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DIGITAL SERVO FORMER

STAMPMAX PRESS

No.4 PRESS
INSTRUCTION MANUAL

Be sure to read this Instruction Manual and fully understand the contents
before using this machine. In addition, keep the manual near the machine, tak-
ing care not to misplace it, so that the operator can access it whenever neces-
sary.

This Instruction Manual is intended for the sole use of AIDA’s customers. The
use of this manual in part or in whole by any third party is prohibited.
Inst.Manual No.

2502 1009
e-08
北村真一郎作成
MODEL SERIAL NO.
For more detailed information, contact us with this serial No.
No.1PRESS SMX-S4-23000(D)-500-250 17023-2286
No.2PRESS SMX-S4-16000(D)-500-250 17016-2287
No.3PRESS SMX-S4-12000(D)-500-250 17012-2288
No.4PRESS SMX-S4-10000(D)-500-250 17010-2289

3
4
INTRODUCTION

INTRODUCTION

Thank you for purchasing this AIDA product.


We are confident that the technology that we have made constant efforts over decades to
refine will contribute to the streamlining of your production system.

WARNING
• Read this instruction manual before using this machine. Be sure to fully understand the
descriptions contained in this instruction manual before starting operation, inspection, or
maintenance of this machine. In particular, the press machine must be installed, oper-
ated, adjusted, and maintained by trained specialists or qualified personnel as directed in
this instruction manual.
If the press machine is operated by anyone other than a trained specialist or other quali-
fied personnel, it can result in damage to the machine or personal injury or death. In such
a case, the manufacturer of the machine shall be released from all responsibility and lia-
bility.

• Any accidents or failures caused by users failing to follow the instructions contained in
this instruction manual shall release the manufacturer of this machine from all responsi-
bility and liability.

• Keep this instruction manual in a specified place near the machine as a quick reference
tool. Please keep this manual in good condition.

• When this machine is transferred to another owner, this instruction manual must be trans-
ferred together with the machine.

<< To the Readers >>


Those who are involved with this machine should read and gain an understanding of the entire
instruction manual.

<< Tips for Finding Information >>


First, open the GENERAL TABLE OF CONTENTS (pg. 6) to find out what section contains the
item you want to see. Next, check the "Contents" of that section to locate the desired item.
You may also be able to find the item using the INDEX located at the end of this instruction
manual.

<< If You Cannot Find the Desired Information in This Instruction Manual >>
When such a problem arises, contact the nearest AIDA Service Office (consult the list at the
end of this instruction manual).
When making inquiries, please be prepared to provide the machine serial number, model des-
ignation, the date of manufacture, and the instruction manual number (found on the lower left
of the front cover).

© Copyright 2008 Aida Engineering, Ltd. ALL RIGHTS RESERVED.


Reproduction of any part of this publication without the written permission of Aida
Engineering, Ltd. is strictly prohibited.

5
GENERAL TABLE OF CONTENTS

GENERAL TABLE OF CONTENTS

A
Section A SAFETY (pg. 13)
Describes important information, instructions to be strictly followed,
and warning plates for the prevention of hazards caused by the
press machine.

B
Section B SPECIFICATIONS (pg. 55)
Describes specifications, limitations of use, warranty, dimensions,
and names of major components of the press machine.

C
Section C INSTALLATION (pg. 79)
Describes preparations for press machine installation, for transporta-
tion, for installation, and preparation for test runs.

D
Section D OPERATION (pg. 89)
Describes operation-related devices, routine inspection, operational
procedures, adjustment operations, and die changes for the press
machine.

E
Section E MAINTENANCE (pg. 321)
Describes periodic inspection, lubrication, maintenance of units and
components, troubleshooting, and provides drawings for the mainte-
nance of the press machine.

APPENDIX
INSTRUCTIONS FOR PRESS MACHINE USAGE
LIST OF LUBRICANTS AVAILABLE ON THE MARKET
TONNAGE MONITOR
EHDC-4000F INSTRUCTION MANUALS(No.1 PRESS)
INDEX

Instruction Manuals for Peripheral Devices and Accessories


(at the end of this instruction manual or in a separate binder)

Instruction Manuals for Accessories


(in a separate binder)

6
GENERAL TABLE OF CONTENTS

CONTENTS

INTRODUCTION .................................................................................................5
GENERAL TABLE OF CONTENTS .....................................................................6

Section A SAFETY

1. WARNING DISPLAY .....................................................................................15

2. SAFETY PRECAUTIONS .............................................................................16


2.1 TO THE EMPLOYER........................................................................................................................ 16
2.2 INSTRUCTIONS FOR AUTHORIZED PERSONNEL AND QUALIFIED PERSONNEL ................... 18
2.3 INSTRUCTIONS FOR DIE SETTERS AND OPERATORS .............................................................. 18
2.4 INSTRUCTIONS FOR MAINTENANCE SPECIALISTS ................................................................... 18

3. SAFEGUARDING .........................................................................................19
3.1 ACTIONS TO PREVENT HAZARDS................................................................................................ 19
3.2 PRESENCE SENSING DEVICES .................................................................................................... 20
3.3 INTERLOCKED GUARD (OPTION) ................................................................................................. 21

4. ACCORDANCE WITH OSHA REGULATIONS.............................................22

5. USING THE PRESS MACHINE SAFELY .....................................................24


5.1 ESSENTIAL BASIC RULES ............................................................................................................. 24
5.2 ESSENTIAL USAGE ENVIRONMENT PRECAUTIONS .................................................................. 26
5.3 ESSENTIAL INSTALLATION PRECAUTIONS ................................................................................. 27
5.4 ESSENTIAL OPERATION PRECAUTIONS ..................................................................................... 28
(Continued) .............................................................................................................................................. 30
5.6 ESSENTIAL PRECAUTIONS WHEN INSTALLING PRESENCE-SENSING DEVICES................... 32

6. SAFETY PROCEDURES DURING ADJUSTMENT .....................................33

7. WARNING PLATES ......................................................................................34

8. PAINTING ON HAZARDOUS AREAS ..........................................................49

9. GLOSSARY ..................................................................................................53

Section B SPECIFICATIONS

1. SPECIFICATIONS ........................................................................................57

7
GENERAL TABLE OF CONTENTS

2. CHARTS .......................................................................................................73

3. NAMES OF MAJOR COMPONENTS ...........................................................74

4. ELEMENTS OF PRESSWORK ....................................................................76


4.1 TONNAGE CAPACITY (NOMINAL CAPACITY) ............................................................................... 76
4.2 TORQUE CAPACITY........................................................................................................................ 77
4.3 STROKE-TONNAGE CURVE........................................................................................................... 77
4.4 ENERGY CAPACITY (WORKING ENERGY)................................................................................... 77

Section C INSTALLATION

1. PREPARATION FOR INSTALLATION ..........................................................81

2. TRANSPORTATION AND INSTALLATION ...................................................82

3. CONNECTING THE AIR SUPPLY ................................................................83


3.1 CONNECTING TO THE AIR SUPPLY.............................................................................................. 83
3.2 AIR CONSUMPTION ........................................................................................................................ 83

4. CONNECTING TO THE POWER SOURCE .................................................84


4.1 CONNECTING TO THE POWER SOURCE AND GROUNDING..................................................... 84
4.2 GROUNDING.................................................................................................................................... 85

5. INITIAL LUBRICATION (OIL SERVICING) ...................................................86

6. POST-INSTALLATION CHECK.....................................................................87

Section D OPERATION

1. CASE-BY-CASE OPERATING INSTRUCTIONS..........................................91

2. OPERATION DEVICES ................................................................................92


2.1 MAIN OPERATION PANEL............................................................................................................... 92
2.2 SUB OPERATION PANEL ................................................................................................................ 93
2.3 MB FENCE RIGHT SIDE SUB OPERATION PANEL ....................................................................... 94
2.4 MB FENCE LEFT SIDE SUB OPERATION PANEL ......................................................................... 94
2.5 STEP FEED OPERATION BOX ....................................................................................................... 95
2.6 OTHER ............................................................................................................................................. 95
2.7 FUNCTION AND OPERATION......................................................................................................... 96
2.8 OPERATION OF KEY SWITCHES................................................................................................. 109
2.9 SYMBOL MARKS FOR SWITCHES............................................................................................... 110

8
GENERAL TABLE OF CONTENTS

3. THE OPERATOR INTERFACE TERMINAL................................................ 111


3.1 SCREEN CONFIGURATION .......................................................................................................... 112
3.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS .................................................... 115
3.3 INITIAL Screen ............................................................................................................................... 118
3.4 THE PRODUCTION SCREEN........................................................................................................ 119
3.5 THE SETTING SCREEN ................................................................................................................ 126
3.6 THE DIE CHANGE SCREEN ......................................................................................................... 149
3.7 THE RECIPE (DATABANK) SCREEN ............................................................................................ 154
3.8 THE MAINTENANCE SCREEN...................................................................................................... 167

4. OPERATION ...............................................................................................186
4.1 PRE-WORK CHECK....................................................................................................................... 187
4.2 ROUTINE INSPECTION AND OPERATION .................................................................................. 188
4.3 LINE MODES.................................................................................................................................. 192
4.4 OPERATION MODES..................................................................................................................... 193
4.5 PRESENCE-SENSING DEVICES AND OPERATION CONDITIONS............................................ 195

5. PROCEDURE WHEN COMPLETING WORK ............................................196

6. RESETTING FAULTS .................................................................................197


6.1 INTERLOCK INFORMATION MESSAGE LIST .............................................................................. 198
6.2 FAULT INFORMATION MESSAGE LIST........................................................................................ 214
6.3 FAULT CHECK UPON POWER ACTIVATION ............................................................................... 239
6.4 HYDRAULIC OVERLOADS............................................................................................................ 243
6.5 OVERRUNS.................................................................................................................................... 245
6.6 WHEN AN EMERGENCY STOP BUTTON HAS BEEN PUSHED ................................................. 245
6.7 WHEN THE EXTERNALLY CONTROLLED BREAKER IS ACTUATED ........................................ 246
6.8 WHEN THE GROUND FAULT BREAKER IS ACTUATED ............................................................. 246
6.9 WHEN A THERMAL RELAY HAS TRIPPED.................................................................................. 247
6.10 STICKING ..................................................................................................................................... 249

7. ADJUSTMENT ............................................................................................250
7.1 SLIDE ADJUSTMENT .................................................................................................................... 250
7.2 COUNTERBALANCE CAPACITY ADJUSTMENT ......................................................................... 253
7.3 SETTING TIMING SWITCHES....................................................................................................... 255
7.4 MOTION PROGRAM AUXILIARY FUNCTIONS ............................................................................ 262

8. CHANGING DIES .......................................................................................265


8.1 MANUAL DIE CHANGE.................................................................................................................. 267
8.2 AUTO DIE CHANGE....................................................................................................................... 271

9. OPERATION OF AUXILIARY EQUIPMENT ...............................................275


9.1 MECHANICAL DEVICE .................................................................................................................. 275

10. Making Motion Program Settings ..............................................................277


10.1 Operating motion .......................................................................................................................... 277
10.2 PROCEDURE FOR MAKING MOTION PROGRAM SETTINGS ................................................. 278
10.3 KEY POINTS WHEN MAKING MOTION PROGRAM SETTINGS ............................................... 286
10.4 MOTION PROGRAM EXAMPLES................................................................................................ 291
10.5 MOTION SETTING FAULTS......................................................................................................... 319

9
GENERAL TABLE OF CONTENTS

Section E MAINTENANCE

1. PERIODIC INSPECTION............................................................................323
1.1 MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION)......................................... 323
1.2 SEMI-ANNUAL INSPECTION (OR EVERY 1500 HOURS OF OPERATION)................................ 325
1.3 ANNUAL INSPECTION (OR EVERY 3000 HOURS OF OPERATION).......................................... 325
1.4 THREE YEAR INSPECTION (OVERHAUL)................................................................................... 327
1.5 PERIODIC INSPECTION OF PERIPHERAL DEVICES AND ACCESSORIES ............................. 328

2. LUBRICATION ............................................................................................329
2.1 FLUSHING...................................................................................................................................... 329
2.2 TYPES AND AMOUNTS OF OIL.................................................................................................... 330
2.3 OIL AND GREASE SERVICING POINTS ...................................................................................... 331
2.4 OIL AND GREASE SERVICING PROCEDURES .......................................................................... 332
2.5 REPLACEMENT OF OIL IN LUBRICATING OIL TANK.................................................................. 333
2.6 HYDRAULIC OVERLOAD PROTECTOR OIL SERVICING ........................................................... 335
2.7 FLOW INDICATOR ......................................................................................................................... 338

3. MAINTENANCE OF MECHANICAL COMPONENTS.................................339


3.1 MEASURING SLIDE GIB CLEARANCE......................................................................................... 340
3.2 INSPECTING THE BRAKE STROKE............................................................................................. 341

4. MAINTENANCE OF ELECTRICAL COMPONENTS ..................................342


4.1 MEGGER MEASUREMENT (INSULATION RESISTANCE MEASUREMENT).............................. 342
4.2 SERVICE LIFE OF ELECTRICAL COMPONENTS........................................................................ 343
4.3 INSPECTING THE GROUND FAULT BREAKER........................................................................... 344
4.4 REPLACING THE BUILT-IN PLC BATTERY .................................................................................. 345
4.5 REPLACING THE SVC BUILT-IN BATTERY.................................................................................. 346
4.6 MAINTENANCE OF OPERATION DISPLAY.................................................................................. 348

5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS ....................349


5.1 AUTO-DRAIN FILTER..................................................................................................................... 349
5.2 THE BRAKE SOLENOID VALVE.................................................................................................... 351
5.3 TOTAL LUB. TANK ......................................................................................................................... 355
5.4 OIL PUMP....................................................................................................................................... 356
5.5 OIL FILTER ..................................................................................................................................... 356

6. TROUBLESHOOTING ................................................................................359

7. DRAWINGS.................................................................................................362
7.1 Mechanical Drawings...................................................................................................................... 362
7.2 Electrical Drawings (Refer to separate volume).............................................................................. 362
7.3 Die Cushion Electrical Drawings (Refer to separate binder ,only No.1 press)................................ 362

10
GENERAL TABLE OF CONTENTS

APPENDIX

INSTRUCTIONS FOR PRESS MACHINE USAGE


LIST OF LUBRICANTS AVAILABLE ON THE MARKET

TONNAGE MONITOR
EHDC-4000F INSTRUCTION MANUALS(No.1 PRESS)

• INDEX

• Instruction Manuals for Peripheral Devices (Option)


<< at the end of this instruction manual or in a separate binder >>

• Instruction Manuals for Accessories


<< at the end of this instruction manual or in a separate binder >>

• Sales offices and Service offices

11
GENERAL TABLE OF CONTENTS

12
Section A SAFETY

Section A
SAFETY

1. WARNING DISPLAY ............................................................................................ 15

2. SAFETY PRECAUTIONS .................................................................................... 16


2.1 TO THE EMPLOYER...................................................................................................................... 16
2.2 INSTRUCTIONS FOR AUTHORIZED PERSONNEL AND QUALIFIED PERSONNEL................. 18
2.3 INSTRUCTIONS FOR DIE SETTERS AND OPERATORS............................................................ 18
2.4 INSTRUCTIONS FOR MAINTENANCE SPECIALISTS................................................................. 18

3. SAFEGUARDING................................................................................................. 19
3.1 ACTIONS TO PREVENT HAZARDS.............................................................................................. 19
3.2 PRESENCE SENSING DEVICES .................................................................................................. 20
3.3 INTERLOCKED GUARD (OPTION) ............................................................................................... 21

4. ACCORDANCE WITH OSHA REGULATIONS .................................................... 22

5. USING THE PRESS MACHINE SAFELY............................................................. 24


5.1 ESSENTIAL BASIC RULES ........................................................................................................... 24
5.2 ESSENTIAL USAGE ENVIRONMENT PRECAUTIONS................................................................ 26
5.3 ESSENTIAL INSTALLATION PRECAUTIONS............................................................................... 27
5.4 ESSENTIAL OPERATION PRECAUTIONS ................................................................................... 28
(Continued) ............................................................................................................................................ 30
5.6 ESSENTIAL PRECAUTIONS WHEN INSTALLING PRESENCE-SENSING DEVICES ................ 32

6. SAFETY PROCEDURES DURING ADJUSTMENT............................................. 33

7. WARNING PLATES.............................................................................................. 34

8. PAINTING ON HAZARDOUS AREAS.................................................................. 49

9. GLOSSARY.......................................................................................................... 53

13
Section A SAFETY

14
Section A SAFETY 1. WARNING DISPLAY

1. WARNING DISPLAY
• Warning displays are made in the instruction manual and warning plates according to the
following categories, which correspond to the level of warning.

This display indicates a serious situation where failure to heed the


DANGER warning will cause death or serious injury.

This display indicates a possible situation where failure to heed


WARNING the warning may cause death or serious injury.

This display indicates a possible situation where failure to heed


CAUTION the warning may cause minor to medium level injury.

This display indicates a possible situation where failure to heed


CAUTION the warning may result in damage to the machine.

• Definition of symbols

This symbol indicates an act that is “prohibited”.

This symbol indicates a “mandatory act” or an “instruction”.

NOTE This mark is used to provide further information.

WARNING
• The warnings contained in this instruction manual and on the warning plates
do not, and cannot, cover all possible hazards under all circumstances. These
warnings describe the minimum level of warning which must be observed for
safe use of the machine.
Please gain an understanding of the meaning of the warning messages and
strictly adhere to them.
AIDA will not take responsibility for any personal injury, death, or machine
damage caused by the machine being operated without regard to these warn-
ings.

NOTE See Section A SAFETY, 9. GLOSSARY (pg. 53) for technical terms.

15
Section A SAFETY 2. SAFETY PRECAUTIONS

2. SAFETY PRECAUTIONS

WARNING
• The employer, authorized personnel, qualified personnel, die setters, operators,
and maintenance specialists must observe all regulations relating to labor safety.

• If the regulations or safety precautions stated in this section are not followed,
accidents causing injury, death or mechanical damage may occur. We will not
bear any liability in such cases.

The press machine is capable of performing a variety of operations. However, the actual pro-
cedure to operate the machine is at the discretion of the user. In general, press machine man-
ufacturers cannot know or control the use of the press machine on a day-to-day basis. Like
other press machine manufacturers, we cannot know what protection measures are required
or suitable for your specific operation or application. Therefore, the user must establish and
implement the most suitable safeguarding measures for the point of operation.
The following shows the minimum safety precautions that are required to be observed. Be
sure to perform all of these items.

2.1 TO THE EMPLOYER

(1) Provide all employees with an employment contract and work place environment
which ensures that no hazardous conditions exist that can result in the accidental
death of or serious injury to an employee.

(2) Assess the risks of the machine and take appropriate safeguarding measures in
accordance with applicable laws and regulations prior to use of the machine.

(3) Implement safeguarding measures to protect operators and other employees from
hazards including the point of operation, rotating parts, splashing objects, and sparks.

(4) Confirm that the operators use safeguarding devices, which have been correctly
installed and properly adjusted, for all press machine operations.
Never allow anyone to modify or remove safeguarding devices.

(5) Designate appropriate persons as authorized personnel, qualified personnel, die set-
ters, operators, and as maintenance specialists for this machine.

Authorized Personnel: Personnel given the authority and responsibility by the


employer to perform particular duties. These personnel
must follow the instructions stated in
2.2 INSTRUCTIONS FOR AUTHORIZED
PERSONNEL AND QUALIFIED PERSONNEL (pg. 18).
The employer must designate appropriate employees
who have special knowledge and experience associ-
ated with the hazards and safety measures of the press
machine, handling and maintenance of the press
machine, and handling of the presswork and dies as
authorized personnel. It is recommended that autho-
rized personnel be selected from company foremen,
supervisors, or shop managers.
(Continued on the next page)

16
Section A SAFETY 2. SAFETY PRECAUTIONS

(Continued)

Qualified Electricians: Personnel who perform adjustment, inspection, and


maintenance relating to the electrical systems accord-
ing to applicable regulations.
Select employees who have special knowledge of and
experience with press machines and electrical systems.
Die Setters: Personnel who perform die setups and adjustments
needed to ensure that dies work properly and safely.
Operators: Personnel who operate the press machine for press-
work.
Maintenance Specialists: Personnel involved in routine checks, inspections, and
maintenance of the press machine.
It is advisable that qualified personnel also serve as
maintenance specialists.

(6) Give authorized personnel, qualified personnel, die setters, operators, and mainte-
nance specialists training in safe operation before they start any kind of work. Also,
ensure that the employees work according to proper operational procedures.

(7) Based on this instruction manual, establish a training program about hazards, safe
operation, setup, and maintenance of the press machine for the authorized personnel,
qualified personnel, die setters, operators, and maintenance specialists.

(8) Assure that the authorized personnel, qualified personnel, die setters, operators, and
maintenance specialists are familiar with the recommended operation, setup, and
maintenance procedures for the press machine.

(9) In order to establish safe operation methods, prepare the following operation guides.
Train the authorized personnel, qualified personnel, die setters, operators, and main-
tenance specialists to perform their operations in accordance with these operation
guides.
(a) Die setup and test operation
(b) Press machine operation (presswork)
(c) Lockout procedures
(d) Routine and periodic inspections

(10)Establish and implement a proper and regular inspection program for the press
machine and for guards and protective devices to confirm that all parts, auxiliary
devices, guards, and protective devices are in good operating condition and that
employees use them properly.
Any defective conditions detected in the inspection should be immediately repaired.
Inspection and maintenance records must be kept.

(11) Inspect the press machine at least once a week. All the required maintenance and
repair work must be completed before the press machine is returned to service.

(12)Use dies and operational procedures which are designed to protect employees from
hazards.

(13)Ensure that all employees fully understand and follow the rule that if an abnormal con-
dition occurs on the press machine that the press machine must be stopped immedi-
ately and the condition remedied before resuming production. The machine must
never be restarted until the problem is resolved.

(Continued on the next page)

17
Section A SAFETY 2. SAFETY PRECAUTIONS

(Continued)

(14)When there is a person who cannot read and understand this instruction manual due
to language barriers or their educational level, either provide him/her with a translated
version containing all of the necessary information, or interpret it to them.

(15)Perform all other duties assigned on the employer by existing laws and regulations.

2.2 INSTRUCTIONS FOR AUTHORIZED PERSONNEL AND QUALIFIED PER-


SONNEL

(1) Perform a pre-work check, a routine inspection, and a periodic inspection of the press
machine, guarding, and safety devices.

(2) When an abnormal condition is noted on the press machine, the guarding, or the
safety devices, stop using the press machine immediately, report the condition to the
employer, and take any necessary actions to repair the condition.

(3) Control the keys for the key switches for the press machine and safety devices, etc.

(4) Perform any other particular operations assigned by the employer.

2.3 INSTRUCTIONS FOR DIE SETTERS AND OPERATORS

You must receive the following safety training in order to operate this machine.

• Die Setter: Training for items relating to die setup, adjustment, and test running. In addi-
tion, you must receive the same training that the operator receives (as
explained below).

• Operator: Training related to press machine hazards and operation, usage and handling
of the guards, safety devices and protective equipment, work procedures,
pre-work check, routine inspection, emergency actions, and evacuation pro-
cedures in case an accident occurs.

2.4 INSTRUCTIONS FOR MAINTENANCE SPECIALISTS

(1) Periodically inspect the press machine, guarding, and safety devices.

(2) When an abnormal condition is found in the press machine, guarding, or a safety
device, stop using the press machine immediately, report the condition to the
employer, and take any necessary actions to repair the condition.

18
Section A SAFETY 3. SAFEGUARDING

3. SAFEGUARDING
3.1 ACTIONS TO PREVENT HAZARDS

WARNING
• The employer must rigidly adhere to the following prior to use of the machine.
Part of someone’s body may enter the danger zone during operation, which may
result in personal injury or death.

(1) On a servo drive press machine, two-hand RUN buttons do not function as
safety devices. It is necessary to use a combination of presence sensing
devices (e.g., light curtains) and side guards to safeguard the servo drive
press machine point of operation at all times, including during setup and
maintenance.

(2) Safeguarding measures must be taken by the user for the point of operation
that are the most appropriate for the user’s operation.

(3) When installing material feeders (such as a coil line, a destack feeder, and/
or a robot), product removal devices, or other peripheral devices, the user
must provide safety fences or enclosures in accordance with applicable
safety regulations and laws for that equipment.

(4) This press machine has been manufactured based upon it being operated
by one person at an operation position located in front of the press
machine. When an assistant operator is involved, or other persons may
have access to any operation zone or danger zone, you must provide safe-
guarding measures so that no part of the body of the assistant operator or
other persons can get inside the danger zone.

(5) Confirm that sections related to safety, guarding, and safety devices are
used in a way which is effective for the work of your company, and that they
are properly maintained, calibrated, and always in use.

(6) Never override, disconnect, or remove any safety feature or interlocking


device.

(7) Only properly trained personnel should be permitted to use machinery and
have access to danger zones.

19
Section A SAFETY 3. SAFEGUARDING

3.2 PRESENCE SENSING DEVICES

A presence sensing device detects interrupted light beams and then outputs an Immediate
Stop signal to the press machine. Accordingly, as long as the presence sensing device is
properly calibrated and functioning properly, if a light beam has been interrupted the slide will
immediately stop in all modes of operation and the servo motor power will be turned off.
See 4.5 PRESENCE-SENSING DEVICES AND OPERATION CONDITIONS (pg. 195).
In case there is a space wide enough for the body of a person or a part of it to remain or enter
between the presence sensing device and the press machine, there will be a supplemental
optical axis.
When the light beam of the supplemental optical axis is interrupted, the slide will make an
immediate stop. Furthermore, while the light beam is being interrupted, the slide will not start
in any operation mode.

WARNING
• Never change the mounting location of a presence sensing device. Presence
sensing devices have been mounted in specific locations in order to maintain the
appropriate distance from the point of operation.

• Never remove side guards.


Using the press machine without side guards may result in personal injury or
death.
If the user modifies or removes the side guards, it is the responsibility of the user
to take the necessary safeguarding measures that prevent an operator or other
person from accessing the point of operation without first passing through the
presence sensing device detection field.

• The upper die front-to-back dimension must not exceed the slide front-to-back
dimension.
If this slide dimension is exceeded, the minimum safety distance must be
increased, otherwise part of an operator's body may enter the danger zone,
resulting in personal injury or death.

• Before starting work, you must confirm that the presence sensing device is prop-
erly calibrated and functioning properly by performing the pre-work check proce-
dure given in the presence sensing device instruction manual. Failure to perform
this pre-work check procedure may result in personal injury or death.
If any problems are found, immediately prohibit press machine usage, discon-
nect power, lockout, tagout and make the appropriate repairs.

20
Section A SAFETY 3. SAFEGUARDING

3.3 INTERLOCKED GUARD (OPTION)

Closing the guard is intended to restrict and prevent operators and other persons from putting
their hands into the point of operation.

WARNING
• Do not start press operation with guard limit switches disabled or non-function-
ing.
Disabling the guard limit switches may cause guarding functions to be inopera-
ble, and may thus result in personal injury or death.

• If the transparent pane section of the guard breaks, replace it immediately.


Injury or damage may be caused if a broken pane falls out of its frame.

21
Section A SAFETY 4. ACCORDANCE WITH OSHA REGULATIONS

4. ACCORDANCE WITH OSHA REGULATIONS


• This press machine is based on to OSHA (Occupational Safety and Health Administration)
Title 29, Section 1910.217 "Mechanical Power Presses", paragraph (b).
It is also based on ANSI (American National Standards Institute) B11-1.
• It is entirely the responsibility of the employer to maintain the press machine so that all
safety devices and interlocks function as they did when the press machine was accepted
and that they always meet the safety requirements of OSHA.
Particular attention must be given to the timing switches so that normal functionality is main-
tained. If, for any reason, the braking distance of the press machine increases to the point
where it is detected by the brake monitor, the press machine must not be operated until the
cause is remedied.
• It is the responsibility of the employer to provide this press machine with point of operation
guarding as stipulated in OSHA Title 29, Section 1910.217, paragraph (c).

The following devices have been installed in accordance with OSHA standards.

(1) EMERGENCY STOP Button


When this button is pushed during operation, the slide stops immediately and the but-
ton remains in this pushed condition until reset.

(2) Control Panel


When the control panel is opened, power cannot be applied to the press machine.

(3) DISCONNECT Switch


When the disconnect switch located on the control panel door is set to OFF, the power
supply to the press machine will be shut off.
(See Section D OPERATION.

(4) POWER White Light (on the Operation Panel)


The press machine is operable only when this light is lit. (See pg. 96.)

(5) CONTROL POWER Switch


This switch shuts off the control power source. By setting the switch to "OFF" and
removing the key, the slide and main motor start circuit will be disabled. (See pg. 96.)

(6) CONT. ARMING Button


When the press machine is ready for operation in the CONTINUOUS, push the lit
CONT. ARMING button.
The CONT. ARMING button light is only lit for a short period of time. The press
machine can be operated in the CONTINUOUS mode by pressing the two RUN but-
tons simultaneously within 5 seconds after this light first comes on. If the button light
begins flashing again, press the button again. (See pg. 96.)

(Continued on the next page)

22
Section A SAFETY 4. ACCORDANCE WITH OSHA REGULATIONS

(Continued)

(7) Slide Counterbalance


The slide counterbalance has a function that is intended to stop the press machine
operation in the event of air supply failure. Set the balance air pressure at a point
where the air pressure is sufficient to maintain the upper die weight.
(See D OPERATION, 7.2 COUNTERBALANCE CAPACITY ADJUSTMENT (pg.
253).)

(8) Presence Sensing Devices


A presence sensing device (e.g., light curtain) is equipment that detects when a light
beam is interrupted and outputs an Immediate Stop signal to the press machine. When
a light beam is interrupted, the slide immediately stops and the servo motor power is
cut. When presence sensing devices (e.g., light curtains) are installed, they are
intended to restrict an operator from accessing the point of operation without first
passing through the presence sensing device detection field. Accordingly, it is neces-
sary to install side guards. 
(See A SAFETY, 3.2 PRESENCE SENSING DEVICES (pg. 20).)

(9) Die Block


The die block is a supporting block to be inserted between the upper die and lower die
to prevent the slide from descending abruptly. (See pg. 33.)
A plug to shut off the control power is connected to the die block with a chain.

WARNING
• Two-hand RUN buttons are not safety devices when on a servo drive press
machine.
The press machine can be operated by simultaneously pushing the two-hand
RUN buttons with both hands. However, on a servo drive press machine the two-
hand RUN buttons do not function as safety devices. Accordingly, some other
type of safety device is required. If the press machine is used without additional
safety equipment having been installed and properly calibrated, maintained and
used, it may result in personal injury or death.

• Before using the die block, always pull the plug, which is connected to the die
block with a chain, out of the connector. When the chain is damaged, repair it
immediately. Be sure to use a chain of the length specified by AIDA (the original
length).
Improper maintenance, repair or length, or misuse of the chain can cause per-
sonal injury or death.

23
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

5. USING THE PRESS MACHINE SAFELY


5.1 ESSENTIAL BASIC RULES

WARNING
• Do not modify the machine and do not modify or remove the control circuits.
In particular, never modify, remove, or relocate the sections related to safety and
safety devices.
If modified, removed, or relocated, the machine or the safety device will no longer
function properly, and there is a possibility that personal injury or death could be
caused.

• Do not use the press machine beyond the specified limits. Furthermore, do not
use the machine under abnormal conditions, such as operating the machine in
an inclined position, or using for hot working.
If used under such circumstances, the machine and safety devices may not func-
tion properly, causing possible personal injury or death.

• Hand feeding tools are not safety devices.


Hand feeding tools are not to be used in place of safety devices.
Hand feeding tools cannot prevent insertion of the operator’s hand into the point
of operation, and may result in personal injury.

• Avoid wearing loose clothes or accessories as they may be caught by the


machine, resulting in personal injury or death. In addition, wear protective gear,
such as a safety helmet, protection goggles, steel-toed shoes, a mask, or gloves,
as necessary.

• Operation and maintenance, etc., must be performed by operators or authorized


persons who have received safety training.
If undertaken by those who have no knowledge of the hazards or the correct
operation of the press machine, there is a possibility that personal injury or death
could result.

• Perform installation, operation, and maintenance work of this machine according


to this instruction manual.
Unsafe usage of the machine or the performance of operation, service or mainte-
nance tasks not specified in this manual could result in personal injury or death.

• The design, manufacture, and use of dies are the responsibility of the user.
Assess the hazards caused by dies and presswork, and implement necessary
countermeasures.

• The front-rear dimension of the upper die must be equal to or less than that of the
slide.
Otherwise, the press machine may be damaged or personal injury or death may
occur.

(Continued on the next page)

24
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

(Continued)

WARNING
• If quick-drying, high-volatility material coating fluids are used in the material oil
coating device, the customer is responsible for assuring that measures are
implemented to prevent the spray, etc., from such coating fluids from coming into
contact with the press and with peripheral devices.
Quick-drying, high-volatility coating fluids can degrade press lubrication oil per-
formance, as well as cause paint coatings, seals, hoses and the plastic coatings
on wiring to harden, expand, and/or peel.
There is a fire hazard risk from electrical short circuits resulting from wire or ter-
minal block deterioration due to contact with such coating fluids.
Take appropriate measures in accordance with the information provided on the
coating fluid Material Safety Data Sheet.

CAUTION
• When water-soluble material coating fluids are used in the material oil coating
device, the customer is responsible for assuring that measures are implemented
to prevent such coating fluids from contaminating the lubricants of the press and
of peripheral devices.
If water-soluble material coating fluids contaminate the machine lubricants, the
lubricants may quickly deteriorate and lose their lubricating properties, resulting
in machine failure.
Should it be impossible to completely prevent material coating fluids from con-
taminating the machine lubricants, an oil-water separator or some other appropri-
ate device should be used. In addition, the standard interval between lubrication
oil changes should be shortened.

25
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

5.2 ESSENTIAL USAGE ENVIRONMENT PRECAUTIONS

DANGER
• Do not operate the machine in a location where combustible gases are present.
There is a possibility that a spark from a switch, etc., could cause an explosion or
fire that could result in personal injury or death.

WARNING
• Do not use the machine under the following conditions, and do not operate the
machine in such a way as to cause such conditions.
Operating the machine under these conditions may damage electronic equip-
ment or machine parts, or may cause a fire, electric shock, or a malfunction that
could result in personal injury or death.
(1) When the machine and the control panel are exposed to excessive airborne
oil, water, or chemicals.
(2) When excessive dust, minute particulates, and/or metal particles are pres-
ent.
(3) When corrosive gases are present.

• Maintain the temperature inside the plant building between 5 and 40°C (41 to 104
°F). (The allowable relative humidity is between 45 and 85%.)
If the temperature is below this range, there is a possibility that the servo motor
will not start, or of galling of the bushings or liners due to insufficient lubrication.
If the temperature is above this range, there is a possibility of degradation of
brake performance, or galling of the bushings or liners due to a degradation of
the lubrication function.
When it is anticipated that the temperature will be beyond the above range, con-
sult with AIDA Service (listed at the end of this instruction manual).

• Do not use the machine at a location higher than 1,000 meters (3,280 ft.) above
sea level.
If the machine is used at a location higher than 1,000 meters (3,280 ft.) above
sea level, there is a possibility that the motor and other parts may overheat and
cause a fire.

CAUTION
• The machine must be installed in a plant building where there is adequate illumi-
nation (750xl more) and floor space for normal work.
Otherwise, operation and inspection cannot be performed properly, and there is a
possibility of injury or machine damage.

26
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

5.3 ESSENTIAL INSTALLATION PRECAUTIONS

DANGER
• Ground the machine properly. (See Section C INSTALLATION,
4. CONNECTING TO THE POWER SOURCE (pg. 84).)
Do not connect grounding cables to the steel frames or the steel props of the
building as an alternative means of grounding.
If grounding is not followed, there is a possibility of accidental electrical shock
which could result in death.

WARNING
• Transportation, hoisting, and installation of the machine requires special techni-
cal expertise. Use a contractor that specializes in such work or AIDA Service
(listed at the end of this instruction manual) to perform such work.
If such work is performed by unskilled workers, there is a possibility that the
machine could be dropped, etc., and could result in personal injury or death.

• Grounding and connection to the power source must be performed by qualified


electricians according to the engineering standards for electrical equipment. (See
Section C INSTALLATION, 4. CONNECTING TO THE POWER SOURCE (pg.
84).
If such work is performed by an unauthorized person, there is a possibility of
accidental electrical shock which could result in death.

27
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

5.4 ESSENTIAL OPERATION PRECAUTIONS

WARNING
• Do not operate the machine with side covers or covers for rotating or moving
areas removed or opened.
Operating the press machine with such covers removed could lead to a serious
accident where a part of someone’s body could get caught in the running
machine.

• Do not put your hand or any other part of your body between the upper and lower
dies while the slide is moving or being adjusted.
Doing such could lead to your hand or other body part getting caught.

• Keep away from the press machine while the slide is moving.
Personal injury or death may be caused by approaching the machine and coming
close to the point of operation.

• Never remove the guard (shutter) or add modification to it such as cutting.


Otherwise, fraction of a die or a product when damaged may hit the operator
leading to an injury.

• Control the keys for the key switches of the press machine and its safety devices,
first making sure that the work methods and operational procedures are totally
safe.
Misuse may result in personal injury or death.
(See Section D OPERATION, 2.1 MAIN OPERATION PANEL (pg. 92).)
Keys: CONTROL POWER Switch
DATA EDIT Switch
OPERATION SELECT Switch
Key Switches for Other Peripheral Devices
• Before starting work, always perform pre-work checks and the Routine Inspec-
tion items (See pg. 187.) If any abnormal conditions are found, repair them
immediately.
Starting work without repairing such items may result in personal injury or death.

• In cases where metal pieces or other chips may possibly fly out of the point of
operation, install guards around the press machine and in front of operator.
Flying metal may lead to personal injury or death.

• Before starting operation, confirm that no personnel or obstructions are present


in the vicinity of the press machine.
It is strictly prohibited to place tools or parts on the bolster, as this could lead to
the possibility of unintentional personal injury due to objects flying out of the
press machine.

(Continued on the next page)

28
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

(Continued)

WARNING
• When materials are fed by hand, operate the press machine in SINGLE mode
using the two-hand RUN buttons.
Do not operate the press machine in the HOME POS.RETURN,STEP FEED,
INCH, or LINE modes.
If any of these other modes is selected, there is the danger of a hand being
caught in the die.

• Never place your hands in the die area or the point of operation.
If it is necessary to access the die area or the point of operation, be sure to use
tongs, etc., instead of your hands to protect yourself from possible serious injury.

• The STEP FEED or INCH. mode operation should be used only for die change or
inspection.

• When pushing the two-hand RUN buttons, always push both of them at the same
time using both hands. For STEP FEED operations, while pressing the STEP
FEED ENABLE button with one hand, be sure to operate the manual pulse gen-
erator with your other hand.
If you push one of the two RUN buttons with some tool, etc., some part of your
body may enter into the point of operation, and personal injury or death may
occur.

• When two or more people are involved in operating the press machine, each of
them must use their own set of two-hand RUN buttons.
Misuse may result in personal injury or death.
• If any problems occur while the slide is in operation, stop the slide immediately
by pushing the EMERGENCY STOP button. Take troubleshooting action accord-
ing to the instructions of authorized personnel.

• Before removing scraps or troubleshooting, always perform steps (1) ~ as


described in Section A SAFETY, 6. SAFETY PROCEDURES DURING
ADJUSTMENT (pg. 33).
Misuse of the press machine may cause personal injury or death.

• Before putting your hand[s] between the upper and lower dies in order to change
dies, to make adjustments, or to perform maintenance, always perform steps (1)
through (4) as described in Section A SAFETY, 6. SAFETY PROCEDURES
DURING ADJUSTMENT (pg. 33).

(Continued on the next page)

29
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

(Continued)

WARNING
• Be sure to conduct periodic inspections of the press machine and safety devices.
Improper inspection and maintenance could result in the possibility of personal
injury or death.
For the inspection items, see Section E MAINTENANCE, 1. PERIODIC
INSPECTION (pg. 323).

• Do not touch the servo motor with your hand while operation and immediately
after operation.
The servo motor reaches a high temperature during operation and could burn
your hand.

• Adjustment and maintenance of electronic equipment must be performed by an


electrician.
If done by an unauthorized person, press machine malfunction or electric shock
may occur, which could lead to personal injury or death.

• Before opening a control panel door, etc., be sure to shut off the power supply
from your power source.
Otherwise, a fatal accident may be caused by electric shock when the insides of
a control panel are touched.

• Even after the power supply is turned off, the capacitor and other parts remain
charged with high-voltage electricity for a short period of time, so be sure to wait
for a period of time before performing maintenance.
Touching high-voltage internal areas can result in death from electric shock.

• Replace parts and components related to safety before they reach their standard
service life even if they are working properly. (See Section E MAINTENANCE,
4.2 SERVICE LIFE OF ELECTRICAL COMPONENTS (pg. 343).) Replace failed
parts--do not repair them.
Personal injury or death may be caused by a malfunction.
When replacing safety parts, such as RUN buttons, EMERGENCY STOP but-
tons, brake solenoid valve, etc., be sure to use replacement parts from the same
manufacturer that have the same model or part number.
(See Section E MAINTENANCE, 7. DRAWINGS (pg. 362) "PARTS LIST".)

• Before performing maintenance, inspection, lubrication, and cleaning of the


machine, be sure to follow all of the steps in Section A SAFETY, 6. SAFETY
PROCEDURES DURING ADJUSTMENT (pg. 33).
Otherwise, there is a possibility of personal injury or death owing to misuse.

30
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

5.5 ESSENTIAL MAINTENANCE PRECAUTIONS

WARNING
• When work is performed at a location that is 1.5 m (4.9 ft.) or higher above floor
level, be sure to use a ladder and platform with safety features suitable for high
lift work. Do not use part of the machine as a scaffold.
Furthermore, when working at a high location, use a safety rope to prevent falls.
Otherwise, there is a possibility of personal injury or death caused by falling
down.

• Die maintenance must be performed after dies are removed from the press
machine.
Otherwise, an unexpected accident may occur.

• When getting onto the crown, open the open-and-shut bar (with deck interlock)
provided at the entrance to the deck, and then get onto the deck. Do not shut the
opened bar until getting down from the deck after the work on the crown has
been finished.
The press becomes operable when the bar is shut, and therefore personal injury
or death can be caused by unintended actuation of the press.

31
Section A SAFETY 5. USING THE PRESS MACHINE SAFELY

5.6 ESSENTIAL PRECAUTIONS WHEN INSTALLING PRESENCE-SENSING


DEVICES

WARNING
• Optical presence-sensing devices are fundamental safety devices, and when
AIDA installs these devices it is done in accordance with the requirements
explained in this section.
• If the user installs the optical presence-sensing device, be sure to install it in
accordance with the requirements given in this paragraph.
• The end-user must assess the risks and investigate and take measures to
reduce such risks in accordance with the "Guidelines for Assessing Risks and
Hazards." (The Japan Ministry of Health, Labor and Welfare Ministerial Notifica-
tion dated March 10, 2006)
Refer to "How to Perform Risk Assessments" on the homepage of the Japan Min-
istry of Health, Labor and Welfare. (Japanese version only.)
http://www.mhlw.go.jp/bunya/roudoukijun/anzeneisei14/dl/press1.pdf
(This address is subject to change.)

5.6.1 Selection of Presence-Sensing Devices

(1) Optical presence-sensing devices that conform to the "Standard for Safety Construc-
tion of Presses or Shears" (The Japan Ministry of Health, Labor and Welfare Ministe-
rial Notification No. 102) will be selected for use.
(2) Optical presence-sensing devices with redundant circuits that can prevent the occur-
rence of a hazardous situation if the device itself, including auxiliary light beams, were
to fail will be selected for use.

5.6.2 Scope of Safeguarding

The optical presence-sensing device must not allow an operator's hand, etc., to reach into
the work area (danger zone) without it first passing through the sensing field of the optical
presence-sensing device.
• It shall not be possible for workers to access the danger zone by entering in between the
side of the bolster and the light beams. (Install auxiliary light beams or guard plates)
• It shall not be possible for workers to access the danger zone by reaching in from above
the highest light beam.
• It shall not be possible for workers to access the danger zone from either the right or left
side of the sensing field. (Install side guards)

5.6.3 Measures for Cases Where a Worker Could Remain within the Safeguarding Zone
(Danger Zone)

(1) In the case of large press machines, if a worker can access the danger zone by pass-
ing through the sensing field of an optical presence-sensing device and then remain in
the danger zone without being detected or can otherwise remain in the danger zone
without being detected, a reset button will be provided in a location that allows the
operator to directly view the danger zone and confirm that all personnel have exited
the danger zone, and this reset button must be pushed in order to enable the restarting
of the press machine.
(2) If any hazardous situation owing to installation of the protection device, installation of
the automation equipment, and temporary deactivation of the protection device at the
time of setting of material or modification is foreseen, even if it is minor, the enterpriser
must make a risk assessment. Further, the enterpriser must provide a reset button to
confirm that no person remains in the danger zone in accordance with 5.6.3 (1).

32
Section A SAFETY 6. SAFETY PROCEDURES DURING ADJUSTMENT

6. SAFETY PROCEDURES DURING ADJUSTMENT

WARNING
• Before an operator enters a hazardous area in order to perform adjustments,
inspections, or maintenance, confirm that the following actions have been taken
by qualified personnel. The keys that have been removed from the key switches
must be held by the operator.
If the press machine is misused, there is a possibility of personal injury or death.

(1) Push the EMERGENCY STOP button. G


ER EN

EM

C
Y
(2) Set the OPERATION SELECT switch to OFF, and
remove the key from the key switch.
STEP
FEED INCH
STOP SINGLE

HOME POS.
RETURN LINE

(3) Set the SLIDE LOCK to LOCK. SLIDE LOCK


OFF
DIE
CHANGE
MANUAL AUTO UNLOCK
OPE. SELECTOR

(4) Set the CONTROL POWER switch to "OFF", and


remove the key from the key switch.

(5) Turn the disconnect switch to OFF, then lock out the circuit LOCK

breaker using a padlock.

(6) Shut off the power supply from your power source and CONT ROL PO WE R
ON OFF

lock out the power supply switch using a padlock. If


the power supply switch cannot be locked out, put up a
sign saying "DO NOT OPERATE" at locations requir-
ing lock-out.

(7) Close the air stop valve (1) located at the press air
O N TRIP OFF
RESET
OPEN

supply port, then lock-out the stop valve using a pad-


lock.
Next, turn the air exhaust valve to the EXH (exhaust) OFF
position. Padlock the valve after all the residual air has
been vented.
See the system drawing for the method for relieving
residual air pressure in each system. DO NOT O PERATE

If lock-out is not possible, put up signs saying “DO (2)


NOT OPERATE” at locations requiring lock-out. (1)

(8) Prepare signs saying "DO NOT OPERATE," and put


them up at easy to see locations.
EXH

DO NOT OP ERA TE

DO NOT OPERATE

NOTE • When restarting operation, perform the above steps in reverse order.

33
Section A SAFETY 7. WARNING PLATES

7. WARNING PLATES

WARNING
• Important messages for the prevention of personal injury or death are contained
on the warning plates.
(1) Rigidly adhere to the message content,
(2) Do not damage or stain, and
(3) Do not remove any warning plates.
When a warning plate has been damaged to the extent that it is not legible, or it
has been taken off and lost, contact AIDA Service (listed at the end of this
instruction manual) immediately.

The warning plates and their standard attachment locations are shown on the following pages.

NOTE • Due to manufacturing requirements, the attachment location of warning plates


may differ slightly.
• Warning plate numbers may be different depending on the machine model.
Check the plate number on the actual machine.

34
Section A SAFETY 7. WARNING PLATES

106-19720 (2286)
106-19721 (2287)
106-19722 (2288)
106-19723 (2289)

35
Section A SAFETY 7. WARNING PLATES

36
Section A SAFETY 7. WARNING PLATES

250-02316

37
Section A SAFETY 7. WARNING PLATES

38
Section A SAFETY 7. WARNING PLATES

Caution (HOLP oil inlet)


REV. Arrow Mark
CAUTION
PERFORM CHECK, REPLENISHMENT, AND DRAINING OF OVERLOAD
PROTECTOR OIL AS DIRECTED IN THE INSTRUCTION MANUAL.

PRECAUTION
REALICE LA INSPECTION. EL RELLENO Y EL DRENAJE DEL ACEITE
DEL PROTECTOR DE SOBRECARGA COMO SE JNDICA EN EL
MANUAL DE INSTRUCTIONS.
N9017es

Caution (Disassembly)

CAUTION 2011N

Read the handling instructions before disassembling in


order to run an inspection or make an adjustment.

PRECAUCION
Lea las instrucciones de manejo antes de desarmar
para hacer una inspeccion o un adjuste.
N2060es

C&B Solenoid valve manual operate prohibit

WARNING
NEVER manually operate the electromagnetic valve of the
clutch brake when the flywheel is turning.
If the electromagnetic valve is manually operated while the
flywheel is turning, it can cause an accident due to the
sudden drop of the runner.
N2068e

ADVERT ENCIA
NUNCA accione manualmente la valvula
electromagnetica del freno del emblague
cuando el volante este girando.
Si la valvula electromagnetica se acciona a mano
mientras gira el volante, puede causar un
accidente debido al descenso subito de N2068s
la
corre dera.

Die Block Warning

DANG ER
Die Block must be used when dies are being repaired or adjusted.
Never remove this Die Block from this machine.
Never use Die Block for other than intended purpose.

PELIGRO
Debe utilizarse un bloque de seguridad cuando se reparen o ajusten
las matrices.
Nunca quite este bloque de seguridad de la maquina.
Nunca use este bloque de seguridad para otro proposito.
N2061es

39
Section A SAFETY 7. WARNING PLATES

Two-Hand Operation Warning

WARNING
NEVER attempt to change or remove the controls or
safety equipment in this machine.
The operator must use both hands at the same time
to start up the press.
ADVERTENCIA
NUNCA intente modificar ni quitar los controles ni
los equipos de seguridad de esta maquina.
El operador debe utilizar simultaneamente ambas
manos para poner la prensa en funcionamiento.
N2056es

Warning about Accessing the Press Machine

DANGER
Do not extend your hands or body beyond this
point while the press is in operation
PELIGRO
No extienda las manos ni su cuerpo más allá
de punto mientras la prensa esté en
funcionamiento.
N2415es

Prohibit invasive hand & finger

DANGER
Keep hands and fingers off moving parts under this cover.
N2052e
PELIGRO
Mantenga las manos y los dedos alejados de las piczas
movibles debajo de esta cubierta.
N2052s

Operation-Related Caution Note

Before starting up the press; check that all the electrical equipment,
tools, dies and safety equipment are adjusted correctly.
Read the safety manual.
The selector keys must be under the strict control of an authorized
person. (The key to the main switch cannot be removed when the
switch is set at ON.)

