.
2. Tap the GENERAL [GENERAL] section.
3. Change the language (1).
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4. Instructions for use
Transferring programs between computers
1. Tap the OPERATOR [OPERATOR] tab.
2. Tap function (1).
3. Tap the source computer (2).
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4. Instructions for use
4. Tap the source machine (3).
5. Select the group of programs and/or the programs to be
transferred.
6. Drag the objects into the drag area (4).
7. Tap button (5).
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4. Instructions for use
8. Tap the target computer.
9. Tap the target machine.
10. Tap Copy [Copy] (6) to start the transfer.
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4. Instructions for use
Switching the control unit off
1. Close all previously activated applications.
2. The machine must not be in production.
3. Tap SERVICE > CLOSE APPLICATION > CLOSE to close the
control interface.
4. Tap SERVICE > RESTART SHUTDOWN > SHUTDOWN to turn
the control unit off.
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4. Instructions for use
4.1.7. Troubleshooting
Error while compiling the program
If section (1) appears at the end of the elaboration when you have
selected the button on the left, this means that the program contains
errors.
A program compilation error prevents production of the program from
starting (the START button does not appear in the interface).
Solution
1. Tap section (1).
2. Display the error.
3. To solve the error, edit the bending program (see the chapter on ).
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4. Instructions for use
Unable to create a new program
When creating a new program, if the error message (1) appears,
preventing the program from being created, this means that the
backgauges have not been set.
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4. Instructions for use
Solution
1. Tap OK to close the message.
2. In the navigation bar, tap the SETTINGS [SETTINGS] tab and then
the BACKGAUGES [BACKGAUGES] section.
3. Enter the details of the backgauges installed.
4. Go back to the procedure for creating a new program.
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4. Instructions for use
4.2. Control and signaling devices
4.2.1. Machine console
Figure 28: Reference P200 on the layout
(1)
Tool clamping/unclamping selector.
Tool clamping position
Tool release position
(2)
Ram movement selector.
Ram slow descent position.
Slow ram descent without the control of the AOPD safety
laser scanner.
Ram ascent position with UP pedal.
Press the UP pedal to raise the ram.
Ram automatic ascent position.
The ram automatically goes back up when pressing the
down pedal.
- 214 -
(3)
Emergency stop button.
(4)
Function disabled.
(5)
Control interface [} 95].
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4. Instructions for use
Slow mode warning device
WARNING
Crushing hazard.
The AOPD safety laser device is not active.
Precautions: take special care when performing operations, even
though the descent speed is slow.
The slow mode warning device is activated when the ram arrives at he
speed change point (see chapter Machine Operation [} 218]). It is used
to remind the operator that, when this device is active, the machine is
operating with the AOPD laser safety device disabled.
Figure 29: Slow mode warning device
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4. Instructions for use
4.2.2. Backgauge reset console
Figure 30: Reference P210 on the layout (the buttons may vary depending on the configuration)
(1)
RESETTING THE SAFETY DEVICE CIRCUIT
Illuminating button which restores machine operation after a safety stop as
a result of the photo-electric barriers being crossed and/or a guard opened).
(2)
- 216 -
Emergency stop button.
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4. Instructions for use
4.2.3. Pedal control device console
Figure 31: Reference P600 on the layout
(1)
FIRST PEDAL CONTROL DEVICE RESET
Illuminating button which restores machine operation after a safety stop as
a result of the photo-electric barriers being crossed and/or a guard opened)
or after an emergency stop.
(2)
RESTORE BALANCE
Button to perform alignment of the ram after an imbalance.
(3)
PEDAL CONTROL DEVICE ENABLED
This lamp, when lit, indicates that the device is enabled.
(4)
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Emergency stop button.
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Operating manual
4. Instructions for use
4.3. Operating modes
4.3.1. Machine Operation
The machine cycle starts with the ram stopped at Top Dead Center (1).
Pressing the DOWN pedal (Hold-to-run control device [} 223]) controls
the ram movement to Bottom Dead Center (3).
The procedures for moving the ram down and back up again depend on
the position of the ram movement selector (see Machine console
[} 214]).
(1)
Top Dead Centre (PMS)
(3)
Bottom Dead Center (PMI)
(2)
Speed change point (mute
point)
Figure 32: Machine operation
- 218 -
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4. Instructions for use
Mode 1: slow descent.
Ram movement selector in the
position:
• Slow downwards movement of the ram with the AOPD Laser safety
device disabled until reaching Bottom Dead Center (3).
• Automatic upwards movement of the ram to the programmed Top
Dead Center (1).
This mode can be selected by enabling a specific function from the
control interface.
Figure 33: Machine operation
WARNING
Crushing hazard.
The AOPD safety laser device is not active.
Precautions: take special care when performing operations, even
though the descent speed is slow.
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4. Instructions for use
Mode 2: automatic raising.
Ram movement selector in the
position:
• Fast descent of the ram, with the AOPD Laser safety device
enabled until reaching the speed change point (2).
• Slow downwards movement of the ram until reaching Bottom Dead
Center (3).
• Automatic upwards movement of the ram to the Top Dead Center
(1).
Figure 34: Machine operation
WARNING
Danger of cutting, impact with and/or crushing of the lower limbs.
During automatic raising of the ram, the sheet could fall when freed by
the grip between the tools.
Precautions: support the sheet during raising of the ram.
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4. Instructions for use
Mode 3: raising with pedal.
Ram movement selector in the
position:
• Fast descent of the ram, with the AOPD Laser safety device
enabled until reaching the speed change point (2).
• Slow downwards movement of the ram until reaching Bottom Dead
Center (3).
• Ram ascent controlled with the UP pedal up to top dead center (1).
Figure 35: Machine operation
Machining Cycle
When performing modes 2 and 3, from the control interface, the
following work cycles can be used:
• Stop at mute [Stop at mute]:: fast downward movement of
the ram to the speed change point, stopping of the ram and
conclusion of the bend by using the down pedal. This cycle
disables the rear beam of the AOPD Laser safety device and is
useful in the event of backgauge interference.
• Tray mode [Tray mode]:used during tray bending, which allows
the front beam of the photocells to be partially disabled; the cycle
obtained allows the ram to move down fast to the point of
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4. Instructions for use
obstruction due to the side that has already been bent, continuation
in fast mode to the speed change point, and the conclusion of the
bend.
• Soft returning [Soft returning]:: re-ascent of the ram after
the bend at reduced speed for the distance defined in the control
interface. During the slow movement stage the down pedal must be
pressed. When the pedal is released, the slow up movement stops
and restarts when the DOWN pedal is pressed again. Once the
slow up movement end position has been reached, the ram will
proceed at fast speed without waiting for the DOWN pedal to be
pressed (like the standard cycle).
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4. Instructions for use
4.3.2. Hold-to-run control device
WARNING
Danger of cutting, impact with and/or crushing of the lower limbs.
During automatic raising of the ram, the sheet could fall when freed by
the grip between the tools.
Precautions: support the sheet during raising of the ram.
(1)
Resume operation pedal
button
(2)
UP pedal
(3)
DOWN pedal
(4)
Rest position (not pressed).
(5)
Run position
(6)
Fully pressed position
Figure 36: Pedal control device
The UP pedal (2) is always active and when pressed it controls the UP
movement of the ram.
The DOWN pedal (3) has the following positions:
• Rest position (4): ram movement not enabled.
• Run position (5): controls the downward movement of the ram for
as long as it is pressed.
• Fully pressed position (6): immediately stops the ram’s downward
movement.
To resume ram movement controls:
– Release the DOWN pedal (3).
– Press the pedal button (1).
– Press the DOWN pedal (3) to position (5).
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4. Instructions for use
NOTICE
Simultaneous activation of the UP pedal (2) and the DOWN pedal
(3).
When activated at the same time, the UP pedal (2) has priority over
the DOWN pedal (3), in order to free anyone who may be trapped.
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4. Instructions for use
4.3.3. AOPD Laser safety device
From the , it is possible to select the operating mode of the AOPD laser
safety device, according to the kind of bend.
During program execution, the AOPD laser safety protection system
automatically switches between the different modes at the start of each
step.
Operating mode:
• Normal mode.
• Tray mode.
• Photocells disabled mode.
• Stop at speed change point (auxiliary mode).
Normal mode
When this mode is enabled, the whole width of the laser beam (front,
central and rear) is activated for detection of obstructions.
