Operating manual

TrumaBend
Operator Manual

TrumaBend V50
TrumaBend V85
TrumaBend V85S
TrumaBend V130
TrumaBend V170
TrumaBend V200

Edition: 04/2001
 Foreword

This operator manual describes the conditions necessary for bending

safety, and explains bending technology. It includes information for set
up, operation, and transportation of the machine, and provides a
description of machine assemblies.

Machine operation is also documented. Control manufacturer docu-

mentation follows the machine maintenance section of this manual.

Observance of the instructions listed in the documentation helps

ensure trouble-free operation and meet warranty terms.

The safety conditions must be strictly observed in order to avoid

accidents.

TRUMPF GmbH + Co.

Industriepark 24
A-4061 Pasching
Tel.: ++43 (0)7221 / 603-0
FAX.: ++43 (0)7221 / 603-50

TRUMPF + Co. retains all rights including any patent applications.

Permission for further provision of this manual, including photocopying and duplication rights must be sought first at TRUMPF.
We reserve the right to make technical changes and are exempt from errors.

Foreword K006eng0
 CONTENT OVERVIEW

FOREWORD

TABLE OF CONTENTS

Chapter 1 SAFETY

Chapter 2 TECHNOLOGY

Chapter 3 SET-UP, OPERATION AND TRANSPORT

Chapter 4 DESCRIPTION

Chapter 5 OPERATION

Chapter 6 MAINTENANCE

Chapter 7 CONTROL DOCUMENTATION DA65 / DA69

OPERATOR MANUAL

Chapter 8 NETWORK CARD OPTION FOR DA65 / DA69

Chapter 9 INSTALLATION – AND OPERATING MANUAL

FLASH DISK CARD DFD Id.Nr. 855204

Chapter 10 MANUAL BAR CODE READER

Chapter 11 OPERATIONAL MANUAL ROBOT INTERFACE

Chapter 12 OPERATIONAL MANUAL BENDGUARD

K006eng0 Content overview

Content overview K006eng0
 Table of Contents
Foreword .......................................................................................... 0-2

CONTENT OVERVIEW..................................................................... 0-3

Chapter 1 Safety

1. For your safety ................................................................. 1-3

2. Definitions......................................................................... 1-4

3. Operating Safety............................................................... 1-4

3.1 Correct use of the machine ................................................ 1-4
3.2 User and operator safety-related requirements ................. 1-5
Instruction of personnel...................................................... 1-5
User and operator safety related requirements.................. 1-6
3.3 Procedure in case of failures.............................................. 1-7
3.4 Use of intended spare parts and working materials ......... 1-17
3.5 Measures taken by the manufacturer............................... 1-18

4. Danger overview ............................................................ 1-19

5. Safety measures to avoid injuries caused by

crushing or cutting ........................................................ 1-24

6. Safety precautions to avoid collision injuries............. 1-25

7. Safety precautions to avoid electrical

voltage injuries............................................................... 1-26

8. The machine has been designed and built

according to the following standards .......................... 1-26

9. Appendix ......................................................................... 1-28

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 Chapter 2 Technology

1. Structure of bending........................................................ 2-2

1.1 Definitions........................................................................... 2-4
1.2 Air bending operation ......................................................... 2-5
1.2.1 Air bending advantages...................................................... 2-5
1.2.2 Determining the press force during air bending ................. 2-6
1.3 Bottoming ........................................................................... 2-9
Important notes for bottoming ............................................ 2-9

2. Spring-back..................................................................... 2-10

3. Guidelines for workpiece designing ............................ 2-10

3.1 Computing the smallest possible joint length ................... 2-10
3.2 Minimal distances and minimal lengths............................ 2-11
3.3 Bending with various bending joint shapes ...................... 2-12
3.4 Smallest possible inner radius ......................................... 2-13

4. Measuring and developing bending parts................... 2-14

Chapter 3 Set-up, operation and transport

1. Conditions for setting up the machine .......................... 3-2

1.1 Securing the machine to the foundation............................. 3-3
1.2 Climate ............................................................................... 3-7
1.3 Securing the work area ...................................................... 3-8

2. Conditions for machine operation.................................. 3-9

2.1 Operating materials for the hydraulics ............................... 3-9
2.2 Pneumatic supply ............................................................. 3-10
2.3 Electrical connection ........................................................ 3-11
Version with extended installation height ......................... 3-11

3. Conditions for machine transportation ....................... 3-12

3.1 Measures to be taken by the customer ............................ 3-13
3.2 Suspension holes and shackle......................................... 3-14

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 4. Planning Aid ................................................................... 3-16

5. Regulation sources........................................................ 3-17

6. Safety measures to be taken by user / operator ......... 3-18

7. Appendix ......................................................................... 3-18

Chapter 4 Description

1. Technical data .................................................................. 4-2

Version with extended installation height ........................... 4-5

2. Machine assemblies ........................................................ 4-6

Options ............................................................................... 4-6

3. Machine Axes ................................................................... 4-7

4. Assembly Descriptions.................................................... 4-8

4.1 Machine frame ................................................................... 4-8
4.2 Press bar ............................................................................ 4-8
4.3 Press bar drive ................................................................... 4-8
4.4 Hydraulics........................................................................... 4-9
4.5 Operating station 1 ............................................................. 4-9
4.6 Die clamping device ......................................................... 4-10
4.7 Rear stop.......................................................................... 4-11
4.8 6-axis rear stop ................................................................ 4-12

5. Description of Options .................................................. 4-13

5.1 Support bracket with precision guide ............................... 4-13
5.2 Hydraulic upper die clamping device................................ 4-16
5.3 Crowning (V axis) ............................................................. 4-17
5.4 Z1, Z2 Axis ....................................................................... 4-19
5.5 6-axis rear stop ................................................................ 4-19
5.6 Control systems................................................................ 4-20
Description of control systems DA65 and DA69 ................ 4-21
5.7 Programming systems ..................................................... 4-22
5.8 Operating station 2 ........................................................... 4-25
Operating panel and control elements on operating
station 2............................................................................ 4-27
Explanation of control elements on operating station 2 ... 4-28
5.9 2nd foot switch ................................................................. 4-29

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 5.10 Dies .................................................................................. 4-30
5.11 Sick-light curtain ............................................................... 4-33
5.11.1. Control panel 1 with optional Sick-light curtain................. 4-32
5.11.2. Function description of Sick-light curtain.......................... 4-35
5.12 Robot Interface................................................................. 4-40

6 Bending aid..................................................................... 4-41

6.1 Function description ......................................................... 4-41
6.2 Performance data............................................................. 4-42
6.3 Working ranges, dimensions............................................ 4-42
6.4 Additional apparatus......................................................... 4-42
6.5 Centre of gravity of the bending aid ................................. 4-43
6.6 Transport and storage...................................................... 4-43
6.7 Installing the bending aid.................................................. 4-44
6.8 Disassembly..................................................................... 4-44
6.9 Control.............................................................................. 4-45
6.10 Adjusting the bending aid ................................................. 4-46
6.10.1 Die width........................................................................... 4-46
6.10.2 Die height ......................................................................... 4-47
6.10.3 Z - position........................................................................ 4-48
6.10.4 Side stop .......................................................................... 4-49
6.10.5 Park position (option) ....................................................... 4-49
6.10.5.1 Short park position ............................................ 4-50
6.10.5.2 Park position ..................................................... 4-50
6.10.6 Table length extension / table width extension................. 4-51
6.10.6.1 Table length extension (standard) .................... 4-51
6.10.6.2 Table length extension / table width extension
(option).............................................................. 4-52
6.10.6.3 Option of machine table for bending
aid extension..................................................... 4-53
6.11 Guide to safe operation .................................................... 4-54
6.12 Servo controller error indications...................................... 4-54

7. Summary of options ...................................................... 4-55

Chapter 5 Operation

Part 1: Control elements ................................................................. 5-2

1. Description of control elements ..................................... 5-2

1.1 Description of control elements on operating station 1 ...... 5-2
1.2 Operating panel and control element
on the control panel 1......................................................... 5-4

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 Explanation of control elements on operating station 1 ..... 5-5
1.3 Operating panel DA-65, DA-69 .......................................... 5-7

Part 2: Work examples .................................................................... 5-8

2.1 Turning on and starting press brake .................................. 5-8
2.2 Turning off the press brake ................................................ 5-9
2.2.1 Turning off in emergencies................................................. 5-9
2.2.2 Turning off at end of work .................................................. 5-9

3. Fitting tools..................................................................... 5-10

3.1 Manual die clamping ........................................................ 5-11
3.2 Hydraulic die clamping device.......................................... 5-12

4. Z1/Z2-Axis ....................................................................... 5-13

4.1 Adjustment of the stop finger with manual Z1/Z2 axis ..... 5-13
4.2 Adjusting stop fingers with CNC controlled Z1/Z2 axes ... 5-15
4.3 Adjusting stop finger with 6-axis rear stop ......................... 5-15
4.4 Detachable stop finger with CNC controlled Z axis at
4-axis rear stop ................................................................ 5-15
Errors, cause and remedy................................................ 5-17
4.5 Gauge finger with micrometer adjustment ....................... 5-17
4.5.1 Micrometer gauge finger for CNC Z1/Z2 axis .................. 5-18
Error messages, causes and remedy .............................. 5-18
4.5.2 Clamp-on micrometer gauge finger for CNC Z axis......... 5-19
Error messages, causes and remedy .............................. 5-19
4.5.3 Micrometer gauge finger for manual Z axis ..................... 5-21
Error messages, causes and remedy .............................. 5-21
4.6 1000 mm gauge finger ..................................................... 5-22

5. Avoiding collisions ........................................................ 5-23

6. Crowning......................................................................... 5-25
6.1 Manual crowning .............................................................. 5-25
6.2 Crowning curve height...................................................... 5-26

7. Flattening ........................................................................ 5-27

7.1 Setting various translation paths for the I axis ................. 5-28
"Changeover of I axis working range" procedure............. 5-28
7.2 Programming with the DA65 and DA69 control ............... 5-30

8. Programming instructions for coining......................... 5-34

9. Additional comments regarding the operation
of the machine.................................................................. 5-36
9.1 Loosening of the hydraulic upper die clamping device
in case of error ................................................................. 5-36
®
9.2 "Swivel downwards" the bending aid when the ACB
angle sensor is used ........................................................ 5-36

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 9.3 Error message "Filter dirty, hydraulics stopped" .............. 5-38

Chapter 6 Maintenance

1. General Guidelines .......................................................... 6-2

2. Maintenance Overview .................................................... 6-3

Lubrication chart – Explanation of Symbols ....................... 6-4

3. Lubrication and Maintenance Plan................................. 6-5

TRB V50, V85, V130, V170, V200 ..................................... 6-7
TRB V50-V200 ................................................................... 6-8

4. Lubrication product table.............................................. 6-10

5. Notes on the Lubrication and Maintenance Plan........ 6-12

6. Bending aid..................................................................... 6-24

Chapter 7 Control Documentation Operator's Manual

Chapter 8 Network card option for DA65/DA69

Chapter 9 Installation - and Operating - Manual

Flash Disk Card Id.Nr.855204

Table of Contents K006eng0

 Chapter 10 Manual Bar Code Reader

Chapter 11 Operational Manual Robot Interface

Chapter 12 Operational Manual BendGuard

K006eng0 Table of contents

Table of Contents K006eng0
 Chapter 1

Safety

K006eng1 Safety 1-1

 1. For your safety

Also regarding safety devices your TrumaBend is up to the latest

developments.