Antes de poner en funcionamiento la prensa, compruebe que todos los


equipos electricos, herramientas, matrices Y equipos de seguridad esten
ajustados correctamente.
Lea el manual de seguridad.
Las llaves de los selectores deben ser estrictamente controlados por
una persona autorizada. [La llave del interruptor principal no puede
sacarse cuando el interruptor esta activado (posicion ON)]
N2059es

40
Section A SAFETY 7. WARNING PLATES

Warning

TO PREVENT SERIOUS BODY INJURY


NEVER PLACE ANY PART OF YOUR HANDS OR BODY WITHIN
THE POINT OF OPERATION OR ANY PRESS
PINCHPOINT UNLESS POWER IS LOCKED OFF, RAM
AND DIE ARE BLOCKED AND FLYWHEEL IS AT REST.
NEVER OPERATE THIS POWER PRESS WITHOUT PROPER
INSTRUCTIONS AND WITHOUT THE USE OF A POINT
OF OPERATION GUARD OR DEVICE.
NEVER OPERATE THIS MACHINE UNLESS SAFETY GUARDS
OR DEVICES ARE IN PLACE AND ADJUSTED
PROPERLY.
NEVER ADJUST OR REPAIR DIES WITHOUT THE USE OF
SAFETY BLOCKS OR INSTALL OR REMOVE DIES
WITHOUT ESTABLISHING SAFE DIE SETTING
PROCEDURES.
NEVER PERFORM MAINTENANCE OR REPAIR WORK IN A
MANNER OTHER THAN OUTLINED IN THE SERVICE
MANUAL PROVIDED BY THE MANUFACTURER OF THIS
POWER PRESS.
IT IS THE EMPLOYER'S RESPONSIBILITY TO IMPLEMENT THE
ABOVE AND ALSO TO PROVIDE PROPER DIES, GUARDS,
DEVICES OR MEANS THAT MAY BE NECESSARY OR REQUIRED
FOR ANY PARTICULAR USE, OPERATION, SET-UP OR SERVICE.
DO NOT REMOVE THIS SIGN FROM THIS POWER PRESS
N2062e

PARA EVITAR SERIOS ACCIDENTES


NUNCA PONGA LAS MANOS O NINGUNA OTRA PARTE DE SU CUERPO DENTRO DEL
PUNTO DE OPERACION O DE LOS PUNTOS DE PRESION DE LA PRENSA SIN
ANTES DE ASEGURARSE QUE LA MAQUINA ESTE APAGADA EN POSICION
(OFF) QUE EL PORTA MATRIZ MOVIL ESTE BLOQUEADO Y EL VOLANTE ESTE
PARADO.
NUNCA PONGA EN OPERACION LA PRENSA SIN TENER LAS INSTRUCCIONES
APROPIADAS Y SIN EL USO DE UN PROTECTOR O GUARDA EN EL PUNTO
DE OPERACION.
NUNCA PONGA EN OPERACION ESTA MAQUINA A MENOS QUE LOS PROTECTORES DE
SEGURIDAD ESTEN BIEN COLOCADOS Y AJUSTADOS.
NUNCA AJUSTE O REPARE LAS MATRICES SIN HABER COLOCADO LOS BLOCKS DE
SEGURIDAD Y NUNCA INSTALE O QUITE LAS MATRICES SIN ANTES
HABERSE ESTABLECIDO LOS PROCEDIMIENTOS SECUROS PARA EL CAMBIO
DE MATRICES.
NUNCA LLEVE A CABO TRABAJOS DE MANTENIMIENTO O REPRACION EN UNA FORMA
QUE 'NO SEA LA QUE ESPECIFICA EL MANUAL DE SERVICIO, PROVEIDO POR
EL FABRICANTE DE ESTA PRENSA MECANICA.
ES RESPONSABILIDAD DE LA EMPRESA HACER CUMPLIR LO ANTEDICHO Y PROVEER LAS
MATRICES, PROTECTORES, DISPOSITIVOS O MEDIOS ADECUADOS QUE SEAN NECESARIOS
O REQUERIDOS PARA EL USO, OPERACION, CAMBIO O SERVICIO ESPECIFICO.

NOTA: NO QUITE ESTE AVISO DE ESTA PRENSA MECANICA.


N2062s

41
Section A SAFETY 7. WARNING PLATES

Warning Safety Device

WARNING
On a servo drive press machine, two-hand RUN buttons
do not function as safety devices. It is necessary to use
presence sensing devices (e.g., light curtains), guards,
and/or other devices to safeguard the servo drive press
machine point of operation at all times, including during
setup and maintenance.
CUIDADO
En una prensa con transmision servo, los dos botones
de RUN, no funcionan como dispositivos de seguridad.
Es necesario utilizar dispositivos de deteccion de
presencia (por ejemplo, cortinas de luz), guardas u otros
dispositivos, para salvaguardar el punto de operacion de
la prensa serve en todo momento, incluso durante el
ajuste y el mantenimiento.
N3245es

Caution (high temp.)

CAUTION PRECAUTIÓN
Alta temperatura. Puede quemarse.
High temperature can burn.
No acerque las manos durante el
Keep hands away during operation and
funcionamiento ni inmediatamente
immediately after stopping operation. después de parar la operación.
N3035e N3035s

Warning (Die area)

CIUDADO WARNING
El troquel puede
aplastarle las Die can crush
manos. hands.
No entrar en la Do not enter
zona de la machine area
maquinamientra while press
la prensa esta en running.
funcionamiento. 2656Nes

Oil Filter Cautions(See pg. 356.)

CAUTION
1.If a warning message informing the operator
of a clogged filter comes up on the display,
replace the element in the line filter
(discharging side) with a new one.
2.Perform normal maintenance only on the suction
filter (on the suction side). Be sure to refer
to the Instruction Manual for details on how
to replace and clean the element. 2751Ne

42
Section A SAFETY 7. WARNING PLATES

Oil Filter Cautions(See pg. 356.)

PRECAUTION
1.Si en la pantalla aparece un mensaje de aviso informando
a la operadora que un filtro esta obstruido, reemplace el
elemento en el filtro del ducto (lado de descarga) por
otro nuevo.
2.Ejecute el mantenimiento normal solamente en el filtro
de succion (en el lado de succion). Para mas detalles
sobre el modo de reemplazar y limpiar el elemento,
consulte sin falta el Manual de Instrucciones. 2751Ns

Caution (danger)

PRECAUTIONS TO PREVENT ACCIDENTS


In no event shall AIDA be liable for any damages due to an
accident caused negligence in taking the following precautions.
1. Operate and maintain the press and the associated equipment
according to description in the instruction manuals.
2. When the press is operated in the SINGLE, CONTINUOUS SINGLE, or
CONTINUOUS mode, or when it is operated by a foot pedal switch, use
all safety devices (such as the barrier guard and light curtain).
3. Before starting the press operation, do the START UP INSPECTION and
ROUTINE CHECK as specified in the instruction manual.
In particular, ensure the following, which directly affect the safety of
operation.
(1) Proper lubrication.
(2) That the slide stops exactly in the preset stop position (within±10 o)
(3) That the slide stops in the preset stop position even if the
RUN buttons are kept depressed during SINGLE mode operation.
4. Do not operate the press with the safety device switch off except
while the dies are being set. Do not operate the press with the
barrier guard removed.
5. When the work is halted, turn off the operation selector switch.
When the operator leaves the machine, turn off the main motor and
depress the EMERGENCY STOP button.
6. When checking or repairing the dies or machine, do step 5 (above),
and put up a "DO NOT OPERATE" sign on the operating panel.
7. Do not modify the machine or electric circuits and do not remove
any component or them. Especially, never modify or remove any
safety device or any component related to safety.
8. Do not adjust the rotary cam or the timing switch that controls the
SINGLE mode operation, stopping the slide in the preset stop
position, and non-repeat function.
9. Drain the sludge from the pneumatic system every day.
10.Do not operate the machine beyond the capacities and limits
specified in the instruction manual.
11.The slide adjusting device cannot pre-load dies. If the device is
not properly adjusted, the device may be overloaded and damaged.
Use the slide adjusting device as explained in the instruction
manual.
12.When starting the machine after a halt of more than 24 hours,
operate the oil pump for five minutes or more before you start the
main motor; this will prevent trouble due to poor lubrication.
(This step is not required on a machine with oil bath lubricating
system.)
13.Periodically measure the actual stroke length of the brake, and
adjust the stroke to be within the allowable limits in accordance
with the instruction manual. If the brake is used in excess of the
allowable stroke limits, the performance of the brake will be
deteriorated and it is detrimental to safety operation. Therefore,
it is very dangerous.

N3364e

43
Section A SAFETY 7. WARNING PLATES

Caution (danger)

PRECAUCIONES PARA LA PREVENCION DE ACCIDENTES


AIDA no será responsabel por los dańos debidos a accidentes
que estén causados por negligencias en la observación de las
siguientes precauciones.
1. Manejar y mantener la prensa y le equipó relacionado con ella de acuerdo con la
descrito en los manuales pertinentes.
2. Antes de manejar la prensa, realice la INSPECCION DE COMIENZO y la COMPROBACION
RUTINARIA como se especifica en el manual de manejo. Asegúrese particularmente de lo
siguiente, ya que afecta directamente la sequridad de operación{
(1) Lubricación correcta
(2) Que la corredera se detiene exactamente en la posición de parada preestablecida
(margen de ±10°)
(3) Que la corredera se detiene en la posición de parada preestablecida aunque se
mantengan oprimidos los botones RUN durante el funcionamiento en modalidad
individual(SINGLE).
3. No maneje la prensa sin las cubiertas fijas.
4. Cuando se interrumpa el trabajo, desconecte el selector de operación. Cuando el
operador deje la máquina, desconecte el motor principal y oprima el botón de parada
de emergencia(EMERGENCY STOP).
5. Cuando compruebe o repare los troqueles o la máquina, realice el paso 4 (arriba) y
ponga un cartel con "NO OPERAR" en el panel de operación.
6. No madificar la máquina ni los circuitos eléctricos y no desmontar ningún componente
de ellos. En especial, nunca modificar ni desmontar dispositivos de seguridad ni
cualquier componente relacionado con la seguridad.
7. Drene diariamente los depósitos del sistema neumático.
8. No maneje la máquina por encima de su capacidad y limites especificados en el
manual de manejo.
9. El despositivo de ajuste no puede precargar troqueles. Si el dispositivo no está
ajustado correctamente el dispositivo puede sobrecargarse y dańarse. Use el dispositivo
de ajuste de la corredera como se explica en el manual de manejo.
10.Cuando ponga la máquina en funcionamiento después de haber estado parada más
de 24 horas, accione la bomba de aceite durante cinco o más minutos antes de
paner en marcha el motor principal, ya que esto evitará problemas debido a una mala
lubricación. (No es necesario realizae este paso con máquinas que empleen un sistema
de lubricación por bańo de aceite).
11.Medir periódicamente la carrera real del freno, y ajustar la carrera dentro de los
límites permitidos de acuerdo con lo explicado en el Manual de Instrucciones. Si se
usa el freno excediendo los limites permitidos de carrera, se deteriorara el rendimiento
del freno lo cual es detrimente para la seguridad de funcionamiento. Es, por lo
tanto, muy peligroso.
N3364s

REG.Adjust unnecessary For approved greases to use

ADJUSTMENT. UNNECESSARY! GREASE


CAUTION
IF YOU BREAK THE WIRE SEALING, EVERY
6 MONTHS
WE ARE NOT RESPONSIBLE FOR
TROUBLES. N2010e
AIDA ENGINEERING, LTD. F001e

Caution (cushion oil)

CAUTION
PERFORM SUPPLEMENT AND DRAINAGE OF OIL AS
DIRECTED IN THE INSTRUCTION MANUAL.
N2694e

44
Section A SAFETY 7. WARNING PLATES

Caution for die cushion use

WARNING
THIS CUSHION SHOULD BE USED UNDER THE
FOLLOWING CONDITIONS FOR THE PURPOSE
OF USING STABLY.
A B
1. IN CASE OF THE PAD BEING DIVIDED IN
FOUR BLOCKS AS A, B, C, AND D. MORE
THAN ONE PIN SHOULD BE LOCATED AT C D
EACH BLOCK.
2. IN CASE OF USING TWO PADS AND TWO
CYLINDERS. EACH PAD SHOULD BE USED CUSHION PAD
UNDER THE CONDITION OF ITEM 1.
3. IN CASE OF UNABLE TO USING CUSHION PINS AT ALL BLOCKS AS
THE TOOLING DIE IS TOO SMALL AT LEAST ONE PIN SHOULD BE
LOCATED AT THE BLOCK WHICH IS NOT USED. TO MEET THE
CONDITION OF ITEM 1.
N2045e

INSTRUCCIONES PARA USO DEL AMORTIGUADOR DEL TROQUEL

1. Supongase gue el cojin amortigudor esta dividido


encuatro bloques iquales -A, B, C y D- segun
lo ensenado
~ a la dereclia. Cada bloque tiene que
poseer por lo menos un pasador amortiguador.
A B
2. Cuando esta provisto del sistema amortiguador
del troquel de dos cojines y dos cilindros, la regla
C D
mencionada arriba en el parrafo l se tendria
que aplicar a cada cojin. AMORTINGUADOR DEL TROQUEL

3. Si no se pueden disponer los pasadores de cojin en todos los bloques a


~ ~
causa del tamano del troquel excesivamente pequeno, el bloque en el que
no se puede disponer el pasador de cojin se debera proveerse de un pas-
ador para cumplir con la regla expresada arriva e el parrafo l.
N2045s

Air pressure caution

WARN ING
CLUTCH AND BRAKE AIR PRESSURE Check daily for correct pressure psi
CLUTCH AND BRAKE AIR PERFORMANCE Check daily for correct stopping position and test
clutch and brake monitor control system (see safety manual).
NEVER operate press when excessive slippage occurs.
PROPER STOPPING TIME FOR THIS MACHINE s.
COUNTER BALANCE AIR PRESSURE Check every day and after every tool change for correct
air pressure. Set according to the data.

CUIDADO
PRESION DE AIRE DEL CLUTCH Y FRENO Cheque diariamente la presion correcta psi
FUNCIONAMIENT DEL CLUTCH Y FRENO Cheque diariaments la posicion correcta de parada y
comprueve el sistema indicator de los controles (vea el manual de seguridad).
NUNCA opere la prensa si hay excesivo patinaje del clutch y freno.
EL TIEMPO CORRECTO PARA QUE ESTA MAQUINA PARE SON s.
PRESION DE AIRE DE CONTRAPESO Cheque todos los dias y despues de cada cambio de
herramienta si la presion de aire es correcta. Ajustela de acuerdo con las
instrucciones indicadas.
N2792es

45
Section A SAFETY 7. WARNING PLATES

Megger Test of Electronic Parts Caution (charge circuit)

CAUTION
1.No megger test is allowed for CAU TI ON
electronic device.
2.No megger test is allowed for OTHER CIRCUITS WILL
proximity switch.
5412Pe REMAIN LIVE EVEN
AFTER THIS SWITCH
Warning Mark Indicating Points of Electricity IS TURNED OFF.
This mark indicates a point of electricity.
Turn off your power supply switch before opening a
door or cover with this mark. If a person touch the
inside components, death from electric shock can
P RE C AU C I O N
result. OTROS CIRCUITOS PRE-
MANECERAN ACTIVOS
INCLUSO DESPUES DE
DESCONETAR ESTE
INTERRUPTOR. N2587es

(JIS B6015)

Warning on Circuits Connected to External Power Supplies

WARNING
Hazardous voltage can shock,
burn or cause death.
Orange wire circuits are connected
to external power source.
Turn off external power before
maintenance. 9118Ne

ADVERTENCIA
La muerte accidente lique por
la descarga electrica,
Naranja instracion electrica es
el suministro circuito de la
fuente desde de exterior. Corte
la inspeccion la fuente de exterior.
9118Ns

46
Section A SAFETY 7. WARNING PLATES

Warning (High Voltage, Hazard-


ous Voltage) Danger (capacitor)

DANGER
WARNING Since the machine is high-voltage equipment,
it can create a shock hazard resulting in a
death accident.
Even after having turned the power off, high
voltage remains in some parts such as a
capacitor.
Be sure to read the Instruction Manual and
follow the instructions given before starting
maintenance and inspection.
・Do not open the door of the control panel while the circuit is energized and within 20 minutes
after shutdown ofthe circuit's main power supply.
・Open the control panel door after confirming that the "RESIDUAL VOLTAGE"
warning lamp
・ on the capacitor panel goes out.
・ Check that, by means of a tester, the DC bus voltage has been totally
discharges.
・ Do not short-circuit between the DC buses.
・ Do not allow any person othe than the designated one to conduct
Hazardous voltage maintenances and inspection.
・ Be sure to use insulated tools and protective equipment.
can shock, burn ・ Be sure to install the inner protective covers after completion of work.
or cause death. 3 3 9 7 Ne

Turn off power


before opening
panel.
2620Ne
PELIGRO
Como la máquina es un equipo de alto
2620Ne voltaje, puede generar el riesgo de
electrochoque, lo que puede resultar en
un accidente mortal.
Aun cuando se haya apagado la máquina,
hay alto voltaje remanente en algunas
partes, tal como el capacitor.

ADVERTENCIA Asegúrese de leer el Manual de


Instrucciones y seguir las instrucciones
indicadas antes de empezar el
mantenimiento y la inspección.
・No abra la puerta del panel de control mientras que el circuito está energizado y
espere 20 minutos después de la desconexión de la fuente de alimentación principal
para abrirla.
・Abra la puerta del panel de control después de confirmar que se haya apagado la
lámpara de advertencia de "VOLTAJE RESIDUAL" en el panel de capacitor.
・Mediante un probador, compruebe que se haya descargado completamente el voltaje
del bus de CD.
・No cortocircuite entre los buses de CD.
・No permita que ninguna persona que no sea la designada ejecute el mantenimiento y
la inspección.
・Asegúrese de utilizar herramientas aisladas y equipos de protección.
・Asegúrese de reinstalar las cubiertas de protección internas al término del trabajo.
33 9 7Ns

El contacto con circuitos


con corriente electrica
puede electrocularte,
lesionarle gravemente o
causarle la muerte.
Corte la alimentacion
electrica antes de
abrir el tablero de control.
2620Ns

2620Ns

47
Section A SAFETY 7. WARNING PLATES

48
Section A SAFETY 8. PAINTING ON HAZARDOUS AREAS

8. PAINTING ON HAZARDOUS AREAS


Hazardous areas, such as moving sections, are painted yellow. (In areas where compliance
with OSHA regulations is required, yellow and black stripes are painted on some areas.) This
is done to call such areas to the attention of operators. Do not touch or approach these areas
as they are hazardous during press machine operation.

49
Section A SAFETY 8. PAINTING ON HAZARDOUS AREAS

50
Section A SAFETY 8. PAINTING ON HAZARDOUS AREAS

306-22441 (2286)
306-22442 (2287)
306-22443 (2288)
306-22444 (2289)

51
Section A SAFETY 8. PAINTING ON HAZARDOUS AREAS

52
Section A SAFETY 9. GLOSSARY

9. GLOSSARY
(1) Point of Operation: An area in which material is actually positioned and sub-
jected to various press machine processes including
shearing, stamping, forming, and assembling.

(2) Safety Device: A press machine controller or accessory with at least


one of the following functions:
1. To prevent the operator from mistakenly accessing
the point of operation.
2. To interrupt slide movement when the operator mis-
takenly puts his/her hand into the point of operation.
3. To push the operator’s hand back automatically
when the operator mistakenly puts his/her hand into
the point of operation during a process in which the
dies are to come into contact.
4. To prevent the slide from stroking if the operator
passes through the sensing area,or, to stop the slide
if the slide is stroking.

(3) Lockout: Disables the machine by locking the power supply


switch or air supply port in the OFF position.
Lockout prevents misuse or unintended operation by
other operators.

53
Section A SAFETY 9. GLOSSARY

54
Section B SPECIFICATIONS

Section B
SPECIFICATIONS

1. SPECIFICATIONS................................................................................................ 57

2. CHARTS............................................................................................................... 73

3. NAMES OF MAJOR COMPONENTS .................................................................. 74

4. ELEMENTS OF PRESSWORK............................................................................ 76
4.1 TONNAGE CAPACITY (NOMINAL CAPACITY)............................................................................. 76
4.2 TORQUE CAPACITY...................................................................................................................... 77
4.3 STROKE-TONNAGE CURVE ........................................................................................................ 77
4.4 ENERGY CAPACITY (WORKING ENERGY)................................................................................. 77

55
Section B SPECIFICATIONS

56
Section B SPECIFICATIONS 1. SPECIFICATIONS

1. SPECIFICATIONS
(1) See the “Technical Document” on the following pages for the specifications, compo-
nents, warranty, and so on of this press.

(2) See Section E MAINTENANCE, 7. DRAWINGS (pg. 362), “GENERAL VIEW” or


“LINE LAYOUT” drawing for the general dimensions of the press.

NOTE The die height means the distance between the top face of the bolster and the bot-
tom face of the slide with the slide adjustment up and the stroke down.

57
Section B SPECIFICATIONS 1. SPECIFICATIONS

58
Section B SPECIFICATIONS 1. SPECIFICATIONS

(1)

59
Section B SPECIFICATIONS 1. SPECIFICATIONS

(2)

60
Section B SPECIFICATIONS 1. SPECIFICATIONS

(3)

61
Section B SPECIFICATIONS 1. SPECIFICATIONS

(4)

62
Section B SPECIFICATIONS 1. SPECIFICATIONS

(5)

63
Section B SPECIFICATIONS 1. SPECIFICATIONS

(6)

64
Section B SPECIFICATIONS 1. SPECIFICATIONS

(7)

65
Section B SPECIFICATIONS 1. SPECIFICATIONS

(8)

66
Section B SPECIFICATIONS 1. SPECIFICATIONS

(9)

67
Section B SPECIFICATIONS 1. SPECIFICATIONS

(10)

68
Section B SPECIFICATIONS 1. SPECIFICATIONS

(11)

69
Section B SPECIFICATIONS 1. SPECIFICATIONS

(12)

70
Section B SPECIFICATIONS 1. SPECIFICATIONS

(13)

71
Section B SPECIFICATIONS 1. SPECIFICATIONS

(14)

72
Section B SPECIFICATIONS 2. CHARTS

2. CHARTS
The following charts are required in order to operate this press machine.
An explanation of the charts and how they are to be used is contained in Section B SPECIFI-
CATIONS, 4. ELEMENTS OF PRESSWORK (pg. 76). The authorized personnel must read
this paragraph, understand the charts, and use the press machine within its capacity limits.

(1) TONNAGE CURVE:

The curve and diagrams are shown on 7. DRAWINGS (pg. 362).

73
Section B SPECIFICATIONS 3. NAMES OF MAJOR COMPONENTS

3. NAMES OF MAJOR COMPONENTS

1 2 3 8 4

6 7

12
33

13 18

14

19
19
19
10
11
15 19

BACK

1. CAPACITOR ENCLOSURE 10.PRESS SUB OPERATION PANEL


2. POWER ENCLOSURE 11.OIL INLET
3. PRESS CONTROL ENCLOSURE 12.CROWN
4. DRIVER ENCLOSURE 13.SLIDE
5. 14.COLUMN
6. UPS ENCLOSURE 15.BED
7. TRANSFORMER 16.BALANCER AIR TANK
8. PLC 17.AIR INLET PANEL
9. TOTAL LUBRICATION 18.SLIDE LOCK

74
Section B SPECIFICATIONS 3. NAMES OF MAJOR COMPONENTS

30

33 33

31
32 19

33

18
29

9
22
19
27
23
29 19
19
20
19
28

19

16
16
19
25 19

17 24

LEFT FRONT

19.EMERGENCY STOP BUTTON 27.DRAIN VALVE


20.PRESS OPERATION PANEL 28.AIR CONTROL PANEL
21. 29.MB(MOVING BOLSTER)
22.STEP FEED OPERATION BOX 30.SERVO MOTOR
23.LOAD ANALYZER 31.BRAKE
24.LUBRICATING OIL TANK 32.BRAKE SOLENOID VALVE
25.HYDRAULIC OIL TANK 33.FLOW INDICATOR
26.

75
Section B SPECIFICATIONS 4. ELEMENTS OF PRESSWORK

4. ELEMENTS OF PRESSWORK

CAUTION
• The employer must observe the following before using and during use of the press
machine.

(1) Use the press within the specified tonnage capacity.


When performing blanking, use the press with a pressing force lower than the value
given in the "Limitation of the tonnage capacity for blanking" subsection below.
If used beyond its capacity, the slide, crankshaft, frame, and other parts can be
damaged.

(2) Use the press machine within the limits of the maximum allowable load indicated on
the stroke-tonnage curve.
If used beyond its allowable load, the slide drive-related parts and other compo-
nents may break.

(3) Use the press machine within its specified energy capacity (Continuous working
energy).
If used beyond its specified energy capacity, the servo motor and other components
may break.

Be familiar with the three elements of the press machine capacity (tonnage capacity, torque
capacity, and energy capacity), so that you can perform press machine operations within the
limits of the machine capacity.

4.1 TONNAGE CAPACITY (NOMINAL CAPACITY)

The tonnage capacity of the press machine is the maximum allowable pressure force that can
be safely sustained by the press machine during presswork with the slide at a position lower
than the rated tonnage point.
Use the machine with an adequate margin for the tonnage capacity by taking the following factors
into considerations.
(1) Variation in material sheet thickness
(2) Variation in material tensile strength (hardness)
(3) Die cutting surface wear
(4) Variation in the die lubrication condition
(5) Whether there is a stripper in the die, and the type of stripper
If the presswork involves blanking, particularly where a shock load due to breakthrough is gener-
ated, make sure that the workload is kept within the value given in the “Limitation of the tonnage
capacity for blanking” subsection below.

Limitation of the tonnage capacity for blanking


Models SMX ............ 70% of the tonnage capacity
See INSTRUCTIONS FOR PRESS MACHINE USAGE in the appendix for countermeasures
for breakthrough.

The tonnage capacity has been calculated on the assumption that the load is uniformly distrib-
uted in an area consisting of 60% of the bolster area, and located in the center of the bolster.
Avoid concentration of a heavy load in a small area, or off-center loading (the center of the
resultant load is not aligned with that of the press machine). If excessive concentration of a
load, or off-center loading is anticipated, contact our sales office shown on the last page of this
instruction manual.
Refer to "TECHNICAL DOCUMENT" in Section B SPECIFICATIONS, 1. SPECIFICATIONS (pg.
57) for the pressure capacity specifications.

76
Section B SPECIFICATIONS 4. ELEMENTS OF PRESSWORK

4.2 TORQUE CAPACITY

The torque capacity indicates the distance (in mm) above bottom dead center at which the
tonnage capacity can be generated.

4.3 STROKE-TONNAGE CURVE

The stroke-tonnage curve shows the relationship between the slide position above bottom
dead center of the strokes and the generated pressure (torque capacity).
The example below indicates that a press machine having a capacity of I is capable of blank-
ing work (1), but bending work (2) would exceed the capacity. Therefore, a press machine of
the torque capacity shown by the curve I cannot perform the bending work (2).
Note that the hydraulic overload protector works against the overload described in
4.1 TONNAGE CAPACITY (NOMINAL CAPACITY) (pg. 76) and does not work against the
overload of torque capacity. When using a tonnage monitor as a torque capacity overload
detector, consult our sales office (see the list at the end of this instruction manual).
A load meter of standard specifications cannot detect torque capacity overload. Furthermore,
even in the case of using a load meter with monitoring function, the load meter has no function
as a safety device against overload. Therefore, never operate the press machine for the work
exceeding the torque capacity.


Press capacity

(2) (1)
Bottom dead center

Stroke (above bottom dead center)


Presswork and stroke-tonnage curve

The above diagram is only an example. See 7. DRAWINGS (pg. 362) for the actual chart for
your machine.

4.4 ENERGY CAPACITY (WORKING ENERGY)

Energy capacity represents the energy that can be used in one cycle of operation. Energy
capacity specifications are given in Section B SPECIFICATIONS, 1. SPECIFICATIONS (pg.
57).

77
Section B SPECIFICATIONS 4. ELEMENTS OF PRESSWORK

78
Section C INSTALLATION

Section C
INSTALLATION

1. PREPARATION FOR INSTALLATION.................................................................. 81

2. TRANSPORTATION AND INSTALLATION .......................................................... 82

3. CONNECTING THE AIR SUPPLY ....................................................................... 83


3.1 CONNECTING TO THE AIR SUPPLY ........................................................................................... 83
3.2 AIR CONSUMPTION...................................................................................................................... 83

4. CONNECTING TO THE POWER SOURCE ........................................................ 84


4.1 CONNECTING TO THE POWER SOURCE AND GROUNDING .................................................. 84
4.2 GROUNDING ................................................................................................................................. 85

5. INITIAL LUBRICATION (OIL SERVICING) .......................................................... 86

6. POST-INSTALLATION CHECK ............................................................................ 87

79
Section C INSTALLATION

80
Section C INSTALLATION 1. PREPARATION FOR INSTALLATION

1. PREPARATION FOR INSTALLATION

CAUTION
• Be sure to take the bearing capacity of the soil into account prior to foundation work.
Otherwise, the press machine may partially sink.

• Be sure to reinforce the concrete of the base section on which the press machine is to be
installed with reinforcing bars.
Otherwise, the foundation concrete may be broken.

• Place anchor bolts perpendicularly.


If the anchor bolt is set in an inclined position, poor tightening or chipping of the bolt can
result.

(1) Have a specialist conduct foundation work in advance according to the foundation
drawings (Section E MAINTENANCE, 7. DRAWINGS (pg. 362))provided by AIDA.
(2) When the ground is soft, use reinforcing bars. Also, strengthen concrete accordingly
by increasing the thickness, etc.
(3) For the weight of the press machine, see the foundation drawings submitted by AIDA.

81
Section C INSTALLATION 2. TRANSPORTATION AND INSTALLATION

2. TRANSPORTATION AND INSTALLATION


For transportation, lifting, and installation, follow the precautions described in Section A
SAFETY, 5.3 ESSENTIAL INSTALLATION PRECAUTIONS (pg. 27).

Before installation, unpack the press machine and wash the machined surfaces with mineral
cleaning oil to remove the rust inhibitor.

NOTE If you need further information about installation, contact our sales office (see the
end of this instruction manual).

82
Section C INSTALLATION 3. CONNECTING THE AIR SUPPLY

3. CONNECTING THE AIR SUPPLY

CAUTION
• Supply dry and clean compressed air that contains no dust or sludge.
If air containing dust or sludge is used, the solenoid valve may malfunction or
rust may accumulate in the cylinder, leading to an accident.

• Examine the air consumption of the Mechanical device and other equipment, and
then determine the capacity of your compressed air source by adding the above-
mentioned air consumption to the air consumption stated in this instruction man-
ual.
If the supply of compressed air is inadequate, problems with the press machine
may occur.

3.1 CONNECTING TO THE AIR SUPPLY

(1) Regarding the piping from your air source, see the “FOUNDATION” (Section E MAIN-
TENANCE, 7. DRAWINGS (pg. 362)) which we submitted earlier.
(2) Set the air exhaust valve to EXH (exhaust).
(3) Close the stop valve on the air supply inlet. Connect the air supply inlet to your air line.
See “FOUNDATION” or “LINE FOUNDATION” in Section B SPECIFICATIONS,
3. NAMES OF MAJOR COMPONENTS (pg. 74) for the description of the air supply
inlet.
Supply air pressure: 0.5-0.7 MPa (73-102 psi)

Air supply inlet

Stop
valve

EXH.

Auto drain filter


Exhaust EXH. Exhaust valve
valve
AIR INLET PANEL(PIT)

3.2 AIR CONSUMPTION

See Section B SPECIFICATIONS, 1. SPECIFICATIONS (pg. 57).

83
Section C INSTALLATION 4. CONNECTING TO THE POWER SOURCE

4. CONNECTING TO THE POWER SOURCE


4.1 CONNECTING TO THE POWER SOURCE AND GROUNDING

CAUTION
• If the R,S, and T phases are wired incorrectly, it will reverse the rotational direction of
motor such as oil pump motors.

(1) Follow Section A SAFETY, 5.3 ESSENTIAL INSTALLATION PRECAUTIONS (pg. 27).
(2) Provide a power source switch in your plant to turn the power to this press machine on
and off.
This power source switch is hereafter referred to as your power source.
(3) Turn your power source OFF.
(4) Connect power source cables from your power supply to the main circuit breaker in
the control enclosure.
When connecting, pay attention to connect the R, S, and T phases correctly.
See foundation drawings submitted by AIDA (“FOUNDATION” or “LINE FOUNDA-
TION” in Section E MAINTENANCE 7. DRAWINGS (pg. 362)) for capacity (size) of
power supply cables and grounding cables.
(5) Connect your factory grounding wire to the grounding terminal of the press machine.

From your power supply

Your grounding cable

Grounding cable
terminal

Main circuit breaker

Power supply to press

84
Section C INSTALLATION 4. CONNECTING TO THE POWER SOURCE

4.2 GROUNDING

CAUTION
• Ground the machine properly by using a specialized contractor or other suitable
means.
Do not connect grounding cables to the steel frames or the steel props of the
building as an alternative means of grounding.

• Connect a grounding cable to each component as shown below in the "Good


Example."
Do not connect grounding cables to a common cable as shown below in the "Bad
Example."

Control Control Control Control Control Control


panel panel panel panel panel panel
A B C A B C

Grounding Grounding Common wire


Good Example Bad Example

• The grounding position should be as near to the control panels as possible.

If the above-mentioned cautions are not followed, noise can be generated in the
signal wires or the accessories, and as a result, improper operation or failure of
the machine can be caused. Further, an injury to or death of the operator can be
caused as a result of unexpected erroneous operation of the machine or by elec-
tric shock.

85
Section C INSTALLATION 5. INITIAL LUBRICATION (OIL SERVICING)

5. INITIAL LUBRICATION (OIL SERVICING)

CAUTION
• Service the press machine and equipment with lubricating oil, hydraulic fluid, and
grease before operating them. Operating the press machine before oil servicing
may cause seizure or breakage of the press machine.

• In order to ensure safe handling of lubricating oils, hydraulic fluid, grease, etc.,
obtain the product safety data sheets prepared by the lubrication manufacturer
from the lubrication supplier. Take proper measures in accordance with the infor-
mation on the data sheets.
Particularly, pay attention to first-aid action and actions in case of fire and spill-
age of these materials.

• Be careful not to spill oil. Wipe up spilled oil immediately.


If oil comes in contact with the control equipment, malfunctions may be caused
due to poor insulation.

• Be sure to use a ladder and platform with enhanced safety when working at high ele-
vations to supply oil.
Do not use any part of the press machine as a scaffold.
In addition, be sure to use a hook-type safety device (such as a lifeline) to prevent
falls when working at high elevations.

After installation, perform initial oil servicing (oil supply) at the following points. Prepare the
appropriate oil in advance (refer to Section E MAINTENANCE, 2.2 TYPES AND AMOUNTS
OF OIL (pg. 330)).

Initial Oil Servicing Point Lubrication Procedure


Supply clean oil through the oil servicing port until the oil quan-
tity upper limit lamp lights up or the upper level of the oil level
Lubricating Oil Tank gauge mounted on the side face of the oil tank is reached.
Hydraulic Oil Tank
Refer to Section E MAINTENANCE, 2.5 REPLACEMENT OF
OIL IN LUBRICATING OIL TANK (pg. 333).
Supply clean oil through the oil servicing port until the oil quan-
tity the upper level of the oil level gauge of the oil tank is
Hydraulic Overload Pro- reached.
tector Oil Tank
Refer to Section E MAINTENANCE, 2.6 HYDRAULIC OVER-
LOAD PROTECTOR OIL SERVICING (pg. 335).
Die Cushion Hydraulic oil
Contact AIDA Service.
(only No.1 press)

86
Section C INSTALLATION 6. POST-INSTALLATION CHECK

6. POST-INSTALLATION CHECK
The following items must be checked by a technician after installation. After making sure that
all the check items meet the evaluation criteria, proceed to the Pre-Work Check (See pg. 187.)
and the Routine Inspection (See pg. 188.) explained in Section D OPERATION.

Items to be Checked after Installation Evaluation Criteria Action

1 Check the oil level of the:


It is within the speci- Service with oil.
• Lubricating oil tank
fied range indicated
• Hydraulic oil tank
on the oil level gauge
• Hydraulic overload protector oil tank
or container or upper
• Die cushion hydraulic oil (only No.1 press).
limit lamp lights up.
2 Check the supplied air pressure
Slowly open the stop valve on the air supply
inlet. It is within the speci- Supplied air pres-
• Check the brake pressure gauge needle: It fied zone of the scale. sure must be
should remain in the white (or green) zone 0.5 - 0.7 MPa.
of the scale. (73 - 102 psi).
3 Check the power supply (to be done by an
electrician).
• Check if the grounding wires are connected Visual check Do the wiring.
to the terminals inside the control panel of
each machine.
Set all breakers inside each control panel to To be as stated in the Examine and
“ON”, and turn your power source “ON”. electrical specifica- inspect the power
• Check if each supplied power voltage is tion. supply.
same as the value stamped in the
“SOURCE” column of the electric specifica- Visual check
tions nameplate.

• Confirm that the (power source) light on


the operation panel comes on.

87
Section C INSTALLATION 6. POST-INSTALLATION CHECK

88
Section D OPERATION

Section D
OPERATION

1. CASE-BY-CASE OPERATING INSTRUC- 6.1 INTERLOCK INFORMATION MESSAGE LIST . 198


TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 6.2 FAULT INFORMATION MESSAGE LIST. . . . . . 214
6.3 FAULT CHECK UPON POWER ACTIVATION . 239
2. OPERATION DEVICES. . . . . . . . . . . . . . 92 6.4 HYDRAULIC OVERLOADS. . . . . . . . . . . . . . . . 243
2.1 MAIN OPERATION PANEL . . . . . . . . . . . . . . . . . 92 6.5 OVERRUNS . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2.2 SUB OPERATION PANEL . . . . . . . . . . . . . . . . . . 93 6.6 WHEN AN EMERGENCY STOP BUTTON HAS
2.3 MB FENCE RIGHT SIDE SUB OPERATION PANEL BEEN PUSHED . . . . . . . . . . . . . . . . . . . . . . . . . 245
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 6.7 WHEN THE EXTERNALLY CONTROLLED
2.4 MB FENCE LEFT SIDE SUB OPERATION PANEL BREAKER IS ACTUATED . . . . . . . . . . . . . . . . . 246
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 6.8 WHEN THE GROUND FAULT BREAKER IS ACTU-
2.5 STEP FEED OPERATION BOX . . . . . . . . . . . . . . 95 ATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
2.6 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 6.9 WHEN A THERMAL RELAY HAS TRIPPED. . . 247
2.7 FUNCTION AND OPERATION. . . . . . . . . . . . . . . 96 6.10 STICKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.8 OPERATION OF KEY SWITCHES. . . . . . . . . . . 109
2.9 SYMBOL MARKS FOR SWITCHES. . . . . . . . . . 110 7. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 250
7.1 SLIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 250
3. THE OPERATOR INTERFACE TERMINAL 7.2 COUNTERBALANCE CAPACITY ADJUSTMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.1 SCREEN CONFIGURATION . . . . . . . . . . . . . . . 112 7.3 SETTING TIMING SWITCHES . . . . . . . . . . . . . 255
3.2 COMMON OPERATION AND DISPLAY SCREEN 7.4 MOTION PROGRAM AUXILIARY FUNCTIONS 262
ELEMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.3 INITIAL Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 118 8. CHANGING DIES. . . . . . . . . . . . . . . . . . 265
3.4 THE PRODUCTION SCREEN . . . . . . . . . . . . . . 119 8.1 MANUAL DIE CHANGE . . . . . . . . . . . . . . . . . . 267
3.5 THE SETTING SCREEN . . . . . . . . . . . . . . . . . . 126 8.2 AUTO DIE CHANGE . . . . . . . . . . . . . . . . . . . . . 271
3.6 THE DIE CHANGE SCREEN . . . . . . . . . . . . . . . 149
3.7 THE RECIPE (DATABANK) SCREEN . . . . . . . . 154 9. OPERATION OF AUXILIARY EQUIPMENT
3.8 THE MAINTENANCE SCREEN . . . . . . . . . . . . . 167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.1 MECHANICAL DEVICE. . . . . . . . . . . . . . . . . . . 275
4. OPERATION . . . . . . . . . . . . . . . . . . . . . 186
4.1 PRE-WORK CHECK. . . . . . . . . . . . . . . . . . . . . . 187 10. Making Motion Program Settings . . . . . 275
4.2 ROUTINE INSPECTION AND OPERATION . . . 188 10.1 Operating motion . . . . . . . . . . . . . . . . . . . . . . . 277
4.3 LINE MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 10.2 PROCEDURE FOR MAKING MOTION PROGRAM
4.4 OPERATION MODES. . . . . . . . . . . . . . . . . . . . . 193 SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.5 PRESENCE-SENSING DEVICES AND OPERA- 10.3 KEY POINTS WHEN MAKING MOTION PRO-
TION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . 195 GRAM SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5. PROCEDURE WHEN COMPLETING WORK 10.4 MOTION PROGRAM EXAMPLES. . . . . . . . . . 291
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 10.5 MOTION SETTING FAULTS . . . . . . . . . . . . . . 319

6. RESETTING FAULTS . . . . . . . . . . . . . . 197

89
Section D OPERATION

90
Section D OPERATION 1. CASE-BY-CASE OPERATING INSTRUCTIONS

1. CASE-BY-CASE OPERATING INSTRUCTIONS

Regarding the case-based detailed explanation of operation, refer to the "Instruction Manual
for EHDC - 4000F" given in the Annex of the Instruction Manual for Press No.1.
It should be noted, however, that "Section A SAFETY" and "Section D OPERATION" in this
Instruction Manual should be read first to understand the basic safe operation of the machine
before fully utilizing the "Instruction Manual for EHDC-4000F".

91
Section D OPERATION 2. OPERATION DEVICES

2. OPERATION DEVICES
• The following illustrations show the operation panel layout under standard configuration.
The layout for your operation panel may be different due to customer requests, etc.
See the operation panel layout drawings in Section E MAINTENANCE, 7. DRAWINGS (pg.
362), 7.2 Electrical Drawings (Refer to separate volume) for the location of the switches
related to any optional devices that are installed on your machine that are not shown in the
illustrations given below.
• The numbers shown in the illustrations correspond to the explanation numbers used in
2.7 FUNCTION AND OPERATION (starting on page 96).
2.1 MAIN OPERATION PANEL

2
LEFT UPPER DIE SENSOR SINGLE/RIGHT UPPER DIE SENSOR

SENSOR 1 SENSOR 2 SENSOR 1 SENSOR 2

3 SENSOR 3 SENSOR 4
CONNECTED
SENSOR 3 SENSOR 4
CONNECTED

4
SENSOR 5 SENSOR 6 SENSOR 5 SENSOR 6

LOAD ANALYZER CRANK ANGLE

SPARE

1
480V 220V

TOP DEAD SERVO


CUSHION WARNING

6
CENTER POWER

PLC BOTTOM LUB.OIL


FAULT DEAD
LOWER END
CENTER

LOAD HYD.OIL
SPARE HOLP
ANALYZER LOWER END

5
DIE HEIGHT

m m

PRESS O.P.

7
8
IN DIE / OUT OF DIE SENSOR IN DIE SENSOR

ZONE 2
SENSOR 1 SENSOR 2
8 ZONE 1 ZONE 3
DIE CORD
CONNECTED
ZONE 4
DIE CORD
CONNECTED SENSOR 3 SENSOR 4

ZONE 6

ZONE 5 ZONE 7
CAM CHECK 1 CAM CHECK 2
ZONE 8

9 11 IN CASE OF No.2~4 PRESS

12
PRESS RUN PRESS RUN
1 2

GROUP STEP
UNIT INCH

10
OFF

10
LINE FEED SINGLE

ALL HOME POS.


LINE RETURN LINE

DIE
OFF CHANGE

LINE SELECTOR OPE. SELECTOR

92
Section D OPERATION 2. OPERATION DEVICES

17 RIGHT SHUTTER EMERGENCY STOP


16 15
13
STOP FAULT
UP ALTERNATIVE RESET RESET
PROTECTION

18
CYCLE STOP SAFE RUN
SP AR E

RIGHT

20 14
LIGHT CURTAIN BUZZER
RESET DOWN RESET

21 RIGHT MB
DIE CLAMPER
UNCLAMP
MANUAL
OPERATION
SLIDE ADJUST.

UP
UPPER DIE
CLAMPER
UNCLAMP
LUBLICATION
OIL PUMP
ON
MASTER
POWER
ON

19
SP AR E SP AR E SP AR E

22 CLAMP MANUAL AUTO DOWN CLAMP OFF OFF

25
SP AR E SP AR E SP AR E

SLIDE LOCK SCRAP CHUTE LIGHT


LUBLICATION

23
MANUAL DIE ROOM LIGHT NEXT DIE OIL HEATER CONTROL POWER
MANUAL AUTO UNLOCK MANUAL AUTO OPEN OVERRIDE OFF ON PREPARATION ON
OFF ON

31 SP AR E
LOCK CLOSE OPEN CLOSE
WORK AREA LIGHT

OFF
FRONT
ON
WORK AREA LIGHT

OFF
REAR
ON OFF
DATA EDIT
ON
LAMP CHECK
27
24
30 29 2826
2.2 SUB OPERATION PANEL
LEFT MB
DIE CLAMPER
UNCLAMP

SPAR E SPAR E SPAR E

CLAMP
32
SPAR E SPAR E SPAR E

14 NEXT DIE
PREPARATION BUZZER RESET
LEFT SHUTTER
UP

27 33
LEFT
LIGHT CURTAIN
CYCLE STOP LAMP CHECK RESET DOWN

16
24 EMERGENCY STOP
34
17
ALTERNATIVE
PROTECTION
SAFE RUN RESET

15 13
93
Section D OPERATION 2. OPERATION DEVICES

2.3 MB FENCE RIGHT SIDE SUB OPERATION PANEL

Refer to transfer instruction manual


RIGHT MB
35
MANUAL
CONTROL POWER AUTO MODE FAULT OPERATION LIFT OUT

MIDDLE MASTER POWER SHUTTER


LIFTER UP MOVE OUT ON MANUAL AUTO DOWN IN
MANUALAUTO

LIFTER DOWN MOVE IN MASTER POWER


OFF
UP(BOTH)
RIGHT SHUTTER
UP 18

LIFTER MIDDLE IN PRESS


POS. PIN OUT UNLOCK DOWN(BOTH) DOWN

LIFTER MIDDLE IN PRESS


POS. PIN IN LOCK EMERGENCY STOP LAMP CHECK

6 24

2.4 MB FENCE LEFT SIDE SUB OPERATION PANEL

LEFT MB
MANUAL
OPERATION LIFT OUT

MANUAL AUTO DOWN IN


36

LEFTSHUTTER
UP

DOWN 18

EMERGENCY STOP LAMP CHECK

24
17

94
Section D OPERATION 2. OPERATION DEVICES

2.5 STEP FEED OPERATION BOX

STEP FEED
17
37 ACTIVE

SLIDE
UP DOWN

38

2.6 OTHER

EMERGENCY STOP

BRAKE TEST BRAKE TEST


OFF ON

17 39
CROWN

95
Section D OPERATION 2. OPERATION DEVICES

2.7 FUNCTION AND OPERATION

Before beginning press machine operation, gain a thorough understanding of the contents of
sections 4. OPERATION (pg. 186) through 9. OPERATION OF AUXILIARY EQUIPMENT
(pg. 275) in Section D OPERATION.

1 SPARE
lndicator Lights
480V 220V
TOP DEAD SERVO
CUSHION WARNING
CENTER POWER

PLC
BOTTOM LUB.OIL
FAULT DEAD LOWER END
CENTER

LOAD HYD.OIL
SPARE HOLP ANALYZER LOWER END

(1) POWER SOURCE Light This light comes on when your power source of
220V is turned ON to indicate that the control cir-
cuit and power circuit are energized.
22 0 V

(2) POWER SOURCE Light This light comes on when your power source of
480V is turned ON to indicate that the control cir-
cuit and power circuit are energized.
48 0 V

(3) RUN OK Light This light comes on to indicate that all prepara-
tions for press operation have been completed.
The press can be operated (slide motion can be
initiated) when the two RUN buttons are pushed
simultaneously.

(4) SERVO POWER Light This light starts flickering when the MASTER
POWER ON button with light is pushed. After the
SERVO completion of charging, the light stops flickering
POWER and comes on.

(5) TOP DEAD CENTER Light


This light comes on when the slide is at top dead
TOP DEAD center.
CE NT ER

(6) BOTTOM DEAD CENTER Light


This light comes on when the slide is at bottom
BOTTOM
DEAD
dead center.
CE NTER

(7) WARNING Light This light comes on in the case an alarm condition
of the item displayed on the "ALARM DISPLAY"
WARNING
screen of the operation display occurs.
When the light comes on, change over the screen
to the "ALARM DISPLAY" screen to check the
description of the alarm.

96
Section D OPERATION 2. OPERATION DEVICES

(8) CUSHION LINE Light This light comes on when the LINE mode setting
is completed on the die cushion operation panel.
CUSHION (Only for Press No.1)

(9) LUBRICATING OIL BUTTON Light This light comes on when the oil tank of the
LUB.OIL lubricating oil unit runs short of oil. Add adequate
LOWER amount of oil.
END This light flickers when the oil amount reaches the
lowest limit to disable the press operation.

(10)HYDRAULIC OIL BUTTON Light This light comes on when the oil tank of the
HYD.OIL
hydraulic oil unit runs short of oil. Add adequate
LOWER amount of oil.
END This light flickers when the oil amount reaches the
lowest limit to disable the press operation.

(11)LOAD ANALYZER Light This light comes on when the load meter detects
an overload, and the press operation cannot be
LOAD continued.
ANALYZER (Refer to the instruction manual for "LOAD
ANALYZER" at the end of this book.)

(12)FAULT Light This light comes on when a failure is detected.


Touch the "!" mark shown in the lower left corner
FAULT
of SUB MENU: "PRESS RUN" screen in MAIN
MENU: "PRODUCTION" on the operation display
to check the detailed description of the failure.
Refer to Section D OPERATION, 6.2 FAULT
INFORMATION MESSAGE LIST (pg. 214) for the
details of failure.

(13)HOLP Light This light comes on when the slide detects an


overload, and the press operation cannot be con-
HOLP tinued.
Refer to Section D OPERATION, 6.4 HYDRAULIC
OVERLOADS (pg. 243).

(14)PLC (BATTERY) Light This light comes on when the PLC battery needs
to be changed. Refer to Section E MAINTE-
PLC
NANCE, 4.4 REPLACING THE BUILT-IN PLC
BATTERY (pg. 345)

97
Section D OPERATION 2. OPERATION DEVICES

2 "LUBRICATING OIL FILTER CLOGGED"Signal Tower

This light comes on when the lubricating oil filter is


clogged.
Refer to Section E MAINTENANCE 5.5 OIL FILTER
(pg. 356)for how to wash or replace the filter.

3 SENSOR 1
LEFT UPPER DIE SENSOR

SENSOR 2
"UPPER DIE SENSOR" Light

CONNECTED
SENSOR (SENSOR No.):
SENSOR 3 SENSOR 4
This light comes on when the upper die sensor detects
the material.
SENSOR 5 SENSOR 6

CONNECTED:
This light comes on when the sensor connector is
connected properly.

4 CRANK ANGLE Crank angle indicator

Indicates crankshaft angle.


