P4-1916 Eng

Salvagnini
T R A I N I N G C E N T E R
A U S T R I A
Training subject:
Service manual
Author: Christian Reingruber (Start-up department, R&D)
Translated by: Siegfried Pierer (training/education)
Salvagnini Maschinenbau GmbH

Training / education
Dr. Guido Salvagninistrasse 1
A-4482 Ennsdorf
Phone: +43-7223-885.291
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Contents
1. Pre start-up procedure ........................................................................................................... 5
1.1 Fundamentals of the CANopen bus system...............................................................................................5
1.2 start-up of the electrical cabinet ................................................................................................................6
1.3 preparation machine ................................................................................................................................13
1.4 computer start-up and update of the machine soft product. ....................................................................15
1.5 Laser scanner S3000...............................................................................................................................20
1.6 Start the control system and pre start-up of the machine ........................................................................25
2. Start commissioning............................................................................................................ 38
2.1 Adjusting of CTMs and making the TOOLDAT.INI..............................................................................38
2.2 Switching on the hydraulic main pump...................................................................................................40
2.3 Flushing of the servo hydraulics..............................................................................................................42
2.4 Calibration of the DFEC pump................................................................................................................43
2.5 Adjusting the switches –SQ16, -SQ17, -SQ150 and –SQ151.................................................................47
2.6 Loading the software for the Lenze drives .............................................................................................48
3. Start-up of the individual actors and calibration................................................................. 54
3.1 Table of axis: ...........................................................................................................................................54
3.2 Explanation of first movement on an axis using "micro cycle" ..............................................................55
3.3 Free movement and calibration of horizontal bending cylinders (AS12/13) ..........................................56
3.4 Free movement and calibration of vertical bending cylinders (AS10/AS11) .........................................57
3.5 Automatic blankholder adjustment (ABA)..............................................................................................58
3.5 Manual blankholder adjustment (MLA)...............................................................................................66
3.6 Free movement and calibration of blank holder (AS9) ...........................................................................66
3.7 First movement and calibration of XZ stop left in X direction (AX1)....................................................67
3.8 First movement and calibration of XZ stop right in X direction (AX3)..................................................67
3.9 First movement and calibration of XZ stop left in Z direction (AX2) ....................................................68
3.10 First movement and calibration of manipulator (AX14) .......................................................................68
3.11 First movement and calibration of transport sledge (AX16).................................................................69
3.12 First movement and calibration of CLA (AX17) ..................................................................................71
3.13 First movement and calibration of rotator (AX15)................................................................................77
3.14 De-bur unit (AX39, RSU) ....................................................................................................................78
3.15 NOT_USED .........................................................................................................................................78
3.15 HPT axis ...............................................................................................................................................79
3.16 PCD-axis................................................................................................................................................80
3.17 RIP-axis .................................................................................................................................................82
3.18 ACP30-Axis .........................................................................................................................................83
3.19 XZ stop left up/down.............................................................................................................................83
3.20 XZ stop right up/down...........................................................................................................................83
3.21 XZ stop right forward/back ...................................................................................................................83
3.22 Z-Pusher forward/backward ..................................................................................................................84
3.23 Lowering blank holder safety device on/off..........................................................................................84
3.24 lowering blade holder safety device on/off ...........................................................................................84
3.25 Rotator clamp ........................................................................................................................................85
3.26 TRD Arm left/right and pincers open/close ..........................................................................................85
3.27 + 3.28 not used ......................................................................................................................................86
3.29 Option PCD ...........................................................................................................................................87
3.30 scissor table (hydraulic).........................................................................................................................88
3.31 Safety flap up/down...............................................................................................................................89
3.32 Automatic calibration ............................................................................................................................89
3.33 Retract manipulator ...............................................................................................................................90
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4. MOOG DMS 2000 digital controller.................................................................................. 90
4.1 general description...................................................................................................................................90
4.2 Manipulator (AX14) ..............................................................................................................................99
4.3 Rotator (AX15)....................................................................................................................................101
4.4 Feeding trolley (AX16) .......................................................................................................................104
4.5 CLA (AX17)........................................................................................................................................107
4.6 upper CLA (AX18)..............................................................................................................................109
4.7 asymmetric CLA (AX17=right, AX37=left).......................................................................................111
4.8 upper asymmetric CLA (AX18=left, AX38=right).............................................................................114
4.9 Left reference in X direction (AX1) ....................................................................................................117
4.10 Left reference in Z direction (AX2) ....................................................................................................119
4.11 Right reference in X direction (AX3)..................................................................................................121
4.12 De-burr device (AX39)........................................................................................................................123
4.13 Left Preadjuster (AX34) ......................................................................................................................125
4.14 Right Preadjuster (AX35)....................................................................................................................127
4.15 RIP transfer (16A1AX1) .....................................................................................................................129
4.16 HPT - AZR (90A1AX1) ......................................................................................................................131
5 . LENZE-drives ................................................................................................................ 133
5.1 PCD/PC ................................................................................................................................................133
5.2 RIP ........................................................................................................................................................139
5.3 ACP30 ..................................................................................................................................................142
6. HYDRAULIC_AXIS (P4-1916) ...................................................................................... 144
6.1 Checking the positioning properties of the blankholder (AS9).............................................................144
6.2 Mechanical Checking of the parallelism of the bending unit................................................................146
6.3 Checking the positive starting position (Lower Tool)...........................................................................147
6.4 Checking the negative starting position (Upper Tool) ..........................................................................148
6.5 Setting the starting position of the positive CLA tool (CLA tool NOT fitted!) ....................................149
6.6 Setting the starting position of the negative CLA tool (CLA tool NOT fitted!) ...................................149
6.7 Setpoint and TRG signal measurement .................................................................................................150
6.8 Checking the positioning properties of the vertical bending cylinder (AS11) ......................................151
6.9 Checking the positioning properties of the horizontal bending cylinder (AS12/AS13)........................153
6.10 Constant velocity test (TRG-Signal- measurement)............................................................................155
6.11 Positioning of the left outer segment adjuster(AS32) ........................................................................156
6.12 Positioning of the right outer segment adjuster(AS33) ......................................................................158
7 General adjustments ........................................................................................................... 160
7.1 Checking the XZ stop right ...................................................................................................................160
7.2 Checking and adjusting the XZ stop left ...............................................................................................161
7.3 Starting the machine (checking the stops on the X axis).......................................................................163
7.4 Determination of the Notch offset:........................................................................................................164
7.5 Determining the ZERO_TRD and TRDMAX for the transport sledge.................................................165
7.6 Setting up PCD/PC/ACP*: ....................................................................................................................167
7.7 Setting up RIP: ......................................................................................................................................167
7.8 Adjustment of the sheet thickness sensors of the PCD .........................................................................168
7.9 Adjustment of the sheet thickness sensors of the TRD .........................................................................169
7.10 Control of PCD/PC/ACP*/RIP positions ............................................................................................171
7.11 Setting up SFL (safety flap): ...............................................................................................................173
7.12 Not used...............................................................................................................................................173
7.13 Checking the increase in pressure at the blank holder.........................................................................174
7.14 Checking pivoting and shifting segments............................................................................................176
7.16 Adjustment of material detection sensor ............................................................................................178
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8. Bending geometry ............................................................................................................. 179
8.1 The basics ..............................................................................................................................................179
8.2 Determining the precise correction factor for +/- bends of every kind .................................................180
8.2 Determining the precise correction factor for +/- bends of every kind .................................................180
8.3 Checking the accuracy of the angle from left to right (+90°/+45°).......................................................183
8.4 Checking the accuracy of the angle from left to right (-90°/-45°) ........................................................184
8.7 Checking +/-130° and 135° bending and +/- open folding: ..................................................................185
9. Rotator, references and CLA ............................................................................................ 186
9.1 Checking the indexation of the rotator index ........................................................................................186
9.2 Determining CTM parameter 1592 (ZERO_MNP)...............................................................................188
9.3 Fine adjustment of stops (AX1, AX2)...................................................................................................189
9.4 CLA settings (calibration point and angle): ..........................................................................................192
9.5 Upper CLA settings (calibration point and angle): ...............................................................................194
10. Adjustment of special tools and options ......................................................................... 195
10.1 Option P...............................................................................................................................................196
10.2 Option CUT .........................................................................................................................................199
10.3 Special tool "Nosetool" (LDN)............................................................................................................204
10.4 RSU ....................................................................................................................................................207
10.5 RBU (Brush cleaning system) ............................................................................................................210
10.6 PSE (bending tool cleaning device)....................................................................................................210
11. Final checks before operating the machine..................................................................... 212
11.1 Checking the temperature ranges ........................................................................................................212
11.2 Adjustment check of SQ17:.................................................................................................................213
11.3 Checking current draw of rotator and transport sledge .......................................................................213
11.4 Saving of Files.....................................................................................................................................214
12. Connections..................................................................................................................... 215
12.1 S4 ........................................................................................................................................................215
12.2 MV......................................................................................................................................................225
12.3 SAR ....................................................................................................................................................230
13 . Tools............................................................................................................................... 232
13.1 UCScope with Tbx .............................................................................................................................232
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1. Pre start-up procedure
1.1 Fundamentals of the CANopen bus system
At application of bus systems different processors (CAN nodes, which are installed on the individual
components) are connected to each other and to the CUSIX of the SIXT control over a serial main.
Data are therefore is transmitted and evaluated on the respective CAN nodes. Because of this fact it is
now unnecessary to wire for each and every input and output an individual line.
Advantages:
less wiring effort
Decentralization (the complete electronics of the control system is contained in the pilot valves,
servomotors and in the hydraulic pump themselves, in which this control system is coordinated with
the respective actors and optimal performance is reached through this.)
On the CPU of the Micro-Mach there are three channels (CAN 1, CAN 2 and CAN 3) for serial
connection available, which work independently from each other . (Illus.1.1)
CAN 1 is for the basic machine

CAN 2 is used for loading/unloading units (PC,PCD,RIP,SAP,…)
CAN 3 is used for regulation units (hydraulics, Z pusher measur system,Moog valves ...).
The serial connection is a 3 wire connection with CAN_H signal (5 volts),

CAN_L signal (0 volts) and GND at a transfer rate of 500 Kbits.
Cusix-Com1: Musix-Com2:
Boot protocol, real time errors Axis errors, axis programming,
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1.2 start-up of the electrical cabinet
Important:
The Main, all power and motor circuit breakers, power supply units and the computer must be
turned off, all electronic cards of the Rack must be pulled out. UPS must be disconnected. Switch
-SA18 must be turned off.
Caution: There is still electrical voltage on QM1 even if the main switch is turned off!
1.2.1 configuration and adjustment of various systems in the electrical cabinet.
A: Optical check of the electrical cabinet and the control desks (connectors, plugs, components)
B: The frequency and supply voltage must refer to the type plate of the electrical cabinet. Apply
bridges to the Transformer (T1, T2, T3 .) .
C: Adjust the main and motor circuit breakers accord to the circuit diagrams.
D: Control of fuses (-FS5-FU1 ..., -FS6-FU1 ..., FU1, . .FU23, ...) accord to circuit diagrams.
E: Adjust the soft starter (G1) of the hydraulic main pump accord to the circuit diagrams.
F: Check bridges of the transformers (T1, T3) accord to the circuit diagrams.
G: Check the Dip switches of power supply unit (GS1, GS2, GS3) accord to circuit diagrams.
H: Put the switches of the electrical cabinet lights (EL1, EL2, EL3) to AUTO.
I: Adjust the temperature switches (ST370=18, ST371 =10 and ST200 =45)
J: Adjust the air water heat exchanger (TN = 33)
K: Configure the electronic cards. It has to be checked that the jumpers on the cards or on the bus
circuit board are set correctly, the toggle switches on the cards are in the right position.
Information about the settings may be found in the enclosed data sheets (wiring diagram). The
cards will be put into the Rack after check the power supply of the electronic cards.
L: Check the DIP-Switches (S1) of the Moog drives accord to circuit diagrams.
M: Check the DIP-Switches of the CAN node -A49 accord to circuit diagrams.
N: Check the address switches of the CAN node -A48 accord to circuit diagrams.
O: Check the address switches of the CAN node –A16Z (PNOZmulti) accord to circuit diagrams.
P: Check the DIP-Switches of the CAN node –A50 (control desk) accord to circuit diagrams.
Q: At the PNOZmulti (-A16) disconnect the two connectors (A1,A1,A2,A2 and T1,T2,T3,
24V,24V,0V,0V). Plug in the Test sim card (32MB) and connect PNOZ test tool.
R: Check the main power circuit in the electrical cabinet.
S: Check and adjust the over voltage safety device P2.

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>U set to 440 (+10% nominal voltage) <U set to 360 (-10% nominal voltage)
Function: set to symbol “X” Delay-t set to 1 Sec.
IMPORTANT: If a wrong field is detected or the unit is triggered, the control voltage is
switched off!
U: Measure the serial cable of the Can-bus system (with test tool).
Apply at Can-Line 2 and Can-Line 3 (at XCAN 2 and XCAN 3) a terminator resistor of
120Ohm. Disconnect the cables of channels 1,2 and 3 at the electronic card RJ45 and check the
resistance.
Between Pin 1 and Pin 2 you must measure a resistance of 120 OHM.
Also check between GND wire and GND of the machine. Re-apply the connectors.
Leave the terminator at Can-Line 2 (otherwise no booting is possible later!)
V: Install the safety signal lamp for the MOOG drives!
24M
KM5
KM5 KM9
KM9
0M
1.2.2 Activation of the main power switch
A: Connect main power supply and connector in main control desk.
B: Check voltage at QM1 while main breaker is still turned off. When QM1 and FS1 is switched
on the electrical cabinet lights must switch themselves on. Check electrical outlets for function.
C: While the main switch is turned off the electrical cabinet heat system (ST370W) must turn on
and off itself (Unit must heat up itself after some minutes).
D: Switch on main switch, check voltage at main power circuit breaker while it is still turned off
(QM*) . Check accord to circuit diagrams on primary side.
E: Control 230 VAC voltage.

Switch on QM6. Voltage on transformer T3 must be secondary 230 VAC.
Switch on FA1 and FS3. KA2W must switch on itself and at the UPS must be VAC 230
measurable. Press the test button of FA1 for control.
F: Adjust output voltage on power supply unit GS7 to 5.2 V.

Check voltage on the PNOZmulti and on the terminal strips and after that switch it on
(watch out for the polarity!).
G: Adjust output voltage on power supply unit GS2 to 24.2 V.

Check voltage on the PNOZmulti and on the terminal strips and after that switch it on
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H: Control voltage. Switch on key selector switch -SA18. KM6 and power supply unit GS6 are
switched on. Measure now +5V to GND at the bus circuit board. Pay attention to the polarity.
Setting value 5.0 V at the bus !!! (watch out for the polarity!).
I: 24 M. Switch on QM10.Output voltage on power supply unit GS3 must be adjusted to 24.2V.
Check voltage on all terminal strips, transition elements and hardware connections with the
necessary fuses (FU1 ....) (watch out for the polarity!).
J: Solenoid valve voltage GS1 . Switch on of QM7 . Activate -KM1 manually.

Adjust Output voltage on power supply unit GS1 to 24.2 V. Check voltage on terminal strips
K: Electrical cabinet cool. Switch on FS2. The ventilator slide-in unit of the electronic cards and the
ventilator of the heat exchangers start independently. Control the direction of rotation
L: Switch on FS4. Adjust Output voltage on power supply unit GS8 to 24.2 V
M: Connect 24VAUX* voltage at the MOOG drive (connectors X3 and X12). Switch on FS9 and
FS10. Check the voltage and disconnect the plugs again.
N: Switch off SA18 and insert the electronic cards.
1.2.3 switch on of the PC and monitor.
Switch off main switch. CONNECT UPS. Connect PC and monitor. Switch on main switch. The PC
will boot. The booting sequence will not be successful. Close the SCON.
1.2.4 Booting sequence of the system
For the start of the control the individual CAN nodes must be turned off.
The file C:\usr2/syscon/P4M_*** _****/rtsoft/conf/NODEDISABLEDfile.ini must be copied on
NODEDISABLED.INI. In this file all “Enable” entries must be changed to “DISABLE” and then the
file must be saved.
After successful booting change in the Nodedisabled –file the entries for node A15, (PNOZMULTI -
A16Z) A48, (Beckhoff) A49 (Salv. CAN80) of line 2 and node A50 (control desk) of line 1 to ENABLE
and then safe the file.
Close SCHON and reboot. After successful booting the traffic light will change to green.
1.2.5 Output test PNOZ
By activation of the DIP switches the corresponding outputs will be activated at the PNOZ unit.
Check at the corresponding relays if the voltages are switched through according to the electrical
diagrams.
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1.2.6 Input / Output test
Press button F2 after successful start of the computer (traffic lights = green.)
Log in as user “Root” /Password “Salvagnini”. Then push button F6. The Monitor will be opened.
A: Open Cabinetinp1.ws. All inputs for the electrical cabinet will be displayed.
B: Open Cabinetinp2.ws. All inputs for the electrical cabinet will be displayed.
C: Open Cabinetout.ws. All outputs for the electrical cabinet will be displayed.
D: Open Pult.ws . All inputs and outputs for the control desk will be displayed.
E: Check all encoder plugs with the Test –Lineal for correct wiring.
F: Switch off control voltage (SA18), replace Test – Chip card of PNOZ with real chip card.
Leave all power breakers, which are already on in ON position. Switch off all motor breakers.
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1.2.7 Loading the PNOZmulti program
Select IBN-PNOZ
The application will be opened.

Select the correct COM port.
Select Edit - SET Interfaces….
Set COM port and acknowledge

with OK
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Now the program must be opened.
Select File - Open….
Select the Pilz directory
Select File and click on Open
Password is
„Salva“
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Program will be opened
Select Online
Load the program on the PILZ module
Select Download to
Hardware
Select all entries
Acknowledge every message with „YES“.

The PNOZmulti will be started.
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Must change to Run. If not, the Software
and hardware is not compatible
1.3 preparation machine
1.3.1 preparations with main switch turned off
A: Open all connectors at the device. (Pilot valves, Encoder, CANbus-

Nodes, hydraulic aggregate, Z pusher system, serial cable at the Rt-CPU / CUSIX card)
B: Adjustment of switches and jumpers of the CANbus nodes accord to circuit diagrams.
Important: every channel has to terminated with a resistor or with a jumper (J2). E.g. If the scissor
table on line 2 (101 A1-A40) is not available, at Node 101 A1A31 jumper 2 or a connector with a 120
Ohms resistor has to be installed.
C: Address switch on the Rexroth main pump (-A39) has to be set to 0.
D: Adjust dip switches and jumper on oil temperature sensor (-A44).
E: Adjust dip switches on BK5120 (-A58).
F: Check rotation field direction at the main power connection. (right spinning field)
G: Control of the cable type of the hydraulic main pump, circulation pump, oil heat system, SAP
motors, PCD motors, scissor table motors and RIP motors.
H: Check hydraulic main pump, circulation pump and scissor table motors accord to the voltage
and type plate and right allocation (star or triangle).
I: Check all motors from SAP, PCD and RIP for right allocation (star).
Check also right connection of the brake.
J: Attach the cool water for the electrical cabinet cool and hydraulics.
K: Establish air connection. Adjust the pressure regulator for the machines and the PCD supply to
6 bar. With the red alter wheel the fast rise in pressure shall be adjusted to approx. 4.0 bar. The
pressure regulator for vacuum of the PCD should be adjusted to 5 bar.
Important: The pneumatic valves must be in mechanical zero position!
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1.3.2 main switch
A: Initial test of the safety module (PNOZmulti) accord to the circuit diagrams.
E.g.: If the emergency stop is pressed on the main desk on PNOZmulti-A16 inputs I0 and I1
must become zero. All key selector switches, light barriers, Emergency stop, protection fence
and safety switches have to be tested.
B: Check power supply voltage for internal CAN nodes. (J11.5 against J11.6 must
be +24 VDC)
Important:
At analogue nodes (A32 PCD and A51 MNP) the input voltage (IN14 ...) of the analogue sensors
must also be disconnected!
C: Check supply voltage for external CAN nodes. At the connector pin J10.01 must be +24 VDC
against J10.17.
D: Check supply voltage for hydraulic aggregate. At the connector A39X Pin 1 must be +24 VD
against Pin 2.
E: Check voltage of Z pusher measuring system. At the connector -BQ31X2 Pin 5 against 6 must
be +24 VDC
F: Check supply voltage for BK5120 (Beckhoff). Terminal 1 against 5 must be +24 VDC.
G: Check supply voltage for MOOG valve (at the connector –AS9,AS10.. Pin A against B must be
+24 VDC ).
H: Check supply voltage for linear encoder (at the connector -BQ9, BQ10, .. Pin 12 against 10 must
be +24 VDC).
I: Check supply voltage of the Z pusher pressure valve (AP6 and AP19).
pin 2 against pin 1 must be +24 VDC at the connectors X1 and X2
J: Check supply voltage for every pressure sensor (BP06, BP07 ...).
pin 2 against pin 1 must be +24 VDC at the connector
K: Check supply voltage for every terminal strip box and control desk.
L: Check the serial cable for connection. Turn SA18 off! Connect all connectors to the CAN nodes.
Now measure through resistance of serial cables channel 1, channel 2 and channel 3. A resistor
of 120 ohms must be measured between pins 1 and 2 on the CAN connections (at the cable).
Important:
It have to be measured also against ground! Should there be a connection, it can be a problem if more than one node is used.
M: Now (with main switch turned off) connect all connectors (CAN node,
Z pusher, ... .... and network cable).
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1.4 computer start-up and update of the machine soft product.
Computer starts when the main switch is turned on. After the boot sequence click on start -
Click on Shutdown – Log off Syscon - computer is shut down and newly started, during boot
sequence keep SHIFT button pressed until computer appears with the Login window.
Log in with User “administrator” and password “Salvagnini”.
Important:
Check if the network connection works. (by us the Explorer)
Check if the software is available for the machine (customer).
(Ask the software department about it)
Attention:
All CTM parameters, Axis files, Siemens files,… and check lists will be overwritten!
Double-click on Setup.exe on the desktop.
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Select “Modify”
Click „Next“ (= continue)
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Press any key to finish the installation after the message:
´´Press any key to continue …`` appears.
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Click „next“.
Select: „No, I will restart my computer later“.

Select Finish.
On the desktop douple-click on „Nach Setup“ (After set-up).
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Reboot the computer:
Select „START“ / „SHUTDOWN“.
Select „Restart“ and click on OK.
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1.5 Laser scanner S3000
1.5.1 Software conditions

The software program for commissioning of the S3000 laser scanner may be found under C:/SICK
applications/cds2.34 .
In this cds folder the program cds_234.exe may be found. This program may also be started with
START/Programs/IBN/SCANNER .
When the machine is delivered to the costumer, remains only a shortcut on the desktop.
1.5.2 Import laser scanner safety field

After the program has been started, select the PROJECT pull down menu and OPEN the file
usr2/syscon/P4M_*_*/CONF/cds/ibn.skp .
There may be two safety fields be found ( Schutzfeld_HPT_1816.skp and Schutzfeld_HPT_2516.skp ).
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1.5.3 Connect computer with laser scanner
• Choose the correct port
Select under the pull down menu EXTRAS the COMMUNICATION CONNECTION entry and in
the now appearing window click on CONNECTION, then on COM1 .
• Establish connection
In the pull down menu PROJECT select CONNECT (F4) . A window will appear and answer the
following questions this way:
LOGON FOR ANOTHER USERGROUP Æ YES
IN THE NEW WINDOW ENTER Æ AUTHORIZED CLIENT
+ PASSWORD: SICKSAFE
Then click on ÆLOG ON!
The connection has been established.
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1.5.4 Transfer safety field
In the browser window (left side of the application) select with the Right mouse button S3000 System
and select then CONFIGURATION DRAFT, then TRANSMIT. The file is transferred. The now
appearing message have to be answered in a ”reasonable” way!
After the file has been transferred, a window will open. In this window the shape of the laser scanner
field may be checked (and if necessary, modified).
Click on „double
arrow“ to activate the
RELEASE button!
With RELEASE the safety field is activated in the laser scanner.
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1.5.5 Modify safety field
Select S 3000 with the RIGHT mouse button and then select CONFIGURATION DRAFT and then
EDIT FIELD SETS to open the safety field.
In this window it is now possible to modify the positions of the laser scanner reference points by
“dragging” them with the mouse to a different location.
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1.5.6 Checking the laser scanner field
With the software for the S 3000 it is possible to check, if the safety filed has been interrupted. It is
also possible to record the safety field for a certain time!
Examples:
The left picture shows a non interrupted safety field, the right window shows a interrupted safety
field.
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1.6 Start the control system and pre start-up of the machine
1.6.1 programming of the node number of the Z pusher measuring system
With this kind of control the Can cables may stay as described in the electrical documentation.
The main pump may stay on.
Z-pusher must be activated. (in Nodedisable.ini File -> „Enable“, refer to chapter 1.6.2)
Rename file c:\usr2\syscon\P4M_***_****\rtsoft\conf\LMTSETUPFILE.ini to LMTSETUP.INI.

Open the file, insert the actual sensor-number under serial_number and save. During the boot
sequence the file will automatically be renamed to LMTSETUPFILE.ini.
LMTSETUP.INI
[CanLine_1]
[CanLine_2]
[CanLine_3]
Node_31_Actor = 122A1GA7 'Z-Pusher Messsystem'
Node_31_Manufacturer_Name = MTSGmbH
Node_31_Product_Name = T3_C304
Node_31_Serial_Number = 04340129
Start the control again, during booting address 31 will be send.

Check with HyperTerminal during boot sequence.
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1.6.2 Programming the nodes of the outer segment translators (ABA)
For programming Can line to this valves must be connected to Can 3 on the electronic card (refer to
electrical diagrams for the Can line number).
The main pump may stay connected.
Valves must be activated (under power and in nodedisable file set to Enable, refer to chapter 1.6.3).
Rename file c:\usr2\syscon\P4M_***_****\rtsoft\conf\LSSSETUPFILE in LSSSETUP. Open the file,

insert under Serial_Number the actual valve-number , then save the file. After booting the file will be
renamed automatically to LSSSETUPFILE again.
LSSSETUP.INI
[CanLine_1]
[CanLine_2]
[CanLine_3]
Node_14_Actor = 106A1GA10 'the axis of the translator of the left hand outer segments'
Node_14_Vendor_Id = 40
Node_14_Product_Code = 149
Node_14_Revision_Number = 1
Node_14_Serial_Number = 17 =>>>>>>>> Serial number of the left valve (e.g. D 17)
Node_15_Actor = 106A1GA11 'the axis of the translator of the right hand outer segments'
Node_15_Vendor_Id = 40
Node_15_Product_Code = 149
Node_15_Revision_Number = 1
Node_15_Serial_Number = 18 =>>>>>>>> Serial number of the left valve (e.g. D 18)
Restart the control, during the booting sequence address 14 (left) and address 15 (right) will be set for
the valves.
Check with hyper terminal during booting sequence.
31/01/2008 Start-up manual P4-1916 26/233

1.6.3 switch on of the machine.
Important:
It must be ensured, that no not connected cables on the output side on the machine are available!
(Ground connection!)
It must be ensured, that the motor breakers of main pump, Moog drives, ... are turned off! If some
nodes are not be installed yet, then these must be turned off by the control for the boot sequence.
The file C:\usr2/syscon/P4M_*** _****/rtsoft/conf/NODEDISABLEDfile.ini must be copied on
NODEDISABLED.INI. In this file all “Enable” entries must be changed to “DISABLE” and then the
file must be saved!
Switch on control switch (-SA18) and main switch.

Control is started. Traffic lights on Syscon must turn green.
IMPORTANT:
If you get torque-loop errors from the MOOG drives during booting the reason may be Parameter
13501 of the respective axis file (refer to chapter 4.* of the corresponding axis).
31/01/2008 Start-up manual P4-1916 27/233

1.6.4 IBN of the cooling aggregate (MTA TAEevo 051, old version)
Chiller setting values (essential settings)
Hardware:
Between connector 5 and 10 in TAE is a potential-free contact of the P4. This is he enable signal fort
he chiller (Remote --> description in a.)
The error signal between contact 18 and 19 has to be connected to input SQ408K (refer to wiring
diagrams)
a.)USER Password and enabling (Remote)
Prg + Sel press for min. 5S 00 set to 22 22 USER LEVEL
Sel-button acknowledge S-P
open main menu open sub menu -H-

Sel-button ┌┘
Sel-button sub parameter H01 parameter H07 H07
Sel-button value of parameter 00 activate remote 01
Sel-button acknowledge H07 Prg open sub menu -H-
b.) Set reference and difference values (based on a.)
-H- Sub menu -r-
Sel-button Sub parameter r 01
Sel-button value of parameter 07 insert reference value 18 Stop of cooling
Sel-button acknowledge r 01 Sub parameter r 02
Sel-button Value of the parameter 04 Set difference Start

04 of cooling (22)
To safe the changed values, press the programming button until the actual temperature appears on
the display.
31/01/2008 Start-up manual P4-1916 28/233
1.6.4 Chiller (TAEVO, new version)
Hardware pre-conditions:
Between contact 5 and 10in the chiller is a contact fort he P4. It is for activation of the chiller.
Between connector 18 and 19 Input SQ408K has to be connected (chiller in error condition).
Actual temperature
Setpoint
temperature
+ press for 3 sec. min. set to St Temp. control

Prg Set All Set -Taste PA bar Set -Taste PA bar
St
+
Set-Button Parameter list ST01
+ St01 setpoint Temp. Set to 18° C
Set- Button 9 Set -T as t e PA b ar Set -T as te PA bar
18 Set- Button
Display blinks 3 times, before the value is saved!
St02 Diff. Temp.

ST02
Set- Button St02 Diff. Temp. 4 Set to 4° C 4

Set -Taste PA bar Set -Taste PA bar
Set- Button
St05 min. setpoint Temp.

ST05
Set- Button St05 min. setpoint Temp. 5 Set -Taste PA bar Set -Taste PA bar
Set to 14° C 14 Set- Button
PA5
Pr2
+
Set- Button + until the actual temperature is displayed 13° C
Set -Taste PA bar
If the setpoint temperature on the display is not displayed (off instead), the PRG-button
has to be pressed for 5 seconds.
31/01/2008 Start-up manual P4-1916 29/233

1.6.5 Flush of the hydraulic tank with circulation pump
Important: Emergency stop and safety fence switches must be quit able with the “fault
acknowledge” button .
A: Open Workspace OILTANK.WS in the monitor. All output signals to be tested are shown.
Carry out test, test motor breaker first and let them be switched on.
B: Fill pump with oil at leak pipeline.

Set KA45K briefly. Circulation pump must switch on itself. Check direction of rotation at the
motor and pressure (about 2.3 bar) at the monitor. Reset KA45K.
C: Set oil flushing switch (-SA28A) to flush.

Switch on with switch “circulation pump” on.
To check the oil level switch (-SL1) disconnect connector briefly. Pump must switch off itself.
Error message “oil level not sufficient” has to be shown on screen.
Attention: the ball cocks must be put vertically for oil flushing mode.
(SQ211 = 1, SQ212 = 0)
D: Flush the oil for 24 hours.

With the circulation pump the oil is cleaned in the hydraulic oil tank through the oil filter. This
flushing cycle should last for 24 hours without the main pump be switched on.
If the filter pollution pressure switch (SF2) is triggered, the filter has to be changed. Only after
the flushing cycle of the hydraulic oil tank the ball cock to the main pump may be opened so that
only filtered oil reaches the hydraulic circuit of the machine.
During the flushing cycle run the start-up may be continued.
1.6.6 Linear encoder test
A: In the monitor open axis window for the horizontal bending cylinder (-AS12, -AS13).
Move linear encoder on the horizontal bending cylinder at the tappet.
Bending unit closer to counter blankholder = positive counting direction.
B: In the monitor open axis window for the vertical bending cylinder (-AS10, -AS11).
Move linear encoder on the vertical bending cylinder at the tappet.
movement up = positive counting direction.
C: In the monitor open axis window for the blankholder (-AS9).

Move linear encoder.
movement up = positive counting direction.
1.6.7 temperature sensors Bending cylinder test
Open in the monitor Workspace Temp.ws. Warm the individual temperature sensors
on the vertical bending cylinder at the tappet with a hairdryer.
When the feeler of the right linear encoder is warmed the value IN9 must increase.
When the feeler of the right bending cylinder at the tappet is warmed the value IN25 must increase.
When the feeler of the left linear encoder is warmed the value IN20 must increase.
When the feeler of the left bending cylinder at the tappet is warmed the value IN26 must increase.
31/01/2008 Start-up manual P4-1916 30/233

1.6.8 adjustment of the Potentiometers of the TRD sheet thickness measuring device
Important:
Glue in screws of the clutches and fasten screws of the Potentiometer!
The supply voltage for the Potentiometer must be stabilized with a diode (V1) and a series
resistor (R37, 470 ohms) to 10V.
The TRD clamps are open. The BECKHOFF analogue converter (-A58) may be found in the
terminal box +S200.
A: IN8 (clamp in front of counter blankholder)

With open clamps a voltage of approx. 4.0 V must be measured on module A58D between
terminal 1 (+) and terminals 2,3 (-) . The adjustment is carried out via the adjustment of the
Potentiometer (oblong holes).
B: IN11-(Clamp away from counter blankholder)

With open clamps a voltage of approx. 4.0 V must be measured on module A58D between
terminal 5 (+) and terminals 6,7 (-) . The adjustment is carried out via the adjustment of the
Potentiometer (oblong holes).
Important:
The Potentiometer may not be adjusted anymore!
1.6.9 Adjustment of the Potentiometers of the double sheet control at the PCD
Important:
Check mechanics!
The supply voltage for the Potentiometer must be stabilized with a diode (101 A1-V1) and a
series resistor (101 A1-R3, 330 ohms) to 10V.
The measurement unit is closed. The analogue node (101A1-A32) may be found in the terminal box
101 A1S320.
A: 101A1IN51 (double sheet measurement device back, nearer to light barrier)

In closed condition a voltage of approx. 0.5 V must be measured on Node (101 A1-A31)
between terminal J2.1 (+) and terminals J3.7 (-) . The adjustment is carried out via the
adjustment of the hex socket head screw at the double sheet measurement device. Check, if the
voltage increases, when you press the device apart.
B: 101A2IN51 (double metal knife in front, nearer to protection fence)

In closed condition a voltage of approx. 0.5 V must be measured on Node (101 A1-A31)
between terminal J2.3 (+) and terminals J3.7 (-) . The adjustment is carried out via the
adjustment of the hex socket head screw at the double sheet measurement device. Check, if the
voltage increases, when you press the device apart.
31/01/2008 Start-up manual P4-1916 31/233

1.6.10 Teach-in of the light sensors (HPT/SAP)
Important:
Sensor may not be covered!
Press 2 Seconds release Set button
Set-button Yellow LED flashes
Cover sensor with metal about 10 mm away
Press 2 Seconds release Set button

Set-button Yellow LED on
1.6.11 Input and output test
Important:
Only in the Workspace available switches and output must be tested,
the remaining ones are tested with Micro-Cycle.
A: Open in the monitor Workspace Bendpress.ws. All inputs and outputs for the
Bending press will be displayed.
B: Open in the monitor Workspace Trolley.ws. All inputs and outputs for the
TRD will be displayed.
C: Open in the monitor Workspace ABA.ws. All inputs and outputs of the ABA will be displayed.
D: Open in the monitor Workspace Blankholder.ws. All inputs and outputs for the blankholder will
be displayed.
E: Open in the monitor Workspace Table.ws. All inputs and outputs for the manipulator and tables
will be displayed.
F: Open in the monitor Workspace Pult_PCD.ws. All inputs and outputs for the PCD control desk
will be displayed.
Open in the monitor Workspace Pult_SAP.ws. All inputs and outputs for the SAP control desk
will be displayed.
G: Open in the monitor Workspace Sap.ws. All inputs and outputs for the SAP will be displayed.
Attention: the optical sensors (95 A1SQ5A, -5B, SQ6 ...SQ570) must correctly be connected (pin
1 on 2 must be connected) and be adjusted.
H: Open in the monitor Workspace Pcd.ws. All inputs and outputs for the PCD will be displayed.
Attention: the optical sensors (101A1SQ30A, -30B, SQ72 ...) must correctly be connected (pin 1
on 2 must be connected) and be adjusted.
I: Open in the monitor Workspace Pcdtable.ws. All inputs and outputs for the PCD scissor table
will be displayed.
J: Open in the monitor Workspace OptionCUT.ws. All inputs and outputs for the option CUT will
be displayed.
K: Open in the monitor Workspace HPT.ws. All inputs and outputs for the HPT will be displayed.
L: Open in the monitor OPTION_P.ws. All inputs and outputs for the Option P will be displayed.
M: Open in the monitor RIP.ws. All inputs and outputs for the RIP will be displayed.
N: Open in the monitor Schutzzaun.ws. All inputs and outputs for the safety fence will be displayed.
31/01/2008 Start-up manual P4-1916 32/233

1.6.12 Adjustment of PCD vacuum switches (Sp33)
Basic setting
Sel-button Press for min. 2 s. PA set to bar bar
Sel-button Output 1 1nc set to normal open 1no
Sel-button Output 2 2nc set to normal open 2no
Sel-button Reaction time 2.5 set to 24ms 24
Sel-button Auto/Manuell AUt set to manual mAn
Sel-button 000
Pressure adjustment
Set with Monitor ***A1YV1(pneumatic on),101A1YV13A and delete 101A1YV13B.
Acknowledge light barrier and safety fence! Vacuum is switched on (101A1YV10A and 101A4YV10B
may not be on).
3 suction cups must be covered by a sheet!
-600 Vacuum will be displayed on switch Æ note the value Æ VAKUUM3
Sel-button Switch point closing contact on P 1 -600 VAKUUM3-0.5 -595
Sel-button Switch point closing contact off P 2 -600 VAKUUM3-1.0 -590
Sel-button Switch point opening contact on n 3 -600 VAKUUM3-0.5 -595
Sel-button Switch point opening contact off n 4 -600 VAKUUM3-1.0 -590
-600
Both 101A1SP33 and 101A2SP33 must be adjusted.
How to check the correct setting:

When 3 suction cups are covered, SP33 must be switch on,
When 2 suction cups are covered, SP33 must not be switch on.
31/01/2008 Start-up manual P4-1916 33/233

1.6.13 Exhaust flow controls and Limit dampers
IMPORTANT: In order to achieve the right speed of movement of the components listed
further down, it is necessary that the exhaust flow controls are adjusted at each individual
pneumatic valve. The "right speed" means that the component moves smoothly and
without jolting. Using the following "Microcycles" (Name.TL) each component is tested in
sequence and adjusted to the best setting.
Important: Emergency stop and safety fence switches must be quit able with the “fault acknowledge”
button . Air supplies must be available. Main hydraulics may not be switched on!
Handling of the Microcycles
Click on the Sysconshell on tools /MICRO CYCLES.