The EC certificate and the CE sign on the machine indicate that the
TrumaBend is built in accordance with the instructions of the EC
guidelines 89/392/EEC plus amendment and corresponds with the
appropriate EN standards at the time of production.

You can find the CE sign on the inside of the sideframe (when you
look at the machine from behind, top left-hand side).

However, danger can occur to untrained personnel, or those who use

the machine inappropriately.
We have worked out a detailed safety chapter for you so that you can
get acquainted with the safety concept of the machine and to draw
your attention to potential dangers.
Anyone who disregards the safety guidelines in chapter 1 is guilty of
gross negligence and therefore unlawful activities. The manufacturer
cannot be made liable for any damages resulting.

Safety information! In addition to chapter 1 we have prepared brief and clear instructions
for both the person setting-up the machine and the machine
operator. These are to be given to the personnel working on the
machine.
For the safety of the operating personnel it is useful to have the
operating instructions for the machine operators hanging up where
they can be easily seen.

F Also observe the relevant safety and accident

prevention regulations in addition to these safety notes!

2. Definitions

Danger zones The danger zones are located within the machine range and along
according to (EN 292-1) the periphery of the machine. These are areas where the safety or
health of any person can be endangered.

1-2 Safety K006eng1

User The user is anyone who sets up or operates the machine on their
premises.

Operator/Personnel The operator/personnel are the people responsible for transporting,

setting up, starting up, operating, maintaining, cleaning and/or
servicing the machine.

3. Operating Safety

The machine is built according to the state-of-the-art and is

operationally safe.
However, danger can occur to untrained personnel, or those who use
the machine inappropriately. Given these unsafe conditions,

· The operator's safety is endangered

· The machine is damaged, along with other equipment belonging to
the user
· The machine is prevented from efficient operation

3.1 Correct use of the machine

Make sure that this machine performs only metal bending tasks (cold
processing – i.e. workpieces close to room temperature). The material
of the sheets as well as thickness must be in accordance to the tool
specification. Tools should be loaded or unloaded should normally be
carried out manually with one or a max. of two operators. If the
machine is equipped for robotic loading, the limitation of the pressing
bar traveling speed, which is switched on automatically in foot/foot
mode, can be increased using the robot switch. For operating the
machine with two operators, a "2nd operating station" is required (see
chapter 4, 5.8). You can bend sheets of different length and thickness
with the machine press force given by the manufacturer. The ratio
between press force, bending length and material thickness is
calculated by the control unit. After inputting thickness, length and
kind of material the necessary press force is indicated.
The use of the machine for any other purpose is inappropriate (e.g.
cutting with "do it yourself dies", bending hot or splitting tools).

F Please note!
Any damages occurring as a result of improper use
are not the responsibility of the manufacturer and
will void the warranty. This risk is borne solely by
the user.

K006eng1 Safety 1-3

 For appropriate use, follow the manufacturer-provided set-up,
operation, transportation and maintenance instruction.

Any method of working which reduces the safety of the machine

should be avoided.

Modifications to the machine User and/or operator changes and modifications to the machine are
not authorized, and exempt the manufacturer from liabilities for
damages resulting thereof.

3.2 User and operator safety-related requirements

Instruction of personnel
Instruction of personnel The machine may only be operated, maintained and set-up by
authorized and specially trained personnel. Such personnel must
undergo a special training session that outlines the potential dangers
of the machine. This applies in particular, to work on electrical,
pneumatic and hydraulic units, which may only be performed by
trained professionals.

Read machine Anyone assigned to operate, maintain and set up the machine must
documentation read and understand the technical documentation of the machine.
The user is advised to have this confirmed in writing.

Clear responsibilities Responsibilities for operation, maintenance and service must be

clearly defined and observed, in the interest of safety, so that no
unclear areas of competence arise.

User and operator safety related requirements

You may run the machine only after making sure that the working
area is made safe by the relevant safety devices.

Run the machine only when The user, or the delegated personnel, is obliged to run the machine
in perfect condition only when it is in perfect condition.

The user is obliged to guarantee cleanliness, and good visibility in the

machine's working range, according to the instructions.
The user is obliged to ensure that machine operators wear protective
clothing, as required (for example, protective gloves, safety shoes).

The user is obliged to set the machine up according to the set-up

plan, and according to the set up conditions.

The machine is intended for use by one operator using two-hand

switching with a maximum of two operating stations (see chapter 4
Option 2nd operating station) or a maximum of 2 operators with the
four-hand switching option.

The user must see to it that only authorized personnel operate the
machine.

1-4 Safety K006eng1

Make sure that no person is Prior to each machine start up, the operator must be assured that no-
in the danger area one is in the danger area.

Report of deficiencies and The operator is obliged to report to the user immediately any
damage changes (including operating behavior of the machine) that reduce
safety. The machine should be examined for any external
deficiencies or damage at least once per shift.
Check and repair safety Any alterations or modifications made to the machine by the user
devices operator themselves are not permitted and exempt the manufacturer
from liability for any injury or damage to persons or to equipment.
The user or operator may not remove or turn off any safety devices.
If safety devices need to be removed or deactivated for maintenance
or service work, they must be reinstalled and switched on
immediately after the work.
Set up and operation of the machine must take place in accordance
with the relevant national regulations in the user's country. The user
is responsible for observing them.

Shut-off procedures must be For all jobs relating to transportation, set-up, start up, operation,
observed maintenance and service of the machine, the prescribed shut-off
procedures should be observed.
For any adjustment, maintenance and service work, the machine
should be shut off at the main machine switch, unless otherwise
given. In addition, the compressed air supply should be shut off
before working on the pneumatics.

K006eng1 Safety 1-5

 3.3 Procedure in case of failures

Safety control system

shuts down
1

POWER F-Stack
3
ST AUTO PG
RUN ST SPS
PG
4
FS RUN
RUN FS
STOP

Diagram: Front of safety control system (in switch cabinet)

1 DISPLAY
The four-figure hexadecimal display outputs error indications or
error codes, status displays and gives the software version number.

Error indication format: F-xx Error in fail-safe section

S-xx Error in standard section
*xxx Fatal error
xxx: Error code 000h.....FFFh
+xxx Fatal error in fail-safe section
xxx: Error code 000h.....FFFh
9xxx Error and status codes from program

System messages Error code Possible cause

F-01 Hardware error

F-04 (S-04) Battery error
F-05 (S-05) Actual arrangement does not correspond to
reference arrangement in DB2
F-06 Module functional error (module test)
F-07 (S-07) Memory contains at least one invalid module
F-0C (S-0C) Cycle time exceeded
F-12 Too many process alarms activated
F-14 Undefined alarm, e.g. from electro-magnetic
interference
F-21 (S-21) Arithmetic error
F-22 (S-22) Data word outside current data module
F-23 (S-23) Attempt to write in Read Only data module

1-6 Safety K006eng1

 F-24 (S-24) Invalid contents in a current parameter
F-25 (S-25) Error with incorrect addressing (e.g. section
exceeded)
F-26 (S-26) Unavailable module called up
F-27 (S-27) Current and formal parameters do not concur
F-28 (S-28) Module nesting depth exceeded
F-70 Operating system error
F-71 Synchronization error
F-72 Communication with neighboring channel
interrupted
F-73 Determined number of PAE inputs too small
F-74 System configuration error
F-75 Communication error with programming device
F-76 Error during compilation
F-77 Error when loading program
F-78 Error when connecting modules
F-79 Error when comparing the PAA
F-80 Serious error in neighboring channel
F-81 Error when calling up operating system
F-82 Error when wiring the test pulse

Division into status messages and error messages

For error messages 9010 to 9094 note the following:

If the error message F06 or F08 appears on the display, a more
exact error analysis can be carried out.

The procedure is as follows:

· Delete error message using selector switch (see diagram
page 1-14). FS is pushed from run to stop and then back to run.
From there it must be pushed very quickly back to stop.
· An error message from 9010 to 9094 then appears if a
corresponding error applies.
· If none of the errors in the list appears, 9006 appears in the
display. The further error search is now carried out as described
on page 1-11 (stack error).