Top dead center is 0°and bottom dead center is 180°.

5 DIE HEIGHT
"DIE HEIGHT" Indicator

Indicates die height.


mm

6 "LOAD ANALYZER" display

On this display, the load analyzer data setting operation is


carried out and the load value and error message are
displayed.
Refer to the instruction manual for "LOAD ANALYZER" at
the end of this book.

98
Section D OPERATION 2. OPERATION DEVICES

7 "DIE SENSOR" Light


IN DIE / OUT OF DIE SENSOR
ZONE 2

ZONE 1 ZONE 3

ZONE 4
DIE CORD
CONNECTED
ZONE (SENSOR No.):
ZONE 6
This light comes on when the lower die sensor detects the
ZONE 5

ZONE 8
ZONE 7
material.

CONNECTED:
This light comes on when the sensor connector is
connected properly.

8 "PRESS O.P." Operation Display

See 3. THE OPERATOR INTERFACE TERMINAL (pg.


111)
Displays messages required for operation of the press and
the devices.

9 "FUNCTION" Button

The function of this button is displayed on the operator


interface terminal.
(See (6) in Common Screen Elements (pg. 115))
When the lamp is flickering → In the case the operation is
possible (a press on the button starts the operation)
When the lamp stays ON → In the case the operation is
completed
It should be noted that the "DEC/-1" ,"DEC/-5" (spm
decrease) and "INC/+1" ,"INC/+5"(spm increase) can be
carried out on the PROD. screen even when the button
lamp stays OFF.

The "FUNCTION" button is used for other operations such


as the operating range selection for STEP FEED(p.120)
, scroll of the cursor or graph in the motion graph(p.123)
, and the slide adjustment(p.250).

10 PRESS RUN PRESS RUN


"PRESS RUN" Buttons

When the two RUN buttons are pushed simultaneously


with both hands, slide motion will be initiated in the opera-
tion mode currently selected on the OPERATION SELECT
switch.

99
Section D OPERATION 2. OPERATION DEVICES

11 "OPE. SELECTOR" Key Switch


STEP
FEED INCH SINGLE This switch is used to select the operation mode.
HOME POS. When the switch is set to OFF, the slide will not move even
RETURN LINE
if the RUN buttons are pushed.
DIE See 2.8 OPERATION OF KEY SWITCHES (pg. 109) for
OFF CHANGE
the procedure for operating the key switch.
OPE. SELECTOR If the key is removed from the key switch, it should be con-
trolled by authorized personnel.

12 OFF UNIT
GROUP
LINE
"LINE SELECTOR" Key Switch

ALL This switch is used to select the line mode.


LINE
When the switch is set to OFF, the slide will not move
even if the RUN buttons are pushed.
See 2.8 OPERATION OF KEY SWITCHES (pg. 109) for
LINE SELECTOR
the procedure for operating the key switch.

13 "FAULT RESET" Button


If the slide has made an immediate stop during press oper-
STOP
RESET
FAULT
RESET
ation, perform the applicable fault reset procedure and
then push this button to reset the press.

"STOP RESET" Button


RIGHT
LIGHT CURTAIN
BUZZER
"RESET" Button(Sub operation panel)
RESET
The light flickers when the press is stopped by means of
the EMERGENCY STOP button and the lockout switch.
After the cause of the stop is removed, push the button to
turn off the light.
RESET

"RIGHT LIGHT CURTAIN RESET" Button


The light flickers when the right-side presence sensing
device is shielded.
The light goes out when the cause of shielding is removed
and this button is pushed.

100
Section D OPERATION 2. OPERATION DEVICES

14 BUZZER
"BUZZER" Button

When pressed, the buzzer will sound. It is used for giving


signals.

15 ALTERNATIVE
PROTECTION
"ALTERNATIVE PROTECTION SAFE • RUN" Key Switch
SAFE RUN
When this switch is set to SAFE while the press is run-
ning, the slide will stop immediately.

16 CYCLE STOP "CYCLE STOP" Button

When this button is pushed while the press is running in


LINE mode, the slide will stop at the preset stop position.

17 "EMERGENCY STOP" Button

When this button is pushed during press operation, the


slide will make an emergency stop (stop immediately).
See 6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245)

18 RIGHT SHUTTER
RIGHT SHUTTER"UP" "DOWN" Button
This button is used to move up/down the guard which is
UP
installed on the right side of the isolator.
SPARE The button is operable when the right MB is at the home
position or at the outside end.
The guard cannot be moved up unless all the slide locks of
presses No. 1 to No. 4 are "locked" and all the scrap
RESET DOWN

chutes of presses No. 2 to No. 4 are "closed".

RIGHT SHUTTER"RESET" Button


Push this button when the shutter reaches its lower end by
the shutter-down operation, and the press operation is
enabled.

101
Section D OPERATION 2. OPERATION DEVICES

19 MASTER
POWER
MASTER POWER "ON" Button
ON When this button is pushed, the servo motor power supply
is turned on and the light turns on.

OFF MASTER POWER "OFF" Button


When this button is pushed, the servo motor power supply
is turned off and the ON light turns off.

20 LUBRICATION OIL PUMP " ON" Button


LUBLICATION
OIL PUMP
When this button is pushed, the lubrication oil pump motor
ON
will start and the light turns on.

OFF
LUBRICATION OIL PUMP " OFF" Button
When this button is pushed, the lubrication oil pump motor
power supply is turned off and the ON light turns off.

21 MANUAL
SLIDE ADJUST. UPPER DIE
CLAMPER
UNIT OPRATION
"MANUAL OPERATION" Light
OPERATION UP UNCLAMP

"MANUAL • AUTO" Key Switch


Select "DIE CHANGE" from the MAIN MENU and "UNIT
OPERATION" screen from the SUB MENU on the opera-
tion display. Set this switch at "MANUAL" when nothing is
MANUAL AUTO DOWN CLAMP
selected for UNIT OPERATION selection on the operation
display. Then, the UNIT OPERATION is enabled on the
main operation panel and the light comes on.

If you select "AUTO", the light goes out and the LINE
operation in conjunction with the automatic die change is
enabled.
The key can be removed at the position marked with □ .

UPPER DIE CLAMPER "UNCLAMP" "CLAMP" Button


SLIDE ADJUST "UP" "DOWN" Button
When the MANUAL OPERATION light stays on and the
relevant interlock conditions are satisfied, the button is
operable.

102
Section D OPERATION 2. OPERATION DEVICES

22 RIGHT MB
DIE CLAMPER
UNCLAMP
RIGHT MB DIE CLAMPER "UNCLAMP" "CLAMP" Button

These buttons are used to clamp/unclamp the lower die


clamper of the right MB.
These buttons are operable when the right MB is inside
CLAMP
the press or at the outside end.
If the right MB is inside the press, set the OPE. SELEC-
TOR switch at OFF or INCH.

23 "CONTROL POWER" Key Switch


CONT ROL PO WE R
OFF ON When this switch is set at "ON" when the 220 V or 440 V
power light stays on, operation by means of the operation
panel is enabled.
When this switch is set at "OFF", the control power is
turned off.
See 2.8 OPERATION OF KEY SWITCHES (pg. 109) for
the procedure for operating the key switch.
The key can be removed at the position marked with □ .

24 LAMP CHECK
"LAMP CHECK" Button

This button is used to check whether the buttons with


light, indicator lights and other lights mounted on the main
operation panel or sub operation panel come on.

25 LUBLICATION
OIL HEATER
"LUBLICATION OIL HEATER" Button
ON
When this button is pushed, the lubrication oil heater will
start and the light turns on.

When lublication oil pump OFF button is pushed, the


heater is turned off and the ON light turns off.

26 BUZZER Button

The buzzer sounds when the scrap chute is opened and


the shutter is not closed.

103
Section D OPERATION 2. OPERATION DEVICES

27 NEXT DIE
PREPARATION
"NEXT DIE PREPARATION" Button

The "NEXT DIE PREPARATION" button light on the main


operation panel flickers when the right MB reaches the
outside end. The light comes on when this button is
pushed with the right MB lower die clamper clamped to
enable starting of the automatic die change die carry-in).
The "NEXT DIE PREPARATION" button light on the sub
operation panel flickers when the left MB reaches the out-
side end. The light comes on when this button is pushed
with the left MB lower die clamper clamped to enable start-
ing of the automatic die change pushed.
Refer to 8.2 AUTO DIE CHANGE (pg. 271) for the
details.

28 DA TA ED IT
"DATA EDIT ON• OFF" Switch
OFF ON
When the switch is set to ON, data such as timing switch
angle settings and databank settings can be inputted.
See Section D OPERATION, 3.5 THE SETTING
SCREEN (pg. 126) and 3.7 THE RECIPE (DATABANK)
SCREEN (pg. 154) for an explanation of data writing.
When the switch is set to OFF, the key can be removed. If
the key is removed from the key switch it should be con-
trolled by authorized personnel.
The key can be removed at the position marked with □ .

104
Section D OPERATION 2. OPERATION DEVICES

29 "LIGHT"
"DIE ROOM LIGHT" Switch
LIGHT
When the switch is set to ON, the lights in die room go on.
MANUAL DIE ROOM LIGHT
OVERRIDE OFF ON
"WORK AREA LIGHT FRONT" Switch
"WORK AREA LIGHT REAR" Switch
When this switch is set at "ON", the corresponding work
area light, front or rear comes on.
WORK AREA LIGHT WORK AREA LIGHT
FRONT
ON OFF
REAR
ON The "WORK AREA LIGHT REAR" switch is only provided
OFF
for the press No. 4.

"MANUAL OVERRIDE" Switch


The die room lights and work area lights automatically go
out 10 minutes after the press operation under the LINE
mode is started.
They come on for three minutes when this switch is
pushed during the LINE mode operation.

30 SCRAP CHUTE
"SCRAP CHUTE"
"OPEN""CLOSE" Light
MANUAL AUTO OPEN
When the scrap chute is opened or closed, the
corresponding light comes on.

"MANUAL • AUTO" Switch


"MANUAL" Unit operation of the scrap chute is enabled.
CLOSE OPEN CLOSE
The scrap chute "open" interlock is
     disabled during the press operation.
"AUTO" The scrap chute operates in conjunction with
     the guard. The scrap chute is closed before the
guard is opened.
     After the guard has been lowered to its lower
end, the scrap chute is opened.

"CLOSE •OPEN" Select Button


This button is enabled by selecting "MANUAL". In this
state, the scrap chute open/close operation is enabled.

The "SCRAP CHUTE" switch and button are only pro-


vided for the presses No.2 to No.4.

105
Section D OPERATION 2. OPERATION DEVICES

31 MANUAL AUTO
SLIDE LOCK
UNLOCK
"SLIDE LOCK"
"MANUAL • AUTO" Switch
"MANUAL" Operation of the LOCK/UNLOCK button with
light is enabled.
"AUTO" The slide lock operates in conjunction with the
opening/closing of the guard for the isolator.
LOCK The slide is locked before the guard is opened.
When the guard is closed, the slide is
SPARE
unlocked.
The key can be removed at the position marked with □ .

"UNLOCK" Button
The button light flickers when the button is operable.
When the button is pushed, the slide is unlocked and the
light comes on.

"LOCK" Button
The button light flickers when the button is operable.
When the button is pushed, the slide is locked and the
light comes on.

32 LEFT MB
DIE CLAMPER
UNCLAMP
LEFT MB DIE CLAMPER "UNCLAMP" "CLAMP" Button

These buttons are used to clamp/unclamp the lower die


clamper of the left MB.
These buttons are operable when the left MB is inside the
press or at the outside end.
CLAMP If the left MB is inside the press, set the OPE. SELECTOR
switch at OFF or INCH.

33 LEFT SHUTTER
LEFT SHUTTER"UP" "DOWN" Button
RESET UP
This button is used to move up/down the guard which is
installed on the left side of the isolator.
The button is operable when the left MB is at the home
position or at the outside end.
DOWN
The guard cannot be moved up unless all the slide locks of
presses No. 1 to No. 4 are "locked" and all the scrap
chutes of presses No. 2 to No. 4 are "closed".

LEFT SHUTTER"RESET" Button


Push this button when the guard reaches its lower end by
the guard down operation, and the press operation is
enabled.

106
Section D OPERATION 2. OPERATION DEVICES

34 LEFT
LIGHT CURTAIN
"LEFT LIGHT CURTAIN RESET" Button

RESET
The light flickers when the left-side presence sensing
device is shielded.
The light goes out when the cause of shielding is removed
and this button is pushed.

35 RIGHT MB
UNIT OPERATION(MB FENCE RIGHT SUB OPERA-
TION PANEL)
MANUAL
OPERATION LIFT OUT "MANUAL OPERATION" Light
"MANUAL/AUTO" Key switch
Select "DIE CHANGE" from the MAIN MENU and "UNIT
OPERATION" screen from the SUB MENU.on the
operation display. When nothing is selected for UNIT
MANUAL AUTO DOWN IN
OPERATION selection on the operation display terminal
and the UNIT OPERATION switch on the MB safety fence
left sub operation panel is set at "AUTO", set this switch at
"MANUAL" to enable the UNIT OPERATION on the right
sub operation panel. Then, the light comes on.

If you select "AUTO", the light goes out and the LINE
operation in conjunction with the automatic die change is
enabled.
The key can be removed at the position marked with □ .

RIGHT MB
"LIFT/DOWN" Button with Light
RIGHT MB RUN "OUT/IN" Button with Light
When the UNIT OPERATION is enabled and the relevant
interlock conditions are satisfied, the button is operable.

36 LEFT MB
UNIT OPERATION(MB FENCE LEFT SUB OPERATION
PANEL)
MANUAL
OPERATION LIFT OUT "MANUAL OPERATION" Light
"MANUAL/AUTO" Key switch
Select "DIE CHANGE" from the MAIN MENU and "UNIT
OPERATION" screen from the SUB MENU.on the
operation display. When nothing is selected for UNIT
MANUAL AUTO DOWN IN OPERATION selection on the operation display terminal
and the UNIT OPERATION switch on the MB safety fence
right sub operation panel is set at "AUTO", set this switch
at "MANUAL" to enable the UNIT OPERATION on the left
sub operation panel. Then, the light comes on.

107
Section D OPERATION 2. OPERATION DEVICES

If you select "AUTO", the light goes out and the LINE
operation in conjunction with the automatic die change is
enabled.
The key can be removed at the position marked with □ .

LEFT MB
"LIFT/DOWN" Button with Light
LEFT MB RUN "OUT/IN" Button with Light
When the UNIT OPERATION is enabled and the relevant
interlock conditions are satisfied, the button is operable.

37 "STEP FEED ACTIVE " Button

STEP FEED
When the OPERATION SELECT switch is set to STEP
ACTIVE FEED (manual step feed), this button will flash. This button
light is lit only while the button is being held down, and
pushing the button enables the manual step feed function.
See STEP FEED in 4.3 LINE MODES (pg. 192).

38 "STEP FEED DIAL"


SLIDE
UP DOWN See STEP FEED (manual step feed) in 4.3 LINE MODES
(pg. 192).

39 BRAKE TEST
ON OFF
BRAKE TEST "BRAKE TEST" Key Switch
"BRAKE TEST" Button

When the "CONTROL POWER" is "ON", "MASTER


POWER" is "OFF" and the "SLIDE LOCK" is "locked", set
the key switch at "ON" to forcibly release the brake as
long as this button is held pushed.
After the completion of the test, set the key switch at
"OFF".
The key can be removed at the position marked with □ .

108
Section D OPERATION 2. OPERATION DEVICES

2.8 OPERATION OF KEY SWITCHES

The keys for key switches must be stored and controlled by authorized personnel. (See Sec-
tion A SAFETY, 5.4 ESSENTIAL OPERATION PRECAUTIONS (pg. 28).)

2.8.1 OPE. SELECTOR,LINE SELECTOR Switch

(1) If the key is turned counterclockwise, the key can


be removed.
The set position of the switch cannot be changed
after the key is removed.
(2) If the key is inserted and turned clockwise, the key
cannot be removed.
You can change the selected position of the switch.

(1) (2)

2.8.2 Key switches other than the OPE.SELECTOR, LINE SELECTOR switches

Depending on the key switch type, the position where the key can be pulled out is different.
Refer to 2.7 FUNCTION AND OPERATION (pg. 96).

NOTE • Two keys are provided for each switch.


If you lose a key, contact AIDA Service (see the end of this instruction manual)
and inform them of the switch model.

109
Section D OPERATION 2. OPERATION DEVICES

2.9 SYMBOL MARKS FOR SWITCHES

Symbol marks are used to indicate the function of switches on the operation panel etc.
The designation of the symbols and marks are as follows. Please use the designation to specify
the switch when marking an inquiry.

Symbols & Symbols &


Designation Designation
marks marks

PLC
BATTERY
POWER SOURCE - +

RUN OK

110
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3. THE OPERATOR INTERFACE TERMINAL

CAUTION
• Do not press down hard on the operator interface terminal or press on it with hard objects
such as a pen.
Doing so could break the liquid crystal display.

The operator interface terminal is a touchscreen system which is operated by lightly pressing
the screen with your fingers.

The operator interface terminal displays information relating to interlocks, and displays data,
on-screen touchbuttons for selecting modes, a numeric keypad for setting data, and on-
screen touchbuttons for changing screens.

Operations such as starting and stopping which are directly related to press machine motion
are not performed using the on-screen touchbuttons, but rather performed by operating the
buttons arranged on the operation panel or the operation button box.
In such cases, the functions of these buttons will be displayed on the operator interface termi-
nal.

The information shown on the screens contained in this instruction manual, such as numeric
values, messages, etc., are provided as examples. The actual screens on your press machine
may be different.

111
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.1 SCREEN CONFIGURATION


※1:Only No.1 Press
※2:Only No.2 ~ No.4 Press

Main menu Sub menu Screen

• Counter setting and displaying


• Press machine no load (spm) setting and
displaying
• Cycle spm and cycle time display
• Micro inch mode select
• Crank angle display
• Slide position display
PRESS RUN
• Die height display
• Slide operating direction display
• Slide setting position, calculated speed
PRODUCTION value display
• Die cushion setting position, Die cushion
load display(※1)
• Die touch speed

• Slide setting position, calculated speed


PROGRAM value display
MONITOR • Die cushion setting position, Die cushion
load display(※1)

ALARM DISPLAY • Device alarm display

• Motion selection
• Press unit/die cushion line select(※1)
• Setting number of processes
• Motion program setting
MOTION • Motion program error display
• Slide setting positiony, speed value
display
• Die cushion setting position, Die cushion
load display(※1)

• Slide setting position, calculated speed


value display
PROGRAM MONITOR
SETTING • Die cushion setting position, Die cushion
load display(※1)

TSW • Timing switches setting

• Design die height display(※1)


MECHANICAL DEVICE • Mechanical device setting/test operation
• No1 press idol setting

VARIATION CIRCUIT • Variation circuit setting/test operation

CUSHION AREA
(No.1PRESS) • Die cushion setting data display(※1)

(Continued on the next page)

112
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

※1:Only No.1 Press


※2:Only No.2 ~ No.4 Press

Main menu Sub menu Screen

• Press run (inch, step feed,


origin point operation)
UNIT • Slide adjustment (auto)
OPERATION • Auto die change
• Unsticker
DIE • Upper die weight setting
CHANGE
UP. CLAMP • Upper die clamper use select
SELECTION • Upper die clamper select

DIE CHANGE • Take out monitor


MONITOR • Take in monitor

DOWN LOAD • Down load die data select

UP LOAD • Up load die data select

COPY • Copy load die data select

CLEAR • Clear die data select

NEXT DIE SELECT • Auto die change next die data select

DIE DATA EDITTING(1/5)


• Die number setting
• Counter setting
• Press machine no load (spm) setting
• Design die height setting(※1)
• Die change height setting
RECIPE • Die height setting
• Upper die mass setting
• Upper die clamper use/no use select
• Upper die clamper select
• Upper die sensor use setting(※2)
(Displayed by pressing
the "EDIT"key on the DIE DATA EDITTING(2/5)
each DATA BANK screen) • Timing switches setting
DIE DATA EDITTING(3/5)
• Motion selection
• Press unit/die cushion line select(※1)
• Setting number of processes
• Motion program setting
DIE DATA EDITTING(4/5)
• Die cushion monitored range data(※1)
• Mechanical device setting
DIE DATA EDITTING(5/5)
• Variation circuit setting
(Continued on the next page)

113
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

※1:Only No.1 Press


※2:Only No.2 ~ No.4 Press

Main menu Sub menu Screen

I/O MONITOR • Controller I/O status display

DATA MONITOR • Controller data status display

FAULT LIST
• Present failure information display
FAULT HISTORY
FAIILURE
• Past failure history display
INPACT SPEED ERROR HISTORY(※1)
MAINTE • Past inpact speed error history display
-NANCE
• Maintenance data display
MAINTENANCE
• Interlock muting set

OPTION SET • Counter function change


TEST MODE • Brake test operation

• Plc timer setting


TIME SETTING
• Energy saving timer setting

114
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS

The operation and display elements found on all screens is described below:

Common Screen Elements

(1) (3)

(2)

(9)
(4)

(5) (8)
(6)

(7)

*1:The "DESIGN DIE HEIGHT", the die cushion related elements, the ENERGY elements ③
and ④ and the MOTOR TEMP. elements ③ and ④ are provided only for the press No. 1.

3.2.1
(1) Main Menu Touchbuttons
These function touchbuttons are used to change the screen mode. The currently active
mode is highlighted.
PRODUCTION: ...............Used to run the press machine. (See 3.4 THE PRODUC-
TION SCREEN (pg. 119).)
SETTING: .......................Used to select the various motions and to set processing con-
ditions, timing switch cams, and mechanical device, variation
circuit etc. (See 3.5 THE SETTING SCREEN (pg. 126).)
DIE CHANGE: .................Used to perform auto die change, slide adjustment , balance
setting and operate unsticker. select upper die clamper
(See 3.6 THE DIE CHANGE SCREEN (pg. 149).)
RECIPE: ..........................Used to make and download databank data settings, etc.
(See 3.7 THE RECIPE (DATABANK) SCREEN (pg. 154).)

MAINTENANCE: .............Used to activate various monitoring functions and to display


fault and error histories. (See 3.8 THE MAINTENANCE
SCREEN (pg. 167).)

(Continued on the next page)

115
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(2) Sub-Menu Touchbuttons


These touchbuttons are used to access the submenu screens for each main menu
mode. The currently active mode is highlighted. The submenus for each main menu
mode are different.

(3) Production Die Number and Product Name Display


Displays the production die number (hereafter referred to as the "die number") and prod-
uct name stored in the databank. (See Section D OPERATION, 3.7 THE RECIPE
(DATABANK) SCREEN (pg. 154).)

(4) Interlock Information Display


Displays information relating to machine operation. (See Section D OPERATION,
6.1 INTERLOCK INFORMATION MESSAGE LIST (pg. 198).)

(5) Fault Detection Display


A flashing "!" mark is displayed when a fault is detected.
When this mark is pressed, the FAULT screen (pg. 178) will be displayed.

(6) Function Button Functionality Display


Displays the functions of the function buttons on the control panel. (See Section D
OPERATION, 2.7 FUNCTION AND OPERATION (pg. 96).)

(7) Energy and Motor-temperature Display


Charging status of the electrical energy stored in each motor capacitor panel and the
motor temperature state are displayed.

Energy............ Red: Either the charging of the motor capacitor is not completed or the
energy level was excessive after the completion of charging as a result of
the presswork being performed.
Yellow: Either the motor capacitor has been charged enough to provide
an adequate voltage, or the energy was close to being excessive after
the completion of charging as a result of the presswork being performed.
Blue: Either the motor capacitor has been fully charged, or there are
energy-related problems as a result of the presswork being performed.

Motor temperature..... Red: The motor temperature is abnormally high.


Yellow: The motor temperature exceeds appropriate levels.
Blue: The motor temperature is within the appropriate temperature
range.

(8) Display of slide motion, current process number, crank angle, and slide position
Displays the name of the currently-selected slide motion, the current process number,
the crank angle, and the height of the slide above bottom dead center.

(9) Stop factor


While this element is flickering, the most recent stop factor is displayed on (4) Interlock
Information Display.
When you touch the element to light it off (in the ground color), the operation-related
information is displayed.
When you touch the element again to light it on (in orange), the most recent stop factor is
displayed. However, three seconds later, the light goes back to the off state (in the
ground color) and the operation-related information is displayed again.

116
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.2.2 Input Keys

When numeric data or character-string data is to be inputted, input keys will be displayed at
the bottom of the screen.

(1)

(2) (3) (4)

*1 The "DESIGN DIE HEIGHT" and the die cushion related elements are provided only for the
press No. 1.

(1) Data Upper and Lower Limit Display


Displays the upper and lower limits for inputted data settings.

(2) Key Input Value Display


Displays the inputted value.

(3) Input Information Display


Displays the method to be used to indirectly input data, such as "0 → OFF, 1 → ON".

(4) Input Keys Display


Displays the keys needed to input numeric values (decimal, hexadecimal) and character
strings.
" ← " " → "" ↑ " " ↓ " .......Used to scroll through the selections (the cursor flashes).
AC ...................................Used to clear an inputted value.
ENT.................................Used to enter an inputted value.

117
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.3 INITIAL Screen

This screen is displayed immediately after the control power is turned ON. On this screen, the
status of the emergency stop button and the initialization processing status of each controller
are displayed.

(1) Emergency stop button status display


The monitor lights up in red when the emergency stop button is pushed, or lights up in
green when the button is reset.

(2) Initialization process display


This section is displayed in red while each controller is being initialized. When the initializa-
tion process is completed, the section is displayed in green.
The initialization process steps proceed in the order of "Step 1 SVC", "Step 2 MPC", and
"Step 3 PLC" until the process is completed. Then, the screen is changed over to the RUN
screen.

(2)

(1)
*1 The die cushion related elements are provided only for the press No. 1.

118
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.4 THE PRODUCTION SCREEN


Access the PRODUCTION screen by pressing the PRODUCTION main menu touchbutton.

<<Submenus >>
"PRESS RUN" .................This screen is used to operate the press. The status of the
press and press operation data are displayed.(pg. 119)
"PROGRAM MONITOR" ..The specified slide and die cushion motion is displayed as a
waveform. (pg. 123)
"ALARM DISPLAY" ..........Alarm signals of the respective devices are displayed..(pg.
124)

3.4.1 PRESS Run Screen

Access the PRESS Run screen by pressing the "PRESS RUN" submenu touchbutton.
This screen is used to operate the press in the operation mode that has been selected using
the OPE. SELECTOR switch.
(This PRESS RUN screen is automatically displayed after the power to the machine has been
turned ON.)

(2)

(1)

(8)

(3)
(5)

(6) (7)

(4)
(3)

*1 :The "DESIGN DIE HEIGHT", the die cushion related elements, the ENERGY elements ③
and ④ and the MOTOR TEMP. elements ③ and ④ are provided only for the press No. 1.

(1) Crank Angle, Slide Position and Die height


Displays the current crank angle. 0° corresponds to top dead center and 180° corre-
sponds to bottom dead center.
Displays the height (mm) of the slide above bottom dead center.
Displays the currently-set design die height value.
Displays the current die height value.

(Continued on the next page)

119
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(2) Slide Die Cushion (only No.1 press ) Motion Display Waveform Selection
The calculated and reference values of the specified slide die cushion (only No.1 press )
motion, etc. are displayed as a waveform.
You can select which waveform to display using the keys on the right side of the screen.

The slide position is displayed on the screen at all times.


When the RE-DRAW key is pressed, the specified motion program is re-calculated and
the updated graph is displayed.

(3) Digital Speed Meter


• Used to make press machine strokes per minute (spm) settings and to confirm the cur-
rent value.
"NO LOAD SPM" ....................... Displays the press machine spm (the basic maximum
speed value) outside of the forming zone (the forming
portion of the stroke).
"RECIPE" .................................... Used to set the no-load spm at the value which has
been stored in the databank.
"MANUAL" .................................. Used to set the no-load spm at the value which has
been manually inputted.
"SETTING".................................. When this key is pressed, the input keys are displayed
at the bottom of the screen to allow to allow you to
manually input the no-load spm as explained in the
"MANU." mode above.
"CONT. CYCLE SPM"
"CONT. CYCLE TIME" ................ Converts the speed of one cycle in Continuous mode
operation to a cycle spm value and a cycle time value.
"DEC/-1" "DEC/-5"
"INC/+1" "INC/+5" ....................... When the above-mentioned "MANU." has been
selected, pressing these buttons will increase or
decrease the no-load spm. This operation can be per-
formed even if the applicable function button light is
not lit.
"MICRO" ..................................... To operate the press in MICRO INCH mode, first set
the OPERATION SELECT switch to INCH then press
this key. The color of the key will change to orange
and the no-load spm will become fixed (at 5 spm).
MICRO INCH mode operation cannot be performed
unless the "OPERATION SELECT" switch is set to
"INCH." To run in a mode other than MICRO INCH, set
the "MICRO INCH" key to the OFF position.
"INCH.LIMIT spm" ......................... If the no-load spm exceeds 20 spm when the "INCH."
mode has been selected, the inching spm limitation
will function to display this key in red reverse video. In
this case, the spm will be automatically decreased to
20 spm by pressing this key. If the mode is changed
over to "INCH." at 20 spm or less, the key will not be
displayed in reverse video.
(4) STEP FEED (Manual Pulsar) Quadrant Selector Display
When the slide is at top dead center or bottom dead center, the range of crank angle
motion for "STEP FEED" operations can be changed by using the relevant function but-
ton. Refer to 4.3 LINE MODES (pg. 192) for an explanation of "STEP FEED" operation.
PLS. [180°- 0°]A movement range that includes the 270 degree crank angle.
PLS.[0°- 180°]A movement range that includes the 90 degree crank angle.

(Continued on the next page)

120
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(5) Work Memory , Work Sensor Setting


This function monitors, by means of the work memory, work sensor and the timing
switch, whether the transferred work is properly placed in the die.
The press No. 1 is in the normal state in the case the work memory is in the ON state,
the die breakage detecting sensor is in the OFF state at the predetermined checking
angle. If the work memory is in the ON state and the die breakage detecting sensor is in
the ON state, the press No.1 is in the faulty state. At the latter case, the press makes an
immediate stop.
The presses No. 2 to No.4 are in the normal state in the case both work memory and
work sensor are in the ON state at the predetermined checking angle. If the work mem-
ory is in the ON state and the work sensor is in the OFF state, the presses No.2 to No.4
are in the faulty state. At the latter case, the press makes an immediate stop.

"WORK MEMORY" ..................... The work status is stored in memory based on the
operation of the transfer device. When the work is
transferred to the die, this section is displayed in
reverse video. When the work is removed from the die,
the section is displayed in normal video. The "work is
present" state is stored in memory by pushing the
switch.
"WORK SENSOR" ...................... The work in the die is monitored. When the work is in
the die, this section is displayed in reverse video.
When the work is not in the die, the section is dis-
played in normal video. (*2 Provided only for the
presses No.2 to No.4)
"WORK SET MISS USE" ............ Use/nonuse of this function is selected. This section is
displayed in normal video when the function is used. It
is displayed in reverse video when the function is not
used.

(6)Preset Counters and Production Counters

ON/OFF touch Displays the


button target setting
Displays the
current value

Used to clear the Setting Keys


current value
The press machine has two different counters.
• Press the ON/OFF touchbutton to toggle a counter between ON and OFF.
• Whether a counter (the green area) can be used as a preset counter or a production
counter depends on whether the inputted target setting is "0" or a numeric quantity.

(Continued on the next page)

121
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(a) Using a Counter as a Preset Counter:


A counter will function as a preset counter when a number other than 0 (zero) is
entered. When the quantity on the counter reaches the target setting, the press
machine stops at the preset stop position. Up to a 6-digit quantity can be inputted.

(b) Using a Counter as a Production Counter:


A counter functions as a production counter when "0" is entered as the target setting.
• When SET is pressed, the touchbutton color changes to orange, and the set value can
be changed. The input touchbuttons are displayed near the bottom of the screen.
• To reset to 0 (zero), press and hold down the RESET (Clear) touchbutton for at least
one second.

• Counter 2 has a function that outputs a "count completed" signal when the preset num-
ber is reached. (See 3.8.6 Optional Settings Screen (pg. 183).)
This signal is outputted for 0.5 seconds when "Preset Auto Reset" has been selected.

(7) Slide Operating Direction


An arrow mark displays the direction in which the slide will travel the next time the press
is started.

Up Down

(8) DIE TOUCH SPEED


"PRE.VALUE".............................. The value stored in the data bank for the die cushion
"CAL.VALUE" .............................. The value newly calculated when the setting is
changed
"MATCH" ..................... If the newly-calculated value at the time of changing
the setting is different from the aforementioned
previous value, the calculated value is copied on the
previous value by pressing this key.

122
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.4.2 PROGRAM MONITOR Screen

Access the PROGRAM MONITOR screen by pressing the "PROGRAM MONITOR" submenu
touchbutton.

(1)

(2)

*1 The die cushion related elements are provided only for the press No. 1.

(1) Slide and Die cushion (only No.1 press) Motion Display Waveform Selection
Displays the slide and die cushion (only No.1 press) motion settings as a waveform.
Since this waveform is a reference value created based on the specified input data, it
does not represent the actual motion. The keys to the right are used to select the
desired waveform.

The slide position is displayed on the screen at all times.


When the RE-DRAW key is pressed, the specified motion program is re-calculated to
re-display the waveform.

(2) Scroll Selection and Scroll Operation


Function keys can be used to scroll through or move the cursor on the displayed wave-
form.
The CURS. key is used to move the cursor.
The "<<" and ">>" function keys are used to scroll through the displayed waveform in
large increments, and the "<" and ">" function keys scroll for short distances.

123
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.4.3 ALARM DISPLAY Screen

When the "ALARM DISPLAY" key on the SUB MENU is pressed, the screen is changed over
to the ALARM DISPLAY screen.

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Alarm output from the respective devices is displayed. The alarm displayed here is not an
urgent one which requires the press to stop. However, if this alarm state remains without tak-
ing any measure, the related devices may fail and the press operation can be disabled. It is
therefore necessary to inspect the alarm-related part whenever the alarm is given.
The device in alarm state is displayed in reverse video (yellow).
(1) SERVO MOTOR No.1-1
The electric current value of the servomotor No. 1 is displayed.

(2) UPS FAULT ,VOLTAGE DROP DETECT


(a) UPS FAULT
This is the UPS-related alarm. Inspect the UPS.

(b) VOLTAGE DROP DETECT


The 200 V system supply voltage has dropped. This alarm is displayed when the power
supply is stopped by power failure or any other cause, and the power supply is restored
afterward.

(3) VARIOUS OIL QUANTITY DETECTION


The various oil quantities have dropped to the warning level. Inspect the oil quantity.
(Continued on the next page)

124
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(4) ENERGY SHORT AGE , OVER VOLTAGE WARNING


(a)ENERGY SHORTAGE
The energy to be supplied to the servomotor during the press operation has dropped to
the warning level. If the press is operated in this state, the press may stop due to energy
shortage. Be sure to review the motion and spm to prevent energy shortage.

(b)OVERVOLTAGE WARNING
The overvoltage of the converter of the power panel has been detected. Check whether
the motion which causes sudden deceleration has been set or whether there is a phenom-
enon where the slide is pushed up by the lower die when it starts the UP stroke.

(5) CONTROL PANEL COOLER


The cooler of the control panel is faulty. If the press is operated continuously in this state,
the equipment inside the control panel can fail due to heat. Carry out inspection.

(6) POWER CONTROL PANEL , DRIVER CONTROL PANEL COOLER


The cooler of the respective control panels is faulty. If the press is operated continuously
in this state, the equipment inside the control panel can fail due to heat. Carry out inspec-
tion.

(7) MOTOR FAN DETECTION


The cooling fan for the servomotor installed in the main body of the machine has stopped.
Carry out inspection.

*1 "No.3,4 ENERGY SHORTAGE", "No.3,4 OVERVOLTAGE WARNING", "POWER CON-


TROL PANEL No.3,4 COOLER", "DRIVER CONTROL PANEL No.3,4 COOLER" and
"No.3,4 MOTOR FAN DETECTION" are provided only for the press No.1.

125
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.5 THE SETTING SCREEN

Access the SETTING screen by pressing the SETTING main menu touchbutton.
This screen is used to make settings for and to edit the motion programs in the production die
data area and to make other settings.
When changing data, set the DATA EDIT “ON” “OFF” to “ON” .
The data cannot be changed while the press is operating.

<<Submenus >>
"MOTION" ........................Used to select the motion of the production die and to set/edit
the motion program. (pg. 127)

"PROGRAM MONITOR" ..The specified slide and die cushion (only No.1 press ) motion
is displayed in waveform. (pg. 137)

"TSW" ..............................Used to make timing switch settings. (pg. 138)

"MECHANICAL DEVICE" Used to set the design die height (only for the press No. 1),
set the press idling (only for the presses Nos. 2 to 4), turn
ON/OFF the mechanical device and select the "TEST" mode.
(pg. 140)

"VARIATION CIRCUIT" ....Used to monitor and test the function which operates the air
actuator, mounted in the die, according to the derived code
given by the centralized operation panel. (pg. 142)
"CUSHION AREA"
(No.1 PRESS)..................Used to display the operation data set on the die cushion
operation panel. (pg. 148)

126
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.5.1 Motion Selection /Setting Screen

Access the Motion Selection screen by pressing the "MOTION" submenu touchbutton.
This screen is used to select the motion type, set the number of processes, and select the
motion program.

(4)

(3)

(1)

(2)

(5)

*1 :The die cushion related elements, the ENERGY elements ③ and ④ and the MOTOR
TEMP. elements ③ and ④ are provided only for the press No. 1.

(1) DATA EDIT Keys


SETTING .........................Press this key to select the motion or edit (set or change) the
motion program data. Input keys are displayed at the bottom
of the screen.
CANCEL ..........................Press this key to discontinue data editing. The data being
edited will be deleted and the original data will be retrieved.
DECISION........................Press this key once the data editing has been completed.
When this key is pressed, the edited data is checked for
errors. If no errors are found, the press will operate based on
the edited data.

(Continued on the next page)

127
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(2) Motion Selection


The following four motion types for use with production dies.
When a motion key is pressed, it turns orange to show that it has been selected.
Crank ...............................Just like a standard mechanical crank press, the crankshaft
rotates at a uniform speed.
Link ..................................Just like a mechanical link press, the crankshaft only rotates
at a non-uniform speed during the forming portion of the
stroke.
Flex ..................................Allows free programming of the motion, enabling the crank-
shaft to reverse direction and hit the material multiple times,
etc.

Fwd/Rev........................ Crank motion where forward motion and reverse motion is


symmetrical with respect to bottom dead center and the crank-
shaft does not pass through top dead center. This pendulum
motion consists of repeating a forward motion downstroke and
upstroke and a reverse motion downstroke and upstroke. This
motion enables forming at high spm levels using short strokes.
However, the start and end positions of this motion are
determined by the set values of the motion program.

(3) Motion Program Set/Edit Area


This area is used to set and edit motion program data.
Editing is enabled by pressing the above-mentioned SETTING key. To select the data to be
edited, directly press the data item on the screen or move the cursor to the data item using
he input keys " ← " " → " " ↑ " " ↓ " displayed at the bottom of the screen. The selected item is
displayed highlighted. (See the items marked with A in the following sample.)

A ⑥
① B ⑦



(Continued on the next page)

128
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

① Setting the Number of Processes


Use the input keys at the bottom of the screen to enter the number of forming processes.
The rectangular block above each active process number will turn orange. (Shown in the
section marked by B in the above example.)
The maximum number of processes for each type of motion is shown in the table below.
Motion Name Maximum Number of Processes
CRANK, LINK 10
FLEX 30
FWD/REV 5

② Settings (*1)
"SLIDE POS.(mm)" ......................The slide position (the height of the slide above bot-
tom dead center) where the forming process starts
for each process.
"SL(SLIDE) VELOCITY(%)" .........The velocity from the start position of the current pro-
cess up to the start position of the next process.
(A percentage of the PRODUCTION screen no-load
spm setting.)
"SL(SLIDE) VELOCITY (mm/s)" ..This represents the numeric value calculated by con-
verting the above-mentioned spm percentage to slide
travel velocity.
* This is not a setting. This value is automatically cal-
culated.
This value may be displayed in red according to the
value of percentage. This indicates that the slide
velocity that the die cushion cannot follow has been
set.
"PAUSE TIME" .............................The stop time at the process start position.
(The data setting range is from 0 to 20.0 seconds.)
"SILENT DECEL ( Deceleration)" .The amount of silent deceleration at the process start
position.
This setting cannot be specified for a final process.
The velocity can be slowed down at a specified point
in the forming zone. When the silent deceleration set-
ting is "100" (100%), the velocity is momentarily
reduced to zero (0), and then the slide is accelerated
again to the set forming velocity and the forming pro-
cess is performed.
For example, in a process where the forming speed
is set at "50" and the amount of "SILENT. DECEL (
Deceleration)" is set at "90", the speed is instanta-
neously slowed to 5% of the no load spm value
[50%×(100%-90%)=5%].
"AUX.FUNCTION" ........................Specifies an auxiliary output signal
[0]: An auxiliary output signal is not outputted.
[1] - [15]: An auxiliary function code with a specified
number is outputted.
For a summary of auxiliary functions and examples of
their use, see Section D 7.4 MOTION PROGRAM
AUXILIARY FUNCTIONS (pg. 262).

(Continued on the next page)

129
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

"VELOCITY SHIFT" ......................Specifies the speed change method to be used when


the next process is reached.
[0](Pre-S-Change): Completes the speed change
before reaching the start position of the current pro-
cess.
[1](Post-S-Change): The press operates at the speed
setting of the preceding process up to the starting
position of the current process, and the speed
changes to the target speed after reaching the
starting position of the current process.
[2](Taper): After the speed has been increased/
decreased to the target speed at the starting position
of the current process, the speed is linearly
increased/decreased in such a way that the target
speed of the subsequent process is reached at the
starting position of that process.
[3](Pre-S-Change + Constant S): After the completion
of increase/decrease of the slide speed before the
starting position of the current process has been
reached, a constant-speed slide operation is per-
formed while maintaining the current slide speed.
[4](Post-S-Change + Constant S): The slide operates
at the speed employed in the previous process until
the starting position of the current process is
reached. Then, the speed is increased/decreased to
the target speed in order to perform constant-speed
slide operation.

(*1):For a final process, only the slide position is valid.

Die Cushion Item (ONLY No.1 PRESS)


"CUSHION POS.(mm)" .................Used to set the position of the cushion (distance from
the forming stroke end) from which the die cushion
process is started.
"CUSHION LOAD(kN)" .................Used to set the cushion force for the current process.
"KNOCKOUT(mm/s)" ....................Used to set the knockout operating speed after
forming.
* This is enabled when the "PRESSURE SHIFT"
described later is set at [3].
"PRESSURE SHIFT" ....................Used to select the die cushion operation mode.
[0]: Die cushion pressure setting is disabled.
[1]: Post-Pressure-Change
[2]: Taper Pressure-Change
[3]: Bottom dead center depressurization and
knockout process
[4]: Machining interruption
* Refer to the Instruction Manual for the die cushion
for details of the Pressure Change mode.
"CUSHION STOP(s)" ....................Used to set the operation stop time in the knockout
process of the die cushion. (The setting range is 0 to
20.0 seconds.)

(Continued on the next page)

130
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

③ Scrolling between Setting Screens


" ", " " .........................Press the " " or " " touchbutton to display the previous or



next screen.

④ Process Insertion and Deletion


Used to insert a process into the program or delete a process out of the program.
INSERT .........................................Pressing this key inserts an unspecified process to
the left side of the process where the cursor rests.
You cannot insert more processes than the maximum
number of processes possible for each motion type.
DELETE. .......................................Pressing this key deletes the process where the cur-
sor rests.
No process is deleted if there are only two pro-
cesses.
The number of processes in " ① " above is automati-
cally increased or decreased when a process is
inserted or deleted.

⑤ Press Unit / Die Cushion Line Select (Only No.1 Press)


This is used to select whether the press is operated under the UNIT mode or under the
LINE mode in conjunction with the die cushion.
Every time this key is pressed, the display is changed over between "PRESS UNIT" and
"DIE CUSHION LINE".
When the press is operated under the UNIT mode, the cushion-related items are disabled.
In this state, the cushion-related data are not checked.

⑥ Slide Position at Cushion Start (Only No.1 Press)


The value of "SLIDE POSITION AT CUSHION START" entered on the die cushion opera-
tion panel is displayed after the die cushion calibration.
Enter this value in the motion program as the "CUSHION POS. (mm)" at which the cushion
process starts.

⑦ Cushion Pressure Keep Time (Only No.1 Press)


This is used to set the die cushion pressure holding time at the bottom dead center. (The
setting range is from 0 to 20.0 sec.)
The die cushion pressure is kept at the set value for the point just before the bottom dead
center during the specified length of time.

(Continued on the next page)

131
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(4) Slide and Die cushion Motion Display Waveform Selection


Calculated values and reference values based on the inputted slide snd die cushion motion
are displayed as a waveform.
Use the "SLIDE POSITION","SLIDE SPEED", "CUSHION POSITION" or "CUSHION
LOAD" key to select and display the desired waveform. The slide position is displayed on
the screen at all times.
When the "RE-DRAW" key is pressed, the specified motion program is re-calculated to re-
display the waveform.

(5) Edited Data Error Display


If there is a motion program data error because the press cannot perform the inputted
motion, a corresponding error message and the number of the process where the error
exists are displayed.

<<Motion Program Troubleshooting>>

No.. Description of Calculation Results Details


250 MOTION SET UP NOT FAULT
The slide stroke range setting in Forward/
MOTION SET UP FAULT/PRESET OF SLIDE IS Reverse motion is inadequate.
251
TOO SHORT Increase the stroke width by increasing the
motion position in process 1, etc.
Settings for multiple passes through bottom
MOTION SET UP FAULT/PLURAL NUMBER OF dead center have been made for a mode
252
STROKES SET other than Flex motion. Change to Flex
motion or correct the multiple-pass setting.
The position of a process where Forward/
Reverse motion has been specified is set to
a higher position than the motion position of
MOTION SET UP FAULT/POS.SET UP FAULT
253 process 1.
WHEN F/R MOTION
Lower the motion position setting in the
specified process to a value smaller than the
motion position setting in process 1.
The motion position in the specified process
MOTION SET UP FAULT/SLIDE POS.SET UP and in the subsequent process are identical.
254
FAULT Change the motion position setting in one of
the two processes.
The motion setting specifies a change in the
direction of the crankshaft rotation in some
MOTION SET UP FAULT/REVERSE STOP mode other that Flex motion. Change to
257
MOTION SET UP Flex motion or change the motion setting so
that the crankshaft direction of rotation does
not change.
The Post-S Change mode has been
MOTION SET UP FAULT/SPEED MODE OF selected for a process that specifies a
258
REV.PROC. NONCONFORMITY change in the direction of movement.
Change to the Pre-S Change mode.
Increase the distance between two pro-
MOTION SET UP FAULT/TARGET SPEED cesses, decrease the difference in speed
259
ISN'T REACHED ON PROC. between the current process and subse-
quent one, or decrease the no-load spm.

132
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

No.. Description of Calculation Results Details


Expand the no-load zone, decrease the dif-
MOTION SET UP FAULT/TARGET SPEED
260 ference in speed between process 1 and the
ISN'T REACHED ON NO-LOAD
last process, or decrease the no-load spm.
You cannot set slide speed to zero in a pro-
cess where a Taper operation has been
MOTION SET UP FAULT/START & FINAL
261 specified or in the following process.
SPEED OF STEP FEED ARE 0
Check the silent deceleration, the stopping
time, the auxiliary function "1" settings.
In Link motion, the speed of the specified
MOTION SET UP FAULT/OVERSPEED OF LINK process exceeds the maximum speed.
263
MOTION Decrease the speed setting or decrease the
no-load spm.
An auxiliary function cannot be stopped in
the specified process.
MOTION SET UP FAULT/A.FUNC. STOP BAND
266 Either expand the range of the preceding
IS TOO SHORT
process, decrease the speed of the preced-
ing process, or decrease the no-load spm.
The setting for the number of processes
MOTION SET UP FAULT/PROCESSES RANGE
268 exceeds the upper/lower limit.
OVER
Set it to a correct value.
MOTION SET UP FAULT/FAULT MACHINE
269 Contact AIDA Service.
PARAMETER(ERROR No.19)
When using a die cushion, set the Auxiliary
MOTION SET UP FAULT/SYNC.A.FUNC. WITH
270 function for the bottom dead center process
DIE CUSHION IS WRONG
to "1."
MOTION SET UP FAULT/SYNC.SPEED WITH The die cushion cannot keep up with the
271
DIE CUSHION IS HIGH slide speed setting.
The bottom dead center process number of
MOTION SET UP FAULT/BDC PROC. WITH DIE
272 the slide and of the die cushion are not iden-
CUSHION IS WRONG
tical.
273
MOTION SET UP FAULT/FAULT MACHINE
| Contact AIDA Service.
PARAMETER(ERROR No.23 ~ 59)
309
310
| INTERLOCK MESSAGE LIST (Refer to pg. 198)
400
The maximum number of processes for
MOTION SET UP FAULT/MAXIMUM TOTAL
401 Crank or Link motion is 10. Set the number
PROC. SET UP RANGE IS 10
of processes to 10 or less.
The maximum number of processes for For-
MOTION SET UP FAULT/MAXIMUM TOTAL
402 ward/Reverse motion is 5.
PROC. SET UP RANGE IS 30
Set the number of processes to 5 or less.
The maximum number of processes for Flex
MOTION SET UP FAULT/MAXIMUM TOTAL
403 motion is 30.
PROC. SET UP RANGE IS 5
Set the number of processes to 30 or less.
Forward/Reverse motion can only be
MOTION SET UP FAULT/DC LINE F/R
404 selected when the press is operating in
MOTION CANNOT BE SELECTED
UNIT mode.