User name is Collaudo and password is P4M_*** _0*** HH:mm enter (current time). <return>.
Microcycle is opened.
Click on INTERPRETER, then Download UCYCLE. A list with the different Cycles appears. The
respective Cycle is loaded by double-clicking on it and may then be activated by clicking on “Start”.
A: XZANLI.TL
The XZ-stop (YV018) is extended and retracted alternately with vertical travel limiter (YV019)
or just with YV018. All relevant inputs and outputs will be tested that way. This way you can set
both valves. Make sure that hard impact is avoided.
B: XZANRE.TL
The XZ-stop (YV022) is extended and retracted alternately with vertical travel limiter (YV023)
or just with YV022. All relevant inputs and outputs will be tested that way. This way you can set
both valves. Make sure that hard impact is avoided.
C: POSSCHL.TL
The Z stop is moved back and forth (Z axis movement 50mm) controlled by valves YV021A and
YV021B. All relevant inputs and outputs will be tested that way. Make sure that hard impact
with the adapting plates is avoided, and that movement is smooth and jolt-free.
D: HUBBEGR1.TL
The vertical travel limiter is adjusted using valves YV043A and YV043B so that the upward and
downward movements can be carried out rapidly since these movements are included in the cycle
time. Make sure that the dampers on both cylinders are adjusted. All relevant inputs and outputs
will be tested that way.
E: HUBBEGR2.TL
The vertical travel limiter is adjusted using valves YV044A and YV044B so that the upward and
downward movements can be carried out rapidly since these movements are included in the cycle
F: TRD_ARM.TL
The movement valves -YV48A and -YV48B have to be adjusted so that the movements are
carried out rapidly but smooth and jolt-free. Make sure that the dampers on both cylinders are
adjusted. All relevant inputs and outputs will be tested that way.
31/01/2008 Start-up manual P4-1916 34/233

G: ZPUSHER.TL
Valve YV014 have to be adjusted that way, that the return movement is without interruption.
Both cylinder final position dampers have to be adjusted.
Valve YV012 has to be adjusted that way, that the upward movement is rapidly.
All relevant inputs and outputs will be tested that way.
H: Z_PUSHER_AUSSEN.TL (optional)
Valve YV058 left and YV061 right have to be adjusted that way, that the return movement is
without interruption. Both cylinder final position dampers have to be adjusted. Valve YV056
and YV059 has to be adjusted that way, that the upward movement is rapidly.
All relevant inputs and outputs will be tested that way.
I: ABSENKKE.TL
The lowering safety device of the bladeholder is pivoted in and out using valve YV029.
Make sure that oscillation is minimized at the limit positions. All relevant inputs and outputs will
be tested that way.
J: ABSENKNH.TL
Attention: This Cycle only may be started if low holder stands high enough!
Move the machine into the tool changing position and then start the microcycle. The lowering
safety device of the blankholder is pivoted in and out by valves YV030A and YV030B. Make sure
that the safety device does not oscillate when it reaches the limit position. Rapid movement is still
important though. This movement is included in the cycle time. All relevant inputs and outputs
K: AIP.TL (OPTIONAL)
The AIP is moved up and down by the valve 95A1YV29. It is necessary, the references move
without interruption and without hard impact. All relevant inputs and outputs will be tested that
way.
L: HPT.TL (OPTIONAL)
Valves 90A1YV1A and 90A1YV1B are set so that the upwards and downwards movements of the
HPT are carried out as fast as possible. The top limit is optimized using the limit stop dampers on
the cylinder and the lower limit is adjusted using a suitable setting value (3.5 to 4.0) on the
damper. All relevant inputs and outputs will be tested that way.
M: UPPER_SCHUTZKLAPPE.TL (optional)
Move the machine into the tool changing position and then start the microcycle. The upper HPT
safety flap is moved up and down using valves YV53A and YV53B. Rapid, jolt-free movement is
necessary to move the safety flap. This movement is included in the cycle time. Make sure that the
dampers on both cylinders are adjusted. All relevant inputs and outputs will be tested that way.
N: LOWER_SCHUTZKLAPPE.TL (OPTIONAL)
Move the machine into the tool changing position and then start the microcycle. The lower HPT
safety flap is moved up and down using valves YV75A and YV75B. Rapid, jolt-free movement is
necessary to move the safety flap. This movement is included in the cycle time. Make sure that the
dampers on both cylinders are adjusted. All relevant inputs and outputs will be tested that way.
O: TRD_KLAPPE.TL
The valves YV54A and YV54B have to be adjusted that way, that the move rapid but jolt-free.
Make sure that the dampers on both cylinders are adjusted. All relevant inputs and outputs will
be tested that way.
31/01/2008 Start-up manual P4-1916 35/233

P: RIP.TL (OPTIONAL)
The valves 16A1YV1 and 16A1YV2 have to be adjusted that way, that the move rapid but jolt-
free. All relevant will be tested that way.
Q: RIP_MOTOR_PINiON.TL (OPTIONAL)
The valve 16A1YV3 has to be adjusted that way, that the movement of the pinion is rapid but jolt-
free. All relevant inputs will be tested that way.
R: CUTFLAP.TL (OPTIONAL)
The valve -A1YV90 has to be adjusted that way, that the movement (opening and closing) of the
CUT safety flap is rapid but jolt-free. All relevant inputs will be tested that way.
S: CUT_Wanne.TL (OPTIONAL)
Adjust the dampers that way, that the movement is a rapid, jolt-free movement. All relevant
inputs will be tested that way. The valves -A1YV145 and -A1YV157 have to be adjusted that way,
that the movement of the CUT trolley is rapid but jolt-free. All relevant inputs will be tested that
way.
T: Option_P.TL (OPTIONAL)
With this cycle the hydraulic and pneumatic valves of the Option P are adjusted and checked
(correct activation and switches). In addition the correct speed is set by adjustment of the air
dampers.
U: TOOL_CLEAN.TL (OPTIONAL)
The tool cleaning system is inserted and removed using valves YV93A and YV93B. Rapid, jolt-free
movement is necessary to move the tool cleaning system. This movement is included in the cycle
V: SWORD_BRUSH.TL (OPTIONAL)
The sheet cleaning system is inserted and removed using valves YV224A and YV224B. Rapid,
jolt-free movement is necessary to move the tool cleaning system. This movement is included in
the cycle time. Make sure that the dampers on both cylinders are adjusted. All relevant inputs and
outputs will be tested that way.
W: KLAPPE_SAP.TL (OPTIONAL)
The valves 95A1YV3A and 95A1YV3B have to be adjusted that way, that the movement of the
SAP flap is rapid but jolt-free. All relevant inputs will be tested that way.
X: PCD_LINE_SEP.TL (OPTIONAL)
The valves 101A1YV30A and 101A1YV30B have to be adjusted that way, that the movement of
the line separator is rapid but jolt-free. All relevant inputs will be tested that way.
Y: PCD.TL (OPTIONAL)
With this cycle all pneumatic devices are tested and adjusted (beside the line separator and
suction cup groups): Sheet stop, sheet raiser, sheet thickness measuring device, sheet stop. In
addition the movement speed is set by adjustment of the air dampers.
Z1: PCD_SUC_SWITCH.TL (OPTIONAL)

IMPORTANT: Set the switches first!
With this cycle the movement of the suction cup groups (1-5) are adjusted and checked (correct
activation and switches).
31/01/2008 Start-up manual P4-1916 36/233

Z2: PCD_SUC_DOUBLE.TL (OPTIONAL)
With this cycle the movement speed of the suction cup groups (1-5) is set by adjustment of the
air dampers. In addition the sheet thickness check position is adjusted (xSQ64).
Speed upward movement
SQ65
400mm
YV11BÆ movement upward
YV11AÆ movement downward
SQ64
145mm
SQ63
60mm
Speed downward movement
Move duides
downward
SQ16Æ switches on when

sheet is dedected
Z3: PCD_RF30.TL (OPTIONAL)

Here all pneumatic devices of the RF (sheet Stopp and index) will be set-up.
Z4: PCD_RF_CENT.TL (OPTIONAL)

Here all pneumatic devices of the PCD centring device when RF is present (pincer and extra
stroke) will be set-up.
1.6.14 start-up scissor table
A: Open Workspace PCDTABLE.WS in the monitor. All relevant inputs and outputs will be
displayed. Carry out input test, test motor breaker (101A1QM1) first and leave it switched on.
B: Press 101 KM1. The scissor table pump will switches itself on. Check the direction of rotation at
the motor.
31/01/2008 Start-up manual P4-1916 37/233

2. Start commissioning
2.1 Adjusting of CTMs and making the TOOLDAT.INI
Open the “configurator”, select the individual actors depending on machine specification. By clicking
on "Set CTMs" the CTMs are typed in correctly and the TOOLDAT.INI file is prepared. (check
Tooldat.ini for correctness)
Attention: CTMs already adjusted too can be overwritten with "Set CTMs"!
Here the maximum sheet thickness for normal steel has to be inserted.
When the bending line is reduced, parameter 201 and 204 in axis-file AI30 have to increased
according to the difference to standard bending line tools.
31/01/2008 Start-up manual P4-1916 38/233

Important:
The following CTMs must be checked on their correctness!
The red values are for 60Hz, the blue values are for 50Hz (22kW motor),
Pressure keeping pump assumed to be a 5.3 kW motor.
1536 (MD_SCDV) = 1.00 SCDV corner tools and ALA
1536 (MD_ALA) = 0.00 For IBN, at IBN of ALA =2, ABA =3,4
1569 (MDE_DFE_POWER_MODE) = -1.00 Performance mode
1616 (BendingUnit.minFDI) = 422.00 Vertical cylinder length
1618 (BendingUnit.minSTI) = 284.00 Horizontal cylinder length
1930 (BLH_ADD_PUMP_RANGE) = 2.00 Add-on pressure holding pump to BLH
2129 (BARBEND) = 25.00 Pressure for Geometry set-up
2144 (OIL_RESET_TIMEOUT) = 500.00 Delay Pressure switchover to Idle
50.00 Min. pressure for pressure holding pump
2161 (ADD_PUMP_PRESS) = (10 bar during flushing)
20.00 Min. pressure for main pump
2174 (MAIN_PUMP_PRESS) = (10 bar during flushing)
2546 (DFE_FLOW) = 83.50/100.00 Pump displacement rating
2548 (DFE_PRESS_IDLE_ST) = 35.00 Standby pressure Standard-Mode (STM)
2550 (DFE_POWER_IDLE_HS) = 32.53/39.01 Overall power in High-Speed-Mode
2551 (DFE_POWER_BLH_HS) = 32.53/39.01 BLH power in High-Speed-Mode
2552 (DFE_POWER_BEN_HS_FAC) = 1.30 Power factor for edging in HSM
2556 (DFE_POWER_BEN_ST_MIN) = 15.47/18.55 Min. power for edging in STM
2557 (DFE_POWER_BEN_ST_MAX) = 25.02/30.01 Max. power for edging in STM
2558 (DFE_POWER_IDLE_EC) = 11.00/13.20 Overall power in Economy-Mode
2559 (DFE_POWER_BLH_EC) = 11.00/13.20 BLH power in Economy-Mode
2560 (DFE_POWER_BEN_EC_FAC) = 0.75 Power factor for edging in ECO
2561 (DFE_POWER_BLH_LFT_EC) = 14.60/17.50 BLH power for air movements in ECO
2573 (DFE_PRESS_MOV_VHC_ST) = 125.00 Pressure for moves VBC + HBC in STM
2575 (DFE_PRESS_MOV_BLH_ST) = 145.00 Pressure for move BLH in STM
Important: The cylinder lengths for the CTMs 1616 and 1618 may be found in the list
\\SW_NT\Office\EXCEL.EXE (open Excel file)
\\Smsalvmb\MASCHINENORDNER\MAßPROTOKOLLE\ZYLINDER
(in Protokoll -folder look fort he cylinder numbers, Æ in Hbc / Vbc- folder the clinder lengts may be found in the excel
file)
Always insert higher value! Attention: The red values are for 60 Hz, the blue for 50 Hz
The electrical power (CTM 2550) may be calculated as follow :

PM = Nominal power of the Motor (22.00 kW at 50 Hz.)
P100% = maximum power of the DFEC pump (76.523kW, 63.806kW)
N = motor nominal speed (1745min, 1455min)
VG = Nominal size of hydraulic pump (71 cm³)
P = System pressure (pressure sensor=315Bar)
η = efficiency value of hydraulic pump ( about 0.85 at max. power)
η = efficiency value of electrical motor ( 0.915)
VG × n × p 71 × 1455 × 315
P 100 % = P 100 % = = 63 . 806 kW
η P × 600000 0 . 85 × 600000
Æ Nominal power of the pump is 63.806Kw.
Motor 50% overloaded = 33.0Kw
Mechanical load = 33.0kW * 0.915 = 30.195kW
30.195kW-5.3kW (pressure keeping pump)= 24.895kW
24.895 / 63.806= 39.01%, 24.895 / 76.523=32.53%
31/01/2008 Start-up manual P4-1916 39/233
2.2 Switching on the hydraulic main pump
Important:
Only after completed flushing the tank.
A: Filling main pump with oil at leak pipeline.
B: The connections X1, X2 and X3 at the Bending unit hydraulic block must get dismantled or
closed.
C: Flushing valves switch to position 0 . (closed)
D: Install additional filter station between tank and machine, open then sucking line and switch on
engine circuit breaker for hydraulic main pump (-QM2) .
E: Open program WINIPED32 REXROTH.

In this application click on country "works" and open C:\REXROTH\PROJECT\PROJEKT._pr.
Afterwards select modify, Select configuration ,the serial interface must be adjusted then under
Settings. (Com8 bzw. Com10, Address 1 and Address switch to 0)
Click on "communication" and select „Transfer firmware“.
Then click on "Communication" again and select "control initialization".
Important: CAN-Bus's plug must be disconnected during firmware transfer and initialization!
Illus. 2.2.1
F: Now connect CAN-knots and boot control again. Click on "modify" and select PROJEKT._pr.
31/01/2008 Start-up manual P4-1916 40/233

Illus. 2.2.2
Illus. 2.2.3
Important: Parameter set 12 must be loaded. The performance limitation must be set to 39.01 % / 32.53%
with 60Hz (CTM 2550).
(CTM 129 may not be 100, node in Nodedisable.ini NOT disabled)
G: Switching on pump in „Tip“-mode and check direction of rotation of these.

The pump must spin to the right, if you look from the fan side.
Watch for leakages.
H: Switch on pump, the pressure set point indication must show 35 bar.
the pressure actual indication must go on approx. 35 Bar. (Illus. 2.2.3)
Adjusting now the mechanical regulator of the pressure hold pump on 160 bar.
You can read it in the monitor(-IN12) or you may measure at the pump block measuring point
M1.
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2.3 Flushing of the servo hydraulics
Important:
Cooling system must be in the operation.
A: Fit the connections X1, X2 and X3 at the Bending unit hydraulic block again.
B: Vertical Kant cylinders flushing.

"Flushing valves" for the vertical Kant cylinders in position “open”, Switch on hydraulics and
carry out leakage check. Let the hydraulics run 2 hours now to flush the vertical bending
cylinders.
C: Horizontal bending cylinders flushing.

Switch flushing valves for the horizontal bending cylinder in position all others stay in position
"open", switch on hydraulics and carrying out leakage check.
Let hydraulics on half a hour to flush the horizontal bending cylinders.
D: Blankholder circuits flushing.

Switch flushing valves for the blankholder in position "open", all others in position “closed”.
Switching on hydraulics and carrying out leakage check.
Let hydraulics run 2 hours to flush the blankholder circuits.
E: Flushing of the outer segment translators.

Flushing valves fort he outer segments adjuster set to „AUF/OPEN, all others set to
„ZU/CLOSED“. Switch on hydraulics, check for leakages
Let hydraulics run 1 hours to flush the BLX/BLH circuits.
F: Mount pilot valves.

At the blankhoder hydraulic block the pilot valve D661-4695 (ServoJet), on the horizontal
bending cylinders the pilot valves D634Z510 (DirectDrive) and on the vertical bending cylinders
the pilot valves D661Z4638 (ServoJet).
Attention: Change the CTM parameters values back after the flushing run
2159 (PILOT_OIL_PRESS) = 30.00-> Threshold value pilot oil pressure sensor

2161 (ADD_PUMP_PRESS) = 50.00-> Threshold value pressure keeping sensor
2174 (MAIN_PUMP_PRESS) = 20.0-> Min. pressure of the pump
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2.4 Calibration of the DFEC pump
IMPORTANT: Save only after the calibration cycle is not running anymore!
2.4.1 Check of parameter set 12
With 60 Hz machines parameter 525 and 526 must be set to 20.

Check all parameters according to the screenshot above.
Parameter 600 must be 0 and 601 must be 100 in the configuration.
Lower internal setpoint ramp must be set to 100 (Parameter 639).
Important:
The oil temperature should be between 35 and 45 degrees. The calibration actions are activated by
selecting „Maschinendaten“, then click on settings and then select the correct action. Save values with
function key <F10>. The order of calibration procedures must be followed!
Important:
During pump calibration CTM 2174 has to be changed from 20bar to 10 bar temporarily!
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2.4.2 Calibration of DMU2
Important: Before the calibration is started, it must be guaranteed, that the hydraulics are turned off
and the system is pressure less.
Status byte: After calibration

must change back to zero!
Save with function key <F10>.
2.4.3 Calibration of the valve
The non-linear valve characteristics will be corrected by this adjustment. 4 pre-defined pressure
values will be used (35-145-190-250 bar). Before the calibration is started, it must be guaranteed, that
the hydraulics are turned ON and the locking valves are in locked position!

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2.4.4 Calibration of the offset of the pivoting angle sensor
Before the calibration is started, it must be guaranteed, that the hydraulics are turned ON and the
locking valves are in locked position!

2.4.5 Calibration of the amplification of the pivoting angle sensor

IMPORTANT:
Swivel angle actual value must be 100% (+-2%), and hydraulic must be switched off!
Proceture:
Switch on hydraulics. Select Ma.-com. PUMP PRESSURE 185 to achive 145bar pressure (keep
manual command button pressed). Then press emergency stop.
Must be 100% Status byte: After calibration

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2.4.6 Calibration of the leakage compensation (145Bar)
Before the calibration is started, it must be guaranteed, that the hydraulics are turned ON and the
locking valves are in locked position!

2.4.7 Check adjustment of maximum pressure protection
Select in Ma.-com. PUMP PRESSURE MAX. by pressing the enable button the Pump will switched
on maximum bending pressure. Pressure set point and real pressure value in the WIN-PED must
roughly correspond to 250 bar.
The maximum pressure protection must be adjusted by 20 bar higher. For control temporary
increase value of CTM 2126 by 30. Click 2x Kill.
Press enable button, Nominal value is 280 Bar

Real value should be about 270 Bar
Should the pressure be higher, the valve must be removed and adjusted at the hydraulic test bed.
Important:
Afterwards correct then CTM 2126 again to 250 bar.
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2.5 Adjusting the switches –SQ16, -SQ17, -SQ150 and –SQ151.
1060-1080
328.0
211.0
223.5
SQ150 251.5 SQ151
98.5 134.5
108.5 146.0
Gegenhalter SQ17 SQ17 SQ17 SQ16
Fixanschlag Hubbegr. 1 Hubbegr. 2
MLA ABA
ABA standard 25/400/140/SO/UEB55
CTM 1988 99.0 109.0
CTM 2106 252.0 252.0
CTM 2107 135.0 147.5
CTM 1630 330.5 330.5
CTM 1640 213.5 226.0
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2.6 Loading the software for the Lenze drives
Using the communication modul LECOM-A and the software application „GLOBAL DRIVE
CONTROL (GDC)“ the correct axis files may b)e stored into the LENZE drives. Connect the drive
using a cable (RS232) with the PC (COM4).
If the file has to be exchanged later (at the customer) the changes have to be carried out by using a
Keypad which is supplied with the machine.
IMPORTANT: The power supply must be ok before you may program the drives.
(Acknowledge light barrier, E-Stops and so on...)
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Open program “Global Drive Control”.
Select Options-Æ Communication
Select correct COM port
Click on Drive and select Find or press the „F2“ button.

The connection to the drive is established.
A drive has been found an

connection is established
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The module “function” opens.
Click on Continue and then on Complete
Select the correct set of parameters.
Click here and then select

read all parameter sets from file
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In directory C:\USR2\SYSCON\P4M_***_****\CONFIG\Lenze\ the correct parameter files may be
found.
Select file and

acknowledge with Ok
By double-clicking on “Code list” the parameters are displayed.
Actual set of
parameters
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Now the file must be transferred to the drive.
Click here and

write current parameter set to
controller (F5)
Check motor data according to the plate on the motor.
First click here and

then on Motor data
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Identify the motor. During this procedure the motor resistor and so on will be determined.
The drive must be under power and enabled!
Enable the motor with the monitor, (with digital drives by setting them under power).
With PCD-Axes set CTM „MD_PCD“ to zero temporary and enable the axis.
With RIP-Axes set CTM „MD_RIP“ to zero temporary and enable the axis.
With TCV-Axes set CTM „TCV_SPEED“ to zero temporary and enable the axis.
With SAP set output 95A1KA1 to one.
Click on STOP!!!
Switch on drive by using monitor
Now start identification.

IF there is no display of current, the
enabling/brakes are not ok!!
After identification disable drive with

monitor and click on START.
IMPORTANT: First click on „start“, otherwise the drive will not be ready (green LED must be
flashing).
With PCD conveyor (101A1AX1) and ACP conveyor (142A1AX4, 83A1AX3), parameter 21 (slip-
compensation) has to be set to 0 in the code-list!
Afterwards safe back the file to C:\USR2\SYSCON\P4M_***_****\CONFIG\Lenze\… .
Click here and then

write all parameter sets to file
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3. Start-up of the individual actors and calibration
3.1 Table of axis:
Name Number Positive Direction

Electrical servo axes
Manipulator AX14 To bend line
Rotator AX15 Counter clock-wise
Transport sledge AX16 From left to right
Additional lower bending tool AX17 From outside to center
Additional upperbending tool AX18 From outside to center
Left ABA preadjusters AX34 From outside to center
Right ABA preadjusters AX35 From outside to center
Additional left lower bending tool AX37 From outside to center
Additional upper left bending tool AX38 From outside to center
RSU AX39 From left to right
X-carriage of XZ stop left AX1 From outside to center
Z-carriage of XZ stop left AX2 To bend line
X-carriage of XZ stop right AX3 From outside to center
Conveyor PCD/PC 101A1AX1 From TRD away
Centering device PCD/PC 101A1AX3 To bend line
Suction cups translator PCD 101A1AX6 Together
Transfer RIP 16A1AX1 To TRD
Trolley RIP 16A1AX2 Away from bend line
Turnover RIP 16A1AX3 Clock-wise
Add. centering device RIP 16A1AX4 Together
HPT table 101A1AX1 To bend line
Hydraulic servo axes
Vertical bending cylinder AS10/AS11 Up
Horizontal bending cylinder AS12/AS13 To bend line
Left ABA translators AS32 To center
Right ABA translators AS33 Tocenter
Blank holder AS9 Up
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3.2 Explanation of first movement on an axis using "micro cycle"
NOTE: Relevant axis must be uncalibrated.

IMPORTANT: Start relevant "Microcycle" (as in -> section 1.6.11), at the operating desk the light
"Automatic cycle activity" lights green. Pressing the pushbutton "Enable manual control" allows the
axis to be moved as long as this button is pressed.
NOTE: Finish that "Microcycle" as soon the check has been completed. Do this either by "killing" the
"Microcycle", or by switching off the machine, "Emergency OFF" or "Hydraulics off“ on the
hydraulic axes.
All fist-time movements of actors and axes are done by using „Micro-Cycles“.
They are used for:

Æ Functionality check of switches, which are used in the cycles.
ÆCheck for correct position of switches, which are used in the cycles.
Æ Functionality check of valves, which are used in the cycles.
ÆCheck for correct position of valves, which are used in the cycles.
ÆFor adjustment of dampers and speed of pneumatic cylinders,…
IN SCON under TOOLS the application „Micro-Cycles“ may be selected.
collaudo
P4M_510_1016 08:38
Always use actual time
Select machine number
From here the cycles are activated
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3.3 Free movement and calibration of horizontal bending cylinders (AS12/13)
3.3.1 First movement and free movement of horizontal bending cylinders
NOTE: Check set points and sensor signals for correct direction of movement (as per table. 3.1).
NOTE: Measuring system must be connected mechanically to the cylinder.
Start "microcycle" ACHSE_HBC.tl and move the blade holder back in jog mode. If it moves in the
wrong direction, check the wiring or axis parameter file.
This process is also used to check the direction of counting (Call up "Monitor" -> check direction of
counting with "Axes" function -> table 3.1) of the measuring system.
With microcycle Absenkke.tl may now the safety device of the bending unit be adjusted.
After the measuring system has been checked, move the blade holder slowly right back to calibrate the
zero zone switch SQ46. Set this switch from the back towards the front so that it switches about 3.0mm
before the limit position of the cylinder is reached.
IMPORTANT: The cylinder must be in its limit position. Carry out Ma.-com. "Bending unit
backward" again to be on the safe side.
3.3.2 Measuring procedure for horizontal bending cylinder
CTM parameters
2462(HBC_RIGHT_OFFSET) = -1.8->Distance zero point to cylinder on block
*Approximate values that must be updated after measurement has been completed.
Procedure:
The measuring procedure is started using Ma.-com. "measurement HBC". This is similar to the
calibration procedure, except it is carried out after the axes have been calibrated by continuing
movement towards "cylinder on block". The distance from zero point to cylinder on block can now be
measured using the axis control. An Insert appears on the monitor screen with the relevant CTM
parameters. These are to immediately entered in the machine constants. Load by selecting SAVE and
DOWNLOAD.
3.3.3 Calibrating horizontal bending cylinders -> do measuring procedure first
IMPORTANT: The CLA must be located on the outside (SQ68/69=1), because otherwise the function
will be interlocked and calibration is not possible.
The calibration procedure is started using Ma.-com. "calibrate HBC".
After the zero zone switches SQ46 have been actuated the axes move free and then towards zero
(backwards). If the zero zone switches are not registered the bending cylinders move immediately to
zero. If the detent is not free, the bending cylinders move to zero first and then the calibration is
started. If the axes move to zero during calibration, and the zero zone switch SQ46 is registered, the
relevant counter is set to zero as soon as the zero pulse is reached (calibration mark in the measuring
system). The blade holder continues moving to the second zero pulse to set the other counter to zero,
completing the calibration procedure.
IMPORTANT: The difference between the two zero points is taken into consideration by the axis
software.
The axes are then positioned at 0.2 mm (+ Delta valve in CTM-file).
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3.4 Free movement and calibration of vertical bending cylinders (AS10/AS11)
3.4.1 First movement and Free movement of vertical bending cylinders
NOTE: Check setpoints and sensor signals for correct direction of movement (as per table 3.1).
NOTE: Measuring system must be connected mechanically to the cylinder.
Start "Microcycle" ACHSE_VBC.tl and move the blade holder upwards in jog mode until the blade
holder is free. If it moves in the wrong direction, check the wiring or axis parameter file.
counting with "Axes" function -> table 3.1) of the measuring system.
After the measuring system has been checked the blade holder is ready for the vertical calibration
procedure.
3.4.2 Measuring vertical bending cylinders
CTM parameters to be determined

2460(VBC_RIGHT_OFFSET) = *-14.70->Distance zero point to cylinder on block
2467(VBC_R_MUTMP_CAL) = *25.00->ALU-Temp. during measuring procedure
2478(VBC_ZYL_R_MUTMP_CAL) = *40.00->cyl.-Temp. during measuring procedure
*Approximate values that must be updated after measurement has been completed.
Procedure:
The measuring procedure is started using Ma.-com. "measurement VBC". This is similar to the
calibration procedure, except it is carried out after the axes have been calibrated by continuing
movement towards "cylinder on block". The distance from zero point to cylinder on block can now be
measured using the axis control. An Insert appears on the monitor screen with the relevant CTM
parameters. These are to immediately entered in the machine constants. Load by selecting SAVE and
DOWNLOAD.
3.4.3 Calibrating vertical bending cylinders -> do measuring procedure first
IMPORTANT: The horizontal bending cylinders must be located at zero zone switches SQ46 because
otherwise the function will be interlocked and calibration is not possible.
The calibration procedure is started using Ma.-com. "calibrate VBC. The calibration procedure is the
same as for the horizontal bending cylinders except that these axes may not be moved away from the
detent. The axes are then positioned at 0.2 mm (+ Delta valve in CTM-file).
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3.5 Automatic blankholder adjustment (ABA)
(Automatic blankholder adjustment)

ABA will be activated by changing CTM-parameter 1557 (MD_ALA) to 3,4,5 or 6.
Two hydraulic axes are used to move the outer segments. Theoretically a gap may be opened in
between each and every tool (embossing).
The two electrical axes are used for setting the inner tooling configuration (combo unit). These motors
are only being allowed to move when the hydraulic motors are inserted and the tool clamping devices
are activated.
IMPORTANT: When the hydraulic motors are disinserted, the spindle of the electrical motors MAY
NOT BE TURNED! Movement of single actors (monitor) may only be carried out by Salvagnini
technicians after excessive training!!!
Actions may only be used when CTM 129 >0 and EXPERT use of manual commands.
3.5.1 Important CTMs
Blue P4-1916 Black P4-3216

Red P4-2516 Green P4-3816
660(ABA_TRA_SPEED) = 400.0 Speed outer segment axis
661(ABA_TRA_ACC_MAX) = 9000.0 Acceleration ramp of
outer segment axis with one tool locked to
axis
662(ABA_TRA_DEC_MAX) = 9000.0 Deceleration ramp of
outer segment axis with one tool locked to
axis
663(ABA_TRA_ACC_MIN) = 8000.0 Acceleration ramp of
6000.0 outer segment axis with all tools locked to
5000.0 axis
4000.0
664(ABA_TRA_DEC_MIN) = 8000.0 Deceleration ramp of
6000.0 outer segment axis with all tools locked to
5000.0 axis
4000.0
665(ABA_PREADJUSTER_SPEED) = 225.0 Speed inner segment adjuster
666(ABA_PREADJUSTER_ACC) = 5000.0 Acceleration inner segment adjuster
667(ABA_PREADJUSTER_DCC) = 5000.0 Deceleration inner segment adjuster
670(ABA_SWING_IN_TIME) = 200.0 Delay time hydraulic motor in ms
671(ABA_PRESS_DIFF) = 245.0 Pressure difference (inc/8=30bar) outer
segment adjuster during measurement
(Hub..) in Inc.
673(ABA_PRESS_SPEED) = 400.0 Speed for disinsertion
674(Right_Tra_Range) = 0.10 Imposition limit for right translator for
middle segment down
675(Aba_Insert_Slow_Range) = 8.0 Speed reduction range
in mm, (Switched to 20mm/sec)
for clamping the first segment.
1536 (MD_SCDV) = 1.0 Extra stroke for VBC because of center
segment
1557 (MD_ALA)/ (MD_ABA) = 3.0 Activates ABA without out. segment check
4.0 Activates ABA without out segment check ,
Bend without outer segments possible
5.0 Activates ABA with outer segment check
6.0 Activates ABA with outer segment check ,
Bend without outer segments possible
(default)
2194 (ExpandingWidth) = 148.0 Stroke between two outer segments in mm
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2194 (ExpandingWidth) = 153.0 Stroke between two outer segments in mm
P4-1916
2195 (CompositSeg_1) = 5.0 combo segment width in mm
2196 (CompositSeg_2) = 12.0 Number of inner segments
2198 (CompositSeg_4) = 65.0 Width of the first outer segment (53.0)
2200 (Middlesegment) = 128.0 Width of center segment
2201 (Komposit_Left) = 135.0 With of whole combo unit left
2202 (Kompos._Right) = 135.0 With of whole combo unit right
2203 (Segment_Left) = 11.0 Number of outer segments left
16.0
21.0
26.0
2204 (Segment_Right) = 11.0 Number of outer segments right
16.0
21.0
26.0
2205 (Contra_Length) = 30.0 Disengagement length in mm
2206 (Mo_Seg_Length) = 65.0 Width of outer segments in mm
2207 (Min_Lenght_st) = 5.0 BLH tooling step in mm
2210 (OUTERSEGREACTIONTIME) = 100 Delay time for tool clamping in ms
2213 (MSPCONTRACTIONTIME) = 150 Delay time center segment up in ms
2216 (CPTSETTIME) = 50 Delay time for extraction of combo in ms
3.5.2 PRE-start-up conditions
Before the hydraulic is switched on for the first time, the following checks have to be carried out:
DANGER: during the measurement the lamp must be on “green”!!!