ERROR MESSAGES 9000 EMERGENCY-STOP circuit interrupted

from the program 9005 E-STOP actuated
9006 Fail-safe section in STOP
9007 Cross short circuit on inputs
9008 Wire break on outputs
9009 Short-circuit for pulses
9010 Error at input I0
9011 Error at input I1
9012 Error at input I2
9013 Error at input I3
9014 Error at input I4
9015 Error at input I5
9016 Error at input I6
9017 Error at input I7
9018 Error at input I8
9019 Error at input I9
9020 Error at input I10
9021 Error at input I11

K006eng1 Safety 1-7

 9022 Error at input I12
9023 Error at input I13
9024 Error at input I14
9025 Error at input I15
9026 Error at input I16
9027 Error at input I17
9028 Error at input I18
9029 Error at input I19
9030 Error at input I20
9031 Error at input I21
9032 Error at input I22
9033 Error at input I23
9034 Error at input I24
9035 Error at input I25
9036 Error at input I26
9037 Error at input I27
9038 Error at input I28
9039 Error at input I29
9040 Error at input I30
9041 Error at input I31

9055 Error at output O0

9056 Error at output O1
9057 Error at output O2
9058 Error at output O3
9059 Error at output O4
9060 Error at output O5
9061 Error at output O6
9062 Error at output O7
9063 Error at output O8
9064 Error at output O9
9065 Error at output O10
9066 Error at output O11
9067 Error at output O12
9068 Error at output O13
9069 Error at output O14
9070 Error at output O15
9071 Error at output O16
9072 Error at output O17
9073 Error at output O18
9074 Error at output O19
9075 Error at output O20
9076 Error at output O21
9077 Error at output O22
9078 Error at output O23
9079 Error at output O24
9080 Error at output O25
9081 Error at output O26
9082 Error at output O27
9083 Error at output O28
9084 Error at output O29
9085 Error at output O30
9086 Error at output O31

1-8 Safety K006eng1

 9087 Error in wiring of test cycle O0
9088 Error in wiring of test cycle O1
9089 Error in wiring of test cycle O2
9090 Error in wiring of test cycle O3
9091 Error in wiring of test cycle O4
9092 Error in wiring of test cycle O5
9093 Error in wiring of test cycle O6
9094 Error in wiring of test cycle O7

9100 Lamp on panel 1 defective (or no panel

connected)
9101 Lamp on panel 2 defective
9111 Valve error on bero support left*
(No signal change after mleaving the OT)
9112 Valve error on bero support right*
(No signal change after leaving the OT
9113 Valve error on proportional valve left*
9114 Valve error on proportional valve right*
9125 Basic position missing (bero support left = low)*
9126 Basic position missing (bero support right = low)*
9127 Basic position missing (zero position for
proportional valve left not fitted)
9128 Basic position missing (zero position for
proportional valve right not fitted)
9135 E-STOP switch contact synch error
9136 E-STOP acknowledgement did not occur
9141 Error in panel 1, left two-hand push-button
9142 Error in panel 1, right two-hand push-button
9143 Error in panel 1, foot switch
9144 Error in light curtain
9145 Error in panel 2, left two-hand push-button
9146 Error in panel 2, right two-hand push-button
9147 Error in panel 2, foot switch
9148 Error in operation mode switch*
9160 Plausibility error OT and MUTE = high
* This error can be acknowledged by pressing
two-hand key on operating station 1.

STATUS MESSAGES from 9210 Two-hand panel 1 not correctly activated

the program 9211 Two-hand panel 2 not correctly activated
9220 Light curtain, protective field interrupted
9221 Light curtain, start-up lock
9222 Light curtain, pulse start-up lock
9223 Light curtain, time exceeded (30 sec.)
9224 Pulse lock active, wait for 1st pulse
9225 Pulse lock active, wait for second pulse
9240 Operating mode switch blocked
9300 Setting, basic position
9301 Two-hand/foot, basic position
9302 Two-hand/two-hand, basic position
9303 Foot/foot, basic position
9304 Light curtain/foot, basic position
9305 Four-hand/foot, basic position
9306 Four-hand/four-hand, basic position

K006eng1 Safety 1-9

 9308 OFF using operating mode switch
9315 Four-hand/foot, waits for two-hand keys
9316 Four-hand/four-hand, waits for two-hand keys
9320 Setting – Mute, then with foot
9321 Two-hand/foot – mute, then with foot switch
9322 Two-hand/two-hand mute, then with two-hand
9323 Foot/foot – mute, then with foot switch
9324 Light curtain/foot – mute, then with foot switch
9325 Four-hand/foot – mute, then with foot switch
(panel 1)
9326 Four-hand/four-hand – mute, then with four-hand
9330 Setting, rapid traverse
9331 Two-hand/foot, rapid traverse
9332 Two-hand/two-hand, rapid traverse
9333 Foot/foot, rapid traverse
9334 Light curtain/foot, rapid traverse
9335 Four-hand/foot, rapid traverse
9336 Four-hand/four-hand, rapid traverse
9340 Setting, pressing
9341 Two-hand/foot, pressing
9342 Two-hand/two-hand, pressing
9343 Foot/foot, pressing
9344 Light curtain/foot, pressing
9345 Four-hand/foot, pressing
9346 Four-hand/Four-hand pressing
9350 Setting, press bar UP
9351 Two-hand/foot, press bar UP
9352 Two-hand/two-hand, press bar UP
9353 Foot/foot, press bar UP
9354 Light curtain/foot, press bar UP
9355 Four-hand/foot, press bar UP
9356 Four-hand/four-hand, press bar UP

2 ERROR-STACK KEY

Error messages are stored in an error stack. The current error

message is always displayed. To display previous error messages,
the ERROR-STACK key should be activated. The previous error
message is displayed for as long as the key remains depressed.
When pressed again, the preceding message appears and so on.

Displaying error After the error has been displayed, hold the key down to display
information additional information in succession.

Displays given when the F106 F: Fail-safe error, 1: last enter in the stack (further
ERROR-STACK key is inputs: 2,3,...E,F), 06: Error class 6
pressed: C_06 Error Class: 06 (module error)
N_1A Error code (FehlerNummer): 1A (error on DO/DOT)
AT The error location is given
FFFE Error location: FF FE = 1111 1111 1111 1110 (binary)
Error in lowest value bit in partial slot, here 16

1-10 Safety K006eng1

 e.g.: F F F E
Error 1111 1111 1111 1110
location
I0 at para 100
O0 at para 101
I15 I16 at para 200
O15 I1
I31 I2
O31 I3

Special case with two-pole outputs:

e.g. F F F E
1111 1111 1111 1110

+ -
O23 O16 O23 O16 at Para 201
O17 O17
O18 O18

PARA The error parameter is given

100 Partial slot: 1 = top I (0-15), Partial slot: 00
101 Partial slot: 1 = top O (0-15), Partial slot: 01
200 Partial slot: 2 = buttom I (16-31), Partial slot: 00
201 Partial slot: 2 = buttom O (16-31), Partial slot: 01
Error location and parameters are only displayed if the error
necessitates this.

Example:

S 0 12
Error in standard section

Error position in error stack

Error class

K006eng1 Safety 1-11

 3 SELECTOR SWITCH STANDARD SECTION
The programmable safety control system is fitted with two selector
switches:
The selector switch for the
AUTO PG Standard setting.
standard section has three
SPS ST The program starts automatically.
functions
PG

AUTO PG
SPS ST The program starts automatically.
PG

AUTO PG The program is halted.

SPS ST
PG

After a system error the standard section immediately changes to one of

the statuses

· STOP
· no ST
· ST-Fatal error

RUN status

ST-LED "RUN" on

The relationships between

error and operating status minor Auto PG Auto PG
fatal fatal or SPS SPS ST
on the PSS 3056 is given error ST
PG
error error PG serious
in the diagram opposite. in FS in ST error
in ST
Fatal Error ST-Fatal Error fatal STOP-status
error
LED "RUN" any LED "RUN flashes
display: "*###" quickly in ST LED "RUN" off
or: "+###" display: "S-80"
display: >9200 no ST
or : "S-##"
fatal LED "RUN flashes
error slowly
in ST display: "S-##"

Diagram: Switchover of operating modes caused by errors or changing the FS selector switch

In the RUN status, if there is no fail-safe error, the display shows a

number > 9200.

1-12 Safety K006eng1

 4 SELECTOR SWITCH FOR FAIL-SAFE SECTION

System errors System errors include:

· error during self-test

· block running time exceeded
· errors preventing program from running correctly
· differences in output process diagram
· errors in power supply
The PSS 3056 switches to one of the following statuses depending
on the type of error following a system error

· STOP
· no FS
· fatal Error

RUN status

LED "RUN" on
display: "0000"

The relationships between minor

error and operating status fatal
error
on the PSS 3056 is given or RUN
error
FS serious
in the diagram opposite. RUN
STOP
error
FS
STOP

Fatal Error fatal status STOP

error no ST
LED "RUN" any LED "RUN" off
display: "*###" LED "RUN flashes
display: >9200 slowly
or: "+###" or : "F-##" display: "F-##"

Diagram: Switchover of the operating modes from errors or changing the FS selector switch

Error types:

Minor errors

The system switches to the STOP status, the "RUN" LED is off and
the error message "F-##" appears on the display. The standard
user program continues to run and all functions are available on the
programming device.

Possible causes: Errors in the user program or minor module errors

Action Rectify the error
Re-start the fail-safe user program by activating the selector switch
FS: move the selector switch from the RUN position to the STOP
position and back to the RUN position.

K006eng1 Safety 1-13

 Serious errors

The system switches to the status "no FS", the "RUN" LED flashes
and the error message "F-##" appears on the display. The standard
user program continues to run and the functions of the
programming device are limited to read-only access.

Possible causes serious component error or irregularities between the three

channels

Action Read off the error stack

Switch off PSS 3056
Rectify the error
Switch on the PSS 3056

Fatal errors

The system switches to the status "Fatal error", the "RUN" LED
takes on a random status and the error message "###" or "+###"
appears on the display. The fail-safe section and the standard
section are not operational. No communication with the
programming device is possible.

Possible causes Possible causes: Serious system error

EMERGENCY SHUT-OFF If a failure occurs during operation, the operator has to decide on
the basis of his specialized knowledge whether the emergency shut-
off should be activated immediately or whether the necessary steps
must be taken using another control element (e.g. Stop task on the
control).

Shut-off using main switch In case of failures which cannot be rectified in the short-term (those
requiring maintenance or servicing) use the main switch to switch off.

1-14 Safety K006eng1

 3.4 Use of intended spare parts and working
materials

Original part usage Original parts and accessories are designed specifically for the
machine. Spare parts for original parts and accessories that have not
been supplied by the machine manufacturer, have not been
inspected or approved by the machine manufacturer. Installation
and/or use of such products can alter the design characteristics of
the machine, and therefore jeopardize safety.

Exclusion of liability The manufacturer assumes no liability for damage occurring due to
use of non-original parts and accessories, or unspecified installation
or replacement of original parts and accessories.

Guidelines for using User instructions are observed by using the operating materials
operating materials supplied (in particular lubricants and cleaning substances). If a
manufacturer DIN Safety Data Sheet (DIN 52 900) exists for a
certain operating material, the instructions noted therein such as:

· chemical characterization
· physical and safety technical data
· transportation
· instructions
· safety measures, storage and usage
· measures for accidents and burns
· toxicology data
· ecology data (environmental-friendliness)

must be observed. This applies, in particular, to appropriate disposal

of operating materials. The safety data sheet describes the correct
removal and disposal methods. The safety data sheet may be
requested from the operating materials' manufacturer.