133
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

No.. Description of Calculation Results Details


If the auxiliary function for the specified pro-
MOTION SET UP FAULT/SET HOLD PRE. TIME
405 cess is set at "0," also set the pressure hold-
0 IF AUX.FUNC. IS 0
ing time to "0."
MOTION SET UP FAULT/SLIDE POS. OUT OF The slide position in the specified process is
411
RANGE outside of the prescribed range.
The slide upstrokes in the forming zone
MOTION SET UP FAULT/SLIDE POSITION IS
412 even though Flex motion has not been
GOING UP
selected.
MOTION SET UP FAULT/SLIDE VEL. OUT OF The slide speed in the specified process is
415
RANGE outside of the prescribed range.
Both the slide operation and die cushion
MOTION SET UP FAULT/SLIDE VEL. IS 0, DC operation are disabled for the specified pro-
416
PRESS. CHANGE IS 0. cess. Delete the process or change the pro-
cess setting to enable these operations.
MOTION SET UP FAULT/SLIDE STOP TIME The slide stopping time in the specified pro-
421
OUT OF RANGE cess is outside of the prescribed range.
The slide stopping time cannot be set
MOTION SET UP FAULT/SET 0 SLIDE STOP because the ’Die Cushion Pressure Change
422
TIME Mode "4"’ (forming interruption program).
Set the slide stopping time to "0.0s."
The silent deceleration setting for the speci-
MOTION SET UP FAULT/S.DECEL. OUT OF
425 fied process is outside of the prescribed
RANGE
range.
429 MOTION SET UP FAULT/SET 0 OR 1 A.FUNC. Set the auxiliary function to "0" or "1."
When the press is operating in UNIT mode,
MOTION SET UP FAULT/A.FUNC. 1-9 SET OF
430 the Auxiliary function cannot be set to val-
DC EXCLUSIVE USE
ues ranging from "1" to "9."
MOTION SET UP FAULT/A.FUNC. OUT OF The auxiliary function in the specified pro-
431
RANGE cess is outside of the prescribed range.
When using a die cushion:
Auxiliary function setting "1" is used for con-
432 MOTION SET UP FAULT/SET 0 A.FUNC. trol at bottom dead center.
Auxiliary function setting "2" is used for the
forming interruption program.
A die cushion is being used, but the bottom
433 MOTION SET UP FAULT/ SET 1 A.FUNC. dead center Auxiliary function is not set to
"1."
A die cushion is being used, but the Auxil-
434 MOTION SET UP FAULT/ SET 2 A.FUNC iary function for a forming interruption pro-
cess is not set to "2."
The slide speed change mode in the speci-
MOTION SET UP FAULT/SLIDE SPEED MODE
435 fied process is outside of the prescribed
OUT OF RANGE
range.
Set the slide speed change mode for the
specified process to "0" if there is a "Start
MOTION SET UP FAULT/SET 0 OR 3 SLIDE
436 die cushion prior to the slide position" set-
SPEED MODE
ting, or to "0" or "3" if there is a knock-out
process.

134
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

No.. Description of Calculation Results Details


The slide speed change mode cannot be set
MOTION SET UP FAULT/SLIDE SPEED MODE to "2" because ’Die Cushion Pressure
437
2 CANNOT BE SET UP Change Mode "4"’ (forming interruption pro-
gram) has been selected.
The slide speed in the specified process
exceeds the maximum speed at which the
MOTION SET UP FAULT/SLIDE SPEED IS TOO
441 die cushion can track along with the slide.
HIGH
Decrease the speed setting or decrease the
no-load spm.
MOTION SET UP FAULT/DC POS. OUT OF The die cushion position in the specified
445
RANGE process is outside of the prescribed range.
MOTION SET UP FAULT/FALSE DC POS. SET The die cushion position in the specified
446
UP process is unsuitable.
Set the die cushion position in the knockout
MOTION SET UP FAULT/DC POS.IS BELOW process to a position that is 1 mm or lower
447
DC START SL POS.-1.Omm than the "slide position where the die cush-
ion starts."
Because ’Die Cushion Pressure Change
MOTION SET UP FAULT/MAKE DC POS.AND Mode "4"’ (forming interruption program) is
448
SL POS. SAME being used, make the die cushion and the
slide positions identical.
MOTION SET UP FAULT/DC LOAD OUT OF The die cushion load setting in the specified
450
RANGE(LOWER END:480kN) process is outside of the prescribed range.
MOTION SET UP FAULT/DC LOAD OUT OF The die cushion load in the specified pro-
451
RANGE(LOWER END:480kN) cess is outside of the prescribed range.
Set the die cushion load setting for the spec-
452 MOTION SET UP FAULT/SET 0 DC LOAD
ified process to "0."
The maximum number of processes that
MOTION SET UP FAULT/DC LOAD SET
453 can have die cushion load settings is six.
BEYOND 6 PROC.
Set the number of processes to six or less.
The die cushion-knockout speed setting for
MOTION SET UP FAULT/OUT OF DC KO
455 the specified process is outside of the pre-
SPEED(LOWER END:5.0mm/s)
scribed range.
Set the die cushion-knockout speed setting
456 MOTION SET UP FAULT/SET 0 DC KO SPEED
for the specified process to "0."
The die cushion pressure change mode set-
MOTION SET UP FAULT/OUT OF DC
461 ting for the specified process is outside of
TRANSFORMATION MODE
the prescribed range.
MOTION SET UP FAULT/SET 0 DC Set the die cushion pressure change mode
462
TRANSFORMATION MODE setting for the specified process to "0."
MOTION SET UP FAULT/SET 1 DC Set the die cushion pressure change mode
463
TRANSFORMATION MODE setting for the specified process to "1."
MOTION SET UP FAULT/DC Set the die cushion pressure change mode
464
TRANSFORMATION MODE IS 0 OR 3 setting for the specified process to "0" or "3."
The die cushion stopping time for the speci-
465 MOTION SET UP FAULT/OUT OF DC PUSE fied process is outside of the prescribed
range.

135
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

No.. Description of Calculation Results Details


Set the die cushion stopping time setting for
466 MOTION SET UP FAULT/SET 0sec DC PAUSE
the specified process to "0."
The maximum number of processes that
MOTION SET UP FAULT/MAX NUMBER OF KO
471 can have a knockout process set to "3" is
PROC. AFTER BDC IS 2
two.
The process is considered to be bottom
dead center because both the slide position
472 MOTION SET UP FAULT/NO BDC PROC.
and the die cushion position are set to 0 mm
in the same process.
The process prior to the bottom dead center
process where the position of the slide and
MOTION SET UP FAULT/NO DC START SL
473 the die cushion become identical for the first
POS. PROC.
time is considered to be the process where
the dies are coming into contact.
Create a post-bottom dead center knockout
MOTION SET UP FAULT/NO KO PROC. AFTER
474 process (pressure change mode setting
BDC
"3").

136
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.5.2 PROGRAM MONITOR Screen

(1)

(2)
*1 The design die height and the die cushion related elements are provided only for the press
No. 1.

(1) ※Slide and Die cushion Motion Display Waveform Selection


Displays the slide and die cushion motion settings as a waveform.
Since this waveform is a reference value created based on the specified input data, it
does not represent the actual motion. The keys to the right( SLIDE POSITION, SLIDE
SPEED, CUSHION POSITION, CUSHION LOAD) are used to select the desired wave-
form.

The slide position is displayed on the screen at all times.


When the RE-DRW key is pressed, the specified motion program is re-calculated to re-
display the waveform.

(2) Scroll Selection and Scroll Operation


Function keys can be used to scroll through or move the cursor on the displayed wave-
form.
The GRAPH key is used to scroll through the displayed waveform, and the CURS. key
is used to move the cursor.
The "<<" and ">>" function keys are used to scroll through the displayed waveform in
large increments, and the "<" and ">" function keys scroll for short distances.
Scrolling of the displayed waveform is enabled only when ZOOM is selected for the
waveform display size.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.5.3 Timing Switch Settings Screen

Access the Timing Switch Setting screen by pressing the TSW sub-menu touchbutton. This
screen is used to make timing switch settings for each cam.

(3)

(1)

(2)

(1) DATA EDIT keys


"SETTING"..........When this key is pressed, the input keys are displayed at the bottom
of the screen to enable the input of timing switch settings.
"CANCEL" ...........Press this key to discontinue data editing. The data settings are dis-
carded and the original data is retrieved.
"DECISION" ........Press this key when the settings are complete.

(2) Timing Switch Settings


Settings can be made by pressing the above-mentioned SETTING key. To select the
target for the setting, directly press on the target item on the screen or move the cur-
sor to the target item using the " ▲ " or " ▼ " input keys displayed at the bottom of the
screen. The selected item will be highlighted on the screen.
"ON TYPE".........Specifies the parameter to be used to turn the timing switch ON.
[0] → Angle, [1] ~ [30] → Process, [31] → Position, [32] → Downstroke
Position, [33] → Upstroke Position (*1)(*2)
"ON ANGLE.".....The timing switch ON angle. This setting is only enabled when the
"ON Type" is set to [0] Angle.
"ON POS." .........The timing switch ON position. This setting is only enabled when the
"ON Type" is set to [31] Position.
"ON LEAD ANG."The advance angle setting for the "ON ANGLE." This setting is only
enabled when the "ON TYPE" is set to [0] (angle).
"OFF TYPE".......Specifies the parameter to be used to turn the timing switch OFF.
[0] → Angle, [1] ~ [30] → Process, [31] → Position, [32] → Downstroke
Position, [33] → Upstroke Position (*1)(*2)
(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

"OFF ANGLE." ...The timing switch OFF angle. This setting is only enabled when the
"OFF Type" is set to [0] Angle.
"OFF POS."........The timing switch OFF position. This setting is only enabled when the
"OFF Type" is set to [31]Position.
"OFF LEAD ANG."The advance angle setting for the "OFF ANGLE." This setting is only
enabled when the "OFF TYPE" is set to [0] (angle).
"DELAY T." .........After the cam is turned ON, it is then turned OFF when the timer time
setting has elapsed.
This setting overrides the "OFF Ang." setting. The time setting range is
0.1~9.9 seconds and settings can be made in increments of 0.1 sec-
onds. A setting of "0" is invalid. Note: The cam cannot be turned OFF if
the timer setting exceeds the time of one press cycle. For example, if
one cycle takes one second, the cam cannot be turned OFF if the
timer setting exceeds one second.

(*1): Angle .............................Specifies the ON angle and the OFF angle.


Process ........................ Specifies the program process number for ON and OFF.
Position ........................ Specifies the ON and OFF position above bottom dead center
(in mm), regardless of whether the slide is upstroking or down-
stroking.
Downstroke Position .... Specifies the ON and OFF positions (in mm) when the slide is
downstroking.
Upstroke Position......... Specifies the ON and OFF positions (in mm) when the slide is
upstroking.
(*2): If process numbers (1~30) have been specified, do not specify a final process. If a final
process is specified, there is a possibility that it may not actuate in accordance with the
settings.

(3) Cam Monitor


If any cam is currently ON, the rectangular block above the Cam No. will turn yellow.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.5.4 MECHANICAL DEVICE Screen

(2)

(1)

(3)

*1 :The "DESIGN DIE HEIGHT", the die cushion related elements, the ENERGY elements ③
and ④ and the MOTOR TEMP. elements ③ and ④ are provided only for the press No. 1.

(1) DESIGN DIE HEIGHT(ONLY No.1 PRESS)


Enter the DESIGN DIE HEIGHT of the die to be used.

(2) PRESS IDOL SETTING (ONLY No.2 ~ No.4 PRESS)


"LEFT MB DIE DETECT / UNDETECT"...... Displays the left MB die detecting sensor sta-
tus.
"RIGHT MB DIE DETECT / UNDETECT" ... Displays the right MB die detecting sensor
status.
"MASTER USE / NO USE SETTING" ......... Displays the idling setting status on the mas-
ter control panel.

(3) MECHANICAL DEVICE


This is the function consisting of the solenoid valve and various timings for operating the air
actuator prepared by the customer. Use/nonuse of the mechanical devices can be selected
by pressing the USE CONDITION "ON/OFF" key on a device-by-device basis.
"ON / OFF" ............ Mechanical devices can be used when "ON" is selected.
In the case there is a mechanical device which is currently in the ON
state, the upper frame of the relevant mechanical device No. lights up
in "orange".
"TEST" ................... The mechanical device can be tested by means of the function key by
pressing the "TEST".

(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

ON / OFF CONDITION "SETTING".........Set the conditions described below with numeric


values.

• Description of ON/OFF condition


<ON CONDITION>
 0:CAM
Timing of the timing switch cam

 1:PANEL + CAM
Timing of turning ON of the work detecting sensor and the timing of the timing switch
cam

<OFF CONDITION>

 0:CAM + TIMER
   Cam and the delay time of the timing switch
In the case the timer is set at 0.5 sec. at 10 degrees of OFF angle, the output is
turned OFF 0.5 sec. after the press angle exceeds 10 degrees.

 1:PANEL NON + TIMER


Timing of turning OFF of the work detecting sensor and the delay time of the timing
switch
When the work runs out, the output is turned OFF after a lapse of the timer setting
time.
 
 2:U/LD VACUUM TIMING (U/LD: UNLOADER (unloading of work))
   Timing at which the transfer device picks up the work
Output is turned OFF at the timing when the work is picked up by the transfer device
for unloading.
 
 3:PANEL+LD ESCAPE TIMING (LD:LOADER (loading of work))
Timing of turning ON of the work detecting sensor and the timing at which the trans-
fer device moves to the escape position
Output is turned OFF at the timing when the work detecting sensor is turned ON and
the transfer device unclamps the work and moves to the escape position.

Refer to Section D OPERATION, 9. OPERATION OF AUXILIARY EQUIPMENT


9.1 MECHANICAL DEVICE (pg. 275) for the actual operation.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.5.5 VARIATION CIRCUIT Screen

When the "VARIATION CIRCUIT" on the SUB MENU is pressed, the screen is changed over
to the variation circuit setting screen.
The variation circuit refers to the function which operates the air actuator, installed in the die,
according to the derived code given by the master control panel.

<<VARIATION CIRCUIT Screen 1/2 >> (No.1 PRESS)

(4)

(1)

(2)

(3)

(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

<<VARIATION CIRCUIT Screen 1/2 >> (No.2 ~ 4 PRESS)

(4)

(1)

(2)

(3)

(1) Operation monitor display


For the press No. 1, the output signals of the valves can be monitored.
The monitor light of the valve is in light blue when the valve is in the OFF state and in
orange when it is in the ON state.

For the presses Nos. 2, 3 and 4, the following displays are given.

② ①

① Input signals of the respective sensors can be monitored.


The sensor monitor light is in light blue when the input signal is in the OFF state and in
orange when it is in the ON state.
② Upper die sensor "USE/NO USE" setting
In the case the "UPPER DIE" is selected, in the operation setting, for the air actuator
installed in the upper die, the press makes an immediate stop due to the "VARIATION
CIRCUIT ACTION FAULT" which occurs in the state where the outside end sensor is in
the "OFF" state and the back end sensor is in the "ON" state at the time when the slide
top dead center is detected and the solenoid valve is activated after the upper die is
clamped.
In the case the "TSW" is selected in the operation setting, or this function is not used,
set the upper die sensor at "NO USE".
(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(2) VALVE SETTING


① USE / NO USE KEY

Used to set use/nonuse of the variation circuit.

② MOTION SETTING KEY

In the case the "UPPER DIE" is selected, the solenoid valve is activated
at the time when the top dead center of the slide is detected after the
upper die is clamped.

n the case the "TSW" is selected, the solenoid valve is activated


according to the ON/OFF setting of the relevant TSW on a cycle-by-
cycle basis subsequent to the detection of the top dead center of the
slide after the upper die is clamped.

③ SOLENOID VALVE SETTING KEY

In the case the "A-PORT USE" is selected, only the solenoid valve of the
A-port is turned ON/OFF according to the operation setting.
The B-port solenoid valve remains OFF.

In the case the "B-PORT USE" is selected, only the solenoid valve of
the B-port is turned ON/OFF according to the operation setting.
The A-port solenoid valve remains OFF.

(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

"A, B-PORT USE" is selectable only when the "TSW"


is selected in the operation setting.
Subsequent to the detection of the top dead center of the slide after the
upper die is clamped, the following operation sequence is carried out in
repetition for every cycle:
When the relevant TSW is in the ON state:
The A-port solenoid valve is turned ON and B-port solenoid valve is
turned OFF;
When the relevant TSW is in the OFF state:
The A-port solenoid valve is turned OFF and B-port solenoid valve is turned ON;

Regardless of the setting of the TSW, both the A and B port solenoid valves are turned
OFF and are placed in the neutral state before the detection of the top dead center of the
slide after the upper die is clamped or at the time when the upper die is unclamped.

(Note) For the "ZIGZAG" of the press No. 1, only the "USE/NO USE" setting is enabled.
In this case, the MOTION SETTING is "TSW" and the SOLENOID VALVE SETTING is
fixed in the "A, B-PORT USE".

(3) Test operation


Test operation is carried out to check the cylinder operation by forcibly turning ON/OFF the
valve or to adjust the sensors.

Test operation is carried out as follows:


* Select "NO USE" in (2) Valve setting "USE/NO USE", and select the test operation.
* "Match" (4) "DERIVATION CODE MEMORY CHECK" switch with the "derived code"
given by the master control panel.

(4) "DERIVATION CODE MEMORY CHECK"SWITCH


Description given in "USE/NO USE", "MOTION SETTING" and "SOLENOID VALVE
SETTING" in (2) VALVE SETTING indicates the setting with respect to the derived code
selected by means of this "DERIVATION CODE MEMORY CHECK" switch.

To change the setting, it is necessary to firstly specify the derived code to be changed by
means of this "DERIVATION CODE MEMORY CHECK" switch. Then, change the settings
as follows:
"USE / NO USE" USE ⇔ NO USE
"MOTION SETTING" UPPER DIE ⇔ TSW*
"SOLENOID VALVE SETTING" A PORT USE ⇔ B PORT USE ⇔ A・B PORT USE
Lastly, touch the "WRITE".

(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)
<<VARIATION CIRCUIT Screen 2/2 >> (No.1 PRESS)
新しい画面と差替え

<<VARIATION CIRCUIT Screen 2/2 >> (No.2 ~ 4 PRESS)


新しい画面と差替え

(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

It is possible to display the list of use/nonuse of the variation circuits with their derived
codes and to set the use/nonuse status.
Details of the following items displayed in "(2) VALVE SETTING" cannot be checked on this
screen.
"MOTION SETTING", "SOLENOID VALVE SETTING"

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.5.6 CUSHION AREA Screen (only No.1PRESS)

When the "CUSHION AREA" key on the SUB MENU is pressed, the current screen is
changed over to the one on which the settings of the die cushion are displayed.

This screen is used for checking the settings regarding the die cushion. Settings of the die
cushion are to be configured on the display of the die-cushion device.

*1 The design die height and the die cushion related elements are provided only for the press
No. 1.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.6 THE DIE CHANGE SCREEN

Access the DIE CHANGE screen by pressing the DIE CHANGE main menu touchbutton.
This screen cannot be accessed while the press is in operation.

<<Submenus >>
"UNIT OPERATION" ........This screen is used for slide adjustment, and to operate the
unsticker device.(pg. 150)

"UP.CLAMP
SELECTION" ...................This screen is used to select the use/nonuse of the upper die
clamper and to select the points of use.(pg. 152)

"DIE CHANGE
MONITOR".......................This screen is used to indicate the progress of automatic die
change process by means of the light.(pg. 153)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.6.1 UNIT OPERATION Screen


Access the UNIT OPERATION screen by pressing the "UNIT OPERATION" submenu touch-
button.
On this screen, the unit operation of the slide, slide adjusting device, upper die clamper and
moving bolster is carried out, the design die height value is set, and the automatic die change
operation is carried out.

(1)

(3)
(2)

(1) UNIT OPERATION Selection


"PRESS RUN" ...The press can be operated in the INCH, STEP FEED and ORIGIN
POINT modes. The OPERATION SELECT switch is used to select the
operation mode. Micro Inch mode operation is also possible if you
press the "MICRO" key while INCH mode is selected.
"SLIDE ADJ.AUTO DIE CHANGE HEIGHT"
...........................The die height to be employed for automatic die change is set. Adjust-
ing operation is also enabled. The input keys are displayed on the
lower part of the screen by pressing the "SETTING" key to enable
setting of the die height. Adjusting device is started by means of the
FUNCTION buttons.
"SLIDE ADJ.AUTO PRODUCT HEIGHT"
...........................The die height to be employed for production is set. Adjusting opera-
tion is also enabled. The input keys are displayed on the lower part of
the screen by pressing the "SETTING" key to enable setting of the die
height. Adjusting device is started by means of the FUNCTION but-
tons.
"AUTO DIE CHANGE"
...........................Automatic die change can be started by using the FUNCTION buttons.
When the "NEXT DIE SELECT" key is pressed, the current screen is
changed over to the data bank screen on which data on the die to be
used for the next production are set. For how to operate the data bank
screen, see 8. CHANGING DIES 8.2 AUTO DIE CHANGE (pg. 271).
"UNSTICKER"....Unsticking operation is enabled. Use the FUNCTION buttons to carry
out the unsticking operation.
(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

"UPPER DIE MASS"


...........................The balancer pressure corresponding to the specified upper-die mass
is calculated to adjust the balancer pressure.

(2) Bolster selection status display


In the case the automatic die change is selected in the UNIT OPERATION selection, it
is possible to select TAKE OUT, TAKE IN or DIE CHANGE by pushing the "BOLSTER
SELECTION" function button.

(3) Balancer pressure status display


The solenoid valve operation in the case of increase/decrease in pressure, and the set
value and current value of the balancer pressure are displayed.
Lubricating oil accumulated in the balance cylinder is drained by pressing the "DRAIN
DISCHARGE".

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.6.2 UPPER DIE CLAMPER Screen

Access the UPPER DIE CLAMPER screen by pressing the "UP. CLAMP SELECTION" sub-
menu touchbutton.
On this screen, selection of use/nonuse of the upper die clamper and the individual selection
of the clamper(s) to be used are carried out.

(1)

(2)

(1) Upper Die Clamper Use Selection


Use/nonuse of the upper die clamper is selected.

(2) Upper Die Clamper Individual Selection


In the case "USE" is selected for the upper die clamper, the upper die clamper(s) to be
used is individually selected.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.6.3 DIE CHANGE MONITOR Screen

Access the DIE CHANGE MONITOR screen by pressing the "DIE CHANGE MONITOR" sub-
menu touchbutton.
This screen is used to indicate the progress of automatic die change process by means of the
light.
The light comes on in yellow while the device is in operation and when the operation is com-
pleted.

<<TAKE OUT MONITOR Screen >>

<<TAKE IN MONITOR Screen >>

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.7 THE RECIPE (DATABANK) SCREEN

A databank system (hereafter referred to as the "databank") is built into this press machine as
a standard item to assist in presswork productivity.
The databank links the press machine data settings for dies (hereafter referred to as "die
data"), which can vary from die to die, with die numbers that are stored in the databank. Data
for up to 100 different dies can be stored.
The die data stored in the data bank is downloaded to/from the production die data area.
Access the RECIPE screen by pressing the RECIP main menu touchbutton.

<< Submenus>>
"DOWN LOAD" ........The die data stored in the data bank is downloaded to the production
die data area.
(pg. 155)
"UP LOAD" ..............The die data in the production die data area in downloaded to the data
bank and saved there. (pg. 156).
"COPY" ....................The die data is copied in the data bank. (pg. 157).
"CLEAR" ..................The die data stored in the data bank is erased on a data-by-data
basis. (pg. 159).
"NEXT DIE SELECT" .When executing the automatic die change, the die data to be used for
next production are selected.. (pg. 160).

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.7.1 Screen on which the Die Data in the Data Bank is transferred to the Production
Die Data

When the DOWN LOAD submenu button is pressed, the screen changes to the screen where
the die data stored in the data bank can be downloaded to the production die data area.

(4) (3)

(2)

(1)

(3)

(1) Product Name List Display


Product names which have been saved in the data bank are displayed. When the "TIME
DISPLAY" key is pressed, the time at which the die data was saved in the data bank is
displayed.
The " " and " " keys located at the top of the list can be used to scroll to other list
pages.

(2) Selecting the Die Data to be Downloaded


When a die name in the above-mentioned list is pressed, the color of the corresponding
die name changes to orange. When the SELECTION key is then pressed, it selects this
die data as the data that is to be downloaded to the production die data area, and the
die number, product name and time at which the data was saved are displayed on the
display area in the upper left part of the screen.

(3) Downloading the Die Data to the Production Die Data Area
When the "DOWN LOAD" key is pressed with the "DB OPE.OK" function button held
pushed, the die data selected in procedure (2) above is downloaded to the production
die data area, and the die number and the product name of the downloaded data and
also the time at which the data was saved are displayed on the upper right display area
of the screen.

(4) Editing Die Data


The description of the die data selected in procedure (2) above can be checked or
edited by pressing the EDIT key. Refer to 3.7.6 DIE DATA EDIT Screen (pg. 161) for
details.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.7.2 Screen on which the Production Die Data is stored in the Data Bank

When the UP LOAD submenu button is pressed, the current screen changes to the screen on
which the die data in the production die data area can be downloaded to the data bank and
stored there.

(4) (3)

(2)
(1)

(3)

(1) Product Name List Display


Product names which have been saved in the data bank are displayed. When the "TIME
DISPLAY" key is pressed, the time at which the die data has been saved in the data
bank is displayed. The list page can be changed over by means of the " " and " " keys
located at the top of the list. The number and name of the production die data which is
currently in use and the time at which the data was saved are displayed on the display
section at the upper right of the screen.

(2) Selection of the Die Number to be Saved


When the die name section displayed inside the above-shown list is pressed, the color
of the corresponding die name section is changed to "orange." When the SELECTION
key is pressed in the above-mentioned state, the die number to be saved in the data
bank is selected.

(3) Storage of the Die Data in the Data Bank


When the "UP LOAD" key is pressed with the "DB OPE.OK" function button held
pushed,the die data shown on the display area at the upper right of the screen is saved
in the data bank under the die number selected in the above-mentioned procedure (2).
When the saving procedure is completed, the die name shown on the display area at
the upper left of the screen is replaced by the current production die name.
* The die number remains the one which has been selected in the above-mentioned
procedure (2).

(4) Edit of Die Data


The description of the die data selected in the above-mentioned procedure (2) can be
checked or edited by pressing the EDIT key. Refer to 3.7.6 DIE DATA EDIT Screen (pg.
161) for details.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.7.3 DIE DATA COPY Screen


When the COPY submenu button is pressed, the current screen changes to the screen where
the die data in the data bank can be copied.

(5) (4)

(2)
(3)

(1)

(1) Product Name List Display


Product names which have been saved in the data bank are displayed. When the "TIME
DISPLAY" key is pressed, the time at which the die data was saved in the data bank is
displayed.
The " " and " " keys located at the top of the list can be used to scroll to other list
pages.

(2) Selection of the Source Die Number for Copying


When the die name section displayed inside the list is pressed, the color of the corre-
sponding die name section changes to orange. When the SELECTION key shown at the
left side of the screen is pressed while in the above-mentioned state, the source die
number is selected.

(3) Selection of the Destination Die Number for Copying


Just as in procedure (2) above, when the die name section in the list is pressed, the
color of the corresponding die name section changes to orange. The destination die
number for copying is selected by pressing the SELECTION key at the right side of the
screen.

(4) Copying the Die Data


When the "COPY" key is pressed with the "DB OPE.OK" function button held pushed,
the source die number for copying shown on the display area in the upper left part of the
screen is saved in the die number selected in the above-mentioned procedure (3). Once
the saving procedure is completed, the die name shown on the display area in the upper
right part of the screen is replaced by the die name shown in the upper left part of the
screen.
* The die number remains the destination die number selected for copying in procedure
(3) above.
(Continued on the next page)

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(5) Editing Die Data


The specifics of the die data selected in procedure (2) or (3) above can be checked or
edited by pressing the EDIT key. Refer to 3.7.6 DIE DATA EDIT Screen (pg. 161) for
details.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.7.4 DIE DATA CLEAR Screen


When the CLEAR submenu button is pressed, the current screen changes to the screen
where die data in the data bank can be deleted. A single data deletion operation only deletes
one piece of die data. It is not possible to use this screen to delete all of the data in the data
bank.

(4) (3)

(2)

(1)

(1) Product Name List Display


Product names which have been saved in the data bank are displayed. When the "TIME
DISPLAY" key is pressed, the time at which the die data was saved in the data bank is
displayed.
The " " and " " keys located at the top of the list can be used to scroll to other list
pages.

(2) Selection of the Die Number to be Deleted


When the die name section in the product name list shown above is pressed, the color
of the corresponding die name section changes to orange. When the SELECTION key
is pressed while in this state, the die number to be deleted will be selected, and the die
number, product name and the time at which the die data was saved will be shown on
the display area at the upper left part of the screen.

(3) Deleting Die Data


The die data in the data bank shown in the upper left display area are deleted by
pressing the "CLEAR" key with the "DB OPE.OK" function button held pushed.

(4) Editing Die Data


The description of the die data selected in procedure (2) above can be checked or
edited by pressing the "EDIT" key. Refer to 3.7.6 DIE DATA EDIT Screen (pg. 161) for
details.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.7.5 NEXT DIE SELECT Screen

When the "NEXT DIE SELECT" on the SUB MENU is pressed, the current screen is changed
over to the one on which the production die data to be set at the carry-in operation of the auto-
matic die change are selected.Refer to 3.6.1 UNIT OPERATION Screen (pg. 150)

(4) (3)

(2)

(1)

(3)

(1) Product Name List Display


Product names which have been saved in the data bank are displayed. When the "TIME
DISPLAY" key is pressed, the time at which the die data was saved in the data bank is
displayed.
The " " and " " keys located at the top of the list can be used to scroll to other list
pages.

(2) Next Die Data Selection


When a product number section in the product numbers list shown above is pressed, the
color of the pressed section becomes "orange".
When the "SELECTION" key is pressed in the aforementioned state, the next die num-
ber is selected to display the die number and product number, and the registered time of
the die data on the upper left display area.

(3) Complete To Select Next Die


When the "NEXT DIE SELECT COMPLETE" key is pressed with the "DB OPE.OK" func-
tion button held pushed, the color of the key becomes "orange". If the carry-in operation
of the automatic die change is conducted at this time, selected data on the next die will
be transmitted to the production die data area.

(4) Editing Die Data


The description of the die data selected in procedure (2) above can be checked or
edited by pressing the EDIT key. Refer to 3.7.6 DIE DATA EDIT Screen (pg. 161) for
details.

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Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.7.6 DIE DATA EDIT Screen


When the EDIT key is pressed after the die data from the data bank screen pages has been
selected, the current screen changes to a screen where the die data stored in the data bank
can be edited.

<<DIE DATA EDIT Screen 1/5 >>

(9)

(8)
(10)

(5)

(2)

(3)

(1)

(7)
(4)

(6)

(1) DATA EDIT keys


"SETTING"..........Press this key to select the motion or edit (make settings or change)
the motion program data. Input keys are displayed at the bottom of
the screen.
"CANCEL" ...........Press this key to discontinue data editing. The edited data is dis-
carded and the original data is retrieved.
"DECISION" ........Press this key once the data editing has been completed. When this
key is pressed, the edited data is checked for errors. If no errors are
found, the press will operate according to the edited data.

(2) Counter and SPM Settings


You can enable/disable the use of the preset counters/production counters, make preset
number settings, and set the no-load spm.
(Reference: 3.4.1 PRESS Run Screen (pg. 119), (3) Digital Speed Meter, (5) Preset Coun-
ters and Production Counters,7.2 COUNTERBALANCE CAPACITY ADJUSTMENT (pg.
253)).

(3) Design Die Height Settings (Only No.1 press)


Input a design die height of the die to be used.
(Reference: 3.6.1 UNIT OPERATION Screen (pg. 150) (1) UNIT OPERATION Selection
)
(Continued on the next page)

161
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(4) Die Change Height, Die Height Settings


Die height value for the automatic slide adjustment is set.
(Reference: 3.6.1 UNIT OPERATION Screen (pg. 150) (1) UNIT OPERATION Selection
)

(5) Upper Die Clamper Settings


Selection of use/nonuse of the upper die clamper and selection of the clamper(s) to be
used are made.
(Reference: 3.6.2 UPPER DIE CLAMPER Screen (pg. 152) )

(6) Upper Die Mass Settings


Upper die mass is set.
(Reference: 3.6.1 UNIT OPERATION Screen (pg. 150) (1) Manual Selection )

(7) Upper Die Sensor Settings(No.2 ~ 4 press)


Selection of use/nonuse of the upper die sensors 1, 2 and 3 is made.
(Reference: 3.5.5 VARIATION CIRCUIT Screen (pg. 142) )

(8) Changing the Edit Screen Page


The page displayed on the screen can be changed by pressing the " " or " " key.



(9) Inputting Product Names
When the CHANGE key is pressed, the input keys are displayed at the bottom of the
screen to enable product name inputting and editing.

(10)Selecting the Die to be Edited


The die number to be edited is selected using the " ▲

" and " ▼

" keys and the " ▲ " and "
▼ " keys.
The die number is increased/decreased in increments/decrements of 10 with the " ▲

"

and " ▼

" keys. It is increased/decreased in increments/decrements of 1 with the " ▲ "
and " ▼ " keys.

(Continued on the next page)

162
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

<<DIE DATA EDIT Screen 2/5 >>

The data regarding the timing switches No. 9 to No. 14 are intended to be used for the press
No. 1.

This screen is used to make all the timing switch data settings.
(Reference: 3.5.3 Timing Switch Settings Screen (pg. 138))
(Continued on the next page)

163
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

<<DIE DATA EDIT Screen 3/5 >>

This screen is used to select the press motion type and make motion program settings.
(Reference: 3.5.1 Motion Selection /Setting Screen (pg. 127))
(Continued on the next page)

164
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

<<DIE DATA EDIT Screen 4/5 >>

This screen is used to make mechanical device settings.


(Reference: 3.5.4 MECHANICAL DEVICE Screen (pg. 140))
The die cushion area data display section on the screen is used for checking the die
cushion settings. (Only for the press No.1)
Setting is made on the display of the die cushion device.

(Continued on the next page)

165
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

<<DIE DATA EDIT Screen 5/5 >>

This screen is used to make variation circuit settings.


(Reference: 3.5.5 VARIATION CIRCUIT Screen (pg. 142))

166
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8 THE MAINTENANCE SCREEN

Access the MAINTENANCE screen by pressing the MAINT. main menu touchbutton. Press
operation is disabled while this screen is active.

<<Submenus>>
"I/O MONITOR" .......................Displays the I/O status of the controllers (MPC and
SVC,PLC) (pg. 168).
"DATA MONITOR" ....................Displays internal data specified by the controllers (MPC
and SVC) (pg. 177).
"FAILURE" ...............................Displays current faults ,fault history and the inpact speed
fault history(pg. 178).
"MAINTENANCE" ....................Displays the maintenance counter and utilization time (pg.
180).
"OPTION TEST MODE" (Optional Settings)Used to make settings for options (pg. 183).
"TIME & DATE" ........................Used to set the clock in the PLC and the energy-saving
timer (pg. 185).

167
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8.1 I/O Monitor Screen

Access the I/O MONITOR screen by pressing the "I/O MONITOR" submenu touchbutton.
This screen is used during operation adjustment operations, etc., to check the I/O status of the
MPC (multi-process press controller), SVC (servo controller) and the PLC (programmable
logic controller). For descriptions of the displayed content, see the I/O Monitor list on the next
page.
<<I/O Monitor Screen 1/11 >>

The page displayed on the screen is changed over by pressing the " " or " " key.

<<I/O Monitor Screen 3/11 >> <<I/O Monitor Screen 4/11 >>

* Input the I/O address of PLC to be moni- * Normal/fault status of the signals which are
tored. (Hexadecimal number) input to the safety PLC is displayed.

168
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

I/O Monitor adress list

This list shows addresses and names to be displayed on the I/O MONITOR screen.

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1800 0 DI_10 MPC Input State: Mode Selection: SINGLE 1/9


D1800 1 DI_11 MPC Input State: Mode Selection: CONT. 1/9
D1800 2 DI_12 MPC Input State: Mode Selection: CONT. SINGLE 1/9
D1800 3 DI_13 MPC Input State: Mode Selection: STEP FEED 1/9
D1800 4 DI_14 MPC Input State: Mode Selection: HOME POS.RETURN 1/9
D1800 5 DI_15 MPC Input State: Mode Selection: LINE 1/9
D1800 6 DI_16 MPC Input State: Mode Selection: 1/9
Foot Switch SINGLE
D1800 7 DI_17 MPC Input State: Mode Selection: Die Change 1/9
D1800 8 DI_00 MPC Input State: Left RUN button 1 NO 1/9
D1800 9 DI_01 MPC Input State: Left RUN button 1 NC 1/9
D1800 10 DI_02 MPC Input State: Right RUN button 1 NO 1/9
D1800 11 DI_03 MPC Input State: Right RUN button 1 NC 1/9
D1800 12 DI_04 MPC Input State: Prior Action 1/9
D1800 13 DI_05 MPC Input State: reserved 1/9
D1800 14 DI_06 MPC Input State: Mode Selection: OFF 1/9
D1800 15 DI_07 MPC Input State: Mode Selection: INCH 1/9
D1801 0 DI_30 MPC Input State: Front guard disabled 1/9
D1801 1 DI_31 MPC Input State: Rear guard disabled 1/9
D1801 2 DI_32 MPC Input State: Step Feed enable button NO 1/9
D1801 3 DI_33 MPC Input State: Step Feed enable button NC 1/9
D1801 4 DI_34 MPC Input State: Front safety guard closed 2 1/9
D1801 5 DI_35 MPC Input State: Rear guard closed 2 1/9
D1801 6 DI_36 MPC Input State: Immediate Stop interlock2 1/9
D1801 7 DI_37 MPC Input State: reserved 1/9
D1801 8 DI_20 MPC Input State: reserved 1/9
D1801 9 DI_21 MPC Input State: Power Control Panel Over Current 1 / 9
Detect
D1801 10 DI_22 MPC Input State: Slide adjust up command 1/9
D1801 11 DI_23 MPC Input State: Slide adjust down command 1/9
D1801 12 DI_24 MPC Input State: Reset button 1/9
D1801 13 DI_25 MPC Input State: Preset Stop Position button 1/9
D1801 14 DI_26 MPC Input State: Stop Position Selection: 1/9
Top dead center

169
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1801 15 DI_27 MPC Input State: Stop Position Selection: 1/9


Preset stop position
D1802 0 DI_50 MPC Input State: Immediate Stop interlock1 1/9
D1802 1 DI_51 MPC Input State: Safety Device OK1 1/9
D1802 2 - 1/9
D1802 3 DI_53 MPC Input State: M-CON2 Contact weld 1/9
detection monitor
D1802 4 DI_54 MPC Input State: Check robot home position 1/9
D1802 5 DI_55 MPC Input State: External device emergency 1/9
stop signal
D1802 6 DI_56 MPC Input State: Slide adjust thermal trip 1/9
D1802 7 DI_57 MPC Input State: Line Select Unit 1/9
D1802 8 DI_40 MPC Input State: Aux. function complete input 1/9
D1802 9 DI_41 MPC Input State: Brake PS 1/9
D1802 10 DI_42 MPC Input State: Feeder master start 1/9
D1802 11 DI_43 MPC Input State: Feeder master restart Aux. 1/9
D1802 12 DI_44 MPC Input State: Master selection: Press Master 1/9
D1802 13 DI_45 MPC Input State: Master selection: Feeder Master 1/9
D1802 14 DI_46 MPC Input State: Front safety guard closed 1 1/9
D1802 15 DI_47 MPC Input State: Rear guard closed 1 1/9
D1803 0 DI_70 MPC Input State: Brake solenoid valve monitor NO 1/9
D1803 1 DI_71 MPC Input State: Brake solenoid valve monitor NC 1/9
D1803 2 DI_72 MPC Input State: Slide Upstroke LS 1/9
D1803 3 DI_73 MPC Input State: Slide Downstroke LS 1/9
D1803 4 - 1/9
D1803 5 - 1/9
D1803 6 DI_76 MPC Input State: Slide motion output monitor 1/9
D1803 7 DI_77 MPC Input State: Emergency Stop signal / 1 1/9
D1803 8 DI_60 MPC Input State: Line select off 1/9
D1803 9 DI_61 MPC Input State: Front Light curtain: active 1/9
D1803 10 DI_62 MPC Input State: Front Light curtain: tripped 1/9
D1803 11 DI_63 MPC Input State: Line select group line 1/9
D1803 12 DI_64 MPC Input State: Line select all line 1/9
D1803 13 DI_65 MPC Input State: Rear Light curtain: active 1/9
D1803 14 DI_66 MPC Input State: Rear Light curtain: tripped 1/9
D1803 15 DI_67 MPC Input State: Emergency Stop/ 2 1/9
D1804 0 DI_100 MPC Input State: PLC Immediate Stop interlock 1/9
D1804 1 DI_101 MPC Input State: PLC Top Stop (Preset stop) 1 / 9
interlock

170
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1804 2 DI_102 MPC Input State: Base cutoff output: OFF monitor 1/9
D1804 3 DI_103 MPC Input State: Base cutoff output: ON monitor 1/9
D1804 4 DI_104 MPC Input State: Die protection sensor / 1 1/9
D1804 5 DI_105 MPC Input State: Die protection sensor / 2 1/9
D1804 6 DI_106 MPC Input State: M-CON2 output: off monitor / 1 1/9
D1804 7 DI_107 MPC Input State: M-CON2 output: off monitor / 2 1/9
D1804 8 - MPC Input State: Brake release output fuse blown /1 1/9
D1804 9 - MPC Input State: Brake release output monitor /1 1/9
D1804 10 - MPC Input State: Brake release output fuse blown /2 1/9
D1804 11 - MPC Input State: Brake release output monitor /2 1/9
D1804 12 - MPC Input State: Base cutoff output monitor 2 1/9
D1804 13 - 1/9
D1804 14 - 1/9
D1804 15 - 1/9
D1805 0 CAM1 MPC Output State: Cam 1 output 1/9
D1805 1 CAM2 MPC Output State: Cam 2 output 1/9
D1805 2 CAM3 MPC Output State: Cam 3 output 1/9
D1805 3 CAM4 MPC Output State: Cam 4 output 1/9
D1805 4 CAM5 MPC Output State: Cam 5 output 1/9
D1805 5 CAM6 MPC Output State: Cam 6 output 1/9
D1805 6 CAM7 MPC Output State: Cam 7 output 1/9
D1805 7 CAM8 MPC Output State: Cam 8 output 1/9
D1805 8 CAM9 MPC Output State: Cam 9output 1/9
D1805 9 CAM10 MPC Output State: Cam 10 output 1/9
D1805 10 CAM11 MPC Output State: Cam 11 output 1/9
D1805 11 CAM12 MPC Output State: Cam 12 output 1/9
D1805 12 CAM13 MPC Output State: Cam 13 output 1/9
D1805 13 CAM14 MPC Output State: Cam 14 output 1/9
D1805 14 CAM15 MPC Output State: Cam 15 output 1/9
D1805 15 CAM16 MPC Output State: Cam 16 output 1/9
D1806 0 CAM17 MPC Output State: Cam 17 output 1/9
D1806 1 CAM18 MPC Output State: Cam 18 output 1/9
D1806 2 CAM19 MPC Output State: Cam 19 output 1/9
D1806 3 CAM20 MPC Output State: Cam 20 output 1/9
D1806 4 CAM21 MPC Output State: Cam 21 output 1/9
D1806 5 CAM22 MPC Output State: Cam 22 output 1/9
D1806 6 CAM23 MPC Output State: Cam 23 output 1/9
D1806 7 CAM24 MPC Output State: Cam 24 output 1/9

171
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1806 8 CAM25 MPC Output State: Cam 25 output (misfeed 1) 1/9


D1806 9 CAM26 MPC Output State: Cam 26 output (misfeed 2) 1/9
D1806 10 CAM27 MPC Output State: Cam 27 output (bottom dead center 1 / 9
cam)
D1806 11 CAM28 MPC Output State: Cam 28 output 1/9
(Top dead center / preset stop position cam)
D1806 12 CAM29 MPC Output State: Cam 29 output (SINGLE cam) 1/9
D1806 13 CAM30 MPC Output State: Cam 30 output 1/9
(Home position stop cam)
D1806 14 CAM31 MPC Output State: Cam 31 output 1/9
(bottom dead center stop cam)
D1806 15 CAM32 MPC Output State: Cam 32 output (MD Cam) 1/9
D1807 0 - 1/9
D1807 1 - 1/9
D1807 2 - 1/9
D1807 3 - 1/9
D1807 4 - 1/9
D1807 5 - 1/9
D1807 6 - 1/9
D1807 7 - 1/9
D1807 8 - 1/9
D1807 9 - 1/9
D1807 10 - 1/9
D1807 11 - 1/9
D1807 12 - 1/9
D1807 13 - 1/9
D1807 14 - 1/9
D1807 15 - 1/9
D1808 0 DO_200A MPC Output State: M-COM2 output 1 1/9
D1808 1 DO_201 MPC Output State: MPC Immediate stop interlock 1/9
D1808 2 DO_202 MPC Output State: MPC Top stop (Preset stop) 1/9
D1808 3 DO_203B MPC Output State: Base cutoff output 1 1/9
D1808 4 DO_204A MPC Output State: Slide motion output 2 1/9
D1808 5 DO_310 MPC Output State: Slide adjust: Upstroke 1/9
D1808 6 DO_311 MPC Output State: Slide adjust: Downstroke 1/9
D1808 7 DO_312 MPC Output State: Operation ready 1/9
D1808 8 DO_313 MPC Output State: Emergency stop (option) normal 1/9
D1808 9 DO_314 MPC Output State: Safety guard closed 1/9

172
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1808 10 DO_315 MPC Output State: Presence sensing device enabled 1 / 9


and normal
D1808 11 BRK1 MPC Output State: Brake release output / 1 1/9
D1808 12 DO_205 MPC Output State: Slide motion output / 1 1/9
D1808 13 BRK2 MPC Output State: Brake release output / 2 1/9
D1808 14 DO_203A MPC Output State: Base cutoff output / 2 1/9
D1808 15 DO_200B MPC Output State: M-COM2 output / 2 1/9
D1809 - MPC Input State: Die height raw data 1/9
D1810
D1811 - MPC Input State: Analog input raw data 1/9
D1812 - MPC Version information: Model & specifications 1/9
D1813 - MPC Version information: Version 1/9
D1814 - SVC Version information 1/9
D1815 - SVC Input State: SVC Input State: Servo R/E input 1/9
D1816
D1817 - SVC Input State: Current monitor input 1/9
D1818 - SVC Input State: Velocity command monitor input 1/9
D1819 - SVC Input State: Step feed counter 1/9
D1820 - SVC Input State: Linear scale counter 2/9
D1821
D1822 - SVC Output State: Velocity command output 2/9
D1823 - SVC Output State: Forward torque output 2/9
D1824 - SVC Output State: Reverse torque output 2/9
D1825 - SVC Output State: Robot angle output 2/9
D1826 0 SVDI_0: SVC Input State: Servo ready 2/9
CN1-6Pin
D1826 1 SVDI_1: SVC Input State: Alarm Bit8 2/9
CN1-7Pin
D1826 2 SVDI_2: SVC Input State: Alarm Bit7 2/9
CN1-8Pin
D1826 3 SVDI_3: SVC Input State: Reserved 2/9
CN1-9Pin
D1826 4 SVDI_4: SVC Input State: Reserved 2/9
CN1-10Pin
D1826 5 - 2/9
D1826 6 - 2/9
D1826 7 - 2/9
D1826 8 DI_0: SVC Input State: Moment stop 2/9
CN3-19Pin
D1826 9 DI_1: SVC Input State: Reserved 2/9
CN3-20Pin

173
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1826 10 DI_2: SVC Input State: Reserved 2/9


CN3-21Pin
D1826 11 DI_3: SVC Input State: Reserved 2/9
CN3-22Pin
D1826 12 DI_4: SVC Input State: Run command 2/9
CN3-23Pin
D1826 13 DI_5: SVC Input State: Mechanical brake sensor 2/9
CN3-24Pin
D1826 14 DI_6: SVC Input State: Reserved 2/9
CN3-25Pin
D1826 15 DI_7: SVC Input State: Reserved 2/9
CN3-26Pin
D1827 0 EXDI_1: SVC Input State: Cushion press monitor 2/9
CN15-1Pin
D1827 1 EXDI_2: SVC Input State: Power control panel 1 voltage change 2 / 9
CN15-2Pin monitor 0
D1827 2 EXDI_3: SVC Input State: Power control panel 1 voltage change 2 / 9
CN15-3Pin monitor 1
D1827 3 EXDI_4: SVC Input State: Power control panel 2 voltage change 2 / 9
CN15-4Pin monitor 0
D1827 4 EXDI_5: SVC Input State: Power control panel 2 voltage change 2 / 9
CN15-5Pin monitor 1
D1827 5 EXDI_6: SVC Input State: Power control panel 3 voltage change 2 / 9
CN15-6Pin monitor 0
D1827 6 EXDI_7: SVC Input State: Power control panel 3 voltage change 2 / 9
CN15-7Pin monitor 1
D1827 7 EXDI_8: SVC Input State: Reserved 8 2/9
CN15-8Pin
D1827 8 CB1_IN: SVC Input State: Power control panel 4 voltage change 2 / 9
CN13-6Pin monitor 0
D1827 9 CB2_IN: SVC Input State: Power control panel 4 voltage change 2 / 9
CN13-8Pin monitor 1
D1827 10 EMG: SVC Input State: Emergency stop 2/9
CN13-10Pin
D1827 11 OPT_IN: SVC Input State: Presence sensing device normal 2/9
CN3-17Pin
D1827 12 2/9
D1827 13 2/9
D1827 14 2/9
D1827 15 - SVC Input State: encoder time out 2/9
D1828 0 SVDO_5: SVC Output State: Servo ON 2/9
CN1-33Pin
D1828 1 - SVC Output State: Base cutoff 2/9

174
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1828 2 SVDO_6: SVC Output State: Reverse 2/9


CN1-15Pin
D1828 3 SVDO_7: SVC Output State: Integral clamp 2/9
CN1-35Pin
D1828 4 SVDO_0: SVC Output State: Gain select 1 2/9
CN1-12Pin
D1828 5 SVDO_1: SVC Output State: Gain select 2 2/9
CN1-32Pin
D1828 6 2/9
D1828 7 2/9
D1828 8 SVDO_2: SVC Output State: Amp alarm reset 2/9
CN1-13Pin
D1828 9 SVDO_3: SVC Output State: Torque bias effective 2/9
CN1-14Pin
D1828 10 SVDO_4: SVC Output State: mode select 2/9
CN1-34Pin
D1828 11 2/9
D1828 12 2/9
D1828 13 CN12-A1,B1 SVC Output State: SVC normal 2/9
D1828 14 BREAK: SVC Output State: Reverse 2/9
CN3-6Pin
D1828 15 CUR_CUTA: SVC Output State: Velocity command response 2/9
CN3-5Pin
D1829 - MPC Input State: Crank angle raw data 2/9
D1834 0 2/9
D1834 1 2/9
D1834 2 EPMON1: SVC Output State: Reverse 2/9
CN13-1Pin
D1834 3 EPMON2: SVC Output State: Reverse 2/9
CN13-2Pin
D1834 4 - SVC Output State: For system 2/9
D1834 5 - SVC Output State: For system 2/9
D1834 6 - 2/9
D1834 7 - 2/9
D1834 8 DO_0: SVC Output State: Aux function slide stop output 2/9
CN3-7Pin
D1834 9 DO_1: SVC Output State: Aux function code 1 2/9
CN3-8Pin
D1834 10 DO_2: SVC Output State: Aux function code 2 2/9
CN3-9Pin
D1834 11 DO_3: SVC Output State: Aux function code 4 2/9
CN3-10Pin

175
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

PLC Adress CONTROLL-


Page
Adress ER Name
Bit No. No.
No. Adress No.

D1834 12 DO_4: SVC Output State: Fwd.Rev motion output 2/9


CN3-11Pin
D1834 13 DO_5: SVC Output State: Aux function code 8 2/9
CN3-12Pin
D1834 14 DO_6: SVC Output State: voltage change 0 2/9
CN3-13Pin
D1834 15 DO_7: SVC Output State: voltage change 1 2/9
CN3-14Pin

176
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8.2 Data Monitor Screen

Access the DATA MONITOR screen by pressing the "DATA MONITOR" submenu touchbut-
ton.
This screen is used when a problem occurs and it is necessary to check the data in order to
perform maintenance or repairs.