Control if the main pressure has 0bar and that the valve YV5 is switched off!!!
Î A: Blankholder must rest on blankholder safety device

Î B: Disconnect plug of valve –YV131A (center segment down)
Î C: The two hydraulic motors must be disconnected and sealed off
Î D: The inner segments must be holt by holding devices (white plastic pieces)
Î E: Measurement of the width of the inner tools (5mm blades) will be done automatically,
insert value of 4 in CTM 2195 for now.
Î F: Move the spindle of both electrical motors to the center stop,
Measure with a depth gage from the inner segment to the carrier,
Must be =0.2mm! (Picture 1)
Î G: Move the spindle of both electrical motors to the outside stop (put a 0.4mm shim in
Between stop and carrier),
Measure with a depth gage from the outermost inner segment to the carrier,
Must be =0.2mm! (Picture 2)
Check, that the pin is inside the guide ( when a 0.2mm shim is inserted at the stop, the pin
must be inside the guide about 0.2-0.3mm) . Test if you may move the guide freely in and out.
Î H: ABA input and output test must be finished (chapter.1.6.10)
Î I: Outer segment hydraulic cylinder units have been flushed (chapter.2.3)
Î J: Pressures of hydraulic motors and preadjusters have to be checked. (100(*)/120 bar each)
Î K: Check all hydraulic lines related to the ABA for tightness.
IMPORTANT: If you have to use ABA manual commands, CTM 129 (IBN) must be 1, CTM 1557 must
be 3+ and in the manual command window you must be logged in as an expert user!
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Picture 1
Spindle moved to
inner stop,
= 0.2mm
Picture 2
Spindle moved to
inner Stop
(0.4mm away)
Distance
= 0.1mm minimum
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3.5.3 Left translator unit (AS32)
First time movement
IMPORTANT: Measurement device must be aligned already (position and parallelism)

In Monitor open „Workspace“ ACHSE_ABA_LI_AUSSEN.
With „Microcycle“ ACHSE_ABA_LI_AUSSEN.tl left translator may be moved to the outside/inside.
Check:
ÆMovement to center (START-button) counting direction of AS32, has to be positive,
if the translator is against inner stroke limit, the pressure of IN27 has to be about 35bar .
ÆMovement to outside (STEP-button) counting direction of AS32, has to be negative,
if the translator is in cylinder stroke limit outside, the pressure of IN28 has to be about 35bar .
ÆWhen pressure to outside is on (IN28 ca. 35bar), adjust calibration switch –SQ506.
First time manual calibration
With Ma.-com. "calibrate left translator" the calibration will be started. When SQ506 is ON, the axis
moves free and then moves to the micro-switch again (to zero position).
After successful calibration, glue in place the switch –SQ506!
3.5.4 Right tooling length adjustment unit (AS33)
First time movement
IMPORTANT: Measurement device must be aligned already (position and parallelism)

In Monitor open „Workspace“ ACHSE_ABA_RE_AUSSEN.
With „Microcycle“ ACHSE_ABA_RE_AUSSEN.tl left translator may be moved to the outside/inside.
Check:
ÆMovement to center (START-button) counting direction of AS33, has to be positive,
if the translator is against inner stroke limit, the pressure of IN30 has to be about 35bar .
ÆMovement to outside (STEP-button) counting direction of AS33, has to be negative,
if the translator is in cylinder stroke limit outside, the pressure of IN29 has to be about 35bar .
ÆWhen pressure to outside is on (IN29 ca. 35bar), adjust calibration switch –SQ507.
First time manual calibration
With Ma.-com. "calibrate right translator" the calibration will be started. When SQ506 is ON, the axis
moves free and then moves to the micro-switch again (to zero position).
After successful calibration, glue in place the switch –SQ507!
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3.5.4 Tool clamping of the inner segments
The clamping device must be open during swing in or swing out movements of the segments.
(SQ431 and SQ434 must be zero, SQ432 and SQ433 must be one)
During insertion and disinsertion movements the clamping device must partly be open.
(SQ431 and SQ434 must be one, SQ432 and SQ433 must be zero)
When bending the clamping device must be closed (max. pump pressure.)
Attention: the switches must be adjusted exactly!
In Monitor open „Workspace“ Innensegmentklemmung.
Start „Microcycle“ Innensegmentklemmung.tl.
Oil draining:
With Monitor switch on valve *A1YV177 activate the inside segment clamping
Æ drain at the lower screws (B3,B4).
By setting to 0 of valve *A1YV177 open the inside segment clamping again.
Repeat this process several times, to guarantee that the clamping unit is fully drained.
Attention: It must be drained at the lower screws. (10.0mm clamping cylinder) Control of the correct
tubing.
With Monitor switch on valve *A1YV176 activate the partial inside segment clamping
Æ drain at the upper screws (A3,A4).
By setting to 0 of valve *A1YV176 open the partial inside segment clamping again.
Repeat this process several times, to guarantee that the clamping unit is fully drained.
Attention: It must be drained at the upper screws. (9.9mm clamping cylinder) Control of the correct
tubing.
3.5.5 contraction cylinders and center segment

The contraction cylinder must always be activated,(bending, calibration...) , only during contraction
the cylinder will be deactivated. With the outer tool adjustment unit the segments will be moved
together (under the middle segment)
In Monitor open „Workspace“ Ausfaedler .
Check:
Set with monitor:

Set Valve -YV163A to 0 and set valve -YV163B to 1. left contraction cylinder deactivated
Set Valve -YV163A to 1 and set valve -YV163B to 0. left contraction cylinder activated
Set Valve -YV164A to 0 and set valve -YV164B to 1. right contraction cylinder deactivated
Set Valve -YV164A to 1 and set valve -YV164B to 0. right contraction cylinder activated
When a contraction cylinder is activated, a gap of 0.10mm-0.12mm has to be between the
corresponding contraction cylinder and the center segment.
Start „Microcycle“ Mittelsegment.tl
Æ Check function and switches of the center segment.
3.5.6 Inner segments holding devices

In Monitor open „Workspace“ Innensegmenthalterung.
Start „Microcycle“ Innensegmenthalterung.tl
Check and adjust:
Æ correct function
Æ adjust related switches
Æ adjust the air dampers (normally totaly turned to outside)
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3.5.7 swivel motors
Attention: The motor spindle of the preadjuster must be moved to the final position by hand!
In Monitor open „Workspace“ Schwenkmotore.
Start „Microcycle“ Schwenkmotor_no_Tool.tl.
Check:
ÆBoth motors will swing in and out.
ÆCheck for both motors movement and switches.
Now move the two spindle manual to the inner stop and check the position again.
Attention: Spindle of the preadjusters must be easy to move!
Start „Microcycle“ Schwenkmotor_mit_Tool.tl.

Adjustment:
Î Now adjust with the two „Microcycles“ Aba_Swing_Motor_WT.tl (..with tool) the final stroke
dampers (until the swing in and out time is correct)
Î The pressures may not be changed (100 bar).
Î Check the final position (refer to picture below).
Î Spindle of the pre-adjusters must be easy to move when segments are clamped!
Gap of 2.3 mm
+/- 0.3mm tolerance
Measured at small gap position
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3.5.8 Left preadjuster (AX34)
First time movement
Attention: clamping must be activated and the swivel motor must be swung in!
In Monitor open „Workspace“ ACHSE_ABA_LI_INNEN.
With the „Microcycle“ ACHSE_ABA_LI_INNEN.tl the left preadjuster may now be moved to the
outside and to the inside.
Check:
ÆMovement to center (START-button) counting direction of AX34, has to be positive,
ÆMovement to outside (STEP-button) counting direction of AX34, has to be negative,
Æ adjust calibration switch –SQ508.
First time calibration
With Ma.-com. " calibrate right preadjuster" " the calibrating process is started. When the calibration
switch SQ508 is 1, the axis will first move away from the switch and when it is free, it will move to zero
(to the outside).
3.5.9 Right preadjuster (AX35)
First time movement
Attention: clamping must be activated and the swivel motor must be swung in!
In Monitor open „Workspace“ ACHSE_ABA_RE_INNEN.
With the „Microcycle“ ACHSE_ABA_RE_INNEN.tl the left preadjuster may now be moved to the
outside and to the inside.
Check:
ÆMovement to center (START-button) counting direction of AX35, has to be positive,
ÆMovement to outside (STEP-button) counting direction of AX35, has to be negative,
Æ adjust calibration switch –SQ509.
First time calibration
With Ma.-com. " calibrate right preadjuster" " the calibrating process is started. When the calibration
switch SQ509 is 1, the axis will first move away from the switch and when it is free, it will move to zero
(to the outside).
3.5.10 First time calibration

Disconnect plug of valve –YV131A (center segment down)
Start the calibration cycle with Ma.-com. "ABA calibration".
After the outer segments have been locked to the translator tooth bars and during movement to the
outside press the STEP button.
The segments are in outer final position Æ Adjust stop screws to 0,15mm-0.25mm.
Then press START button.
Cycle stops with timeout „center segment down“.
Check, that there will be no collision between center segment and contraction segments.
Connect plug of valve –YV131A (center segment down) and press RETRY.
The cycle will continue and finish the calibration.
Calibrate the ABA again (double-check).
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3.5.11 drift calibration
IMPORTANT: The valve must already be activated by the CAN-bus!

With Ma.-com. “Drift adjustment left/right translator" the automatic drift calibration will be started.
Start netprint (connect cable W17 to Com1 on Cusix card).
Insert displayed value in file C:\usr2\syscon\P4M_*10_0***\conf\ax_par\*A1GA10/11.

// GenericActor 10/11 NODE-ID 14/15
// Moog valve for AS32/33 Dxx
// Translator of the left/right hand outer segments
0x6324 Æ 1 Æ IN17 Æ -210 Æ
S408_ValvePositionControl_DemandValueGenerator_ZeroCorrection_Offset
3.5.12 Ctm 2195

Open program Netprint.exe and calibrate the machine. In Cycle ORS the width of the left and right
composition segments are displayed. Insert the average in Ctm 2195.
3.5.13 Continous ABA test

WICHTIG: ABA has to be calibrated!
Start Ma.-com. "ABA LENGHT TEST".
After 2 hours stop the test.
Mount all covers and restart the test for another hour.
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3.5 Manual blankholder adjustment (MLA)
It is activated by setting CTM-parameter 1557 (MD_ALA) to 0.

CTM-parameter 1536 (MD_SCDV) must be set to 1.
3.5.1 BLC
With Ma.-com. "Blc in bending position" move swivel segments to bend position.
Switches SQ135 and SQ136 must be 0, SQ137 and SQ138 must be 1.
With Ma.-com. "Blc not in bending position" move swivel segments to disengagement position.
3.5.2 BLX
With Ma.-com. "Blx closed" close gap in BLH tooling.
With Ma.-com. "Blx open" open gap in BLH tooling.
3.6 Free movement and calibration of blank holder (AS9)
3.6.1 First movement and free movement of blankholder
NOTE: Check set points and sensor signals for correct direction of movement (as per table. 3.1)).
NOTE: Measuring system must be adjusted mechanically (gap and alignment).
Start "microcycle ACHSE_BLH.tl and move the blade holder up in jog mode. If it moves in the wrong
direction, check the wiring or axis parameter file.
counting with "Axes" function -> table 3.1) of the measuring systems.
After the measuring system has been checked the blank holder is ready for the calibration procedure.
3.6.2 Adjusting BLH safety device
Important: The switches for the BLH safety DEVICE have to be adjusted exactly, or else it may come
to the destruction of the safeguarding bolts.
With Ma.-com. " BLH ab " put the blankholder down. Now adjust the Switches -SQ361, -SQ363
-SQ365 and –SQ367, that by removing the clearance in the cylinders the respective switch switches off
(Switch hydraulics off!).
Control of CTMs 1679. (TRDNOSE.BLHUPPOS) must be 73.00.
The remaining switches (-SQ360, -SQ362, -SQ364, -SQ366, -SQ368 und –SQ369) should already have
been adjusted in chapter 1.6.10.
3.6.3 Calibrating the blank holder
IMPORTANT: The horizontal bending cylinders must be located at zero zone switches SQ45/SQ46
and the transport sledge must be located either to the left or right because otherwise the function will
be interlocked and calibration is not possible.
The calibration procedure is started using Ma.-com. "calibrate BLH . After the zero zone switch SQ55
has been actuated the axis moves free and then towards zero (downwards). If the zero zone switch is
not registered the blank holder moves immediately to zero. If the axis moves to zero during calibration,
and the zero zone switch SQ55 is registered, the servo valve is actuated briefly in this direction so that
the hydraulic cylinder definitely moves to the block. The calibration point is not at the end of the
cylinder but when the blank holder is at the counterblade.
After calibration the blank holder is raised to 10.0mm.
NOTE: SQ55 should have the status 1 only up to around 1.5mm above the counterblade.
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3.7 First movement and calibration of XZ stop left in X direction (AX1)
Danger: During the manual adjustment phase the warning lamp must be GREEN (Controller
disabled) -> CHECK EVERY TIME!!!
NOTE: Check set points and sensor signals for correct direction of movement (as per table 3.1).
IMPORTANT: Switch off the controller and bring the axis manually into the centre position using the
belt.
Start "microcycle" ACHSE_Li_X.tl and move the stop into the centre in jog mode. If it moves in the
counting with "Axes" function ->table 3.1) of the measuring systems.
IMPORTANT: Switch off the controller and bring the axis into its mechanical final position manually
using the belt. Now move the reference table 3.0mm before the limit (measure with a gage) and adjust
SQ 32 accordingly.
After the zero pulse switch SQ032 has been actuated the axis moves away from this limit switch and
then towards zero. If the zero pulse switch is not registered the axis moves immediately to zero. The
calibration point has been reached, when the axis is at zero pulse switch SQ032. The calibration
procedure has been completed when the axis returns to zero.
The calibration procedure is controlled internally by the software and the description above is merely
to give a clearer overview of what is happening. So that the function is not blocked, the XZ stop must
be lowered, or the transport sledge located to the left. The calibration procedure is started using Ma.-
com. "calibrate left XZ in X" and to be run until the action has been completed.
3.8 First movement and calibration of XZ stop right in X direction (AX3)
belt.
Start "microcycle" ACHSE_Re_X.tl and move the stop into the centre in jog mode. If it moves in the
using the belt. Now move the reference table 3.0mm before the limit (measure with a gage) and adjust
SQ 34 accordingly.
The microcycle will only run, when the XZ-reference is down and the feeding trolley is in the left
position . Start the calibration cycle with the MA.-com. "calibrate right XZ in X" and continue so,
until the action is finished.
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3.9 First movement and calibration of XZ stop left in Z direction (AX2)
belt.
Start "microcycle" ACHSE_Li_Z.tl and move the stop forward in jog mode. If it moves in the wrong
direction, check the wiring or axis parameter file.
using the belt. Now move the reference table 0.6mm before the limit (measure with a gage near the
mechanical final position / guides) and adjust SQ 33 accordingly.
The microcycle will only run, when the XZ-reference is down and the feeding trolley is in the left
position. Start the calibration cycle with the MA.-com. "calibrate left XZ in Z" and continue so, until
the action is finished.
3.10 First movement and calibration of manipulator (AX14)
IMPORTANT: Switch off the controller and bring the axis manually into the centre position.
Start "microcycle" ACHSE_MNP.tl and move the manipulator forward in jog mode. If it moves in the
IMPORTANT: So that the function is not blocked the transport sledge has to be located to the left.
The manipulator is calibrated using Ma.-com. "calibrate manipulator". The calibration sequence is the
same as for the servo hydraulic axes.
If the manipulator triggers the rear axis limit switch SQ16 during the calibration procedure then the
zero zone switch SQ15 is not set correctly. When it is possible to calibrate the axis, use a tape measure
to measure the preliminary calibration point of the axis and enter and save it as provisional CTM
parameter 1592 (Zero.MNP). The calibration point of the manipulator must be at least according to
the minimum value shown in chapter 2.5.1 from the line of bending to the centreline of rotation.
NOTE: If this measurement is not achieved, the brackets on which switches SQ15/16 are mounted will
need to be moved.
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3.11 First movement and calibration of transport sledge (AX16)
Danger: After drift calibration make a „KILL"! The warning light system have to change back to
GREEN under all circumstances!!!
3.11.1 Drain the air off the belt tightener
Remove cover plate from counter blankholder and insert draining screw.
Switch on the hydraulic and set with monitor –YV45 and –YV46. Belt is tightened.
Now drain with “minimess” tube. Remove tube again, deactivate valve –YV46 and then set it again,
and so on, until the cylinder is completely drained.
3.11.2 Checking tooth belt tightness and SQ233
Switch hydraulics on, switch on–YV45 and –YV46 by using the monitor. Tooth belt is stretched.
Now set back –YV46 to zero. The distance can be checked now.
120mm
Belt
Limit stop screw
Sledge
Belt tension 5.90mm P4-1916

6.60mm P4-2516
8.00mm P4-3216
9.00mm P4-3216
NOTE: SQ233 = 1 only in tight condition -> set tight.

Activate -YV45 and –YV46. Switch –SQ233 must be adjusted, that this switches (=1) when belt is
tightened. By deactivation of –YV46 the switch –SQ233 must go back to 0.
Belt
Sledge
SQ233
3.11.3 Adjustment of TRD zero position switch (SQ157)
Bring the axis into its mechanical limit position manually.

Now move 25.0mm (reducing scale) away from the limit stop and set zero pulse switch SQ0157 status
= 1.
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3.11.4 calibration of the axis
NOTE: Check set points and sensor signals for correct direction of movement (as per Tab. 3.1).
First of all the belt tension needs to be checked.
Start "microcycle" ACHSE_TRD.tl and move the TRD to the right in jog mode. If it moves in the
counting with "Axes" function -> Tab. 3.1) of the measuring systems.
So that the function is not blocked the transport sledge has to be located to the left, the light barrier
must be unobstructed and the lowering safety device of the blank holder pivoted in. Both the stops
must be lowered and the Z pusher must be retracted.
Start the calibration procedure with Ma.-com. "calibrate TRD" and wait until the action has been
completed.
NOTE: TRD is automatically positioned at CTM parameter 2003.
2003(TRDMIN) = -20.00->Min. position for transport sledge SQ157=1

2002(TRDMAX) P4-1916 = 3500.00->Max. position for transport sledge SQ158=1
-2090.00 MNP-center to TRD switches SQ162/164 in
1594(ZERO_TRD) P4-1916PCD = calibration position
1594(ZERO_TRD) P4-1916HPT = calibration position
1594(ZERO_TRD) P4-2516PCD = calibration position
1594(ZERO_TRD) P4-2516HPT = calibration position
1494(ZERO_TRD) P4-3216 = calibration position
1494(ZERO_TRD) P4-3816 = calibration position
3.11.5 adjustment of switches SQ159 and SQ158
´Drive feeding trolley to the right, so that the position of the TRD is 127mm right of the MNP center.
(Switching point of –SQ162, –SQ164 Æ Rotator clamp center)
-Adjust SQ159 that way, that the switch at this position switches to 1. Move now feeding trolley
remaining distance to the right and check, that the switch state stays on 1.
Is the feeding trolley on the final right position (Pos. CTM 2002), –SQ158 has change to 1 too..
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3.12 First movement and calibration of CLA (AX17)
3.12.1 Lower symmetrical CLA tool (AX17)
Start "microcycle" Achse_CLA.tl and move the CLA into the centre in jog mode. If it moves in the
First of all, check that the CLA tools are located symmetrically to the centreline. Switch off the servo
controller and move the CLA tools to the bending tool. The CLA must be flush with the bending tool
on the left and right. This is to be adjusted by shifting the motor and/or tightening the belt.
Fixed stop 3-5mm

CLA tools flush gap to sledge
Belt CLA
Bending tool
Tightening screw for Setting spindle

tooth belt
Servo motor
Switch off the controller and bring the axis into its mechanical limit position manually using the
pulley.
Now move 4.0mm (reducing scale) away from the limit stop and set zero pulse switch SQ069 status = 1.
For calibration to be possible, the blade holder must be located right at the back (SQ45/SQ46=1).
Switch on the servo controller and with "calibrate CLA" calibrate the CLA.
Then press Emergency stop and move the CLA together by hand. Read the CLA position in the
monitor axis window and insert this value into CTM 1591.
Par 13022 (i2c) -32767 Axis parameter file AX17

Par 13023 (t2i) -0.076335 Axis parameter file AX17
1531 (MD_CLA) = 1.0 Lower symmetrical CLA (AX17)
1571(TRDNOSE.AUXMAXPOS) = xxxx.x->Maximum position in X for CLA
1591 (ZERO_CLA) = xxxx.x-> Distance cal. position CLA to machine center
1981 (CLAMAX) = 0.1-> Maximum position for CLA (gap in center)
1982(CLAMIN) = -1.0->Minimum position for CLA
After calibration, set the safety switch SQ68, so that approximately half of it is covered.
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3.12.2 Upper symmetrical CLA tool (AX18)
Start "microcycle" ACHSE_UPPER_CLA.tl and move the CLA into the centre in jog mode. If it
moves in the wrong direction, check the wiring or axis parameter file.
First of all, check that the CLA tools are located symmetrically to the centreline. Switch off the servo
controller and move the CLA tools to the bending tool. The CLA must be flush with the bending tool
on the left and right. This is to be adjusted by shifting the motor and/or tightening the belt.
pulley.
Now move 4.0mm (reducing scale) away from the limit stop and set zero pulse switch SQ294 status =
barely 1 (from machine number 864 onward).
For calibration to be possible, the blade holder must be located right at the back (SQ45/SQ46=1).
Then press Emergency stop and move the CLA together by hand. Read the CLA position in the

1532 (MD_UPPER_CLA) = 1.0 Upper asymmetrical CLA (AX18)
2324(UPPER_CLA_MIN) = -1.0->Minimum position for CLA
2325 (UPPER_CLA_MAX) = 0.1-> Maximum position for CLA (gap in center)
After calibration, set the safety switch SQ295, so that approximately half of it is covered.
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3.12.3 Lower non-symmetrical right CLA tool (AX17)
Start "microcycle" ACHSE_CLA.tl and move the CLA into the centre in jog mode. If it moves in the
pulley.
Then press Emergency stop and move the CLA to the center by hand. Read the CLA position in the
Now move the CLA tool to the left side of the bending unit, until the trolley edge is flush with the edge
of the lower bending tool. Read the CLA position in the monitor axis window and insert this value
minus the value of CTM 1591 into CTM 1981.
e.g. CTM1591=1400.0, Position in monitor is 2500mm -> CTM 1981 = -1100
Par 13022 (i2c) 32767 Axis parameter file AX17

Par 13023 (t2i) 0.076335 Axis parameter file AX17
1531 (MD_LOWER_CLA) = 2.0 Lower asymmetrical CLA (AX17,AX37)
1981 (CLAMAX) = -xxxx.x-> Maximum position for CLA on left side
1982(CLAMIN) = -1.0->Minimum position for CLA
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3.12.4 Lower non-symmetrical left CLA tool (AX37)
Start "microcycle" ACHSE_LEFT_CLA.tl and move the CLA into the centre in jog mode. If it moves
in the wrong direction, check the wiring or axis parameter file.
pulley.
Now move the CLA tool to the right side of the bending unit, until the trolley edge is flush with the
edge of the lower bending tool. Read the CLA position in the monitor axis window and insert this
value minus the value of CTM 1583 into CTM 1943.

1531 (MD_CLA) = 2 Asymmetric. Cla
1583 (ZERO_LEFT_CLA) = xxxx.x-> Distance cal. position CLA to machine center
1943 (CLAMAX_LEFT) = -xxxx.x-> Maximum position for CLA on left side
1944(CLAMIN_LEFT) = -1.0->Minimum position for CLA
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3.12.5 Upper non-symmetrical left CLA tool (AX18)
Start "microcycle" ACHSE_UPPER_CLA.tl and move the CLA into the centre in jog mode. If it
pulley.
Switch on the servo controller and with "calibrate upper CLA" calibrate the CLA.
Par 13022 (i2c) 32767 Axis parameter file AX18

Par 13023 (t2i) 0.076335 Axis parameter file AX18
1532 (MD_UPPER_CLA) = 2.0 Upper non-symmetrical CLA (AX18,AX38)
2324(UPPER_CLA_MIN) = -1.0->Minimum position for CLA
2325 (UPPER_CLA_MAX) = -xxxx.x-> Maximum position for CLA (gap in center)
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3.12.6 Upper non-symmetrical right CLA tool (AX38)
Start "microcycle" ACHSE_UPPER_RIGHT_CLA.tl and move the CLA into the centre in jog mode.
If it moves in the wrong direction, check the wiring or axis parameter file.
pulley.
Switch on the servo controller and with "calibrate upper CLA" calibrate the CLA.

1532 (MD_UPPER_CLA) = 2.0 Upper asymmetrical CLA (AX18,AX38)
1627 (ZERO_UPPER_CLA_RIGHT) = xxxx.x-> Distance cal. position CLA to machine center
2530(UPPER_CLA_MIN_RIGHT) = -1.0->Minimum position for CLA
2531 (UPPER_CLA_MAX_RIGHT) = -xxxx.x-> Maximum position for CLA on left side
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3.13 First movement and calibration of rotator (AX15)
3.13.1 Adjustment of switch SQ18 and SQ19
Switch on index with monitor action. Index bolt must switch on. Now adjust switch -SQ19, so that the
switch is just barely on (-SQ19 =1, -Sq18=0). Turn now indexation off again. Now adjust switch -
SQ18, so that the switch is just barely on (-SQ18 =1, -Sq19=0).
Attention: The index cylinder must be bled (open the line nearby the cylinder).
3.13.2 Calibration of the Rotator
Attention: The index must be turned off. (-SQ18 =1, -Sq19=0)

The rotator clamp must be up (SQ023=1) and the manipulator may not be in the limit stroke position
(SQ150=1).
Start "microcycle" 10_65A1AX15_ROT.tl and move the rotator counter-clockwise in jog mode. If it
Using the Ma.-com. „Calibrate Rotator calibrate the rotator. The rotator clamp must be up to do this
(SQ023=1) and the manipulator must not be located above the front damper area (SQ150=1). During
calibration the rotator moves clockwise (if not, the setpoint has been swapped) and the counter reading
must decrease.
If the axis does not remain stationary during calibration, the zero pulse of the encoder and the
calibration zone switch (SQ020=1) do not agree. Adjust the cam on the calibration switch until the axis is
calibrated. When calibrated, call up the "Monitor" and check the actual position of AX15 in the "axis
graph". Now enter the value of the current position from the "axis graph" in the CTM parameter 1996
(make sure you enter the correct sign in front).
NOTE: If indexing is NOT possible (tooth on tooth), interrupt the calibration procedure and remove
the indexing using the "Monitor", switch off the controller and check the alignment of the lower
clamp unit and counterblade. Correct if required (move rotator by hand) and at the "Monitor" enter
the indexing -> read out the current position and enter as CTM parameter 1996 (make sure you enter
the correct sign in front)!!
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3.14 De-bur unit (AX39, RSU)
Start "microcycle" ACHSE_RSU.tl and move the CLA into the centre in jog mode. If it moves in the
By using Ma.-com. "calibrate RSU" the unit will be calibrated.

When the calibration switch SQ544 is activated, the axis moves free of the switch first, Stopps and then
moves to the calibration switch again. If the calibration switch is not on, the axis moves immediately
to the calibration switch. The calibration point is reached, as soon the calibration switch SQ0544
changes from zero to one.
The axis moves afterwards to position -1.0.
Maximum position right (RSU_MAX)
Center of machine (Zero_RSU)
Ctm 1530 (MD_RSU) 1 Activation RSU unit

Ctm 830 (Zero_RSU) xxxx Distance calibration point to center machine
Ctm 834 (RSU_MIN) -1.0 minimum position (left)
Ctm 835 (RSU_MAX) xxxx maximum position (right)
(~5.0mm before mechanical stop)
3.15 NOT_USED
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3.15 HPT axis
Adjust calibration switch 90A1SQ9.

Start "microcycle" ACHSE_HPT_AZR.tl and move the HPT forward in jog mode. If it moves in the
733 (HPT_AZR_MIN) = 0.00 Minimum position HPT (to the back)
734 (HPT_AZR_MAX) = 0.00 Position HPT – sheet-stop to bend line
~
739 (HPT_AZR_Zero) = 290.00 Calibration position (distance to bend line)
1516 (MD_HPT) = 2.00 1 =HPT,
2…9=HPT with automatic axis (AZR)
With CTM 1516 the drop position in Z direction may be altered with AZR option.
D.H.: value = 2…………..…2mm gap between sheet and references (default)
value = 3……………..3mm gap between sheet and references
up to max. value = 9……………..9mm gap between sheet and references
With Ma.-com. "calibrate HBT" the axis will be calibrated.
In this position measure the distance between bend line and sheet stop on HPT table and insert this
value in CTM 739.
THen use Ma.-com. "HBT forward" to move the HPT completely forward.
Open the safety flap and put a long sheet against the sheet stop of the HPT table..
If the sheet is not flush to the bend line, change CTM 739 accordingly!
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3.16 PCD-axis
3.16.1 First movement and calibration of stop ruler (AX3) -> with PCD/PC
Start "microcycle" ACHSE_CENT.tl and move the stop ruler forward in jog mode. If it moves in the
NOTE: Switch off the controller, release the brake and bring the axis to around 65 mm in front of its
mechanical limit position manually using the drive shaft (measure hoop to rear edge of ruler). Set zero
pulse switch SQ15 to status = 1.
2824 (PC_CENT_MIN) = -10.00-> Minimum position for ASR

2836 (PC_CENT_MAX) = 200.00-> Maxmum position for ASR
2837 (PC_CENT_CERO) = 1840.00-> Calibration position for ASR
2837 (PC_CENT_CERO) = 1870.00-> Calibration position for ASR with RIP
2854 (PC_SUC_3_CEN_DEV_DIS) = 880.00-> Distance cal. pos. ASR to centre 3.suction cup
Using the Ma.-com. calibrate the stop ruler. In this position you may measure the different distances now.
NOTE: ASR is automatically positioned at CTM parameter 2824.
CTM 2837 Inside edge fixed stop to the stop inside edge –10mm (CTM 2824) with RIP
CTM 2837 Stop inside edge to the bend line –10mm (CTM 2824) –4mm (gap).
CTM 2836 Minimum reachable position of the ASR-Lineal related to Inside edge fixed stop
(plus 2-3mm Piston stroke reserve at the drive).
CTM 2854 Stop inside edge to the middle 3.suction cup group –10mm (CTM 2824).
3.16.2 First movement and calibration of conveyor (AX1) -> with PCD/PC
Start "microcycle" ACHSE_CONV.tl and move the conveyor to the left in jog mode. If it moves in the
2839 (PC_CONV_OFFSET) = 190.0-> Distance last brush to the sheet stop

2841 (PC_CONV_OPEN_SUC) = 785.0-> Distance magnetic guid. plate to the sheet stop
2842 (PC_CONV_CLOSED) = x.x-> Distance container to SQ30A/B
2853 (PC_DIST_IGNORE_TRD) = x.x-> Distance container to inner edge of TRD-pincer
With the according Ma.-com. the conveyor will be calibrated. In this position the individual distances
may be measured now.
CTM 2839 last brush to inside edge sheet stop.
CTM 2841 Distance Magnetic stop (sloping position top edge) to inside edge sheet stop.
CTM 2842 Distance inside edge sheet stop to the switches SQ30A/B.
CTM 2853 Distance inside edge sheet stop to starting point (Switching point –SQ162,
-SQ164) feeding pincer.
Attention: Make sure, that the feeding trolley stands on TRD_MIN –Position.
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3.16.3 First movement and calibration of the suction cups (AX6) -> with PCD
Start "microcycle" ACHSE_SUC.tl and move the suction cups to the left in jog mode. If it moves in the
347 (PC_SUC_MAX) = 300.00-> Maximum position (5 suction cups)

347 (PC_SUC_MAX) = 400.00-> Maximum position (4 suction cups)
2844 (PC_SUC_3_POS) = 798.00-> Middle suc. cup to ref. point scissor table*
* will be adjusted in chapter 4.23 (Adjustment of the scissor table)
Release the break and move the axis by hand (pull the chain) to a position, where the chain fixtures are
1115mm apart from each other (measure between the outer edges of the chain fixtures close to the
motor). Adjust the micro switch SQ12 very accurate (should be "on" in this position).
With the according Ma.-com. the suction cups will be calibrated. Move the suction cups totally
together (with Ma.-com.) -> Check the maximum stroke (CTM 347).
3 . 16 . 4 TCV (AX11)
Start „Microcycle“ ACHSE_PCD_TCV.tl and move the scissor table in jog mode to inwards. If it
About adjustments of switxhes and CTM’s refer to chapter 12.2.
3 . 16 . 5 RF (AX10)
Start „Microcycle“ ACHSE_PCD_TUR.tl and move the turning device in jog mode clockwise. If it
840 Zero_RF_Rotator =x.x Zero position of RF turning device

844 RF_Rotator_Min =x.x Min. Pos., calibration position, vertical
845 RF_Rotator_Max =x.x Max. Pos., vertical
1581 MD_RF =1.0 Aktivation of RF unit
3 . 16 . 6 RF Roller
With monitor:
Set 101A1KA27, slow movement to PCD centring device
Set 101A1KA27 and 101A1KA28, fast movement to PCD centring device
Set 101A1KA29 and 101A1KA27, slow movement away from PCD centring device
Set 101A1KA29 and 101A1KA28 and 101A1KA27,
fast movement away from PCD centring device
Check direction and speed of the movements.
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3.17 RIP-axis
3.17.1 First movement and calibration of transfer unit (16A1AX1)
Start "microcycle" ACHSE_RIP_TRA.tl and move the transfer in jog mode. If it moves in the wrong
direction, check the wiring or axis parameter file. This process is also used to check the direction of
counting (Call up "Monitor" -> check direction of counting with "Axes" function -> table 3.1) of the
measuring systems. Using the Ma.-com. calibrate the conveyor. In this case the counter is set to zero
during calibration.
3.17.2 First movement and calibration of trolley (16A1AX2)
Switch off the controller, release the brake, and bring the axis manually into the centre position.
Start "microcycle" ACHSE_RIP_TRO.tl and move the trolley back in jog mode. If it moves in the
Switch off the controller, release the brake and bring the axis in front of its mechanical limit position
manually (distance between trolley and rubber bumper about 3 mm). Set zero pulse switch SQ2 to status
= 1.
Using the Ma.-com. calibrate the trolley. The calibration sequence is the same as for the stop axes. The
calibration point of the trolley must be about 240mm from the line of bending to the centreline of the
transfer belt. Measure this dimension with a measure tape, enter as provisional CTM parameter 557
(TRO_ZERO) and load with SAVE and DOWNLOAD.
557 (TRO_ZERO) = 240.0-> Calibration point (BL / center RIP-transfer)
3.17.3 First movement and calibration of turning unit (16A1AX3)
Start "microcycle" ACHSE_RIP_TUR.tl and move the turner clockwise in jog mode. If it moves in the
Switch off the regulator, release the brake and bring the axis into the horizontal position manually
(extend indexing using "Action"). Set zero pulse switch SQ1 to status = 1.
The calibration sequence is the same as for the stop axes.
When calibrated (indexing retracted), call up the "Monitor" and check the actual position of AX3 in
the "axis graph". Enter this value as CTM parameter 2317 (RIP_TURN_HOMING_OFFS) and load
with SAVE and DOWNLOAD.
2317 (RIP_TURN_HOMING_OFFS) = x.x-> Offset to index
3.17.4 First movement and calibration of stop ruler (16A1AX4)
Start "microcycle" ACHSE_RIP_ZEN.tl and move the turner clockwise in jog mode. If it moves in the
Switch off the regulator, release the brake and bring the axis into the zero position manually
(distance between arm and mechanical limit position about 3mm). Set zero pulse switch to 1.
Using the Ma.-com. calibrate the stop ruler. The calibration point of the ruler must be about 825mm from
the inner part of the ruler to the centreline of the transfer belt. Measure this dimension with a measure
tape, enter as provisional CTM Parameter 2373 and load with SAVE and DOWNLOAD.
2373 (RIP_CEN_ZERO) = 825.0-> Calibration point Stop ruler (to center of RIP)
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3.18 ACP30-Axis
3.18.1 Centering device (AX5)

Start "microcycle" ACHSE_ACP30_CENT.tl and move the stop ruler forward in jog mode. If it moves
in the wrong direction, check the wiring or axis parameter file.
IMPORTANT: Risk of collision between ASR-centring device and MVP suction cup group
Switch off the controller, release the brake and bring the axis to around 15 mm in front of its mechanical
limit position manually using the drive shaft (measure hoop to rear edge of ruler). Set zero pulse switch
SQ24 to status = 1.
733 (ASR_MIN) = -1.00 Minimum position for ASR
734 (ASR_MAX) = 400.00 Maximum position for ASR
739 (ASR_ZERO) = 1885.00 Calibration position for ASR (distance to bend line)
Using the Ma.-com. calibrate the stop ruler. In this position you may measure the different distances now.
NOTE: ASR is automatically positioned at CTM parameter 733!!!
The distance between front edge of guide and calibration position has to be at least 1955mm!
3.18.2 Conveyor (AX4)

Start "microcycle" ACHSE_ACP30_CONV.tl and move the conveyor in jog mode. If it moves in the
IMPORTANT: Risk of collision between conveyor and MVP suction cup group
516 (MAXCON) = 2700.0-5000.0 Maximum conveyor distance moved during transfer

from S4
With the according Ma.-com. the conveyor will be calibrated. In this position the individual distances
may be measured now.
3.19 XZ stop left up/down
The transport sledge should be located on the left. Move upwards or downwards using Ma.-com. Nr.xx.
The XZ stop then makes the vertical movement for the disengaged sheet. To make the vertical
movement for sheets that are not disengaged, the XZ stop must be lowered and the Ma.-com. „Left XZ
up without Notch moved to the left. Make sure too that the stop is free hanging at the relevant limit
stops for not disengaged and disengaged sheets.
3.20 XZ stop right up/down
The transport sledge should be located on the left. Move upwards or downwards using Ma.-com. Nr.xx.
The XZ stop then makes the vertical movement for the disengaged sheet. To make the vertical
movement for sheets that are not disengaged, the XZ stop must be lowered and the Ma.-com. „Right XZ
up without Notch“ moved to the left.
Make sure too that the stop is free hanging at the relevant limit stops for not disengaged and
disengaged sheets.
3.21 XZ stop right forward/back
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So that the function is not blocked, the XZ stop must be lowered, or the transport sledge located to the
left. Move left and right using Ma.-com. Nr.xx.
3.22 Z-Pusher forward/backward
IMPORTANT: To avoid any damage of the Z-pusher measuring device, it is necessary to check, that
for the whole stroke of the Z-pusher there is no contact between the read head and the measuring
system tube. Check that by moving the Z-pusher manually fully forward and back.
The Z pusher is moved back and forth using Ma.-com. (pressure is set to about 4.5 bar). During the
forwards movement both the function of the measuring system ("Monitor" -> Axis -> counter ->
AT31) and the ORIGA cylinder can be checked (Rotator clamp must be parallel to the bending line).
For the return movement the limit stop dampers on the ORIGA cylinder are to be set so that the pusher
is braked slightly. See chapter 1.6.11 for setting the ideal speeds.
Start Ma.-com. „Z-Pusher Test“. The pneumatic valve YV014 has to be set that way, that the
movement back is fast enough.
Both limit stop dampers has to be adjusted (YV058 left and YV061 right).
The Pressure for movement forward has to be approx. 0.9bar (CTM 1866 set to15).
2219 (ZPF_TEST_PRESS) = 30.00-> %pressure for forward movement with

manual command
1866 (PushForce_Z.Default) = 15.00-> Minimum Pressure %for forward
movement
Do check the minimum %-value for movement, reduce CTM 1866 accordingly. When you see no
movement anymore (approx. at 15%), set CTM 1866 about 2-3% higher. The movement now should
be a continuous movement. If not, keep increasing CTM 1866.
3.23 Lowering blank holder safety device on/off
Using Ma.-com. „BLH on safety Block“ to the left the calibrated blank holder can be moved to the tool
changing position. After this position has been reached the lowering safety device is pivoted in
automatically. If the hydraulics have been switched off for an extended period of time so that the
blank holder is resting on the safety device, then it will have to be raised slightly. Now the lowering
safety device is free and the blank holder can move downwards.
3.24 lowering blade holder safety device on/off
Switching the hydraulics on and off moves the lowering safety device of the blade holder. If the
horizontal bending unit is in the calibration position, the lowering safety device must engage with the
torque rod when the hydraulics are switched off. With the hydraulics switched on the torque rod must
be free of the lowering safety device.
Adjust the reed contacts (SQ50 "switched on" and SQ51 "switched off").
Procedure:
The best thing to do is to leave the hydraulics switched on and the horizontal bending unit in the rear
position. Start MicroCycles AbsenkKe.tl and repeatedly move the lowering safety device in and out
until the reed contacts have been set.
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3.25 Rotator clamp
2524 (AP4_0_press_proz) = 5 Minimum pressure of 135bar.