After the operator has confirmed the speed change point, the Normal
mode operation includes:
1. The approach of the punch to the part to bend, at high speed;
2. When the speed change point has been reached, the fast movement
becomes slow;
3. Bending the part with the guarding functions muted.
When the punch moves towards the workpiece, the laser detects
obstructions in front of the punch tip until it reaches the speed change
point, covering in this way the field in which the tools are allowed to
close at high speed. If an obstruction is detected at any point of the
down movement of the ram, the PCSS stops the ram. The 4220 status
code appears on the control interface indicating that the first obstruction
has been detected and stopping the down movement.
At this point, ram movement will depend on the following conditions:
• No other obstructions detected.
If the DOWN pedal is released and pressed again with no more
obstructions in the path, the ram will continue the down movement
at high-speed up to the speed change point;
• Other obstructions detected.
If the obstruction is detected again after the DOWN pedal down
has been released and pressed again, the ram down movement
will be prevented and the 4221 status code will appear on the
PCSS, indicating that a second interruption has been detected
causing the down movement to stop. Any further action by the
DOWN pedal will move the ram at slow speed until reaching the
speed change point, with the 4228 status code displayed to
indicate that only slow movement is allowed due to the second
detection of interruption in normal mode.
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If the single interruption detection option has been selected, when the
interruption is still being detected after releasing and pressing again the
DOWN pedal, the ram will descend to the speed change point only at
slow speed, with the 4228 condition code displayed on the PCSS. If,
however, after selecting the option for the forced detection of
interruption at slow speed, the obstruction is still detected after the
DOWN pedal has been released and pressed again, the ram movement
cannot continue until the obstruction is removed, with the 4221 status
code displayed on the PCSS each time the DOWN pedal is pressed
down. Once the speed change point has been reached, the stroke will
be completed at slow speed to bend the material.
The PCSS constantly monitors the speed change point position to
detect any changes in material thickness that can cause a dangerous
increase of the opening between the punch and material. In this
situation, the PCSS detects that the opening has increased beyond the
acceptable limits and will not allow the closing of the tools until the
speed change point has been calculated again according to the new
material thickness. The 4203 status code is displayed to indicate that no
material has been detected below the speed change point position.
In some situations in which large V openings of the die are used with
very thin material (less than 2 mm), the material may not be detected,
causing the down movement to stop and displaying the 4203 status
code. The operator will still be able to move the ram down after having
released and pressed the DOWN pedal again, but only at slow speed
and with the 4257 status code displayed.
Tray mode
To make boxes and/or trays, the two opposite side parts are bent first.
The workpiece is then turned horizontally so as to bend the two
remaining side parts. The two previously bent sides break the laser
beam and the system stops the ram movement. In this case, if the
system is in Normal mode, the PCSS interprets the interruption as an
obstruction and stops the ram. Leaving the part in its place and pressing
the DOWN pedal again, the down movement is prevented again by an
obstruction, which is considered as a second interruption. The ram will
move only after pressing the DOWN pedal again, but only at slow
speed, thus causing a loss of time.
Enabling tray mode eliminates this loss of time allowing the tools to
continue to run at high speed up to the speed change point. All the
segments (front, middle and rear) are active from the beginning of the
stroke up to the top of the side walls. When they reach the side walls,
the front and rear segments are deactivated for the rest of the stroke,
while the middle segment remains active.
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The part bending can therefore be completed in a single stroke without
stopping, despite external interruptions due to the sides of the
workpiece that have already been bent.
NOTICE
When the machine is stopped near an opening of 8 mm or less, the
detection for the front and rear segments has been deactivated and it
will only be allowed at slow speed due to the reduced protection
provided in tray mode.
To proceed with bending in tray mode, the operator must first confirm
this mode pressing the DOWN pedal, which will display the 4236 status
code on the PCSS. This code informs the operator that the down
movement has been stopped due to a height set in the tray mode on the
control interface and the operator must confirm before proceeding. The
operator is aware that the front and rear laser segments are disabled for
the next bend and the ram movement will continue at high speed
regardless of external interruptions. The central segment remains
always active and if an obstruction is detected, the 4223 status code
appears.
If an obstruction is detected above or below the side height
programmed for the box, tray mode will behave as if no tray height
value has been programmed.
Photocells Disabled mode
WARNING
Crushing hazard.
The AOPD safety laser device is not active.
Precautions: take special care when performing operations, even
though the descent speed is slow.
With this mode enabled, the laser is muted for the whole stroke and
therefore no optical protection is provided. Although the protection
system guarantees that the machine moves only at slow speed (10 mm/
s) in this mode, you must always pay due attention.
When changing from normal or tray mode to the photocells disabled
mode, you must press the DOWN pedal to confirm the mode change
before starting the next cycle. This confirmation appears on the control
interface. By pressing the DOWN pedal again, the tools close at slow
speed. The same applies when changing from the photocells disabled
mode to normal or tray mode.
The photocells disabled mode should only be used when it is not
possible to use other protected modes.
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Stop at Speed Change Point Mode
If this operating mode is enabled, the machine will always stop after
reaching the speed change point, thus alerting the operator to the need
to press the pedal again in order to proceed with the bending.
The 4224 status code appears on the control interface to inform the
operator that the ram has stopped at the speed change point due to the
selection of this mode. The operator of the bending press must
therefore release the DOWN pedal. By pressing it again, the ram will
proceed to complete the processing of the material. This mode is
particularly useful when the operator must reposition the material to be
bent.
Changing the value of the speed change point
When using Normal or Tray mode, the PCSSautomatically sets the
speed change point to 2 mm above the surface of the material,
according to the value of the material thickness. In some cases, when
the material is not flat but deformed of curved, the surface of the
material can go beyond the 2 mm of the speed change point. Any
material that exceeds the speed change point is detected by the laser
causing the ram to stop.
The user must confirm by pressing the down pedal once or twice to
complete the stroke at slow speed. To avoid these problems, you can
change the value of the speed change point via the . This value brings
the speed change point to the desired height in order to release the
material and to avoid interference with the laser beam.
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4.4. Switching on the machine
4.4.1. Procedure
1. Turn the main machine switch to the ON position and wait for the
operating system to start up.
2. Enter the access password and wait for the control interface to load
(follow any messages on the control interface).
3. Press the blue reset button on the pedal control device, see Pedal
control device console [} 217].
NOTICE
Before performing the operation, reset the machine.
4. Confirm start-up of the Machine resetting [} 233] cycle via the
control interface. On conclusion of the reset cycle, the machine will
be ready for production.
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4.5. Production
4.5.1. Starting production
See chapter Running a program [} 202] of the control interface.
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4.6. Resetting the machine
4.6.1. After activating the emergency stop button
1. Resolve the causes that have led to the activation of the
emergency stop button.
2. Reset the emergency stop button turning the actuator to the unlock
position or using the key (if present).
3. Press the blue reset button on the pedal control device, active.
4.6.2. After opening the rear guard
1. Close the rear guard or exit the beam of the optical barriers.
2. Press the blue RESET SAFETY DEVICE CIRCUIT button located
near the rear guard.
3. Press the blue reset button on the pedal control device, active.
4.6.3. After opening the side guards (both)
1. Close both side guards.
2. Press the blue reset button on the pedal control device, active.
4.6.4. After a ram imbalance
1. Press the yellow RESET IMBALANCE button on the console of the
pedal control device.
2. While holding down the yellow RESET IMBALANCE button, press
the blue reset button on the same console;
3. When the blue reset button switches off, release the blue button
only;
4. Keeping the yellow RESET IMBALANCE button held down, enable
the machine cylinders manual reset command in the control
interface.
5. After the reset operation has completed, release the yellow RESET
IMBALANCE button.
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4.7. Shutting off the machine
WARNING
Crushing and/or shearing hazard for the upper limbs.
If the machine is not used for a long time, the top-beam may drop.
Precautions: position two blocks above the lower toolholder so as to
prevent the top-beam from dropping.
1. Use the DOWN pedal to lower the ram onto the blocks of wood.
2. Switching the control unit off [} 210].
3. Turn the master machine switch to the OFF position.
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4.8. Setting up the machine
4.8.1. Machine resetting
The resetting procedure is used to find the “zero point” from which the
machine will start and to which reference is made to count its
movements.
Procedure
1. Restore all the safety devices and confirm any diagnostic
messages on the control interface.