* Input the memory address of MPC to be monitored. (Hexadecimal number)

177
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8.3 Fault Screen

Access the FAULT DISPLAY screen by pressing the "FAILURE" submenu touchbutton.
For a description of messages and how to reset faults, see Section D OPERATION,
6.2 FAULT INFORMATION MESSAGE LIST (pg. 214)

(1)

(1) Switching between the FAULT LIST and FAULT HISTORY Screens
The screen can be switched between the "FAULT LIST screen", the "FAULT HISTORY
Screen - 1/2" , "FAULT HISTORY screen - 2/2"or "INPACT SPEED ERROR HISTORY
screen"by pressing the respective keys shown in the frame.
The FAULT LIST screen displays the description of up to 20 faults which are currently
occurring.
The FAULT HISTORY screen displays the description and time of the most recent 40
faults, starting from the most recent fault. (20 fault items x 2 pages)
On the IMPACT SPEED ERROR HISTORY screen, details and time of occurrence of
480 impact speed errors occurred in the past are displayed in the reverse chronological
order.(30 error items x 16pages)

(Continued on the next page)

178
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

<<FAULT HISTORY Screen-1/2>> <<FAULT HISTORY Screen-2/2>>

<<INPACT SPEED ERROR HISTORY Screen>>

179
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8.4 Maintenance Screen

Access the MAINTENANCE screen by pressing the "MAINTENANCE" submenu touchbutton.


This screen displays the MAINTENANCE COUNTER, HOUR METER, SERVO ON TIME,
BRAKE ON TIME (the number of brake actuations), and the SLIP ANGLE OF BRAKE.

(1) MAINTENANCE COUNTER


Displays the cumulative number of press strokes.

(2) HOUR METER (h)


Displays the press utilization time (the servo motor operation time).

(3) SERVO ON TIMES


Displays the number of times the servo motor has been turned on.
The counter is reset by pressing and holding the "CLEAR" for at least 2 seconds.

(4) SERVO ON HOUR(h)


Displays the number of hours the servo motor has been ON.

(5) CONTACTOR ON TIME(SECONDARY)


Counts the number of times the contactor in the press operation circuit has been turned
ON.
The counter is reset by pressing and holding the "CLEAR" for at least 2 seconds.

(6) FAN ON HOUR


Displays the cumulative operation time of the servo motor cooling fans.

(Continued on the next page)

180
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

(7) CONTACTOR ON TIME(SLIDE ADJ.)


Counts the number of times the contactor in the slide adjustment circuit is turned ON.
The counter is reset by pressing and holding the "CLEAR" for at least 2 seconds.

(8) BRAKE ON TIMES


Displays the number of brake actuations.

(9) SLIP ANGLE OF BRAKE


Displays the total slip angle when the brake is actuated.

(10) INTERLOCK MUTING SET


When this key is pressed, the current screen is changed over to the user password
entry screen. When the password specified by the customer is entered, the screen is
changed over to the interlock setting screen.
(The password has been factory-set to "1111" at the time of delivery.)

<<Input The User Password Screen>>

181
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8.5 Interlock Settings Screen

WARNING
• When the interlock settings and the wiring of devices have been completed, be
sure to check the devices for proper operation before starting production. Incor-
rect settings and/or wiring may lead to unexpected operation, resulting in an acci-
dent causing personal injury or death

When the password is entered on the user password entry screen, the screen is changed over
to the interlock setting screen.
On this screen, enabling/disabling of each interlock and presence/absence of the die number
connector and the password can be changed.

(1) INTERLOCK MUTING SET


When the key is pressed, "MUTING SET" is displayed and the interlock is disabled.
Another press on the key changes over the setting to "ACTIVE" to enable the interlock
again.

(2) DIE No.RECEPTACLE


Press the "USE/NO USE" key and set it at "USE" in the case the die number connector is
to be used.

(3) PASSWORD CHANGE


Input a new password with the numeric keys displayed on the screen and press the "ENT"
key to accept the change.

182
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8.6 Optional Settings Screen

WARNING
• When the optional settings and the wiring of optional devices have been com-
pleted, be sure to check the devices for proper operation before starting produc-
tion. Incorrect settings and/or wiring may lead to unexpected operation, resulting
in an accident causing personal injury or death

Access the OPTION SET TEST MODE screen by pressing the "OPTION SET TEST MODE"
submenu touchbutton.
The operator can set various options on this screen by pressing down on the applicable
touchbutton for two seconds.
When an option is provided, the touchbuttons for that option mode will be displayed.

(1) Option Setting


"PX1" Counter 1 Auto Reset ...................When the preset quantity is reached on Counter 1,
the current value is automatically reset to zero (0)
without pressing the RESET touchbutton.
"PY1" Counter 1 Auto Stop: OFF .............The press machine normally stops when a preset
quantity is reached on Counter 1, but in this mode
the press machine continues to run without stopping.
"PX3" Counter 2 Auto Reset...............When the preset quantity is reached on Counter 2,
the current value is automatically reset to zero (0)
without pressing the RESET touchbutton.
"PY3" Counter 2 Auto Stop: OFF .............The press machine normally stops when a preset
quantity is reached on Counter 2, but in this mode
the press machine continues to run without stopping.

(Continued on the next page)

183
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

(Continued)

"PZ3" Counter 2 Output Selection: UP-OFF. The Counter 2 preset quantity output signal logic is selectable.
(The touchbutton is orange when this is selected.)
When not selected: The output is turned ON when
Counter 3 reaches the preset quantity.
When selected: The output is turned OFF when
Counter 3 reaches the preset quantity.
*: For further details about counters, see page 119.
Counter 2 has the function of outputting a signal to notify that a preset quantity has been
reached.

(2) Test Mode


"TEST FOR BRAKE SOL.V." (Brake Solenoid Valve Test)
Refer to 5.2.2 Solenoid Valve Monitor Function Test (pg. 352).
This test mode is used to verify that the brake solenoid valve is actuating normally.
If the press is operated while in this test mode, one side of the dual solenoid valve used
for the brake is not energized intentionally, which results in a fault.
The normal operation of the brake solenoid valve is verified if the brake solenoid valve
monitor sensor detects a fault when only one side of the dual valve actuates.
The fault message "642 BRAKE SOLENOID VALVE MONITOR DETECT" will be dis-
played in the above-mentioned case. In this case, however, there is no problem since
the faulty condition has been intentionally caused by the test operation.

"TEST FOR BRAKE PERFORMANCE" (Brake Performance Test)


Refer to 5.2.3 Braking Test (pg. 353).
This test mode is used to verify that the braking force being applied when the brake
activates is normal. When the test mode is selected, several conditions must be met in
order to enable the test, including setting the OPERATION SELECT switch to "SIN-
GLE." and selecting "CRANK" as the motion mode. However, these necessary condi-
tions will be displayed for reference in the interlock information field.
If the press is operated in this test mode, the press will perform a protective stop at the
90-degree press crank angle position.
(A protective stop condition is not a normal interlock-induced stop where the servo
motor first decelerates and stops before the mechanical brake is applied, but rather
assumes that there is a fault in the servo controls or controllers and thus only the
mechanical brake is used in order to stop the press.)
The braking force is normal as long as no faults occur after the protective stop has been
performed during the brake performance test.
If the fault message "673 SLIDE STOP TIME OVER" is displayed after the test, contact
AIDA Service because some braking force problem exists.

184
Section D OPERATION 3. THE OPERATOR INTERFACE TERMINAL

3.8.7 Timer Setting Screen

Access the Clock / Energy Saving Timer screen by pressing the "TIME SETTING" submenu
touchbutton.
On this screen the calendar, the PLC internal clock time, and the energy saving timer are set
using the numeric input keys.

Calendar/Clock Time Setting Directly press the setting value area or select the section
using the " ▲ " or " ▼ " key, then use the numeric input keys
to input a numeric value.

ENERGY SAVING TIMER .... If the press machine is not started within a preset time
period, the servo power is turned off and the brake is
applied in order to conserve power. The preset time set-
ting is inputted using the ten-key pad. The allowable
range is between 0~99 minutes. Enter "0" to disable the
energy saving timer.

* After completing these settings, the entered numeric values are set by means of the
DECISION key.

185
Section D OPERATION 4. OPERATION

4. OPERATION

CAUTION
• Do not perform presswork in the STEP FEED, and INCH modes.
Doing such may result in sticking.

• When operating the press machine for the first time, operate the machine only
after performing all of the actions described in Section C INSTALLATION.
If the press machine is operated without adequate preparation, there is a possi-
bility of injury or death due to press machine damage or malfunction.

• Before starting work and after every 8 hours of operation, conduct an inspection
according to the procedure described in 4.2 ROUTINE INSPECTION AND
OPERATION (pg. 188).
If the procedure sequence is ignored or inspections are omitted, there is a possi-
bility of injury or death due to press machine damage or malfunction.

• If abnormal sounds, smells, smoke, or other abnormalities occur during press


machine operation, stop the operation immediately and investigate and remove
the cause.
If the cause cannot be identified, contact AIDA Service (see the end of this
instruction manual).

• Be sure to perform the steps described below before starting work after press
machine operation has been halted for 24 hours or more in order to prevent an
accident resulting from lubricating oil shortages.
(1) Perform the procedure given in 4.2 ROUTINE INSPECTION AND OPERA-
TION (pg. 188).
(2) Perform run-in for five minutes or more.

• Be sure to perform the steps described below before restarting the press
machine after press machine operation has been halted for an extended period
of time (approximately one week).
(1) Perform the procedure given in 4.2 ROUTINE INSPECTION AND OPERA-
TION (pg. 188).
(2) Perform the monthly inspection. (See pg. 323.)
(3) Remove the dies and perform run-in for 30 minutes or more to check for
unusual sounds, heat, or abnormal vibration.

• Operate the side guards (option) after having checked to make sure that nobody
is present around the guards.

Before beginning operation, review and follow the instructions given in Section A SAFETY.
Read the Instruction Manual for the presence sensing device (the manual is contained in the
instruction manuals for accessories in a separate binder or provided at the end of this instruc-
tion manual) before operation. Do not start operation until you read through the instruction
manual.

186
Section D OPERATION 4. OPERATION

4.1 PRE-WORK CHECK

The following pre-work check items must be performed by the employer, authorized person-
nel, and qualified personnel.

(1) Stop function check


• In the INCH operation mode, confirm that the slide only moves when the RUN buttons
are held down and immediately stops when the buttons are released.

(2) Check the bolts on the crankshaft, slide, connecting rod, and connecting screw, making
sure they are all secure.

(3) Single stroke mechanism function check


• In the SINGLE operation mode, confirm that the press machine is allowed to operate in
the INCH mode from the preset stop position up to approximately 180° (for more infor-
mation, see the electrical circuit drawings contained in Section E MAINTENANCE,
7. DRAWINGS (pg. 362), 7.2 Electrical Drawings (Refer to separate volume)), and that
after approximately 180° that the press machine always stops at the preset stop position
whether the RUN buttons are held down or released.

(4) Immediate Stop function and Emergency Stop equipment function check
• Confirm that the slide immediately stops when the EMERGENCY STOP button(press
side , die cushion side) is pushed during operation.
• Confirm that slide movement is disabled when the EMERGENCY STOP button is
pushed and then released.

(5) Slide and/or die safety mechanism function check


(a) Presence sensing device
• Confirm that slide movement is disabled with beams interrupted.
• Confirm that the slide stops immediately when the beam is intercepted during operation
of the slide.
(b) Side guard (option)
• Confirm that the chains for guards are not faulty.
• Confirm that the slide cannot be started unless the guard is closed .
(c) Two-hand RUN buttons
• Confirm that the slide does not move unless the two RUN buttons are pushed with both
hands simultaneously (It should be noted, however, that the STEP FEED (manual pul-
sar) is excluded.)

(6) Press machine die and bolster condition check


• Confirm that no tools or parts are lying on the die or bolster.

187
Section D OPERATION 4. OPERATION

4.2 ROUTINE INSPECTION AND OPERATION

For the location of operation switches and equipment, see Section B SPECIFICATIONS,
3. NAMES OF MAJOR COMPONENTS (pg. 74) and Section D OPERATION, (pg. 91).
The items marked with an asterisk (*) must always be conducted by qualified personnel.
In addition to this work, carry out the daily inspection of the die cushion.

1 Clean up the area around the press machine and the floor to keep them neat and orga-
nized.

* 2 Confirm that the oil is above the lower limit line of the oil gauge of each oil reservoir or
within the specified range of the container. If the oil level is low, add oil. (See pg. 330.)
Also check for any leakage.

3 Check whether the auto drain filter is dirty.


If dirty, clean the filter. Periodic cleaning (every week) is recommended. (See pg. 349.)

4 Set the air exhaust valve to SUP (supply).


Slowly open the air supply inlet stop valve.
Listen for the sound of any air leakage from the pneumatic devices and piping.

* 5 Confirm that the pressure gauge shows that the brake pressure level is within the white
(or green) zone and that the counterbalance pressure is appropriate for the upper die
weight.

6 Open the drain cock and confirm that no sludge comes out.
Also check your air compressor in the same manner.

* 7 Turn your power source ON. Set the disconnect switch to ON.
Confirm that the POWER light comes on.
In addition, supply the power to the die cushion.

* 8 Insert the key into the CONTROL POWER switch, and turn it clockwise to "|" (ON).
Confirm that the key cannot be removed when in this position.
In addition, turn on the control power of the die cushion.

(Continued on the next page)

188
Section D OPERATION 4. OPERATION

(Continued)

* 9 Confirm that all EMERGENCY STOP buttons remain down when they are pushed and
released, and that they return to their original position when turned in the reset (arrow)
direction.

*10 Push the LUBRICATING OIL PUMP button. The lubricating oil pump will start. After
approximately one minute, the flashing lamp will change to a steadily lit state
In addition, push the MASTER POWER ON button with light. The servo system power
is also turned ON by pushing this button. Once the energy charging is completed, the
SERVO POWER light comes on instead of flickering.

* 11 Confirm that the pressure gauge shows that the lubricating oil unit pressure level is
within the green zone. (See the instruction manual for the lubricating oil unit (in the
Instruction Manuals for Accessories).)

*12 Confirm that the devices and switches are set as follows. In addition, set all of the
safety devices so that they work effectively. When a key is removed it from a key switch
it must be held by authorized personnel.
• LINE SELECTOR key switch ........................................... UNIT
• Slide lock ......................................................................... UNLOCK
• Upper die clamper ........................................................... CLAMP or NO USE
• Guard ............................................................................... CLOSE
• MB ................................................................................... DOWN or OUT END

13 Push the "STOP RESET" button. Check that the "SERVO POWER" light comes on.

*14 Insert the key into the OPERATION SELECT switch, turn the key clockwise and set the
switch to INCH.

15 Confirm that the message OPERATION READY is displayed in the interlock information
field on the operator interface terminal. Also confirm that the RUN OK light is lit.

16 Push the two PRESS RUN buttons simultaneously with both hands to start slide
motion.
Confirm that the slide moves as long as the PRESS RUN buttons are held down and
immediately stops when they are released.

17 While operating the slide for two or three strokes in the INCH mode, confirm that no
unusual sounds are emitted from the slide or related parts.

18 Move the slide to the preset stop position.

(Continued on the next page)

189
Section D OPERATION 4. OPERATION

(Continued)

*19 Set the OPERATION SELECT switch to SINGLE, then confirm the following items:
(a) Confirm that the RUN OK light turns on.
(b) Confirm that the RUN OK light turns off and that the slide does not start when only
one of the two PRESS RUN buttons is pushed.
(c) Push the PRESS RUN buttons simultaneously with both hands to activate the slide.
Confirm that the slide stops (in the INCH mode) when the PRESS RUN buttons are
released in the range from the preset stop position to approximately 180° (see Sec-
tion E MAINTENANCE, 7. DRAWINGS (pg. 362), 7.2 Electrical Drawings (Refer to
separate volume) for details), and that after approximately 180° that the press
machine always stops at the preset stop position whether the PRESS RUN buttons
are held down or released.
(d) Run the press machine several times in the SINGLE mode, and confirm that the vari-
ation of the stopping position is 10° or less.
(e) Push and release the EMERGENCY STOP button when the RUN OK light is lit, and
confirm that slide movement is disabled.
(f) Push the EMERGENCY STOP button while the press machine is in operation and
confirm that the slide immediately stops.
< Restart Procedure >
• Reset the EMERGENCY STOP button (by turning it).
• Push the "LUBRICATION OIL PUMP" button with light. The lubricating oil pump is
started. Approximately one minute later, the light comes on instead of flickering.
• Confirm that the "SERVO POWER" light comes on.

• Using the HOME POS.RETURN mode, inch the slide to the preset stop position.
(g) Check that the RUN OK light turns off and that the slide movement is disabled with
beams interrupted.
(h) Check that the slide stops immediately when the beam is interrupted during slide
descending stroke.

*20 In the case the operation selection such as LINE can be made, check the actuation of
the respective slides described in 4.4 OPERATION MODES (pg. 193). In addition,
check items (e) to (h) in step19 above and items (a) to (c) in step 24 for each operation
mode.

*21 Perform the pre-work check of the presence sensing device according to the instruc-
tion manual of the device.

(Continued on the next page)

190
Section D OPERATION 4. OPERATION

(Continued)

*22 Perform the check specified in Section D OPERATION, 4.1 PRE-WORK CHECK (pg.
187).

*23 Check that the servo power cannot be turned ON when the slide lock is in the locked
state.

*24 If the press machine is equipped with a guard (option), perform the following inspection
in the SINGLE mode.
(a) Confirm that the press machine point of operation is out of reach when the guards
are closed.
(b) Confirm that the RUN OK light does not go on and that slide movement is disabled
unless the guard is closed and locked.
(c) Confirm that the slide immediately stops when the guard is opened while the press
machine is in operation.

*25 Set the OPERATION SELECT key switch to the desired operation mode. Next, confirm
that the RUN OK light turns on. Then turn the key counterclockwise and remove the
key. The key must be controlled by authorized personnel.

*26 If you have changed the stop position during operation, perform check items (a) to (d)
in Step * 19 before resuming operation.

*27 Set the load meter so that it detects a load.


Refer to the APPENDIX "LOAD ANALYZER (LOAD METER)" given at the end of this
volume for details.

This completes the inspection.

191
Section D OPERATION 4. OPERATION

4.3 LINE MODES


GROUP
This section describes the operation modes that can be selected using the OFF UNIT
LINE

LINE SELECT key switch. ALL


LINE

LINE SELECTOR

Operation Mode Description


OFF Operation Mode • Operation is disabled excluding tests of the mechanical device
and variation circuits and pressure adjustment of the balancer.

UNIT Operation Mode • Press operation, slide adjustment and press die change can be
carried out under the UNIT mode.

GROUP LINE Operation • One press and one transfer device on the unloading side can be
Mode operated under the LINE mode. In this case, the press and
transfer device are activated from the master control panel.

ALL LINE Operation • Production operation can be carried out and the dies of all
Mode devices can be changed concurrently. All presses and all transfer
devices are activated from the master control panel.

192
Section D OPERATION 4. OPERATION

4.4 OPERATION MODES


STEP
This section describes the operation modes that can be selected using the FEED INCH SINGLE

OPERATION SELECT key switch. HOME POS.


In the following descriptions, "push or release the buttons" means to "push RETURN LINE

or release the two RUN buttons simultaneously using both hands." DIE
OFF CHANGE

OPE. SELECTOR

Operation Mode Description


HOME POS.RETURN • The slide moves at the HOME POS.RETURN return speed only
Operation Mode while the buttons are held down, and will stop at the preset stop
position. If the slide start position is before bottom dead center,
the slide will move in reverse. If it is beyond bottom dead center,
the slide will move forward.
The HOME POS.RETURN return speed is a fixed speed set by
AIDA.
• This mode is used to resolve an overloaded or stuck condition.
STEP FEED Operation • When the STEP FEED dial is turned while the STEP FEED
Mode ENABLE (manual step feed enable) button is held down, the
slide moves in 0.1 mm increments. The slide will stop at top or
bottom dead center and will not move farther.
• Turn the STEP FEED dial clockwise to lower the slide, and
counterclockwise to raise the slide.
• This mode is used for die alignment. It cannot be used for test
stamping.
INCH Operation Mode • The slide moves as long as the buttons are held down, and
immediately stops when the buttons are released.
The slide also stops at the top dead center when the buttons are
held pushed.
• This mode is used when performing inspections or when insert-
ing or removing dies.
• MICRO INCH Operation Mode
Under the INCH operation mode, the slide speed is set to a micro
speed by pressing the MICRO INCH on the operator interface
terminal. The micro speed is a constant speed which is lower
than the normal speed of production.
SINGLE Operation Mode • The slide moves in the same manner as it moves in the INCH
mode within the range from the preset stop position to approxi-
mately 180° (see the electrical circuit drawings contained in Sec-
tion E MAINTENANCE, 7. DRAWINGS (pg. 362), 7.2 Electrical
Drawings (Refer to separate volume) for details). From approxi-
mately the 165° position and beyond, the slide stops at the pre-
set stop position regardless of whether the RUN buttons are held
down or released.
LINE Operation Mode • This mode is selected in the case the press is activated from the
master control panel. To carry out the production operation and
die change which are activated by the command from the mas-
ter control panel, set the switch at this position.
DIE CHANGE Operation • To carry out the automatic die change on the press under the
Mode UNIT mode, select this mode. The slide automatically starts up
and stops.
Refer to 8.2 AUTO DIE CHANGE (pg. 271)
(Continued on the next page)

193
Section D OPERATION 4. OPERATION

(Continued)

NOTE • The slide moves according to the motion program selected on the operator
interface terminal for all operation modes except the HOME POS.RETURN and
STEP FEED operation modes. However, in the case of FWD/REV mode motion,
operations in the INCH and SINGLE modes start at the preset stop position, and
then the slide returns to the preset stop position after completing one forming
cycle. (See Section D OPERATION, 3.5.1 Motion Selection /Setting Screen (pg.
127).)

194
Section D OPERATION 4. OPERATION

4.5 PRESENCE-SENSING DEVICES AND OPERATION CONDITIONS

Presence-sensing devices are active at all times in all operation modes regardless of the posi-
tion of the slide and the direction of the motion of the slide.

<<Explanation of The Table Below>>


• ○ .......Operation using two-hand RUN buttons is enabled.
*1 "STEP FEED" mode operation using the Step Feed dial is enabled.
*2 In the case of "DIE CHANGE" mode operation, automatic die change operation by
the FUNCTION button on the operation panel is enabled.
• × .......Operation is disabled.

HOME INCH
Presence- STEP DIE
POS.RET (MICRO- SINGLE CONT.
Sensing Device FEED CHANGE
URN INCH)
Light Beams I
nterrupted × × × × × ×

Light Beams
Active ○ ○※1 ○ ○ ○ ○ ※2

195
Section D OPERATION 5. PROCEDURE WHEN COMPLETING WORK

5. PROCEDURE WHEN COMPLETING WORK

CAUTION
• When stopping the air supply from the source for three hours or longer while die
clampers are in use, lower the slide to bottom dead center to prevent misalign-
ment between the upper and lower dies.
In order to prevent the dies from striking directly or sticking, use the slide adjust-
ment feature to raise the slide up 2 to 3 mm (0.08 to 0.12 in.).
Otherwise, the upper die may become misaligned with the lower die due to a
decrease in die clamper hydraulic pressure.

Perform the following operation when press machine operations have been completed or
before halting press machine operation.
The items marked with an asterisk (*) must always be performed by authorized personnel.

1 With no die clampers: Move the slide to the preset stop position.
With die clampers: Perform the procedure given in the above Caution statement.

* 2 Insert the key into the OPERATION SELECT switch, turn the key clockwise and set it
to OFF, and then remove the key.

3 Push the MASTER POWER "O" (OFF) button and confirm that the button light goes
on.

* 4 Set the CONTROL POWER switch to "OFF" and remove the key.
Removed keys must be controlled by authorized personnel.

5 Turn the power source OFF.

6 Drain the sludge in each air line.


Also drain the sludge in your air compressor.

7 Close the air supply port stop valve at the press machine.
Set the air exhaust valve to EXH (exhaust).

* 8 Check the entire press machine for cracks, damaged parts, and loose bolts.

9 Clean up the area around the press machine and the floor to keep them neat and orga-
nized.

196
Section D OPERATION 6. RESETTING FAULTS

6. RESETTING FAULTS

CAUTION
• Faults are to be reset under the supervision of qualified personnel.

• Investigate and eliminate the causes of slide stoppage, and confirm that no more
faults exist before restarting slide operation. If you cannot reset a fault because
the cause of the fault is unclear, contact AIDA Service (see the end of this
instruction manual).

• All operations involving electrical equipment must be performed by a qualified


electrician, or contact AIDA Service (see the end of this instruction manual).

Before eliminating a fault, read and follow the instructions given in Section A SAFETY.

(Continued on the next page)

197
Section D OPERATION 6. RESETTING FAULTS

6.1 INTERLOCK INFORMATION MESSAGE LIST

The interlock information message list gives the details of the interlock messages that are dis-
played on the operator interface terminal, and they are arranged in the order of the message
numbers. Find a message by using the message number displayed on the operator interface
terminal. (See (4) in Common Screen Elements (pg. 115).)
Note that this list may include messages that are not displayed on your system due to the
options of your press machine.

No. Interlock Message Description & Resetting Method


001 OPERATION READY Operation in the selected operation mode is enabled.
002 RUNNING The slide or the equipment is currently in operation.
An automatic operation, such as an automatic die
003 COMPLETED change or automatic slide adjustment has been com-
pleted.
A fault has been detected. Check the description of the
004 FAULT DETECT fault on the "FAULT LIST" screen on the "MAINTE-
NANCE" screens.
The system is initializing. Please wait (approx. 30 sec-
onds). If any of the following occur, the initialization pro-
cess will not be completed. In such cases, cancel the
initialization process and take appropriate measures.
• The "EMERGENCY STOP" button has been pushed.
• The operation button box has been removed and the
INITIALIZING/RELEASE jumper plug is not inserted into the receptacle socket.
005
EMERGENCY STOP BUTTON • The Step Feed operation box has been removed.
• The emergency stop line from other equipment has
been interrupted.
If the operation power supply has been turned OFF and
then back ON during the initialization process, turn the
main breaker at the press control panel OFF and then
back ON.
An "EMERGENCY STOP" button (including the button
box home position, system normal operation monitor
outputs, etc.) has been pressed. Perform the reset
operation. (△△indicates the location of the emergency
stop button that was pressed.) Other possible causes
could include the operation button box having been
removed without the jumper plug being inserted into
006 the receptacle socket. Connect the operation button
EMERGENCY STOP BUTTON
|
(△△)
box or insert the jumper plug into the receptacle socket.
014 Confirm that the Step Feed operation box has been
securely inserted into the prescribed receptacle socket.
This interlock message is also displayed if an "EMER-
GENCY STOP" button is pushed so lightly that it
doesn’t lock. In this case, push the button in until it
locks, then perform the reset operation. (Refer to
6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245).)
PERIPHERAL EQUIPMENT An external emergency stop signal has caused the
015
EMERGENCY STOP SIGNAL slide to come to an emergency stop.

198
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


The controller’s normal output signal has turned OFF.
017 ALL CPUS NORMAL OUTPUT Turn the press control panel’s main breaker OFF and
then turn it back ON.
018 MPC CONTROLLER SETTING Check the MPC controller settings.
An "EMERGENCY STOP" button of bed front deck
has been pressed. Perform the reset operation.
This interlock message is also displayed if an "EMER-
GENCY STOP" button is pushed so lightly that it
EMERGENCY STOP BUTTON doesn’t lock. In this case, push the button in until it
019
(BED DECK/FRONT SIDE) locks, then perform the reset operation. (Refer to
6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245).)

The PLC’s built-in battery has not been installed or its


voltage is low. Check whether the battery is installed. If
020 PLC BATTERY FAILURE the service life of the battery has been exceeded,
replace the battery with a new one. (E MAINTENANCE,
4.4 REPLACING THE BUILT-IN PLC BATTERY (pg. 345))

An "EMERGENCY STOP" button of operation box has


been pressed. Perform the reset operation.
EMERGENCY STOP This interlock message is also displayed if an "EMER-
BUTTON(MAIN OPERATION
GENCY STOP" button is pushed so lightly that it
021 doesn’t lock. In this case, push the button in until it
PANEL) locks, then perform the reset operation. (Refer to
6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245).)

022 MASTER POWER "ON" Press the "MASTER POWER ON" button.
LUBRICATING BUTTON ON Press the "LUBRICATING oil pump" button. The mes-
023
AND WAIT sage will change to "LUBRICATING WAIT (1 min.)."
Once the lubrication pump has been started, wait for
024 LUBRICATING WAIT(1 min.)
approximately one minute.
An "EMERGENCY STOP" button (including the button
box home position, system normal operation monitor
outputs, etc.) has been pressed. Perform the reset
operation. (△△indicates the location of the emergency
stop button that was pressed.) Other possible causes
could include the operation button box having been
removed without the jumper plug being inserted into
025 the receptacle socket. Connect the operation button
EMERGENCY STOP BUTTON
|
(△△)
box or insert the jumper plug into the receptacle socket.
030 Confirm that the Step Feed operation box has been
securely inserted into the prescribed receptacle socket.
This interlock message is also displayed if an "EMER-
GENCY STOP" button is pushed so lightly that it
doesn’t lock. In this case, push the button in until it
locks, then perform the reset operation. (Refer to
6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245).)

199
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


LUBRICATING OIL LOWER The lubricating oil level has reached its lower limit. Add
031
LIMIT oil.
HYDRAULIC OPERATING The hydraulic oil level has reached its lower limit. Add
032
FLUID LOWER LIMIT oil.
An "EMERGENCY STOP" button (including the button
box home position, system normal operation monitor
outputs, etc.) has been pressed. Perform the reset
operation. (△△indicates the location of the emergency
stop button that was pressed.) Other possible causes
could include the operation button box having been
removed without the jumper plug being inserted into
033 the receptacle socket. Connect the operation button
EMERGENCY STOP BUTTON( box or insert the jumper plug into the receptacle socket.
|
△△) Confirm that the Step Feed operation box has been
034 securely inserted into the prescribed receptacle socket.
This interlock message is also displayed if an "EMER-
GENCY STOP" button is pushed so lightly that it
doesn’t lock. In this case, push the button in until it
locks, then perform the reset operation. (Refer to
6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245).)

The lubricating oil pressure has dropped. Check the


LUBRICATING PRESSURE
035 line filter and oil filter for clogging. If the filter is dirty,
FAILURE
clean the element or replace it with a new one.
The hydraulic oil pressure has dropped. Check the oil
HYDRAULIC PRESSURE
036 filter for clogging. If the filter is dirty, clean the element
FAILURE
or replace it with a new one.
An "EMERGENCY STOP" button has been pressed.
Perform the reset operation (△△indicates the location
of the emergency stop button that was pressed.).
037 EMERGENCY STOP BUTTON( This interlock message is also displayed if an "EMER-
| GENCY STOP" button is pushed so lightly that it
△△)
039 doesn’t lock. In this case, push the button in until it
locks, then perform the reset operation. (Refer to
6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245).)
040
FLOW INDICATOR (△) A flow indicator fault (clogging) has been detected. ( △
|
indicates the location of the faulty flow indicator (A~D).)
043
An "EMERGENCY STOP" button of MECHA-DEV.
PORTABLE has been pressed. Perform the reset opera-
tion.
EMERGENCY STOP This interlock message is also displayed if an "EMER-
044 BUTTON(MECHA-DEV. GENCY STOP" button is pushed so lightly that it
PORTABLE) doesn’t lock. In this case, push the button in until it
locks, then perform the reset operation. (Refer to
6.6 WHEN AN EMERGENCY STOP BUTTON HAS
BEEN PUSHED (pg. 245).)

200
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


The lubricating oil pump is not started. Push the
LUBLICATION OIL PUMP
045 LUBRICATION OIL PUMP "ON" button with light to
MOTOR START
start it.
INTERMITTENT LUBRICATION Check the intermittent lubrication (oil) piping, check for
046
CYCLE CHECK a clogged distributor, etc.
INTERMITTENT LUBRICATION The intermittent lubrication oil quantity has reached the
047
LOWER LIMIT lower limit. Add oil.
FLOW INDICATOR(DIE
048 A flow indicator fault (clogging) has been detected.
CUSHION LUBLICATION)
LUBLICATING OIL LOWER The lubrication oil quantity has reached the lower limit.
049 LIMIT(DIE CUSHION Add oil.
LUBLICATION)
050 OIL FILTER CLOG (No.1) The indicated filter is clogged. Inspect the filter and
clean it. See E MAINTENANCE,.5.4 OIL PUMP (pg.
051 OIL FILTER CLOG (No.2) 356).

TOTAL LUBRICATION OIL


052 The Total Lube unit’s oil level is low. Add oil.
LOWER LIMIT
053 SUCTION FILTER CLOG(No.1) Suction filter of the lubricating oil pump in the pit is
clogged. Inspect the filter and replace it with a new one
054 SUCTION FILTER CLOG(No.2) if necessary.
Check whether the power to the chiller has been turned
055 DRAIN EVAPORATOR
ON.
The 220 V power is not supplied or the power supply is
POWER FAILURE temporarily interrupted. Check whether 1ELB16 or
056
DETECTED(220V) 1CPB62 of the control panel No. 1 has tripped. In addi-
tion, check whether the customer's power is supplied.
The scrap conveyor does not run. Operate the scrap
057 SCRAP CONVEYOR
conveyor.
TURN OFF DISCHARGE
058 Turn "OFF" the servo power forced discharge switch.
SWITCH(SERVO POWER)
PUSH SERVO POWER "ON"
060 Push the servo power " | " (ON) button.
BUTTON
061 POWER UNIT CHARGING The power unit is being charged.
The energy saving timer has started to automatically
SERVO POWER ENERGY SAVE
062 turn the servo power OFF. To re-start the servo power,
TIMER ON
push the "RESET" button.
FRONT PRESENCE SENSING
072 The indicated optical presence-sensing safety device
DEVICE/RESET
has been interrupted. Remove the cause of the beam
REAR PRESENCE SENSING interruption, then push the "RESET" button.
073
DEVICE/RESET

201
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


FRONT PRESENCE SENSING
074 DEVICE/CUT OPTICAL BEAM There is a time lag occurring in the signal input from the
AGAIN indicated optical presence-sensing safety device. Inter-
rupt the optical beams of the device again, then restore
REAR PRESENCE SENSING it to its normal state, and then push the "RESET" but-
075 DEVICE/CUT OPTICAL BEAM ton.
AGAIN
LEFT SIDE INNER PRESENCE The indicated side-mounted presence sensing device
076
SENS.DEVICE has been interrupted. Interrupt the optical beams of the
RIGHT SIDE INNER PRESENCE device again, then restore it to its normal state, and
077 then push the "RESET" button.
SENS.DEVICE
LEFT SIDE INNER PRESENCE The indicated side-mounted presence sensing device
080
SENS.DEVICE has been interrupted or the guard is not closed. Con-
firm that no personnel are present in the vicinity of the
RIGHT SIDE INNER PRESENCE guard, then close the guard and perform the reset
081
SENS.DEVICE operation.
Bolster travel cannot be enabled unless the left side
LEFT SIDE GUARD UPPER
082 guard is opened. Open the right side guard to its upper
LIMIT
limit.
LEFT SIDE GUARD LOWER Slide operation cannot be enabled unless the left side
083
LIMIT guard is closed. Close the left side guard.
Bolster travel cannot be enabled unless the right side
RIGHT SIDE GUARD UPPER
084 guard is opened. Open the right side guard to its upper
LIMIT
limit.
RIGHT SIDE GUARD LOWER Slide operation cannot be enabled unless the right side
085
LIMIT guard is closed. Close the right side guard.
LEFT SIDE GUARD LOWER
086 There is a time lag occurring in the signal input from the
LIMIT/OPERATE AGAIN
side guard. Open the guard again, then close it and
RIGHT SIDE GUARD LOWER push the "RESET" button.
087
LIMIT/OPERATE AGAIN
094
PRESS IMMEDIATE STOP An " IMMEDIATE STOP BUTTON" button has been
|
BUTTON( △△ ) pressed. Perform the reset operation (△△indicates the
095
location of the immediate stop button that was pressed.)

The ejector is currently in test mode. To perform other


097 TESTING EJECTOR operations, cancel the test mode.

TESTING MECHANICAL The mechanical device is currently in test mode. To per-


098
DEVICE form other operations, cancel the test mode.

TESTING VARIATION CIRSUIT


The variation cirsuit is currently in test mode. To perform
099
other operations, cancel the test mode.
OPERATING SELECTOR To operate the press, set the OPERATION SELECT
100
"OFF" switch to any position other than "OFF."
OPERATING SELECTOR The operation cannot be performed unless the OPER-
101 "INCH./STEP FEED/HOME ATION SELECT switch is set to "INCH," "STEP FEED"
POS. RETURN" or "HOME POS.RETURN."

202
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


OPERATING SELECTOR The operation cannot be performed unless the OPER-
102 "OFF,INCH,STEP FEED,HOME ATION SELECT switch is set to "OFF," "INCH," "STEP
POS.RETURN" FEED," or "ORIGIN POINT."

OPERATING SELECTOR "DIE The operation cannot be performed unless the OPER-
103
CHANGE" ATION SELECT switch is set to "DIE CHANGE."
Continuous operation cannot be performed unless the
104 CONT. SWITCH "ON" "CONTINUOUS OPERATION" key switch is set to " | "
(ON).
Operation cannot be performed unless the "CONTINU-
105 CONT. SWITCH "OFF"
OUS OPERATION" key switch is set to " ○ " (OFF).
The data cannot be changed unless the "DATA EDIT"
107 DATA EDIT SWITCH ON
switch is set to "ON"
Waiting for the brake air pressure to build back up after
109 CHECKING BRAKE PS SW
the brake has been released.
AIR INLET PRESSURE The air inlet pressure has dropped. Inspect the pri-
110
FAILURE mary-side air pressure in the factory.
BALANCER PRESSURE The counterbalancer pneumatic pressure has dropped.
111
FAILURE Inspect the counterbalancer for air leakage.
An overload has occurred. Perform the reset operation.
113 OVERLOADED (HOLP)
(See 6.4 HYDRAULIC OVERLOADS (pg. 243).)
The load meter has detected an overload. Perform the
OVERLOADED (LOAD
114 reset operation. (Refer to the Instruction Manual for the
ANALYZER)
load meter (at the end of this volume).)
The hydraulic pressure of the hydraulic overload pro-
OVERLOADED (HOLP IS
115 tector is currently building back up to its normal pres-
RESETTING)
sure.
An external immediate stop signal has caused the slide
EXTERNAL IMMEDIATE STOP
117 to come to an immediate stop. Reset the faulty condi-
INTERLOCK
tion and push the "RESET" button.
The external continuous operation conditions are not
118 EXTERNAL CONT. INTERLOCK met. Reset the faulty state and push the "RESET" but-
ton.
The slide has stopped due to a preset stop position
EXTERNAL PRESET POSITION
119 stop signal. Reset the faulty state and push the
STOP INTERLOCK
"RESET" button.
LOCATE SLIDE AT TOP DEAD The operation cannot be performed unless the slide is
121
CENTER at top dead center.
LOCATE SLIDE AT PRESET The operation cannot be performed unless the slide is
122
STOP POSITION at the preset stop position.
LOCATE SLIDE AT BOTTOM The operation cannot be performed unless the slide is
123
DEAD CENTER at bottom dead center.
The slide has not returned to its origin point. Set the
124 RETURN SLIDE ORIGIN POINT OPERATION SELECT switch to ORIGIN POINT. Then
move the slide to the preset stop position.

203
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


125 ORIGIN RETURN COMPLETED The origin point return operation has been completed.
The slide has stopped due to a preset stop position
129 MPC PRESET STOP SIGNAL
stop signal from the MPC.
MPC IMMEDIATE STOP
130 The slide has stopped due to an immediate stop signal.
SIGNAL
The restart operation needs to be performed again, so
OPERATION BUTTON
131 release the "RUN" buttons momentarily and then push
ANTIREPEAT
them again.
132 PRESS RUNNING The slide is in operation.
133 PRESS STOP The slide is stopped.
PUSH STEP FEED ENABLE To perform the STEP FEED operation, press the STEP
134
BUTTON FEED ENABLE button.
Since the two "RUN" buttons have not been pushed
RUN BUTTONS WITH BOTH
135 simultaneously, push the two "RUN" buttons again
HANDS CONCURRENTLY
simultaneously with both hands.
138 PRESET STOP BUTTON ON The "PRESET STOP" button has been pushed.
GAS PRESSURE SENSOR FOR The upper die gas pressure is equal to or less than the
139
UPPER DIE specified value. Check the gas pressure.
140 MOTION SET UP FAULT The motion program is faulty. Check the program.
The specified motion program is being calculated.
141 MOTION CREATING
Please wait.
MOTION The motion for the spm setting is being calculated.
142
CREATING(CHANGING SPM) Please wait.
CHECK The ON/OFF timing of the auxiliary function completion
144 AUX.FUNC.COMPLETION input signal is wrong. (See 7.4.2 Signal Names and
SIGNAL Auxiliary Function Codes (pg. 263).)
RESTRICTION FOR INCHING Set the spm at a value which is equal to or smaller than
148
spm the inching spm limit.
CYCLE STOP BUTTON An "CYCLE STOP" button has been pressed. Perform
150
RELEASE the reset operation
151 COUNT-UP STOP 1
The indicated preset counter has reached the preset
152 COUNT-UP STOP 2 number.
Reset the counter.
153 COUNT-UP STOP 3
LEFT MOVING BOLSTER
154
TRAVEL END The bolster is not at the outside end. Move it to the out-
RIGHT MOVING BOLSTER side end.
155
TRAVEL END
UPPER DIE CLAMPER NO Select the clamper(s) to be used on the upper die clam-
156
SELECTION per selection screen for the die change.
The upper die clamper is not clamped. Check how the
157 UPPER DIE CLAMPER
upper die clamper is clamped.

204
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


158 UPPER DIE CLAMPER CLAMP Clamp the upper die clampers.
UPPER DIE CLAMPER
159 Unclamp the upper die clampers.
UNCLAMP
The die number set on the master control panel does
ACTUAL DIE NUMBER
160 not match the die number downloaded to the press.
MISMATCHED
Match the die numbers.
The die identification metal connector mounted on the
NEXT DIE NUMBER
161 bolster does not match the die number set in the data
MISMATCHED
bank. Match the die numbers.
MOVING BOLSTER TRAVEL The bolster is not at the outside end. Move it to the out-
162
END side end.
163 BOLSTER UPPER LIMIT Lift the bolster.
164 BOLSTER LOWER LIMIT Lower the bolster.
Use the bolster selection button to select the bolster
travel direction. If the arrow faces towards the press
when in automatic die change mode, the bolster will be
165 BOLSTER OPE. SELECTOR
inserted into the press, and if the arrow is pointing
away from the press it will remove the bolster from the
press.
166 BOLSTER START POSITION Move the bolster to its normal position inside the press.
The time check circuit has been actuated due to exces-
167 BOLSTER RUN TIME OVER
sive bolster travel time. Push the "RESET" button.
COVER FOR BOLSTER RAIL
168 Open the bolster rail covers.
OPEN
169 BOLSTER GUARD CLOSE Close the bolster guard.
POWER SWITCH FOR The bolster power switch is not turned "ON". Turn ON
170
BOLSTER "ON" the bolster power switch.
LEFT MB / BAUMER SENSOR
171 The bumper sensor of the left bolster has been acti-
WORKED
vated. Remove the obstacle and then push the
RIGHT MB / BUMPER SENSOR "RESET" button to re-start operation.
172
WORKED
DATA BANK; SELECT NEXT
173 Select the next die using the data bank screen.
DIE DATA
PUSH NEXT DIE READY Select the next die using the data bank screen, then
174
BUTTON push the "NEXT DIE READY" button.
The time check circuit has been actuated due to an
AUTO DIE CHANGER TIME
175 excessively long automatic die change. Push the
OVER
"RESET" button and perform the operation again.
SHORT PLUG / MAIN
176
OPERATION PANEL The carry-on plug of the operation panel is not placed
SHORT PLUG / SUB in the home position. Return it to the home position.
177
OPERATION PANEL

205
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


DIE BLOCK PLUG(LEFT
178
REAR) The die block plug is not placed in the home position.
DIE BLOCK PLUG(RIGHT Return it to the home position.
179
FRONT)
180 SLIDE LOCK SWITCH "ON" Set the SLIDE LOCK switch to "ON"

181 SLIDE LOCK SWITCH "OFF" Set the SLIDE LOCK switch to "OFF"

182 SLIDE LOCK RELEASE Set the SLIDE LOCK to RELEASE

186 SLIDE LOCK Set the SLIDE LOCK to LOCK


TURN OFF TEST SW. FOR
194 Turn off test sw. for brake sol. valve of crown.
BRAKE SOL. VALVE (CROWN)
197 RELEASE UNSTICKER Turn the unsticking function OFF.
DIE HEIGHT FOR "DIE
198 Set the die height at "die change height" ±5.00 mm.
CHANGE"
To operate a device individually, select the target item
199 MANUAL OPERATION SELECT
to be operated.
MANUAL OPERATION SWITCH The UNIT OPERATION switch on the main operation
200 "ON" (MAIN OPERATION panel is not set at the "MANUAL" position. Set it at the
PANEL) "MANUAL" position.
MANUAL OPERATION SWITCH The UNIT OPERATION switch on the main operation
201 "OFF" (MAIN OPERATION panel is not set at the "AUTO" position. Set it at the
PANEL) "AUTO" position.
SELECT PAGE OF HMI / DIE
202 Select the DIE CHANGE screen.
CHANGE
SELECT OPERATION ITEM /
203
DIE CHANGE PAGE Select the item to be operated on the DIE CHANGE
CANCEL OPERAION ITEM / screen.
204
DIE CHANGE PAGE
MANUAL OPERATION The UNIT OPERATION switch on the sub operation
205 SWITCH "ON" (SUB panel is not set at the "MANUAL" position. Set it at the
OPERATION PANEL) "MANUAL" position.
MANUAL OPERATION SWITCH The UNIT OPERATION switch on the sub operation
206 "OFF" (SUB OPERATION panel is not set at the "AUTO" position. Set it at the
PANEL) "AUTO" position.
DRIVE SHAFT BEARING
207
(R.R.F.)
DRIVE SHAFT BEARING
208
(R.L.F.)
The flow indicator has detected a fault. Inspect and
DRIVE SHAFT BEARING investigate the cause of the fault.
209
(R.R.R.)
210 DRIVE SHAFT BEARING (L.R.)
211 DRIVE SHAFT BEARING (L.F.)
LOWER DIE CLAMPER CLAMP The lower die clamper of the left MB is not clamped.
212
(LEFT MB) Clamp it.

206
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


LOWER DIE CLAMPER The lower die clamper of the left MB is not unclamped.
213
UNCLAMP (LEFT MB) Unclamp it.
LOWER DIE CLAMPER CLAMP The lower die clamper of the right MB is not clamped.
214
(RIGHT MB) Clamp it.
LOWER DIE CLAMPER The lower die clamper of the right MB is not
215
UNCLAMP (RIGHT MB) unclamped. Unclamp it.
The setting made on the master control panel does not
PRESS IDOL / SETTING
217 match the setting made on the press operation panel.
MISMATCHED
Match the settings.
The idling setting status does not match the upper die
RESS IDOL / UPPER DIE detection. If the relevant press is set as an idle
218
DETECT SENSOR MEMOLY machine, cancel the setting. If not, set it as an idle
machine.

207
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


220 MAIN PIN (LEFT FRONT) 1
221 MAIN PIN (LEFT FTONT) 2
222 MAIN PIN (LEFT FTONT) 3
223 MAIN PIN (LEFT FTONT) 4
INTERMEDIATE SHAFT
224
BEARING(LEFT FRONT)
INTERMEDIATE SHAFT
225
BEARING(RIGHT FRONT)
226 MAIN PIN (RIGHT FTONT) 1
227 MAIN PIN (RIGHT FTONT) 2
228 MAIN PIN (RIGHT FTONT) 3
229 MAIN PIN (RIGHT FTONT) 4
DRIVE SHAFT BEARING
230
(L.L.F.)
231 IDOL PIN (LEFT)
DRIVE SHAFT BEARING
232
(L.L.R.)
233 IDOL PIN
DRIVE SHAFT BEARING
234 The flow indicator has detected a fault. Inspect and
(L.L.R.)
investigate the cause of the fault.
235 DRIVE SHAFT BEARING (R.F.)
DRIVE SHAFT BEARING
236
(L.R.F.)
237 DRIVE SHAFT BEARING (R.R.)
238 IDOL PIN (RIGHT)
DRIVE SHAFT BEARING
239
(R.L.R.)
240 MAIN PIN (RIGHT REAR) 1
241 MAIN PIN (RIGHT REAR) 2
242 MAIN PIN (RIGHT REAR) 3
243 MAIN PIN (RIGHT REAR) 4
INTERMEDIATE SHAFT
244
BEARING(RIGHT REAR)
INTERMEDIATE SHAFT
245
BEARING(LEFT REAR)
246 MAIN PIN (LEFT REAR) 1
247 MAIN PIN (LEFT REAR) 2
248 MAIN PIN (LEFT REAR) 3
249 MAIN PIN (LEFT REAR) 4

208
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


250
(See 10.3 KEY POINTS WHEN MAKING MOTION
| MOTION SET UP FAULT
PROGRAM SETTINGS(286 ページ).)
309
LINE SELECTOR SWITCH
340
"UNIT"
LINE SELECTOR SWITCH
341
"OFF"
LINE SELECTOR SWITCH Set the LINE SELECTOR switch at the mode instructed
342
"GROUP LINE" in the message.
LINE SELECTOR SWITCH
343
"ALL LINE"
LINE SELECTOR SWITCH
344
"UNIT ・ OFF"
OPERATION SELECTOR
345
SWITCH "SINGLE" Set the OPERATION SELECTOR switch at the mode
OPERATION SELECTOR instructed in the message.
346
SWITCH "LINE"
RELEASE TEST MODE AND
350
RETURN SLIDE ORIGIN POINT
TEST MODE/SET CRANK
351
MOTION
TEST MODE/SET TOTAL
352
PROC. 02
TEST MODE/SET 100%
353
VELOCITY
354 TEST MODE/SET 0sec PAUSE
355 TEST MODE/SET 0 S.DECEL. These are the procedural instruction messages that are
to be followed when test mode has been selected.
356 TEST MODE/SET 0 A.FUNC.
357 TEST MODE/SET MAX spm
TEST MODE/SET OPERATING
358
SELECTOR "SINGLE".
TEST MODE/SET TEST
359
SETUP TO ON
TEST MODE/OPERATION
360
READY
361 TEST MODE/COMPLETED
VALVE IN DIE/SENSOR A short-circuit fault has occurred in the sensor of the
369
FAULT valve inside the die. Inspect and check the sensor.
The test mode has been selected for the operation of
370 VALVE IN DIE/TESTING the valve inside the die. To perform other operations,
cancel the test mode.
VALVE IN DIE/PANEL NOT The panel detecting sensor is in the OFF state. Set the
371
DETECTED material properly.