2525 (AP4_0_dac_proz) = 7 Software value for minimum pressure
2526 (AP4_1_press_proz) = 100 Maximum pressure of 135bar.
2527 (AP4_1_dac_proz) = 27 Software value for maximum pressure
2528 (AP4_2_press_proz) = 100 Maximum pressure of 135bar.
2529 (AP4_2_dac_proz) = 27 Software value for maximum pressure
IMPORTANT: Manipulator should be in calibration position, rotator and rotator clamp must be either
both normal or parallel to bend line. Remove mechanical rotator clamp holding device!
Move rotator clamp with Ma.-com. up and down and adjust limit switches (SQ023 and SQ025).
Adjust the activator of SQ025 so that when the difference between rotator clamp upper and lower part
is 4.5mm SQ025 is just barely activated.
Adjust the activator of SQ296 so that when the difference between rotator clamp upper and lower part
is 15mm SQ296 is still (barely) activated.
Procedure SQ025:
Lift the rotator clamp, insert a 4.5mm shim and then close the rotator clamp.
IMPORTANT:
Switch off hydraulic and then use Ma.-com. „Clamp up“. Now the switch may be adjusted.
Adjustment of pressure level (AP4)
Use Ma.-com. „Clamp Warmup“ for 15 minutes to heat up the valve.
Now close the rotator clamp and check with monitor „IN13“. The value must be between 105 to 110
bar. If necessary, change CTM’s 2527 and 2529! Open clamp and redo this job until the pressure is
ok.
Adjustment of minimum pressure level (AP4)
Change CTM 2529 temorary to 7, open rotator clamp and close it again.
If the rotator clamp does not move, increase the value. Maximum pressure is 10bar!
Save the value found to CTM 2525.
Set CTM 2529 back to the original value.
IMPORTANT: CTM 2527 and 2529 must always have the same value!!!
3.25.1 Determining CTM parameter 2529 (AP4_2_dac_proz):
NOTE: Oil temperature should be 42° C.

Close the rotator clamp with Ma.-com. Nr.xx and make sure that valve YV162 (160bar pressure
holding pump) has switched. Now use the peak pressure meter (connected to M1 of the manipulator
valve manifold) to read the pressure. The pressure must be in the range 130 to 135 bar, regardless of
whether the pump is running on standby or high pressure. If the pressure reading is not within this
range, CTM parameter 2529 (AP4_2_dac_proz) must be changed accordingly. Changing this
parameter can be done either by Saving and Downloading the CTM parameter or closing the rotator
clamp again.
3.26 TRD Arm left/right and pincers open/close
Using Ma.-com. pivots the grab in and out. Using Ma.-com. opens and closes the grab. Check here too
whether the actuator is finished.
Important: Bleed off the feeding trolley clamps by using the correct tool.
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3.27 + 3.28 not used
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3.29 Option PCD
1573 MD_PC = 1.00 PC

1573 MD_PC = 2.00 PCD
3.29.1 Construction of the suction cup groups 1 - 5
Important: x stands for suction group 1- 5
Speed upward movement
SQ65
400mm
YV11BÆ movement upward
YV11AÆ movement downward
SQ64
145mm
SQ63
60mm
Speed downward movement
Move duides
downward
SQ16Æ switches on when

sheet is dedected
With the Ma.-com. „PCD“ select all functions and test all movement respectively.
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3.30 scissor table (hydraulic)
The light barrier may be broken. -SQ136 must be activated. By pressing „movement out“ and
„manual movement TC“ together the scissor table is moved outside (loading position).
If the direction is wrong, valves -YV20A und -YV20B must be swapped. The switch –SQ21 must be
activated short before the limit position. Also, -SQ136 must be activated in this position!
Afterwards by pressing „movement in“ and „manual movement TC“ together the scissor table is
moved inside (destacking position). The switch –SQ20 must be activated 48mm before the scissor
table is in the center of the PCD. Also, -SQ37 must be activated 50mm before this position (slow
speed). Also, -SQ136 must NOT be activated in this position anymore!
2844 (PC_SUC_3_POS) = 798.00-> Centre central suction cup to ref.point scissors t.*
2849 (PC_SUC_1_POS) = 30.00-> Centre 1. suction cup to ref. point scissors table*
827 (PCD_D_T1) = 205.00-> Centre 1. sheet thickn. to ref.point scissors table*
828 (PCD_D_T1) = 1055.00-> Centre 2. sheet thickn. to ref.point scissors table*
*These parameters have only to be adjusted if there are differences to the standard distance of 48.0mm
between scissors table centre to centre 3. suction cup.
Movement table surface

The scissor table has to be in loading position (outside PCD).
Select Ma.-com. „table surface“ and by pressing the button „manual movement TC“
Move the surface in both final positions. Look for correct movement direction and functioning and
position of the switches (-SQ22 and –SQ23).
Then move the table in de-stacking position. Acknowledge the light barrier and with Ma.-com „table
surface forward“ move the table surface to the magnetic separator.
Adjust the final position -SQ4, and the emergency shutdown position –SQ76 switches.
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Upward and downward movement
The scissor table has to be in de-stacking position and the table must be in forward position.
With Ma.-com „table up“ move the table upward.
Adjust the final position –SQ5, and the emergency shutdown position –SQ6 switches.
Then move with Ma.-com „table down“ the table downward.
Adjust the limit switch –SQ19.
Microcycle Table.tl
With this cycle the scissors table movement will be checked for correct function -> correct activation
and switch adjustment.
SQ3AX/TX
description:
SQ3AX/TX Slow speed for table surface-> switch to slow speed

SQ4AX/TX Stop movement table surface in magnetic guiding plate direction
SQ5AX/TX Stop upward movement of the table
SQ5AX/TX emergency stop upward movement of the table
SQ76AX/TX emergency stop movement table surface in magnetic guiding plate direction
SQ30A/B Sheet ready at entry of PCD (from S4)
3.31 Safety flap up/down
The laser scanner must be free.

Use the Ma.-com. to move the safety flap up and down. So that the function is not blocked the
transport sledge has to be located to the left.
3.32 Automatic calibration
Not until all axes have been "calibrated manually" can the machine be calibrated automatically by
pressing the "calibrate" button at the operating desk.
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3.33 Retract manipulator
Since the manipulator is mounted on a ball spindle, it must be retracted first. Lubricate the spindle
using "Klüber Isoflex (old)" or ”BEM 34 (new)” grease.
Every cycle for 15 minutes and greased in between.
NOTE: To retract the manipulator the CTM parameters need to be temporarily set as follows:
1990(MNPACC) = 2500.0->Acceleration
1991(MNPDEC) = 3000.0->Deceleration
50% (speed and movement).

Change current limit of the MNP by using the DMS-Hyperterminal to 50% (27.75NM).
(A1 c 13085 0.14 description in chapter 4.1.7)
Move MNP with Ma.-com. „Mani run in 50%“
NOTE: Enter the original values after the manipulator has been retracted.
4. MOOG DMS 2000 digital controller
4.1 general description
The MOOG DMS 2000 is (unlike the SIMODRIVE 611) a pure digital controller with an autonomous
axis control which communicates via an Ethernet interface with the SIX control.
This means, that only simple orders for axis positioning commands are sent from the MUSIX card to
the CPU of the controller and the controller performs then the real movement. These data are then
transferred to the respective axis card by a bus system for the further processing and actual
execution.
The communication to the two CPUs (MPC boards) of the controllers is carried out via 2 Ethernet
interfaces at the MUSIX card. When using more than 2 Controllers the 2nd Ethernet interface is split
into two lines.
With the SYNC interface the sampling rate is synchronized between the CPU (MPC board) and the
MUSIX card.
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4.1.1 The principle construction
PC
COM 1 COM 5 TU 0
Control
Power Cusix Musi Mach Mach Minp Minp Mout

supply
COM1 COM2 COM1
it
COM3 COM4 COM2
CAN1 CAN2 CAN
SYNC CAN3 SYNC
ETH2 ETH2
ETH1 ETH1
HUB
Drive 1 Drive 2 Drive 3
MPC DS DS DS DS MPC DS MPC DS

Cpu 1 Cpu 2 Cpu 3
X12 X12 X12
24Volt 24Volt 24Volt
X3 X3 X3
ETH1 ETH1 ETH1
X4 X4 X4
Ser.Pc Ser.Pc Ser.Pc
X5 X5 X5
Sync Out Sync Out Sync Out
X6 X6 X6
Sync In Sync In Sync In
A1 A3 A5 A7 A1 A1
AX14 AX2 AX17 AX34 AX15 AX37
Sw 1 Sw 1 Sw 1
Manipulator
Pre-adjuster
Lower CLA
Lower CLA
Adr. Adr. Adr.

(asym left)
referenc Z
Left ABA
Rotator
(right)
192.1.1.2
192.1.2.2
192.1.2.3
Left
X8 X8 X8
A2 A4 A6 A8 A2 A2
Analog Out Analog Out Analog Out
AX1 AX3 AX18 AX35 AX16 AX38
Pre-adjuster
X9 X9 X9
(asym right)
Upper CLA
Upper CLA
reference X
reference X
Right ABA
Feeding
X10 X10 X10

trolley
Right
(left)
Left
X11 X11 X11
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4.1.2 movement distance calculation
Example: the manipulator (AX14)

• Moog-resolver produces 1024 sinus-signals/motor-rotation [P13507]
DSP board produces a resolver-sinus 2048bits
Therefore is a full motor rotation 2048*1024bits=2097152bits
• A motor rotation = 40.0mm =40000µm [P13030]
• Internal conversion factor is 40000µm/2097152bits=0.01907µm/imp [P13023]
DSP-Board MPC-Board
motor
40mm/Umd 1024Sin/rot
* 2048 =
T2i
1024Sin/Umd Par13023
(Par13507) 2097152bits Internal MPC
221bits (*0.01907)
units (µm)
Set point specification

Musix (Speed,Pos,..) E2i_s
Specification in
mm external-units
mm * 1000 external units for MPC internal-units
Par13021 (*1.0) Setpoint for
(Par72) Controller
external units from MPC E2i_s

internal-units
external-units Feedback signal
Feedback signal for Musix Par13021 (/1.0) for Controller
DSP 1Sin. =2048 bits
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4.1.3 structure of the axis parameter files
Axis parameters may be altered by the MM-hyperterminal (general parameters) and by the DMS-
hyperterminal (other parameters) temporary. These alterations are lost during booting!
That means, after testing the parameters must be saved to the respective axis files!
NEVER EDIT THE PARAMETERS WITH THE axis parameter editor !!!
Don’t use this editor at all. It will destroy the axis files.
Change axis parameters with Windows explorer and a text editor instead.
General axis parameter settings (as with MicroMach)
Axis initialization:
p11001,p11002......sample rate for position- and speed controller in µs
p11003,p11004......Type of controller: PID or PID with activated filters
Axis configuration:
p13001…..Switch drive to passive.................................................................= 1 (def=0)
p13077…..Disable write protection...............................................................= 1 (def=1)
p13021…..conversion factor distance Musix to MPC.................................= 1
p13022….. conversion factor current controller DSP (inverted)...............= (-) 32767
p13023….. conversion factor distance Resolver to MPC (inverted)......…= (-) xxxxx
p13003…..following Error Check.................................….................….…...= 1 (def=1)
p13054…..Motion Check.....................................................................……...= 1 (def=0)
p13051…..Current- and indirect torque limit (from Par 13508)..…..…....= xxxxx
DSP- parameter
p13501…..max current DSP-Board (Apeak*10)……………..…………....= xxxxx
p13503…..number of poles motor…………….………………..……..…….= xxxxx
p13508…..max current motor (Apeak*10)…………………………..….....= xxxxx
p13509…..Nominal voltage motor..............……………………..……….....= xxxxx
p13510…..Nominal RPM motor...............……………………………….....= xxxxx
p13511…..Nominal current motor (*10)...........…...…………………….....= xxxxx
Position controller parameters

for PID- controller (11003 =3)
p14101…..KP…………....….....…...........= xxxxx
p14102…..TI…………………..………...= xxxxx
p14103…..TD……….........……………...= xxxxx
p14206…..AxT2Pos_SwIntGain…….....= xxxxx
for advanced PID- controller (11003 =5)
p14202…..KP…………....….....………..= xxxxx
p14204…..TI…………………...………..= xxxxx
p14205…..TD……….........…….……......= xxxxx
p14209…..switchIntTime……....….........= xxxxx
Speed controller parameters

for PID- controller (11004 =3)
p14601…..KP…………....….....….........….= xxxxx
p14602…..TI…………………..……….….= xxxxx
p14603…..AxT2Vel_VelIntValue………..= xxxxx
p14604….. AxT2Vel_VelIntDesatTime....= xxxxx
for advanced PID-controller (11004 =5)
p14701…..KP…………....….....………..= xxxxx
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4.1.4 Enabling of a drive
The regulator is connected to the net over relayKM5K, however, the real activation is carried out via
the MUSIX. The command to this may be seen in an open axis window of the monitor:
Attention: The activation over the axis window always means the COMPLETE controller!
That means that all other axes on the respective regulator are also activated!
Is ON, if the drive is activated
Command to activate drive
If the SAT flag is "ON" in the axis window, the regulator is activated and the axis may be moved.
Drive is activated
Now each axis may be enabled
and moved
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4.1.5 Disabling of a drive
Drive is de-activated
Command to de-activate drive
4.1.6 fault of a drive
A error of the axis is always announced by a "yellow axis window" from the SCON, this contains also
further information about the type of error and the drives affected by it.
The "SDE" flag of all attached axes is set at the same time.
An error may be reset by pressing „fault acknowledge“ button on the main control desk or manually
as described below:
SIX ERROR EDITOR

Shows „Axis in
ERROR condition“
Command to reset errors
Error Code 47900
Loc Code 1044
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4.1.7 Procedure for optimizing an electrical axis (DMS 2000)
Measuring at the Moog drive
For optimizing the respective drive use the HyperTerminal (RS232 interface / at the PC COM 5 and
at the Moog-drive CPU connector X4).
At the Moog-drive (CPU connector X8) two signals are send (high.low.high.low) and may be shown at
the oscilloscope.
Open the HyperTerminal, the respective interface to the DMS has to be connected and use password
„supermario“.
e.g.: Showing AX1 VelRef and VelCur
What may be done?:
Change axis parameters temporary.

e.g. a1 c 14202 80Æ change axis 1 parameter 14202 (PosGain) to 80.
Æ Start a UCScope recording.
m f tm 3
a1 y 1 18
Recording mask (DAC curr and REF curr)

Axis signal
Output
Number of axis / drive
m f br ***
m f ty ***
Æ press right mouse button and select “receive file“.
Open the recording with the UCScope.
Important: To display the correct current reading use a 5Hz filter for the DACCurr signal!
Select DAC
Set filter
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Æ Two analogue signals may be sent through the MachT card (Connector x8)
>a2 w 1 0 4.096 0
0............Offset
4,096.....Conversion factor
0............Test jack.......1
1............Signal 1 (=VelRef according to UCScope-list for the recording mask)
w...........write ?
a2 .........AX1 (=Order at the Drive)
>a2 w 2 8 4.096 0
0............Offset
4,096.....Conversion factor
8....... Test jack.......2
2............Signal 1 (=VelCur according to UCScope-list for the recording mask)
w...........write ?
a2 .........AX1 (=Order at the Drive)
Recording of speed: 1µm (the smallest unity) / 500µs (loop sample time) = 2mm/s
2048 bits = 10.0Volt
204.8 bits = 1.0Volt = 2mm/s
409.6 bits = 1.0Volt = 1mm/s
therefore command >a1 w 2 8 0.4096 0 Æ 1Volt =1000m/s
Recording of current: [Par13502] = 32767

[Par13508] = 91 = 9,1Apeak max.
2048 bits = 10Volt = 32767
2048 bits / 32767 = 0.0625
therefore command >a1 w 5 8 0.0625 0 Æ 10Volt =63.2Apeak=44.82Aeff (100%Par 13508)
Measuring at the Musix
For optimizing the respective drive use the HyperTerminal (RS232 interface / at the PC COM1 and at
MUSIX COM 2). At the MachS-V (orange Connector/backside, first Analogue from top) two signals are
send (high7,low7,high8,low8) and may be shown at the oscilloscope.
Open the HyperTerminal, the respective interface to the MUSIX card has to be connected and use password
chiffon“
What may be done?:
Æ Change axis parameters temporary.

e.g. a1 c 2 30Æ Change axis 1 parameter 2 (Poserror) to 30.
Æ Two analogue signals may be sent through the MachT card (Connector x8)
Recording Target error: 1µm (the smallest unity) / 500µs (loop sample time) = 2mm/s
8192 bits = 10.0Volt = 0.001mm
819.2 bits = 10.0Volt = 0.01mm
81.92 bits = 10.0Volt = 0.1mm
8.192 bits = 10.0Volt = 1.0mm
therefore command >a1 o t 81.92 0x100 7 1Volt = 0.01mm
Recording of Q-signal: therefore command >a1 o q 2048 0x100 8
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Adjusting speed controller
Attention: There are two types of controllers.

The choice of the controller is carried out with parameter 1104
3 = simple PID-controller (without filters)
5= advanced PID-controller (with filters)
Carry out test movements with Microcycle, 1 short, 1 long movement with original acceleration, braking
and speed values!
For optimization of the PI-Speed regulator the speed signals VelRef and VelCur are displayed (Reference
and real signal of the speed) and send to 2 test jacks at the drive and by them to the oscilloscope.
The goal is, the course of the real value follows the set point as good as possible.
To keep the influencing of the position regulator as low as possible, the Kp factor (p14101/p14202) must for
this measuring be set temporarily very small, otherwise the measuring result would be wrong.
Simultaneous the speed dependent FeedForward (p14604/p14704) must be set to 100% .
Then set Ki factor speed regulator (p14603/p14703) to 0 to adjust the Kp factor only.
The axis should be able to follow the ramp as good as possible without causing overshooting.
Parameter 1103=3: Parameter 1103=5:

>a2 c 14101 0.0001..........Kp PosController >a2 c 14202 10….............Kp PosController
>a2 c 14104 1 1................FF 100% >a2 c 14203 1 1................FF 100%
>a2 c 14602 0.0................Ki VelController >a2 c 14702 0.0................Ki VelController
If the signals are compared, it may be seen, that the speed set point can never be reached after acceleration,
since no integral part is active in the regulator.
Now - starting with small values – increase the Kp-Factor (p14601/p14701) until VelRef and VelCur are
practically one line.
After this set FeedForward (p14603/p14703) back on original value again.
Again watch out that there is no overshooting.
When the speed regulator is adjusted, you can start with the adjustment of the position regulator.
But before that set back FF (p14604/p14704) back to original values.
Adjusting position controller
Attention: There are two types of controllers.

The choice of the controller is carried out with parameter 1103
3 = simple PID-controller (without filters)
5= advanced PID-controller (with filters)
The position regulator is also a PI controller, the adjustments have to be carried out in the usual way.
With the HyperTerminal the values are changed temporarily, after this they must be corrected in the AxPar
file also and during the next booting of the DMS they will automatically be stored in the ROM of the drives.
Parameter 1103=3: Parameter 1103=5:

>a2 c 14101 0.038..........Kp PosController >a2 c 14202 85.0 Kp PosController
>a2 c 14102 0.000..........Kd PosController >a2 c 14209 50.0 Ki PosController
>a2 c 14103 0.000..........Ki PosController
31/01/2008 Start-up manual P4-1916 98/233

4.2 Manipulator (AX14)
Basically, there are two factors that need to be considered for setting this controller. The P factor is the
speed controller ( P=Kp ) and the I factor is the time controller ( I=Tn ).
With this axis an advanced PID controller is used which is equipped with additional filters to increase
the performance of the axis. The speed controller has a fixed setting and should not be changed
anymore. Also, acceleration, deceleration and speed should not be changed anymore.
CTM- and axis parameter-file: ***A1AX14_ip10008_v1

1990 6549 MNPACC (Acceleration ramp)
1991 8295 MNPDEC (Deceleration ramp)
1992 1250 MNPSPEED (Speed)
13501 900 max. current DSP Board * 10 (peak)
13508 632 max. current Motor * 10 (peak)
13511 152 max. current Motor * 10 (Arms)
13051 1.00 Current and torque limit(%/100 of max. current Par.13508)
13085 0.30 I2T – error limit and indirect torque limit
I Npeak M lim 152× 2 57.5

I ²t = × I ²t = × I ²t = 0.29998
I max peak M max 632 65.0
13086 0.92 I2T – Warning (92% = 52.9NM > ACC and DEC is reduced)
14202 85 PosGain
14701 2.5e-5 VelGain
Measurements
After the parameters have been checked the corresponding signals have to be set.
Carry out the measurements using test program Ma.-com. "Mani Test".
If the axis overruns an improvement can be made only by reducing the Kp parameter (14202). Reduce
this parameter only until the oscillation is back within the limits and the positioning time is within the
time specified.
Make sure you check the SAR flag.
Call up in "Monitor" -> "Axes" -> Manipulator. This Flag must be in the position ON and must not
be flickering. If this is the case, increase parameter 3 in the axis parameter file of the manipulator
until it no longer flickers.
Connect Oszilloskop to MPC1

(Connector X8ÆSpeed-REF and CURR value)
In addition connect Oszilloskop to the MachT card 1.
(DAC-Out 7ÆTarget-Signal, / 8ÆQ-Signal)
Hot to set the output signals with the Hyperterminal:

Connected toCOM2 (MUSIX):
a1 o t 81.92 0xe00 7 target Error (10Volt=0.1mm)
a1 o q 2048 0xe00 8 Q-Signal (inPos-Flag SE)
Connected toCOM5 (MOOG PowerDrive 1):
a1 w 2 0 4.096 0 RPM current value (1V=100mm/s)
a1 w 5 8 0.0625 0 Current value (100%DAC=10V=63.2Apeak)
31/01/2008 Start-up manual P4-1916 99/233

IMORTANT: Probes of oszilloskop has to be set to 1x!
Current
TRG-Signal
Short movement Long movement Movement to peak
Speed
60ms 120ms 440ms Q-Signal
channel 1: Speed...........................1Division=200mm/s
channel 2: Current.......................1Division=50% von Imax (63.2Apeak)
channel 3: Target error...............1Division=0.01mm
channel 4: Position flag (Se-FlagÆat 0.02mm switch to ON)
31/01/2008 Start-up manual P4-1916 100/233

4.3 Rotator (AX15)

1743 4.8 Rotator_Torque_Motor (max. torque limit for ACC calculation)
1754 75.00 Rotator_Gewichtsgrenze (Value smallerÆACC smaller)
1750 58.25 Rotator_Max_M_Blech (Weight of maximum sheet)
1751 95/15* RotatorDefSlopeDown (Correction value DEC.) /*for ball casters
1997 10500 ROTACC (Acceleration ramp)
1998 7500 ROTDEC (Deceleration ramp)
1999 540 ROTSPEED (Speed)

I ²t = × I ²t = × ÷ 0.6 I ²t = 0.2186
(16.6 Apeak= 19Nm, so 15.0 Apeak=17.2Nm)
14202 80 PosGain
Adjustment CTM 1996

Move the rotator index out by using the monitor. (set -YV7A to OFF and set –YV7Bto ON)
Now calibrate the axis and move the axis to the value of CTM 1996.
Move the rotator index in by using the monitor. If the lastTarget-signal moves by more then 0.01mm,
the CTM has to be adjusted accordingly. Repeat this procedure until the correct Value of CTM 1996
is found.
Measurements
Carry out the measurements using test program Ma.-com. "Rot Test"
time specified.

a2 o l 81.92 0xe00 7 last target Error (10Volt=0.1mm)
a2w 2 0 4.096 0 RPM current value (1V=100mm/s)
a2 w 5 8 0.0625 0 Current value (100%DAC=10V=15.0Apeak)
31/01/2008 Start-up manual P4-1916 101/233
Current
LTRG-Signal
Speed
90 degree 180 degree
540ms 712ms
Q-Signal
31/01/2008 Start-up manual P4-1916 102/233

Testmax
Measurement is carried out in chapter 11.3 (TSTMAX18->3.00mm).
Use the UCScope for recording (chapter. 4.1.7).
Recording is only possible with UCScope! Set current limit to 8Nm. Picture=2516
DacCur must be set up with a filter (5Hz) / (Math#1)

Multiply Math#1 by 0.00045777 (15A / 32767),
The result is Apeak. Apeak / 1.41 is Aeff.
This value has to be multiplied with 1.61 (Nm/A) to get the value of the torque.
31/01/2008 Start-up manual P4-1916 103/233

4.4 Feeding trolley (AX16)
With this axis a PID controller is used.
The speed controller has a fixed setting and should not be changed anymore.
Also, acceleration, deceleration and speed should not be changed anymore.
CTM- and axis parameter-file: 122A1AX16_ip10046_v1

1642 4.2 TRDunit.Torque (max. torque limit for ACC calculation)
2004 11500 TRDACC (Acceleration ramp)
2005 9000 TRDDEC (Deceleration ramp)
2006 1460 TRDSPEED (Speed)

I ²t = × I ²t = × ÷ 0.8 I ²t = 0.1844
14202 35 PosGain
IMPORTANT: Parameter 14202 and 14701 have to bet he same value for TRD and RIP to guarantee
good performances (e.g if operation stop has been pressed or light barrier has been broken).
Measurements
Carry out the measurements using test program Ma.-com. "Trd Test"
time specified.


a3 o t 8.192 0xe00 7 target Error (10Volt=1.0mm)
a3w 2 0 4.096 0 RPM current value (1V=100mm/s)
a3w 5 8 0.0625 0 Current value (100%DAC=10V=15.0Apeak)
31/01/2008 Start-up manual P4-1916 104/233

left side
Current
Long
movement
to cal. point Speed
TRG-Signal
Short movement to the left
150ms 200ms
Q-Signal

right side
Current
Long
movement
to the right Speed
TRG-Signal
Short movement to the right
Q-Signal
31/01/2008 Start-up manual P4-1916 105/233

Testmax
Measurement is carried out in chapter 11.3 (TSTMAX19->3.00mm).
Use the UCScope for recording (chapter. 4.1.7).
Recording is only possible with UCScope! Set current limit to 9.00Nm. Picture=2516!!
DacCur must be set up with a filter (5Hz) / (Math#1)

Multiply Math#1 by 0.00045777 (15A / 32767),
The result is Apeak. Apeak / 1.41 is Aeff.
This value has to be multiplied with 1.61 (Nm/A) to get the value of the torque.
31/01/2008 Start-up manual P4-1916 106/233

4.5 CLA (AX17)
the performance of the axis.

1983 13000 CLAACC (Acceleration ramp)
1984 16000 CLADEC (Deceleration ramp)
1985 3550 CLASPEED (Speed)
1983 7000 CLAACC (with 1500mm CLA and goose-neck CLA)
1984 10000 CLADEC (with 1500mm CLA and goose-neck CLA)
1985 3550 CLASPEED (with 1500mm CLA and goose-neck CLA)
1984 10000 CLADEC (with spring-loaded CLA)
1986 355 CLA_SLOW_SPEED (Slow speed with spring-loaded CLA)
1987 150 CLA_SLOW_SPEED_RANGE (area slow speed with spring-loaded CLA)
13501 130/150 max. current DSP Board * 10 (peak) with 8 axis drives
13501 150 max. current DSP Board * 10 (peak) with 2 axis drives

I ²t = × I ²t = × I ²t = 0.2186
(16.6 Apeak= 19Nm, so13.0 Apeak=14.88Nm)
14202 30 PosGain
Measurements
Carry out the measurements using test program Ma.-com. "Cla Test".
If the axis overruns an improvement can be made only by reducing the Kp parameter (14202).
If the axis vibrates an improvement can be made only by reducing the Kp parameter (14701).
IMPORTANT: Check positioning with minimum speed!
IMPORTANT: Check tension of the tooth belt!
Connect Oszilloskop to MPC

How to set the output signals with the Hyperterminal:

a* o t 8.192 0xe00 7 target Error (10Volt=1.0mm)
a* o q 2048 0xe00 8 Q-Signal (inPos-Flag SE)
a*w 2 0 0.4096 0 RPM current value (1V=1000mm/s)
a*w 5 8 0.0625 0 Current value (100%DAC=10V=13.0Apeak)
31/01/2008 Start-up manual P4-1916 107/233

IMPORTANT: connect to the CORRECT Moog drive!
IMORTANT: Probes of Oszilloskop has to be set to 1x!
(with tools max. tooling)
Current
TRG-Signal
Together short Appart short
Speed
220ms 220ms
Q-Signal

(without tools)
Current
TRG-Signal

Speed
200ms 210ms Q-Signal
channel 2: Current.......................1Division=10% von Imax (13.0/15.0Apeak)
31/01/2008 Start-up manual P4-1916 108/233

4.6 upper CLA (AX18)

2326 13000 UPPER_CLAACC (Acceleration ramp)
2327 16000 UPPER_CLADEC (Deceleration ramp)
2328 ´ 3550 UPPER_CLASPEED (Speed)
2326 7000 UPPER_CLAACC (with 1500mm CLA and goose-neck CLA)
2327 10000 UPPER_CLADEC (with 1500mm CLA and goose-neck CLA)
2328 3550 UPPER_CLASPEED (with 1500mm CLA and goose-neck CLA)
2327 10000 UPPER_CLADEC (with spring-loaded CLA)
2329 355 UPPER_CLA_SLOW_SPEED (Slow speed with spring-loaded CLA)
2330 150 UPPER_CLA_SLOW_SP_RANGE (area slow speed with spring-loaded CLA)
11003 5.0 PID controller with filter

I ²t = × I ²t = × I ²t = 0.2186
(16.6 Apeak= 19Nm, so13.0 Apeak=14.88Nm)
14202 30 PosGain
Measurements
Carry out the measurements using test program Ma.-com. "Upper Cla Test".


a*w 5 8 0.0625 0 Current value (100%DAC=10V=13.0/15.0Apeak)
31/01/2008 Start-up manual P4-1916 109/233

(with tools max. tooling)
Current
TRG-Signal
Speed
220ms 220ms
Q-Signal

(without tools)
Current
TRG-Signal

Speed
channel 2: Current.......................1Division=10% von Imax (13.0/15.0Apeak)
31/01/2008 Start-up manual P4-1916 110/233

4.7 asymmetric CLA (AX17=right, AX37=left)

1983 13000 CLAACC (Acceleration ramp)
1984 16000 CLADEC (Deceleration ramp)
1985 ´ 3550 CLASPEED (Speed)
1983 8000 CLAACC (acceleration ramp goose-neck CLA)
1984 10000 CLADEC (deceleration ramp goose-neck CLA)
1985 3550 CLASPEED (speed goose-neck CLA)
1984 10000 CLADEC (deceleration ramp with spring-loaded CLA)
1986 355 CLA_SLOW_SPEED (Slow speed with spring-loaded CLA)
1987 -1250 CLA_SLOW_SPEED_RANGE (area slow speed with spring-loaded CLA)

I ²t = × I ²t = × I ²t = 0.2186
14202 30 PosGain

1949 13000 CLA_ACC_LEFT (Acceleration ramp)
1950 16000 CLA_DEC_LEFT (Deceleration ramp)
1951 ´ 3550 CLA_SPEED_LEFT (Speed)
1949 8000 CLA_ACC_LEFT (acceleration ramp goose-neck CLA)
1950 10000 CLA_DEC_LEFT (deceleration ramp goose-neck CLA)
1951 2000 CLA_SPEED_LEFT (speed goose-neck CLA)
1950 10000 CLA_DEC_LEFT (deceleration ramp with spring-loaded CLA)
1952 355 CLA_SLOW_SPEED_LEFT (Slow speed with spring-loaded CLA)
1987 -1250 CLA_SLOW_SPEED_RANGE (area slow speed with spring-loaded CLA)
11003 5.0 PID controller with filter

I ²t = × I ²t = × I ²t = 0.2186
(16.6 Apeak= 19Nm, somit 13.0 Apeak=14.88Nm)
14202 30 PosGain
31/01/2008 Start-up manual P4-1916 111/233

Measurements
Carry out the measurements using test program Ma.-com. "Cla Test"


Connected to COM2 (MUSIX):
a* o t 8.192 0xe00 7 target Error (10Volt=1.0mm) (AX17)
a* o q 2048 0xe00 7 Q-Signal (inPos-Flag SE) (AX17)
Connected to COM5 (MOOG PowerDrive 1):
a* w 2 0 0.4096 0 RPM current value (1V=1000mm/s) (AX17)
a* w 5 0 0.0625 0 Current value (100%DAC=10V=13.0/15.0Apeak) (AX17)
31/01/2008 Start-up manual P4-1916 112/233

Speed and Q-Signal measurement(with tools max. tooling)
220ms 230ms
Q-Signal AX17
speed AX17
speed AX37
together Short appart appart Short together
220ms 230ms
Q-Signal AX37
channel 1: Speed (AX17)....1Division=1000mm/s

channel 2: Speed (AX37)….1Division=1000mm/s
channel 3: Position flag AX 17 (Se-FlagÆat 0.2mm switch to ON)

Speed and TRG-Signal measurement(with tools max. tooling)
current AX17
TRG-Signal AX 17
TRG-Signal AX 37
current AX37
channel 1: Current (AX 17).......................1Division=10% von Imax (13.0Apeak)

channel 3: Target error (AX 17)...............1Division=0.1mm
31/01/2008 Start-up manual P4-1916 113/233

4.8 upper asymmetric CLA (AX18=left, AX38=right)

2326 13000 UPPER_CLA_ACC (Acceleration ramp)
2327 16000 UPPERCLA_DEC (Deceleration ramp)
2328 ´ 3550 UPPER_CLA_SPEED (Speed)
2326 8000 UPPER_CLA_ACC (acceleration ramp goose-neck CLA)
2327 10000 UPPER_CLA_DEC (deceleration ramp goose-neck CLA)
2328 3550 UPPER_CLA_SPEED (speed goose-neck CLA)
2327 10000 UPPER_CLA_DEC (deceleration ramp with spring-loaded CLA)
2329 355 UPPER_CLA_SLOW_SPEED (Slow speed with spring-loaded CLA)
2330 -1250 UPPER_CLA_SL_SP_RANGE (area slow speed with spring-loaded CLA)

I ²t = × I ²t = × I ²t = 0.2186
14202 30 PosGain
2532 13000 UPPER_CLA_RI_ACC (Acceleration ramp)

2533 16000 UPPER_CLA_RI_DEC (Deceleration ramp)
2534 ´ 3550 UPPER_CLA_RI_SPEED (Speed)
2532 8000 UPPER_CLA_Ri_ACC (acceleration ramp goose-neck CLA)
2533 10000 UPPER_CLA_Ri_DEC (deceleration ramp goose-neck CLA)
2534 3550 UPPER_CLA_Ri_SPEED (speed goose-neck CLA)
2533 10000 UPPER_CLA_RI_DEC (deceleration ramp with spring-loaded CLA)
1993 355 UPPER_CLA_SL_SP_RI (Slow speed with spring-loaded CLA)
2330 -1250 UPPER_CLA_SL_SP_RANGE (area slow speed with spring-loaded CLA)

I ²t = × I ²t = × I ²t = 0.2186
14202 30 PosGain
31/01/2008 Start-up manual P4-1916 114/233

Measurements
Carry out the measurements using test program Ma.-com. "Upper Cla Test".