2. If the machine has not yet been reset, and therefore it is only the
first time after turning on the electrical cabinet, a machine reset
request and confirmation request message is displayed.
Providing confirmation to this message starts the resetting phase,
in which all the enabled axes of the machine move in search of
their respective zero points.
3. Follow the messages on the control interface.
4.8.2. Bend angle measuring device reset
CAUTION
Danger of impact with upper limbs.
Precautions: pay particular attention to the movement of the bend
angle measurement device during the reset phase.
Automatic resetting
During the Machine resetting [} 233] procedure, the bend angle
measurement device is reset automatically.
Manual resetting
1. Open the Manual commands management application from the
control unit.
2. Select and enable the manual command which performs a reset of
the bend angle measurement device.
3. Confirm the reset movement (by pressing the descent pedal, see
Hold-to-run control device [} 223]).
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4.8.3. Tests on the AOPD laser safety device
The following three tests must be performed:
• On an annual basis with the punch installed on the entire length of
the machine.
• After any modification of the bending tool set-up.
(1)
Handle
Figure 37: Tester
Test 1: detection capability
Test the detection capability between the tip of the punch and the laser
beam (closest to the punch). The distance must be <= 14 mm along the
entire area of the punch.
The test must be performed using the handle (1) of the tester.
Test 2
A tester 10 mm thick, made of flexible material such as plastic, lying on
the die, must not be touched during the downward stroke of the punch.
In addition, a tester 15 mm thick must pass between the tools.
Test 3
A tester 35 mm thick, lying on the die, must not be touched during the
high-speed downward stroke of the top-beam.
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4.8.4. Tool Set-Up Procedure
WARNING
Cutting hazard.
The cutting edges of the tools and metal sheet may cause cutting
injuries.
Precautions:
- Wear protective gloves (see the chapter on Clothing and protective
equipment).
- Take special care when performing the operations.
- Respect the general safety rules.
WARNING
Impact and/or crushing hazard for the lower limbs.
The tools and metal sheet may cause impact and/or crushing injuries if
they fall.
Precautions:
- Wear safety shoes (see the chapter on Clothing and protective
equipment).
- Take special care when performing the operations.
- Respect the general safety rules.
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Automatic clamping/release
Procedure:
1. Turn the tool locking/unlocking selector to the tool unlocking
position (see Machine console [} 214]).
2. Press the tool (2) safety buttons (3).
3. Extract (1) the tool (2) vertically.
Figure 38: Upper tool-holder
Figure 39: Lower tool-holder
4. Insert the tool vertically.
5. Turn the release tools selector to the locked position.
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6. If the tools for the new set-up have a length different to those
previously installed, you must:
• Perform the alignment procedure for the AOPD Laser safety
device, as indicated in the specific chapter of OEM
Documentation – Appendix.
• Perform the Tests on the AOPD laser safety device.
NOTICE
For tools over 12 kg in weight, extract and insert the tools from the
side.
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4.8.5. Bending Techniques
The bending techniques are:
• Bending in air (1).
The punch forms the sheet giving it the angle defined in the
program, without reaching the bottom of the die slot. This kind of
bending achieves profiles with different angles using the same
tools. The precision depends on the residual elasticity of the
material.
• Coined bending (2).
The punch forms the sheet until it reaches the bottom of the die
slot. This type of bending is characterized by a high precision of the
angle obtained according to the tools used. The elasticity of the
material is canceled out as the material assumes the form of the
dies with the bending action.
Figure 40: Bending Techniques
Refer to chapter Bending Parameters [} 240] for usage.
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Bending Parameters
(S)
Sheet thickness (mm)
(B)
Minimum edge (mm)
(Ri)
Internal profile radius [mm]
(V)
Die opening [mm]
Figure 41: Bending Parameters
Formula for calculating air bending force:
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Material
Strength of material R [N/mm2]
Aluminum
200
Mild steel
420
Stainless steel
700
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Bending force calculation table
Figure 42: Bending force for air bending of mild steel sheet (R=420 N/mm2) and bend angle of 90°.
Bend angle [°]
Minimum edge (mm)
30°
B x 1.6
60°
B x 1.1
90°
B x 1.0
120°
B x 0.9
150°
B x 0.7
Table 2: Table for calculating the minimum edge with different bend angles.
Material
Inner radius Ri [mm]
Force F [kN/m]
Aluminum
Ri x 0.8
F x 0.5
Mild steel
Ri x 1.0
F x 1.0
Stainless steel
Ri x 1.4
F x 1.7
Table 3: Table for calculating force and inner radius for different materials.
Coined bending requires 4 or 5 times the force required for air bending:
V=S x 5; Ri=S x 0.4
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4.8.6. Factors influencing the precision of bends
Factors influencing the precision of bends are:
• Sheet thickness [} 242]
• Crowning (flexing) [} 243]
• Tool Condition [} 244]
Sheet thickness
Commercially available sheets may vary in thickness with respect to
their nominal thickness. These deviations can cause irregularities in the
nominal bend.
For example, with an air bend on a sheet of mild steel with strength R=
40 kg/mm2 and an angle of 90° in a V opening corresponding to 8 times
the thickness of the sheet, the irregularity is as follows:
• If the actual thickness of the sheet is greater than the nominal
thickness, the bend angle will be less.
• If the actual thickness of the sheet is lower than the nominal
thickness, the bend angle will be greater.
The irregularity will be approximately 1/20 rad or between 2° and 3° with
a difference in thickness of 0.1 mm for a V opening of 8 (sheet 1 mm
thick).
If the V opening is larger than 8 times the thickness, the bend angle
deviation will be smaller.
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Crowning (flexing)
Since the forces (1) are generated at the sides of the bending press, the
ram (2) and the lower tool-holder (3) are subject to flexing. The effect of
this flexing is a bending angle that is more open in the middle (4).
Figure 43: Crowning (flexing)
The larger the bending press, the greater the possibility of the structure
flexing. In these cases an automatic compensation system is used in
order to keep the bend angle value constant across the entire length of
the profile.
Automatic crowning (flexing) correction
The flexing is automatically offset by a system of wedges (6) under the
lower tool-holder. The corrective deformation to be made (5) is
calculated automatically as a function of various parameters of the
machine and of the material to be bent so that the bending angle is
constant over the entire length (7).
Figure 44: Automatic crowning correction
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Tool Condition
Bend accuracy and regularity also depends on tool condition.
You are advised to:
• Store tools with care.
• Not exceed the maximum admissible load.
• Check the accuracy of the tools in section.
The sum of tool tolerances should not exceed 0.1 mm. With this
tolerance, the angle can deviate by 2° when a small V-die is used.
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4.9. Troubleshooting
WARNING
Danger of injury to the operator.
In the event of a machine stop due to an error condition that calls for
an intervention on the machine, the production operator must take no
direct action other than requesting the intervention of the competent
personnel (see Qualification and training of the personnel [} 14]).
4.9.1. Machine stop
A machine stop can be caused by:
• Emergency stop: pressing one of the emergency stop buttons (see
chapter Emergency stop buttons [} 67]).
DO NOT use the emergency stop buttons for normal stopping of the
machine.
• Opening both side guards (see chapter Side guard [} 59]).
• Opening/cut off of theRear guard.
•
Stop push button: pressing this push button from the cuts off
production instantly.
4.9.2. AOPD Laser safety device
PCSS messages and status codes
During operation, the PCSS constantly monitors the critical safety
functions of the bending press. The PCSS generates the status codes
that are then displayed on the control interface as text messages.
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Classification of status codes
The PCSS status codes are four-digit alphanumeric codes. These
codes are divided into three categories.
• [I] – Information.
These inform the operator of a series of statuses that occur during
the normal operation. These codes do not require any action by the
operator.
• [OA] - Operator action:
These indicate events which require a specific action by the
operator so that the bending press can continue to operate.
• [SA] - Service action:
These inform the operator that the PCSS has detected a fault
condition in the bending press that may cause an emergency stop.
Many service action [SA] codes can be deleted by pressing the
reset button once or twice. If the fault status persists, the PCSS
displays the status code again. In this case, you should contact
customer service to correct the fault status. If you cannot delete a
service action code [SA] via the reset button, cut off the power
supply to machine for at least 5 seconds and then restore it.
NOTICE
All status codes, (information, operator action or service action,
which are not deleted after resetting and/or shutting down and
restarting the machine, must be reported to the Salvagnini
customer service department.