209
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


VALVE IN DIE/ The sensor selected to be used is not turned ON but
372 UNASCERTAIND SENSOR/A- stays OFF. Check the settings of the valve for actua-
OUT tion.
VALVE IN DIE/
The sensor selected to be used is not turned OFF but
373 UNASCERTAIND SENSOR/A-
stays ON. Check the settings of the valve for actuation.
RETURN
VALVE IN DIE/
374 UNASCERTAIND SENSOR/B- Refer to interlock message No.372
OUT
VALVE IN DIE/
375 UNASCERTAIND SENSOR/B- Refer to interlock message No.373
RETURN
VALVE IN DIE/
376 UNASCERTAIND SENSOR/C- Refer to interlock message No.372
OUT
VALVE IN DIE/
377 UNASCERTAIND SENSOR/C- Refer to interlock message No.373
RETURN
VALVE IN DIE/
378 UNASCERTAIND SENSOR/D- Refer to interlock message No.372
OUT
VALVE IN DIE/
379 UNASCERTAIND SENSOR/D- Refer to interlock message No.373
RETURN
380 CHECK DIE HANGING PIN Place the die hanging pin at the designated place.

CHECK DIE HANGING PIN OR Place the die hanging pin at the designated place.
381
MOTION PROGRAMS Or, check the motion program.
388 DC UNIT SELECTOR Set the die cushion to UNIT mode.
Perform the die cushion calibration operation using a
180° crank angle range that starts at 270° and passes
DC CALIBRATION;WORKING through top dead center.
389
OUT OF RANGE The die cushion calibration operation cannot be per-
formed if the OPERATION SELECT switch is set to
SINGLE or CONT. mode.
DC OPERATION SERVO
390 Turn the die cushion control power ON.
POWER ON
391 DC OPERATION READY OK Perform the prior action operation for die cushion use.
An immediate stop signal from the die cushion has
392 DC IMMEDIATE STOP caused the slide to immediate stop.
Reset the faulty state and push the "RESET" button.
DC A.FUNC. STOPPING TIME The die cushion’s auxiliary function stop time has been
393
OVER exceeded. Check for faults.
The die cushion’s top stop (preset stop position Stop)
395 DC TOP STOP SIGNAL
signal has been actuated.

210
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


The die cushion pad is not at its lower limit. Perform the
"die change position" operation at the die cushion oper-
396 DC PAD LOWER LIMIT
ation panel to bring the die cushion to the die change
position (the lower limit position of the die cushion).
The die cushion is not set to LINE mode. Perform the
397 DC LINE OK SIGNAL "LINE mode setting" operation at the die cushion oper-
ation panel to set the die cushion to LINE mode.
The LINE mode is not selected as the die cushion oper-
398 DC LINE SELECTOR ation mode. Select "LINE" at the die cushion operation
panel.
The AUTO DIE CHANGE mode is not selected as the
399 DC DIE CHANGE SELECTOR die cushion operation mode. Select "AUTO DIE
CHANGE" at the die cushion operation panel.
The UNIT mode is not selected as the die cushion
400 RELEASE LINE OK operation mode. Select "UNIT" at the die cushion oper-
ation panel.
401
(See 10.3 KEY POINTS WHEN MAKING MOTION
| MOTION SET UP FAULT
PROGRAM SETTINGS(286 ページ)).
474
The motion program on the setting screen can be
DC CALIBRATION; BACK UP
480 erased if a power failure occurs during calibration.
THE DATA
Backup important motion programs in the data bank.
Push the pushbutton located below the "START" dis-
DC CALIBRATION;DC SIDE played to the right in the lower left part of the die cush-
481
CALIBRATION READY ion operation screen to bring the die cushion to the
standby position.
DC CALIBRATION;MODE
482 Set the OPERATION SELECT switch to "INCH."
SELECTOR SWITCH IS INCH
DC CALIBRATION;DIEHEIGHT
Perform die cushion calibration with the die height set
483 DESIGN IS WITHIN BAND OF
within +/-5 mm of the designed die height.
5mm
Scrap chute of any one of the press machines Nos. 2-4
608 ALL SCRAP CHUTES CLOSE
is open. Close the scrap chute.
All slide locks of all press machines (Nos. 1-4) are not
609 ALL SLIDE LOCKS LOCK locked. Check all press machines and lock the slide
locks.
Carry-on plug and die block plug of any one of the
ALL SHORT PLUGS & DIE press machines Nos. 1-4 are unplugged. Check all
612
BLOCK PLUGS press machines and set the plugs back to their original
position.
The guards of all press machines (Nos. 1-4) are not
613 ALL GUARDS CLOSE
closed. Close the guards.
MB SAFETY FENCE NORTH 1
620 Close the MB SAFETY FENCE NORTH 1.
CLOSE
MB SAFETY FENCE NORTH 2
621 Close the MB SAFETY FENCE NORTH 2
CLOSE

211
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


MB SAFETY FENCE NORTH 3
622 Close the MB SAFETY FENCE NORTH 3
CLOSE
MB SAFETY FENCE SOUTH 1
623 Close the MB SAFETY FENCE SOUTH 1.
CLOSE
MB SAFETY FENCE SOUTH 2
624 Close the MB SAFETY FENCE SOUTH 2
CLOSE
GUARD CHECK/ALL
625 Check the guard status of all transfer units (Nos. 1-4).
TRANSFER UNIT
GUARD CHECK/DESTACK The power of destack feeder or sheet loader is not ON
626 FEEDER, SHEET LOADER or the guard is open. Check the power of the destack
POWER ON feeder or sheet loader, and close the guard.
GUARD CHECK/AUTO The power of auto palletizer is not ON or the guard is
627 PARETT CHANGER POWER open. Check the power of the auto palletizer, and close
ON the guard.
OPE. VOLTAGE MONITOR
1426 UNMATCHED/REGENERATIVE
CONVERTER No.1
OPE. VOLTAGE MONITOR
1427 UNMATCHED/REGENERATIVE
CONVERTER No.2 A fault has occurred inside regenerative converter
No.ᇞ. If the system is not restored by resetting, contact
OPE. VOLTAGE MONITOR AIDA Service.
1428 UNMATCHED/REGENERATIVE
CONVERTER No.3
OPE. VOLTAGE MONITOR
1429 UNMATCHED/REGENERATIVE
CONVERTER No.4
The transferred material is not placed at an appropriate
1467 WORK SET MISS/IN DIE
position in the die.
UPPER DIE VALIATION It is a sensor error of the upper die variation circuit.
1486
CIRCUIT SENSOR FAULT Check the operational status of the sensor.
Operation of the upper die variation circuit cannot be
UPPER DIE VALIATION
1487 confirmed. Check the sensor for confirming the upper
CIRCUIT ACTION FAULT
die variation circuit operation.
Operation of the lower die cam cannot be confirmed.
LOWER DIE CAM MOTION
1492 Check the sensor for confirming the lower die cam
FAULT
operation.
MASTER CONTROL PANEL Immediate stop is activated from the master control
1495
IMMEDIATE STOP panel. Reset the fault on the master control panel.
Group operation approval on the master control panel
MASTER CONTROL PANEL
1496 cannot be confirmed. Refer to the instruction manual
GROUP LINE OPERATION O
for the master control panel.
All line mode settings on the master control panel can-
MASTER CONTROL PANEL
1500 not be confirmed. Refer to the instruction manual for
ALL LINE MODE SETTING
the master control panel.

212
Section D OPERATION 6. RESETTING FAULTS

No. Interlock Message Description & Resetting Method


MASTER CONTROL PANEL/ Home position interlock on the master control panel
1510 TRANSFER PRESET POS. cannot be confirmed. Check the positions of the trans-
INTERLOCK fer devices in the front and back of the press machine.

213
Section D OPERATION 6. RESETTING FAULTS

6.2 FAULT INFORMATION MESSAGE LIST

The fault information message list shows various fault messages that are displayed on the
MAINTENANCE screen on the operator interface terminal explained in 3.8.3 Fault Screen
(pg. 178), and they are arranged in the order of the message numbers. Find a message by
using the message number displayed on the operator interface terminal.
Note that this list may include messages that are not displayed on your system due to the
options of your press machine.

If the message fault detected.check it by pressing ! at btm left on screen and an exclamation
mark "!" (item (5) in Common Screen Elements (pg. 115)) are displayed, see 3.8.3 Fault
Screen (pg. 178).

No. Fault Information Message Description & Resetting Method


LEFT GUARD PINCH
90 DETECT The detecting device to prevent being caught in the guard on the side
RIGHT GUARD PINCH has been activated. Remove the obstacle.
91 DETECT
SLIDE LOCK TIME OVER Because the slide lock activation time is long, the time check circuit
185 has been activated. Push the “RESET” button, and operate once
again.
LOWER DIE CLAMPER Lower die clamping operation of the left MB has not been completed
212 CLAMP (LEFT MB) within the specified time. There is no input of the pressure switch for
the clamp confirmation. Check the pressure switch and the wiring.
LOWER DIE CLAMPER Lower die unclamping operation of the left MB has not been com-
UNCLAMP (LEFT MB) pleted within the specified time. Input of the pressure switch for the
213 clamp confirmation is kept in ON state. Check the pressure switch
and the wiring.
LOWER DIE CLAMPER Lower die clamping operation of the right MB has not been completed
214 CLAMP (RIGHT MB) within the specified time. There is no input of the pressure switch for
the clamp confirmation. Check the pressure switch and the wiring.
LOWER DIE CLAMPER Lower die unclamping operation of the right MB has not been com-
UNCLAMP (RIGHT MB) pleted within the specified time. Input of the pressure switch for the
215 clamp confirmation is kept in ON state. Check the pressure switch
and the wiring.
OPERATING SELECTOR
512 FAILURE The OPERATION SELECT switch signal is faulty. Check the switch,
and replace it if necessary.
OPERATING SELECTOR
513 FAULT
514 LINE SELECTOR FAILURE It is a fault of the “LINE SELECTOR” switch. Inspect the switch and
replace it if necessary.
515 LINE SELOCTOR FAULT
EXTERNAL-BUTTON
518 SELECTOR FAILURE The external operation selector switch signal is faulty. Check the
switch, and replace it if necessary.
EXTERNAL-BUTTON
519 SELECTOR FAULT
MASTER SELECTOR FAIL- Set the Master selector signal (Press/Feeder) to the proper position.
522 URE
MASTER SELECTOR The Master selector signal (Press/Feeder) is faulty. Check the selec-
523 tor, and replace it if necessary.
FAULT
F.PRESENCE
534 SENS.D.SW.FAILURE The front presence-sensing device selector switch signal is faulty.
Check the switch, and replace it if necessary.
F.PRESENCE
535 SENS.D.SW.FAULT

214
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


F.PRESENCE A failure has been detected in the presence-sensing device. Stop
539 using the press machine immediately, and contact AIDA Service (see
SENS.D.OUTPUT FAULT the end of this instruction manual).
R.PRESENCE
542 SENS.D.SW.FAILURE The rear presence-sensing device selector switch signal is faulty.
R.PRESENCE Check the switch, and replace it if necessary.
543 SENS.D.SW.FAULT
R.PRESENCE (The rear presence-sensing device has failed. Stop using the press
547 machine immediately, and contact AIDA Service (see the end of this
SENS.D.OUTPUT FAULT instruction manual).
FRONT GUARD LIMIT
555 SWITCH FAULT
REAR GUARD LIMIT
563 SWITCH FAULT The indicated guard limit switch signal is faulty.
Check the limit switch and replace it if necessary.
ADD.1 GUARD LIMIT
567 SWITCH FAULT
ADD.2 GUARD LIMIT
571 SWITCH FAULT
TWO-HAND RIGHT BUT-
580 TON FAULT The RUN button switch signal is faulty. Check the switch, and replace
TWO-HAND LEFT BUTTON it if necessary.
581 FAULT
ADD.TWO-HAND RIGHT
582 BUTTON FAULT A RUN button switch signal at a location other than the right front is
faulty.
ADD.TWO-HAND LEFT Check the button, and replace it if necessary.
583 BUTTON FAULT
EXTERNAL RUN SIGNAL
587 The external start signal is faulty. Check and replace it if necessary.
FAULT
The external start signal is faulty (in cases where an external starting
EXTERNAL RUN SIGNAL device is connected to the machine). Turn the start signal OFF
588 NOT CONNECTED momentarily then re-start the device. If the same fault message
remains, check the external start signal.
MASTER RUN SIGNAL The Autohand / TCS master start signal is faulty. Check, and replace
590 FAULT if necessary.

MASTER RUN SIGNAL The Autohand / TCS master start signal is faulty. Turn the start signal
591 OFF momentarily then perform the restart operation. If the message
FAILURE still remains, check the autohand / TCS master start signal.
FEEDER MASTER RUN The feeder master start signal is faulty. Check, and replace if neces-
593 SIGN.FAULT sary.

FEEDER MASTER RUN The feeder master start signal is faulty. Turn the start signal OFF
594 momentarily then perform the restart operation. If the message still
SIGN.FAILURE remains, check the feeder master start signal.
LEFT MB / OIL FOR LOWER
600 DIE CLAMPER IS LOW
LEVEL Oil level of the lower die clamper of MB is low. Inspect the lower die
RIGHT MB / OIL FOR clamper.
601 LOWER DIE CLAMPER IS
LOW LEVEL
OIL FOR UPPER DIE Oil level of the upper die clamper is low. Inspect the upper die clam-
602 per.
CLAMPER IS LOW LEVEL
OIL FOR HOLP IS LOW Oil level of the overload protector is low. Inspect the overload protec-
603 LEVEL tor.

215
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


606 SCRAP CHUTE OPEN Scrap chute is not open. Open the scrap chute.

607 SCRAP CHUTE CLOSE Scrap chute is not closed. Close the scrap chute.

PRESET STOP Set the stop position "PRESET STOP POSITION/TOP DEAD CEN-
610 POS.SELECTOR FAILURE TER" switch to the correct position.

PRESET STOP The stop position "PRESET STOP POSITION/TOP DEAD CENTER"
611 POS.SELECTOR FAULT switch is faulty. Check the selector, and replace it if necessary.

LEFT GUARD / LOCK CYL-


614 INDER SENSOR FAULT
It is a sensor error of the guard lock cylinder. Inspect the sensor.
RIGHT GUARD / LOCK
615 CYLINDER SENSOR FAULT
LEFT GUARD / LOCK CYL-
616 INDER THERMAL RELAY
TRIPPED Thermal relay of the guard lock cylinder motor has tripped. Remove
RIGHT GUARD / LOCK the cause for the overload, and reset the thermal relay.
617 CYLINDER THERMAL
RELAY TRIPPED
The 5 V power supply voltage inside the MPC controller is faulty.
628 CPU 5VDC FAULT(MPC) Contact AIDA Service.
The 24 V power supply voltage being supplied to the MPC controller
629 CPU 24VDC FAULT(MPC) is faulty. Check and adjust the power voltage.
MPC CONTROLLER NOR- A controller normal output contact weld fault has been detected.
633 MAL OUTPUT Check whether the Emergency Stop wiring has a short.
A backup error has occurred in the parameters stored in the press
634 PARAMETER SUM FAULT controller. Set the parameters of the faulty block again.
LOADING DATA SUM Turn the power to the machine ON again. If this error occurs repeat-
635 FAULT edly, contact AIDA Service.

The slide motion output monitor has activated. Immediately stop


SLIDE OP. OUTPUT MONI- presswork and push the SERVO POWER " ○ " (OFF) button. Then
636 TOR
perform all the steps described in Section A SAFETY, 6. SAFETY
PROCEDURES DURING ADJUSTMENT (pg. 33) and contact AIDA
Service.
A write error has occurred in the press controller’s internal memory
637 EEPROM WRITE IN FAULT (EEPROM). Turn the power on again. If this error occurs repeatedly,
contact AIDA Service.
A read error has occurred in the press controller’s internal memory
638 DPRAM READ OUT FAULT (DPRAM). Push the RESET button. If this error occurs repeatedly,
contact AIDA Service.

DOUBLENESS COMPARI- A cross-check mismatch has been detected in the press controller’s
639 internal dual processing. Turn the power on again. If this error occurs
SON FAILURE repeatedly, contact AIDA Service.
A failure of press controller internal brake release output circuit has
640 BRAKE OUTPUT FAULT been detected. If the failure occurs repeatedly, contact AIDA Service.

BRAKE REL. OUTPUT An open fuse in the press controller internal brake release output cir-
641 cuit has been detected. If the failure occurs repeatedly, contact AIDA
FUSE CUT OFF Service.
BRAKE SOLENOID VALVE The brake release output monitor has been actuated. Contact AIDA
642 MONITOR DETECT Service.
A faulty signal has been inputted to the press controller. Check the
643 INPUT SIGNAL FAULT switch and other devices, and replace if required. This message rep-
resents all input signal failures shown in the fault list.

644 OVERRUN DETECT (MPC) An overrun has occurred. (See 6.5 OVERRUNS (pg. 245).)
VELOCITY INST. MONITOR A disagreement between the velocity commands from the SVC con-
645 troller and from the servo amplifier has been detected. If this error
DETECT occurs repeatedly, contact AIDA Service.

216
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


COMMUNICATION FAIL-
A communication data error has occurred between the PLC and
646 URE;MPC DETECT(MPC MPC. Check the communication cable.
<==> PLC)
Communication between the PLC and MPC has been interrupted.
647 PLC BREAKDOWN Check the communication cable.
ENCODER CONVERTER
648 The absolute encoder converter has failed. Contact AIDA Service.
BREAKDOWN
CRANK ENCODER BIT Data loss has been detected in the crank angle data. Check the crank
649 WRONG motion detector for proper installation and the cable connections.
A crank motion detector problem has been detected. Check the crank
CRANK MOTION MONI- motion detector for proper installation and the cable connections. If
650 TOR DETECT the press machine is being operated at a speed level lower than the
speed specification range, increase the speed.

TIMING SWITCH CAM SIG- The cam signal and motion detection proximity switch pattern is
651 faulty. The motion detection proximity switch is faulty. Check the
NAL(MPC) installation and wiring.
M-CON2 OUTPUT MONI- An M-CON2 output monitor has been detected. Contact AIDA Ser-
652 TOR DETECT vice.

DIEHEIGHT ENCODER BIT Data loss has been detected in the die height data. Check the die
653 WRONG height detector for proper installation and the cable connections.

SLIDE ADJUSTMENT The thermal relay for the slide adjust motor has tripped. (See
654 THERMAL TRIP 6.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 247).)

SLIDE ADJ. MOTION MONI- The slide adjustment device is faulty. Check that there are no
655 TOR obstructions in the slide.

SLIDE ADJ. COUNTER The limit switch in the die height indicator is faulty. Check the limit
656 FAULT switch, and replace it if necessary.

SLIDE ADJ. AUTO.SLIDE Slide adjustment has not been done successfully. Confirm that there
657 are no obstructions in the slide. Check the target value, and adjust
ADJ.OUT OF TARGET the slide again.
PC COMMUNICATION A communication error has occurred between the MPC and the per-
658 FAILURE sonal computer. Check the communication cable connections.

RECEIVE PARAMETER Data that exceeds the preset range has been entered. Check the
659 OUT OF RANGE inputted data and the input location and then re-enter the data.
An SVC bus fault has occurred. Turn on the power again. If this
660 SVC BUS FAULT occurs repeatedly, contact AIDA Service.
BRAKE TORQUE CHECK The motor encoder has turned 0.5 degrees or more of crank angle
661 TEST FAULT during the brake torque check test. Contact AIDA Service.
The brake has not been released even though the brake release sig-
662 BRAKE PS SW FAULT nal has been outputted. Contact AIDA Service.
The difference between the press crank angle (crank angle meter)
CRANK ANGLE SYNC. and the current angle of the crankshaft (motor encoder) has
663 exceeded the allowable crank angle synchronization error range.
ERROR (MPC) Turn on power to the machine again. If this error occurs repeat-
edly, contact AIDA Service.

SVC COMMUNICATION Mismatched SVC communication DPRAM has been detected twice.
664 Turn on the power again. If this occurs repeatedly, contact AIDA Ser-
FAILURE vice.
The SVC monitor counter has remained unchanged for 1.5 ms. Turn
665 SVC FAULT on the power again. If this occurs repeatedly, contact AIDA Service.
Reverse movement of the slide has been detected while it is moving
666 TAKE OVER FAULT upward. Push the RESET button. If this error occurs repeatedly, con-
tact AIDA Service.

SLIDE DECELARATION Deceleration of the slide has not been detected after the slide motion
667 signal has changed to an OFF state. Push the RESET button. If this
FAULT error occurs repeatedly, contact AIDA Service.

217
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SLIDE MOTION DEREC- The slide has moved in the opposite direction of the set motion. If this
668 TION FAULT error occurs repeatedly, contact AIDA Service

M-CON2 MAGNET WELDS The M-CON2 contactors have been welded together. Contact AIDA
669 CONTACT POINT FAULT Service.

M-CON2 MAGNET CON-


670 The M-CON2 contactor is faulty. Contact AIDA Service.
TACTOR FAULT
BASE CUT OFF OUT A base cutoff output circuit fault has been detected. Contact AIDA
671 FAULT Service.

672 BASE CUT OFF MONITOR The


vice.
base cutoff output monitor has been actuated. Contact AIDA Ser-

The slide stopping time has exceeded the allowable limit. If this error
673 SLIDE STOP TIME OVER occurs repeatedly, contact AIDA Service
5V POWER SUPPLY FAIL- The 5 V power voltage inside the SVC controller is faulty. Contact
676 URE (SVC) AIDA Service.

15V POWER SUPPLY FAIL- The 15 V power voltage supplied to the SVC controller is faulty. Con-
677 URE (SVC) tact AIDA Service.

CPU POWER SUPPLY The CPU power voltage inside the SVC controller is faulty. Contact
678 FAILURE (SVC) AIDA Service.
The SVC controller internal memory (DPRAM) reading or writing is
679 DPRAM FAULT (SVC) faulty. Turn on the power again. If this occurs repeatedly, contact
AIDA Service.

EEPROM DATA FAULT A SVC controller internal memory (EEPROM) checksum fault has
680 occurred. Turn on the power again. If this occurs repeatedly, contact
(SVC) AIDA Service.
BACKUP DATA FAULT The R/E data is faulty. Turn on the power again. If this occurs repeat-
681 (SVC) edly, contact AIDA Service.
The SVC built-in battery is not installed or the voltage of the built-in
battery has dropped. Check whether the battery is installed. Replace
682 BATTERY FAILURE (SVC) the batteries if the service life has been exceeded. (See Section E
MAINTENANCE, 4.5 REPLACING THE SVC BUILT-IN BATTERY
(pg. 346))
SVC NORMAL OUTPUT
683 The SVC normal output weld check is faulty. Contact AIDA Service.
FAULT
The difference between the press machine crank angle (crank angle
CRANK ANGLE SYNC. indicator) and the current crankshaft angle (motor encoder) has
684 ERROR (SVC) exceeded the allowable crank angle non-synchronization limit. Turn
on the power again. If this occurs repeatedly, contact AIDA Service.
While slide motion has been stopped, the press machine crank angle
SLIDE MOTION FAULT (crank angle indicator) or the current crankshaft angle (motor
685 (SVC) encoder) has exceeded the slide motion fault detection range. Turn
on the power again. If this occurs repeatedly, contact AIDA Service.
After the command pulse transmission stopped, the deviation counter
did not enter the positioning completion range even after the position-
686 POSITIONING FAULT (SVC) ing completion time had elapsed. Turn on the power again. If this
occurs repeatedly, contact AIDA Service.
The position deviation has exceeded its allowable range. Press the
RESET button, or turn the machine power OFF and then back ON.
POSITION DEVIATION The main cause of this fault can be excessive energy. Excessive
687 energy is likely to be caused during presswork where the forming
FAULT (SVC) workload is large and a motion such as a "constant-speed slide oper-
ation" has been specified.
If this error occurs repeatedly, contact AIDA Service.

MECHANICAL BRAKE The motor encoder has turned by 0.5 degrees or more of the crank
689 angle when torque was applied to the motor while the mechanical
FAULT (SVC) brake was engaged. Contact AIDA Service.

ENCODER INPUT FAIL- SVC encoder communication could not be performed normally. Turn
693 the machine power OFF and then back ON. If this occurs repeatedly,
URE (SVC) contact AIDA Service.

218
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


MASTER ANGLE RANGE
694 The master main shaft angle speed has exceeded the allowable limit.
FAULT (SVC)
MASTER ANGULAR The master main shaft angle speed has exceeded the allowable limit.
695 SPEED FAULT (SVC)
(Allowable limit = the main shaft max. speed × (100 + the speed fault
allowable limit) /100)
ROBOT ANGLE RANGE The master robot angle does not fall within the following range:
696 FAULT (SVC) 0 degrees ≦ the master robot angle < 360 degrees

ROBOT ANGLE SPEED The master robot angle speed has exceeded the allowable limit.
697 (Allowable limit = main shaft max. speed × (100 + speed fault allow-
FAULT (SVC) able limit) /100)

STEP FEED SPEED FAIL- The manual step feed speed has exceeded the allowable limits.
698 (Allowable limit = manual step feed max. speed × (100 + speed fault
URE (SVC) allowable limit) /100). Contact AIDA Service.

LINEAR SCALE SPEED The linear scale speed has exceeded the allowable limit.
699 (Allowable limit = linear scale max. speed × (100+speed fault allow-
FAULT (SVC) able limit)/100)

MOTOR ENCODER SPEED The motor encoder speed has exceeded the allowable limits.
700 (Allowable limit = motor encoder max. speed × (100 + speed abnor-
FAULT (SVC) mality allowable limit) /100)
VELOCITY INSTRUCTION When the slide was stopped, the speed command output exceeded
701 RANGE ERR. the allowable limit. If this occurs repeatedly, contact AIDA Service.

R/E COMMUNICATION R/E communication is faulty. Turn the machine power OFF and then
702 ERROR (SVC) back ON. If this occurs repeatedly, contact AIDA Service.

LINEAR SCALE INPUT Turn the machine power OFF and then back ON. If this error occurs
703 FAULT (SVC) repeatedly, contact AIDA Service.

RESOLVER TRANSDUCER
704 The resolver transducer is faulty. Contact AIDA Service.
FAULT (SVC)
STEP FEED ENABLE CIR-
740 The manual step feed enable signal is faulty. Check and replace it.
CUIT SHORT
EM.STOP BUTTON OUT- A fault has been detected in the emergency stop button circuit.
744 PUT FAULT Contact AIDA Service.
POWER FAILURE
748 DETECTED (SVC) A power failure has been detected. Push the RESET button.

INTERNAL ANGLE SYN- A fault was detected during motion control. Place the OPERATION
754 CHRO. ERR. (SVC) SELECT switch to "ORIGIN POINT" and move the slide to the preset
<RETURN ORIGIN POINT> stop position (top dead center).
PARAMETER BLOCK 0 The entered data (the Die No.) is outside the preset range or the data
756 is corrupt. Confirm the data to be entered and the entry location, then
FAULT enter the data again.

PARAMETER BLOCK 1 The entered data (the cam angle data for cams 1 and 2) is outside the
757 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 2 The entered data (the cam angle data for cams 3 and 4) is outside the
758 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 3 The entered data (the cam angle data for cams 5 and 6) is outside the
759 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 4 The entered data (the cam angle data for cams 7 and 8) is outside the
760 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 5 The entered data (die protection data) is outside the preset range or
761 the data is corrupt. Confirm the data to be entered and the entry loca-
FAULT tion, then enter the data again.

219
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


PARAMETER BLOCK 6 The entered data (the cam angle data for cams 9 and 10) is outside
762 the preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 7 The entered data (the cam angle data for cams 11 and 12) is outside
763 the preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 8 The entered data (the cam angle data for cams 13~16) is outside the
764 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 9 The entered data (the cam angle data for cams 17~20) is outside the
765 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 10 The entered data (the cam angle data for cams 21~24) is outside the
766 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 11 The entered data (the Cam ON gain angle data) is outside the preset
767 range or the data is corrupt. Confirm the data to be entered and the
FAULT entry location, then enter the data again.

PARAMETER BLOCK 12 The entered data (the automatic slide adjustment data) is outside the
768 preset range or the data is corrupt. Confirm the data to be entered
FAULT and the entry location, then enter the data again.

PARAMETER BLOCK 13 The entered data (the Cam ON gain angle data) is outside the preset
769 range or the data is corrupt. Confirm the data to be entered and the
FAULT entry location, then enter the data again.
The entered data (the selected motion, the number of processes, and
PARAMETER BLOCK 14 Motion 1~4) is outside the preset range or the data is corrupt. Confirm
770 FAULT the data to be entered and the entry location, then enter the data
again.

PARAMETER BLOCK 15 The entered data (Motion 5~8) is outside the preset range or the data
771 is corrupt. Confirm the data to be entered and the entry location, then
FAULT enter the data again.

PARAMETER BLOCK 16 The entered data (Motion 9~12) is outside the preset range or the
772 data is corrupt. Confirm the data to be entered and the entry location,
FAULT then enter the data again.

PARAMETER BLOCK 17 The entered data (Motion 13~16) is outside the preset range or the
773 data is corrupt. Confirm the data to be entered and the entry location,
FAULT then enter the data again.

PARAMETER BLOCK 18 The entered data (Motion 17~20) is outside the preset range or the
774 data is corrupt. Confirm the data to be entered and the entry location,
FAULT then enter the data again.

PARAMETER BLOCK 19 The entered data (conveyance) is outside the preset range or the
775 data is corrupt. Confirm the data to be entered and the entry location,
FAULT then enter the data again.

220
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


PARAMETER BLOCK 20
776 FAULT
PARAMETER BLOCK 21
777 FAULT
PARAMETER BLOCK 22
778 FAULT
PARAMETER BLOCK 23
779 FAULT The entered data (set by the manufacturer) is outside the preset
PARAMETER BLOCK 24 range or the data is corrupt. Contact AIDA Service.
780 FAULT
PARAMETER BLOCK 25
781 FAULT
PARAMETER BLOCK 26
782 FAULT
PARAMETER BLOCK 27
783 FAULT
PARAMETER BLOCK 28
784 FAULT
PARAMETER BLOCK 29
785 FAULT The entered data (option parameters) is outside the preset range or
the data is corrupt. Confirm the data to be entered and the entry loca-
PARAMETER BLOCK 30 tion, and then enter the data again.
786 FAULT
PARAMETER BLOCK 31
787 FAULT
790
No. △ DISCHARGE CON- The discharge contactor/No. △ has failed.
 | TACTOR BR0KE Check the contactor, and replace it if necessary.
794
800 FUSE BLOWOUT (POWER
The fuse of power unit/No. △ has blown out. Check and replace the
 | UNIT/No. △ ) fuse.
804
SERVO DRIVER OVER
890 CURRENT/SOFT DETEC-
TION(No.5)
SERVO DRIVER POWER
891 MODULE FAULT(No.5)
SERVO DRIVER BASE
892 CONNECTOR FAULT(No.5)
SERVO DRIVER
GROUNDED DETEC- The protective function of the servo driver has been actuated.
893 If the faulty state is not reset by pushing the "RESET" button, contact
TION(No.5) AIDA Service.
SERVO DRIVER ENCODER
894 CONNECTOR DISCON-
NECTED(No.5)
SERVO DRIVER ENCODER
895 ERROR(No.5)
SERVO DRIVER CON-
896 TROL POW.SOURCE
FAULT(No.5)

221
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SERVO DRIVER CT
897 FAULT(No.5)
SERVO DRIVER MAIN CIR-
898 CUIT VOLTAGE LOW(No.5)
SERVO DRIVER
EXTREMELY OVERLOAD/
899 ELECTRONIC THER-
MAL(No.5)
SERVO DRIVER AMPLI-
900 FIER OVERHEATED(No.5)
SERVO DRIVER COMMU-
901 NICATION MASTER
FAULT(No.5)
SERVO DRIVER CONNEC-
902 TION DRIVERS
FAULT(No.5)
The protective function of the servo driver has been actuated.
SERVO DRIVER MEMORY If the faulty state is not reset by pushing the "RESET" button, contact
903 FAULT(No.5) AIDA Service.
SERVO DRIVER MIS-
904 MATCH ERROR(No.5)
SERVO DRIVER CON-
905 TROL COMMAND SIGNAL
FAULT(No.5)
SERVO DRIVER CPU
906 FAULT(No.5)
SERVO DRIVER OVER-
909 LOAD PREDICTED(No.5)
SERVO DRIVER MOTOR
910 THERMAL(No.5)
SERVO DRIVER AMPLI-
911 FIER OVERHEAT PRE-
DICTED(No.5)
SERVO DRIVER BASE
913 CONNECTOR FAULT(No.5)
POWER UNIT EEPROM R/
928 W MODE(No.5)
POWER UNIT SWITCH SET
930 UP ERROR(No.5)
POWER UNIT COMMUNI-
931 CATION ERROR(No.5) The protective function of the power unit has been actuated.
If the faulty state is not reset by pushing the "RESET" button, contact
POWER UNIT ABNORMAL AIDA Service.
932 DISCHARGE CUR-
RENT(No.5)
POWER UNIT CHARGING
933 FAILURE(No.5)
POWER UNIT CHARGING
934 VOLTAGE SAG (No.5)

222
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


POWER UNIT CHARGING
935 VOLTAGE RISES FAIL-
URE(No.5)
POWER UNIT CHARGING
936 OVERVOLTAGE(No.5)
POWER UNIT CHARGING
937 START FAULT(No.5)
POWER UNIT SMOOTHING
938 OVERVOLTAGE(No.5)
POWER UNIT TEMP.
939 ALARM 1/THERMIS-
TOR(No.5)
POWER UNIT TEMP.
940 FAULT/PROTECTOR(No.5)
POWER UNIT LOAD SHO-
941 TED OUT(No.5)
POWER UNITOVER CUR-
942 RENT OF CHARGE(No.5)
POWER UNIT INITIAL
943 ERROR 1(No.5)
POWER UNIT INITIAL
944 ERROR 2(No.5)
POWER UNIT INITIAL The protective function of the power unit has been actuated.
945 ERROR 3(No.5) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
POWER UNIT INITIAL
946 ERROR 4(No.5)
POWER UNIT CPU
947 ERROR(No.5)
POWER UNIT WATCH
948 TIMER(No.5)
POWER UNIT GRA CON-
949 VEYOR MATCH
ERROR(No.5)
POWER UNIT CHECK
950 PASS ON(No.5)
POWER UNIT OVERVOLT-
951 AGE(No.5)
POWER UNIT AC INPUT
952 FAULT(No.5)
POWER UNIT STANDBY
953 FAULT(No.5)
POWER UNIT CHALK CUR-
954 RENT RESISTANCE PASS
CONTACTOR FAULT(No.5)
POWER UNIT DIRECT
955 VOLT FIXED TIME
DECREASE(No.5)

223
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


NO FUSE BREAKER TRIP/
The breaker of the distribution board has tripped. Check the enclo-
960 DISTRIBUTION ENCLO-
sure.
SURE
NO FUSE BREAKER TRIP/
The breaker of the pressure rising/lowering transformer has tripped.
965 UP AND DOWN TRANS-
Check the transformer.
FORMER
971 CPB,NFB,TRIP/No. △
The breaker and circuit protector of the driver panel No. △ have
 | SERVO DRIVER ENCLO-
tripped. Check the enclosure.
975 SURE
980 NO FUSE BREAKER TRIP/
The breaker of the control panel No. △ has tripped. Check the
 | No. △ CONTROL ENCLO-
enclosure.
981 SURE
985 CIRCUIT PROTECTOR
The circuit protector of the control panel No. △ has tripped. Check
 | TRIP/No. △ CONTROL
the enclosure.
986 ENCLOSURE
990
COOLER STOPPED/No. △
 | The cooler of the control panel No. △ is faulty. Check the enclosure.
CONTROL ENCLOSURE
991
995
COOLER STOPPED/No. △ The cooler of the indicated power panel is faulty. Check the enclo-
 | POWER ENCLOSURE sure.
998

100VAC,24VDC The 24 V power voltage supplied to the press controller is faulty.


1001 Inspect and adjust the power voltage.
SCREEN COMMUNICA- Communication between the PLC and the touch panel is faulty. Turn
1002 TION FAILURE the control source power OFF and then back ON.
NFB TRIP (CONTROL
1005 ENCLOSURE)
NFB TRIP (DRIVER The breaker inside the indicated panel has tripped. Eliminate the
1006 ENCLOSURE) cause of the fault, then turn the breaker ON.
NFB TRIP (POWER
1007 ENCLOSURE)
CPB TRIP (CONTROL
1008 ENCLOSURE)
CPB TRIP (DRIVER The circuit protector inside the indicated panel has tripped. Eliminate
1009 ENCLOSURE) the cause of the fault, then turn the circuit protector ON.
CPB TRIP (POWER
1010 ENCLOSURE)
The fuse in the indicated capacitor panel has tripped.
Turn the breaker of the power panel (400 V system) OFF and check
1011 FUSE TRIP (CONDENSER that the voltmeter of the power panel shows no voltage and the resid-
 | ENCLOSURE No. △ )]
ual voltage confirmation lamp on the capacitor panel has gone out.
After you have fully confirmed that there is no residual voltage by
1015 means of the above-mentioned procedure, eliminate the cause of the
fault and replace the fuse with a new one.

The fuse in the indicated driver panel has blown.


1016 Turn the breaker of the power panel (400 V system) OFF and check
FUSE MELTDOWN that the voltmeter of the power panel shows no voltage and the
 | (DRIVER ENCLOSURE No. residual voltage confirmation lamp on the capacitor panel has gone
1020 out.
△ After you have fully confirmed that there is no residual voltage by
means of the above-mentioned procedure, eliminate the cause of
the fault and replace the fuse with a new one.

224
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


1021 COOLER SHUTDOWN
 | (DRIVER ENCLOSURE No.
1025 △) The cooler in the indicated panel has stopped.
The protective circuit of the cooler has been activated. Eliminate the
COOLER SHUTDOWN cause of the fault, then turn the power to the cooler OFF and then
1026 (CONTROL ENCLOSURE) back ON.
COOLER SHUTDOWN
1027 (POWER ENCLOSURE)

1030 PLC I/O LINK BREAKDOWN The PLC remote I/O link is faulty.
Contact AIDA Service.
PLC CPU LINK BREAK- The PLC link between the CPUs is faulty.
1031 DOWN Contact AIDA Service.

1032 PLC LINK SET UP FAILURE The PLC network link setting is faulty.
Contact AIDA Service.
PLC LINK COMMUNICA-
1033 TION FAILURE (NUMBER
OF RETRY) The PLC network link communication is faulty.
PLC LINK COMMUNICA- Contact AIDA Service.
1034 TION FAILURE (LINK
SCAN)
The PLC stations have stopped.
1035 PLC EACH CPU STOP Contact AIDA Service.
PLC A/D CONVERTER The PLC A/D converter unit is faulty
1036 UNIT FAILURE Contact AIDA Service.

PLC COMPUTER LINK The PLC computation link unit is faulty.


1037 UNIT FAILURE Contact AIDA Service.
An open circuit fault of the PLC normal output contact has been
detected.
1038 PLC NORMAL OUTPUT The corresponding PLC output card’s ON may be faulty, or the relay
contact may have become welded.
Check the PLC, and replace it if necessary.
OVER VOLTAGE JUDGE- Overvoltage unit has detected a fault.
1039 MENT UNIT FAULT Contact AIDA Service.

MPC-PLC COMMUNICA- Communication between the PLC and MPC has been interrupted.
1040 TION FAILURE Check the communication cable connection.

EMERGENCY STOP RELAY An emergency stop relay wire has broken.


1042 FAILURE Check the relay, and replace it if necessary.

EMERGENCY STOP RELAY The emergency stop relay has short-circuited.


1043 FAULT Check the relay, and replace it if necessary.

EMERGENCY STOP SIG- A breakage has occurred in the emergency stop signal wire. Check
1044 the wiring of the emergency stop circuit. Then push the "RESET" but-
NAL FAILURE (PLC) ton. If this error occurs repeatedly, contact AIDA Service.
EMERGENCY STOP MPC-
There is a communication fault between the controllers. Push the
1045 PLC COMMUNICATION RESET button.If this error occurs repeatedly, contact AIDA Service.
FAILURE
LUBRICATING OIL PUMP 1
1047 RUN CHECK FAULT
HYDRAULIC OPERATING
1048 FLUID PUMP RUN CHEKCK Turning ON of the magnet for pump cannot be confirmed. Inspect the
magnet and replace it if necessary.
FAULT
DIE CUSHION LUB. OIL
1049 PUMP RUN CHECK FAULT

225
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


The thermal relay for the lubricating oil pump has tripped. (See
LUBRICATING OIL PUMP 1 6.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 247).)
1050 THERMAL TRIP Check the oil filter for clogging. Reset the faulty state and then push
the RESET button.

HYDRAULIC OPERATING The thermal relay for the hydraulic oil pump has tripped. (See
6.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 247).)
1051 FLUID PUMP THERMAL Check the oil filter for clogging. Reset the faulty state and then push
TRIP the RESET button.
Thermal relay for the die cushion intermittent lubrication pump has
DIE CUSHION LUBLICAT- tripped.(Refer to 6.9 WHEN A THERMAL RELAY HAS
1052 ING OIL PUMP THERMAL TRIPPED (pg. 247))Check the oil filter for clogging. After
TRIP resetting the fault, push the “RESET” button.

SERVO MOTER DRIVE It is a fault in the relay for servomotor disable selection. Output signal
1055 and input signal for checking do not match. Inspect the relay and
SELECT CIRCUIT FAULT replace it if necessary.
GUARD SELECTOR (LEFT/ The "LEFT/BOTH/RIGHT" guard selector key switch has failed.
1059 BOTH/RIGHT) FAULT Check the selector, and replace it if necessary.

LEFT GUARD LIMIT The signal of the left guard limit switch or the output of the presence
1060 SWITCH & I.PRESENCE sensing device is faulty. Check the limit switch, and replace it if nec-
SENS.D. FAULT essary.

RIGHT GUARD LIMIT The signal of the right guard limit switch or the output of the presence
1061 SWITCH & I.PRESENCE sensing device is faulty. Check the limit switch, and replace it if nec-
SENS.D. FAULT essary.

LEFT GUARD MOTOR


1064 THERMAL TRIP The thermal relay for the side guard motor of the indicated part has
tripped.(See 6.9 WHEN A THERMAL RELAY HAS TRIPPED (pg.
RIGHT GUARD MOTOR 247).)
1065 Reset the faulty state and then push the RESET button.
THERMAL TRIP
LEFT GUARD INVERTER
1066 FAILURE The inverter for the indicated side guard is faulty.
Check the error description of the relevant inverter in the control
RIGHT GUARD INVERTER panel and reset the fault. Then push the "RESET" button on the
1067 inverter body.
FAILURE
RIGHT GUARD A.RELAY
1068 FAULT The auxiliary relay for the guard has failed.
LEFT GUARD A.RELEY Check the relay, and replace it if necessary.
1069 FAULT
OPERATION READY CIR- The relay for the prior action has failed.
1070 CUIT FAULT Check the circuit, and replace it if necessary.

OPE.SELECTOR OFF SIG- The OPERATION SELECT switch PLC input signal is faulty.
1072 NAL FAULT Check the selector, and replace it if necessary.

PRESS RUN MONITOR The press operation monitor PLC input signal has failed. Check the
1073 OUTPUT FAULT (PLC) input.

1074 OVERRUN DETECT (PLC) An overrun has occurred. (See 6.5 OVERRUNS (pg. 245).)

PRESET STOP CAM FAULT The PLC input signal of the preset position stop cam has failed.
1075 (PLC) Check the cam.

SINGLE TAKE OVER CAM The PLC input signal of the upper position retaining cam for the SIN-
1076 FAULT (PLC) GLE operation has failed. Check the cam.

PRESS RUN INTERLOCK The controller has detected a fault.


1077 FAILURE Contact AIDA Service.
The motion computation failed to finish within the predetermined time.
1080 MOTION CREATION WDT Re-examine the motion program.

226
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SLIDE ADJ. MODE MPC-
1090 PLC WRONG There is faulty communication between the PLC and the MPC con-
troller. Turn the main breaker OFF and then back ON again. If this
DIE HEIGHT OUT OF TAR- error occurs repeatedly, contact AIDA Service.
1091 GET MPC-PLC WRONG
BOLSTER RUNNING The thermal relay for the bolster travel motor has tripped. (See
1100 6.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 247).) Reset
MOTOR THERMAL TRIP the faulty state and then push the RESET button
The bolster travel inverter is faulty.
BOLSTER RUNNING Check the error description of the relevant inverter in the control
1101 INVERTER FAILURE panel and reset the fault. Then push the "RESET" button on the
inverter unit.
A short-circuit fault has occurred in the slide lock operation check
1105 SLIDELOCK PRX FAULT proximity switch.
Check the proximity switch, and replace it if necessary.
A short-circuit fault has occurred in the safety-pole operation check
1106 SAFETY POLE PRX FAULT proximity switch.
Check the proximity switch, and replace it if necessary.

BOLSTER RUNNING The protective function of the power unit has been actuated.
1110 If the faulty state is not reset by pushing the "RESET" button, contact
MOTOR THERMAL TRIP AIDA Service.

1111 SERVO MOTOR THERMAL


 | (No. △ )
1115 The protective function has been actuated because the temperature
of the indicated servo motor is high.
POWER UNIT EEPROM R/ Wait until the motor temperature drops.
1118 W MODE (No.1) If this error occurs repeatedly, contact AIDA Service.
POWER UNIT OVER VOLT-
1120 AGE ALARM(No.1)
The protective function of the power unit has been actuated.
If the faulty state is not reset by pushing the "RESET" button, contact
1121 POWER UNITALARM(No.1) AIDA Service.

POWER UNIT OVER VOLT-


1122 AGE WARNING(No.1)
POWER UNIT ELEC-
1123 TRONIC THERMAL WARN-
ING(No.1)
POWER UNIT CHARGING The protective function of the power unit has been actuated.
1124 If the faulty state is not reset by pushing the "RESET" button, contact
VOLTAGE SAG (No.1) AIDA Service.
POWER UNIT CHARGING
1125 VOLTAGE RISES FAILURE
(No.1)
POWER UNIT CHARGING
1126 OVERVOLTAGE (No.1)
POWER UNIT CHARGING
1127 START FAULT
POWER UNIT SMOOTHING
1128 OVERVOLTAGE (No.1)
The protective function of the power unit has been actuated.
POWER UNIT TEMPERA- If the faulty state is not reset by pushing the "RESET" button, contact
1129 TURE ALARM 1/THERMIS- AIDA Service.
TOR (No.1)
POWER UNIT TEMPERA-
1130 TURE FAULT 2/PROTEC-
TOR (No.1)

227
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


POWER UNIT OVERLOAD
1131 FAULT (No.1)
POWER UNIT CHARGING
1132 OVER CURRENT (No.1)
POWER UNIT INITIAL
1133 ERROR 1 (No.1).
POWER UNIT INITIAL
1134 ERROR 2 (No.1) The protective function of the power unit has been actuated.
If the faulty state is not reset by pushing the "RESET" button, contact
POWER UNIT INITIAL AIDA Service.
1135 ERROR 3 (No.1)
POWER UNIT INITIAL
1136 ERROR 4 (No.1)
POWER UNIT CPU ERROR
1137 (No.1)
POWER UNIT WATCH
1138 TIMER (No.1)
POWER UNIT GRA CON-
1139 VEYOR MATCH ERROR
(No.1)
POWER UNIT CHECK The protective function of the power unit has been actuated.
1140 PASS ON (No.1) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
POWER UNIT OVERVOLT-
1141 AGE(No.1)
POWER UNIT AC INPUT
1142 FAULT (No.1)
POWER UNIT STANDBY
1143 FAULT(No.1)
POWER UNIT CHALK CUR-
1144 RENT RESISTANCE PASS
CONTACTOR FAULT(No.1)
The protective function of the power unit has been actuated.
POWER UNIT DC VOLT- If the faulty state is not reset by pushing the "RESET" button, contact
1145 AGE SAG(No.1) AIDA Service.

POWER UNIT EEPROM R/


1148 W MODE (No.2)
POWER UNIT OVER VOLT-
1150 AGE ALARM(No.2)
1151 POWER UNITALARM(No.2)
POWER UNIT OVER VOLT-
1152 AGE WARNING(No.2)
POWER UNIT ELEC-
1153 TRONIC THERMAL WARN- The protective function of the power unit has been actuated.
ING(No.2) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
POWER UNIT CHARGING
1154 VOLTAGE SAG (No.2)
POWER UNIT CHARGING
1155 VOLTAGE RISES FAILURE
(No.2)

228
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


POWER UNIT CHARGING
1156 OVERVOLTAGE (No.2)
POWER UNIT CHARGING
1157 START FAULT (No.2)
POWER UNIT SMOOTHING
1158 OVERVOLTAGE (No.2)
POWER UNIT TEMPERA-
TURE ALARM 1/THERMIS- The protective function of the power unit has been actuated.
1159 If the faulty state is not reset by pushing the "RESET" button, contact
TOR (No.2) AIDA Service.
POWER UNIT TEMPERA-
1160 TURE FAULT /PROTECTOR
(No.2)
POWER UNIT OVERLOAD
1161 FAULT (No.2)
POWER UNIT CHARGING
1162 OVER CURRENT (No.2)
POWER UNIT INITIAL
1163 ERROR 1 (No.2)
POWER UNIT INITIAL
1164 ERROR 2 (No.2)
POWER UNIT INITIAL
1165 ERROR 3 (No.2)
POWER UNIT INITIAL
1166 ERROR 4 (No.2) The protective function of the power unit has been actuated.
POWER UNIT CPU ERROR If the faulty state is not reset by pushing the "RESET" button, contact
1167 AIDA Service.
(No.2)
POWER UNIT WATCH
1168 TIMER (No.2)
POWER UNIT GRA CON-
1169 VEYOR MATCH ERROR
(No.2)
POWER UNIT CHECK
1170 PASS ON (No.2)
POWER UNIT OVERVOLT-
1171 AGE(No.2)
POWER UNIT AC INPUT
1172 FAULT (No.2)
POWER UNIT STANDBY
1173 FAULT(No.2)
POWER UNIT CHALK CUR- The protective function of the power unit has been actuated.
1174 RENT RESISTANCE PASS If the faulty state is not reset by pushing the "RESET" button, contact
CONTACTOR FAULT(No.2) AIDA Service.
POWER UNIT DC VOLT-
1175 AGE SAG(No.2)
POWER UNIT EEPROM R/
1178 W MODE (No.3)
POWER UNIT OVER VOLT-
1180 AGE ALARM(No.3)

229
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


POWER UNIT
1181 ALARM(No.3)
POWER UNIT OVER VOLT-
1182 AGE WARNING(No.3)
POWER UNIT ELEC-
1183 TRONIC THERMAL WARN-
ING(No.3)
POWER UNIT CHARGING The protective function of the power unit has been actuated.
1184 If the faulty state is not reset by pushing the "RESET" button, contact
VOLTAGE SAG (No.3) AIDA Service.
POWER UNIT CHARGING
1185 VOLTAGE RISES FAIL-
URE (No.3)
POWER UNIT CHARGING
1186 OVERVOLTAGE (No.3)
POWER UNIT CHARGING
1187 START FAULT(No.3)
POWER UNIT SMOOTHING
1188 OVERVOLTAGE (No.3)
POWER UNIT TEMPERA-
1189 TURE ALARM 1/THERMIS-
TOR (No.3)
POWER UNIT TEMPERA-
1190 TURE FAULT 2/PROTEC- The protective function of the power unit has been actuated.
TOR (No.3) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
POWER UNIT OVERLOAD
1191 FAULT (No.3)
POWER UNIT CHARGING
1192 OVER CURRENT (No.3)
POWER UNIT INITIAL
1193 ERROR 1 (No.3)
POWER UNIT INITIAL
1194 ERROR 2 (No.3)
POWER UNIT INITIAL
1195 ERROR 3 (No.3)
POWER UNIT INITIAL
1196 ERROR 4 (No.3)
POWER UNIT CPU ERROR
1197 (No.3) The protective function of the power unit has been actuated.
POWER UNIT WATCH If the faulty state is not reset by pushing the "RESET" button, contact
1198 AIDA Service.
TIMER (No.3)
POWER UNIT GRA CON-
1199 VEYOR MATCH ERROR
(No.3)
POWER UNIT CHECK
1200 PASS ON (No.3)
POWER UNIT OVERVOLT-
1201 AGE(No.3)

230
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


POWER UNIT AC INPUT
1202 FAULT (No.3)
POWER UNIT STANDBY
1203 FAULT(No.3)
POWER UNIT CHALK CUR-
1204 RENT RESISTANCE PASS
CONTACTOR FAULT(No.3)
POWER UNIT DC VOLT- The protective function of the power unit has been actuated.
1205 AGE SAG(No.3) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
POWER UNIT EEPROM R/
1208 W MODE (No4)
POWER UNIT OVER VOLT-
1210 AGE ALARM(No.4)
1211 POWER UNITALARM(No.4)
POWER UNIT OVER VOLT-
1212 AGE WARNING(No.4)
POWER UNIT ELEC-
1213 TRONIC THERMAL WARN-
ING(No.4)
POWER UNIT CHARGING
1214 VOLTAGE SAG (No4)
POWER UNIT CHARGING
1215 VOLTAGE RISES FAILURE
(No4)
The protective function of the power unit has been actuated.
POWER UNIT CHARGING If the faulty state is not reset by pushing the "RESET" button, contact
1216 OVERVOLTAGE (No4) AIDA Service.