Connected to COM2 (MUSIX):
Connected to COM5 (MOOG PowerDrive 1):
31/01/2008 Start-up manual P4-1916 115/233

Speed and Q-Signal measurement(with tools max. tooling)
220ms 230ms
Q-Signal AX18
speed AX18
speed AX38
220ms 230ms Q-Signal AX38
channel 1: speed (AX17)....1Division=1000mm/s

channel 2: speed (AX37)….1Division=1000mm/s

Speed and TRG-Signal measurement(with tools max. tooling)
current AX18
TRG-Signal AX 18
TRG-Signal AX 38
current AX38

31/01/2008 Start-up manual P4-1916 116/233

4.9 Left reference in X direction (AX1)

1920 1000 LEFT_REF_X_ACC (Acceleration ramp)
1921 1000 LEFT_REF_X_DEC (Deceleration ramp)
1922 160 LEFT_REF_X_SPEED (Speed)
1922 145 LEFT_REF_X_SPEED (Speed P4-3816)
13501 130 max. Strom DSP Board * 10 (peak)

I ²t = × I ²t = × ÷ 0.50 I ²t = 0.1549
14202 40 PosGain
14701 5e-6 VelGain
Measurements
Carry out the measurements using test program Ma.-com. "Left Ref in X Test”.
time specified.


31/01/2008 Start-up manual P4-1916 117/233

IMORTANT: Probes of Oszilloskop has to be set to 1x !
current
speed
TRG-Signal
Short movements
296ms 165ms
Q-Signal
channel 1: speed...........................1Division=100mm/s
31/01/2008 Start-up manual P4-1916 118/233

4.10 Left reference in Z direction (AX2)

1927 400 LEFT_REF_Z_ACC (Acceleration ramp)
1928 1000 LEFT_REF_Z_DEC (Deceleration ramp)
1929 33 LEFT_REF_Z_SPEED (Speed)

I ²t = × I ²t = × ÷ 0.50 I ²t = 0.1549
14202 40 PosGain
14701 4e-5 VelGain
Measurements
Carry out the measurements using test program Ma.-com. "Left Ref in Z Test".
time specified.


31/01/2008 Start-up manual P4-1916 119/233

current
speed
TRG-Signal
TRG-Signal
speed
lange Bewegung kurze Bewegung
1330ms
340ms 370ms 160ms Q-Signal
Q-Signal
31/01/2008 Start-up manual P4-1916 120/233

4.11 Right reference in X direction (AX3)

1913 1000 RIGHT_REF_X_ACC (Acceleration ramp)
1914 1000 RIGHT_REF_X_DEC (Deceleration ramp)
1915 160 RIGHT_REF_X_SPEED (Speed)
1922 145 RIGHT_REF_X_SPEED (Speed P4-3816)

I ²t = × I ²t = × ÷ 0.50 I ²t = 0.1549
14202 40 PosGain
14701 5e-6 VelGain
Measurements
Carry out the measurements using test program Ma.-com. "Right Ref in X Test ".
time specified.


31/01/2008 Start-up manual P4-1916 121/233

current
speed
TRG-Signal
Short movements
296ms 165ms
Q-Signal
31/01/2008 Start-up manual P4-1916 122/233

4.12 De-burr device (AX39)
CTM- and axis parameter-file: ***A1AX39_IP10181_v1

831 5000 RSU_ACC (Acceleration ramp)
832 10000 RSU_DEC (Deceleration ramp)
833 2500 RSU_SPEED (Speed)
13511 30 nominal current Motor * 10 (Arms)

I ²t = × I ²t = × ÷ 0.7 I ²t = 0.2808
14202 50 PosGain
Measurements
Carry out the measurements using test program Ma.-com. "RSU Test".
time specified.


31/01/2008 Start-up manual P4-1916 123/233

current
Bew. nach außen

speed
Bew. nach innen
TRG-signal
1570ms 1210ms
Q-signal
31/01/2008 Start-up manual P4-1916 124/233

4.13 Left Preadjuster (AX34)

665 225 ABA_PREADJUSTER_SPEED (Speed)
666 5000 ABA_PREADJUSTER_ACC (Acceleration ramp)
667 5000 ABA_PREADJUSTER_DEC (Deceleration ramp)
76 700 Push distance

I ²t = × I ²t = × ÷ 0.6 I ²t = 0.3231
14202 90 PosGain
Measurements
Carry out the measurements using test program Ma.-com. "Left Preadjuster Test".
time specified.


31/01/2008 Start-up manual P4-1916 125/233

Movment to Movment to Movment to

inside outside outside
current
speed
TRG-Signal
335ms 80ms 260ms

Q-Signal
31/01/2008 Start-up manual P4-1916 126/233

4.14 Right Preadjuster (AX35)

665 225 ABA_PREADJUSTER_SPEED (Speed)
666 5000 ABA_PREADJUSTER_ACC (Acceleration ramp)
667 5000 ABA_PREADJUSTER_DEC (Deceleration ramp)
76 700 Push distance

I ²t = × I ²t = × ÷ 0.6 I ²t = 0.3231
14202 90 PosGain
Measurements
Carry out the measurements using test program Ma.-com. "Right Preadjuster Test".
time specified.


31/01/2008 Start-up manual P4-1916 127/233

Movment to Movment to Movment to

inside outside outside
current
speed
TRG-Signal
335ms 80ms 260ms

Q-Signal
31/01/2008 Start-up manual P4-1916 128/233

4.15 RIP transfer (16A1AX1)
CTM- and axis parameter-file: 16A1AX1
790 11500 TRAACC (Acceleration ramp)
791 9000 TRADEC (Deceleration ramp)
792 1460 TRA_FAST_SPEED (fast speed)
793 50 TRA_SLOW_SPEED (slow speed)
2316 1050 DCL_TRA_SPEED (transfer speed of PC/PCD/ACP)
2316 800 DCL_TRA_SPEED (transfer speed of S4)

I ²t = × I ²t = × ÷ 0.6 I ²t = 0.2186
14202 35 PosGain
Measurements
Carry out the measurements using test program Ma.-com. ""Rip Transfer Test".
time specified.
IMPORTANT: Parameter 14202 and 14701 must be equal to the parameter of the TRD to guarantee
an optimum performance during following movements.

31/01/2008 Start-up manual P4-1916 129/233

current
Last TRG-Signal
900mm fast movement 100mm fast movement

speed
920ms 410ms
Q-Signal
31/01/2008 Start-up manual P4-1916 130/233

4.16 HPT - AZR (90A1AX1)
CTM- and Axisparameter-file: 90A1AX1_ip10214_v1

735 1000 HPT_AZR_ACC (Acceleration ramp)
736 1000 HPT_AZR_DEC (Deceleration ramp)
737 100 HPT_AZR_SPEED (speed)
Par13511 * 1.41 = Apeak / Par13508 = 0.155 / Par13051 / 4[NM] = 0.0775 *2.0[NM] =0.155
14202 70 posGain
Measurements
Carry out the measurements using test program Ma.-com. "HPT AZR Test".
time specified.
Connect Oszilloskop to MPC (Connector X8ÆSpeed-REF and CURR value)
In addition connect Oszilloskop to the MachT card 1. (DAC-Out 7ÆTarget-Signal, / 8ÆQ-Signal)

A* o l 8.192 0xe00 7 last target Error (10Volt=1.0mm)
A* o q 2048 0xe00 8 Q-Signal (inPos-Flag SE)
31/01/2008 Start-up manual P4-1916 131/233

IMPORTANT: connect to the CORRECT Moog drive! Probes of Oszilloskop has to be set to 1x!
Stromistwert
Geschwindigkeit
Last TRG-Signal
zum Gegenhalter zurück
3340ms 3880ms
Q-Signal
31/01/2008 Start-up manual P4-1916 132/233

5 . LENZE-drives
5.1 PCD/PC
5.1.1 conveyor 1.5KW motor (101A1AX1)

The P controller = Kp must be optimized to compensate for the mechanical differences. The objective
is to prevent the axes from overrunning during positioning (P factor is too low), and to prevent
braking noise (speed process value not reduced smoothly toward the end of the braking phase = P
factor too high).
IMPORTANT:
Check that the chain tension !
The brake may not be mechanical opened!
Parameter 21 (Slip-compensation) must be set to 0 in LENZE inverter!
CTM
2825 900 PC_CONV_FAST_SPEED fast speed (adjust to the S4 IA speed!!!)
2826 1100 PC_CONV_ACC acceleration ramp (adjust to the S4 IA speed!!!)
2827 700 PC_CONV_DEC deceleration ramp (adjust to the S4 IA speed!!!)
2832 500 PC_CONV_MED_SPEED medium speed
2843 30 PC_CONV_SLOW_SPEED slow speed
Axis parameters: 101A1AX1_ip10065_v3

2 40.0 ErrPos Positioning offset limit (0.2199mm)
53 0.6 Kp P sensitivity (potential gain)
55 1.0 Kd D sensitivity (derivative gain)
59 8.0 Kp additional P sensitivity (Gain)
64 0.01 Offsetcomp I sensitivity for positioning (dynamic)
68 40.0 Bias-Deadzone Incremental switch-off position for Par70,71
70 300.0 Bias-Pos Offset positive direction
71 50.0 Bias-Neg Offset negative direction
151 500.0 Off/com/lim From 500 Inc. Par 65 changes (I sensitivity)
Setting the output signals

a* o l 20.48 0xe00 7 last target Error (1 DIV = 40 INC = 0.2199mm)
a* o q 2048 0xe00 8 Q signal (inPos-Flag SE)
600mm 170mm 30mm 1000mm

to the right to the right to the right to the left
40 INC. = 0.2199mm
lastTRG-Signal
1660ms 860ms 1020ms 3060ms

Q-Signal
31/01/2008 Start-up manual P4-1916 133/233

5.1.1 conveyor 1.1KW motor (101A1AX1)
factor too high).
IMPORTANT:
Parameter 21 (Slip-compensation) must be set to 0 in LENZE inverter!
CTM
2825 900 PC_CONV_FAST_SPEED fast speed (adjust to the S4 IA speed!!!)
2826 1100 PC_CONV_ACC acceleration ramp (adjust to the S4 IA speed!!!)
2827 700 PC_CONV_DEC deceleration ramp (adjust to the S4 IA speed!!!)
2832 500 PC_CONV_MED_SPEED medium speed
2843 30 PC_CONV_SLOW_SPEED slow speed


a* o q 2048 0xe00 8 Q signal (inPos-Flag SE)
600mm 170mm 30mm 1000mm

to the right to the right to the right to the left
40 INC. = 0.2199mm
lastTRG-Signal
1900ms 1100ms 1020ms 2400ms

Q-Signal
31/01/2008 Start-up manual P4-1916 134/233

5.1.2 Centering device (101A1AX3)
factor too high).
IMPORTANT:
Check that the belt tension !
Height of centering device must be adjusted (over the brushes)!
CTM
2821 270 PC_CENT_FAST_SPEED fast speed
2822 1000 PC_CENT_ACC acceleration ramp
2823 600 PC_CENT_DEC deceleration ramp
2838 50 PC_CENT_SLOW_SPEED slow speed
Achsparameter: 101A1AX3_ip10066_v3

Long forward Short forward
Short bofore
40 INC. = 0.0548mm forward
lastTRG-Signal
980ms 280ms
Q-Signal
31/01/2008 Start-up manual P4-1916 135/233

5.1.3 suction cup groups (101A1AX6)
factor too high).
IMPORTANT:
CTM
2833 260 PC_SUC_SPEED speed
2834 800 PC_SUC_ACC acceleration ramp
2835 800 PC_SUC_DEC deceleration ramp


40 INC. = 0.057mm
lastTRG-Signal
To outside To inside To inside
31/01/2008 Start-up manual P4-1916 136/233

5.1.4 TCV
factor too high).
Carry out measurement with Microcycle AAA_PCD_TCV! CTM 2331 must be zero!
IMPORTANT:
CTM
2331 300 TCV_SPEED speed
2332 200 TCV_ACC acceleration ramp
2333 500 TCV_DEC deceleration ramp
2350 100 TCV_SLOW_SPEED slow speed


a* o t 204.8 0xe00 7 last target Error (1 DIV = 4 INC = 0.215mm)
40 INC. = 2.15mm
TRG-Signal
To outside To inside
3740ms 3900ms
Q-Signal
31/01/2008 Start-up manual P4-1916 137/233

5.1.5 RF unit
factor too high).
Carry out measurement with Microcycle AAA_PCD_TUR! CTM 1581 must be zero!
IMPORTANT:
CTM
841 70 RF_ROTATOR_ACC acceleration ramp
842 100 RF_ROTATOR_DEC deceleration ramp
843 50 RF_ROTATOR_SPEED speed
Achsparameter: 101A1AX10_ip10211_v3
2 1800.0 ErrPos Positioning offset limit (0.501 degree)

a* o t 2.048 0xe00 7 last target Error (1 DIV = 400 INC = 0.116 Grad
400 INC. = 0.116mm
TRG-Signal
Clock-wise Counter clock-wise
ms ms
Q-Signal
31/01/2008 Start-up manual P4-1916 138/233

5.2 RIP
5.2.1 Trolley (16A1AX2)

factor too high).
IMPORTANT:
CTM
785 750 TRO_ACC acceleration ramp
786 750 TRO_DEC deceleration ramp
787 450 TRO_SPEED fast speed
788 450 TRO_SLOW_SPEED slow speed


40 INC. = 0.552mm
Long back Short back Forward to

zero position
lastTRG-Signal
1560ms 4460ms
Q-Signal
31/01/2008 Start-up manual P4-1916 139/233

5.2.2 Turnover (16A1AX3)
factor too high).
IMPORTANT:
CTM
780 150 TUR_ACC acceleration ramp
781 150 TUR_DEC deceleration ramp
782 60 TUR_SPEED fast speed
783 5 TUR_SLOW_SPEED slow speed

2 2.0 ErrPos Positioning offset limit (0.055 Grad)

a* o l 204.8 0xe00 7 last target Error (1 DIV = 4 INC = 0.11 Grad)
Rotation
4 INC. = 0.11 Grad
clock-wise
lastTRG-Signal
3780ms Q-Signal
31/01/2008 Start-up manual P4-1916 140/233

5.2.3 Additional cantering device (16A1AX4)
factor too high).
IMPORTANT:
CTM
2369 500 RIP_CEN_ACC acceleration ramp
2370 500 RIP_CEN_DEC deceleration ramp
2368 400 RIP_CEN_SPEED fast speed
2371 50 RIP_CEN_SLOW_SPEED slow speed
Axis parameters: 16A1AX4


40 INC. = 0.075mm
Short movement Long movement

together appart
lastTRG-Signal
1250ms 2200ms
Q-Signal
31/01/2008 Start-up manual P4-1916 141/233

5.3 ACP30
5.3.1 conveyor (142A1AX4)

factor too high).
IMPORTANT:
CTM
740 1100 DCL_ACC acceleration ramp (adjust to the S4 IA speed!!!)
741 900 DCL_DEC deceleration ramp (adjust to the S4 IA speed!!!)
742 900 DCL_FAST_SPEED fast speed (adjust to the S4 IA speed!!!)
743 60 DCL_SLOW_SPEED slow speed
Axis parameters: 142A1AX4


40 INC. = 0.252mm
1000mm 300mm 50mm

fast fast slow
lastTRG-Signal
1360ms 1270ms
Q-Signal
31/01/2008 Start-up manual P4-1916 142/233

5.3.2 Centering device ACP30 (142A1AX5)
factor too high).
IMPORTANT:
CTM
735 1000 ASR_ACC acceleration ramp
736 550 ASR_DEC deceleration ramp
737 270 ASR_FAST_SPEED fast speed
738 50 ASR_SLOW_SPEED slow speed


40 INC. = 0.0599mm
Short
Long forward before slow
lastTRG-Signal
31/01/2008 Start-up manual P4-1916 143/233

6. HYDRAULIC_AXIS (P4-1916)
6.1 Checking the positioning properties of the blankholder (AS9)
6.1.1 CTM- and axis parameter-file: 148A1AS9_ip10045_v2

2582 135.00 Speed (maximum power)
2588 80.00 Speed (Minimum power)
1934 2500.00 Acceleration ramp
1935 2500.00 Decelleration ramp
53 9.00 P sensitivity (potential gain)
55 2.00 D sensitivity (derivative gain)
59 10.00 Feed-Forward-Offset / Additional D sensitivity
64 0.01 I sensitivity for positioning (dynamic)
Speed for upward movement is reduced to 90%!
6.1.2 Measurement
Carry out measurement with Ma.-com. "BLH Testpresure".

Connect Oszilloskop to the MachT card 1.

a* o t 204.8 0xe00 7 target Error (1Volt=4INC)
Ax -> Axis number, o -> Output command, t -> Target signal, 204.8 -> Scale factor,
0xe00 Address of MachT-card 1, 7/8 -> Output 7 or 8 on MachT card extension board
Carry out measurement with maximum and with minimum power setting.
NOTE: If the axis overruns by more than 2 Increments, an improvement can be made only by
reducing the Kp parameter (53). Reduce this parameter only until the oscillation is back within the
limits and the positioning time is within the time specified.
From time to time, measure the offset voltage (contacts on extension board A40 between AS9 RF- and
AS9 RF+) during positioning.
31/01/2008 Start-up manual P4-1916 144/233

Maximium power (probes of oszilloskop have to be set to 1x!)
Setpoint
TRG-signal
Movements with
high preasure
normal up normal down
1330ms 1210ms 140ms

Q-signal
Minimum power (probes of oszilloskop have to be set to 1x!)
Setpoint
TRG-signal
Movements with
high preasure
2260ms 2080ms 165ms

Q-signal
31/01/2008 Start-up manual P4-1916 145/233

6.2 Mechanical Checking of the parallelism of the bending unit
1709 (UppererTool.Rad) = xxx.x-> Horizontal distance of the upper bending tool

1712 (UpperTool.Phi) = xxx.x-> Vertical distance of the upper bending tool
1716 (UpperTool.Rad) = xxx.x-> Horizontal distance of the lower bending tool
1719 (UpperTool.Phi) = xxx.x-> Vertical distance of the lower bending tool
NOTE: If CTM 1709/1716 is too small, there will be a collision between bending tool and
blankholder!! CTM 1716 must always be bigger then 723.5mm!!!
If the value is smaller because of the previous measurements, double-check the value!
Use Ma.-com. "Geometrie lower Tool setup“ to bring the bending unit into the correct measuring
position. The lower bending tool is now located in a position where the horizontal gap should be 5.0
mm and the vertical gap 5.0 mm. Using suitable measuring equipment you can now establish the exact
location (left to right) of the bending unit and enter the results in the checklist.
With MLA the BLX tools have to be removed for measurement.
Picture 2:
DANGER: During the whole adjustment phase the warning light system have to stay GREEN!!!
Check, that the main pump pressure (Trace) is approx. 25bar and that the valve YV5B is switched
on!!!
NOTE: Measure with
5.0mm (vertical) slide gauge
Counterblade
NOTE: Measure with

slide gauge
5.0mm (horizontal)
Lower tool
NOTE: The values 5.0 and 5.0 mm quoted above are not important at the moment.
With reference to the measured values that have been entered in the checklist, grind the shims for the
positioning starting position at the ends with the lower value.
Compare vertical and horizontal from left to right.
As a starting point grind 63% of the difference values away from the shims.
Vertical shim Use torque wrench to tighten (560Nm)
Torque rod - right pillow block

Torque rod thrust bearing
Horizontal shim
31/01/2008 Start-up manual P4-1916 146/233

Move now the horizontal and vertical bending cylinder with Ma.-com. "HBC, bzw. VBC Measurement
“ in position for measurement and enter the values into the checklist.
Use Ma.-com. "Geometrie lower Tool setup“ to bring the bending unit into the correct measuring
position again. The lower bending tool is now located in a position where the horizontal gap should be
5.0 mm and the vertical gap 5.0 mm. If the position is not correct, adjust the shims again.
Determine CTM-parameters (max. tolerance of the difference is +/-0.02m)
The parallelism of the negative bending tool may not be adjusted in this way.
6.3 Checking the positive starting position (Lower Tool)
IMPORTANT Repeat Ma.-com. "HBCMeasurement“ and “ VBC Measurement “ and save the values in
the CTMs.
Use Ma.-com. "Geometrie upper Tool setup“ to bring the bending unit into the correct measuring
position. The upper bending tool is now located in a position where the horizontal gap should be 5.0
IMPORTANT: With MLA the BLX tools have to be removed for measurement!
Determine CTM parameters (Max. tolerance for gaps +/-0.03mm)
By reducing CTM-value 1716 the horizontal gap will be reduced
(0,1 value is about 0.1mm distance)
By reducing CTM-value 1719 the vertical gap will be reduced
(0,01 value is about 0.1mm height difference)
31/01/2008 Start-up manual P4-1916 147/233

6.4 Checking the negative starting position (Upper Tool)
Use Ma.-com. "Geometrie upper Tool setup“ to bring the bending unit into the correct measuring
By reducing CTM-value 1712 the vertical gap will be increased
Picture 3
Check, that the main pump pressure (IN7) is approx. 15bar and that the valve YV5B is
switched on!!!
Upper tool
NOTE: Measure with

Slide gauge
Blank holder
Counterblade
5.0mm (vertical) NOTE: Measure with

slide gauge
5.0mm (horizontal)
31/01/2008 Start-up manual P4-1916 148/233

6.5 Setting the starting position of the positive CLA tool (CLA tool NOT fitted!)
Use Ma.-com. "CLA Geometrie setup“ to bring the bending unit into the correct measuring position.
The upper bending tool is now located in a position where the horizontal gap should be 5.0 mm and the
vertical gap 5.0 mm. Using suitable measuring equipment you can now establish the exact location
(left to right) of the bending unit and enter the results in the checklist.
Picture 4
switched on!!!
CLA tool placed by hand

5.0mm (vertikal)
Counter
blankholder
NOTE: measure
5.0mm (horizontal) using special device
lower bending tool
6.6 Setting the starting position of the negative CLA tool (CLA tool NOT fitted!)
Use Ma.-com. "CLA upper Geometrie setup“ to bring the bending unit into the correct measuring
31/01/2008 Start-up manual P4-1916 149/233

6.7 Setpoint and TRG signal measurement
Oscilloscope
MachS card
in control panel
Connections:
DAC-Out 7 AS10/12 CRT leads
DAC-Out 8 AS11/13
Connections:
connectors AS10/12
connectors AS11/13
Measuring equipment required:
1 four-trace oscilloscope, 4 probes, 2 lines for measuring setpoint, 1 DAC-Out cable.

The TRG signals from the probes are read direct by the MachS card (DAC out 7 and 8). A
comparison should be made with the associated setpoint signals (either AS10/11 or AS12/13), read by
the probes from the contacts in the control panel.
31/01/2008 Start-up manual P4-1916 150/233

6.8 Checking the positioning properties of the vertical bending cylinder (AS11)
Standard values for CTM- und axis parameter-file: ***A1AS11_ip10144_v1

2580 160.00 Speed for move VBC in HSM
2586 85.00 Speed for move VBC in ECO
2590 2000.00 Acceleration VBC in HSM
1963 1800.00 Deceleration
59 15.00 Additional D sensitivity (add. potential gain)
Measurement
Carry out measurement with Ma.-com. "VBC-Test".


Setpoint value may be measured on extension board A40 contact AS11 RF- and AS11 RF+.
From time to time, measure the offset voltage (contacts on extension board A40 between AS11 RF-
and AS11 RF+) during positioning.
IMPORTANT: the oil temperature must be at least 42°.
31/01/2008 Start-up manual P4-1916 151/233

Fig 1 Measuring setpoint and TRG signal in HSM mode:
NOTE: Time and position is recorded at 200ms intervals, trace time axis scale is in 500ms units
+ Bending
/return
Setpoint
TRG-signal
- Bending
/return
1030ms 104ms each 1020ms 104ms each

Q-signal
Fig 1A Measuring setpoint and TRG signal in ECO mode:
+ Bending
/return
Setpoint
TRG-signal
normal up normal down - Bending
/return
1795ms 155ms each 1780ms 155ms each

Q-signal
31/01/2008 Start-up manual P4-1916 152/233

6.9 Checking the positioning properties of the horizontal bending cylinder (AS12/AS13)
Standard values for CTM- und axis parameter-file: ***148A1AS13_ip10044_v1

2581 140.00 Speed for move VBC in HSM
2587 75.00 Speed for move VBC in ECO
1977 1800.00 Deceleration
59 12.00 Additional D sensitivity (add. potential gain)
Measurement
Carry out measurement with Ma.-com. "HBC-Test".


Setpoint value may be measured on extension board A40 contact AS13 RF- and AS13 RF+.
From time to time, measure the offset voltage (contacts on extension board A40 between AS13 RF-
and AS13 RF+) during positioning.
IMPORTANT: the oil temperature must be at least 42°.
31/01/2008 Start-up manual P4-1916 153/233

Fig 1 Measuring setpoint and TRG signal in HSM mode:
NOTE: Time and position is recorded at 200ms intervals, trace time axis scale is in 500ms units
Setpoint AS13
TRG-signal
forward backward
Bending
/return
312ms 104ms each 312ms

Q-signal AS13
Fig 1A Measuring setpoint and TRG signal in ECO mode:
Setpoint AS13
TRG-signal
forward Bending backward

/return
490ms 120ms each 510ms

Q-signal AS13
31/01/2008 Start-up manual P4-1916 154/233

6.10 Constant velocity test (TRG-Signal- measurement)
This is the final test to check the relationship between the horizontal and vertical bending cylinders
during circular interpolated movements. If the graphs are not congruent, the parameter 53 (Kp) must
be changed.
The general rule is, that at the slower pair of axis the parameter 53 (Kp) should be increased. If
increasing of parameter 53 (Kp) during previous tests resulted in overshooting, the parameter of the
faster pair of axis have to be decreased.
After the parameters have been checked, run the Ma.-com. "Interpolation Test" for a while, before the
measurement will be started.
Standard values for CTM-Parameter-file:
2563 0.55 %speed reduction for interpolated movement /HSM mode

2589 0.65 %speed reduction for interpolated movement /ECO mode
Setting the output signals at the RTMONITOR:
TRG-Signal Ax o t 204.8 0xe00 7 (VBC)

Q-Signal Ax o q 2048 0xe00 8 (HBC)
ca. 180ms ca. 240ms

about 190ms about 256ms
InIn
this
this
area
area
the
the
signals
signals
must
must
bebe
congruent!!
congruent!!
Small radius Big radius

bending bending
movement movement
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6.11 Positioning of the left outer segment adjuster(AS32)
6.11.1 Adjustment of the hydraulic axis
Standard values for CTM’s and axis parameters 122A1AS32_ip10118_v2:
660(ABA_TRA_SPEED) = 400.0 Speed outer segment adjustment unit

661(ABA_TRA_ACC_MAX) = Acceleration ramp
9000.0 Outer segment adjustment unit with one
outer segment
662(ABA_TRA_DEC_MAX) = Deceleration ramp
outer segment
663(ABA_TRA_ACC_MIN) = Acceleration ramp
8000.0 Outer segment adjustment unit with all
outer segment
664(ABA_TRA_DEC_MIN) = Deceleration ramp
outer segment
673(ABA_Press_SPEED) = 400.0 Speed for insertion/disinsertion
3(SAR) = 10.0 Speed error
53 und 701 (kp) = 3.5 Kp value for positioning control
55 und 703 (kd) = 0.0 Kd value for positioning control
64 und 741 (Offsetcomp) = 0.01 Dynamic I value for positioning control
59 und 704 (Veloff) = 15.0 Offset during speed changes
10.0 Error limit for Bias adjustments
68 (Bias Deadzone) =
(Par70,71,706,707)
70 und 706 (Bias pos) = 100.0 Offset for positive direction
71 und 707 (Bias neg) = 100.0 Offset for negative direction
92 ( ) = 1.0 Reset Offset comparator
403 (Gain A) = 0.8 Additional P value for force control
404 (Gain B) = 1.6 Additional P value for force control
398 ( ) 60.0 Force tolerance
IMPORTANT: The values of parameter pairs 53 and 701, 55 and 703, 64 and 741, 59 and 704, 70
and 706, 71 and 707 have to be equal!
Before force control is used for the first time Par. 53,55,… are used. Whenever control is switched
from position control to force control or from force control to position control Par. 701,703,.. are used.
TRG-Signal Ax o t 204.8 0xe00 7

Q-Signal Ax o q 2048 0xe00 8
For measurement use Ma.-com. "left Translator Test".
With parameters 70 / 706 the positioning to the inside may be improved, with parameters 71 / 707 the
positioning to the outside may be improved.
IMPORTANT: Oil temperature should be approx. 40 degrees and the drift calibration of the axis
should be repeated once more.
31/01/2008 Start-up manual P4-1916 156/233

6.11.2 Q and TRG measurements (one tool)
With one segment
To the inside Short to the Short to the To the outside

outside inside
TRG-Signal AS32
540ms 140ms 150ms 550ms Q-Signal AS32
6.11.3 Q and TRG measurements (all tools)

With all segments

outside inside
TRG-Signal AS32
31/01/2008 Start-up manual P4-1916 157/233

6.12 Positioning of the right outer segment adjuster(AS33)
6.12.1 Adjustment of the hydraulic axis
Standard values for CTM’s and axis parameters 122A1AS33_ip10118_v2:
660(ABA_TRA_SPEED) = 400.0 Speed outer segment adjustment unit

661(ABA_TRA_ACC_MAX) = Acceleration ramp
outer segment
662(ABA_TRA_DEC_MAX) = Deceleration ramp
outer segment
663(ABA_TRA_ACC_MIN) = Acceleration ramp
outer segment
664(ABA_TRA_DEC_MIN) = Deceleration ramp
outer segment
673(ABA_Press_SPEED) = 400.0 Speed for insertion/disinsertion
3(SAR) = 10.0 Speed error
53 und 701 (kp) = 3.5 Kp value for positioning control
55 und 703 (kd) = 0.0 Kd value for positioning control
64 und 741 (Offsetcomp) = 0.01 Dynamic I value for positioning control
59 und 704 (Veloff) = 15.0 Offset during speed changes
10.0 Error limit for Bias adjustments
68 (Bias Deadzone) =
(Par70,71,706,707)
70 und 706 (Bias pos) = 100.0 Offset for positive direction
71 und 707 (Bias neg) = 100.0 Offset for negative direction
92 ( ) = 1.0 Reset Offset comparator
403 (Gain A) = 0.8 Additional P value for force control
404 (Gain B) = 1.6 Additional P value for force control
398 ( ) 60.0 Force tolerance
IMPORTANT: The values of parameter pairs 53 and 701, 55 and 703, 64 and 741, 59 and 704, 70
and 706, 71 and 707 have to be equal!
Before force control is used for the first time Par. 53,55,… are used. Whenever control is switched
from position control to force control or from force control to position control Par. 701,703,.. are used.
TRG-Signal Ax o t 204.8 0xe00 7

Q-Signal Ax o q 2048 0xe00 8
For measurement use Ma.-com. "right Translator Test".
With parameters 70 / 706 the positioning to the inside may be improved, with parameters 71 / 707 the
positioning to the outside may be improved.
IMPORTANT: Oil temperature should be approx. 40 degrees and the drift calibration of the axis
should be repeated once more.
31/01/2008 Start-up manual P4-1916 158/233

6.12.2 Q and TRG measurements (one tool)
With one segment

outside inside
TRG-Signal AS33
6.12.3 Q and TRG measurements (all tools)
With all segments

outside inside
TRG-Signal AS33
31/01/2008 Start-up manual P4-1916 159/233

7 General adjustments
7.1 Checking the XZ stop right
Use Ma.-com. Nr.xx to move axis AX3 after it has been calibrated (XZ stop right along X axis) with
the microcycle „Anschlag_Vermessen_rechts.tl“ into the various measuring positions. Carry out the
measurement in line with the sketch, and grind down the shims on the positioning sledge if required.
CTM1671
CTM1670
NOTE: The microcycle, that is used for this test, asks for certain safety conditions, that have to be
met, otherwise the cycle will stop at a certain point during the cycle!!!
The microcycle moves to the measuring points M1 to M6 by itself. At each point a message on the
screen will appear with the request for measurement. Measure the distance between the reference and
the bending line with a suitable slide gauge and note the result. After that check the result.
M1 to M3 may deviate by now more than 0.1mm. The same applies to points M4 to M6. The difference
between the results of points M4 to M3 and M6 to M1 may also not exceed 0.1 mm. The difference
between the mean value of points M4 and M6 and M3 to M1 may however deviate by +/-0.1mm from
the measurement at point M5 or M2. This just checks the precision of the THK guide.
If the measured values are within the tolerances specified, then you can enter the mean value of the
measurements M1 to M3 and M4 to M6 in the CTM file [M1 to M3 as 1670 (Right_Ref_Z_Max) and
M4 to M6 as 1671 (Right_Ref_Z_Min)].
Load by selecting SAVE and DOWNLOAD.
31/01/2008 Start-up manual P4-1916 160/233

7.2 Checking and adjusting the XZ stop left
7.2.1 Measuring alignment:
After calibration of Axis AX1 (XZ-reference left in X-direction) and Axis AX2 (XZ-reference left in
Z-direction), start the microcycle “Anschlag_Vermessen_links” and measure at the stop points of the
cycle (M1 to M3 according to the figure below).
Z-Direction ->CTM1587
7.2.2 Measuring procedure:
NOTE: The microcycle, which is used for this test, asks for certain safety conditions, that have to be
met, otherwise the cycle will stop at a certain point during the cycle!!!
The microcycle moves to the measuring points M1 to M3 by itself. At each point a message on the
screen will appear with the request for measurement. Measure the distance between the reference and
the bending line with a suitable slide gauge and note the result. After that check the result.
The difference between the measurements at points M1 to M3 and may not exceed 0.1 mm. If the
difference is greater however, adjust the right-hand drive wheel (1 tooth = 0.06mm).
If measuring points M1 to M3 are within the tolerance, point M2 may deviate by +/-0.1mm from the
mean value of measuring points M1 to M3.
The XZ stop right has a vertical travel of approx. 50 mm along the Z axis, and the XZ stop left should
have a movement of approx. 52 mm. The 2mm extra travel on the XZ stop left is to be achieved as
follows: The measurement of point M1 on XZ stop left must be approx. 1.0mm more than point M1 on
the XZ stop right. The measurement of point M6 on XZ stop right must be approx. 1.0mm more than
furthest forward limit position on the XZ stop left.
31/01/2008 Start-up manual P4-1916 161/233

* Should be 1-2mm more
Enter measured value 1 1587 (Zero_Left_Ref_Z) in the CTM file and load by selecting SAVE and
DOWNLOAD.
Procedure:

If the values in the drawing are not achieved then there is a mechanical problem.
If points M1 and M2 comply with the measurements in the drawing then the calibration point is
automatically set correctly. Measurement point M1 (calibration point for AX2) can now be entered as
CTM parameter 1587 (Zero_Left_Ref_Z) and loaded by selecting SAVE and DOWNLOAD. The front
most limit position of the XZ stop left on the Z axis can now be checked.
After AX2 has been calibrated, move it forward so that it reaches its front most limit position. It is
possible to physically limit the path of travel at end position. Check the limit position using a slide
gauge and compare the measurements with those in the drawing.
31/01/2008 Start-up manual P4-1916 162/233

7.3 Starting the machine (checking the stops on the X axis)
The machine must have been calibrated. Move the rotator into the 90° position and shift the
manipulator into position (as per fig 1). Move XZ references fully together. Use a suitable slide gauge
to measure the stops.