List and description of status codes
Status code
00CA [I]
Description
Left-hand side guard open.
When the left-hand side guard of the bending press is open, the PCSS allows the ram
to move down only at slow speed. If the other guard is opened too, the system performs
an emergency stop. In this status, the machine cannot be started up until at least one of
the two side guards is closed.
00CB [I]
Rear guard open or optical barrier broken.
When the rear guard/optical barrier of the bending press is open/broken, the PCSS
activates the emergency stop status. In this status, the machine cannot be started up
until the rear guard/optical barrier is closed/reset. To delete the code and continue the
processing, press the reset button.
00CC [I]
Emergency stop button activated.
When you press an emergency stop button on the bending press, the PCSS activates
the emergency stop status. In this status, the machine cannot be started up until the
emergency stop button is released. To delete the code and continue the processing,
press the reset button.
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Status code
00D2 [I]
Description
Tools released.
This signals that the clamping (hydraulic or pneumatic) of the tools (lower, upper or
both) is not active, therefore the tools are free and the ram down movement is not
allowed. To delete the code and continue the processing, lock the tools via the
dedicated command and wait for the pressure switch (hydraulic or pneumatic one) to
confirm the closing of the tools.
00D3 [I]
Pump start-up error.
Incorrect start-up sequence on the main hydraulic pump has been reported in the event
of installations with hydraulic technology. Check the electrical system of the bending
press; to delete the code and continue the processing, press the reset button.
00D6 [I]
Right-hand side guard open.
When the right hand side guard of the bending press is open, the PCSS allows the
descent of the ram only at slow speed. If the other guard is opened too, the system
performs an emergency stop. In this status, the machine cannot be started up until at
least one of the two side guards is closed.
00FA [I]
Y1 encoder error.
This indicates a fault while detecting the position of the left-hand cylinder/screw of the
bending press ram; the detection is performed by means of an optical scale fitted on the
left-hand side of the ram itself. Check the wiring and the operation of the left-hand
optical scale; to delete the code and continue the processing, press the reset button.
00FB [I]
Y2 encoder error.
This indicates a fault while detecting the position of the right-hand cylinder/screw of the
bending press ram; the detection is performed by means of an optical scale fitted on the
right hand side of the ram itself. Check the wiring and the operation of the right-hand
optical scale; to delete the code and continue the processing, press the reset button.
00FC [I]
Y1 encoder power supply error.
This indicates a fault in the power supply to the optical scale fitted on the left-hand side
of the ram. Check the wiring and the operation of the left-hand optical scale; to delete
the code and continue the processing, press the reset button.
00FD [I]
Y2 encoder power supply error.
This indicates a fault in the power supply to the optical scale fitted on the right-hand
side of the ram. Check the wiring and the operation of the right-hand optical scale; to
delete the code and continue the processing, press the reset button.
00FF [I]
Dual channel fault for the perimeter gates open/closed signal (robotic system).
It signals a fault (simultaneity check) in the connection of the gates closed signal on the
system integrated with robot. Check the wiring of the series of limit switches on the
gates of the robotic cell; to delete the code and continue the processing, press the reset
button.
0100 [I]
Dual channel fault for the panic pedal signal.
It signals a fault (simultaneity check) in the connection of the panic signal (DOWN pedal
fully pressed). Check the wiring of the pedal control device (or devices); to delete the
code and continue the processing, press the reset button.
0101 [I]
Dual channel fault for the emergency signal.
It signals a fault (simultaneity check) in the connection of the signal of the emergency
buttons series. Check the wiring of the consoles and the control unit; to delete the code
and continue the processing, press the reset button.
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Status code
0102 [I]
Description
Plausibility error for TM dead-man signals (robotic system).
It signals a fault (simultaneity check) in the connection of the signal on the dead-man
buttons in the portable terminal of the robot (robotic system). Check the wiring of the
portable terminal of the robot; to delete the code and continue the processing, press the
reset button.
0103 [I]
Bending press side guards are not closed properly (robot system).
Bending press side guards check is signaled when the system is used with external
integrated robot. Check the wiring of the bending press side guards; to delete the code
and continue the processing, press the reset button.
0104 [I]
Robot cell guards open signal (robotic system).
It signals the opening of the robotic cell guarding, with external integrated robot. Check
the wiring of the robotic cell guarding; to delete the code and continue the processing,
press the reset button.
0105 [I]
Bending-flattening tool bypass circuit fault.
It signals that the pneumatic door opening circuit of the bending-flattening tool has a
fault on the bypass return signal. Check the wiring of the bending-flattening tool circuit,
contact the customer service department; to delete the code and continue the
processing, press the reset button.
0106 [I]
Punch clamping fault.
It signals that the punch clamping circuit has a fault on the return signal of the pressure
control. Check the wiring of the tool clamping circuit, contact the customer service
department; to delete the code and continue the processing, press the reset button.
0107 [I]
Die clamping fault.
It signals that the die clamping circuit has a fault on the return signal of the pressure
control. Check the wiring of the tool clamping circuit, contact the customer service
department; to delete the code and continue the processing, press the reset button.
0118 [I]
UP pedal fault.
It signals that the UP pedal control circuit has a fault on the redundancy signal (mutual
exclusivity). Check the wiring of the pedal control device (or devices), contact the
customer service department; to delete the code and continue the processing, press the
reset button.
0119 [I]
Bending-flattening tool pressure sensor fault.
It signals that the pressure-switch that controls the opening of the bending-flattening
tool circuit has a fault (or lack of pressure). Check the wiring of the bending-flattening
tool circuit, contact the customer service department; to delete the code and continue
the processing, press the reset button.
011A [I]
Bending-flattening tool safety valve fault.
It signals that the return signal of the safety valve of the bending-flattening tool circuit
has a fault. Check the wiring of the bending-flattening tool circuit, contact the customer
service department; to delete the code and continue the processing, press the reset
button.
403E [OA]
Anti-repeat still active. Release DOWN pedal.
This code indicates that the anti-repeat function is still active and prevents the operation
of the tools. Release the DOWN pedal. Press the DOWN pedal again to continue
working. If the down pedal is released and pressed too quickly, the anti-repeat function
remains active. In this case, you should briefly alternate the action on the pedal.
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Status code
4080 [OA]
Description
Start-up test stop. Test 1 OK. Release DOWN pedal.
This code indicates that the PCSS has started a startup test to check the time or
stopping capacity of the machine and that the test has been successful. When the
machine stops, release the DOWN pedal. Press the UP pedal to allow the ram to carry
out the second start-up test.
4081 [OA]
Start-up test stop. Test 2 OK. Release DOWN pedal.
This code indicates that the PCSS has started a startup test to check the time or
stopping capacity of the machine and that the test has been successful. When the
machine stops, release the DOWN pedal. Press the DOWN pedal again to continue
working.
4089 [OA]
Machine stop for stop test. Release DOWN pedal.
This code indicates that the PCSS has started an automatic stop test to check the
stopping capacity of the machine and that the test has been successful. When the
machine stops, release the DOWN pedal. Press the DOWN pedal again to continue
working.
40A0 [OA]
Down movement not permitted. Pump not running.
This code indicates that the machine cannot be activated because the hydraulic pump
is not working. Start up the hydraulic pump.
40A1 [I]
Down movement not permitted. Machine not ready.
This code indicates that the machine cannot be activated because the machine control
system has not sent the machine ready signal to the PCSS. This may be due to one of
the following reasons:
• Y axes not in position.
• Machine backgauges not in position.
• Control interface not active.
• The control interface is displaying a status or error message.
For further details, consult the control interface manual.
4200 [OA]
No movement detected. Press reset error.
This status occurs when the PCSS does not detect any movement despite the
activation of the DOWN pedal. Press the reset button to delete the code and continue
the processing.
4203 [OA]
No material detected. Raise the ram and reposition the material.
This code indicates that the PCSS has not detected any material in the expected
position. The position for the material is calculated on the basis of the information
received from the control interface relating to the height of the tools, the material
thickness and the distance between the laser and punch. The PCSS expects an
interruption of the laser beam near the position calculated for the material. If the
material is not detected in the calculated position, the closing of the tools stops. To
continue processing, raise the ram and reposition the material. If this status is reported
again, check as follows:
• Check that the laser is set at the correct distance below the punch tip.
• Check that the actual material thickness is the same as the one selected in the
control interface.