K006eng1 Safety 1-15

 3.5 Measures taken by the manufacturer
The machine is fitted with two-hand switching, protective guards to
make the danger area safe and a safety control system as standard.

Notes on the safety control The safety control system corresponds to the requirements of category
system 4 of the pr EN 954-1, which specifies the following:

- a single error in the control unit must not reduce the

effectiveness of the safety functions (one error safety) and
- if possible, a single error should be recognized during or before
the next time the safety functions are required or
- if possible, an accumulation of errors should not lead to a
reduction in effectiveness of the safety functions.

RISK EVALUATION: The safety functions remain when an error occurs. The error has
been recognized in time to prevent a reduction in effectiveness of the
safety functions.

The safety is achieved using the:

- safety control system

- approved software modules
- use of two channel outputs (e.g. with the rapid traverse valve)

When warming up the safety control system, the software version is

given on the four-figure display.

Software version number for

the fail-safe component A 0 1 3
indicator on the display

Caution! The manufacturer accepts absolutely no responsibility if the

safety control system software is used with other machines or
for any other illegal use or modification of the software.

Notes on working safety The general safety and accident prevention regulations should be
observed in addition to this operating manual.

4. Danger overview

Whenever anyone is in the working area, there is potential danger.

The following overview summarizes potential dangers to the life

and health of personnel who work with the machine. Crushing
(Q), collision (ST) and cutting (S) pose particular risk.

1-16 Safety K006eng1

 Additional1
Kind of danger Danger point Danger measures

Danger from movement of (1 Measures taken

force operated machine parts workpiece (stopped) injury risk (Q, ST, S) by customer)
workpiece clamping injury risk (Q, ST, S)

flapping and sliding of the injury risk (Q, ST, S)

workpiece

X-stop injury risk (Q, ST)

press bar injury risk (Q)

lower die adjustment injury risk (Q, ST)

device
injury risk (Q)
side adjustment of the stop
finger

Danger from instability falling over of the injury risk (Q, ST)
workpiece du to own
weight

falling down due to own injury (Q)

weight (tool/workpiece)

Danger from shapes on the machine injury risk (Q, ST)

(Cutting, points, corners ...)
from the workpiece injury risk (Q, ST)

Danger from pressurized hydraulic hoses injury risk

materials
pneumatic hoses injury risk

Danger from electrics directly from parts which life endangered

are normally live

indirectly from live parts life endangered

when the machine is
malfunctioning

Danger from extreme

temperature Oil up to 80 °C burn danger

Danger from explosions The machine is not suited for

use in an area where there is
danger of explosion or of
accidents with corrosives. Its
use is subject to special
regulations in both cases.

K006eng1 Safety 1-17

Fig. 3893
a Danger point when
setting parts at the rear
stop. Never allow a
body part to enter the
area between the upper
and lower bar.
b Danger point when
upper tool travels to top
edge of the workpiece,
prior to bending.

Fig. 3894

Danger point during the bending

operation.

Fig. 3895

Danger point when workpiece

swivels back after the bending
operation.

1-18 Safety K006eng1

Fig. 3896

Danger point where stop finger has

shifted
(not with CNC-controlled Z1/Z2
axis or with models with 6-axis
back-stop).

Keep an eye on the movements of

the workpiece and the bending aid
(option) which have to take place
during the bending.

K006eng1 Safety 1-19

Danger point between upper and
bottom die and danger point
between stop finger and upper and
lower die.

F Attention!
Never reach into the area between the upper and
lower die when the press brake is switched on or off.

Danger zone in rear working area The following must be strictly

observed if it is necessary to
stand at the rear of the machine:

· When standing at the rear of

the machine for a short
amount of time, safety is
provided by the limit switch on
the protective cover.

· When standing at the rear of

the machine for any length of
time, the main switch (on the
outside of the switch cabinet)
should be moved to the 0
position (OFF). This should
also be secured using a pad-
lock (see diagram).

1-20 Safety K006eng1

 5. Safety measures to avoid injuries caused
by crushing or cutting

Protection goal Protection from hand injuries during any potentially dangerous
movement of the X, Y, R or Z-axis, or of the workpiece.

Solution principle · The protective covers mounted onto the press prevent body parts
entering the working area by accident.
· The two-hand operation forces the operator to keep his hands
outside the danger zone during the dangerous final movement of
the press bar.
· The Y-axis self-monitoring installed prevents intended or
unintended re-running on the Y-axis after an error has been
recognized in one of the components.
· Machine parameters for safety functions can be programmed only
in menus protected with code numbers, so that it is impossible to
change these parameters by accident.

Solution descriptions
Protective covers F All opening functions of the protective covers provided by the
manufacturer are locked with the safety control system. If all
protective covers are not closed, no movement of the press
bar can be executed. If a protective cover is opened during
operation, the press bar movement, as well as all other axes
are stopped immediately.

Two-hand switching F The two-hand switching is set up, so that if a component

fails, the press bar neither performs or misses its operation.
The safety control system software has been designed in
such a way that even when a component fails causing
"Simultaneousness" or when switching is done with one
hand, the press bar cannot move.

After a component fails (like ZH1/456 Chapter 3.7.1) the

press bar cannot close. The hand keys are furnished with a
contact monitor which is incorporated in the safety control
system, so that any type of bridge between the contacts of
each two-hand key can be self-controlled.
Removing dies F Remove bending dies from the TrumaBend that are not
required for an active bending process!
Machine control F The machine control, according to ZH1/457 chapter 3.4.1 is
self monitoring during a machine cycle. The safety control
system performs the self-monitoring in the machine cycle.

K006eng1 Safety 1-21

 6. Safety Precautions to Avoid Collision
Injuries

Safety goal To ensure that the edges of the workpiece are not bumped by self
moving axis. This eliminates collision injuries to the operator.

Solution principle The time of X and R axis positioning, as well as press speed can be
selected to allow perfect workpiece manipulation.

Solution description By programming the program parameter CX (for example CX = 2

"step change in upper dead point") the positioning of the axis can take
place at a convenient time for the operator. Removal of workpiece –
then axis positioning follows – workpiece is reinserted and pressed
against the stop finger.

7. Safety Precautions to Avoid Electrical

Voltage Injuries

Solution goal The electrical unit must be insulated, so that any incidental contact
with electrical elements does not endanger personnel. Also, if a short
circuit occurs in the control cable, no drives should operating.

Solution principle Electrical elements, as far as it is technically possible, should be

housed in an interface cabinet or an operator's drawer. Unit
arrangement should follow VDE 0113, part 7. In addition, electrical
components should be built according to VDE0106 part 100 in a
safety-contact manner. Control transformers have an isolation foil
between the upper and lower voltage side, and are built according to
VDE 0551. For protection against unintentional starting in the event of
a failure, the GND cable is set with a bridge to PE.

Solution description To protect against unintentional operation in the event of a failure, a

secondary cable is set with a bridge to PE. If a voltage monitor unit is
installed, bridges L6-PE, L8-PE and L12-PE must be removed.

1-22 Safety K006eng1

 8. The machine has been designed and built
according to the following standards

Standards

· EN 60204 Part 1 "General requirements" and VDE 0113 "Safety of

Machines – Electrical Set-Up of Machines"

· DIN VDE 0106 "Protection from Electrical Shock"

· DIN 40008 Part 1 "Safety Labels for Electronics Technology"

· DIN 40011 "Electronics Technology, Ground, Insulation, Foreign

Voltage-Free Ground, Designation of Machinery Materials, Labels"

· DIN 40713 "Switching Signs, Switching Units, Drives"

· EN 292-1 "Safety of Machines – Basic Terminology; General

Structure Rules; Part 1 Basic Terminology, Methodology"

· EN 292-2 "Safety of Machines – Basic Terminology; General

Structure Rules; Part 2 Technical Rules and Specifications"

· EN 294 Safety Distances when Upper Body Parts Reach Danger

Areas

· Accident Prevention Instruction "Eccentric and Similar Presses"

(VBG 7n 5.1)

· EN 349 "Minimal Distances to Avoid Squeezing Body Parts"

· EN 574 "Two Hand Switching"

· EN 418 "Emergency Off Devices"

· Accident Prevention Instruction "Hydraulic Presses" (VBG 7n 5.2)

· Accident Prevention Instruction "Spindle Presses" (VBG 7n 5.3)

· Safety Regulations for Controls for Force Operating Presses in

Metal Fabrication (ZH 1/457)

· Safety Regulations for two-handed Switching for Force Operating

Presses in Metal Fabrication (ZH 1/456)

· Safety Regulations for no-contact Protection Devices in Force-

Operating Presses for Metal Fabrication (ZH 1/281)

· Safety Regulations for Mobile Screens on Force-Operating

Countersinking Bending Presses (folding presses) for metal
fabrication (ZH 1/508)

K006eng1 Safety 1-23

 · Accident Prevention Instructions "General Instructions" (VBG 1)

· Accident Prevention Instructions "Electrical Units and Machinery

Materials" (VBG 4)

· Accident Prevention Instructions "Working Machines (General)"

(VBG 7a)

· Pressure Container Instructions ZH 1/400

· Safety Regulations for Bending Operations on Force Operating

Countersink Bending Presses (folding presses) in Metal
Fabrication (ZH 1/387)

· VDE 0100 (5.73) Regulations for Setting Up High Voltage Units

with up to 1000 V Rated Voltage

A-valued equivalent continuous sound level at working place:

smaller than 70 dB (A)

Highest value of the current C-valued sound level:

Leq C-valued 70.8 dB
Lmax C-valued 85.0 dB

9. APPENDIX

Safety information! Colour documentation:

- Operating instructions for the person setting-up the

machine
- Operating instructions for the machine operator

1-24 Safety K006eng1

 OPERATING INSTRUCTIONS
Work place : Line V of TrumaBend Job: Set up person

RANGE OF APPLICATION
Setting-up bending press !
DANGER TO LIFE AND ENVIRONMENT
Danger of finger and hand injury
q with improper handling or malfunction of the machine
q with elimination of malfunctions

SAFETY MEASURES AND CODE OF CONDUCT

q Armoured gloves must be worn

q Pay attention to order and cleanliness in the work place

q Work on setting-up the machine of the line of products stated above may only be
carried out by press set-up persons over 18 appointed in writing and instructed to
do so!
q The set-up person must secure the operation mode selector switch after finishing
setting-up (withdraw key).
q The set-up person is responsible for the proper operation of the bending press
q The set-up person must document the safety measures set in a control book.
q Only one person may work on presses with two-handed operation!
q It is forbidden to change the safety features or make them ineffective.
q The information in the operating instructions must be observed at all times!