Procedure:
Use the slide gauge to measure the outer edge of the clamping unit and the outer edge of the stop.
Subtracting the width of the stop and half of the width of the clamp (19.0 mm) yields the actual position
of the stop (for X axis AX1 and AX3).
The set points are 132 mm left / 129mm right side (CTM 1911 and 1918) with P4-1916, P4-2516.
The set points are 140 mm left / 140mm right side (CTM 1911 and 1918) with P4-3216, P4-3816.
If the measured value is larger than the actual position (for example), that indicate that the CTM
parameter needs to be increased by the difference.
Call up CTM file, change parameter 1586 (Zero_Left_Ref_X) or 1585 (Zero_Right_Ref_X) and select
Save and DOWNLOAD, repeat measurement procedure to check (fig 1).
IMPORTANT: The XZ stop right (AX3) must be measured very precisely, because otherwise the
penetration during pushing (XPF 10-100% in program) will not be correct.
Determining CTM parameters

1586(Zero_Left_Ref_X) = x.xx->Gap calibration point left stop on X to MM
1585(Zero_Right_Ref_X) = x.xx->Gap calibration point right stop on X to MM
31/01/2008 Start-up manual P4-1916 163/233

7.4 Determination of the Notch offset:
Switch on the pneumatic air supply valve (YV01) by using the monitor while the hydraulic is not
running. Use the correct Ma.-com. „linken Innenanschlag auf “ and „rechten Innenanschlag auf“ and
move both references up (in “N” position). Now check the difference between the “N” and not ”N”
positions of both references. Adjust the following CTM-parameters accordingly:
1666 (left_Ref_NotchOffset_Z) = 14.00-> Compensation value for „N“ position left

1675 (right_Ref_NotchOffset_Z) = 14.00-> Compensation value for „N“ position right
References in „N“ position (top view):
31/01/2008 Start-up manual P4-1916 164/233

7.5 Determining the ZERO_TRD and TRDMAX for the transport sledge
7.5.1 Determining TRD_ZERO
The machine must have been calibrated. Move the rotator into the 90° position and shift the
manipulator into position.
NOTE: Check with the monitor the TRD position. Should be -20.00 (CTM 2003).
Carry out the measurements in line with "fig 2" below and make a note of the results. "Fig 1" is
intended to illustrate the starting situation.
Figure 1
Defining the correct handover position of the sheet in the TRD pincer
Version PCD/PC
TRD pincer
Sheet 0
Gap between sheet and pincer 5mm
Starting point for determining CTM parameter 1594 (ZERO_TRD)
Figure 2B
Determining CTM parameter 1594 (ZERO_TRD) and 2002 (TRDMAX)
1) 2)
TRD pincer in sheet TRD pincer in limit
handover position (left- position (right-hand
hand side) side)
Measuring point 1594
0 0
(ZERO_TRD) to centreline
Machine centreline
5.0mm 5.0mm
-...mm Vector for 1594 (ZERO_TRD) Vector for 2002 (TRDMAX) +...mm
1) First determine CTM parameter 1594 2) If CTM parameter 2002 (TRDMAX) is

(ZERO_TRD) (measure using tape, record altered then the limit position of the pincer
results). This value determines the starting changes accordingly. Only switch SQ158 needs
point (calibration point) in relation to the to be reached.
centerline of the machine. This influences the TRDMAX is total distance traveled.
handover position of the sheet.
Machine centreline on Z axis

31/01/2008 Start-up manual P4-1916 165/233
PROCETURE:
Use a tape measure to measure the distance from the outer edge of the rotator to the starting point (fig
1) in the TRD pincer. Now subtract half the clamping unit width (19.00mm) from the value measured
and also CTM 2003 (20.00mm), enter this value as CTM parameter 1594 (ZERO_TRD) and save.
Load by selecting SAVE and DOWNLOAD.
The (ZERO_TRD) -value has to be considered as absolute value the – may be ignored).
7.5.2 Determining of TRD_MAX and Control of –SQ158 and –SQ159
1. SQ158
2002(Trd_Max) = x.x->Max. position of the feeding trolley
Move machine into tool changing position and move TRD with Ma.-com. To the right stop position.
TRD base Set CTM-parameter 2002 (Trd_Max) and lever so that the
switch point of SQ 158 is in the middle of the ramp.
Cam to right of
table
SQ158
2. SQ159
Move TRD with Ma.-com. "TRD SQ159" to minimal position (in question SQ159) and adjust the cam
accordingly.
TRD base
Set cam so that the switch SQ159 is
SQ159 on over the whole length of the cam.
Cam to right of table
Attention: Should the CTM-Parameter 1594 (ZERO_TRD) is later changed again, SQ159 has to be
readjust again.
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7.6 Setting up PCD/PC/ACP*:
The height (fig 3) of the PCD/PC in relation to the transport car pincer is important here (sheet on
PCD must be at the same level as the middle of the slant in the pincer). Switch SQ162/164 is to be set
so that it is zero when the plunger is 1.5mm away from its limit position.
Figure 3
7.7 Setting up RIP:
The height (fig 3) of the RIP transfer in relation to the transport sledge pincer is important here (sheet
in RIP transfer must be at the same level as the middle of the slant in the pincer). Switch SQ162 is to
be set so that it is zero when the plunger is 1.5mm away from its limit position.
Figure 4
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7.8 Adjustment of the sheet thickness sensors of the PCD
Check the following CTM-parameter:

234 (Sheet_testin_Time) = 1200-> Measuring time
815 (MD_DoubleSheet) = 1.0-> Switches the PCD sheet thickness checking device on
827 (PCD_DOUBLE_SHEET_1_D) = 205.0-> Position sheet thickness sensor (back) (-A1IN52)
828 (PCD_DOUBLE_SHEET_2_D) = 1055.0-> Position sheet thickness sensor (forward) (-A2IN52)
Before you may use these programs, you have to adjust the position of the sheet on the scissor table
with the visual stacker!
IMPORTANT: Light barriers and doors must be closed. CTM 815 must be 1. Machine has to be
calibrated.
7.8.1 Adjustment of the zero position sheet thickness
Procedure:
Open the „Trace“ application and press the „adjustment of components“ button.
In the window which now appears, select the „ SETUP PCD “ program.
• Insert exact sheet thickness
• Select pack position,

value >CTM 827= forward
sensor will be tested (A2IN52)
• Select „IBN“ directory.
• Select program „Zange.P4“.
• With button
MOVE CLAMP (Zero adjustment)
and LOAD PROGRAM (ramp)
the sensor will be tested.
• When the sensor is moved out,

click on „load constants“ button.
The values will be loaded into
„CTM-file” and „Analoginputfile“.
7.8.2 Adjustment of the ramp of the sheet thickness
Has to be carried out immediately after the zero position has been determined.
Use a sheet with 2.00mm thickness (measure with caliber), position it on the scissor table. Enter
material thickness into DimS entry of the application.
By using this tool, the analoginput file will also be updated.

Check 101A1IN51 and 101A2IN52 in Monitor (Close Monitor and reopen to update the values)!
Check sensors with shims for correct functioning.
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7.9 Adjustment of the sheet thickness sensors of the TRD
Check the following CTM-parameter:
2376 Reload_Tolerance = 0.05-> +/- Tolerance without reloading (0=no reloading at all)
IMPORTANT: Light barriers and doors must be closed. CTM 815 must be 1. Machine has to be
calibrated.
7.9.1 Adjustment of the zero position sheet thickness
Procedure:
Open the „Trace“ application and press the „adjustment of components“ button.
In the window which now appears, select the „ SETUP TRD “ program.
• Select "Ibn".
• Select Program „Zange.P4“
• With button MOVE CLAMP activate the

Zero position measurement.
• If the sensor is used, press the “LOAD

CONSTANTS LOWER“ button. Now the
CTM parameters are calculated
automatically and then updated in the
CTM-file.
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7.9.2 Adjustment of the ramp of the sheet thickness
Has to be carried out immediately after the zero position has been determined.
Use a sheet with 2.00mm thickness (measure with caliber), position it on the scissor table. Enter
material thickness into DimS entry of the application.
• Insert messured sheet thichness
• With button LOAD PROGRAM activate

the measurement.
• A Kill will be activated, as soon as the part
is measured.
• After the sheet has been measured, press

the “Load constants“ button. Now the
CTM parameters (slope and offset values)
are calculated automatically and then
updated in the CTM-file and the
“analoginputs”-file.
By use of this tool the analoginput file is also corrected.
Attention: To exclude wiring errors, close the outer clamp (IN11) with the locking valve
Now close clamps with Man.com. Open „Monitor“ and check the analog inputs „IN8“ and „IN11“, see
if IN8 is zero and IN11 > 3. Afterwards open valve again.
Double-check clamps by watching the analog inputs during start-up.
During production the clamps are calibrated every time the machine is calibrated (in case the clamps
become worn out).
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7.10 Control of PCD/PC/ACP*/RIP positions
7.10.1 Control of the position of the conveyor
Maximum movement when transferin from S4

516 MAXCON 2700...5000
(also with ACP*)
2847 PC_CONV_OFFSET_LINE ~-450 Distance high brush to end of sheet in Line mode
Distance Last brush to sheet stop
2839 PC_CONV_OFFSET ~200
With RIP muss value has to be less than 190 mm!
Enabling for centering device for synchronized movement
2846 PC_CENT_ENABLE ~1000
with conveyor
Compile program REF.P4, check for right sheet development.

Load program. With sheet, manual loading. Put sheet REF.P4 on conveyor and start automatic
production. Continue up to that point in single step, until the conveyor presses the sheet against the
sheet stop. The distance sheet edge to last brush should now be 1.0mm. Otherwise CTM 2839 has to
be changed accordingly. Load by selecting SAVE and DOWNLOAD. Even when you adjusted the
CTM value, you may continue.
7.10.2 TRD sheet drop position
In production manager select “REQUEST TO ENTER WORKING AREA”, then select “1”.
Let the machine continue to the position where the sheet is ready to be pushed at the hand over
position, and the stops are raised. The machine will stop automatically (Measurement 1->PCD/PC).
Control if the main pressure is 6bar and that the valve YV5 is switched on!!!
3.0mm 5.0mm
5.0mm
with HPT adjust HPT table
with HPT-AZR adjust HPT_AZR_ZERO
with PCD/PC adjust PC_CENT_ZERO
with ACP* adjust ASR_ZERO
with PCD/PC/ACP* mit RIP, adjust ZERO_RIP_TROLLEY
TRD-pinvers
With PCD/PC/ACP* the
are on the other side
739 HPT_AZR_ZERO 290 Calibration position HPT-Lineal to bend line

739 ASR_ZERO 1880 Calibration position centring device to bend line with ACP*
2837 PC_CENT_ZERO 1880 Calibration position centring device to bend line with PCD/PC
557 ZERO_RIP_TROLLEY 240 Calibration position Transfer belt center to bend line
1594 ZERO_TRD xxxx Calibration position TRD-pincer to center of machine
Z-direction: Distance sheet to reference should be 5mm , otherwise adjust position of centring device.
X-direction: Distance sheet to reference (left) should be 3mm and
Distance sheet to reference (right) should be 5mm, if not, adjust position of TRD.
Reduction CTM-parameter 1594 (ZERO_TRD) Æ sheet is dropped more left.
Increase CTM-parameter 1594 (ZERO_TRD) Æ sheet is dropped more right.
7.10.3 RIP
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739 ASR_ZERO ~1770 Calibration pos. centring device with ACP*
2837 PC_CENT_ZERO ~1770 Calibration pos. centring device with PCD/PC
734 ASR_MAX xxxx Maximum pos. centring device with ACP*
2836 PC_CENT_MAX xxxx Maximum pos. centring device with PCD/PC
625 RIP_ADP_OFFSET ~738 Offset RIP to PCD/ACP
557 ZERO_RIP_TROLLEY ~240 Calibration pos. RIP trolley (to bend line)
556 TRA_MAX xxxx Position of sheet during rotation
2315 ADD_POS_RIP xxxx Position sheet where sheet transfer changes from fast to slow
2373 RIP_CEN_ZERO ~825 Calibration pos. additional centring device to RIP center
2374 RIP_CEN_MAX ~ 55 Maximum pos. additional centring device to RIP center
PCD/PC/ACP30 RIP
Bend line TRO in calibration position
CTM 625
ASR-fixed stop CTM 557
CTM 2836 PCD/PC

CTM 734 ACP*
CTM 2374
ASR- Max. position CTM 2837 PCD/PC Centring device in
CTM 739 ACP* Max position center RIP transfer
CTM 2373
ASR/PCD in Centring device in calibration position
CTM 2315
calibration position
CTM 556
Compile program REF.P4 and check for correct sheet development.

Imortant: measured development have to be similar to calculated development!
Calibration position centring device (CTM 739 bzw.2837) :
Load program REF.P4. But sheet on conveyor and start in automatic mode. Move in single Stepp to
that point, where the sheet is pushed by the centring device forward.. Front side of sheet must line up
with last brush!
Calibration position additional centring device of RIP(CTM 2373):
Move in single Stepp mode until sheet Stopp goes down (PCD/PC). Move sheet by hand in between
additional centring device of RIP. Sheet must be 2mm smaller than distance between additional
centring device of RIP.
Centric alignment PCD/PC/ADP* to RIP(CTM 625):
Move sheet by hand along PCD centring device in between additional centring device of RIP. Between
sheet and additional centring device of RIP must be a gap of 1mm on each side.
Turning position of sheet in RIP (CTM 556):
In the program POS: TURN_AROUND must be programmed! Move in automatic mode, until the
sheet is pulled into the RIP. The sheet should move until the 2nd-last roller bar.
Final stop position of the sheet (CTM 2315):
After rotation the sheet should be moved forward fast to a position 50mm before 16A1SQ5.
Sheet drop position on P4 work surface (CTM 557):
As described in chapter 7.10.2.
The difference in drop position may vary between rotated and not rotated to a maximum of 2mm!
IMPORTANT: If CTM 557 is changed, CTM 625 has to be changed by half of this value too.
7.10.4 PREPARE_CENT function (ACP*)
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Move sheet forward by hand along PCD centring device, the 4 light barrier switches -SQ16A..-SQ16D
must go from 0 to 1 at the same time (adjust sensitivity and paralelism).
With ACP30 only one switch exists -SQ22)!
Also switch –SQ8 (cylinder up position) and the dampers have to be adjusted.
Scematic diagram of PREPARE_CENT- funktion:
1. Activation Sensor 2. Stop point of sensor (running after position) (CTM 2307)
SQ16 reflector/ SQ22
cylinder
sheet
SQ162
SQ164
Emiter SQ16
3. Switch of pos. of TRD by SQ162/SQ164 4. Clamping of TRD pincers
TRD-pincer
By changing CTM-parameter 2307 (Offset _Prepare_cent) the switch point of SQ16 may be changed.
In sheet pick-up position the TRD (SQ162) should be about in calibration position
= -19.0mm on the Monitor window.
This pick-up version may be activated by POS: PREPARE_CENT.
7.11 Setting up SFL (safety flap):
The safety flap is aligned in relation to the centerline of the machine in accordance with the layout
drawing (2365 mm). This provides a gap of approx. 15mm between the folding table and the edge of
the stop.
It is IMPORTANT here that the two stops (safety flap and HPT) are at right-angles to another.
7.12 Not used
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7.13 Checking the increase in pressure at the blank holder
7.13.1 Introduction:
Modifying the software enables the pressure to be increased by servo valve (AS9). The pressure set
point is converted into a pressure factor which is monitored by pressure sensors.
The blank holder is forced by the pressure factor to move in under the sheet so that the extension of
the piston rod (=spring-powered) is used as active force. The pressure factor is calculated based on the
holding force required, and generates the resultant holding pressure [= pressure difference between
IN5 (lower cylinder=BP4) and IN4/1.75 (upper cylinder=BP3)].
At the same time a pressure limit is calculated, which on being reached (triggered by pressure sensor)
starts the vertical bending cylinder, and stops STOP AXI AS9 = positioning = holding pressure. On
machines with 4 holding cylinders, the inside pair [AP 7 -> IN6 (BP5)] are operated as normal, but
are also supervised by a pressure sensor. This means that bending cannot take place without the
necessary holding pressure. In addition, the pressure increase time and pressure relief time do not
need to be monitored because a switch is no longer made between the servo valve and the pressure
relief valve.
7.13.2 Used Ctm_parameters

1690 (FOLD_FACTOR_1mm) = 60.00 For the pressure calculation when folding 1916
1690 (FOLD_FACTOR_1mm) = 70.00 For the pressure calculation when folding 2516
1690 (FOLD_FACTOR_1mm) = 80.00 For the pressure calculation when f. 3216/3816
1691 (BEND_FACTOR_1mm) = 65.00 For the pressure calculation when folding 1916
1691 (BEND_FACTOR_1mm) = 45.00 For the pressure calculation when folding 2516
1691 (BEND_FACTOR_1mm) = 43.00 For the pressure calculation when f. 3216/3816
1692 (CUT_FACTOR_1mm) = 70.00 For the pressure calculation when folding 1916
1692 (CUT_FACTOR_1mm) = 70.00 For the pressure calculation when folding 2516
1692 (CUT_FACTOR_1mm) = 80.00 For the pressure calculation when f. 3216/3816
1873 (BLH_PRESS_POS_MIN) ~ 0.27 Initial value of the characteristics
1874 (BLH_PRESS_POS_MAX) ~ 1.35 Final value of the characteristics
1875 (BlankPresHight.Def) = 0.60 Add-on for pressure into outer cylinders
1938 (BLHDelta) ~ 0.25 Presetting tow-bar at the calibration
1931 (BLH_RANGE) = 1.20 Switchover to BLH_DEC_PRESS (2537)
1937 (BLHACCSHORT) = 250.00 Acc. ramp coming from PRESS_POS 25/32/3816
1937 (BLHACCSHORT) = 400.00 Acceleration ramp coming from PRESS_POS 1816
2535 (BLH_SEN_CONFACTOR) = 255.00 Max. Converter value (8 Bit)
2536 (BLH_MAX_PRESS) = 240.00 Max. Hold pressure P4-3216,3816,1916,P2
2536 (BLH_MAX_PRESS) = 220.00 Max. Hold pressure P4-2516
2537 (BLH_DEC_PRESS) = 400.00 Braking ramp moving to PRESS_POS
2538 (BLH_POS_PROZ) = 0.00 must be Zero!!
2539 (BLH_FOLD_SPEED) = 8.00 Speed at closed folding
2540 (BLH_PRESS_PROZ) = 0.00 must be Zero!!
2541 (BLH_ADD_MIN) = 0.00 must be Zero!!
Adjustment of the penetration depth during
2542 (BLH_ADD_SLOPE) = 0.05 Pressurization(DimS)
2543 (BLH_ADD_MAX_LENGH) = 0.00 must be Zero!!
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7.13.3 CTM-1938 (BLHDELTA)
This is the cylinder pressure during calibration. This value is calculated by placing the calibrated
blank holder on the counterblade at ZERO. Calibrate the BLH with manual commands, set internal
state P4_125Free and the output –YV91 to „0“, then move the NLH to zero (must be done with
“Monitor / Actions”).
Activate valve YV34 if not activated, switch off the hydraulics and wait for about 1 minute before
reading the value at the monitor (status axes) and entering it as parameter CTM-1938. To check, if
the value is correct, redo this procedure a second time!
7.13.4 Adjustment of the blankhoder pressurization
Run the machine with manual command „BLANKHOLDER TEST PRESSURE“ for about 5 minutes
(warm-up of the valves).
Then start manual command „BLH PRESSURE SETUP“. The pump will be switched on maximum
pressure. The characteristics for AP7 will be determined. The determined values will be displayed on
the screen and have to be entered into the CTMs.
At the end the characteristics for the middle cylinders (CTM 1873 und CTM 1874) will be
determined. These values are also shown at the display and have to be inserted into the CTM’s.
To check, if the value is correct, redo this procedure a second time!
7.13.5 Check the BLH pressure build-up
The check should be done during adjustment of the bending angles with different material thick
nesses (1mm and 2mm).
By setting CTM 128 to „2“ may by using „Netprint.exe“ the penetration depth be checked.
IST_POSITION – BLH_QTA = Penetration depth. Should be 0.15mm. (+,- 0.05mm). With CTM 2542
may the penetration depth be adjusted for different sheet thick nesses.
(command: OPEN dos window – NETPRINT_DOS rsys_mm P4M_***_**** [enter])
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7.14 Checking pivoting and shifting segments
7.14.1 Note the following during assembly (prerequisites)
Pivoting segments:
A 1.0mm orifice must be built into the valve manifold block (P line). A 1.5 mm orifice must be fitted to
each of the tools.
Set the proximity switches (SQ137/138 and SQ135/136) to a 3/4 turn away from the end of travel. In
other words, screw the proximity switch right in and then undo it again by ¾ of a rotation.
Shifting segments:
A 0.8mm orifice must be built into the valve manifold block (T line) und a 1.5mm orifice must be built
into the valve manifold block (B line). The pressures for movement should be about 85 bar.
Proximity switches (SQ139/140 and SQ141/142) should be set as precisely as possible. This means that
the switches do not change to "1" until the very end of the movement.
7.14.2 CTM parameters:
2116 (INSIRDLY) = 100.00ms switch delay IR / pivot segment for pivoting inwards
2117 (DISINSIRDLY) = 100.00ms switch delay IR / pivot segment for pivoting outwards
7.14.3 Checking the orifices in use for the pivoting segments
Attention: Check 125bar pressure with " Production manager "
These times are used to delay the start of the movement to ensure that the pivoting and shifting
segments are in their relevant positions.
Check the pivoting times by using the UCScope and replace the orifices if required. The machine
must run with for at least 5 minutes with the test program Ma.-com. "BLC Test".
Check the times for the left and right side with UCScope!
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7.14.4 Checking the pressures set for the shifting segments
Attention: Check 125bar pressure with " Production manager "
Check the shifting times by using the UCScope and adjust the pressures if required. The machine
must run with for at least 5 minutes with the test program Ma.-com. "BLC Test".
NOTE: Where a branch is fitted (new design), make sure that the supply is the same to the left and
right. You can do this by checking to see that the limit switches (SQ 141/142 and SQ139/140) switch
over simultaneously, and that the pressures are adjusted to cope with any variations in resistance.
Only then is the motion smooth enough for the switch points to be actuated simultaneously.
Check the times for the left and right side with UCScope!
Now you can leave the machine to run in automatic mode to check for any leaks and look out for any
malfunctions (let the machine run for approx. 1 hour).
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7.16 Adjustment of material detection sensor
When the sheet is transported in, the material is checked.

The machine may not be fooled anymore by the customer.
If the sensor is defect, the sensor may be deactivated by setting CTM 1579 (MD_NO_MAT_CHECK)
to 1.
The Beckhoff node must be limited to 10V.
Use the command line and go to directory C:\usr2\syscon\bin\tool.
With the DOS command C:\usr2\syscon\bin\tools\ dis_overvolt 0 58 4
<return> the voltage will be limited to 10 V.
0 .........for CAN LINE 1
58 ........for node address 58
4........ for connection point 4 (58A connector=1, 58B connector 2, 58C connector 3, 58D connector
4....)
The control must run!
Check by moving a sheet fast on the sensor several times.
If no error occurs, the node is limited to 10 V.
For adjustment of the position (height) of the sensor, clamp a normal cold rolled steel sheet with the
TRD clamps, read the value of IN31, this value must be 1.6Volt (+/-0.2Volt).
As final test fort he sensor, the following sheet metals have to be used (Check IN31 voltage):
Steel: Voltage between 0.0Volt and 2.5Volt.
Stainless: Voltage between 2.5Volt and 5.0Volt.
Aluminum: Voltage between 5.0Volt and 9.8Volt.
Other materials beside these have to be set up in the tooldat.ini file like in the example below:
> [Sensor_Spannung]
> Material_Typ_1 = 0.9
In the bending program the material will be defined by writing POS: MAT_TYP 1..... .
The measured voltage tolerance is always be +/- 0.5Volt.
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8. Bending geometry
8.1 The basics
IMPORTANT: Basically, the bending unit moves in 2 different ways during the bending process. The
first is the standard version (MODE 1) -> which is a circular interpolated movement, and second the
conventional version (MODE 0) -> which is series of vertical and horizontal movements.
Checking CTM parameters
1502 MD_ABT = 3.0-> New Tooldat.ini file activated

1524 MD_Y2K = 1.0-> New UNI formula activated
1542 MD_INS_AC = 5.0-> activates proportional degree/minutes input
1758 Lower_Length_Cor = 0.0-> Will be adjusted in Tooldat.ini file
1761 Upper_Length_Cor = 0.0-> Will be adjusted in Tooldat.ini file
2414 Upper_Thickness_Cor = 0.0-> Will be adjusted in Tooldat.ini file
2415 Lower_Thickness_Cor = 0.0-> Will be adjusted in Tooldat.ini file
2416 Lower_Comp_AC = 0.0-> Will be adjusted in Tooldat.ini file
2417 Lower_Comp_Angle = 0.0-> Will be adjusted in Tooldat.ini file
2418 Upper_Comp_AC = 0.0-> Will be adjusted in Tooldat.ini file
2419 Upper_Comp_Angle = 0.0-> Will be adjusted in Tooldat.ini file
2038 TwinTool.DistanceY = 6.0-> Vertical piston stroke reduction with LDN (NoseTool)
2420 LowerAC_0 = 0.0-> Angle correction factor for zero degree
IMPORTANT: All xxxAC_xx (2420-2426, 2430-2436, 2440-2446 and 2450-2456) parameters must be
set to ZERO to start with.
Important: The material strength and angle limitations for the different materials will now be
determined by the Tooldat.ini file too.
(lower_angle_max_thickness / upper_angle_max_thickness)
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8.2 Determining the precise correction factor for +/- bends of every kind
In both cases the various angles are measured and entered in the checklist in this section. The deviation
from the set point angle is entered as CTM parameter, then it is checked and the relevant CTM
parameter corrected if required, until the deviation from the set point angle is equal to or lower than
20’.
8.2.1 Procedure for calculating angle correction factor
Here we use the programs "Winkel.P4" -> NOT interpolated bends, "Winkel_interpol.P4" ->
interpolated bends and "Winkel_Radius.P4" -> +/- 90° radius.
NOTE: Always use sheet 500mm long and 1.00mm thick.

NOTE: Measure DIM S carefully and enter into the program!
In each program the instruction LET: ANGLE_A and ANGLE_B is used to establish the bending
angle.
e.g. 90° and 75° or 60° and 45° or 30° and 15° for both positive and negative bends.
The parts can now be bent during the FIRST run (total of 7 parts). Then the angle at the centerline of
each part can be measured and entered in the checklist and the deviation from the set point angle
(correction factor) can be calculated and also entered in the checklist.
NOTE: The correction factors e.g. CTM 2424 (LowerAC_60) are entered in degrees/minutes (e.g. 1°
30’ -> entered as 1.3). Use "-" or "+" sign to indicate whether the bend was too low or too high. If the
angle measured is larger than the set point angle then the + sign should be used, if the measured angle
is smaller then the – sign should be used.
e.g. The set point angle is +75°, the measured angle is 74° 20’, the difference is 40’ and the angle
correction factor is –0.4.
IMPORTANT: Measured angles that are within the +/-20’ tolerance after the first run do not need to
have the CTM parameters (xxxAC_xx) changed for the moment.
Procedure for establishing correction factors for radius:
NOTE: The correction factors for the positive and negative radius are treated the same with regard to
the +/- sign; only the correction factor values are a product of the division of the difference (set point
to actual angle) and the number of steps in the program "Winkel_Radius.P4".
e.g. actual angle is 95° 40’, the difference is 5° 40’, -> convert degrees into minutes -> 5x60+40=340’ ->
convert to decimal figure -> 340x100/60=566.7 -> divide by number of steps -> 566.7/20=28.3 ->
convert into degrees -> 28.3x60/100=17 -> angle correction factor is 0.17.
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8.2.2 Entering various correcting factors in the CTM file
8.2.2.1 Positive bend NOT interpolated (MODE 0)
Enter CTM parameters

2420LowerAC_0* = 0.0->angle correction factor for radius
2421LowerAC_15 = 0.0->angle correction factor for 15° degrees
2427 LowerAC_105 = 0.01-> angle correction factor for 105° degrees
2428 LowerAC_130 = 0.01-> angle correction factor for 130° degrees
*CTM 2420 and 2430 must have the same value!
8.2.2.2 Positive bend INTERPOLATED (MODE 1)

2430CircularLowerAC_0* = 0.0->angle correction factor for radius
2431CircularLowerAC_15 = 0.0->angle correction factor for 15° degrees
2437 CircularUpperAC_105 = 0.01-> angle correction factor for 105° degrees
8.2.2.3 Negative bend NOT interpolated (MODE 0)

2440UpperAC_0* = 0.0->angle correction factor for radius
2441UpperAC_15 = 0.0->angle correction factor for 15° degrees
2447 UpperAC_105 = 0.01-> angle correction factor for 105° degrees
2448 UpperAC_130 = 0.01-> angle correction factor for 130° degrees
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8.2.2.4 Negative bend INTERPOLATED (MODE 1)

2450CircularUpperAC_0* = 0.0->angle correction factor for radius
2451CircularUpperAC_15 = 0.0->angle correction factor for 15° degrees
NOTE: After the last entry has been completed, DOWNLOAD and recompile the programs.
8.2.3 Procedure for second run (optimizing angle correction factors)
NOTE: Only carry out the bends where the angle correction factors still needs to be optimized.
The parts can now be bent during the SECOND run. Then the angle at the centerline of each part can
be measured and entered in the checklist under "second run".
IMPORTANT: Normally all the angles should now be within a tolerance of +/-20’ (radius +/- 1°).
If angles are still outside the tolerance (probably the radius), then a new angle correction factor must
be calculated. The same procedure is to be used as in section 7.2 except that the existing angle
correction factor is updated to obtain the new correction factor.
e.g. The set point angle is +75°, the measured angle is 75° 30’, the difference is 30’ and the angle
correction factor is –0.4. -> -0.4+0.3=-0.1 -> the new angle correction factor is –0.1.
Enter the new angle correction factors in the checklist.
NOTE: After the last entry has been completed, DOWNLOAD and recompile the programs.
8.2.4 Procedure for third run (optimizing angle correction factors)
NOTE: Only carry out the bends where the angle correction factors still needs to be optimized.
The parts can now be bent during the THIRD run. Then the angle at the centerline of each part can
be measured and entered in the checklist under "third run".
IMPORTANT: Normally all the angles should now be within a tolerance of +/-20’ (radius +/- 1°). If
one or two angles are still outside the tolerance then the angle correction factor will need to be
optimized yet again. Repeat the procedure described for the second and third run.
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8.3 Checking the accuracy of the angle from left to right (+90°/+45°)
NOTE: Use degreased sheet only! There is otherwise a risk of the sheet sticking to the counterblade
when it is pushed away, causing the TRD to fail.
Use programs WINxx10.P4 (or WINxx075.P4) or RAD.P4 to check +/-90°, +/-45°, +/- 130°/135° and
+/-90° radius at bending lengths of 1750mm with the relevant sheet thickness, and adjust if required.
NOTE: Mechanical realignment is required however if the error is greater than 20 min.
Example +90°:
If (during a 90° bend) the sheet is bent 1° too little on the left, the shim on the right (horizontal) must
be ground down by 0.04 to 0.06 mm.
Example +45°:
If (during a 45° bend) the sheet is bent 1° too little on the left, the shim on the right (vertical) must be
ground down by 0.04 to 0.06 mm.
NOTE: A radius part (program Rad.P4) does not need to be made until the +90° and +45° are in a
range of approx. 20min.
IMPORTANT: The tolerance for the radius from left to right is 1°, and approx. 2° for the centre.
Use the transition software to save the oscilloscope traces in the TRACES directory and copy them
into the checklist.
Figure 1 (positive radius with sheet in HSM mode-> Program RAD.P4)
+Bending
return
setpoint AS9
TRG-signal AS11
Uniform trace
no overrun!
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8.4 Checking the accuracy of the angle from left to right (-90°/-45°)
Example -90° bend:
The critical aspect here is whether the error applies in the same direction (-90° to +90°). i.e., the +/-
sign (e.g. bend too slight on right for both +90° and -90°) of the angle of error on one side is in the same
direction. The angle of error on the positive bend (already set) and the angle of error on the negative
bend (still to be adjusted) can now be balanced out. Mechanical adjustment is required. The
mechanical adjustment must be carried out that way, that the error of angle of the +90° bend will be
brought to the opposite tolerance and the -90° bending is within tolerance (+/-20’).
Example -45° bend:
The critical aspect here is whether the error applies in the same direction (-45° to +45°). i.e., the +/-
sign (e.g. bend too slight on right for both +45° and -45°) of the angle of error on one side is in the same
direction. The angle of error on the positive bend (already set) and the angle of error on the negative
bend (still to be adjusted) can now be balanced out. Mechanical adjustment is required. The
mechanical adjustment must be carried out that way, that the error of angle of the +45° bend will be
brought to the opposite tolerance and the -45° bending is within tolerance (+/-20’).
If the error of angles is still too big, the bending tools itself have to be adjusted (shimmed)!
Figure 2 (positive radius with sheet HSM mode-> Program RAD.P4)
-Bend
return
setpoint AS9
TRG-signal AS11
Uniform trace
no overrun!
8.5 Checking length correction and CTM parameters
If the +/-90° or +/-45° bend in a part with the maximum length on average over the whole length
deviates more than the obligatory 20’ then the tooldat.ini file needs to be adjusted accordingly.
NOTE: Enter the values in the correct material sections of the file !!!
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8.6 Checking thickness correction and CTM parameters
If the +/-90° or +/-45° at 2.00mm bend in a part with the maximum length on average over the whole
length deviates more than the obligatory 20’ then the tooldat.ini file needs to be adjusted accordingly.
NOTE: Enter the values in the correct material sections of the file !!!
8.7 Checking +/-130° and 135° bending and +/- open folding:
Use program ANGxxxx.P4 (tool-based, e.g. LIA, LI, ..), if required for bending and folding, refer to
chapter 14 tables 1-10 for the ZF and YF or AC values. Calculate the program and load. The setting
plates 3200x400x0.75 or 1.0 [mm] can be used as test sheets. First start the machine without a sheet
and watch the gap between the bending tool, the counterblade and the blankholder during various
130°/135° bends at the bending end point (figure 1).
Figure 1:
IMPORTANT:
In no circumstances may the bending tool touch the blank holder or counterblade. At least 1 sheet
thickness (as shown in figure 1) should always be free. It is best to check each individual step with
BENSPEED 5. If this gap is not detectable then the CTM-Parameters have to be checked. Once this
has been done run the machine with a sheet and measure the angle and fold height. If the angle is not
correct, then the values in the TOOLDAT.ini file need to be corrected.
NOTE:
Do not use a SPEED command in the program and the 130° / 135° bending must not be carried out in
single step mode!
After all the angles have been set, make all the bends in the checklist with the various test sheets for
+/-90°, +/-45°, +/-130°/135° and the folds, measure the results and enter them in the checklist.
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9. Rotator, references and CLA
9.1 Checking the indexation of the rotator index
9.1.1 General and check the index arm
The direct controlled pressure reducing valve must be predefined on 70 bar. Control that, when the
valve –YV89 is activated, the index arm is stretched.
Important: Must the pressure of the pressure reducing valve be changed, the hydraulic construction
department has to be informed about this newly adjusted pressure!
In addition, the valve must be leaded again.
Important: Use sheet with longest possible bending length!