POWER UNIT CHARGING


1217 START FAULT
POWER UNIT SMOOTHING
1218 OVERVOLTAGE (No4)
POWER UNIT TEMPERA-
1219 TURE ALARM 1/THERMIS-
TOR (No4)
POWER UNIT TEMPERA-
1220 TURE FAULT 2/PROTEC-
TOR (No4)
POWER UNIT OVERLOAD
1221 FAULT (No4)
POWER UNIT CHARGING
1222 OVER CURRENT (No4)
The protective function of the power unit has been actuated.
POWER UNIT INITIAL If the faulty state is not reset by pushing the "RESET" button, contact
1223 ERROR 1 (No4) AIDA Service.

POWER UNIT INITIAL


1224 ERROR 2 (No4)
POWER UNIT INITIAL
1225 ERROR 3 (No4)
POWER UNIT INITIAL
1226 ERROR 4 (No4)

231
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


POWER UNIT CPU ERROR
1227 (No4)
POWER UNIT WATCH
1228 TIMER (No4)
POWER UNIT GRA CON-
1229 VEYOR MATCH ERROR
(No4)
POWER UNIT CHECK
1230 PASS ON (No4)
POWER UNIT OVERVOLT- The protective function of the power unit has been actuated.
1231 If the faulty state is not reset by pushing the "RESET" button, contact
AGE AIDA Service.
POWER UNIT AC INPUT
1232 FAULT (No4)
POWER UNIT STANDBY
1233 FAULT(No.4)
POWER UNIT CHALK CUR-
1234 RENT RESISTANCE PASS
CONTACTOR FAULT(No.4)
POWER UNIT DC VOLT-
1235 AGE SAG(No.4)
1240 No. △ PRIMARY CONTAC-
The primary contactor of the power unit/No. △ has failed.
 | TOR BROKE IN POWER Check the contactor, and replace it if necessary.
1244 ENCLOSURE
SERVO DRIVER OVER
1250 CURRENT/SOFT DETEC- The protective function of the servo driver has been actuated.
TION (No.1) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
SERVO DRIVER POWER
1251 MODULE FAULT (No.1)

232
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SERVO DRIVER BASE
1252 CONNECTOR FAULT (No.1)
SERVO DRIVER
1253 GROUNDED DETECTION
(No.1)
SERVO DRIVER ENCODER
1254 CONNECTOR DISCON-
NECTED (No.1)
SERVO DRIVER ENCODER
1255 ERROR(No.1)
SERVO DRIVER CON-
1256 TROL POW.SOURCE
FAULT(No.1)
SERVO DRIVER CT FAULT
1257 (No.1)
SERVO DRIVER MAIN CIR-
1258 CUIT VOLTAGE LOW (No.1)
SERVO DRIVER
EXTREMELY OVERLOAD/
1259 ELECTRONIC THERMAL
(No.1)
SERVO DRIVER AMPLI-
1260 FIER OVERHEATED (No.1)
SERVO DRIVER COMMU-
1261 NICATION MASTER FAULT The protective function of the servo driver has been actuated.
(No.1) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
SERVO DRIVER CONNEC-
1262 TION DRIVERS FAULT
(No.1)
SERVO DRIVER MEMORY
1263 FAULT (No.1)
SERVO DRIVER MIS-
1264 MATCH ERROR (No.1)
SERVO DRIVER CON-
1265 TROL COMMAND SIGNAL
FAULT (No.1)
SERVO DRIVER CPU
1266 FAULT (No.1)
SERVO DRIVER OVER-
1269 LOAD PREDICTED (No.1)
SERVO DRIVER MOTOR
1270 THERMAL (No.1)
SERVO DRIVER AMPLI-
1271 FIER OVERHEAT PRE-
DICTED (No.1)
SERVO DRIVER BASE
1273 CONNECTOR FAULT (No.1)
SERVO DRIVER OVER
1280 CURRENT/SOFT DETEC-
TION (No.2)

233
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SERVO DRIVER POWER
1281 MODULE FAULT (No.2)
SERVO DRIVER BASE
1282 CONNECTOR FAULT (No.2)
SERVO DRIVER
1283 GROUNDED DETECTION
(No.2)
SERVO DRIVER ENCODER
1284 CONNECTOR DISCON-
NECTED (No.2)
SERVO DRIVER ENCODER
1285 ERROR (No.2)
SERVO DRIVER CON-
1286 TROL POW.SOURCE
FAULT (No.2)
SERVO DRIVER CT FAULT
1287 (No.2)
SERVO DRIVER MAIN CIR-
1288 CUIT VOLTAGE LOW (No.2)
SERVO DRIVER
EXTREMELY OVERLOAD/
1289 ELECTRONIC THERMAL
(No.2)
SERVO DRIVER AMPLI- The protective function of the servo driver has been actuated.
1290 FIER OVERHEATED (No.2) If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
SERVO DRIVER COMMU-
1291 NICATION MASTER FAULT
(No.2)
SERVO DRIVER CONNEC-
1292 TION DRIVERS FAULT
(No.2)
SERVO DRIVER MEMORY
1293 FAULT (No.2)
SERVO DRIVER MIS-
1294 MATCH ERROR (No.2)
SERVO DRIVER CON-
1295 TROL COMMAND SIGNAL
FAULT (No.2)
SERVO DRIVER CPU
1296 FAULT (No.2)
SERVO DRIVER OVER-
1299 LOAD PREDICTED (No.2)
SERVO DRIVER MOTOR
1300 THERMAL (No.2)
SERVO DRIVER AMPLI-
1301 FIER OVERHEAT PRE-
DICTED (No.2)
SERVO DRIVER BASE
1303 CONNECTOR FAULT (No.2)

234
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SERVO DRIVER OVER
1310 CURRENT/SOFT DETEC-
TION (No.3)
SERVO DRIVER POWER
1311 MODULE FAULT (No.3)
SERVO DRIVER BASE
1312 CONNECTOR FAULT
(No.3)
SERVO DRIVER
1313 GROUNDED DETECTION
(No.3)
SERVO DRIVER ENCODER
1314 CONNECTOR DISCON-
NECTED (No.3)
SERVO DRIVER ENCODER
1315 ERROR (No.3)
SERVO DRIVER CON-
1316 TROL POW.SOURCE
FAULT (No.3)
SERVO DRIVER CT FAULT
1317 (No.3)
SERVO DRIVER MAIN CIR-
1318 CUIT VOLTAGE LOW
(No.3)
SERVO DRIVER The protective function of the servo driver has been actuated.
If the faulty state is not reset by pushing the "RESET" button, contact
EXTREMELY OVERLOAD/ AIDA Service.
1319 ELECTRONIC THERMAL
(No.3)
SERVO DRIVER AMPLI-
1320 FIER OVERHEATED
(No.3)
SERVO DRIVER COMMU-
1321 NICATION MASTER FAULT
(No.3)
SERVO DRIVER CONNEC-
1322 TION DRIVERS FAULT
(No.3)
SERVO DRIVER MEMORY
1323 FAULT (No.3)
SERVO DRIVER MIS-
1324 MATCH ERROR (No.3)
SERVO DRIVER CON-
1325 TROL COMMAND SIGNAL
FAULT (No.3)
SERVO DRIVER CPU
1326 FAULT (No.3)
SERVO DRIVER OVER-
1329 LOAD PREDICTED (No.3)
SERVO DRIVER MOTOR
1330 THERMAL (No.3)

235
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SERVO DRIVER AMPLI-
1331 FIER OVERHEAT PRE-
DICTED (No.3)
SERVO DRIVER BASE
1333 CONNECTOR FAULT
(No.3)
SERVO DRIVER OVER
1340 CURRENT/SOFT DETEC-
TION (No4)
SERVO DRIVER POWER
1341 MODULE FAULT (No4)
SERVO DRIVER BASE
1342 CONNECTOR FAULT (No4)
SERVO DRIVER
1343 GROUNDED DETECTION
(No4)
SERVO DRIVER ENCODER
1344 CONNECTOR DISCON-
NECTED (No4)
SERVO DRIVER ENCODER
1345 ERROR (No4)
SERVO DRIVER CON-
1346 TROL POW.SOURCE
FAULT (No4) The protective function of the servo driver has been actuated.
If the faulty state is not reset by pushing the "RESET" button, contact
SERVO DRIVER CT FAULT AIDA Service.
1347 (No4)
SERVO DRIVER MAIN CIR-
1348 CUIT VOLTAGE LOW (No4)
SERVO DRIVER
EXTREMELY OVERLOAD/
1349 ELECTRONIC THERMAL
(No4)
SERVO DRIVER AMPLI-
1350 FIER OVERHEATED (No4)
SERVO DRIVER COMMU-
1351 NICATION MASTER FAULT
(No4)
SERVO DRIVER CONNEC-
1352 TION DRIVERS FAULT(No.4
SERVO DRIVER MEMORY
1353 FAULT (No4)
SERVO DRIVER
1354 MISMATCH ERROR (No4)
SERVO DRIVER CON-
1355 TROL COMMAND SIGNAL
FAULT (No4)
SERVO DRIVER CPU
1356 FAULT (No4)

236
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


SERVO DRIVER OVER-
1359 LOAD PREDICTED (No4)
SERVO DRIVER MOTOR
1360 THERMAL (No4) The protective function of the servo driver has been actuated.
SERVO DRIVER AMPLI- If the faulty state is not reset by pushing the "RESET" button, contact
AIDA Service.
1361 FIER OVERHEAT PRE-
DICTED (No4)
SERVO DRIVER BASE
1363 CONNECTOR FAULT (No4)
A fault has been detected in the emergency stop button circuit.
EM.STOP BUTTON OUT- Check the emergency stop button and the wiring from the button for a
1370 PUT FAULT(PILZ) fault.
If no fault is found, contact AIDA Service.

TWO-HAND BUTTON A fault has been detected in the operation button circuit.
1371 Check the operation button and the wiring from the button for a fault.
FAULT(PILZ) If no fault is found, contact AIDA Service.
A fault has been detected in the operation button selection circuit.
OPERATION STAND Check the operation stand selector switch and the wiring from the
1372 SELECTOR FAILURE(PILZ) switch for a fault.
If no fault is found, contact AIDA Service.

FEEDBACK SIGNAL Short-circuit failure or a break in the wire of the emergency stop but-
1373 ton.
FAULT(PILZ) Check the signal, and replace it if necessary.
SAFETY PLC 1/STATION
1375 No.2 FAULT
SAFETY PLC 2/STATION The controller has detected a fault.
1376 No.3 FAULT Contact AIDA Service.

SAFETY PLC 3/STATION


1377 No.4 FAULT
RELAY MONITOR FAULT /
A fault has occurred in the relay for base cutoff output. Replace the
1383 BASE BLOCK OUTPUT relay.
(SAFETY PLC)
RELAY MONITOR FAULT /
A fault has occurred in the relay for emergency stop output. Replace
1384 EMERGENCY STOP OUT- the relay.
PUT (SAFETY PLC)
RELAY MONITOR FAULT /
1385 IMMEDIATE STOP OUTPUT A fault has occurred in the relay for immediate stop output. Replace
the relay.
(SAFETY PLC)
RELAY MONITOR FAULT /
A fault has occurred in the relay for operation ready output. Replace
1386 OPERATION READY OUT- the relay.
PUT (SAFETY PLC)
DEVICE NET COMMUNICA- It is a communication error with the safety PLC. Check the communi-
1387 TION FAULT cation cable between the safety PLC and the PLC.
Communication with the die cushion PLC has been interrupted.
1400 DC PLS FAULT Check the communication cable.

237
Section D OPERATION 6. RESETTING FAULTS

No. Fault Information Message Description & Resetting Method


400V OFF(POWER ENCLO-
1410 SURE/No.1)
400V OFF(POWER ENCLO-
1411 SURE/No.2) The breaker for receiving the power in the power enclosure No.△ has
400V OFF(POWER ENCLO- tripped, or 400V power is not being supplied.
1412 SURE/No.3)
400V OFF(POWER ENCLO-
1413 SURE/No.4)
NFB TRIP(POWER ENCLO-
1415 SURE/No.1)
NFB TRIP(POWER ENCLO-
1416 SURE/No.2) The breaker inside the No. △ power enclosure has tripped. Eliminate
NFB TRIP(POWER ENCLO- the cause of the fault, then turn the breaker ON.
1417 SURE/No.3)
NFB TRIP(POWER ENCLO-
1418 SURE/No.4)
CPB FOR INPUT The circuit protector for input inside the No.1 control enclosure has
1420 TRIP(CONTROL ENCLO- tripped.
SURE/No.1) Eliminate the cause of the fault, then turn the circuit protector ON.

CPB FOR DISPLAY(CON- The circuit protector for display inside the No.1 control enclosure has
1421 tripped.
TROL ENCLOSURE/No.1) Eliminate the cause of the fault, then turn the circuit protector ON.
CPB FOR OUTPUT The circuit protector for output inside the No.1 control enclosure has
1422 TRIP(CONTROL ENCLO- tripped.
SURE/No.1) Eliminate the cause of the fault, then turn the circuit protector ON.

CPB FOR SOL. The circuit protector for solenoid valve inside the No.1 control enclo-
1423 VALVE(CONTROL ENCLO- sure has tripped.
SURE/No.1) Eliminate the cause of the fault, then turn the circuit protector ON.

CPB FOR DIE SENSOR The circuit protector for sensor inside the No.1 control enclosure has
1424 tripped.
TRIP(CONTROL ENC./No.1) Eliminate the cause of the fault, then turn the circuit protector ON.
POWER UNIT STANDBY Standby status of the power unit cannot be confirmed.
1433 WDT Contact AIDA Service.

POWER UNIT CAPACITOR Start of charging at the capacitor panel cannot be confirmed.
1434 CHARGE WDT Contact AIDA Service.

CHARGE START TIME Completion of charging at the capacitor panel cannot be confirmed.
1437 OVER Contact AIDA Service.

238
Section D OPERATION 6. RESETTING FAULTS

6.3 FAULT CHECK UPON POWER ACTIVATION

If the dedicated controllers installed inside the control panel (hereafter referred to as the MPC
and the SVC) or any of their peripheral circuits are faulty at the time the control power is sup-
plied to this machine, the message "INITIALIZING/RELEASE EMERGENCY STOP BUTTON"
will be continuously shown on the operation panel display and no detailed message will be
shown. See the corrective measures below if this occurs.

When the externally-operated breaker is set to ON, '8' will be displayed on the MPC and SVC
LED displays. The initial checks will be performed when the control power switch is set to ON.
As the checks are being performed, the LED displays will change in sequence, displaying ’c.'
and 'b.' to show the progress status of the checks. When the initial checks are completed, the
MPC LED will read ’0’ and the SVC LED will read '1.' (Refer to the figure and table below.)

MPC-DⅡ SVC

MPC (upper dis- MPC (lower dis-


play) play) SVC

Breaker ON

Initial check

Normal comple-
tion

If some fault occurs during the initial checks, the checks will be immediately stopped. Refer-
ring to the table below, confirm what is being shown on the MPC and SVC LED displays, then
perform the checks for the specified item. If the fault is not resolved even after the checks are
performed or if the initial checks are frequently being interrupted by faults, contact AIDA Ser-
vice (at the end of this volume).

239
Section D OPERATION 6. RESETTING FAULTS

No. MPC (UPPER) MPC (LOWER) SVC Items to be inspected when the initial check is stopped

• Confirm that relay 14CR83 is ON.


• Confirm that the voltage between wire
1 numbers 1483 and N24A is 24 volts.
• Confirm that the voltage between wire
numbers 1484 and N24A is 0 volts.

• Check the cable connections between the


2 MPC and SVC for looseness, etc.


• Confirm that the voltage between wire
numbers 1483 and N24A is 24 volts.

• Confirm that relay 92CR01 is OFF.


5 • Confirm that the voltage between wire
numbers 9215 and N24A is 24 volts.

• Confirm that the voltage between wire


6 numbers 9717 and N24A is 0 volts. (No
voltage.)

• Confirm that the voltage between wire


7 numbers 9802 and N24A is 24 volts.

• Confirm that relay 14CR83 is ON.


• Check relay 92CR01. If it is normal, it will
8 cycle from OFF to ON momentarily, then
back to OFF.

• Confirm that relay 92CR01 is OFF.


9 • Confirm that the voltage between wire
numbers 9215 and N24A is 24 volts.

• Confirm that relay 92CR02 is OFF.


10 • Confirm that the voltage between wire
numbers 9211 and N24A is 0 volts.

240
Section D OPERATION 6. RESETTING FAULTS

No. MPC (UPPER) MPC (LOWER) SVC Items to be inspected when the initial check is stopped

• Confirm that relay 14CR83 is ON.


• Check relay 92CR02. If it is normal, it will
11 cycle from OFF to ON momentarily, then
back to OFF.

• Confirm that relay 92CR02 is OFF.


12 • Confirm that the voltage between wire
numbers 9214 and N24C is 0 volts.

• Confirm that relay 90CR07 is OFF.


• Confirm that relay 90CR08 is OFF.
13 • Confirm that the voltage between wire
numbers 9001 and N24A is 0 volts.

• Confirm that relay 14CR83 is ON.


• Check relay 90CR08. If it is normal, it will
14 cycle from OFF to ON momentarily, then
back to OFF.

• Confirm that relay 90CR07 is OFF.


• Confirm that relay 90CR08 is OFF.
15 • Confirm that the voltage between wire
numbers 9001 and N24A is 0 volts.

• Confirm that relay 14CR83 is ON.


• Check relay 90CR07. If it is normal, it will
16 cycle from OFF to ON momentarily, then
back to OFF.

• Confirm that relay 90CR07 is OFF.


• Confirm that relay 90CR08 is OFF.
17 • Confirm that the voltage between wire
numbers 9001 and N24A is 0 volts.

241
Section D OPERATION 6. RESETTING FAULTS

No. MPC (UPPER) MPC (LOWER) SVC Items to be inspected when the initial check is stopped

• Check the connection of the MPC’s JA5


connector for looseness etc.
• Check the wiring going from the MPC to
the PLC’s QJ71C24 communication unit
for looseness etc.
• Check whether the CPU1 dipswitches on
the MPC are set exactly as shown in the
figure below.
18 CPU-1 CPU-2
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8

242
Section D OPERATION 6. RESETTING FAULTS

6.4 HYDRAULIC OVERLOADS


When a press machine overload occurs, the hydraulic overload protector will actuate, the
message overload will be displayed in the interlock information field, and the slide will immedi-
ately stop. Perform the following procedure to reset the overload.

1 Set the main circuit breaker to the OFF position to shut off the power supply, and then
return the circuit breaker to the ON position. Prepare to operate the press again by set-
ting the CONTROL POWER button to "|" (ON), pushing the LUBRICATING OIL button,
pushing the SERVO POWER "|" (ON) button, etc.

2 Set the TOP DEAD CENTER•PRESET POSITION Slide Upper Limit Switch (option) or
PRESET STOP POSITION•TOP DEAD CENTER stop position switch (option) to TOP
DEAD CENTER.

3 Set the OPERATION SELECT switch to HOME POS.RETURN, and push the RESET
button.

4 Move the slide to top dead center by pushing the PRESS RUN buttons.
When the overload has stopped the slide before bottom dead center, the motor will run in
reverse mode, and when the slide has stopped beyond bottom dead center, the motor will
run in forward mode.

5 When the overload is cleared, the hydraulic overload protector pneumatic pump will oper-
ate for approximately one minute to restore the hydraulic pressure to its normal level. The
pneumatic pump will stop when the hydraulic pressure reaches the predetermined level.

Stop the slide at top dead center; and if the pump does not stop after three minutes, see
Section E MAINTENANCE, 2.6 HYDRAULIC OVERLOAD PROTECTOR OIL SERVIC-
ING (pg. 335).

6 Perform all the steps except step (7) of the procedure described in Section A SAFETY,
6. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).

7 The following inspection must be performed by qualified personnel.


Repair work on dies must be performed according to Section A SAFETY, (Continued)
(pg. 30).
(1) Confirm that the specified tonnage capacity has not been exceeded.
(2) Check whether the dies have failed (including seizure, breakage, double-blank stamp-
ing, misalignment, loose bolts, and improper installation).

8 Reverse the steps of the Safety Procedures During Adjustment performed in step 6
above.

(Continued on the next page)

243
Section D OPERATION 6. RESETTING FAULTS

(Continued)

9 Push the MASTER POWER "|" (ON) button. Confirm that the button light comes on.

10 If required by the die configuration, use the slide adjust function to raise the slide by
approximately 3 mm (0.12 in). (See pg. 250.)

11 Operate the slide in INCH mode for two or three strokes to confirm that there are no
faults.

12 Operate the slide in SINGLE mode for two or three strokes to confirm that there are no
faults.
(Continued on the next page)

244
Section D OPERATION 6. RESETTING FAULTS

6.5 OVERRUNS

When an overrun is detected during operation, the slide immediately stops and a "!" symbol is
displayed on the operator interface terminal. (See Section D OPERATION, 3.2 COMMON
OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 115).)
When you access the 3.8.3 Fault Screen (pg. 178), the message OVERRUN DETECT (MPC)
or OVERRUN DETECT(PLC) is displayed.

In either case, immediately stop press machine operations and perform all the steps except
step (7) of the procedure described in Section A SAFETY, 6. SAFETY PROCEDURES DUR-
ING ADJUSTMENT (pg. 33) and consult with AIDA Service (see the end of this instruction
manual).

6.6 WHEN AN EMERGENCY STOP BUTTON HAS BEEN PUSHED

Whenan EMERGENCY STOP button is pushed while the slide is in motion, the slide immedi-
ately stops and the message EMERGENCY STOP BUTTON PUSHED is displayed in the
interlock information field. Follow the procedure described below to reset the machine.

1 Perform steps (2) through (4) described in Section A SAFETY, 6. SAFETY PROCE-
DURES DURING ADJUSTMENT (pg. 33).

2 Eliminate the causes that led to the EMERGENCY STOP button being pushed.

3 Reverse the steps of the Safety Procedures During Adjustment performed in step 1
above.

4 Turn the EMERGENCY STOP button in the reset (arrow) direction.

5 Set the operation selector of the die cushion at "UNIT". (Only for the press No. 1)

6 Set the OPERATION SELECT key switch to HOME POS.RETURN and inch the slide to
the preset stop position.

7 In the case of the LINE mode operation with the die cushion, select the LINE mode and
move the die cushion to the DC standby position. (Only for the press No. 1).

245
Section D OPERATION 6. RESETTING FAULTS

6.7 WHEN THE EXTERNALLY CONTROLLED BREAKER IS ACTUATED

When the disconnect switch is actuated, the slide immediately stops


and the POWER light goes out.
If this occurs, immediately stop press machine operations and find the ON

IP
cause.

TR
Follow the resetting procedure described below.

T
SE
RE
• Turn the handle once from TRIP to RESET, and then return it to ON.

6.8 WHEN THE GROUND FAULT BREAKER IS ACTUATED

When the ground fault breaker is actuated, the slide immediately stops and the POWER light
goes out.
If this occurs, immediately stop press machine operations and find the cause. If the cause
remains unknown after troubleshooting, contact AIDA Service (see the end of this instruction
manual). Follow the resetting procedure described below:

1 Perform all the steps except step (7) of the procedure described in Section A SAFETY,
6. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).

2 Open the control panel door.

3 Move the ground fault breaker handle down once to OFF, then return it to ON. (See pg.
344.)

4 Close the control panel door.

5 Reverse the steps of the Safety Procedures During Adjustment performed in step 1
above.

246
Section D OPERATION 6. RESETTING FAULTS

6.9 WHEN A THERMAL RELAY HAS TRIPPED

CAUTION
• The rated current of the thermal relays are preset at the factory before shipment. Any
additional adjustment is strictly prohibited.

• If motors are frequently started and stopped, a thermal relay can trip. Avoid such frequent
starting/stopping operations.
The thermal relay may trip due to improper adjustment of the counterbalance capacity.
Be sure to adjust the counterbalance capacity properly. (See 7.2 COUNTERBALANCE
CAPACITY ADJUSTMENT (pg. 253).)

When the thermal relay for the oil pump trips, the oil pump stops, and the message LUB.OIL
PUMP THERMAL RELAY TRIPPED is displayed in the interlock information field.
When the thermal relay for the slide adjust motor trips, the slide adjustment feature is dis-
abled. At the same time, a "!" symbol is displayed on the operator interface terminal. (See
Section D OPERATION, 3.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS
(pg. 115).) When you access the 3.8.3 Fault Screen (pg. 178), the message SLIDE ADJUST-
MENT THERMAL TRIP is displayed.
Reset the fault by following the procedure described below.
In addition, if a thermal relay on an option has been tripped, perform the applicable fault reset-
ting procedure.
See the electrical circuit drawings shown in Section E MAINTENANCE, 7. DRAWINGS (pg.
362) for details.

1 Perform all the steps except step (7) of the procedure described in Section A SAFETY,
6. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).

2 Open the control panel door.

3 Push the thermal relay reset button located on the lower side of the electromagnetic
switch. The relay will make a clicking sound when it is reset.

(Continued on the next page)

247
Section D OPERATION 6. RESETTING FAULTS

(Continued)

4 Close the control panel door.

5 Reverse the steps of the Safety Procedures During Adjustment performed in step 1
above.

6 If the thermal relay trips again, one of the mechanical parts may be faulty. In this case, be
sure to immediately stop press machine operations and perform troubleshooting.
If you cannot ascertain the cause of the problem, contact AIDA Service (see the end of
this instruction manual).

Electromagnetic switch Electromagnetic switch


for oil pump for slide adjusting motor

Thermal relay Thermal relay


reset button reset button
Rated current Rated current
setting scale setting scale
• The actual shape of the electromagnetic switch may differ slightly.

248
Section D OPERATION 6. RESETTING FAULTS

6.10 STICKING

Sticking is a condition where the upper and lower dies ram into each other in the vicinity of
bottom dead center, thereby preventing slide movement.
The "!" symbol will be displayed on the operator interface terminal. When you access the
3.8.3 Fault Screen (pg. 178) on the MAINTENANCE screen, the message CRANK MOTION
MONITOR DETECT will be displayed.
When unsticking the press machine, follow the instructions described in Section A SAFETY,
(Continued) (pg. 30).

CAUTION
• Be sure to follow the procedure described below when performing unsticking operations.
Never use the slide adjustment device to attempt to unstick the press machine. This can
damage the slide adjustment mechanism.

1 Set the OPERATION SELECT key switch to OFF.

2 On the "DIE CHANGE" main menu on the


operator interface terminal, press the "UNIT
OPERATION" submenu touchbutton to display
the UNIT OPERATION screen.
(See 3.6.1 UNIT OPERATION Screen (pg.
150).)

Press "UNSTICKER" on the OPERATION


ITEM list on this screen.

3 Press the FUNCTION button corresponding to ON (see screen element (6) in Common
Screen Elements (pg. 115)) to release the hydraulic pressure of the hydraulic overload
protector.

4 Stop the slide at top dead center according to the procedure in Section D OPERATION,
6.4 HYDRAULIC OVERLOADS (pg. 243).
Confirm that the hydraulic overload protector builds up to the normal hydraulic pressure.

5 Perform all the steps of the procedure described in Section A SAFETY, 6. SAFETY PRO-
CEDURES DURING ADJUSTMENT (pg. 33) again.
Eliminate the cause of sticking.

6 Perform Step 7 and the subsequent steps of the resetting procedure explained in Section
D OPERATION, 6.4 HYDRAULIC OVERLOADS (pg. 243).

249
Section D OPERATION 7. ADJUSTMENT

7. ADJUSTMENT
Complete the inspection and operation described in Section D OPERATION, 4.2 ROUTINE
INSPECTION AND OPERATION (pg. 188) before performing adjustments.

7.1 SLIDE ADJUSTMENT

CAUTION
• Do not use the slide adjustment device for any purpose other than slide adjustment.
The slide adjustment device has no pre-loading capability to press the upper and lower
dies together.
If the slide adjustment device is used for performing presswork or for pressing the upper
and lower dies together, the motor can overheat or slide adjustment components can be
broken.

The die height indicator displays the distance between the top of the bolster and the bottom of
the slide when the slide is at bottom dead center. Slide adjustment must be performed by
qualified personnel according to the procedure described below.

250
Section D OPERATION 7. ADJUSTMENT

7.1.1 Manual Slide Adjustment

Perform the following procedure to manually adjust the die height:

1 Perform steps (2) and (7) described in Section A SAFETY, 6. SAFETY PROCEDURES
DURING ADJUSTMENT (pg. 33).

2 Confirm that there are no other operators present in the point of operation.

3 On the "DIE CHANGE" main menu on the operator interface terminal, press the "UNIT
OPERATION" submenu touchbutton to display the UNIT OPERATION screen. (See
3.6.1 UNIT OPERATION Screen (pg. 150).)
Make sure that no operation item is selected on this screen, then operate the UNIT
OPERATION SLIDE ADJUST "UP/DOWN" button described in item No. 21 in
2.7 FUNCTION AND OPERATION (pg. 96).

4 Confirm that the message OPERATION READY is displayed in the interlock information
field.
If any other message is shown, reset the applicable interlock according to Section D
OPERATION, 6.1 INTERLOCK INFORMATION MESSAGE LIST (pg. 198).

5 Press the FUNCTION button corresponding to raising or lowering the slide (see screen
element (6) in Common Screen Elements (pg. 115)) to move the slide up or down.
Release the button to stop slide motion.
Perform this adjustment while observing the die, the knockout bar and the die-height
meter.

NOTE • Die conditions permitting, AIDA recommends that slide adjustments be per-
formed with the slide at the preset stop position.

251
Section D OPERATION 7. ADJUSTMENT

7.1.2 Auto Slide Adjustment

Adjust the slide automatically to the preset target value of the die height.

Perform steps (2) and (8) described in Section A SAFETY,5. USING THE PRESS
1 MACHINE SAFELY (pg. 24).

Confirm that no other worker remains inside the danger limit zone.
2

Press the "DIE CHANGE" in the MAIN MENU and the "UNIT OPERATION" in the
3 SUB MENU on the operation display to display the "UNIT OPERATION" screen.
(Refer to 3.6.1 UNIT OPERATION Screen (pg. 150) .)
Press the "SLIDE ADJ.AUTO DIE CHANGE HEIGHT" or "SLIDE ADJ.AUTO PROD-
UCT HEIGHT" key on this screen.

Press the "SETTING" on the screen and enter a desired target value of the die height.
4

Check that the message "OPERATION READY" is displayed in the interlock


5 information field. If any other message is displayed, reset the message referring to
Section D OPERATION, 6.1 INTERLOCK INFORMATION MESSAGE LIST (pg. 198).

Push the function button for which "START" is displayed on the function button
6 functionality display ((6) in Common Screen Elements (pg. 115)). Then, the slide comes
down or goes up until it automatically stops at the target die height value. To
temporarily stop the slide during automatic adjustment, push the function button cor-
responding to the "STOP" displayed on the functionality display.
Before starting the adjustment procedure, confirm that the die and the knockout bar
do not interfere with the slide.
(The current die height value after the slide stops automatically may slightly deviate
from the target value due to slippage of the brake.)

252
Section D OPERATION 7. ADJUSTMENT

7.2 COUNTERBALANCE CAPACITY ADJUSTMENT

To allow the balancer capacity to correspond to the mass of the upper die, adjust the air pres-
sure of the balancer.

WARNING
・Before starting the operation and the slide adjusting procedure, properly adjust the
balancer capacity so that it corresponds to the mass of the upper die. The
adequate balancer capacity is to be achieved by adjusting the balancer air
pressure according to the "Relation between upper die mass and balancer air
pressure" nameplate.
If the balancer capacity does not correspond to the mass of the upper die, the slide
can come down unexpectedly to cause an accident resulting in injury or death.

Stop the slide at the top dead center. Then, perform steps (2) and (8) described in
1 Section A SAFETY, 5. USING THE PRESS MACHINE SAFELY (pg. 24).

Confirm that no other worker remains inside the danger limit zone.
2

Press the "DIE CHANGE" in the MAIN MENU and the "UNIT OPERATION" in the
3 SUB MENU on the operation display to display the "UNIT OPERATION" screen.
(Refer to 3.6.1 UNIT OPERATION Screen (pg. 150).)
Press the "UPPER DIE MASS" key on this screen.

(Continued on the next page)

253
Section D OPERATION 7. ADJUSTMENT

(Continued)

Press the "SETTING" key for the UPPER DIE MASS on the screen to display the
4 numeric keys on the lower section of the screen.
Input a desired upper die mass by means of the numeric keys and confirm your entry
to start the adjustment.

NOTE The balancer air pressure is not adjusted unless the slide is located within
the air pressure adjustable range (top dead center).

254
Section D OPERATION 7. ADJUSTMENT

7.3 SETTING TIMING SWITCHES

WARNING
• Timing switch settings must be performed by qualified personnel in cooperation
with a qualified electrician.
Settings made by unqualified personnel may lead to an accident causing per-
sonal injury or death.

• Except for ejector and automation device (option) data, do not change the data
settings made by AIDA.
If changed, personal injury or death can be caused due to unexpected actuation
and motion.

• AIDA will not be held liable for any accidents resulting in personal injury or death
nor for any damages to the press machine that are caused by entering data that
is different from the preset data entered by AIDA at the time the press machine
was shipped from the factory, or by the usage of data entered by the user on a
user-furnished device without consulting AIDA.

• Be sure to set the OPERATION SELECT switch to OFF before operating the tim-
ing switch.
Otherwise, the slide or other related devices may inadvertently start, leading to
an accident causing personal injury or death.

7.3.1 What is a Timing Switch?

A timing switch is used to synchronize ejectors, automation devices (option), and other equip-
ment with the press machine. For instance, if you require an ejector to actuate at a press
machine crank angle of 10° and stop at 20°, you can set this operational sequence using a
timing switch.
In this case, you would set the ON angle to 10° and the OFF angle to 20°.
For cam settings, see 7.3.4 Cam Allocation List (pg. 257).
To change the timing switch settings, set the DATA EDIT "OFF" • "ON" Switch to "ON".
To make data settings using the operator interface terminal, see Section D OPERATION,
3.5.3 Timing Switch Settings Screen (pg. 138).

7.3.2 Types of Timing Switch Cams

<< Regular Cams >>


A cam that turns on at a preset ON angle and turns off at a preset OFF angle.

<< Timer Cams >>


A cam that turns on at an ON angle and turns off when a preset time has elapsed. No OFF
angle is used for timer cams.
The time can be set between 0.1 to 9.9 seconds in increments of 0.1 seconds.
When a cam is not used as a timer cam (i.e., the TIMER is set to "0"), the cam will function
as a regular cam and will simply operate according to the ON and OFF angles.

(Continued on the next page)

255
Section D OPERATION 7. ADJUSTMENT

(Continued)

<< Automatic Gain Angle Cams >>


These cams allow the ON and OFF angles to gain (advance) in proportion to the press
machine speed (spm).
The gain angle settings are made by specifying the maximum gain angle for the maximum
press machine speed (spm).
When a cam is not used as a gain angle cam (i.e., the ON GAIN and OFF GAIN are set to
"0"), the cam will function as a regular cam and will simply operate according to the ON and
OFF angles.
ON GAIN .........Sets the gain angle for the ON angle.
OFF GAIN........Sets the gain angle for the OFF angle.

7.3.3 About the Automatic Gain Angle Function

The gain angle function automatically adjusts the signaling timing for equipment actuation (for
example, the timing of peripheral device ON and OFF signals) in relation to changes in the
press machine speed.
If the gain angle function is not used (i.e., no gain angle is set), devices synchronized with the
press machine operation will lag behind press machine motions as the press machine speed
increases.
When comparing operation at two different press machine speeds, for example at 30 spm and
at 100 spm, the responsiveness of press machine peripheral devices would lag more at 100
spm than at 30 spm. In this scenario, although the actuator is actuating at 50° when the press
machine is running at 30 spm, at 100 spm it would be actuating at 70°, etc.
To compensate for such time delays, the gain angle function can be effectively used to offer
better responsiveness to increases in press machine speed.
<< Determining the Gain Angle Settings >>
The gain angle settings for ON GAIN and OFF GAIN should be set by specifying the maxi-
mum gain angle at the maximum press machine speed (spm).
Calculate the maximum gain angle (the setting value) at the maximum press machine speed
(spm) by using the formula below, which is based on your actual press machine speed
(spm) and the desired gain angle.
If the maximum press machine speed (spm) equals the actual press machine speed (spm),
or the motor used is a fixed-speed type, the desired gain angle value becomes the setting
value.
The maximum speed (spm) of your press machine is shown on the specification plate.
Desired gain angle
Gain setting value "A" = × Max. spm
Actual speed
Example) Actual press machine speed = 65 spm, Desired gain angle = 10°, Max press
machine speed = 75 spm.
10
×75 = 11.5 → 11
65
Therefore, the setting would be "11".
When you want to individually set the ON GAIN and OFF GAIN, determine each setting
value separately.

NOTE • AIDA recommends that the ON GAIN and OFF GAIN be set to the same value.
• If the ON GAIN and OFF GAIN are set to different values, it is very important that
the gain OFF ANGLE does not precede the gain ON ANGLE. Otherwise, the
cam outputs may be reversed.

256
Section D OPERATION 7. ADJUSTMENT

7.3.4 Cam Allocation List

Note that your actual cam allocation may be different from the allocation pattern shown in this
list due to differences in options, etc.
To confirm your actual cam allocation, see the electrical circuit drawings in Section E MAIN-
TENANCE, 7. DRAWINGS (pg. 362), 7.2 Electrical Drawings (Refer to separate volume).

Cam Standard Cam Type Is the data stored in the


data bank?
1 Mechanical device-1 Timer cam Yes
2 Mechanical device-2 Timer cam Yes
3 Mechanical device-3 Timer cam Yes
4 Mechanical device-4 Timer cam Yes
5 Reserved Gain angle cam Yes
6 Reserved Gain angle cam Yes
7 Reserved Gain angle cam Yes
8 Reserved Gain angle cam Yes
9 Variation circuit-1 Gain angle cam Yes
10 Variation circuit-2 Gain angle cam Yes
11 Variation circuit-3 Gain angle cam Yes
12 Variation circuit-4 Gain angle cam Yes
13 Variation circuit-5 Regular cam Yes
14 Variation circuit-6 Regular cam Yes
15 Lower die cam check Regular cam Yes
16 Brank set check Regular cam Yes
Top dead center (for
17 transfer)
Regular cam No

Reserved (for
18 master)
Regular cam No

Reserved (for
19 master)
Regular cam No

Reserved (for
20 master)
Regular cam No

Bottom dead center


21 Regular cam No
(for die cushion)
Top dead center (for
22 Regular cam No
die cushion)
23 Reserved Regular cam No
Reserved (for
24 master)
Regular cam No

257
Section D OPERATION 7. ADJUSTMENT

7.3.5 How to Make Cam ON/OFF Settings

(1) Angle Settings


If you want to change the cam output (ON or OFF) based on the crank angle, enter '0’
as the ON TYPE and OFF TYPE setting for the cam number being used, then input the
ON and OFF angle settings.
Note that an angle setting of '0' has to be entered into both the ON TYPE and OFF
TYPE setting fields when using angle settings.

(2) Process Settings


If you want to change the cam output based on the process number and the slide posi-
tion, enter process numbers between 1~30 into the ON TYPE and OFF TYPE fields of
the cam number being used. The output will change when the slide passes the desig-
nated position in the specified motion program process. Process settings are used when
you want to change cam signal outputs in synchronization with the motion program.
Note that a process number between 1~30 has to be entered into both the ON TYPE
and OFF TYPE setting fields when using process settings.

(3) Position Settings (Region Settings)


If you want to change the cam output based on a slide position region, enter '31' into the
into the ON TYPE and OFF TYPE fields of the cam number being used. This method is
used when you want to turn cam signal outputs ON and OFF while the slide is within a
specific region.
The output timing differs depending on the positional relationship of the ON and OFF
positions.

<< If the ON position is higher than the OFF position >>


The cam signal output changes to ON when the slide is located between the ON and
OFF positions. When the slide is at any position outside this region, the cam signal out-
put turns OFF.

<< If the ON position is lower than the OFF position >>


The cam signal output changes to OFF when the slide is located between the ON and
OFF positions. When the slide is at any position outside this region, the cam signal out-
put turns ON.
Note that the position designation setting '31' has to be entered into both the ON TYPE
and OFF TYPE input fields when using position settings.

(4) Downstroke Settings


If you want to change the cam output based on the slide passing a designated position
while downstroking, enter '32' into the ON TYPE and OFF TYPE fields of the cam num-
ber being used. This method is mainly used when the crank shaft motion is reciprocal
(pendulum) motion. The cam signal status does not change when the slide passes the
designated position while upstroking.
It is possible to use downstroke ON/OFF settings in combination with the upstroke ON/
OFF settings described below.

(5) Upstroke Settings


If you want to change the cam output based on the slide passing a designated position
while upstroking, enter '33' into the ON TYPE and OFF TYPE fields of the cam number
being used. This method is mainly used when the crank shaft motion is reciprocal (pen-
dulum) motion. The cam signal status does not change when the slide passes the desig-
nated position while downstroking.
It is possible to use upstroke ON/OFF settings in combination with the downstroke ON/
OFF settings described above.

258
Section D OPERATION 7. ADJUSTMENT

7.3.6 Examples of Timing Switch Settings and Outputs

Using a sample Flex motion program where the slide passes through bottom dead center
twice, the following section explains how to set each of the timing switches and their accom-
panying outputs.

Sample Flex Motion Program Settings


Top dead
Process 1 2 3 4 5 6 7 center
Slide Pos. 100.0 10.0 0.0 100.0 10.0 0.0 30.0 No-load zone. No-load zone.
Slide Vel 50 5 50 50 5 50 0
100.0 mm 100.0 mm
Pause 0 0 0 0 0 0 0 Proc. 4
Proc. 1
S Decel. 0 0 0 0 0 0 0 30.0 mm Proc. 3
0 0 0 0 0 0 0 Proc 6 10.0 mm 10.0 mm
Aux function
0 0 0 0 0 0 0 BDC Proc. 5 BDC Proc. 2
Change Speed

Sample Timing Switch Settings


Cam No. 1 2 3 4 5 6
ON Type 0 1 31 31 32 33
ON Angle (Deg.) 120 0 0 0 0 0
ON Position (mm) 0.0 80.0 50.0 10.0 50.0 10.0
OFF Type 0 2 31 31 32 33
OFF Angle (Deg.) 180 0 0 0 0 0
OFF Position (mm) 0.0 0.0 10.0 50.0 10.0 50.0
Delay Time (sec) 0 0 0 0
Designation method
[0] → Angle, [1] ~ [30] → Process, [31] → Position, [32] → Downstroke Position,
[33] → Upstroke Position

工程
Process 非加工領域
No-load zone 1 2 3 4 5 6 非加工領域
No-load zone

80.0mm
50.0mm 120度
120deg.
10.0mm
180度
180deg.
0.0mm

CAM1

CAM2

CAM3

CAM4

CAM5

CAM6

Motion and Timing Switch Output Chart

(Continued on the next page)

259
Section D OPERATION 7. ADJUSTMENT

(Continued)

Explanatory Table of the ON and OFF Signals for Cams 1 thru 6


ON Position OFF Position ON Region
Fwd The signal turns ON when the The signal turns OFF when the
crankshaft passes the 120- crankshaft passes the 180-
degree position in clockwise degree position in clockwise
motion. motion.
(Bottom dead center)

Rev As shown in the illustration to The signal turns OFF when the
the right, the ON region is where crankshaft passes the 120-
Cam 1 the crankshaft passes through degree position in counterclock-
(Angle the 180-degree position (bottom wise motion.
Setting) dead center) in counterclock-
wise motion.

Rev. The signal turns ON when the For each motion direction, when
crankshaft passes the 90- the crankshaft direction of rota-
in ON degree position in clockwise tion is reversed after entering
regio motion or the 180-degree posi- the ON region, the signal will
tion in counter-clockwise motion. turn OFF at the same position it
n turned ON.

The signal turns ON when the The signal turns OFF when the
slide passes through the 80 mm slide passes through bottom
slide position when going from dead center when going from
the Process 1 position to the the Process 2 position to the
Process 2 position (from 100 Process 3 position (from 10 mm
mm to 10 mm) in the program. to bottom dead center) in the
Cam 2 program.
(Process Setting)
If the setting is greater than the If the setting exceeds the region,
region, the ON position will be the OFF position will be the
the region limit, which in this region limit, which in this case
case would be the 10 mm or 100 would be the 10 mm or 100 mm
mm position. position.

The signal turns ON when the The signal turns OFF when the
slide position enters the range slide position reaches the 50
between the 10 mm and 50 mm mm position or higher or the 10
positions. mm position or lower.
Cam 3
(Position Setting) (This is an ÅeON regionÅf set-
ting.)

’ON Region’ Setting: If the ON position setting is higher than the OFF position setting,
the signal will be ON within the set range and OFF outside the set range.

The signal turns ON when the The signal turns OFF when the
slide position is at the 50 mm slide position enters the range
position or higher, or the 10 mm between the 10 mm and 100
position or lower. mm positions.
Cam 4
(Position Setting) (This is an ÅeOFF regionÅf set-
ting.)

’OFF Region’ Setting: If the ON position setting is lower than the OFF position setting,
the signal will be OFF within the set range and ON outside the set range.

260
Section D OPERATION 7. ADJUSTMENT

The signal turns ON when the The signal turns OFF when the
slide downstroke motion passes slide downstroke motion passes
through the 50 mm position. through the 10 mm position.
Cam 5
(Downstroke
Setting)
If the ON position setting is lower than the OFF position setting, the ON region will
encompass a wide range including top dead center, and signal will turn ON simultane-
ously with the timing setting.

The signal turns ON when the The signal turns OFF when the
slide upstroke passes through slide upstroke passes through
the 10 mm position. the 50 mm position.
Cam 6
(Upstroke Setting)
It is possible to make region settings that span across top dead center or bottom dead
center by making the ON and OFF settings different for the downstroke and
the upstroke.

NOTE
•If you operate the press in STEP FEED or ORIGIN POINT Return mode after stopping the
slide in the middle of a press operation, the cam signal will continue to maintain the state it
was in at the time the press stopped. However, once you complete the STEP FEED or
ORIGIN POINT Return operation, the cam signal will change to reflect the current crank
position. This is because the press considers Inch mode operations as being equivalent to
a stopped condition.

•When the ON and OFF settings are not angle settings, the ON and OFF position data is
used and the ON and OFF angle data is ignored. Likewise, when the ON and OFF set-
tings are angle settings, the ON and OFF angle data is used and any other data is ignored.

•A delay time can be set for cams 1 through 4. When a delay time value other than Åg0Åh
is inputted, an ON signal will turn OFF after the delay time has elapsed. However, please
note that you must set an appropriate OFF setting even when a delay time setting has
been made. If no OFF setting is inputted, the OFF operation will not be performed after the
signal turns ON. Also note that if you input a delay time setting value that is greater than
the time required to complete one cycle, the ON signal will never turn OFF.

261
Section D OPERATION 7. ADJUSTMENT

7.4 MOTION PROGRAM AUXILIARY FUNCTIONS

WARNING
• Motion program settings must be performed by qualified personnel in coopera-
tion with a qualified electrician.
If it is done by an unqualified person, it could result in personal injury or death.

• Do not make changes to any control circuits except for auxiliary output signals
and auxiliary motion completion input signals. If changes are made, the normal
functionality of the press machine will be impaired and could result in personal
injury or death.

When setting up the control circuit, follow the instructions given in Section A SAFETY, (Contin-
ued) (pg. 30).
When changing the motion program settings, set the DATA EDIT "OFF" • "ON" Switch on the
operation panel to "ON" .
For the procedure for making data settings using the operator Interface terminal, see item of
Section D OPERATION, 3.5.1 Motion Selection /Setting Screen (pg. 127).

7.4.1 Overview of Auxiliary Functions

The following motions can be done by inputting Auxiliary Function settings in the motion pro-
gram and installing the necessary wiring.

(1) The slide stops at a specific position, and then performs some auxiliary function (such
as mechanical motions not involving slide motion, such as pressurizing or heating).
Then, after confirming that the auxiliary motion has been completed, it continues on to
the next process. If the completion of an auxiliary motion is not a requirement, auxiliary
motions can be specified by using timing switch signals.
(2) Just like a timing switch, the motion program begins performing auxiliary motions from
a specific slide position without stopping the press machine, and, in cases where the
auxiliary motions are not completed by the time the slide target position is reached, it
halts the slide at a target position until the auxiliary motions are completed. If the auxil-
iary motions are completed before the slide target position is reached, the press
machine does not stop.
(3) When there is a possibility that peripheral devices such as conveyance actuators and
robot hands might collide with the slide or the dies, it is possible to set up a control cir-
cuit that outputs an auxiliary motion signal once the peripheral device has been
retracted to a position where it will not collide with the press machine. Because of this
auxiliary function, when there is the possibility of a collision with a peripheral device, it
is possible to pause press machine operation at a position where a collision is not pos-
sible. Once the peripheral device has been retracted, the press machine automatically
continues operation. If the press machine and peripheral devices are synchronized so
that they cannot collide, it is possible to control the press machine so that it does not
have to stop.
(4) [0]:Outputs no auxiliary output signal
[1] ~ [15]:Outputs the auxiliary function code corresponding to the set number.
Codes [1] to [9] are used for the die cushion. Codes [10] to [15] are used for peripheral
devices.