• Check that the tools are the same as the ones selected in the control interface.
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4. Instructions for use
Status code
4204 [OA]
Description
No movement detected. Press reset error.
This status occurs when the down movement starts and stops unexpectedly and the
PCSS does not detect any other down movement. Press the reset button to delete the
code and continue the processing.
4207 [OA]
The opening is too low to perform the Start-up test.
During the start-up tests performed after switching on the machine, the PCSS checks
the opening height of the tools. Check that the tools are fully open.
420D [OA]
No movement detected at slow speed. Press reset error.
This status occurs when the PCSS does not detect any movement despite the
activation of the DOWN pedal at slow speed. Press the reset button to delete the code
and continue the processing.
4220 [OA]
Stop by the first interruption of the laser beam. Release DOWN pedal.
This code indicates the interruption of the laser beam and the consequent machine
stop. When the machine stops, release the DOWN pedal. Press the DOWN pedal again
to continue working. The processing will continue at high speed if the laser is not
interrupted.
If there are no parts obviously interrupting the laser beam (such as a workpiece or the
operator's hand), check as follows:
• Check that the laser emitter and receiver are correctly aligned.
• Check that the laser is set at the correct distance below the punch tip.
• Clean the emitter in the laser beam emission zone and the receiver in the reception
zone.
• Check that there is no turbulence and/or drafts which could interfere with the laser
beam (see chapter Distortion of the laser beam).
4221 [OA]
Stop by the second interruption of the laser beam. Release DOWN pedal.
This code indicates the detection of a second laser beam interruption that causes the
machine to stop. When the machine stops, release the DOWN pedal. Press the DOWN
pedal again to continue working. The stroke continues at slow speed with the optical
detection function deactivated.
If there are no parts obviously interrupting the laser beam (such as a workpiece or the
operator's hand), check as follows:
• Check that the laser emitter and receiver are correctly aligned.
• Check that the laser is set at the correct distance below the punch tip.
• Clean the emitter in the laser beam emission zone and the receiver in the reception
zone.
• Check that there is no turbulence and/or drafts which could interfere with the laser
beam (see chapter Distortion of the laser beam).
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4. Instructions for use
Status code
4222 [OA]
Description
Stop by external interruption of the laser beam. Release DOWN pedal.
This code indicates the detection of a laser beam interruption by the front or rear sensor
in tray/box mode, which causes the machine to stop. When the machine stops, release
the DOWN pedal. Press the DOWN pedal again to continue working. Processing
continues at high speed if the laser middle sensor is not interrupted.
If there are no parts obviously interrupting the laser beam (such as a workpiece or the
operator's hand), check as follows:
• Check that the laser emitter and receiver are correctly aligned.
• Check that the laser is set at the correct distance below the punch tip.
• Clean the emitter in the laser beam emission zone and the receiver in the reception
zone.
• Check that there is no turbulence and/or drafts which could interfere with the laser
beam (see chapter Distortion of the laser beam).
4223 [OA]
Stop by middle interruption of the laser beam. Release DOWN pedal.
This code indicates the detection of a laser beam interruption by the middle sensor in
tray/box mode, which causes the machine to stop. When the machine stops, release
the DOWN pedal. Press the DOWN pedal again to continue working. The stroke
continues at slow speed with the optical detection function deactivated.
If there are no parts obviously interrupting the laser beam (such as a workpiece or the
operator's hand), check as follows:
• Check that the laser emitter and receiver are correctly aligned.
• Check that the laser is set at the correct distance below the punch tip.
• Clean the emitter in the laser beam emission zone and the receiver in the reception
zone.
• Check that there is no turbulence and/or drafts which could interfere with the laser
beam (see chapter Distortion of the laser beam).
4224 [OA]
Stopping at speed change point. Release DOWN pedal.
This happens when a stop near the speed change point has been selected in the
control interface, which causes the machine to stop on reaching this point. When the
machine stops, release the DOWN pedal. Press the DOWN pedal again to continue
working. Processing continues at slow or working speed (depending on the height of
the tool opening) with the optical detection function deactivated.
4225 [OA]
Confirm photocells disabled mode. Release DOWN pedal.
When the operation mode is changed from Normal or Tray/Box to Photocells Disabled
or from Photocells Disabled to Normal or Tray/Box, the PCSS prompts the operator to
press the DOWN pedal to confirm the mode change. Release the DOWN pedal. Press
the DOWN pedal again to continue working.
4226 [OA]
Stopping caused by opening the side guard. Release DOWN pedal.
This code indicates that a side guard was opened while the tools were closing. This
causes the machine to stop. When the machine stops, release the DOWN pedal. Press
the DOWN pedal again to continue processing at slow speed.
4227 [I]
Slow speed due to photocells disabled mode.
This means that the PCSS has forced the ram to move at slow speed, in photocells
disabled mode, with the optical detection function deactivated.
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4. Instructions for use
Status code
4228 [I]
Description
Slow speed due to the second interruption.
It indicates that, in Normal mode, the PCSS has detected a second interruption of the
laser beam on the same stroke. The PCSS has forced the ram to close at slow speed
with the optical detection function deactivated.
4229 [I]
Slow speed due to middle interruption.
It means that, in Tray/Box mode, the PCSS has detected an interruption of the middle
sensor. The PCSS has forced the ram to close at slow speed with the optical detection
function deactivated.
422A [I]
Slow speed due to side guard open.
It means that the PCSS has forced the ram to close at slow speed, in any mode, with a
side guard opened.
422B [I]
Slow speed due to muted guard.
This code indicates that the optical detection function is deactivated and that the PCSS
has forced the ram to close at slow speed because the speed change value set by the
control interface is higher than the one calculated by the PCSS.
422D [OA]
Operator mode changed. Press reset error.
This code indicates that the selection of the operator mode in the control interface has
been changed.
4230 [OA]
Emergency stop condition. Press reset error.
This code indicates that an emergency stop status is still active. Press the reset button
to delete the code and continue processing.
4236 [OA]
Stopped for height confirmation. Release DOWN pedal.
This occurs if the upwards parameter has been programmed in the control interface in
Tray/Box mode. The PCSS prompts the operator to press the DOWN pedal to confirm
this operation. Release the DOWN pedal. Press the DOWN pedal again to continue
working.
423F [I]
Slow speed due to no machine reset.
This code indicates that the Y axes of the ram have not been reset and that the PCSS
has forced the tools to close at slow speed with the optical detection function
deactivated.
4241 [OA]
Stop by the first interruption. Release DOWN pedal.
This code indicates the detection of a laser beam interruption by the front or rear sensor
in Tray/Box mode, which causes the machine to stop. When the machine stops, release
the DOWN pedal. Press the DOWN pedal again to continue working. Processing will
continue at high speed if the middle sensor of the laser is not interrupted.
If there are no parts obviously interrupting the laser beam (such as a workpiece or the
operator's hand), check as follows:
• Check that the laser emitter and receiver are correctly aligned.
• Check that the laser is set at the correct distance below the punch tip.
• Clean the emitter in the laser beam emission zone and the receiver in the reception
zone.
• Check that there is no turbulence and/or drafts which could interfere with the laser
beam (see chapter Distortion of the laser beam).
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4. Instructions for use
Status code
4242 [OA]
Description
Stop by the second interruption. Release DOWN pedal.
This code indicates the detection of a laser beam interruption by the front or rear sensor
in Tray/Box mode, which causes the machine to stop. When the machine stops, release
the DOWN pedal. Press the DOWN pedal again to continue working. Processing will
continue at high speed if the middle sensor of the laser is not interrupted.
If there are no parts obviously interrupting the laser beam (such as a workpiece or the
operator's hand), check as follows:
• Check that the laser emitter and receiver are correctly aligned.
• Check that the laser is set at the correct distance below the punch tip.
• Clean the emitter in the laser beam emission zone and the receiver in the reception
zone.
• Check that there is no turbulence and/or drafts which could interfere with the laser
beam (see chapter Distortion of the laser beam).
4243 [I]
Slow speed due to the second interruption.
This indicates that, in Tray/Box mode, the PCSS has detected a second interruption of
the laser beam on the same stroke. The PCSS has forced the tools to close at slow
speed with the optical detection function deactivated.
Operation with distortion of the laser beam
Distortion of the laser beam
NOTICE
Under no circumstances will laser distortion in any way reduce
the level of safety and reliability provided by an AOPD laser
safety device.