It may no ROT-Speed, QSU or QSD being programmed.
Used Ctm
2113 (ROT_INDEX_MASK) = x.x-> Binary coded index numbers for stretching

2125 (ROT_INDEX_MASK_AB) = x.x-> Binary coded index Numbers for stretching
The value of the CTM is binary encoded.
Side 1 uses Bit 1 (1)

Illus. 8.1
M2
S 4, S 1
S 3, S 2
M1
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9.1.2 Adjustment with normal pick-up (side 4 und 3)
Bend and measure program INDEXTST.P4. (pay attention to right material development, no AB or
JMP may be programmed)
If M2 is bigger than M1 Index must be turned on side 3.
Change CTM 2113 set to 4 and save it (Illus. 9.1).
If M2 is bigger than M1 Index must be turned on side 4, 2 and 1 (Illus. 9.1).
Bend and measure another part. Should the measurement results have not changed or changed too
little, the pressure at the pressure reducing valve must be increased.
Should the measurement results have turned, the pressure has to be reduce.
Repeating this process until the parallelism of 0.15 mm has been achieved.
Important: Should the dimension not correspond to the programmed one, CTM 1592
(Zero_MNP) has to be changed! (Dimension too big = Ctm-value increased about half the dimension
error)
9.1.3 Adjustment with normal pick-up (side 4 und 3) with JMP
In the program INDEXTST.P4 at Rot: S 3 program a JMP. Bend a sheet and measure. (pay attention
to right material development, no AB may be programmed and a JMP in ROT: S 3 must be
programmed).
Should the parallelism error be on the same side like with the sheet without JMP, but bigger (max.
0.5mm), the pressure has to be adjusted accordingly to average the errors.
e.g. without Jmp with Jmp

M1 300.10 300.40
M2 299.90 299.60
Adjust pressure!
without Jmp with Jmp

M1 299.90 300.20
M2 300.10 299.80
Important: If the parallelism fault is more than 0.5 mm or it cannot be averaged, a more exact
examination of the rotator has to be carried out. (Round run of the rotator)
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9.1.4 Adjustment with turned pick-up (Side 1 und 2)
Bend and measure program INDEXTST.P4. (pay attention to right material development, AB has to
be programmed, JMP may be programmed)
If M2 is bigger than M1 Index must be turned on side 2.
If M2 is bigger than M1 Index must be turned on side 1, 3 and 4 (Illus. 9.1).
Bend another sheet and measure it.
Important: The pressure reduction valve may not be adjusted anymore!
9.1.5 Adjustment with turned pick-up (Side 1 und 2) with JMP
In the program INDEXTST.P4 at Rot: S 2 program a JMP. Bend a sheet and measure. (pay attention
to right material development, AB must be programmed and a JMP in ROT: S 2 must be
programmed).
Important: If the parallelism fault is more than 0.5 mm or it cannot be averaged, a more exact
examination of the rotator has to be carried out. (Round run of the rotator)
9.2 Determining CTM parameter 1592 (ZERO_MNP)
1592(ZERO_MNP) = x.xx->Gap calibration point manipulator to BL
The CTM already became adjusted in chapter 9.1.2.
Measure DIM X and DIM Z with a suitable slide gauge on the finished bend and note the
measurements (it is essential that the + 90° bends are perfect). If the error is not the same in both
dimensions then calculate the mean value. CTM parameter 1592 (ZERO_MNP) is now adjusted by
the mean error value. Load by selecting SAVE and DOWNLOAD, recalculate program REF.P4, load
and make a new part.
e.g. SP dim. X = 860.0mm Z = 270.0mm
PV dim X = 865.6mm Z = 275.8mm
error X = 5.6mm Z = 5.8mm mean value = 5.7mm
CTM parameter 1592 (ZERO_MNP) is now corrected by one half of the error value (instead of
5.7mm, only 2.85mm). If the part is too large, the calibration point value must be increased. The
manipulator then moves further into the machine (twice the value of each dimension = why only half
the error value is used) and the part is then smaller.
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9.3 Fine adjustment of stops (AX1, AX2)
It is essential that the length of the length of the notch on the sheet (840mm -> S4 and 250mm ->
S1+S2 -> measure using slide gauge) with double the value of X1 - (420mm) and Z1 -(125mm) is
identical with the Program. If this is not the case then the values of X1 and Z1 must be adjusted
accordingly. The results of the measurements will otherwise be incorrect and the accuracy of the
CTM parameters below cannot be guaranteed.
1670(Right_Ref_Z_Max) = x.xx->Max. distance of right stop in Z to BL

1671(Right_Ref_Z_Min) = x.xx->Min. distance of right stop in Z to BL
Measurement:
Measure the notches on the finished part using a diminishing scale. The stating point is the Z axis of
the XZ stop right (located with measured value 1670 [Right_Ref_ Z_max] and 1671 [Right_Ref_
Z_min], because this stop is the reference point for the manipulator (on the Z axis).
Plan view of the finished REF part
Explanation of drawing:
9.3.1 CTM parameter 1637 (Mnp.PickUpcorr.)
This factor changes the pickup position of the manipulator on the Z axis in relation to the XZ stop
during alignment of the sheet. If M1 is larger than 10mm then the difference compared to the fixed
value (10mm) must be added to CTM parameter 1637 (Mnp.PickUpcorr.)
and resaved. Load by selecting SAVE and DOWNLOAD, recalculate program REF.P4, load, and
make another bend.
1637(Mnp.PickUpcorr) = x.xx->Pick up correction factor for manipulator
e.g. M1: = 10.5mm; error = 10.5mm - 10.0mm (fixed value) = +0.5mm;

+0.5mm change to CTM-Parameter 1637 (Mnp.PickUpcorr.)
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9.3.2 CTM parameter 1586 (Zero_Left_Ref_X)
If M2 is larger then 10.0mm, then 2 factors are responsible.

1. a possible DIM X error that has an effect on M2 and must be taken into consideration.
2. CTM parameter 1586 (Zero_Left_Ref_X) itself is still wrong.
1586(Zero_Left_Ref_X) = x.xx->Gap calibration point left stop on X to MM
e.g. M2: = 13.0mm; DIM X = 864.0mm; the error in M2: is 3.0mm

Calculation: 3.0mm - 2.0mm (half DIM error) = 1.0mm change in value of
CTM parameter 1586 (Zero_Left_Ref_X)
Determine the direction of shift of the sheet in relation to the symmetrical axes of the machine.
M2:
The +/- sign for CTM parameter 1586 (Zero_Left_Ref_X) can now be determined based on the
calibration point vector. Arrows (vector and direction of shift) in the same direction mean + calibration
point -change and arrows in opposite directions mean –calibration point -change. Change CTM
parameter 1586 (Zero_Left_Ref_X) accordingly. Load by selecting SAVE and DOWNLOAD,
recalculate program REF.P4, load, and make another bend.
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9.3.3 CTM parameter 1587 (Zero_Left_Ref_Z)
If M3 is not 10.0mm, this can simply be changed using CTM parameter 1587 (Zero_Left_Ref_Z). This
is conditional though on M1 being 10.0mm. Determine the direction of shift again so that the sign for
the change in value can be determined.
1587(Zero_Left_Ref_Z) = x.xx->Gap calibration point left stop on Z to BL
M3:
e.g. M3: = 10.5mm; error = 10.5mm - 10.0mm (setpoint) = 0.5mm;

0.5mm change in CTM parameter 1587 (Zero_Left_Ref_Z)
The +/- sign for CTM parameter 1587 (Zero_Left_Ref_Z) can now be determined based on the
calibration point vector. Arrows (vector and direction of shift) in the same direction mean + calibration
point -change and arrows in opposite directions mean –calibration point -change. Change CTM
parameter 1587 (Zero_Left_Ref_Z) accordingly. Load by selecting SAVE and DOWNLOAD,
recalculate program REF.P4, load, and make another bend.
Run REF.P4 again, measure and adjust if required.
If the REF.P4 part is now dimensionally correct, make 3 parts and enter the measured values in the
checklist.
9.3.4 Checking the notch offsets
Run the REF.P4 program one more time (adjust the program accordingly -> consult the checklist),
measure the REF part and, if necessary, correct the notch offset, which will compensate the eventual
difference to the measurement points M1 (Z1) and/or M3 (Z2) of the “normal” centered REF part
(without BZ commands).
1666 (left_Ref_NotchOffset_Z) = 14.00-> Correction value for „N“ centering left

1675 (right_Ref_NotchOffset_Z) = 14.00-> Correction value for „N“ centering right
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9.4 CLA settings (calibration point and angle):
9.4.1 Adjusting the CLA carriages symmetrically with the stops
It is essential that you check that the CLA carriages are symmetrical with the stops, even though the
bending tool is not exactly centered between the stops
Procedure
Elaborate, load and run the program REF.P4 in single step mode (with sheet). Let the program
continue, until the rotator clamp clamps the sheet. KILL the production and move the manipulator
forward by hand, until side 4 project over the bending line.
Danger: During the manual adjustment phase the warning lamp must be GREEN!
Move the CLA-slide (with at least 1 tool mounted each side) by hand to the centre until the CLA-tool
touches the sheet. if there is a gap between one of the CLA-tools and the edge of the sheet, the screw of
the belt stretcher (of the CLA-tool) have to be adjusted according to chapter 4.10.
9.4.2 Adjusting the calibration parameter 1591 (ZERO_CLA):
Important The CLA has to be in calibrated state!
Procedure
touches the sheet (check, that there is no gap between CLA-tool and sheet edges!) and then check the
value of the counter from the "CLA axis window" of the monitor. This now the new value CTM-
parameter 1591 (ZERO_CLA).
Change the CTM-parameter 1591 (ZERO_CLA), then press SAVE and DOWNLOAD.
Move the machine into the tool changing position, move the CLA carriages together again and check
the gap (0.4 mm) (Ma.-com. "CLA -><-").
Compare the calculated and the real value in the "CLA axis window". If there is a difference, change
the CTM-parameter 1591 (ZERO_CLA) by half the error until the gap is 0.4mm.
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9.4.3 Adjusting the asymmetric calibration parameter (ZERO_CLA)
Because the CLA tools are not exact symmetric to the references, but they should be, this has to be
checked.
1591 (ZERO_CLA) = x.x-> Distance right CLA to center of machine

1583 (ZERO_Left_CLA) = x.x-> Distance left CLA to center of machine
Procedure
Calculating program Ref.P4, load it and run it in single Step with sheet. Run the program until the
part is turned to side 1. „KILL“ the production, move the MNP forward by hand until the sheet sticks
out over the bending line.
Move the CLA in until it touches the sheet.. No gap is allowed between the sheet and the CLA (at least
one tool mounted on each side)! Read the axis position value from the Monitor axis windows (AX17
right, AX37 left) , add halve the cut size and save the calculated values in CTM-parameter 1591
(right) and 1583 (left).
Important Double check the correctness of the measurement by moving the CLA together. The gap
in the center should be 0.4mm.
9.4.4 Adjustment of the asymmetric CLA – maximum position (CLA_MAX)
Procedure
With manual command move right CLA fully to the left, the inside edge of the innermost CLA tool
mounted must be flush with the bending tool edge. If the CLA is not in the position (sticks out), the
CTM 1981 has to be reduced.
With manual command move left CLA fully to the right, the inside edge of the innermost CLA tool
1981(CLAMAX) = -*.*->Maximum position on the right

1943(CLAMAX_LEFT) = -*.*->Maximum position on the left
9.4.5 Check of the 90° and 45° bending with CLA
Control of the angles may be carried out simultaneous with the adjusting of the references.
(chapter 4.2) Mount CLA-Tools according to program (250mm complete).
In the program REF.P4 the first bending on Side 1 has to be a CLA 90° bending
and on side 2 the first bending has to be a CLA 45° bending.
Check the angles and at angle error amend the corresponding parameters.
Procedure:
1723 (AuxLowerTool.Rad) = x.x-> For lower bending tool with CLA

1726 (AuxLowerTool.Phi) = x.x-> For lower bending tool with CLA
Reduce value of CTM 1723 if +90°-Winkel is under bend (0.1=ca.1°)

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9.5 Upper CLA settings (calibration point and angle):
9.5.1 Adjusting the CLA carriages symmetrically with the stops
It is essential that you check that the CLA carriages are symmetrical with the stops, even though the
bending tool is not exactly centered between the stops
Procedure
Elaborate, load and run the program REF.P4 in single step mode (with sheet). Let the program
continue, until the rotator clamp clamps the sheet. KILL the production and move the manipulator
forward by hand, until side 4 project over the bending line.
touches the sheet. if there is a gap between one of the CLA-tools and the edge of the sheet, the screw of
the belt stretcher (of the CLA-tool) have to be adjusted according to chapter 4.10.
9.5.2 Adjusting the calibration parameter 1591 (ZERO_CLA):
Important The CLA has to be in calibrated state!
Procedure
touches the sheet (check, that there is no gap between CLA-tool and sheet edges!) and then check the
value of the counter from the "CLA axis window" of the monitor. This now the new value CTM-
parameter 1625 (ZERO_UPPER_CLA).
Change the CTM-parameter 1625 (ZERO_UPPER_CLA), then press SAVE and DOWNLOAD.
Move the machine into the tool changing position, move the CLA carriages together again and check
the gap (0.4 mm) (Ma.-com. "UPPER_CLA -><-").
Compare the calculated and the real value in the "CLA axis window". If there is a difference, change
the CTM-parameter 1625 (ZERO_UPPER_CLA) by half the error until the gap is 0.4mm.
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9.5.3 Adjusting the asymmetric calibration parameter (ZERO_CLA)
Because the CLA tools are not exact symmetric to the references, but they should be, this has to be
checked.
1625 (ZERO_UPPER_CLA) = x.x-> Distance left CLA to center of machine

1627 (ZERO_UPPER_CLA_RIGHT) = x.x-> Distance right CLA to center of machine
Procedure
Calculating program Ref.P4, load it and run it in single Step with sheet. Run the program until the
part is turned to side 1. „KILL“ the production, move the MNP forward by hand until the sheet sticks
out over the bending line.
Move the CLA in until it touches the sheet.. No gap is allowed between the sheet and the CLA (at least
one tool mounted on each side)! Read the axis position value from the Monitor axis windows (AX18
left, AX38 right) , add halve the cut size and save the calculated values in CTM-parameter 1625 (left)
and 1627 (right).
Important Double check the correctness of the measurement by moving the CLA together. The gap
in the center should be 0.4mm.
9.5.4 Adjustment of the asymmetric CLA – maximum position (CLA_MAX)
Procedure
With manual command move right CLA fully to the left, the inside edge of the innermost CLA tool
With manual command move left CLA fully to the right, the inside edge of the innermost CLA tool
2325(UPPER_CLA_MAX) = -*.*->Maximum position on the left (AX18)

2531(UPPER_CLA_MAX_RIGHT) = -*.*->Maximum position on the right (AX38)
9.4.5 Check of the 90° and 45° bending with CLA
Control of the angles may be carried out simultaneous with the adjusting of the references.
(chapter 4.2) Mount CLA-Tools according to program (250mm complete).
In the program REF.P4 the first bending on Side 1 has to be a CLA 90° bending
and on side 2 the first bending has to be a CLA 45° bending.
Check the angles and at angle error amend the corresponding parameters.
Procedure:
2090 (AuxUpperTool.Rad) = x.x-> For upper bending tool with CLA

2091 (AuxUpperTool.Phi) = x.x-> For upper bending tool with CLA

10. Adjustment of special tools and options

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10.1 Option P
10.1.1 Standard values for CTM machine constants
0.0-> No option P tool

1.0-> Option P – tool with groove in Blankholder
2.0-> Option P – tool without groove in blankholder
1533 (MD_OPTION_P) = 3.0-> Option P – tool without groove in blankholder overlapping
with nose
4.0-> Option P – tool with groove in blankholder overlapping
(Option CUT with ABA)
With option CUT the following CTM’s have to checked:
2185 (OptionP_Thickness) = 21.84-> Thickness of the metal plate (tool)

2186 (OptionP_YmaxPos) = 167.0-> Max. bending height with inserted option P tool
2186 (OptionP_YmaxPos) = 147.0-> Max. bending height before cut action
2187 (OptionP_ZminPos) = 280.0-> Only used with old option P version (Bend height 95mm)
10.0-> Min. height between BLH and option P for insertion
2188 (OptionP_FreeHight) = 15.0-> Min. height between BLH and option P for insertion with
groove
2189 (OptionP_ZminPosIn) = 163.0-> Min. free space in Z-direction with inserted option P
2190 (OptionP_BenPointZ) = 1.7-> bending line offset in Z-direction left!!!
2496.0 Min. BLH tooling for P4-2516
2191 OptionP_Tool_Length = 2510.0 Min. BLH tooling for P4-3216
0.0 Without CUT
2192 (OptionP_BenPntZ_R) = 1.7-> bending line offset in Z-direction right!!!
If option P tools without CUT are used the data of the P tool must be inserted in the Tool-Files
(e.g.UP012.too).
Several different option P tools may be used that way at the same machine.
Each tool must be entered in the Tooldat.ini file under [P-TOOL] and every tool must have its own
***.too file.
This files may be found in the c:\usr2\syscon\P4M_*10_****\Conf directory.
IMPORTANT: For option P adjustment, chapter 7 have to be finished already.
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10.1.2 Option P already mounted
DANGER: During the manual adjustments phase the warning light system have to change back to
GREEN under all circumstances!!! -> Check that every time !!!
With the Ma.-com. "Move Option P in" and "Move Option P out" the switches may be adjusted (wait
for the timeouts).
Important: Check before this test that the switches are not colliding with the cams!
P-tool with nose: (old version)

The switches –A1SQ289 and –A1SQ290 „Z-slide against blankholder“ have to be adjusted very
carefully.
The switches –A1SQ273 and –A1SQ286 „Z-slide in forward position“ may not be „1“ in this position
under any circumstances!
No gap allowed between option P and blankholder tooling !! Æ check with shim!!!
P-tool with key: (new version)

The switches –A1SQ289 and –A1SQ290 „Z-slide against blankholder“ are not used in this
configuration.
The switches –A1SQ273 and –A1SQ286 „Z-slide in forward position“ have to be „1“ in this position.
With Ma.-com. "Option P Test" the switches and exhaust flow control valves may now be adjusted.
First adjust the switches step by step (press for each step „cycle start„ separate =„single-step mode“).
NOTE: Insert option P-tool with Ma.-com. option P-tool and check the gap in X-direction
(0.02mm!!!).
gap 0.02mm check with
P-Tool left P-Tool right
10.1.3 Option P not mounted yet
Set CTM 1533 to 1 or 4 !
If the option P - tools are not mounted yet, the switches may be adjusted. -> set CTM 1533 to 1.0.
Procedure like in chapter 10.1.2
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10.1.4 P-tool distance adjustment in Z-direction
Fist the BLH must be moved on the counter blankholder Ma.-com. "Blankholder down". Now
measure with a digital or analogue measuring device the parallelism and how much the BLH projects
over the counter blankholder and insert the values in the checklist under„Niederhalter zu
Gegenhalter“ (M1=links).
With Ma.-com. "Option P Distance" the machine is moved to the correct measurement position.
Now check the distance between the P-tool and the counter blankholder with special measurement tool
and insert value into CTM-file or tooldat-file.
Important: When the Option P sticks out over the bend line differently (because of a not perfectly
adjusted blankholder),
with nose Æ the nose has to compensate for that
with key Æ use different sizes of keys.
If the projection is parallel, the measured value should be inserted in the tooldat.ini file, or with CUT
tool in CTM 2190 and CTM 2192 (should be equal).
In addition fill in this values in the checklist under „P-Platte zu Gegenhalter“ (M1=links und
M8=rechts).
IMPORTANT: The projections have to be entered BEFORE the first automatic cycle, because they
are used for calculation of the HBC positions.
(INFO – window CTM 2190 +0,1mm cutting gap Æ check is absolutely necessary).
blankholder
CUT-P-tool
counter blankholder
Attention: Check with

special measuring tool
x.xmm (horizontal) CTM 2190/2192
10.1.5 Programming example
TOOL: 'Name' -> Name of the corresponding tool in the tooldat-files*

TB: L 50 A 50 MODE 1 -> Bending with inserted P - tool
TB-: L 50 A 50 MODE 1 -> Negative bending with inserted P - tool
TA: H 0 RL 0.5 Æ Folding with P-tool (tubular bend)
Tooldat-file must exist in Conf-directory.

A reference about different „TOOL“ files exists under
\\Sw_nt\IBN-Anlei\IBN-Anle\Optionen\OptionP
By using the correct code (e.g. UP012) drawings may be checked and example programs are also
stored here.
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10.2 Option CUT
10.2.1 Standard values for CTM machine constants in dependence of the option
0 No CUT tool
=
1 Rad and Phi are related to P plate (old version)
1517 MD_CUT
2 Rad and Phi are related to counter blankholder
3 New calculation (Standard with MOOG machines)
2022 (CutTool.Rad) = 726.0-> Rad for lower bending tool with option CUT
2023 (CutTool.BladR) = 0.001-> tool radius -> theoretically 0.0
2024 (CutTool. Step_Tol) = 0.5-> Tolerance calculated/programmed STEP length
2025 (CutTool.Phi) = 24.50-> Phi for lower bending tool with option CUT
2026 (CutTool.Unload_Z) = 25.0-> unloading position of bending unit in Z-direction
2027 (CutTool.Unload_Y) = 0.0-> unloading position of bending unit in Y-direction
2028 (CutTool.Distanc_Z) = 0.1-> Min. cut gap
2510-> Length of the CUT-tool with P4-2516
2029
(CutTool.Length) = 2510-> Length of the CUT-tool with P4-3216
2030 (CutTool.Default_S) = 30-> Default speed -> may be changed by programming com.
2031 (CutTool.Schnitthö) = 15.5-> height diff. from the left to the right side of cutting tool
2164 (Hbc_CutOffset) = x.x*-> Offset of the right HBC -> + value = closer to blankholder
1957 Cut_Vbc_Speed = 140.00 Max. speed for cut of the VBC (def 30% =CTM 2030)
2012 Cut_Vbc_Acc = 2000.00 Acceleration cut movement VBC
2013 Cut_Vbc_Dec = 150.00 Negative Acceleration cut movement VBC
IMPORTANT: For option P adjustment, the bending geometric set-up has to be finished already.
Every change of the delta values has an influence on the CUT geometry!
With micro cycle „CUT_Wanne.tl“ and „CUT_Flap.tl“ exhaust flow control valves and adjustable
orifice plate of the hydraulic system may be adjusted (info about hydraulic orifice plates : turning
them more inward->slower).
Record with the speed and save the CUT.UCX file in CHECK/KURVEN.
References for speed: tolerance +-200ms

INSERTION: 1000ms
DISINSERTION: 650ms ( Limit set by unloading of profile repeatability)
Moving in and out of the trolley: about 2700 ms each
31/01/2008 Start-up manual P4-1916 199/233

10.2.2 Adjustment of Rad and Phi on the left side
With Ma.-com. " Geometrie Cut offset setup" the machine is moved to the correct measurement
position. Measure now the horizontal and vertical distance with special measurement tool on the left
side. The values have to be exact 5.0/5.0 mm. if not, adjust RAD and PHI values accordingly. Insert
value into CTM-file or tooldat-file.
2022 (CutTool.Rad) = 726.00 Rad for lower bending tool with option CUT
2025 (CutTool.Phi) = 24.50 Phi for lower bending tool with option CUT
Note: Measure in outermost

5.0mm (vertical) position ->CUT tool is inclinated
from left to right side!!!
Counter blankholder
IMPORTANT
CUT-tool measure with
special tool
Lower 5.0mm (horizontal)

bending tool
31/01/2008 Start-up manual P4-1916 200/233

10.2.3 Adjustment of Rad and Phi on the right side and HBC_CutOffset calculation
With Ma.-com. „Geometrie Cut offset setup“ the machine is moved to the first measurement position.
Measure the value and insert the value in the checklist in row„CUTgeometrie“ (M1=left).
Now press the "cycle start" button. The machine is moved to the second measurement position.
Measure the value and insert the value in the checklist in row„CUTgeometrie“ (M5=center).
Now press the "cycle start" button. The machine is moved to the second measurement position.
Measure the value and insert the value in the checklist in row„CUTgeometrie“ (M8=right).
Measure now the horizontal distance with special measurement tool on the right side. The values have
to be 5.0 mm. if not, adjust CTM-parameter 2164 (HBC_CutOffset) accordingly.
IMPORTANT: Whenever CTM 2164 is changed the Right side has to be checked BEFORE the
LEFT side (because of bearing tolerances)!!!
Also the position of the horizontal cylinder has to be checked (SE –Flag must be ON and note the
cylinder position), to assure that the bending unit is not drifting because of the pressure differences.
That would have an impact on the measurement accuracy.
Change the offset (CTM 2164) until the BLH is parallel to the counter blankholder (+-0,01 mm) and
then, if necessary, change RAD and PHI values.
The amount of shimming of the BLH may be seen in the center measurement value „M5”. Also if the
CUT tool is not straight may be seen here.
2164 (Hbc_CutOffset) = x.x*-> Offset of the right HBC -> + value = closer to blankholder
Measurement1 ctm2164
5,00 4,86 4,92 -0,08
M1 M2 M3 M4 M5 M6 M7 M8
5,04 4,93 5,04 -0,20
M1 M2 M3 M4 M5 M6 M7 M8
Æ RAD and PHI adjusted

5,00 4,89 5,00 -0,20
M1 M2 M3 M4 M5 M6 M7 M8
31/01/2008 Start-up manual P4-1916 201/233

10.2.4 Measurement of the gap factor and grinding for parallelism
With Ma.-com. „Geometrie Cut offset steps“ the bending unit is moved to the first measurement point
(with inserted CUT tool). By using a knife-edge find the point where the CUT tool is in the same
height as the counter blankholder. Mark this point as first measurement point.
Press „continue cycle“ and move to the following measurement (stop) points, find the point where the
CUT tool is in the same height as the counter blankholder and mark these points as measurement
point (seven positions).
Now start Ma.-com. „Geometrie Cut offset steps“ again, move to the 7 measurement points and with a
special tool check the distance between the 2 CUT tools. Insert the values in the checklist under
„CUTgeometrie“ (CUT tool to P – CUT tool).
Scematic diagram
Dial gauge
If the error in parallelism is more then 0.02mm, the feather keys of the option P plates have to be
altered (exchanged) to compensate for the error.
IMPORTANT: If the feather keys are exchanged, the projection have to be checked again and the value
have to be inserted in CTMs again! (chapter. 10.1.4)
Then repeat the procedure above and measure by using the Ma.-com. „Geometrie Cut offset steps“ the
distances between the 2 CUT tools again.
31/01/2008 Start-up manual P4-1916 202/233

10.2.5 Check of the cutting gap
2164 Hbc_CutOffset = x.x Offset for HBC on right side (+value =closer to counter BLH)
2022 CutTool.Rad = xxx.x Rad for lower tool for CUT
By using 0.1mm shims the correct gap for the cut is checked / adjusted. Increase CTM 2022 for 0.1
temporary.
IMPORTANT: The projection has to be adjusted already (chapter. 10.1.4) (Ctm’s 2190 und 2192).
Start the program „CutProg.P4“ without sheet (in the „cutting-BEN:“ instruction must be VERS 94
and in the „CUTEND:“ instruction must be NOOPT programmed). Machine moves to the position
where the P plates are inserted and stops there.
Now insert 7 shims.
Danger: The control lamp must be „green“ during the whole set-up!
Now press the „continue cycle“ button and by the „single step“ button move the machine to that point,
where the blankholder goes on pressure and the CUT tool is in pre-cut position. Now on the left side a
gap of 0.2mm must be measured.
By pressing „single step“ again the cut is performed and now on the right side a gap of 0.2mm must
be measured.
Then continue the cycle until the P plates are disinserted, then execute a KILL“.
By pressing the „request to enter“ button move the machine into safe position so the shims may be
checked and removed.
Now decrease CTM 2022 by 0.02mm and run the program again. The CUT gap has not to be checked
anymore. Repeat this procedure until the shims are cut.
In the best case all shims are cut at the same time. The difference between first shim cut and last shim
cut should be 0.02mm and from experience we know, that the cutting gap is then normally 0.08mm. If
the shims are not cut in an 0,02mm window, the feather keys of the option P have to be altered
(chapter.10.2.4).
IMPORTANT: After successful adjustment set CTM parameter 2022 (CutTool.Rad) back to its
original value.
31/01/2008 Start-up manual P4-1916 203/233

10.3 Special tool "Nosetool" (LDN)
10.3.1 Standard values for CTM machine constants in dependence of the option
1509 (MD_NOSETOOL) = 2.0-> Option Nosetool until machine no. 759

1509 (MD_NOSETOOL) = 1.0-> Option Nosetool with new bending point calculation
2032 (TwinTool.Rad) = 737.0->* Rad for lower part of the Nosetools (CTM 1716 + 12.5)
2035 (TwinTool.Phi) = 22.11->* Phi for lower part of the Nosetools (CTM 1719 – 1.5)
2033 (TwinTool.BladR) = 0.8-> tool radius -> theoretically 0.0
2034 (TwinTool. BladW) = 20.0-> With of the tool
2038 (TwinTool.Dis_Y) = 6.0-> Stroke limit in vertical direction
2039 (TwinTool.Angle) = 130.0-> Up to this angle the bending is done by the upper part of
the Nosetool
2080 (TwinTool.FirPnt_Z) = 3.0-> Distance of the 1. point of the bending tool radius center
to the counterblankholder in Z-direction
2081 (TwinTool.FirPnt_Y) = 11.0-> Distance of the 1. point of the bending tool radius center
to the counterblankholder in Y-direction
2082 (TwinTool.SecPnt_Z) = -5.0-> Distance of the 2. point of the bending tool radius center
to the counterblankholder in Z-direction
2083 (TwinTool.SecPnt_Y) = 11.0-> Distance of the 2. point of the bending tool radius center
to the counterblankholder in Y-direction
2084 (TwinTool.FinPnt_Z) = -5.6-> Distance of the last point of the bending tool radius
center to the counterblankholder in Z-direction
2085 (TwinTool.FinPnt_Y) = 0.0-> Distance of the last point of the bending tool radius
center to the counterblankholder in Y-direction
2086 (TwinTool.BlhHeigh) = 73.0-> Min. Position of the BLH during folding in MODE 1 or 2
2038 (TwinTool.FreeSpac) = 6.0-> Free space between tool radius and tool throat
*Start values for the Rad and Phi adjustments of the lower Nosetool part
31/01/2008 Start-up manual P4-1916 204/233

10.3.2 Adjustment of the Rad and Phi values of the lower Nosetool part
2032 (TwinTool.Rad) = x.x-> Rad for lower part of the Nosetools

2035 (TwinTool.Phi) = x.x-> Phi for lower part of the Nosetools
IMPORTANT: For option P adjustment, chapter 11 have to be finished already.-> that means, that
CTM-parameter 1716 (Lowertool.Rad) and 1719 (Lowertool.Phi) have been adjusted already.
switched on!!!
Procedure:
With Ma.-com. " Geometrie Nosetool setup " the machine is moved to the correct measurement
position. Measure now the horizontal and vertical distance with special measurement tool on the left
and right side. The values have to be 10.0/5.0 mm. If not, adjust RAD and PHI values accordingly.
Insert value into the checklist and the CTM-file.
Attention: Check with

special measuring tool
10.0mm (vertical)
counter blankholder
Lower part of
nose tool
5.0mm (horizontal)
31/01/2008 Start-up manual P4-1916 205/233

10.3.3 Adjustment of the Rad and Phi values of the lower Nosetool part
WARNING: Whenever you insert the brass shims / distance check you have to wait for the monitor
screen message „The machine is in secure state. Entry is possible“.
Also, during the whole adjustment phase the warning light system have to be GREEN!!!
Check, that the main pump pressure (IN7) is approx. 15bar and that the valve YV5B is switched on!!!
In the program „NOSETOOL.P4“ RAD and PHI of the lower part of the Nosetool are checked by the
programming instruction MODE 2 (FLD: RL 0.2 H 2.5 MODE 2 SPEED 10) for folding. When the
machine is in the final position of the folding movement, Y and Z values may be measured. Run the
program „CUTPROG.P4“ in „empty mode“ and in „single step mode“ and continue, until the
Nosetool is in final position. Now press the „Manual Commands“ button and the machine is moved
into secure state (Wait for the screen message). The final position in Y direction must be 2.5mm
(without 0.8mm tool radius) above the counterblankholder. In Z direction should be a gap of 5.6+0.8
(tool radius) = 6.4mm be measurable. Between counterblankholder and tool throat should be a gap of
0.2-0.5mm. If the values are different, correct them by changing RAD and PHI accordingly.
0.2 – 0.5mm (horicontal)

Lower part of
nose tool
2.5mm (vertical)
counter blankholder
6.4mm (horizontal)
Important: The sequence of the bending will be changed the following way:
When a angle of A 150 degrees programmed, the maximum interpolated angle will be bent the normal
way and then the nosetool finishes the bend according to the preset values of the tooldat.ini file. The
movement of the MNP is also stated in the tooldat.ini file.
31/01/2008 Start-up manual P4-1916 206/233

10.4 RSU
Activated with CTM 1530 set to 1.
If option RSU is used the tooling data has to be inserted in the correct Tool-Files
(e.g.RSU_FOLIE.too).
Multible tooling may be used on the same machine, but for every tool the correct tooling file has to be
present on the hard-disc.
The files may be found in the following directory: c:\usr2\syscon\P4M_***_****\conf.
IMPORTANT: Before the RSU option may be set up, the bending geometry must be set up already.
10.4.1 Debur device
Drawing number 45M11269 Æ RSU_ENTGRAT.TOO

Lever in UP positionÆ for ALUMINIUM,
Lever in DOWN positionÆ for STEEL and STAINLESS STEEL
Roller_Support_Unit…………. 1.0 DEbur device no. 1=deburring from left
RSU_ToolRadius 710.742+0.2 Rad from drawing, to penetrate 0.2mm less
RSU_BladeRadius 0.0 not used at the moment
RSU_BladeWidth 10.0 not used at the moment
RSU_ToolPhi 29.317 Angle from drawing
RSU_ToolDistance_X 0.0 not used at the moment
RSU_ToolDistance_Y 0.0 not used at the moment
RSU_ToolDistance_Z 6.3 Projecting over counter blankholder
RSU_MaxAngle 0.0 not used at the moment
RSU_MaxThickness 2.0 maximum sheet thickness
RSU_X_Offset 49.3-3 Starting point
RSU_ToolCode 0.0 not used at the moment
RSU_AxiSlowSpeed 50.0 % of 2500mm/sec (CTM 833)
RSU_AxiSlopeUpSlow 50.0 % of 5000mm/sec2 (CTM 831)
31/01/2008 Start-up manual P4-1916 207/233

10.4.2 Cutting plastic cover
Drawing number 45M12021 Æ RSU_Folie.TOO

Roller_Support_Unit…………. 2.0 Cutting device. 2, cutting from right side
RSU_ToolRadius 710.131-0.3 Rad from drawing, to penetrate 0.3mm more
RSU_X_Offset 119.0 Starting point
31/01/2008 Start-up manual P4-1916 208/233

10.4.3 Offset tool
Drawing number 45M12135 Æ RSU_Rollen.TOO

Roller_Support_Unit…………. 1.0 Cutting device. 2, cutting from right side
RSU_ToolRadius 670.557 Rad from drawing
RSU_X_Offset 110-10 Starting point
31/01/2008 Start-up manual P4-1916 209/233

10.5 RBU (Brush cleaning system)
2889 MD_CLEANING_SYSTEM = 1 Activation of RBU
2890 CLEANING_POS = 150 Position of TRD when option is closed
After the TRD has picked up the sheet and moved to CTM 2890, the upper part of the brush cleaning
system is moved down and switched on. As soon as –SQ 527 is reached also the lower brush is
activated. The brushes are stopped as soon as the sheet is dropped in between the references.
10.6 PSE (bending tool cleaning device)
10.6.1 CTM’s
680 Left_TRD_PSE_Position ~900.00 Position of the TRD, before the bending
(mm) tool is changing from lower to upper tool
for cleaning. Also the position, where the
TRD is moved, after the lower tool has been
cleaned and is then positioned to CTM´s
= 1680+1681.
681 Right_TRD_PSE_Position P4-1916 Position of the TRD, before the bending
~3400.00 tool is changing from upper to lower tool
= (mm) for cleaning.
~4???.00 tool is changing from upper to lower tool
2176 Upr_Blade_Pos_Z__ ~19.50 Horizontal distance of the upper bending
(mm) tool radius center to the counter
= blankholder, when the TRD is cleaning.
2177 Upr_Blade_Pos_Y__ ~40.00 Vertical distance of the upper bending tool
(mm) radius center to the counter blankholder,
= when the TRD is cleaning.
2178 Tool_Clean_Time__ ~20.00 Activation of the valve –YV92, which is
(ms) responsible for oiling the sponge. This CTM
= regulates the amount of oil.
2180 Lwr_Blade_Pos_Z__ ~19.50 Horizontal distance of the lower bending
(mm) tool radius center to the counter
= blankholder, when the TRD is cleaning.
2181 Lwr_Blade_Pos_Y__ ~17.50 Vertical distance of the lower bending tool
(mm) radius center to the counter blankholder,
= when the TRD is cleaning.
31/01/2008 Start-up manual P4-1916 210/233

10.6.2 Adjustments of the positions
IMPORTANT: Before the PSE option may be set up, the bending geometry and the feeding trolley
positions must be set up already.
Adjust with Micro Cycle „Tool_Clean.tl“ switches, dampers and final positions of the swinging arm.
Use Ma.-com. "Upper_Pse_Setup" in single step mode to the single-step, where the TRD moves to
CTM 680. Check the position of the TRD!
During vertical positioning of the bending unit avoid collision with the swinging arm of the TRD
(check lower and upper CLA, counter blankholder…)!
Eventually change CTM and redo the test.
With the next step the bending unit is moved to the upper cleaning position.
Now move the TRD to the bending blade.
The teflon scrapper has to line up vertically exact in the center of the tooling radius and horizontally
the scrapper has to touch the blade, so that the built up material is removed!
Adjustment:
CTM 2176 increased Æ less penetration dept
CTM 2177 increased Æ bending tool is positioned lower
Control if the main pressure has 25bar (TRACE) and that the valve YV5 is switched off!!!
Use Ma.-com. "Lower_Pse_Setup" in single step mode to the single-step, where the TRD moves to
CTM 681. Check the position of the TRD!
During vertical positioning of the bending unit avoid collision with the swinging arm of the TRD
(check lower and upper CLA, counter blankholder…)!
Eventually change CTM and redo the test.
With the next step the bending unit is moved to the lower cleaning position.
Now move the TRD to the bending blade.
The teflon scrapper has to line up vertically exact in the center of the tooling radius and horizontally
the scrapper has to touch the blade, so that the built up material is removed!
Adjustment:
CTM 2180 increased Æ less penetration dept
CTM 2181 increased Æ bending tool is positioned higher
Control if the main pressure has 25bar (TRACE) and that the valve YV5 is switched off!!!
10.6.3 Programming commands

POS:
CLEAN_TOOL n the upper and lower tool will be cleaned
CLEAN_UPPER_TOOL n the upper tool will be cleaned
CLEAN_LOWER_TOOL n the lower tool will be cleaned
CLEAN_BLH_TOOL n only BLH will be cleaned
(n= interval)
31/01/2008 Start-up manual P4-1916 211/233

11. Final checks before operating the machine
11.1 Checking the temperature ranges
11.1.1 Checking temperature: operating temperature (30°C):
NOTE: The sensor can only be checked in the morning before the oil heating is switched on and
cylinder temperature (IN25) is still under 20°C (CTM 2485).
IMPORTANT: Disconnect YV2 during heating up and set ST5 to around 65°C.
Procedure:
When the machine is switched on the alarm lamp goes on at the terminal. Start automatic mode with
sheet. The error message “Oil temperature is too low, press ok for warm up” appears, acknowledge
with ok. As soon as 20°C is reached or a increase of 1°C has been achieved, the error lamp will be
switched of and the machine is ready for automatic production.
11.1.2 Checking the oil heating and cooling settings
Switch on the hydraulics and let Ma.-com. "Warm up" run.