262
Section D OPERATION 7. ADJUSTMENT

7.4.2 Signal Names and Auxiliary Function Codes

(1) Output Signals (see Electric Circuit Diagram PM-05101 in Section E MAINTENANCE,
7. DRAWINGS (pg. 362), 7.2 Electrical Drawings (Refer to separate volume))
8507 ..... Auxiliary Function Slide Stop Output
When the auxiliary function value is set to 1~7, this signal is turned ON when
the slide stops. It is turned OFF when signal 9707 (Auxiliary Function Comple-
tion Input) shown below is turned ON.
When the auxiliary function value is set to 0, it is always OFF.
8508 ..... Auxiliary Function Code 1
8509 ..... Auxiliary Function Code 2
8510 ..... Auxiliary Function Code 4
8512 ..... Auxiliary Function Code 8
(2) Input Signals (see Electric Circuit Diagram in Section E MAINTENANCE,
7. DRAWINGS (pg. 362), 7.2 Electrical Drawings (Refer to separate volume))
9707 ..... Auxiliary Function Completion Input
(3) The motion program auxiliary function settings and the relationship between outputted
signals are shown below.
Auxiliary Function
Value 0 1 2 3 4 5 6 7

Auxiliary Function OFF ON OFF ON OFF ON OFF ON


Code 1
Auxiliary Function OFF OFF ON ON OFF OFF ON ON
Code 2
Auxiliary Function
Code 4 OFF OFF OFF OFF ON ON ON ON

7.4.3 An Example of Auxiliary Function Usage

The following is an example of how to set up a motion program which stops the slide at a spe-
cific position and then performs auxiliary motions.

<<Press Machine Specifications and Slide Motion Setup Details>>


Stroke Length: 200 mm; Motion Selection: Crank Motion.

<<Overview of Slide Motion>>


(1) At the base spm speed, the slide descends from the preset stop position to a slide
height of 100 mm, and then stops.
(2) The air actuator is actuated.
(3) When the limit switch for air actuator operation completion goes ON, the slide contin-
ues to descend through the forming portion of the stroke (from 100 mm through 0 mm)
at 30% of the no load spm speed. When the slide reaches bottom dead center the
base spm speed is resumed.
(4) The slide is raised to the preset stop position at the base spm speed, thereby complet-
ing one cycle.
Preset Stop Position
no load spm Speed

Auxiliary Motion:
The Air Actuator is Actuated.
no load spm Speed Forming Stroke Speed Setting: 30% of
the no load spm Speed

(Continued on the next page)

263
Section D OPERATION 7. ADJUSTMENT

(Continued)

<<Setting Up the Motion Program>>


The motion consists of two processes (see item (3) of 3.5.1 Motion Selection /Setting
Screen (pg. 127)), and the settings for these processes are shown in the following table.
PROC. 1 2
Slide pos.(mm) 100 0
SL Velocity.(%) 30 0
SL Velocity.(mm/s) --- ---
Pause time(s) 0 0
AUX. Function 1 0
Change speed 0 0
If an auxiliary function is used, set up the program for the forming portion of the stroke only.
If program settings are made for the no-load portions of the stroke (from the preset stop
position to the forming start position and from the forming completion position to the preset
stop position), the auxiliary function will not work correctly. The slide speed in the no-load
portion of the stroke will become the maximum speed (the maximum no load spm speed set-
ting made on the RUN screen).
For Slide, Position, Velocity, Pause, and Acceleration and Deceleration details, see item of
3.5.1 Motion Selection /Setting Screen (pg. 127).

264
Section D OPERATION 8. CHANGING DIES

8. CHANGING DIES
When setting up the control circuit, follow the instructions given in Section A SAFETY,
4.2 ROUTINE INSPECTION AND OPERATION (pg. 188).

WARNING
(1) When it is necessary to place your hand between the upper and lower dies
in order to change or adjust dies, or for maintenance or repairs, first be sure
to perform steps (1) through (4) described in Section A SAFETY,
6. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).

(2) Before operating the moving bolster at the time of carry-out/carry-in of the
die, be sure to check that no worker remains in the operating range of the
moving bolster and that no obstacles (such as a tool) which can interfere
with the bolster operation are left there. In addition, never enter the
operating range of the moving bolster while it is in operation. Be aware that
an accident resulting in injury or death can occur if you enter the
aforementioned range.

(3) Die hoisting work must be performed by qualified personnel in compliance


with applicable laws and regulations.
If the die hoisting work is performed by any unqualified person, the dies can
drop out of position.
(4) Be sure to follow the steps of procedure described below to unload the die
from the moving bolster.
(a) Bring the moving bolster to the outside end.
(b) Unclamp the lower die fastening device or the lower die clamper of the
moving bolster or the lower die clamper.
(c) Hoist the die on the moving bolster to move it to the storage position while
taking care of horizontalness and parallelism of the die.
(5) Be sure to follow the steps of procedure described below to load the die in
the moving bolster.
(a) Check that the moving bolster is at the outside end.
(b) Put the die on the moving bolster (do not apply a physical shock to the
die) while taking care of horizontalness and parallelism of the die and
place the die correctly in the moving bolster.
(c) Clamp the lower die fastening device or the lower die clamper of the mov-
ing bolster.

265
Section D OPERATION 8. CHANGING DIES

CAUTION
• Perform die changes under the direct supervision of authorized personnel.

• Die hoisting work must be performed by qualified personnel in compliance with


applicable laws and regulations.
If the die hoisting work is performed by any unqualified person, the dies can drop
out of position.

• When lowering the slide to bottom dead center after putting dies in position, oper-
ate the slide while visually confirming that the knockout pin of the dies, etc., that
protrude above the top face of the die do not come in contact with the bottom of
the slide.

• Before removing dies, use the slide adjust device to separate the slide from the
upper die.
Otherwise, the upper die could possibly remain attached to the bottom of the
slide, and when the slide is raised it could also be lifted and then subsequently
fall.

• When stopping the air supply from the source for three hours or longer while die
clampers are in use, lower the slide to bottom dead center to prevent misalign-
ment between the upper and lower dies.
Otherwise, the upper die may be misaligned with the lower die due to a decrease
in die clamper hydraulic pressure.

When you manually change the die, it is necessary to carry out the die change while visually
checking the operation of each device.

266
Section D OPERATION 8. CHANGING DIES

8.1 MANUAL DIE CHANGE


8.1.1 Die take in

Hoist the die with a crane or the like and carefully put it on the moving bolster
1 (hereinafter referred to as the bolster) which is located outside the press machine.
Place the die in the predetermined position and fix it there.

Proparatory operation (only for the press No. 1)


2 Set the operation selector on the die cushion operation panel at "UNIT" and bring the
die cushion to "DIE CHANGE POSITION".

Bring the guard to the upper end.


3
Clean up the top surface of the bolster running rail.
4
Select "DIE CHANGE" from the MAIN MENU and "UNIT OPERATION" screen from
5 the SUB MENU on the operation display. When nothing is selected for UNIT
OPERATION selection on the operation display terminal . Set the "MANUAL/AUTO"
switch of the "UNIT OPERATION" at "MANUAL" on the MB fence right side sub
operation panel (for the right bolster) or on the MB fence left sub operation panel(for
the left bolster).
Check that the MB RUN "IN" button with light on the operation panel flickers. If the
light stays off, check the relevant interlock message.
When the MB RUN "IN" button with light is pushed, the bolster starts running. When it
is released, the bolster stops.
Run the bolster to the normal position inside the press by carrying out the above
operation.
When the bolster reaches the position, the MB RUN "IN" button with light comes on.

Check that the bolster stays in the normal position inside the press machine. Then,
6 lower the guard to the lower end.

Check that the MB "DOWN" button with light on the MB fence right side sub operation
7 panel (for the right bolster) or on the MB fence left sub operation panel(for the left
bolster) is flickering. If it stays off, check the relevant interlock message.
When the MB "DOWN" button with light is pushed, the bolster starts coming down.
When the bolster reaches the lower end, the MB "DOWN" button with light comes on.

Adjust the slide so that the distance from the bottom face of the slide at the bottom
8 dead center to the top face of the bolster (value indicated on the die height indicator)
is larger than the installing height of the die to be carried in by approximately 10 mm.
See Section D OPERATION, 7.1 SLIDE ADJUSTMENT (pg. 250).
(Continued on the next page)

267
Section D OPERATION 8. CHANGING DIES

(Continued)

Move the slide near to the top face of the upper die through the slide adjustment, so
9 that the clearance between the top face of the upper die and the bottom face of the
slide is 0.1 to 1 mm.
See Section D OPERATION, 7.1 SLIDE ADJUSTMENT (pg. 250).

Clamp the die by means of the upper die clamper .


10
Set the "OPE. SELECTOR" switch at "STEP FEED", "INCH" or "HOME POS.
11 RETURN" and stop the slide at the preset stop position (0°).
See Section D OPERATION, 4.2 ROUTINE INSPECTION AND OPERATION (pg.
188).
After the slide has stopped at the preset stop position, set the "OPE. SELECTOR"
switch at "OFF".

Adjust the balancer capacity.


12 See Section D OPERATION, 7.2 COUNTERBALANCE CAPACITY ADJUSTMENT (pg.
253).

For the die data which have been used by this press machine for production, select
13 the "LINE" in the operation selector on the die cushion operation panel. Place the die
cushion in the "LINE SET" state and raise the die cushion pad.
For the die data which have not been used by this press machine for production, carry
out the "CALIBRATION" operation through the die cushion operation panel and save
the calibration data in the data bank as appropriate.
(Only for the press No. 1)

Set the "OPE.SELECTOR" switch at "INCH." Run the slide under the "INCH" mode by
14 two or three strokes to verify that no fault occurs.
After the verification, bring the slide to the preset stop position.

While carrying out a trial run (trial punching) under the "SINGLE" mode, adjust the set
15 die height.

<In the case the set die height is unknown>


While carrying out a trial run, adjust the slide gradually in the lowering direction.
The value indicated on the die height indicator at which a required product is pro-
duced is the set die height.
It is recommended to record the set die height so as to facilitate the production using
the same data for the second time and beyond.

<In the case the set die height is known>


Carry out operation according to the customer's work standard.

268
Section D OPERATION 8. CHANGING DIES

8.1.2 Die take out

Set the "OPE. SELECTOR" switch at "STEP FEED", "INCH" or "HOME POS.
1 RETURN" and stop the slide at the set point (0°).
See Section D OPERATION, 4.2 ROUTINE INSPECTION AND OPERATION (pg.
188).
After the slide has stopped at the preset stop position, set the "OPE. SELECTOR"
switch at "OFF".

Preparatory operation (only for the press No. 1)


2 Set the operation selector on the die cushion operation panel at "UNIT" and the bring
die cushion to "DIE CHANGE POSITION".

In the case a space is required between the upper die and lower die when the slide is
3 at the bottom dead center due to the customer's die condition, lift the slide by a
required amount through the slide adjustment.
See Section D OPERATION, 7.1 SLIDE ADJUSTMENT (pg. 250).

Set the "OPE. SELECTOR" switch at "STEP FEED" or "INCH" and stop the slide at
4 the bottom dead center.
See Section D OPERATION, 4.2 ROUTINE INSPECTION AND OPERATION (pg.
188).
After the slide has stopped at the bottom dead center, set the "OPE. SELECTOR"
switch at "OFF".

Lower the slide through the slide adjusting device so that the upper and lower dies
5 slightly come in contact with each other. At this time, do not press the dies firmly.

Unclamp the upper die clamper.


6
Lift the slide by 3 to 5 mm through the slide adjustment, and confirm that the top face
7 of the upper die is fully separated from the bottom face of the slide.
See Section D OPERATION, 7.1 SLIDE ADJUSTMENT (pg. 250).

Set the "OPE. SELECTOR" switch at "STEP FEED", "INCH" or "HOME POS.
8 RETURN" and stop the slide at the set point (0°).
See Section D OPERATION, 4.2 ROUTINE INSPECTION AND OPERATION (pg.
188).
After the slide has stopped at the preset stop position, set the "OPE. SELECTOR"
switch at "OFF".

(Continued on the next page)

269
Section D OPERATION 8. CHANGING DIES

(Continued)

Clean up the top surface of the bolster running rail.


9
Select "DIE CHANGE" from the MAIN MENU and "UNIT OPERATION" screen from
10 the SUB MENU on the operation display. When nothing is selected for UNIT
OPERATION selection on the operation display terminal . Set the "MANUAL/AUTO"
switch of the "UNIT OPERATION" at MANUAL on the MB fence right side sub
operation panel (for the right bolster) or on the MB fence left sub operation panel (for
the left bolster).
Check that the MB "LIFT" button with light on the MB fence right side sub operation
panel (for the right bolster) or on the MB fence left sub operation panel (for the left
bolster) is flickering. If is stays off, check the relevant interlock message.
When the MB "LIFT" button with light is pushed, the bolster starts going up.
When it reaches the upper end, the MB "LIFT" button with light comes on.

Bring the guard to the upper end.


11

Check that the MB RUN "OUT" button with light on the MB fence right side sub
12 operation panel (for the right bolster) or on the MB fence left sub operation panel (for
the left bolster) is flickering. If it stays off, check the relevant interlock message.
When the MB RUN "OUT" button with light is pushed, the bolster starts running.
When it is released, the bolster stops.
Run the bolster by taking the aforementioned operation until its outside end is
reached.
When it reaches the outside end, the MB RUN "OUT" button with light comes on.

Remove the die on the bolster.


13

270
Section D OPERATION 8. CHANGING DIES

8.2 AUTO DIE CHANGE


8.2.1 Auto die change take in

Hoist the die with a crane or the like and carefully put it on the bolster which is located
1 outside the press machine.
Place the die in the predetermined position and fix it there.
For the right MB, push the "NEXT DIE PREPARATION" button on the main operation
panel.
For the left MB, push the "NEXT DIE PREPARATION" button on the sub operation
panel.

Preparatory operation (only for the press No. 1)


2 Set the operation selector on the die cushion operation panel at "AUTO DIE
CHANGE".

Next die selecting operation


3 Set the "OPE. SELECTOR" switch at "DIE CHANGE." Select the "DIE CHANGE"
from the MAIN MENU and select the "UNIT OPERATION" from the SUB MENU.
Then, select the "AUTO DIE CHANGE" on the "UNIT OPERATION" screen. Push the
"BOLSTER SELECTION" function button to select "TAKE IN".
In this state, select the "RECIPE" from the MAIN MENU and the "NEXT DIE SELECT"
from the SUB MENU. On the NEXT DIE SELECT screen, select the next die and
press the "NEXT DIE SELECT COMPLETE". Select again the "DIE CHANGE" from
the MAIN MENU and the "UNIT OPERATION" from the SUB MENU. Check that the
"AUTO DIE CHANGE" has been selected and the "TAKE IN" has been selected in the
"BOLSTER SELECTION".

<<Caution>>
If you operat the "BOLSTER SELECTION" in this stage, the "NEXT DIE SELECT
COMPLETED" selected in the "NEXT DIE SELECT" of the SUB MENU under the
"RECIPE" of the MAIN MENU will be cleared.

Push the "NEXT DIE PREPARATION" button .


Check that the light comes on instead of flickering.

When the "START" function button is pushed, the automatic die change "TAKE IN" is
4 started. To interrupt the operation, push the "STOP" function button. The operation is
stopped. The operation flowchart can be checked on the "DIE CHANGE MONITOR"
of the SUB MENU under the "DIE CHANGE" of the MAIN MENU.
(Continued on the next page)

271
Section D OPERATION 8. CHANGING DIES

(Continued)

272
Section D OPERATION 8. CHANGING DIES

8.2.2 Auto die change take out

Set the "OPE. SELECTOR" switch at "STEP FEED", "INCH" or "HOME POS.
1 RETURN" and stop the slide at the preset stop position (0°).
See Section D OPERATION, 4.2 ROUTINE INSPECTION AND OPERATION (pg.
188).
After the slide has stopped at the preset stop position, set the "OPE. SELECTOR"
switch at "DIE CHANGE".

Preparatory operation (only for the press No. 1)


2 Set the operation selector on the die cushion operation panel at "AUTO DIE
CHANGE".

TAKE OUT selecting operation


3 Set the "OPE. SELECTOR" switch at "DIE CHANGE". Select the "DIE CHANGE"
from the MAIN MENU and "UNIT OPERATION" from the SUB MENU. Then, select
the "AUTO DIE CHANGE" on the "UNIT OPERATION screen". Push the "BOLSTER
SELECTION" function button to select "TAKE OUT".

When the "START" function button is pushed, the automatic die change "TAKE OUT"
4 is started. To interrupt the operation, push the "STOP" function button. The operation
is stopped. The operation flowchart can be checked on the "DIE CHANGE
MONITOR" of the SUB MENU under the "DIE CHANGE" of the MAIN MENU.

273
Section D OPERATION 8. CHANGING DIES

8.2.3 Auto die change

Set the "OPE. SELECTOR" switch at "STEP FEED", "INCH" or "HOME POS.
1 RETURN" and stop the slide at the preset stop position (0°).
See Section D OPERATION, 4.2 ROUTINE INSPECTION AND OPERATION (pg.
188).
After the slide has stopped at the preset stop position, set the "OPE. SELECTOR"
switch at "DIE CHANGE".

Preparatory operation (only for the press No. 1)


2 Set the operation selector on the die cushion peration panel at "AUTO DIE CHANGE".
Push the "NEXT DIE PREPARATION" button for the carry-in side bolster.

Next die selecting operation


3 Set the "OPE. SELECTOR" switch at "DIE CHANGE." Select the "DIE CHANGE"
from the MAIN MENU and select the "UNIT OPERATION" from the SUB MENU.
Then, select the "AUTO DIE CHANGE" on the "UNIT OPERATION" screen. Push the
"BOLSTER SELECTION" function button to select "DIE CHANGE".
In this state, select the "RECIPE" from the MAIN MENU and the "NEXT DIE SELECT"
from the SUB MENU. On the NEXT DIE SELECT screen, select the next die and
press the "NEXT DIE SELECT COMPLETE". Select again the "DIE CHANGE" from
the MAIN MENU and the "UNIT OPERATION" from the SUB MENU. Check that the
"AUTO DIE CHANGE" has been selected and the "DIE CHANGE" has been selected
in the "BOLSTER SELECTION".

<<Caution>>
If you operate the "BOLSTER SELECTION" in this stage, the "NEXT DIE SELECT
COMPLETE" selected in the "NEXT DIE SELECT" of the SUB MENU under the
"RECIPE" of the MAIN MENU will be cleared.

Push the "NEXT DIE PREPARATION" button on the press operation panel. Check
that the light comes on instead of flickering.

When the "START" function button is pushed, the automatic die change "TAKE OUT/
4 TAKE IN" is started. To interrupt the operation, push the "STOP" function button. The
operation is stopped. The operation flowchart can be checked on the "DIE CHANGE
MONITOR" of the SUB MENU under the "DIE CHANGE" of the MAIN MENU.

274
Section D OPERATION 9. OPERATION OF AUXILIARY EQUIPMENT

9. OPERATION OF AUXILIARY EQUIPMENT


See Section B SPECIFICATIONS, 3. NAMES OF MAJOR COMPONENTS (pg. 74) and Sec-
tion D OPERATION, (pg. 91) for the location of operating switches and devices.

9.1 MECHANICAL DEVICE

The mechanical device is a device which consists of a four-way valve and a timing switch for
activating the customer-prepared air actuator.
It is possible to operate the press in synchronism with the customer's actuator by using the
mechanical device.

Press the "SETTING" in the MAIN MENU on the operation display and press the
1 "MECHANICAL DEVICE" in the SUB MENU.(See (1), (2) in Section D OPERA-
TION, Common Screen Elements (pg. 115).)
The mechanical device setting screen is displayed.
Press the "ON/OFF" on the screen and turn "OFF" all mechanical devices.
(See 3.5.4 MECHANICAL DEVICE Screen (pg. 140).)

Perform steps (1) to (4), (7) and (8) described in Section A SAFETY, 5. USING THE
2 PRESS MACHINE SAFELY (pg. 24) .

The mechanical device has two air connectors A and B. The hoses of the customer-
3 prepared actuator should be connected to them.
Check that no risk is invited by activating the customer-prepared air actuator.
Example of activating timing of A and B is as shown in the table below.

Crank angle indicator 0° (360°) 180° 360°


Slide stroking position Top dead center Bottom dead center Top dead center
Timing switch setting OFF ON OFF
Connector A Supplies air Vents air Supplies air
Connector B Vents air Supplies air Vents air

4 Reverse the steps of the Safety Procedures During Adjustment performed in step 2
above.

(Continued on the next page)

275
Section D OPERATION 9. OPERATION OF AUXILIARY EQUIPMENT

(Continued)

Press the "ON/OFF" on the mechanical device setting screen to turn "ON" the
5 mechanical device.
To check the air actuator performance, press the "TEST" on the screen to enter the
mechanical device test mode.
When the button corresponding to the "TEST" is pushed according to the function
button functionality display (See (6) in Common Screen Elements (pg. 115)), the
solenoid valve is changed over to cause the air actuator to operate in the opposite
direction regardless of the slide operation.

After the completion of the test, push the function button corresponding to the
"RESET" to return to the normal state.
Then, re-press the "TEST" on the screen to reset the mechanical device test mode.

6 Press the PRODUCTION main menu touchbutton on the operator interface terminal to
display the PRESS RUN screen.
Using the INCH mode, check the air ejection timing.
Adjust the timing as directed in Section D OPERATION, 7.3 SETTING TIMING
SWITCHES (pg. 255).

276
Section D OPERATION 10. Making Motion Program Settings

10. Making Motion Program Settings


10.1 Operating motion
10.1.1 Motion Mode Characteristics

Motion Mode Characteristics


Crank • The crankshaft rotates at a constant velocity. However, it is pos-
sible to change, stop, or reduce the crankshaft rotation velocity
while it is in motion. Once the velocity has been changed, the
crankshaft will rotate at the new velocity.
Link • The slide motion is controlled within a range that begins at
approximately 1/3 of the slide stroke above bottom dead center
in order to make the slide downstroke velocity approach a con-
stant velocity.
• Motion is controlled so that the velocity of the slide is reduced in
the upper position of this range, and then as the slide
approaches bottom dead center the crank rotation velocity is
gradually increased to where it is at a high velocity near bottom
dead center. Accordingly, the maximum spm of link motion is
several spm lower than that of crank motion.
• You can make various setting changes in the same way you
make setting changes for crank motion.
Flex • The motion is crank motion. It is possible to reverse the motor
during presswork.
Fwd/Rev • The presswork starting and ending position is at top dead center.
During presswork, the drive mechanism swings back and forth
like a pendulum between bottom dead center and a preset height
above bottom dead center. Accordingly, the shorter you make
the distance between bottom dead center and the preset height,
the higher the achievable product output will become when com-
pared with crank motion.

10.1.2 The Relationship between Each Motion and the Selected Press Operation Mode

Motion Selec-
tion/
Crank Link Flex Fwd/Rev
Ope.Mode
Selection

Inch The press starts the


stroke from top dead cen-
ter, performs one work-
Single ing motion, and returns to
The press performs the motion of the
selected program. top dead center.

The press performs the


Cont.(Continu-
motion of the selected
ous)
program.

The press does not perform the motion of the selected program.
Step Feed
The slide merely moves up or down at a rate of 0.1 mm per pulse.

277
Section D OPERATION 10. Making Motion Program Settings

10.2 PROCEDURE FOR MAKING MOTION PROGRAM SETTINGS

Perform the following procedure to make motion program settings.


(1) Insert the key into the CONTROL POWER switch, and turn it clockwise to "|" (ON).
set the DATA EDIT "OFF" /"ON" Switch to "ON".
(2) Select the motion and set the program. (10.2.1 Motion Selection and Program Setting
(pg. 279))
(3) Confirm the motion program setting result. (10.2.2 VERIFYING THE MOTION
PROGRAM (pg. 284))

278
Section D OPERATION 10. Making Motion Program Settings

10.2.1 Motion Selection and Program Setting

The "DESIGN DIE HEIGHT", the die cushion related elements, the ENERGY elements ③ and
④ and the MOTOR TEMP. elements ③ and ④ are provided only for the press No. 1.

(1) Press the "SETTING" key located at the top of the operator interface terminal (" ① " in
the figure below).

(2) Press the "SETTING" key on the "DATA EDIT" menu (" ② " in the figure below) to activate
the numeric keys. This will enable the "DATA EDIT" function.

② "DATA EDIT" menu


To select the motion or program,
first press the "SETTING" key. After
completing the settings, press the
"DECISION" key.
If you press the "CANCEL" key, all
the data settings you have made up
to that time will be cancelled.
(Continued on the next page)

279
Section D OPERATION 10. Making Motion Program Settings

(Continued)

(3) Edit item


Set and edit the motion program data.
Default values of the motion program data are shown below as an example.
It is not necessary to have numeric values in the shaded boxes. Even if there are already
some numeric value settings in the shaded boxes, they are irrelevant for this example.
The explanations about die cushion are only applicable to the press No. 1.

SLIDE POSITION
AT CUSHION START
100.0 mm ③
SLIDE POSITION 100.0
2.0 ④
AT CUSHION START S

⑦ CUSHION ⑤
PROC 3 1 2 3 4 LINE
SLIDE POS.(mm) 100.0 0.0 100.0
SL VELOCITY(%) 100 100 100   
CRANK
⑧ SL VELOCITY(mm/s) *

* *
PAUSE TIME(s) 0.0 0.0 0.0 LINK
SLIENT DECEL.(%) 0 0 0
AUX.FUNCTION 0 0 0
FLEX
VELOCITY SHIFT 0 0 0
CUSHION POS.(mm) 100.0 0 50.0
F/R
CUSHION LOAD(kN) 480.0 0 0
KNOCKOUT(mm/s) 0 100.0 100.0
PRESSURE SHIFT 1 3 3
CUSHION STOP(s) 0 0 0
*:Calculation value

③ SLIDE POSITION
AT CUSHION START(mm) ...... The "SLIDE POSITION AT CUSHION START" entered
through the die cushion operation panel after the
calibration of the die cushion is displayed.
This value is to be entered when setting a motion program
as the "cushion position" from which the die cushion
process starts.
* Refer to the Instruction Manual for the die cushion for
details of the calibration of the die cushion.
④ CUSHION PRESSURE
KEEP TIME(s).......................... This is used to set the die cushion pressure holding time
at the bottom dead center.
(The setting range is from 0 to 20.0 sec.)
The die cushion pressure is kept at the set value for the
point just before the bottom dead center during the
specified length of time.

⑤ CUSHION LINE
/PRESS UNIT .......................... This is used to select whether the press is operated under
the UNIT mode or under the LINE mode in conjunction
with the die cushion.
Every time this key is pressed, the display is changed over
between "PRESS UNIT" and "CUSHION LINE".
When the press is operated under the UNIT mode, the die
cushion related items are disabled. In this state, the die
cushion related data are not checked.
(Continued on the next page)

280
Section D OPERATION 10. Making Motion Program Settings

(Continued)

⑥ MOTION SELECTION ............Crank:


This motion can be used even in the CUSHION LINE
operation as same as in the UNIT operation.
Link:
This motion can be used even in the CUSHION LINE
operation as same as in the UNIT operation.
Flex:
In the case of the CUSHION LINE operation , unlike in the
case of the press UNIT operation, a restriction is applied
to the reversal of slide motion during machining and the
setting of motion in which the slide passes the bottom
dead center twice or more.
Fwd/Rev:
Not usable in the LINE operation in conjunction with the
DC.

⑦ Number of processes
Maximum Number
Motion Name
of Processes
CRANK, LINK 10

FLEX 30

Not usable in the LINE


FWD/REV operation with the die
cushion.

⑧ Settings
"SLIDE POS.(mm)" ........... This is used to set the slide position (height from the bottom
dead center position of the slide) from which the press
process is started.
"SL(SLIDE)
VELOCITY(%)" ................. This is used to set a speed to be employed from the starting
position of the current process to that of the subsequent pro-
cess. (Ratio with respect to no-load spm which is set on the
"PRODUCTION" screen) In the case the speed is set at 0
(zero) %, the slide control used in the preceding process
continues. In this case, the slide position (mm) has to be set
as a pass point between the preceding process and the
subsequent one. This pass point should be used in the case
the die cushion load is changed without changing the slide
control.
"SL(SLIDE)
VELOCITY (mm/s)" .......... This is the numeric value which is obtained by converting the
aforementioned SPM ratio into the slide travel speed.
* This item is not a setting item. It is automatically
calculated. The numeric value may be displayed in red
depending on the value of ratio. The value displayed in red
means that the slide speed which cannot be followed by the
die cushion is set.
"PAUSE TIME" .................. This is used to set the time during which the machine is at
rest at the process starting position.
(The setting range is from 0 to 20.0 sec.)
(Continued on the next page)

281
Section D OPERATION 10. Making Motion Program Settings

(Continued)

"SILENT DECEL
( Deceleration)" ................. This is used to set the deceleration amount by which the
slide operates silently at the starting position of process.
* The speed at which the slide reaches the specified position
in the forming zone can be reduced.
In the case the silent deceleration amount is set at "100" %,
the speed is once reduced to 0 (zero) in the process, and
then it is re-increased to the forming speed to carry out
forming. For example, for a process for which the "speed" is
set at "50" and the "silent deceleration amount" is set at
"90", the slide instantaneously decelerates to 5% of the no-
load spm [50 % x (100 %?90 %) = 5 %]. Note that the silent
deceleration cannot be specified for the last process.
"AUX.FUNCTION" ............ This is used to specify the auxiliary function code output
signal.
"0": Auxiliary function code output signal is not output.
"1" - "15": Auxiliary function code of the set number is
output.
Auxiliary function codes "1" to "9" are intended for the die
cushion. In the case the auxiliary function code "1" is
selected when the press is operated in conjunction with the
DC, the slide temporarily stops at the bottom dead center
until the die cushion depressurization is completed and
starts running after the acknowledgement of the
depressurization completion signal.
The auxiliary function code "2" is used for controlling
immediate stop of the intermediate stop function.
The auxiliary function codes "3" to "9" are manufacturer-
reserved codes.
The auxiliary function codes "10" to "15" are used for the
peripheral devices. (Option)
"VELOCITY SHIFT" .......... This is used to specify the speed changing method at the
process changeover point.
"0" Pre-Speed-Change: Acceleration/deceleration is
completed before the starting position of the current process
is reached.
"1" Post-Speed-Change: The speed employed in the
preceding process is used until the starting position of the
current process is reached. Then, the speed is increased/
decreased to a target speed.
"2" Taper: After the speed has been increased/decreased to
the target speed at the starting position of the current
process, the speed is linearly increased/decreased in such a
way that the target speed of the subsequent process is
reached at the starting position of that process.
"3" Pre-Speed-Change + Constant Speed: The acceleration/
deceleration is completed before the starting position of the
current process is reached. Then, keeping that slide speed,
the constant-speed slide operation is carried out.
"4" Post-Speed-Change + Constant Speed: The speed
employed in the preceding process is used until the starting
position of the current process is reached. Then, the speed
is increased/decreased to a target speed. Keeping the slide
speed at the target speed, the constant-speed slide
operation is carried out.

* For the last process, only the slide position setting is


enabled.

(Continued on the next page)

282
Section D OPERATION 10. Making Motion Program Settings

(Continued)

"CUSHION POS.(mm)" ..... Usedto set the position of the die cushion (distance from the
forming stroke end) from which the die cushion process is
started.
"CUSHION LOAD(kN)" ..... Used to set the die cushion load for the current process.
The die cushion load can only be set for the die cushion
process.
The maximum number of processes for which the die
cushion load can be set is six.
For any process other than the die cushion process, set this
value at "0" kN.
"KNOCKOUT(mm/s)" ........ Used to set the knockout operating speed after forming.
The knockout operating speed can only be set for the
knockout process.
For any process other than the knockout process, set this
value at "0" mm/s.

"PRESSURE SHIFT" ........ Used to select the die cushion operation mode.
"0": Die cushion load setting is diabled.
"1": Post-Pressure-Change
"2": Taper Pressure-Change
"3": Bottom dead center depressurization and knockout pro-
cess
"4": Intermediate stop function
* Refer to the Instruction Manual for die cushion for details of
the pressure change mode.

"CUSHION STOP(s)" ........ Used to set a duration in which the die cushion is at rest at
the bottom dead center and that during the knockout
process after forming.
(The setting range is from 0 to 20.0 sec.)

283
Section D OPERATION 10. Making Motion Program Settings

10.2.2 VERIFYING THE MOTION PROGRAM

CAUTION
• The waveform and numeric values representing the slide position and velocity that are
displayed on the motion waveform display area or the program monitor screen are calcu-
lated values or reference values derived from the setting values. They do not ensure the
actual press motion.

After setting up a motion program, press the "DECISION" key on the "DATA EDIT" menu (" ② "
in the figure shown below). Pressing the "DECISION" key will initiate the verification process
in the controller that checks whether the press can actually move in accordance with the spec-
ified motion program.
* The time required for the verification process results to be displayed will differ depending on
the content of the motion program and the number of processes.

⑪ Motion waveform dis-


play area

⑫ "PROGRAM MONI-
TOR" key

② "DATA EDIT" menu

⑩ Edit data error display area

If there are any program settings (errors) found during the verification process that the press
cannot actually do, the description of the error and the number of the process containing the
error is displayed in the edit data error display area (" ⑩ " in the figure above). If the program
settings related to press operation are error-free, the message "NG process: 0" will be dis-
played in the error process number area and nothing will be displayed on the edit data error
display area. In addition, the motion waveform display (" ⑪ " in the figure above) will be
updated to display the waveform that shows the slide position and other settings of the speci-
fied motion program, thereby allowing you to confirm that the displayed waveform matches
the desired press operation settings.
Waveform colors: White: Slide Position; Yellow: Slide Velocity; Purple: Process

(Continued on the next page)

284
Section D OPERATION 10. Making Motion Program Settings

(Continued)

When the "PROGRAM MONITOR" key in SUB MENU ⑫ shown in the figure on the previous
page is pressed, the screen changes to the program monitor screen (see below) where you
can perform a detailed check of the motion program.

Program Monitor Screen

The setting procedure is completed using the above procedure. When you run the press
according to the numeric values set in the example given above, the press runs using stan-
dard crank motion where a constant velocity is maintained for each cycle. If the slide velocity
in process No. 1 is set at "50" (%), the press will change velocity from a position 100 mm
above bottom dead center and run at 50% of the no-load spm until the slide reaches bottom
dead center.

285
Section D OPERATION 10. Making Motion Program Settings

10.3 KEY POINTS WHEN MAKING MOTION PROGRAM SETTINGS

(1) The Forming Zone and No-Load Zone Concepts


The motion program requires the starting and end points of forming (presswork) with
respect to the slide position. The area between these two points is called the forming zone,
and the remainder of the stroke is called the no-load zone.
(No-load zone → From top dead center up to the starting point of presswork, and the end-
ing point of presswork up to top dead center)
The press velocity in the forming zone is set in the motion program, and the press velocity
in the no-load zone is set by the no-load spm. (See the figure below.)

TDC

No Load Zone Presswork


starting point
& Forming Zone
No Load SPM
&
Presswork
ending point Motion Setting Velocity

In the case of press UNIT operation, minimum two processes will be required for the pro-
cess to be set by the motion program. (See figure 10.3-1.)
In the case of LINE operation with the die cushion, because the knockout process of the
die cushion will be required, minimum three processes will be required for the process to be
set by the motion program. (See figure 10.3-2)
Figure 10.3-2 represents the motion program set in the previous paragraph of
"10.2 PROCEDURE FOR MAKING MOTION PROGRAM SETTINGS (pg. 278)".

(Continued on the next page)

286
Section D OPERATION 10. Making Motion Program Settings

(Continued)

Presswork Starting Presswork Ending


Position Position

PROC 2 1 2 3 4 PRESS
UNIT
SLIDE POS.(mm) 100.0 0.0
SLIDE VELOCITY(%) 100 100
SLIDE VELOCITY(mm/s) * *
PAUSE TIME(s) CRANK
0.0 0.0
SILENT DECEL(%) 0 0
AUX.FUNCTION 0 0
VELOCITY SHIFT 0 0
*:Calculation value

Figure 10.3-1 Press unit

Presswork Starting Presswork Ending KNOCKOUT PROCESS-


Position Position ES

PROC 3 1 2 3 4
SLIDE POS.(mm) 100.0 0.0 100.0
CUSHION
SL VELOCITY(%) 100 100 100 LINE
SL VELOCITY(mm/s) * * *
PAUSE TIME(s)
0.0 0.0 0.0
SLIENT DECEL.(%) 0 0 0
AUX.FUNCTION 0 0 0
CRANK
VELOCITY SHIFT 0 0 0
CUSHION POS.(mm) 100.0 0 50.0
CUSHION LOAD(kN) 480.0 0 0
KNOCKOUT(mm/s) 0 100.0 100.0
PRESSURE SHIFT 1 3 3
CUSHION STOP(s) 0 0 0

*:Calculation value

Figure 10.3-2 Cushion line

287
Section D OPERATION 10. Making Motion Program Settings

(Continued)

(2) Designating a Zone beyond Bottom Dead Center as a Forming Zone


Normally, presswork can be performed by just using motion settings that designate a form-
ing zone that starts from any specified height above bottom dead center and continues to
bottom dead center. However, depending on the forming requirements or the usage of
peripheral devices there may be times where specific slide motion settings are required
even after the slide has passed beyond bottom dead center. In such cases, it is necessary
to include a process that specifies the bottom dead center position (0.0 mm). (See Process
3 below.)
(Reference example)

PROC 4 1 2 3 4 PRESS
UNIT
SLIDE POS.(mm) 50.0 30.0 0.0 30.0
SLIDE VELOCITY(%) 10 25 25
SLIDE VELOCITY(mm/s) * * *
PAUSE TIME(s) 0.0 0.0 0.0
TDC(200mm)
SILENT DECEL(%) 0 0 0 100%up 100%down

AUX.FUNCTION 0 0 0 50.0mm
CRANK
10% velocity
VELOCITY SHIFT 0 0 0
30.0mm 30.0mm

*:Calculation value 25%velocity 25% velocity


BDC(0mm)

The figure above is an example of settings in the case of press UNIT mode operation.
In the case of LINE operation with the die cushion, aim for a safe setting without interfer-
ence by paying attention to the relationship between the slide speed and the knockout
speed during the knockout process at and beyond the bottom dead center, and further-
more try to narrow down to an optimum setting through verification by trial runs.

(Continued on the next page)

288
Section D OPERATION 10. Making Motion Program Settings

(Continued)

(3) Important Considerations When Changing the Slide Velocity


When changing the slide velocity when making motion program setting, the relationship
between velocity change and slide position is very important. An acceleration/deceleration
period is required in order to allow the slide to increase/decrease its current velocity to
reach the target velocity. This velocity change period is roughly proportional to the magni-
tude of the velocity change, and it is also affected by the process-to-process slide position
distance and the no-load spm. If a motion program setting calls for a large velocity change
within a short process-to-process distance,the slide will reach the next process before it
reaches the target velocity. In this case, the slide velocity is increased/decreased while tak-
ing the velocity employed in the next process as the target one.
For example, in the case of the motion program described in (2) above, the slide is oper-
ated at the specified target velocity since there is only a small change in velocity.

Velocity
No-load zone Proc.-1 Proc.-3 No-load zone

100%

25%
10%
TDC 50.0mm 30.0mm BDC 30.0mm TDC the height above BDC

On the other hand, the following operation will be carried out if the position of Process-2 is
changed from 30.0 mm to 48.0 mm.

Velocity Proc.-1
No-load zone Proc.-2 Proc.-3 No-load zone

100%

25%
10%
TDC 50.0mm BDC 30.0mm TDC the height above BDC
48.0mm

(Continued on the next page)

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Section D OPERATION 10. Making Motion Program Settings

(Continued)

(4) Creating a Process with a Constant Crankshaft Velocity


The crankshaft velocity can be made to remain constant throughout a particular process by
using a post-process velocity change setting.
The example program settings below illustrate a case where Process 2 maintains a con-
stant crankshaft velocity throughout the process. This is accomplished by inputting a post-
process velocity change setting of "1" in the next process (Process 3).
In the SINGLE mode operation example shown in the graph below, you can see that the
motion velocity is uniform for Process 2. However, if a pre-process velocity change value of
"0" were inputted for Process 3, a velocity change would be initiated during Process 2 (as
shown by the dotted line) and the crankshaft velocity for Process 2 would no longer be con-
stant.

PROC 5 1 2 3 4 5
SLIDE POS.(mm) 50.0 30.0 10.0 0.0 30.0
SLIDE VELOCITY(%) 10 25 50 75 0
SLIDE VELOCITY(mm/s) * * * * *
PAUSE TIME(s) 0.0 0.0 0.0 0.0 0.0
SILENT DECEL(%) 0 0 0 0 0
AUX.FUNCTION 0 0 0 0 0
VELOCITY SHIFT 0 0 1 0 0

*:Calculation value

If the velocity change setting is set to "0," a pre-process velocity change is performed. If the
velocity change setting is set to "1," a post-process velocity change is performed.
For the final process, a post-process velocity change is always performed regardless of the
setting. 

Example of SINGLE Mode Motion Velocities

When the change peed setting is 0 for Proc.3

When the change peed setting is 1for Proc.3


Velocity
No-load zone Proc.-1 Proc.-2 Proc.-3 No-load zone
100%

50%

25%
10%
TDC 50.0mm 30.0mm BDC 30.0mm TDC

(5) Final Process Data


In the final process, the slide position setting is the only valid data--any velocity, pause
time, auxiliary function, and acceleration/deceleration settings are ignored. This is
because the final process is at the end point of the forming zone (as explained in (1)
above), and the following zone is a no-load zone where the motion is at 100% velocity.

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Section D OPERATION 10. Making Motion Program Settings

10.4 MOTION PROGRAM EXAMPLES

10.4.1 Crank Motion Example 1

In the following example, the forming zone begins from a position 100 mm above bottom dead
center. The slide moves at a constant velocity that is 100% of the no-load spm. It is not neces-
sary to have numeric values in the shaded boxes. Even if there are already some numeric
value settings in the shaded boxes, they are irrelevant for this example.

PROC 2 1 2 3 4
PRESS
SLIDE POS.(mm) 100.0 0.0 UNIT
SLIDE VELOCITY(%) 100
SLIDE VELOCITY(mm/s) *
TDC
PAUSE TIME(s) 0.0 100%Down
SILENT DECEL(%) 0 CRANK
100%Up
AUX.FUNCTION 0
100.0mm
VELOCITY SHIFT 0
100%Velocity
*:Calculation value
BDC

10.4.2 Crank Motion Example 2

IIn this example, we want the slide to enter the forming zone at 50.0 mm above bottom dead
center and then reduce the crank rotation velocity to 10% of the no-load velocity.

PROC 2 1 2 3 4 PRESS
SLIDE POS.(mm) 50.0 0.0 UNIT

SLIDE VELOCITY(%) 10
SLIDE VELOCITY(mm/s) * TDC
PAUSE TIME(s) 0.0 100%Down
SILENT DECEL(%) 0 CRANK
100%Up
AUX.FUNCTION 0
50.0mm
VELOCITY SHIFT 0
10%Velocity
*:Calculation value
BDC

Velocity No-load zone Proc.-1 No-load zone

100%

10%
TDC 50.0mm 0.0mm TDC the height above BDC

(Continued on the next page)

291
Section D OPERATION 10. Making Motion Program Settings

(Continued)

10.4.3 Crank Motion Example 3

In this example, we want the slide to enter the forming zone at 100.0 mm above bottom dead
center and move at a crank rotation velocity that is 50% of the no-load SPM. Then at 50.0 mm
above bottom dead center the slide velocity is to be lowered to 10% velocity. From bottom
dead center it is to then return to top dead center at 100% of the no-load SPM.

PROC 3 1 2 3 4 PRESS
UNIT
SLIDE POS.(mm) 100.0 50.0 0.0
SLIDE VELOCITY(%) 50 10
SLIDE VELOCITY(mm/s) * * TDC
PAUSE TIME(s) 100%Down
0.0 0.0
50%Velocity
SILENT DECEL(%) 0 0 100%Up 100.0mm

AUX.FUNCTION 10%Velocity
0 0 CRA NK
50.0mm
VELOCITY SHIFT 0 0

*:Calculation value BDC

Velocity Proc.-1 Proc.-2


No-load zone No-load zone
100%

50%
10%
TDC 100.0mm 50.0mm 0.0mm TDC height above BD C

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Section D OPERATION 10. Making Motion Program Settings

10.4.4 Velocity Change Mode Usage Examples

<<When the Velocity Change Setting is ’0’>>


Pre-Process Velocity Change: Acceleration/deceleration is completed before the start of the
current process.
For example, in Process-1 in 10.4.3 Crank Motion Example 3, the velocity is set to 50% at
the 100 mm position. This is an example where velocity change mode "0" (Pre-Process
Velocity Change) is being used.

<<When the Velocity Change Setting is ’1’ >>


Post-Process Velocity Change: The velocity used in the preceding process is maintained
up to the starting position of the current process, and then the velocity is accelerated/decel-
erated to the target velocity after passing the starting position of the current process.
If the motion program is using velocity change mode "0" and the velocity is changing for
each process in the forming zone, it is not possible to have a zone where the slide motion
is at a constant velocity. To solve this problem, velocity change mode "1" (Post-Process
Velocity Change) should also be used. Using this mode will enable you to designate a
constant-velocity zone.
In the table below, Process-2 is set to velocity change mode "1" (Post-Process Velocity
Change). In this mode, the slide velocity is maintained at 50% at the 50 mm position, and
is changed to 10% after the 50 mm position has been reached. This enables you to desig-
nate Process-1 (from the 100 mm position to the 50 mm position) as a constant-velocity
zone.

PROC 3 1 2 3 4
PRESS
SLIDE POS.(mm) 100.0 50.0 0.0 UNIT
SLIDE VELOCITY(%) 50 10
SLIDE VELOCITY(mm/s) * *
PAUSE TIME(s) 0.0 0.0 TDC
SILENT DECEL(%) 0 0 100%Down
AUX.FUNCTION 0 0 50%Velocity
0 1 100.0mm
VELOCITY SHIFT
100%Up
CRA NK
50.0mm
10%Velocity
*:Calculation value BDC

Velocity
No-load zone Proc.-1 Proc.-2 No-load zone
100%

50%
10%
TDC 100.0mm 50.0mm 0.0mm TDC
Height of above BDC

293
Section D OPERATION 10. Making Motion Program Settings

<When the Change Spees Setting is 2>>


Taper: After the slide velocity is increased/decreased to the target velocity at the start of the
current process, linear acceleration/deceleration is carried out until the target velocity of
the next process is reached by the time its starting position is reached.
In the table below, the Process-2 is set to velocity change mode "2" (taper). In this mode,
the velocity when the slide reaches the 50 mm position will be 10%, and the velocity at bot-
tom dead center will be 100%. Linear acceleration/deceleration is then performed between
these two positions.

PROC 3 1 2 3 4 PRESS
UNIT TDC
SLIDE POS.(mm) 100.0 50.0 0.0
100%Down
SLIDE VELOCITY(%) 50 10 50%Velocity
100.0mm
SLIDE VELOCITY(mm/s) * * 100%Up
CRANK
10%Velocity
PAUSE TIME(s) 0.0 0.0 50.0mm
SILENT DECEL(%) 0 0
AUX.FUNCTION 0 0 BDC

VELOCITY SHIFT 0 2
Taper
*:Calculation value

Velocity
No-load zone Proc.-1 Proc.-2 No-load zone
100%

50%
10%
TDC 100.0mm 50.0mm 0.0mm TDC
Height of above BDC

*Caution: Taper motion settings where the slide velocity in a process and in the subsequent
process is set to 0 (zero) are prohibited, including the following:
Silent deceleration of 100%
Stop (dwell) time
Auxiliary function codes, etc.

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Section D OPERATION 10. Making Motion Program Settings

<<When the Velocity Change Setting is ’3’ >>


Pre-Process Velocity Change + Constant Velocity: After the acceleration/deceleration is
completed before the current process start position is reached, the slide will maintain a
constant velocity.
In the table below, Process-2 is set to velocity change mode "3" (Pre-Process Velocity
Change + Constant Velocity). In this mode the velocity is decreased to 10% by the time
the slide reaches the 50 mm position and the slide motion is then maintained at a constant
velocity. The velocity is then increased to 100% until bottom dead center is reached.

PROC 3 1 2 3 4 PRESS
UNIT
SLIDE POS.(mm) 100.0 50.0 0.0 TDC
SLIDE VELOCITY(%) 50 10 100%Down
50%Velocity
SLIDE VELOCITY(mm/s) * * 100.0mm
CRANK 100%Up
PAUSE TIME(s) 0.0 0.0 10%Velocity
SILENT DECEL(%) 0 0 50.0mm

AUX.FUNCTION 0 0
BDC
VELOCITY SHIFT 0 3
Pre-S-Change
*:Calculation value + Constant S

Velocity
No-load zone Proc.-1 Proc.-2 No-load zone
100%

50%
10%
TDC 100.0mm 50.0mm 0.0mm TDC
Height of above BDC

295
Section D OPERATION 10. Making Motion Program Settings

<<When the Velocity Change Setting is ’4’ >>


Post-Process Velocity Change + Constant Velocity: The operation is performed at the
velocity of the previous process until the starting position of the current process is reached.
After that starting position is reached, the velocity is increased/decreased to the target
velocity. Once the target velocity is reached, the operation is performed with the slide mov-
ing at a constant velocity.
In the table below, Process-2 is set to velocity change mode "4" (Post-Process Velocity +
Constant Velocity). In this mode, the slide velocity is decreased to 10% after the slide
reaches the 50 mm position, and the slide maintains that velocity. The velocity is then
increased to 100% until bottom dead center is reached.

PROC 3 1 2 3 4 PRESS
UNIT TDC
SLIDE POS.(mm) 100.0 50.0 0.0
100%Down
SLIDE VELOCITY(%) 50 10 50%Velocity
100.0mm
SLIDE VELOCITY(mm/s) * * 100%Up
PAUSE TIME(s) CRANK 10%Velocity
0.0 0.0 50.0mm
SILENT DECEL(%) 0 0
AUX.FUNCTION 0 0 BDC

VELOCITY SHIFT 0 4
Post-S-Change
+ Constant S
*:Calculation value

Velocity
No-load zone Proc.-1 Proc.-2 No-load zone

100%

50%
10%
TDC 100.0mm 50.0mm 0.0mm TDC
Height of above BDC

296
Section D OPERATION 10. Making Motion Program Settings

10.4.5 Example of Vibration Reduction

This is an example of a program that decreases the slide velocity in order to reduce the vibra-
tion and noise that occurs at the time the material comes in contact with the die and when the
material separates from the die.
(Depending on factors such as the die, the shape of material, and the forming method, this
program may not always be an effective means of reducing vibration and noise.)
If the settings bel