In most cases the distortion due to air effects has no impact on the
operation of the AOPD laser safety device. Robust software algorithms
in the PCSS-A control system (in the receivers) are designed to operate
reliably over a wide range of environmental conditions, and will
effectively differentiate between distortion effects and actual
obstructions.
Only in extreme conditions can distortion affect the operation of the
AOPD laser safety systems. See chapter Possible Solutions [} 255] for
operation in these conditions.
Operation of the protection systems will also be affected if the distortion
changes as the tools are closing. This can be interpreted as an obstacle
and the safety controller will stop the movement of the ram. If the
distortion continues, the machine will only be allowed to move down in
slow speed, with the guarding muted.
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4. Instructions for use
The software in the receiver processes the image of the tool shadow
and detects the position of the tool tip. Under normal circumstances this
provides the best possible alignment for maximum safety and
productivity.
The figure below shows that the true size of the punch (1) is enlarged
by the distortion, and the image (2) seen by the receiver camera does
not accurately define the tool tip position.
(1)
Real punch image
(2)
Distorted punch image
Figure 45: Tool image distortion
In extreme cases, distortion that is constantly changing due to airflow
across the tool may also make it difficult (or impossible) for the receiver
to complete the tool alignment process that is required before the
system can operate.
A difference in temperature between the inside and the outside of the
bending press will cause airflow between the tools. Near the pinch point
this airflow is concentrated and increases in speed and turbulence as
the opening between the tools closes. This may lead to localized, fluid
distortion around the tool tip, as shown in the figure below.
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4. Instructions for use
Figure 46: Laser distortion caused by air flow as tools close.
The different light patterns can cause intermittent interruptions which
occur near the speed change point.
Possible Solutions
During normal operation, the laser receiver protects a region around the
tool tip as shown in the figure below. The camera pixel resolution is
2x2mm. If an object larger than 2 mm x 2 mm is detected in the
protected zone, it is considered an obstruction and the ram stops.
Figure 47: Tool tip protection zone.
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4. Instructions for use
When laser distortion (or other extreme environmental factors) is
present, the possible solutions are:
• Modification of the algorithms used by the laser to improve
distortion tolerance.
• Modification of the speed change point (increase from a minimum
of 2 mm to a maximum of 4mm above the pinching point).
Please contact Salvagnini Customer Service for support in configuring
these options.
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4. Instructions for use
4.9.3. Procedure for freeing any parts trapped between tools
The condition of the blue illuminated reset button, located on the
enabled pedal control device (see Pedal control device console [} 217]),
determines the actions to be perform to raise the ram.
CONDITION
ACTION
Off
1. Press the UP pedal.
On
1. Read the messages on the control interface to identify
the origin of the emergency.
2. Remove the causes of the emergency:
– Close the guards.
– Restore the optical barriers.
– Reset the emergency stop buttons.
3. Press the illuminated blue reset button on the enabled
pedal control device.
4. Follow the instructions of any messages on the control
interface.
5. Press the UP pedal.
4.9.4. Troubleshooting
Problem
Cause
The machine is turned off.
Black-out
Solution
1. Turn the master switch to
OFF.
2. Proceed as described in the
chapter on Switching on the
machine [} 229].
The bend angle measurement
device (AMS) is seen to be dirty.
Proceed as indicated in the chart
on Cleaning the bend angle
measuring device [} 270].
The AOPD safety laser device is
visibly dirty.
Proceed as indicated in the
information sheet Clean the AOPD
laser safety device [} 276].
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5. Maintenance
5. Maintenance
5.1
5.2
5.2.1
5.3
5.4
5.5
5.5.1
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
General information...................................................................................................
Organizing maintenance interventions ......................................................................
Contents of the maintenance sheet...........................................................................
Using Salvagnini Maintenance Manager...................................................................
Access procedure......................................................................................................
Maintenance task ......................................................................................................
Accessing high areas ................................................................................................
Weekly maintenance .................................................................................................
Cleaning the bend angle measuring device ..............................................................
Monthly maintenance ................................................................................................
Check the oil level in the toolholder hydraulic unit ....................................................
Clean the electrical cabinet filters..............................................................................
Clean the AOPD laser safety device .........................................................................
Three-monthly maintenance......................................................................................
Lubricating the backgauges ......................................................................................
Maintenance every 100 hours of operation ...............................................................
Replacing the cartridge of the oil filter on the hydraulic unit......................................
Maintenance every 500 hours of operation ...............................................................
Replacing the cartridge of the oil filter on the hydraulic unit......................................
Maintenance every 6000 hours of operation .............................................................
Change the hydraulic fluid.........................................................................................
Non-scheduled maintenance.....................................................................................
Top up the oil in the toolholder hydraulic unit............................................................
Special maintenance .................................................................................................
Replacing the cartridges of the hydraulic unit's pump protection filters ....................
Conclusion of maintenance task ...............................................................................
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261
263
265
266
266
266
267
270
270
272
272
274
276
278
278
283
283
286
286
289
289
292
292
295
295
297
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5. Maintenance
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5. Maintenance
5.1. General information
Correct preventive maintenance is essential if you want to ensure the
perfect operation and long working life of this machine.
• The equipment needed to perform maintenance tasks on the
machine is that which is normally provided in a mechanical and
electrical maintenance department.
Customers in countries where imperial units of measurement are used
must equip themselves with metric measurement tools.
• Observe the general safety regulations, the safety instructions
given in this manual and the requirements of local authorities.
• Handle oils and greases with care (refer to the specific safety data
sheet provided as an annex in the OEM documentation Appendix) volume of the documentation), and always ensure
maximum cleanliness.
• The contractually agreed warranty does not relieve the owner or
manager of the need and obligation to carry out the required
periodic preventive maintenance right from the time of initial
startup.
Routine maintenance
Both programmed and non-programmed routine maintenance includes
the following tasks:
• Inspection.
• Cleaning.
• Lubrication.
• Replacement.
which keep the efficiency of the machine unaltered while minimizing
unproductive times.
The frequency of programmed interventions refers to normal operating
conditions, which comply with the conditions of use provided for and
established in the contract.
Special maintenance
Special maintenance includes the following tasks:
• Repair.
• Adjustment.
• Replacement.
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5. Maintenance
which allow the machine to continue to operate under normal conditions
of use.
Special maintenance can only be performed by Salvagnini technicians
or technicians authorized by Salvagnini. This type of intervention needs
in-depth, specialist knowledge of the machines, of the operations
required, the risks connected with the same and the correct procedures
for operating under safe conditions (see chapter on Qualification and
training of the personnel [} 14]).
In the event of special maintenance, the user's regular maintenance
personnel must contact the manufacturer or authorized service center
who will evaluate the specific situation and chose the most appropriate
intervention solution.
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5. Maintenance
5.2. Organizing maintenance interventions
Maintenance operations are described on sheets divided by time.
Each maintenance sheet is marked by an alphanumeric code
specifying:
• Type of operation.
• Frequency.
• Progressive number.
Type of operation
The type of operation indicates the nature, organization and
responsibility of the maintenance operation.
Code
Description
I*
Scheduled routine inspection task.
M*
Scheduled routine maintenance task.
EM*
Non-scheduled routine maintenance task.
SM*
Non-scheduled extraordinary maintenance task.
Frequency
The frequency indicates how often the scheduled maintenance
operation is to be performed, on the basis of:
• Calendar.
• Hours of operation.
Code
Description
*D*
Daily / each change of shift.
*W*
Weekly.
*M*
Monthly.
*B*
Two-monthly.
*T*
Three-monthly.
*Q*
Four-monthly.
*S*
Six-monthly.
*Y*
Yearly.
*nY*
Every “n” years.
*n-*
Every “n” hours of operation.
Progressive number
The progressive number identifies the maintenance operation. It does
NOT indicate the order in which to perform the operation.
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5. Maintenance
Code
Description
*1
Maintenance operation no. 1.
*2
Maintenance operation no. 2.
*3
Maintenance operation no. 3.
*...
Maintenance operation no. ...
Examples
Designation
[M1000-n]
Scheduled routine maintenance operation to be
performed every 1000 hours of operation, number n.
[IDn]
Scheduled routine inspection operation to be performed
daily, number n.
[MYn]
Scheduled routine maintenance operation to be
performed yearly, number n.
[MMn]
Scheduled routine maintenance operation to be
performed monthly, number n.