Open “TRACE” application and monitor the oil temperature. Up to 34°C the output KA46K must be
switched on (oil heating on), at 44°C the output YV2 must be switched on (oil cooling on).
11.1.3 58°C ,61°C check (switch off using sensor):
IMPORTANT: Disconnect YV2 during heating up and set ST5 to around 65°C.
Program Ma.-com. "Warm up" can be run to warm-up. This is the fastest method of increasing the oil
temperature. Read the oil temperatures in the "Oil temperatures" Insert and watch the reactions.
When 58°C is reached the machine should switch over automatically to a program (e.g. REF.P4
without sheet) that stops after the next sheet. Then you switch back to program Ma.-com. "Warm up"
and let it run until the next step.
IMPORTANT: Adjust during testing phase ST5 to 65°C .

NOTE: The sensor switches the hydraulics off immediately at 61°C, even during automatic operation.
IMPORTANT: When the machine switches off the window "Oil temperature too high" is displayed.
Check whether the cooling (YV2) is active. The circulation pump is also switched on.
11.1.4 60°C check (switch off using thermostat ST5):
NOTE: The circulation pump switches on only when the machine cuts out because ST5 is triggered.
Set ST5 to 60°C, switch on the hydraulics and let Ma.-com. "Warm up" run again.
IMPORTANT: When the machine switches off (60°C) the window "Oil temperature too high ST5K =
0" should be displayed, if it does not appear then adjust ST5 to cause cut-out. Check whether the
cooling (connect YV2 again) and the circulation pump are active. Keep the machine in this state until
the window "Oil temperature normal" appears (44°C).
31/01/2008 Start-up manual P4-1916 212/233

11.2 Adjustment check of SQ17:
Adjustment check SQ17 with program:
Refer to chapter 2.5 about these settings.

With reduced blankholder tooling (e.g.. Zumtobel) each CTM will be reduced by the same amount.
Attention: Values refer to distance bending line to rotator clamp center!
Preparations:
Temporarily reduce the CTM-parameters 1988 (MNP_MAX, 2107 (Stroke_Limit_RCL) and 2106
(Stroke_Limit_TRD) by 0.5 mm.
Check:
With the manual commands "Mani run 99, 135, 252" check, if you receive the SQ17 error message.
To find the exact switching point increase the CTM-Parameter by 0.1mm in steps.
Important: Switching point should be about 0.4-0.6mm lower than the Ctm value. Change CTM after
the test back to its origin value.
11.3 Checking current draw of rotator and transport sledge
Calculate and load TSTMAX**.P4. In the production - Manager select

"Request to enter work are" . The machine stops as soon as the sheet is on the work area.
Until this step record the current of the feeding trolley (and if present, the current of the RIP
transfer) by using the UCscope.
Save the recording by pressing the „Print Screen“ button and save into the checklist.
The continue the cycle and record the current of the by using the Ucscope, then save the recording by
pressing the „Print Screen“ button and save into the checklist.
The recordings are saved in chapter 4. Refer to chapter 4.1.7 for information’s of the recording.
IMPORTANT: Use a 3.00mm sheet for this recording!
31/01/2008 Start-up manual P4-1916 213/233

11.4 Saving of Files
11.4.1 Lenze
Each axis-file of the „Lenze“ drives directory has to be saved to
C:\USR2\SYSCON\P4M_***_****\CONFIG\Lenze .
11.4.2 Rexroth
The DFEC-File of the „Winiped32 Rexroth“ directory has to be saved to
C:\USR2\SYSCON\P4M_***_****\CONFIG\Rexroth.
Important: The program can, however, only of the directory C:\REXROTH\PROJECT\ *.* be
loaded onto the pump!
11.4.3 Pilz
The safety file of „PNOZ-MULTI“ have to be saved to
C:\USR2\SYSCON\P4M_***_****\CONFIG\PILZ with the according name.
11.4.4 Laser-Scanner
The program of „Scanner“ has to be saved to C:\USR2\SYSCON\P4M_***_****\CONFIG\Scanner
with the according name be stored back.
11.4.5 Carry out security protocol according to procedure
31/01/2008 Start-up manual P4-1916 214/233

12. Connections
12.1 S4
12.1.1 General
Line mode is the term, which is used by Salvagnini Maschinenbau, to describe the linked production
unit between 2 machines (normally an S4 punching machine and a P4 panel bender).
The panel bender is connected to the S4 by a loading device (ACP, PC, PCD, DA) so that punched
sheets may directly transferred from the S4.
Electrical signals are used for synchronisation. In addition a network link is used to transfer all
necessary information’s for production.
31/01/2008 Start-up manual P4-1916 215/233

12.1.2 Hardware
Connect cable S4 ( ) to P4 (E200 X500).

(If there are bridges in the electrical cabinet of the S4 or P4, remove them!)
Connect the network cable from the S4 (TU1:) to the P4 (TU1:),
or make sure, both machines are connected to the company network and responding to each other
(Dos window, ping wsys…).
At the P4 open the workspace Line.ws.

Select at the S4 the corresponding signals with the monitor.
Inputs/Outputs:
Set at P4 with monitor: S4 Inputs:
*A1KA21 *A1SQ104K should change to on
Press Emergency stop *A1SQ284K should change to off
Set at S4 with monitor: P4 Inputs:
Emergency stop pressed *A1SQ320K should change to off
Cooling system:
Set at S4 with monitor: P4 Inputs:
*A1KA95W *A1SQ408K should change to on
Switch on control P4: Switch off S4 main switch:
*A1KM6 on Chiller should switch on (1850 and 1851 at XT11 at S4 = 24V)
*A1SQ408K on is connected through *A1KA94W at the S4
Line separator:
Adjust the air dampers of the line separator.

Adjust the switches „Sheet at entrance PCD“ (SQ30A and SQ30B).
Check the switches SQ130 and SQ131 for correct installation.
31/01/2008 Start-up manual P4-1916 216/233

B r e a k th e lig h t b a r r ie r o f th e P 4 ( P C D ):
P N O Z m u lti S 4 :
W h e n lig h t b a r r ie r P C D is b r o k e n o r th e
P C D d o o r is o p e n e d , in p u t 1 6 m u s t c h a n g e
to o ff .
B r e a k lig h t b a r r ie r o f S 4 (I A ) a n d p r e s s S 4 E m e r g e n c y s to p :
P N O Z m u lti o f th e P 4 :
W h e n lin e s e p a r a to r is o p e n
I 1 m u s t c h a n g e to o ff (P 4 ).
W h e n E m e r g e n c y s to p is p r e s s e d (S 4 )
I f th e S 4 lig h t b a r r ie r is b r o k e n ,
31/01/2008 Start-up manual P4-1916 217/233

12.1.3 CTM’s
P4 CTM [ 611] - ENABLE_REQ :
0 ... trd has put the sheet into centering position
1 ... trd starts moving
2 ... after sheet is clamped
3 ... centering_p4 cycle finished
4 ... sheet is at the end of rip (used with RIP)
5 ... trd has moved near the centering position
CTM [1549] - MD_NO_LINE_SEPARATOR:
0 ... line seperator
1 ... no line separator mounted
2 ... no S4 (to avoid messages of external systems)
CTM [2847] – PC_Conv_OFFSET_LINE (-450)
S4 CTM [ 559] - :
0 ... Do not send data to P4
1 ... Send data, as soon as production has been started
2 ... Send data, when part is cutted of from sheet
3 ... Send data, when the sheet is ready at the IA
CTM [ 800] - :
0 ... Send data only with „with sheet“ production
1 ... Send data also in „no load“ mode
12.1.4 Network
Connect network cable from S4 (TU1:) to P4 (TU1:) ,

or connect both machines to company network.
File entries
on P4 PC
In directory C:\WINDOWS\system32\drivers\etc open hosts file.
In this file inserte IP-address of S4 together with Wsys name (128.2.61.224 wsys2011).
In addition insert IP-address of the Office PC with WCA name..
In directory C: \usr2\syscon\P4M_*_*\scsfiles\scs_config open file Prdmgr.ini.
enable_linesocket = 1 (0= only hardware connection)
set_protocoltyp = 0 (0= normal connection, 1=OPS connection)
set_linetyp =1 (0= no line, 1=in line with S4, 2=in line with PCR, 3=customer interface)
on S4 PC
In directory C:\WINDOWS\system32\drivers\etc open hosts file.
In this file insert IP-address of P4 together with Wsys name (128.2.61.96 wsys1976).
In addition insert IP-address of the Office PC with WCA name..
In directory C: \usr2\syscon\S4M_*_*\scsfiles\scs_config open file stk_server.ini.
In this file insert IP-address of P4 too.
With IP-Config in the DOS command line the IP address of the PC is displayed.
With PING 128.2.61.96 in the DOS command line the connection to other PC’s may be tested.
IMPORTANT:
The hosts file is only saved correctly, if you are logged in as administrator Salvagnini !
Check the connection in the PRDMGR plug-in:
31/01/2008 Start-up manual P4-1916 218/233

If everything is correct, the connection may be visualised and checked in the PRDMGR plug-in:
Double-click on the TCP symbol and the TCP/connection window opens.

In this window the IP address of the S4 has to be inserted.
This entry is not substituting the entry in the hosts file!!!
31/01/2008 Start-up manual P4-1916 219/233

12.1.5 S4-P4 Interface
Conveyor runs (Signal =low)
Sheet at conveyor entrance (SQ30)
Line-separator closed (YV30B)
Line-separator öopen (YV30A)
S4 ready for transfer (SQ407K)
Sheet read from S4 (SQ406K)
P4 ask for transfer (KA23)
P4 sends sheet request (KA22)
S4 is in line (SQ405K)
P4 is in line (KA21)
Sheet request for next sheet (P4ÆCTM 611)
Sheet on P4, line-separator will be closed
P4 ready for sheet transfer, sheet ready from S4 is set to off
Sheet is ready on S4 and may be sent to P4, sheet request is reset
Sheet request, program data is sent to P4. (S4 ÆCTM 559)
12.1.6 Safety
The safety has to be carried out according to the safety protocol, which is provided by Salvagnini
Italia (S4 – start-up technician).
With open line separator:

EMERGENCY STOP is pressed on P4:
• P4 Emergency condition like P4 stand-alone system
• S4 connection unit is shut down, production is NOT killed.
S4 may continue in single-step mode.
EMERGENCY STOP is pressed on S4:
1. P4 connection unit is shut down, production is NOT killed.
Operation Stop is executed, with Continue Cycle the production in the main unit may be
continued.
With closed line separator:

EMERGENCY STOP is pressed on P4:
• P4 Emergency condition like P4 stand-alone system
• S4 Æ production is NOT killed. S4 may continue in single-step mode.
EMERGENCY STOP is pressed on S4:
2. P4 Æ Operation Stop is executed, with Continue Cycle the production in the main unit may be
continued.
3. S4 Emergency condition like S4 stand-alone system
31/01/2008 Start-up manual P4-1916 220/233

12.1.7 Function check
If the P4 is ready for line production, the sheet request is immediately send to the S4. This may be
checked by the graphic display in the layout or by using the monitor (e.g. 65A1KA22). IF no job data
arrives, the following has to be checked:
1. Check the network connection

2. No error allowed from the production manger during booting
3. Hydraulic must run
4. No error condition allowed
5. S4 and P4 have to be in line mode
If in this condition no job data is sent to the P4, check first the settings of the S4. If the data arrives
correctly, the colour of the sheet in the PrdMgr changes from grey to blue and the job data is
written under the sheet. If the colour stays grey, only SQ406K signals the presence of a sheet, but
no data has been sent.
*The sheet transfer may only take place, if the program data has already been sent from the S4 to the P4*
Jobanforderung ein
S4 ist auf Linienbetrieb
Netzwerkverbindung
ist in Ordnung
31/01/2008 Start-up manual P4-1916 221/233

12.1.8 Example bending program
In the following program panel dimensions are used to change the angle correction values.
The parameter XCOR, ZCOR, ... may be send by the Jobmanager S4PeLine but are not necessary,
because they are already pre-defined in the program.
COD: 'RW_MASTER'
***:---------------------------------------------------------------------------
***: Date : 15-10-98
***: Product : TS – back wall
***: drawing number : A 1642604TS22
***: Cycle time : 25 sec
***:---------------------------------------------------------------------------
LET: XCOR 0.00 ***: Heigth correction
LET: ZCOR 0.00 ***: Width correction
LET: X1COR 0.00 ***: X1 correction (incresed-->bending hight side 1 incresed)
LET: Z1COR 0.00 ***: Z1 correction (incresed-->bending hight side 4 left incresed)
LET: Z2COR 0.00 ***: Z2 correction (incresed-->bending hight side 4 right incresed)
***:---------------------------------------------------------------------------
DIM: X (ParX-3) XC (XCOR)
Z (ParZ-7.6) ZC (ZCOR)
S 1.5
REF: X1 ((ParX+10)/2+X1COR)
X3 ((ParX+28)/2)
Z1 ((ParZ+22)/2+Z1COR)
Z2 ((ParZ+22)/2+Z2COR)
ZPF 90 N
ROT: S 1 ROTONBLH
BEN: L 18.0 ZF 2.0 AC (ParZ*0.001+2)
ROT: S 2 ROTONBLH
BEN: L 18.0 ZF 2.0 AC (ParZ*0.001+2)
ROT: S 3 ROTONBLH
BEN: L 18.0 ZF 3.0 AC (ParX*0.001+3)
ROT: S 4 ROTONBLH
BEN: L 18.0 ZF 3.0 AC (ParX*0.001+3)
END:
12.1.9 Example punching program

In the following example the PIE: instruction defines where the part goes to and which paramters are
sent. T30_10.P4 is the bending program, the relevant P4 group is doors, Udimx and Vdimy are cut-
size of the part, parameters are option, ofsx und ofsy.
COD: T 30-1-50-DE-1.0
;---------- Include paramters -----
INC:"..\doors\parameter.S4"
;---------- Änderung der Zuschlagparameter manuell -----
PAR: addition = 66
DIM:X(flgmh+additionx+stepb) Y(flgmb+additiony) Ssheetd "Fep01"
;---------- Include head setup
INC:"..\head_configurations\head_standard.PUN"
;---------- Punchings
REC: X(200+stepb)-(70/2) Y27 P22 S270 V70;left
REC: X((dimx-268)-(77/2)) Y27 P81 S270 V77 ;right
;---------- Türschließer
IF door_lock (1) THEN
GRI: Xdimx-84 Y166 P19 S90 U160 V16 W2 Z2
ENDIF
IF leftright (0) THEN

ESM
ENDIF
PAR: ab = 123 cb = 321 cd = 333

PIE:"doors\T30_10.P4/" +"option" +FTOA(ab,0)+"ofsx"+FTOA(cb,0)+"ofsy"+FTOA(cd,0) X0 Y0 Udimx Vdimy
or
PIE:"doors\T30_10.P4” X0 Y0 U1000 V500
END
31/01/2008 Start-up manual P4-1916 222/233

12.1.10 Example of a PRO-NEST programm
The parts, which will be send to the P4, are marked in bolt letters.
All other parts are put down on the IA scissor table.
COD: WOCHE42:4220D
OPT: S
; --------------------------------------------------------------------
; salvagnini LINE S4/P4
; --------------------------------------------------------------------
; Datum : 23.10.99 Bearbeiter :
; --------------------------------------------------------------------
; MATERIAL -----------------------------------------------------------
MAT: FE S1.50 P7.85
STS: X2500-10 Y1250-10 F5 G5 U5 V5
STS: X3000-10 Y1500-10 F5 G5 U5 V5
; PRODUKTION ---------------------------------------------------------
BTC: [Kuehler_prog]ATA10831O.S4/Kuehler_prog\ATA10831O.S4/6978669976070/.* Q4 HRZ TRU
& LET: a1296 b213 s1.50
BTC: [Hygiene_prog]TF1275.S4/Hygiene_prog\TF1275.S4/6978669788032/.* Q2 HRZ TRU
& LET: a2470 b164 s1.50
BTC: [Ventila_prog]KAN3030.S4/Ventila_prog\KAN3030.S4/6978670015034/.* Q2
& LET: a1310 b1250 s1.50
BTC: [Einbau_prog]E30U30.S4/Einbau_prog\E30U30.S4/6978669788016/.* Q2 HRZ TRU
& LET: a1525 b129 s1.50
BTC: [Klappen_prog]KLAPPENLL.S4/Klappen_prog\KLAPPENLL.P4/6999270001006/.* Q2 HRZ TRU
& LET: a850 b204 s1.50
& LET: a1310 b204 s1.50
BTC: [Klappen_prog]KLAPPEN22.S4/Klappen_prog\KLAPPEN22.P4/6999270001004/.* Q2 HRZ TRU
& LET: a854 b204 s1.50
BTC: [Klappen_prog]KLAPPEN22.S4/Klappen_prog\KLAPPEN22.P4/6999270035004/.* Q2 HRZ TRU
& LET: a884 b204 s1.50
BTC: [Hutprofil_prog]HP4045.S4/Hutprofil_prog\HP4045.S4/7005570056051/.* Q2 HRZ TRU
& LET: a550 b173 s1.50
BTC: [Einbau_prog]E25U25.S4/Einbau_prog\E25U25.P4/7005570072017/.* Q2 HRZ TRU
& LET: a608 b204 s1.50
& LET: a480 b204 s1.50
& LET: a575 b204 s1.50
BTC: [Klappen_prog]KLAPPEN22.S4/Klappen_prog\KLAPPEN22.S4/7005570075004/.* Q4 HRZ TRU
& LET: a584 b204 s1.50
BTC: [Klappen_prog]KLAPPEN22.S4/Klappen_prog\KLAPPEN22.S4/7005570073040/.* Q2 HRZ TRU
& LET: a594 b204 s1.50
END
31/01/2008 Start-up manual P4-1916 223/233

12.1.11 Problems...
Description of the problem Possible solutions

In file PrdMgr.ini the entry
In the PRDMGR the condition of line parts are not displayed set_linetyp = 0
is missing
In file PrdMgr.ini the entry

Not all conditions are displayed enable_linesocket = 0
is missing
Line mode may not switched on

P4 must be ready (Hydraulic on, no errors, …)
In file PrdMgr.ini the the following entry is written:

Automatic job data request may not be ACTIVATED in menue production enable_custom_jobs_file = 0 or
The P4 is not in line
Automatic job data request must be ACTIVATED in menue
Output for automatic job data request KA22 does not change to green production or
In file PrdMgr.ini the the following entry is written:
set_protocoltyp = 0 or
the P4 is not ready for loading data or
The actual production state does not allow the automatic job
data request
Sheet is displayed in grey color in S4but the sheet is not transferred to P4
Sheet is physically present but noi data is transfered from S4
(If the program is loaded correctly, the color changes to

blue. If an elaboration error happens, the color changes to
orange.)
Check the S4 settings:
Syscon.ini, ctm[559], ctm[800], stk_server.ini,

punching program
(refer to description above)
Check the S4 settings:

Evering is „green“ but no data is received
Syscon.ini, ctm[559], ctm[800], stk_server.ini,
punching program
(refer to description above)
31/01/2008 Start-up manual P4-1916 224/233

12.2 MV
12.2.1 TCV-Layout
TCV
SQ53 SQ21 SQ136 SQ24 SQ20 SQ37

CTM 2336 ON ON OFF OFF OFF OFF
Endposition MV
TCV
CTM 2335
ON OFF OFF OFF ON OFF
CTM 2351
Wechselposition
LS SQ53 bei LS- LS

Unterbrechung auf OFF !
1000mm
TCV
+ SQ53 SQ21 SQ136 SQ24 SQ20 SQ37

ON OFF OFF OFF OFF OFF
Sicherheitsposition
Eichposition = 0 48.0mm PCD

TCV

CTM 2334 OFF OFF OFF ON ON ON
Entstappelposition
LS LS
TCV

CTM 2378 OFF ON ON OFF OFF OFF
Endposition auf Bedienerseite
31/01/2008 Start-up manual P4-1916 225/233

12.2.2 CTM parameter
• 824 YESMAG......For MV YESMAG=1, for Tivox-Connections (Tower) the number of

stores is indicated
• 2331 TCV_SPEED... speed TCV, the table is deactivated at value 0.
(nominal 300mm/s)
• 2332,2333 TCV_ACC/DEC…Acceleration and braking ramp of the TCV
(nominal 500mm/s²)
• 2334 TCV_CENTER_POS…Position of the table in the production
(SQ20/SQ37/SQ24=1) Distance calibration fixture - fixture SQ20 (nominal –90mm)
• 2335 TCV_CHANGE_UP_POS... Position of the table when it carries out the height
adjustment.
If no fast change station QCS is available, this value corresponds the following way:
• 2351 TCV_CHANGE_DOWN_POS... Position when the table after destacking of the
pallet goes again to down position. Only applies to QCS!
Otherwise CTM 2335=2351 (SQ53/SQ20=1)
• 2336 TCV_STOPA_POS... loading/unloading position in the store (with QCS only
unloading position), table is at the stop position of the tracks, SQ53/SQ21=1. The
positioning works the following way: The TCV/TCR will be slowed down from
TCV_SPEED to TCV_SLOW_SPEED 50 mm before the STOPA_POS, then the axis will
be switched to „Pushing Inc.“. The movement is stopped, when SQ21=1. Therefore it is
guaranteed, that the table always takes and unloads the pallet in the same place.
• 2350 TCV_SLOW_SPEED…slow speed of the table (slow positioning, Calibration,
nominal 50mm/s)
• 2378 TCV_MIN... defines the loading-/ unloading position of the TCV on the operator
side. (SQ21=1, SQ127=1)
• 2886 TCV_ROTATING_POS…for TCR only, rotating position,
SQ140=1(Drilling according to layout!)
• 2384 WMS_STATION_ID1 und 2385 WMS_STATION_ID2 … give the address of the
tower , where the stores are located from which the P4 gets the pallets. Refer to WMSshell
!!!
31/01/2008 Start-up manual P4-1916 226/233

12.2.3 adjusting Ini files
Type in all IP-addresses in the host file of all the machines connected to the store:
128.2.59.127 wsys1505 #S4N_0992
128.2.59.128 wsys1506 #MV_0026 (wms server)
128.2.59.129 wsys1507 #MV_0026 (manual unloading station 10+11)
128.2.59.187 wsys1617 #P4M_0798
128.2.59.213 salva001 #Office
In the file syscon.ini the menu entry “cargra….” must be activated for the SysconShell:
#-------- Abilitazione delle voci del menu' APPLICAZIONI -----------#cad =

bin\tools\metalstudio.bat # CAD/CAM
#pnt = bin\cadcam\pnt\pnt.exe # PRO-nest
#mNest = bin\cadcam\pnt\mNest.exe # man-nest
ctm = bin\cadcam\ctm\ctm.exe # Costanti macchina
#stat = bin\stat\stat.exe # Analisi produzione
diario = bin\MMngr\exec_mmngr.bat
cargra = bin\wms\WmsShell.exe # Magazzino in
alimentazione
#txmgra = bin\stacker\ss_shell\stateshell.exe # Magazzino in

scarico
The file wmsserver.ini contains the most important adjustments for the communication with the store:
#------------------------
# CONNECTIONS PARAMETERS:
#------------------------
[clients_conn]
port = 2424
sock_type = SOCK_STREAM
[dsp_conn]
port = 2423
sock_type = SOCK_STREAM
[rc_channel_conn]
# Host name (128.1.1.2 = PLC STOPA, rsys??? = SW RT SALVAGNINI)
host_name = wsys1506 #Enter here the name of the WMS-Server computer!

port = 6010
type_of_card = SALVAGNINI_RT_SW
answer_delay = 3000
max_retry = 3
plc_polling_freq = -1
plc_ask_dev_status_while_sheduling = 0
#blocking_connect = 1
check_conn_timeout = 30000
check_conn_stations = 0
Additional entries must be made in the wmsShell.ini:
31/01/2008 Start-up manual P4-1916 227/233

#---------------------
# APPLICATION OPTIONS:
#---------------------
[options]
server_NT =1
master =0 # client master ? [0/1]
office =0 # client office ? [0/1]
shutdown =1 # abilita/disabilita la finestra di shutdown

query_ask =0
#------------------------------
# SERVER CONNECTION PARAMETERS:
#------------------------------
[server_conn]
host_name =wsys1506
#port = -1
port = 2424
sock_type = SOCK_STREAM # tipo connessione ('SOCK_STREAM' o 'SOCK_DGRAM')

client_name = WMSSHELL
ping_delay = 200
answer_delay= 5000
-and in the SMDsp.ini for the connection of the control part with the wmsserver:
[wms_server]
host_name = wsys1506 # host name
port = 2423 # socket port
sock_type = SOCK_STREAM # socket connection type ('SOCK_STREAM' or
'SOCK_DGRAM')
ping_timeout=800 # timeout (msec) to verify if the server
application is alive
server_id = 32 # server application ID code (see file drt.h macro
WMS_SERVER)
protocol = wms # associated protocol name (see syscon\bin\protocolos
folder)
The file wmsShellgraph.ini is responsible for the graphic representation of the store in the wmsShell.
The best way is to ask the MV-IBN about the settings or to copy a the files from a working loading or
unloading station (if available).
Important: Do not copy from computers of the opposite side machines, otherwise the representation is
turned by 180°!
31/01/2008 Start-up manual P4-1916 228/233

All above mentioned .INI files may be found in the directory:
C:\usr2\syscon\P4M_xxx_0xxx\scsfiles\scsconfig
IMPORTANT: You have to update WMS-Application! That means to copy the folder
C:\usr2\syscon\bin\wms from another (Italian) machine.
Attention: RESTART Sysconshell after changes!
When all steps have been carried out as shown above the WMSshell may be opened.
SysconShell→Applications→Input Store:
Example SALVA INDUSTRIAL MV_0026:
Station 2/6//3/7: Unloading S4
Station 5/9: Loading S4

„TE“=MV-
Manipulator
Station 10/11:
Station 1: Station 13: Loading P4 Manual unloading
LOADING ( 2 press brakes)
+ control MV
If the connection symbols doesn’t

look as displayed (disconnected),
the connection to the server has to
be checked (ping wsys****)
31/01/2008 Start-up manual P4-1916 229/233

12.3 SAR
12.3.1 CTM parameters and file entries
CTM’s
559 (SEND_DATA_TO_UNLOADER) = 2 Data is send to unloading system
1518 (MD_LAST_BEND_NEG) = 2 Last bend down allowed (SAR with ACP)
SAR.INI
When the TX software is on the same computer as the P4 software, this file may be found in:
C:\usr2\syscon\P4M_xxx_xxxx\scsfiles\scs_config
Entry: [jobmngr]
Port = 4299 (may be different!)
Remote = 1
Programming instruction:
Must be stated in the END command:
END: NEXT_UNIT 10
To define the unloading parameter with the PRDMGR (in the parameter dialog window),
it is recommended to state the parameter the following way in the program:
LET: SAR (10)
DIM:
REF:
….
….
END: NEXT_UNIT (SAR)
31/01/2008 Start-up manual P4-1916 230/233

12.3.2 general function
-A1KA72 (the P4 system is ready) when calibrated -> ON,

operation stop -> OFF
-A1KA69 (the Panel is ready) for program send name set to ON
Part on transfer unit (-A1SQ298K=0) auf OFF
-A1SQ297K (Sar in line) is ON, if the roboter is calibrated, when function selector
IS set to automatic and slave-mode on Scon-Tx
12.3.3 DESCRIPTION OF THE CYCLE

When the part is finished on the P4 KA 69 (Panel ready) is changed to ON and the program is send to
the TX in the same moment.
TX starts (lamp ZYKLUS AKTIV is on) and opens controlled by the TX the safety flap (SQ 525K =
OFF). With the signal „SAR free“ (SQ298K = ON) the unloading rollers of the SAP are switched on
together with the SSR rollers. SQ 298K = OFF finishes the transfer. The safety flap will be closed.
Æ Exceptional conditions:
The TX is not in line (SQ 297K = OFF):
In this case the part is produced on the P4, but the program will not be send to the robot.
(KA 69 is set to ON) Æ Message 50 appears: The unloading system is not in Line
Answer with YES to wait for SQ 297K; Answer with NO to unload from SAP manually. This setting will
stay the same fort he whole JOB!
Operation stop during transfer:
Signal KA 72 changes to zero.
Request to enter:
The P4 waits fort he safety flap to be closed (SQ525 = ON)
Request to enter work area:
The P4 waits fort he safety flap to be closed (SQ525 = ON)
Æ Safety:
Emergency stop and roboter:

With closed safety flap:
TX not in line P4 continues without error message
TX in linie P4 stops operation – Message
Continue with „continue“ appears
With opened safety flap:
The P4 stops operation – Hardware-Stop according PNOZmulti and wiring diagrams
Emergency stop P4:

With closed safety flap:
TX not in line TX continues without error message
TX in line TX is stopped by software
With opened safety flap:
TX Stops operation – Hardware-Stop according PNOZmulti and wiring diagrams
31/01/2008 Start-up manual P4-1916 231/233

13 . Tools
13.1 UCScope with Tbx
With the TBX application the data is not transferred by a serial cable, instead the are transferred by the
etherlink port.
The transfer is about 20x faster. Also, the recording mask is more easy to program. Instead of hex codes
may the real name of a switch/axis be used.
This recording mode works only with TBX version V6.3.5 or higher (Version V 6.3.7 recommended).
Circular buffer recordings may not programmed that way. For circular buffer recording related commands
use the Hyperterminal instead. The signals which should be recorded may still be set by using the TBX. The
name of the file on the Musix card MUST BE trace.ocx!
Otherwise the tbx –gffm command may not be used for transfer.
Open the command line (DOS window).

How to set the Trigger mask:
tbx –trg mode 3
How to record an input signal:
tbx –trg 106A1SQ17 1 S17
Text for display

Digital channel 1
Name of the input signal
Syntax
How to record an output signal:
tbx –trg 106A1YV1 2 YV1
Text for display

Digital channel 2
Name of the output signal
Syntax
How to record axis flags:
tbx –trg 106A1SE14 3 SEM
Text for display

Digital channel 3
SE-Flag of the manipulator
Syntax
31/01/2008 Start-up manual P4-1916 232/233

How to record an command:
tbx –trg 106A1AS32_SINC_CMD 1 C32
Text for display

Analog channel 1
Command for left translator
Syntax
How to record an analogue signal:
tbx –trg 106A1IN29 2 I29
Text for display

Analog channel 2
Pressure of the right translator
Syntax
How to record an axis:

tbx –trg 106A1AX15 3
Mask 3 (Reference- und Current speed, refer to Rec.-

Mask)
Rotator
Syntax
How to set a counter:

tbx –trg 106A1AT31 12
Mask 12 (Reference- und Current speed, refer to

Rec.-Mask)
Counter 1
Syntax
Begin recording:
tbx –brec (begin recording)
Stop recording:
tbx –erec (end recording)
Transfer the recorded file from Music card to PC hard disc:

tbx –gffm example.ucx
Name of the recorded file on the hard disc, will be saved to c:\teleservice.
Filename is example.ucx.
get-file-from-Musix
31/01/2008 Start-up manual P4-1916 233/233

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Author: Christian Reingruber (Start-up department, R&D)

Translated by: Siegfried Pierer (training/education)

Salvagnini Maschinenbau GmbH

31/01/2008 Start-up manual P4-1916 1/233

31/01/2008 Start-up manual P4-1916 2/233

31/01/2008 Start-up manual P4-1916 4/233

CAN 1 is for the basic machine

The serial connection is a 3 wire connection with CAN_H signal (5 volts),

31/01/2008 Start-up manual P4-1916 5/233

1.2.1 configuration and adjustment of various systems in the electrical cabinet.

J: Adjust the air water heat exchanger (TN = 33)

R: Check the main power circuit in the electrical cabinet.

S: Check and adjust the over voltage safety device P2.

V: Install the safety signal lamp for the MOOG drives!

1.2.2 Activation of the main power switch

A: Connect main power supply and connector in main control desk.

E: Control 230 VAC voltage.

F: Adjust output voltage on power supply unit GS7 to 5.2 V.

G: Adjust output voltage on power supply unit GS2 to 24.2 V.

31/01/2008 Start-up manual P4-1916 7/233

J: Solenoid valve voltage GS1 . Switch on of QM7 . Activate -KM1 manually.

N: Switch off SA18 and insert the electronic cards.

1.2.3 switch on of the PC and monitor.

1.2.4 Booting sequence of the system

1.2.5 Output test PNOZ

31/01/2008 Start-up manual P4-1916 8/233

31/01/2008 Start-up manual P4-1916 9/233

The application will be opened.

Select Edit - SET Interfaces….

Set COM port and acknowledge

31/01/2008 Start-up manual P4-1916 10/233

Select File - Open….

Select the Pilz directory

Select File and click on Open

31/01/2008 Start-up manual P4-1916 11/233

Load the program on the PILZ module

Select all entries

Acknowledge every message with „YES“.

1.3 preparation machine

1.3.1 preparations with main switch turned off

A: Open all connectors at the device. (Pilot valves, Encoder, CANbus-

C: Address switch on the Rexroth main pump (-A39) has to be set to 0.

D: Adjust dip switches and jumper on oil temperature sensor (-A44).

E: Adjust dip switches on BK5120 (-A58).

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Double-click on Setup.exe on the desktop.

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Click „Next“ (= continue)

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Select: „No, I will restart my computer later“.

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Select „START“ / „SHUTDOWN“.

Select „Restart“ and click on OK.

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1.5.1 Software conditions

1.5.2 Import laser scanner safety field

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The connection has been established.

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With RELEASE the safety field is activated in the laser scanner.

Rename file c:\usr2\syscon\P4M_*_**\rtsoft\conf\LMTSETUPFILE.ini to LMTSETUP.INI.

Rename file c:\usr2\syscon\P4M_*_**\rtsoft\conf\LSSSETUPFILE in LSSSETUP. Open the file,