CONDUCT IN DANGEROUS SITUATIONS / WITH MALFUNCTIONS

q The EMERGERGENCY STOP button must be activated if irregularities or
malfunctions occur.
q Switch off main switch and take steps to prevent the machine being
switched on again if necessary.
q The person in charge must be notified.

FIRST AID
q Save the injured! Initiate first aid measures!
q NOTIFY FIRST AID HELPER! ë (( See first aid box)
q NOTIFY EMERGENCY SERVICES IN HOUSE VIA THE GATE ë 444

MAINTENANCE
q Maintenance may be only carried out by appointed and competent people.
q The machine must be switched off at the main switch and secured (lock)
when maintenance or cleaning work is carried out !

The freedom from physical injury takes absolute precedence !

Non-observance of these operating instructions can lead to serious injuries !

MANAGEMENT : Date: OPERATING SAFETY :

 OPERATING INSTRUCTIONS
Work place: Line V of TrumaBend Job: Machine operator

RANGE OF APPLICATION
Sheet metal forming!
DANGER TO LIFE AND ENVIRONMENT
Danger of finger and hand injury
q with improper handling or malfunction of the machine
q with elimination of malfunctions

SAFETY MEASURES AND CODE OF CONDUCT

q Armoured gloves must be worn

q Pay attention to order and cleanliness in the work place

q The machine of the line of products stated above may only be operated by
appointed personnel who are instructed to do so.
q Young people over 16 may only use the press for training purposes and only
under the supervision of an expert!
q Make a visual check for faults before the start of work.
q The operator must ensure that there is nobody in the danger area before the start
of work!
q Only one person may work on presses with two-handed operation!
q It is forbidden to change the safety features or make them ineffective.
q The information in the operating instructions must be observed at all times!

CONDUCT IN DANGEROUS SITUATIONS / WITH MALFUNCTIONS

q The EMERGERGENCY STOP button must be activated if irregularities or
malfunctions occur.
q Switch off main switch and take steps to prevent the machine being
switched on again if necessary.
q The person in charge must be notified.

FIRST AID
q Save the injured! Initiate first aid measures!
q NOTIFY FIRST AID HELPER! ë (( See first aid box)
q NOTIFY EMERGENCY SERVICES IN HOUSE VIA THE GATE ë 444

MAINTENANCE
q Maintenance may be only carried out by appointed and competent people.
q The machine must be switched off at the main switch and secured (lock)
when maintenance or cleaning work is carried out !

The freedom from physical injury takes absolute precedence !

Non-observance of these operating instructions can lead to serious injuries !

MANAGEMENT : Date: OPERATING SAFETY :

 Chapter 2

Technology

K006eng2 Technology 2-1

 1. Structure of bending

The structure of the bending process, which is principally concerned

with metal workpieces, is based on DIN 8586.

Bending

Bending with Straight Bending with rotational

Line tool movement tool

Air Bot- Simulta- Roller Fold Rolling Swivel Round Revol-

bending toming neous bending bending bending bending bending ving
bending bending

Direct Free Hori- Counter Counter Counter Winding Roller Direct Wave Roller Roller Coiling
bending roun- zontal sunk sunk sunk rounding rolling bending profiling draw-
ding force air roun- crimp- flanging bending
bending ding ing

Fig. 3813 Structure of bending

2-2 Technology K006eng2

 The TrumaBend brake press performs AIR BENDING and
BOTTOMING.

Air bending

Fig. 3815

Bottoming

Fig. 3816

K006eng2 Technology 2-3

 1.1 Definitions

Fig. 3814

1 upper die
2 radius (upper die)
3 lower die
4 V opening
5 radius (lower die)
6 workpiece
7 outer radius of workpiece
8 inner radius of workpiece

2-4 Technology K006eng2

 1.2 Air bending operation
Air bending Air bending is a flexible bending operation often used in manu-
facturing. Air bending is carried out when the workpiece is contacted
at three points:
· at the upper die point
· at the lower draw radii of the lower die

The die geometry is created "freely" during air bending, i.e. it is

dependent firstly on the behavior of the material being processed and
the sink depth. The bending angle is determined by the position of the
upper die.

During air bending, there is no uniform bending radius, but rather a

curving path with the smallest curve in the bend curve maximum.

Fig. 3817

1 contact point on the top

of the upper die
2, 3 contact points on both
draw radii of the lower die

1.2.1 Air bending advantages

· Any angle between 180° and virtually the angle of the tools (spring-
back resilience) can be produced without tool change.

· When compared to forming, air bending utilizes very small bending

forces.

K006eng2 Technology 2-5

 1.2.2 Determining the press force during air bending

Fig. 3858

F Press force [N]

w Sink depth [mm]
l Brake length [mm]
s Material thickness [mm]
Rm Tensile strength [N/mm2]

1.33 · l · Rm · s²
F = ———————— (determined empirically by TRUMPF)
w

The following notes should be observed:

· F is the press force required for air bending.

· 1.33 is an empircally-determined factor. It includes overcoming the

frictional resistance between the lower die and the material. To
achieve the factor of 1.33, the surfaces of the pull-in radii of the
lower die should be kept clean. The material to be processed
should also be clean, rust-free and lightly lubricated. Scaly, rusty
and non-lubricated materials considerably increase the press force
required. The above should therefore particularly be observed in
borderline cases.

· Rm in the maximum tensile strength according to normal

conditions.

2-6 Technology K006eng2

 · Sheets to be folded which are suitable for the process (normally
heated) should be prepared.
· It is advisable to position the bending edge diagonally to the roller
direction; this prevents the sheet from breaking.

· For the sheet thickness "s", the actually measured thickness

should be used. It is not permissible that the thickness
measurement of the prepared sheet is used in the formula.
According to EM 10029, a 2000 mm wide and 5 mm thick sheet
can be 4.25 – 6.5 mm thick, for example. 4.25 or 6.25 in the
formula give a required press force of 240 kN or 562 kN
2
respectively with 400 N/mm tensile strength and 40 mm sink
depth and a bending length of 1 m.
· It is possible to prepare sheets with smaller thicknesses.

· If the sink width "w" is larger than the 8-fold material thickness "s",
the measurement for "w" can be used in the formula without
deductions.
· With sink widths "w" smaller than 8 times the material thickness
"s" the resistance to deformation is greater; the rest with of the
upper die should be taken from "w" in this case.
· 2·w1 should be inserted into the formula for w.
· Compare with Fig. 3855.

If
w < 8s,
2·w1 should be
inserted into the
formula for w.

Fig. 3855

w sink depth
2·w1 sink depth less the upper die rest width
R radius of the top

K006eng2 Technology 2-7

 In extreme cases with a large upper die radius, the workpiece is not
bent, but rather the material is pressed into the lower die. A very high
press force is required to do this.

The characteristics of the press force process when bending a 90°

angle is such that the press force requirement until the flow limit
increase sharply to remain near constant until the end of the bending
process.
With a deformation of the working material exceeding 90°, the press
force required is reduced.

Caution! To avoid excessive dispersion of the required press force, the

permissible tolerances of the material strength, sheet thickness
and surface quality should be observed when preparing the
sheet. The figures for the maximum sheet thickness in particular
should be observed.

2-8 Technology K006eng2

 1.3 Bottoming
Bottoming operation For bottoming, the angular bend is obtained by pressing the material
into a defined shape (lower die). The angle between the upper and
lower die determines the angle of the workpiece.

Fig. 3816 Bottoming

Important notes for bottoming

Bottoming is used when

· workpieces require a high level of accuracy
· if the material's inner radius has to be smaller than the sheet
thickness

For various angles and various inner radii various corresponding

upper and lower tools are required.

Depending on material and thickness, shaping requires 3 to 10 times

more bending force than air bending.

The workpiece springs up after the bending operation.

Spring-back must be taken into account for tool geometry.

Bottoming (tool cost/set up time) is only practical for larger-scale

series production.

K006eng2 Technology 2-9

 2. Spring-back
Potential buckling and stretching that occur in the bending zone must
be compensated for in the material shifting. Tensions arise, that only
subside after the bending operation, and therefore create a spring-
back of the bent joint. The greater the bend on the workpiece, (that is
to say the smaller the relationship of inner radius of the
workpiece/sheet metal thickness) the smaller the spring-back of the
bent workpiece.
Through corresponding overbending, the spring-back action can be
counteracted.
The amount of spring-back and equalization of unavoidable
overbending is contingent on the tensile properties of the material.

3. Guidelines for workpiece designing

3.1 Computing the smallest possible joint length

Fig. 3856

b smallest possible joint

length
w V opening

* applies only to 90° lower dies in

air bending and bottoming
b = 1/ 2 ×w × 2 *

2-10 Technology K006eng2

 3.2 Minimal distances and minimal lengths
Workpieces that contain a notch or hole in the area of the bending
zone prior to bending, may not exceed a minimal distance of the hole,
or slit margin from the bent edge, if the hole shape or notch is to be
retained.

Fig. 1412

x1, x2 minimal distance

b width of the notch
d hole diameter
Ri inner bent radius
s workpiece thickness
l joint length

The minimal distance x1 or x2 is contingent on the hole diameter d, or

the notch width b, the bend radius Ri and the material thickness s.

With sufficient approach the following applies

for round holes

x1 = (d · s)1/2 + 0.8Ri · (l/d)1/2

for notches and right angle perforations

x2 = 1.1 · (b · s)1/2 + 0.8Ri · (l/b)1/2

K006eng2 Technology 2-11

 3.3 Bending with various bending joint shapes

During the bending operation, distortions take place in the bending

zone which must be taken into account in the workpiece shape.
In figure 1413 examples of incorrect and correct shaping of work-
pieces are given.

To 1. The bending line may not

run into the contour path
of the other bending joint.
The compression and
expansion is prevented in
the bending zone and this
causes tears.

b = 1.5 s

To 2. Beveled edges on the

bent edge should be
avoided.

lmin. = 1/2 w + s

To 3. Instead of a short angle

joint y, it is better to use
the edge of the other joint
in order to allow the
x dimension to retreat.

xmin. = (1 – 1.5) s

To 4. Instead of the short

bending joint y, guiding
the perforation around the
bending edge is
recommended.

xmin. = (1 – 1.5) s

w sink width
s material thickness

Fig. 1413

I incorrect
II correct
Ri interior bending radius

2-12 Technology K006eng2

 3.4 Smallest possible inner radius

Minimal values The minimal value for the Ri inner radius is contingent on the tool
geometry, the material and the location of the bending line to the
rotating direction.