[EMn]
Non-scheduled routine maintenance operation, number n.
[SMn]
Non-scheduled special maintenance operation, number n.
[MWn]
Scheduled routine maintenance operation to be
performed weekly, number n.
[M500-n]
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Description
Scheduled routine maintenance operation to be
performed every 500 hours of operation, number n.
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5. Maintenance
5.2.1. Contents of the maintenance sheet
Frequency
(Sheet code and frequency of the maintenance operation).
Duration
(Estimated time required to perform the maintenance operation).
Machine operating mode
(Machine status).
Safety devices involved
(List of safety devices the operator is required to work on during the
maintenance operation).
Number of operators
(Number of operators required for the maintenance operation).
Operator qualifications
(Qualifications required for the maintenance operation).
Personal protective
equipment
(PPE required for the maintenance operation).
Equipment
(List of equipment needed to perform the maintenance operation which is not
normally readily available in a mechanical and electrical maintenance
department).
Materials
(List of lubricants and/or spare parts required to perform the maintenance
operation).
Zone of intervention
(Image showing the area in which the maintenance operation is to be
performed).
Instructions:
(Operational sequence for the maintenance operation).
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5. Maintenance
5.3. Using Salvagnini Maintenance Manager
Salvagnini Maintenance Manager is the application that manages the
maintenance of the machine. For further information please refer to the
appropriate manual in the Software and programing manual volume
of the documentation.
5.4. Access procedure
To access the machine in a safe manner, the information provided in
chapter must be followed.
5.5. Maintenance task
WARNING
Danger of injury to the operator.
Precautions: during the maintenance task it is mandatory to use
appropriate personal protective equipment (see the chapter on
Clothing and protective equipment) and respect the general accident
prevention regulations.
• Inform the personnel assigned to production before starting the
maintenance task.
• For maintenance operations performed with the machine switched
off, perform the Lockout and release procedure (Lockout/Tagout)
[} 69].
NOTICE
Damage to the machine due to undefined/incorrect position.
An undefined/incorrect position is when machine parts are moved, with
the machine switched off, to positions that cannot be normally reached
or to positions that are unknown to the control system and therefore
dangerous.
Precautions: do not move machine parts manually unless explicitly
required by the maintenance task procedure.
• For maintenance operations performed in the upper sections of the
machine, access to the work area must be gained using
appropriate equipment.
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5. Maintenance
5.5.1. Accessing high areas
Accessing the Upper Sections of the Machine
Safety devices involved
• Safety line.
• Anchor points.
• Connectors.
Number of operators
2
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
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Ladder.
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5. Maintenance
Instructions:
WARNING
Fall hazard for the operator.
1. Position the ladder near the machine on a strong, level, stable and
immobile surface of suitable size to ensure that the rungs are and
remain horizontal.
2. While operative no. 1 holds the bottom of the ladder, operative no.
2 fastens the ladder to the anchor points (1) with suitable
connectors.
3. Operator no. 2 climbs up the ladder.
4. Operator no. 2 fastens the safety harness to the safety line (2) with
suitable connectors.
5. On conclusion of the operation, while operator no. 2 climbs down
the ladder, operator no. 1 must hold the bottom of the ladder.
Figure 48: Accessing the Upper Sections of the Machine.
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5. Maintenance
5.6. Weekly maintenance
Cleaning the bend angle measuring device
Frequency
[MW1] Weekly.
Duration
Machine operating mode
Machine off (see chapter Lockout and release procedure (Lockout/Tagout)
[} 69].
Safety devices involved
/
Number of operators
1
Operator qualifications
The indicated symbols are described in chapter Qualification and training of
the personnel [} 14].
Personal protective
equipment
The indicated symbols are described in chapter Obligations symbols [} 38].
Equipment
Microfiber cloth.
Materials
/
Work Area
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5. Maintenance
Instructions:
NOTICE
Avoid using detergents that could damage the window surface.
If the window presents scoring, please contact Salvagnini's customer
service department.
1. Access the bend angle measurement device (AMS) (1).
2. Clean the rear camera (2) window (3) with a microfiber cloth.
3. Remove any traces of dust, grease or oil limiting the propagation of
the laser beam, taking care not to damage the surface.
4. Repeat the procedure on the opposite camera.
5. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
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5. Maintenance
5.7. Monthly maintenance
Check the oil level in the toolholder hydraulic unit
Frequency
[IM1] Monthly.
Duration
/
Machine operating mode
Machine on.
Safety devices involved
Number of operators
1
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
Ladder.
Materials
/
Zone of intervention
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5. Maintenance
Instructions:
WARNING
Fall hazard for the operator.
Precautions: follow the instructions given in chapter Accessing high
areas [} 267].
1. Check that the level of hydraulic fluid in the tank (1) is between the
maximum (2) and minimum (3) levels.
2. Check that there are no hydraulic oil leaks.
3. If the quantity of hydraulic fluid is below the minimum level (3),
proceed as indicated on sheet Top up the oil in the toolholder
hydraulic unit [} 292].
4. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
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5. Maintenance
Clean the electrical cabinet filters
Frequency
[MM1] Monthly.
Duration
Machine operating mode
Machine off, see chapter Lockout and release procedure (Lockout/Tagout)
[} 69].
Safety devices involved
/
Number of operators
1
Operator qualifications
The indicated symbols are described in chapter Qualification and training of
the personnel [} 14].
Personal protective
equipment
The indicated symbols are described in chapter Obligations symbols [} 38].
Equipment
• Ladder.
• Compressed air.
Materials
/
Work Area
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5. Maintenance
Instructions:
DANGER
Electrocution hazard.
Opening the doors of the power cabinet does not cut off the voltage.
Precautions: wait 8 minutes for the capacitors to discharge before
opening the doors.
1. Open the electrical cabinet doors (1) with the specific key.
2. Unscrew the fasteners in order to remove the grilles (2) on the air
filters.
3. Clean the grilles (2) with compressed air.
4. Screw on the fasteners to reposition the grilles (2).
5. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
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5. Maintenance
Clean the AOPD laser safety device
Frequency
[MM2] Monthly.
Duration
Machine operating mode
Machine off, see chapter Lockout and release procedure (Lockout/Tagout)
[} 69].
Safety devices involved
/
Number of operators
1
Operator qualifications
The indicated symbols are described in chapter Qualification and training of
the personnel [} 14].
Personal protective
equipment
The indicated symbols are described in chapter Obligations symbols [} 38].
Equipment
Microfiber cloth.
Materials
/
Work Area
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Operating manual
5. Maintenance
Instructions:
NOTICE
Avoid using detergents that could damage the window surface.
If the window presents scoring, please contact Salvagnini's customer
service department.
1. Access the receiver (1).
2. Clean the window (2) with a microfiber cloth.
3. Remove any traces of dust, grease or oil limiting the propagation of
the laser beam, taking care not to damage the surface
4. Repeat the procedure on the emitter.
5. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
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5. Maintenance
5.8. Three-monthly maintenance
Lubricating the backgauges
Frequency
[MT1] Every three months.
Duration
/
Machine operating mode
Machine turned off, see the chapter on Lockout and release procedure
(Lockout/Tagout) [} 69].
Safety devices involved
/
Number of operators
1
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
• Manual grease pump.
• Brush for greasing.
Materials
KLUBERPLEX BEM 34-132 grease.
Zone of intervention
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Operating manual
5. Maintenance
Instructions:
1. Lubricate the points indicated in the table below.
Point
s
B3.135-3000 - MB_0791 - 1.0 - en
Description
Application
(1)
Ball-bearing runner block for the Z1
backgauge
Manual grease pump
(2)
Ball-bearing runner block for the Z2
backgauge with X5 trigger
Manual grease pump
(3)
Ball-bearing runner blocks for the right-hand
R AXIS
Manual grease pump
(4)
Ball-bearing runner blocks for the left-hand R
AXIS
Manual grease pump
(5)
Right-hand R AXIS rack
Brush for greasing
(6)
Left-hand R AXIS rack
Brush for greasing
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Operating manual
5. Maintenance
2. Lubricate the points indicated in the table below (in the points with
an asterisk, remove the rubber cap before lubricating).
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Point
s
Description
Action
(7)*
Upper ball-bearing runner block for the right-hand
X AXIS
Manual grease pump
(8)*
Upper ball-bearing runner block for the left-hand X
AXIS
(9)*
Ball-bearing lead screw for the right-hand X AXIS
(10)*
Ball-bearing lead screw for the left-hand X AXIS
(11)
Lower ball-bearing runner block for the right-hand
X AXIS
(12)
Lower ball-bearing runner block for the left-hand X
AXIS
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Operating manual
5. Maintenance
3. Lubricate the points indicated in the table below.
4. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
Point
s
B3.135-3000 - MB_0791 - 1.0 - en
Description
(13)
Ball-bearing runner blocks for X5 trigger
(14)
Ball-bearing lead screw for X5 trigger
Action
Manual grease pump
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5. Maintenance
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Operating manual
5. Maintenance
5.9. Maintenance every 100 hours of operation
Replacing the cartridge of the oil filter on the hydraulic unit
Frequency
After the first 100 hours of operation.
Duration
Machine operating mode
Machine turned off, see the chapter on Lockout and release procedure
(Lockout/Tagout) [} 69].
Safety devices involved
Number of operators
1
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
Materials
Ladder.
• Replacement for the component that is to be replacement.
• MOBIL DTE 10 Excel 32 oil.
Zone of intervention
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Operating manual
5. Maintenance
Instructions:
WARNING
Fall hazard for the operator.
Precautions: follow the instructions given in chapter Accessing high
areas [} 267].
WARNING
Injury and fire hazard.
Any work on the hydraulic system may cause oil to leak at high
temperature and/or under pressure.
Precautions: no smoking, naked flames or sparks.
WARNING
Injury hazard caused by contact with chemical substances.
Precautions: take great care while using chemical substances (refer
to the relative safety data sheet).
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Operating manual
5. Maintenance
1. Remove the oil filter body (2) from the hydraulic power pack (1).
2. Replace the oil filter cartridge (3) with a new cartridge.
3. Reposition the oil filter body (2).
4. Fill the oil filter cartridge (3) with oil.
5. Make sure that all the tubes and all the connectors of the hydraulic
power pack (1) are secured properly so as to prevent any oil leaks.
6. Repeat the procedure on the second hydraulic power pack.
7. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
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Operating manual
5. Maintenance
5.10. Maintenance every 500 hours of operation
Replacing the cartridge of the oil filter on the hydraulic unit
Frequency
[M500-1] Every 500 hours of operation.
Duration
Machine operating mode
Machine turned off, see the chapter on Lockout and release procedure
(Lockout/Tagout) [} 69].
Safety devices involved
/
Number of operators
1
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
Materials
Ladder.
• Replacement for the component that is to be replacement.
• MOBIL DTE 10 Excel 32 oil.
Zone of intervention
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Operating manual
5. Maintenance
Instructions:
WARNING
Fall hazard for the operator.
Precautions: follow the instructions given in chapter Accessing high
areas [} 267].
WARNING
Injury and fire hazard.
Any work on the hydraulic system may cause oil to leak at high
temperature and/or under pressure.
Precautions: no smoking, naked flames or sparks.
WARNING
Injury hazard caused by contact with chemical substances.
Precautions: take great care while using chemical substances (refer
to the relative safety data sheet).
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Operating manual
5. Maintenance
1. Remove the oil filter body (2) from the hydraulic power pack (1).
2. Replace the oil filter cartridge (3) with a new cartridge.
3. Reposition the oil filter body (2).
4. Fill the oil filter cartridge (3) with oil.
5. Make sure that all the tubes and all the connectors of the hydraulic
power pack (1) are secured properly so as to prevent any oil leaks.
6. Repeat the procedure on the second hydraulic power pack.
7. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
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Operating manual
5. Maintenance
5.11. Maintenance every 6000 hours of operation
Change the hydraulic fluid
Frequency
[M6000-1] Every 6000 hours of operation.
Duration
Machine operating mode
Machine turned off, see the chapter on Lockout and release procedure
(Lockout/Tagout) [} 69].
Safety devices involved
/
Number of operators
1
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
• Ladder.
• Rubber hoses.
• Container for collecting the used hydraulic fluid.
• Compressed air.
Materials
MOBIL DTE 10 Excel 32 oil.
Zone of intervention
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Operating manual
5. Maintenance
Instructions:
WARNING
Fall hazard for the operator.
Precautions: follow the instructions given in chapter Accessing high
areas [} 267].
WARNING
Injury and fire hazard.
Any work on the hydraulic system may cause oil to leak at high
temperature and/or under pressure.
Precautions: no smoking, naked flames or sparks.
WARNING
Injury hazard caused by contact with chemical substances.
Precautions: take great care while using chemical substances (refer
to the relative safety data sheet).
WARNING
Crushing and/or shearing hazard for the upper limbs.
If the machine is not used for a long time, the top-beam may drop.
Precautions: position two blocks above the lower toolholder so as to
prevent the top-beam from dropping.
Position the ram at maximum height before switching off the machine.
Only when the ram is at maximum height is the hydraulic fluid level
visible on the maximum level indicator. When the ram is lowered, on
the other hand, the hydraulic fluid level is not visible because the oil
flows in the cylinders.
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Operating manual
5. Maintenance
1. Attach the end of a rubber hose to the drain cock (2) on the
hydraulic unit (1) and place the other end in a container to collect
the used hydraulic fluid.
2. Open the drain cock (2) and collect the spent hydraulic fluid.
3. Remove the bleed filter (4).
4. Add oil via the bleed hole (5), ensuring it does not get
contaminated, until the maximum level indicator (3) is reached.
5. Clean the bleed filter (4) with compressed air.
6. Reposition the bleed filter (4).
7. Check that all lines and connections on the hydraulic unit (1) are
correctly fastened to prevent oil leaks.
8. Repeat the procedure on the second hydraulic unit.
9. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
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Operating manual
5. Maintenance
5.12. Non-scheduled maintenance
Top up the oil in the toolholder hydraulic unit
Frequency
[EM2] Not programed.
Duration
Machine operating mode
Machine turned off, see the chapter on Lockout and release procedure
(Lockout/Tagout) [} 69].
Safety devices involved
/
Number of operators
1
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
Ladder.
Materials
HAYDN 22 hydraulic fluid (ISO 6743-4).
Zone of intervention
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Operating manual
5. Maintenance
Instructions:
WARNING
Fall hazard for the operator.
Precautions: follow the instructions given in chapter Accessing high
areas [} 267].
WARNING
Injury hazard caused by contact with chemical substances.
Precautions: take great care while using chemical substances (refer
to the relative safety data sheet).
NOTICE
Do not mix hydraulic fluids of the same type from different
manufacturers, or of different types from the same manufacturer.
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Operating manual
5. Maintenance
1. Remove the cap (1) from the tank (2).
2. Top up until you reach a level between the minimum (4) and the
maximum (3).
3. Replace the cap (1).
4. Check that there are no hydraulic oil leaks.
5. At the end of the procedure, see chapter Conclusion of
maintenance task [} 297].
NOTICE
Approved hydraulic fluids
The approved hydraulic fluids are indicated on the tank in point (5).
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Operating manual
5. Maintenance
5.13. Special maintenance
Replacing the cartridges of the hydraulic unit's pump
protection filters
Frequency
[SM1] Not programmed.
Duration
Machine operating mode
Safety devices involved
Number of operators
1
Operator qualifications
The symbols indicated are described in the chapter on Qualification and
training of the personnel [} 14].
Personal protective
equipment
The symbols indicated are described in the chapter on Obligations symbols
[} 38].
Equipment
Materials
Zone of intervention
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Operating manual
5. Maintenance
Instructions:
For the task of replacing the cartridges (2) of the pump protection filters
(1), please contact the Salvagnini customer service department.
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Operating manual
5. Maintenance
5.14. Conclusion of maintenance task
WARNING
Hazard due to removed or modified safety devices.
Precautions: if the machine's safety devices have been removed or
modified during the maintenance task, you should:
- Restore the original status of the safety devices.
- Check the correct operation of the safety devices.
After the maintenance task is complete, perform the following steps to
reset the machine to the operating status:
1. Remove all the tools and auxiliary equipment from the machine.
2. Record the completed work in the Salvagnini Maintenance
Manager application.
3. Dispose in a safe and eco-friendly manner of:
- Operating materials.
- Auxiliary materials.
- Replaced parts.
The machine is now ready once more for production. Proceed as
indicated in the Resetting the machine [} 231] procedure.
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