Small inner radii are more easily achieved, when they are per-
pendicular to the rotating direction. When this is the case, the
following approx. values apply for the smallest possible inner radii:

Approximate values for the Soft Material Ri = 0.7·material thickness

smallest possible inner radii
Hard Material Ri = 1.0·material thickness
Springy Material Ri = 2.5·material thickness

The soft, hard and springy designations are contingent on the

material. For the various types of materials, there are, for example,
various tensile ranges. More detailed information can be taken from
the material manufacturer's catalogs.

Basically:

The smallest possible inner radius of the workpiece may not be

smaller than the upper tool radius.

K006eng2 Technology 2-13

 4. Measuring and developing bending parts

Measuring bending parts

Fig. 3853

Recommended for measuring bending parts

· Measure outside (measure outer cut point)
· Cite internal bending angle

The TrumaBend press brake basically allows programming with the

inner or outer dimension; however, the entire program can only be
input in one form or the other.

Measuring developments

Fig. 3854

Recommended for measuring developments

· Essentially, coordinate dimensions

2-14 Technology K006eng2

 Chapter 3

Set-up, operation and transport

TrumaBend series V50 - 200

Ident. no. 863 848

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-1

 1. Conditions for setting up the machine

Space requirements The layout of the individual system components and the space
required for installation of the system are specified in the respective
foundation and installation plan. The space required for opening the
doors is given on the plan.

Specified in the respective foundation and installation plan are:

– arrangements of individual options
– space requirements for opening switching cabinet doors
– control traverse field
– outer dimensions of covers, and space requirements when
protective cover is open
– electrical connection
– pneumatic connections

Floor quality Criterion Requirements

Floor conditions Concrete plate (B25), >200 mm thick

See DIN 1045 for detailled specifications.

Levelness The floor must be as level as possible,

maximum height difference <10mm for the
entire installation surface (see installation
plan)

Installation area Free of expansion joints, cracks etc.

between the load-bearing points

Consistency The floor must be oil-proofed

Observe the water protection regulations for the relevant

country!

Caution! The machine's center of gravity is very far towards the front,
creating danger of tipping. Utmost caution is advised when
transporting and assembling the machine.
In the interests of safety it is, therefore, essential that you fasten
the machine to the foundation!

3-2 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 1.1 Securing the machine to the foundation:

Fig. 5421

1 floor
2 drill hole
3 base plate
4 support plate
5 machine foot
6 adjusting screw
7 lock nut
8 tie rod

F Tie rods, base plates, support plates, adjusting screws, and

lock nuts are supplied.

Procedure: Drilling the lock holes

· Option 1
Place the machine on the desired installation spot and drill the
fixing holes

· Option 2
Mark and drill the holes for the fixing screws in the machine's
installation location
(Refer to the installation plan for the dimensions of the 4 drill holes
(1), (2))

Vacuum drill holes (clean)

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-3

 Set adhesive plug

Place one of the four base plates on each drill hole

Place machine on base plates

Screw in tie rods

(observe curing times)

Determine the base plate with the highest top edge; the remaining
3 base plates should be brought to this level.
To do this:
Lift the machine either using the adjusting screws or hydraulic hoisting
jacks and place spacers of a suitable thickness underneath the
machine legs.

Loosen the adjusting screws

Tighten 4 lock nuts

Use a precision level (0.05 mm/m reliability), check to see if the

machine is level.
(Before measuring, test the level by changing the right and left end)

3-4 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

Fig. 5300

1, 2 Measuring points
(vertical alignment)
for Y1, Y2 press bar guide

3, 4 Measuring points
(horizontal alignment)
on the top table edge

All fixing components required for setting up the machine are supplied.

4 armature rods HAS M16x260 No. 259941/3, Fa. Hilti

4 adhesive cartridges HVU M16x125 No. 2566941 Fa. Hilti

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-5

Weight distribution The load carrying capacity of the floor must be checked prior to
installation.

V50 V85 V85S V130 V170

Total machine weight

4750 7750 8600 11250 16450
[kg]

Weight per support point

1820 3140 3490 4500 7500
(1) [kg]

Weight per support point

555 735 810 1125 725
(2) [kg]

Weight support for each

foot on a surface of 160 x 200 160 x 200 160 x 200 160 x 200 160 x 200
[mm2]

Version with expanded die space

V85 V85S V130 V170

Total machine weight [kg] 8400 9800 12950 18000

Weight per support

3570 3940 5180 7700
point (1) [kg]

Weight per support

880 960 1295 1300
point (2) [kg]

Weight support for each foot

2 160 x 200 160 x 200 160 x 200 160 x 200
on a surface of [mm ]

* Refer to the installation plan for the location of the support points (1)
and (2).

3-6 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 1.2 Climate

Ambient temperature The temperature in the room must not be outside the range +10 °C to
+40 °C. For temperatures below +10 °C over 40 °C, special measures
need to be taken.

F 10 to 40 °C

Hydraulic unit Max. permissible operating temperature (oil temperature)

F 80 °C

Temperature limit values for pump, hydraulic elements and seals

F –20 to +80 °C

Control Temperature range limits for transporting or turning off the machine

F –20 to +70 °C

Humidity

F 20 to 75 % (short time 90 %, not producing condensate)

Do not operate controls in humid conditions, as this can result in the

corrosion of the contactor and relay contacts and subsequently in the
failure of the control unit.

The control unit is cooled through a vent on the back. The drawn-in air
provides sufficient cooling of the control unit. (Ensure regular filter
cleaning). This provides protection against excessive temperatures
and dust.

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-7

 1.3 Securing the work area

It is the responsibility of the employer to ensure that all relevant safety

regulations of the respective country be observed during installation of
the machine.

Caution! The main switch should be secured with a padlock to

prevent machine start-up by unauthorized personnel.

In the event of an emergency, ensure that an exit can be reached

from the side area of the unit if the interface cabinet or covers are
open.
(*VDE 0100 §30a)

Machine start-up Prior to machine start-up, the operator must ensure that
the danger area of the machine is clear.

If areas where there is a danger of being crushed as a result of local

conditions, these should be made safe by the operator in accordance
with *EN 294, EN 349.

The operator must then ensure that all hazards arising from the
processing of work pieces have been safeguarded where the work
pieces are

F larger than the nominal working area of the machine,

F hazardous due to the shape (notches, points etc.).

3-8 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 2. Conditions for machine operation

Machine start-up The initial machine start-up, start-up inspections and checks must be
performed by a TRUMPF technician. Start-up includes the precise
adjustment of the machine and a function inspection.

Operating materials Hydraulic oil must be available before the machine is delivered.

2.1 Operating materials for the hydraulics

The hydraulic tank of the machine should only be filled with filtered oil.
The filter unit must have a filter rating level of 3 mm.
Caution: Inform operators and maintenance personnel accordingly!

Recommended hydraulic oils are summarized in the following table

and can be used as desired.
Similar lubricants supplied by other manufacturers can be used,
provided they have the same characteristics (specification according
to DIN 51524).

Hydraulic oils: Aral Vitam DE 46

BP Energol HLP-D46
Castrol Hyspin AWH-M 46 (used in works)
ELF Elfonla HMD 46
Esso HLPD Oil 46
Fuchs Renolin MR 15
Mobil Hydralic Oil HLPD 46
Shell Tellus Oil DO 46

V50 V85 V85S V130 V170

Oil quantity [l]

80 200 200 250 350
(identical for version with raised mounting height)

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-9

 2.2 Pneumatic supply

The compressed air connection can either be flexibly or rigidly piped.

The lead must be 1/2" and come directly from the main supply.
A shut-off valve must be provided. There is a maintenance device on
the machine (filter controller B07 mounted). Specification diagram
and description included at end of chapter.

Connection pressure 6 ±1 bar

Minimal diameter of main pipe 13 mm (1/2")

Air consumption approx. 0.1 m³ / hour

The pneumatically driven parts of the press brake can be controlled

with oil-free compressed air.

In the interests of improved working conditions and

environmental protection, we recommend using oil-free
compressed air from the press manufacturer

Use of compressors If a sufficient pneumatic air power supply is not available, a suitable
compressor must be provided.

The max. distance of the compressor to the machine should not

exceed 50 m.

The pipes should be 1" diameter up to the connection point of the

machine. For greater lengths, 100 to 300 l volume air cartridges are
provided for the machine. These air cartridges must be secured to the
power supply with a return valve.

Necessary supplies for the compressor are:

Cold dryer and micro filter combination.

Cold dryer The pressurized air is kept condensation-free with the cold dryer.

Micro filter combination The micro filter combination consists of 2 filter levels. The first level
filters out solid impurities. The second level is an activated charcoal
filter and absorbs oil vapor.

Further recommendations for the use of

compressors, cold dryers and micro filter
combinations are available upon request!

3-10 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 2.3 Electrical connection
Prior to delivery, the unit is wired according to customer voltage and
frequency requirements.
Perform electrical connection only by a trained and authorized
professional.

The mains voltage must be measured before turning on the main

switch. Make sure that the transformers T17, G13 are adjusted to
the mains voltage.

V50 V85 V85S V130 V170

Connection value [KVA] 8 10 14 18.7 29

Fuse protection at 400 V
3x25 3x25 3x50 3x50 3x50
(slow fuse) [A]

Version with extended installation height

V85 V85S V130 V170

Connection value [KVA] 14 14 23 29
Fuse protection at 400 V (slow fuse) [A] 3x50 3x50 3x50 3x50

– net voltage tolerance ±5%

– frequency 50 Hz ± 2 %
– max. interruption time 10 ms every 10 s

A four-pole connection with copper cables is required for power

supply to the machine (L1, L2, L3 + PE).

Connection cross section and protective ground of the machine

should follow the VDE 0100.

Continuous over or under voltage, relative to given net voltage is not

allowed. For greater voltage deviations, full machine capacity and
trouble-free production cannot be guaranteed.

The TrumaBend may not be connected to power supplies that are

contaminated by welding machines (short term voltage spikes). In this
case, and in cases of highly loaded power supplies, one should lay a
direct cable from the transfer distribution.

OPTION Additional feed for "OPTION 220 VAC plugs"

Fuse protection: 1x10A (to phase)
Cable: A 3-pole cable with a cross section of 3x2,5 m² (phase, zero
conductor, potential earth) is required for power supply to the
plug.

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-11

 3. Conditions for machine
transportation
All system components must be examined upon receipt for damage
incurred during transit. Visible damage should be given on the delivery
note and confirmed by the truck driver. Concealed transport damages
should be reported to TRUMPF and the insurance company within 6
days.

Moving the machine parts from the truck to the final duty station must
be prepared and executed by the customer.

The transportation path to the machine installation position must be

decided well in advance of delivery. Checks must be carried out on
gateways, potholes, boarded cabling excavations, whether the ground
is suitable for supporting armoured rollers etc. in particular.
The machine dimensions according to the installation plan should be
taken into account in deciding the transportation path!

V50 V85 V85S V130 V170

Main machine-
dimensions Length 1930 2680 3190 3640 4620
(Measurements in mm) Width 2030 2100 2100 2210 2210
Height 2375 2375 2375 2375 2375
with expanded die space Optional
- 2885 2885 2885 2885
height

Auxiliary transportation devices ❑ Crane truck for unloading the truck. A hydraulic crane truck
with the relevant lifting capacity (see weight table 3-6) is
recommended. If local conditions require a larger lever arm, a
crane truck with greater lifting power should be used instead
❑ Fork lift truck (loading capacity at least 3t) for transporting the
additional units.
❑ Gantry crane (loading capacity at least 20 t) for transporting the
machine or
❑ armoured rollers (1 steerable and 2 rigid), each with a loading
capacity of at least 10 t) and
❑ at least 2 hydraulic hoisting jacks (each with a loading capacity
of at least 8 t, min. Fixing height: < 30mm)
❑ Crow bar (1m) and extension

Caution! The machine's center of gravity is far towards the front, creating
a dangerous tipping condition. Use utmost caution in
transporting and assembling the machine.

3-12 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 3.1 Measures to be taken by the customer

Unloading the ❐ Unloading the machine from the truck

machine using a crane truck with the relevant
from the truck loading capacity.
❐ A shape A (DIN 82101) shackle for
the eyebolts on the machine. See 3.2.
for details.
❐ Removing the wooden bars from the
machine legs when the machine is
suspended from the crane shackle.
❐ The accessories box supplied and
the specially packed accessories can
be tranported to the machine
installation position directly using a
fork lift truck.

❐ Transporting the machine from the

Transporting the yard into the factory hall on armoured
machine from rollers.
yard to the ❐ Further tranportation to the
installation installation position either using a
position gantry crane with the relevant loading
capacity or on armoured rollers.

Installing the ❐ Hydraulic hoisting jacks are required

machine at the if using armoured rollers for
installation positioning and setting up the
position machine at the installation position.
❐ Lift the machine using the hydraulic
hoisting jacks and push the spacers
underneath.
F The floor requirements on the
installation position must be deter-
mined according to the requirements
of these installation conditions.

TRUMPF- The machine is levelled and put into operation by TRUMPF

Services specialists. Putting the machine into operation includes installing the
system components according to the installation plan, connecting
the machine to the supply, instructing personnel and testing
machine functions.

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-13

 3.2 Suspension holes and shackle

Detail
x
D

Fig.: Positions of the suspension holes of the machine

Dimensions and positions of D Measurement X Thickness of

the suspension holes Type Hole- Distance from top side plate
Diameter edge
(mm) (mm) (mm)

V50 50 75 40

V85/S 60 100 60

V130 70 100 70

V170 70 100 70

3-14 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 Permissible
Bolt Main dimensions
Machine load in
diameter
Type
in inches
Shackle to be used as per DIN d5 d1 h1 b1
t N mm mm mm mm
82101

6 58840 1 1/2“ 39 34 119,5 53

V50 8 78453 1 3/4“ 45 38 139,5 60
V85 10 98066 1 7/8“ 48 42 147 66
V85S 12 117680 2“ 52 47 158 73

12 117680 2“ 52 47 158 73
V130
16 156906 2 3/8“ 60 52 185 81
V170
20 196133 2 3/4“ 68 58 211 90

WARNING! Non-standardised shackles do not necessarily fit into the

suspension hole even if they have the correct loading capacity!

Two shackles are required per machine!

Shackle shape and dimensions

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-15

 4. Planning Aid

Time before machine delivery Planning criterion Action

15 weeks Personnel and training Appoint a member of staff to be re-

sponsible for the machine commissioning
preparations.
Select operatives, maintenance staff and
programmers and agree training
schedules for your specialists.

14 weeks, Installation position Determine the machine location. Take the

or by ......... at the latest space required and the installation plan
into account.
Check the floor requirements (floor quality,
levelness, oil-proof floor without expansion
joints)
Take the weight and dimensions of the
machine into account.
Check that the requirements for the
ambient conditions are met (ambient
temperature,...)
Check the transportation path (doorways,
potholes, boarded cable excavations,
clearance space around corners, etc.)

12 weeks, Electrical power supply Install the electrical connections at the

or by ......... at the latest installation position. The conductor cross-
section and the fuse protection should be
made according to legal guidelines.

12 weeks, Compressed air supply Install a compressed air supply at the

or by ......... at the latest installation position (connection, purity,
compressed air requirement).

4 weeks, Working materials Obtain supplies of the working materials

or by ......... at the latest required (hydraulic oil)

4 weeks, Transportation aids Make sure that the transportation aids

or by ......... at the latest required are available.

3-16 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 5. Regulation sources

VDE pressure regulations:

Publishers: Verband Deutscher Elektrotechniker
(VDE; Association of German
Electrotechnical Engineers)
Stresemannalle 23
60696 Frankfurt
Germany

Sales: VDE-Verlag GmbH

Bismarckstraße 33
10591 Berlin
Germany

or:

Beuth Verlag
Postfach 1145
Burggrafenstraße 6
10787 Berlin
Germany

The DIN standards:

Publishers: DIN Deutsches Institut für Normung e.V.
Postfach 1107
10787 Berlin
Germany

Sales: Beuth Verlag

(see above for address)

EURO Standards:

Publishers: Office for official publications

of the European Community
2, Rue Mercier
2985 Luxembourg

Sales: Beuth Verlag

(see above for address)

K006eng3 Edition 1 v 02/2000 Set-up, operation and transport 3-17

 6. Safety measures to be taken by
user / operator
All necessary safety measures must be met when operating
the machine. Work on the machine may only be carried out by
qualified personnel.

For fire protection reasons a hand fire extinguisher must be

provided for metal fires (fire classification D) with powder foam.

If the machine is to be scrapped the hydraulic oil must be

drained first and disposed of according to the usual guidelines
and laws. The cabling as well as the control elements of the
switch cabinet are electrical scrap and consequently hazardous
waste. This is to be disposed of according to the usual laws as
well. The rest of the machine is mainly scrap metal and as
such should be recycled.

7. Appendix

Installation plans:

839 746 TrumaBend V50

839 747 TrumaBend V85
839 748 TrumaBend V85S
839 749 TrumaBend V85 + 150
840 229 TrumaBend V85S + 150
839 750 TrumaBend V130
839 751 TrumaBend V130 + 150
839 752 TrumaBend V170
840 781 TrumaBend V170 + 150

3-18 Set-up, operation and transport Edition 1 v. 02/2000 K006eng3

 Chapter 4

Description

K006eng4 Description 4-1

 1. Technical data

6
4 5

Travel path X-axis  Installation height

 Max.stop range in X  Throat depth
 Travel path R axis  Table width
 Stroke  Working height with lower tool 100 mm
(3.9 in)

Travel paths, stop range and dimensions

4-2 Description K006eng4

 TrumaBend V50 V85 V85S V130 V170 V200

Max. press force [kN] 500 850 850 1300 1700 2000

Connection Electric [KVA] 8 10 14 18,7 29 29

values
Pneumatic [bar] 6±1 6±1 6±1 6±1 6±1 6±1

Oil fill-up Hydraulic reservoir [l] 80 200 200 250 350 350

Dimension Weight approx. [kg] 4750 8160 8960 10650 14900 18000

Machine
dimensions [mm]

Length 1930 2680 3190 3640 4620 4620

Width 2030 2100 2100 2210 2210 2210

Press bar Rapid traverse [mm/s] 200 200 200 200 200 200
speeds
Working traverse 1-10 1-10 1-10 1-10 1-10 1-10
[mm/s]

Return [mm/s] 135 135 135 135 135 135

Axis Travel speed in X

500 500 500 500 500 500
[mm/s]

Travel speed in R
300 300 300 300 300 300
[mm/s]

Travel speed in Z
- 1000 1000 1000 1000 1000
[mm/s]

Accuracy Positioning accuracy

of the axes [mm]

Y axis 0,01 0,01 0,01 0,01 0,01 0,01

X axis 0,04 0,04 0,04 0,04 0,04 0,04

R axis 0,08 0,08 0,08 0,08 0,08 0,08

Z axis - 0,06 0,06 0,06 0,06 0,06

K006eng4 Description 4-3

 TrumaBend V50 V85 V85S V130 V170 V200

Max. press force [kN] 500 850 850 1300 1700 2000

Dimensions Travel path

600 600 600 600 600 600
X-axis [mm]

Max. stop range

860 860 860 860 860 860
in X [mm]

Travel path
250 250 250 250 250 250
R-axis [mm]

Travel path
- 1370 1810 2310 3260 3260
Z-axis [mm]

Stroke [mm] 215 215 215 215 215 365

Bend length [mm] 1275 2050 2550 3060 4080 4080

Installation height [mm] 385 385 385 385 385 535

Tilt position [mm] ± 10 ± 10 ± 10 ± 10 ± 10 ± 10

Clear distance
1040 1750 2260 2690 3680 3680
between housing [mm]

Throat clearance [mm] 410 410 410 410 410 410

Working height
with lower tool 1050 1050 1050 1050 1050 1050
100 mm [mm]

Table width 100 120 120 120 200 200

4-4 Description K006eng4

 Version with extended installation height

V85 V85S V130 V170

Weight [kg] 8400 9800 12950 18000

Height 2885 2885 2885 2885

Stroke [mm] 365 365 365 365

Installation height [mm] 535 535 535 535

K006eng4 Description 4-5

 2. Machine assemblies

Bac kgauge Hydraulics Ramdrive Ram Control

Machine frame Die clamps Support c onsole Operating station 1

Options

All optional devices available for the TrumaBend machine are listed in
a summary. This overview is included at the end of this chapter.

4-6 Description K006eng4

 3. Machine Axes

Y1 Y2

R1 X2
X1 X2
X1
I R2
Z1 Z2

BH2
BH1 V

R-axis CNC: (with 6-axle rear stop R1 and R2)

Stop finger-height adjustment

Y-axis (Y1/Y2) CNC:

stroke press bar-height adjustment/press bar-angle setting

Z-axis (Z1/Z2) manual or optional CNC:

Stop finger-adjustment left/right

X-axis CNC: (with 6-axle rear stop X1 and X2)

travel forward/return

I-axis pneumatic:
Lower tool adjustment forward/return

V-axis: Crowning device

BH1, BH 2: Bending aid

K006eng4 Description 4-7

 4. Assembly Descriptions

4.1 Machine frame

The machine frame is a welded construction, composed entirely of

steel. It is hardened to be torsion-free, and consists of two side
stands, a table and a connection support.

• particularly stable
• generous throat depth

4.2 Press bar

The press bar is generously proportioned. It is also hardened to be

torsion-free.

• high bend rigidity

• ball socket press bar suspension

4.3 Press bar drive

The upper drive is a two cylinder electro-hydraulic drive, controlled

with the help of two proportional valves.

• exact simultaneous movement of both cylinders (Y1/Y2)

• long life of guides and sealing components
• great positioning repeatability of the press bar. The machine is
furnished with an incremental press bar travel measuring system
with integrated deflection compensation.
• tilting of the press bar

4-8 Description K006eng4

 4.4 Hydraulics

The machine is supplied with a modern hydraulics system that has a

high-pressure inner gear wheel pump.

• press force quickly accessible

• great repeatability
• quiet

4.5 Operating station 1

The operating station 1 is ergonomically designed and user friendly.

K006eng4 Description 4-9

 4.6 Die clamping device

Upper die clamping device:

The upper die clamping device is self-centering.

Following a tool change, the individual die segments can be aligned

precisely without idle strokes.

The upper die can be inserted quickly.

Head and shoulder supporting upper dies may be used.

Vertical die change is possible.

Lower die clamping device:

A program command can be used to slide the lower die clamping

device.

4-10 Description K006eng4

 4.7 Rear stop

Rearstop system Rearstop system

V130, V170 V50, V85, V85S

6-axis
rearstop

Flexibility X- and R-axes are CNC-controlled

with the 6-axis rear stop, the X1 X2, R1 R2 and the Z1 and Z2 axes
are CNC-controlled
• stop depth and height can be freely programmed
This means:
can be set to any level within RANGE
• minimal set-up times for the X- and R-axis
• high positioning speeds

Broad Parts Spectrum Large travel paths

• Extremely large work open space

• Maximized parts spectrum that can be produced on the machine
• Great rigidity and repeatability

K006eng4 Description 4-11

Work safety High level of safety
• easy positioning of the rear stops from the front.
This means:
If the stop fingers in the set-up mode are moved, they travel to a
safe set-up position for the operator in front of the tool level. The
operator does not have to reach into the tool zone.
Manual adjustment can take place only at the front of the machine
as jobs change, if at all.
With the model with CNC-controlled Z1/Z2 axis and with the 6-axis
rear stop, the stop finger is moved completely automatically.

User-friendly Very user-friendly

• Automatic opening and clamping of stop fingers.

This means:
The operator requires no additional tool to position stop fingers.
• High positioning speeds
• Large travel path

4.8 6-axis rear stop

Flexibility When components bent from a sheet with a highly-complex shape are
to be manufactured, with bending lines which do not meet on the
vertical or the horizontal, the system offers optimum flexibility in
manufacturing.
Independence To ensure that the sheets are precisely angled for the working
process, the stop fingers are located on two moving units which can
traverse fully independently from one another allowing the greatest
possible visibility onto the traverse area.
By inputting the sheet contours and sheet lengths in the control unit,
the required axis values for the stop are calculated and displayed. The
stop moves to the required position when activated.
The following axes are controlled: X1, X2, R1, R2, Z1 and Z2.
Efficiency Even the most complex of geometry with a minimum of non-
productive times can be manufactured cost-effectively thanks to the
program-controlled process of the moving units.

4-12 Description K006eng4

 5. Description of Options

5.1 Support bracket with precision guide

The option includes a console system which consists of two consoles

and the guide rail.
The console can be moved up and down and to the side and is also
detachable. To detach the console, the two socket head screws
(spanner width 8 or 5/16“) need to be loosened.

• Can be quickly positioned

• Short set-up times
• Same guide system as with the bending aid
• Can be used together with the bending aid
• Tape measure on the slot strip

K006eng4 Description 4-13

 Lever for additional strip adjustment

Lever for height adjustment

Bolts for height adjustment 100 and

150 mm

Lever for moving to the side

(both sides), adjusting the clamping
force by disengaging and
continuing to turn

Screw for detaching the console

(both sides)

Attention! When moving the additional strip in "plus X direction" and an I axes
position in maximum "minus X direction" it must be ensured that the
distance is not less than 120 mm - otherwise there is a risk of rusking
or being struck ans of shearing. This is ensured by the stop screw in
the slot strip. Do not remove this, as oterhwise the aditional strip may
project into the danger area.

The support bracket's slot strip is for holding tilting dogs with
micrometer adjustment. The side stopper function is provided by
placing two tilting dogs one behind the other on the slot strip.

A support extension in plus X or minus X direction is also possible by

using additional strips:
Additional strip 500 mm
Additional strip 1000 mm

It is also possible to use an additional table with brushes fixed to the

surface.
Support area: 450 x 750 mm
The pull-out part enables you to extend the table surface by 600 mm.

For details of the different variants see the following page:

4-14 Description K006eng4

 Support bracket

Additional
table

Micrometer tilting dog

Additional strip 500 mm

Additional strip 1000 mm

K006eng4 Description 4-15

 5.2 Hydraulic upper die clamping device

diaphragm
force plate
release spring

The above illustration shows the design of an hydraulic upper die

clamping device. Pressure applied to the diaphragm is transmitted to
the force plates, which in turn clamp the upper die.

As an option, the machine can be equipped with a hydraulic upper or

lower die clamping device.

Refer to chapter 5 for information on how to operate the device.

The upper die is equipped with a "Safety click" lock to prevent it from
falling out.

4-16 Description K006eng4

 5.3 Crowning (V axis)

Figure above shows a CNC crowning device

Crowning compensates for the deflection of table and beam during

bending in order to achieve a constant and precise angle over the
whole bending length.

K006eng4 Description 4-17

 The deflection is compensated for by two rails with inclined surfaces,
which are moved in longitudinal direction to obtain the crowning curve.

TrumaBend can be delivered in the following combinations:

• Table plate without crowning

• Crowning with manual central adjustment

Movement of wedges by crank

• CNC crowning
Automatic crowning using the control
However, the operator can also change the values
calculated by the control unit.

In contrast to manual crowning, CNC crowning gives

increased efficiency when processing a wide range of
products.

4-18 Description K006eng4

 5.4 Z1, Z2 Axis

The stop fingers can be adjusted in transversal direction by means of

the control unit. A symmetrical or non-symmetrical adjustment can be
programmed. If this option is used, manual adjustment of the stop
fingers from the front is no longer necessary.

On the rear of each Z-axis guide each gauge finger has its own drive
unit.

See chapter 7 in Operator Manual on how to program the Z1 / Z2-axis

5.5 6-axis rear stop

With the 6-axis rear stop the control unit is used for sideways
adjustment of the stop fingers (Z-axis), the adjustment of the work
direction (X-axis) and the adjustment of height. This can be carried
out symmetrically and asymmetrically, i.e. both stop fingers are
completely independent of one another. Manual adjustment is there-
fore not generally necessary.

K006eng4 Description 4-19

 5.6 Control systems

The standard machine is supplied with a Delem DA65 control unit.

• interactive control with 4 gray levels and a 12" monochrome screen

• quick and easy to program

• shop floor programming

• control components

arranged at the front (user friendly)

can be rotated (no long paths)

• upwardly-compatible

4-20 Description K006eng4

 Description of control systems DA65 and DA69

Control type DA65 DA69

Screen size 12" 12"

Screen color 4 gray levels color
Number of controllable axes 30 30
Memory capacity 2500 2500
program program
steps steps
90 90
Tools Tools
Program number 7-digit 7-digit
Computation of bending time yes yes
Computation of bending sequence yes yes
3-D visualization / programming no yes
Computation of pressing force yes yes
Computation of drawn-out length yes yes
Computation of bending radii yes yes
Number of bending repetitions max 99 max 99
Auto. embossing function yes yes
Preselection of no. of workpieces yes yes
Interface DNC-RS232 DNC-RS232
Data storage 3.5" disk HD 3.5" disk HD
Axis approach with handwheel yes yes

K006eng4 Description 4-21

 5.7 Programming systems

The TrumaBend can also be programmed via an external pro-

gramming system, independent of the machine.

The required programming software is PROFILE.

Versions: PROFILE is available in 2 Versions:

• Programming software PROFILE 2D

• Programming software PROFILE 3D

PROFILE is a modern CNC programming instrument. The CNC

controlling of the TrumaBend is easily programmable, while the
product is drawn in two or three dimensions. PROFILE calculates an
optimum bend sequence and prepares a CNN product program.
PROFILE consists of a machine and a die card file with which the
quick, automatic, interactive or manual bending sequence calculation
can be prepared.

System requirements: PROFILE runs on the following computer and operating systems:

• IBM compatible (min. 386) and PS/2

• MS-DOS Version 3.0 or higher compatible versions
• VGA monitor
• At least 540 K free RAM memory
• Parallel printer port
• hard disk station
• floppy disk drive 3.5“ (1.44 MB)

You require at least 2.4 MB free memory space on your hard disk to
be able to install PROFILE.

Data can be transferred to the machine via data cable or via diskette.

PROFILE components The PROFILE Software packet consists of the following parts:
• a 3.5“ 1.44 MB diskette
• software key (registered number)
• documentation

4-22 Description K006eng4

Programming software Advantages of the PROFILE 2D programming software:
PROFILE 2D
• Capacity similar to Delem DA65 control software

• 2D-visualisation

• Production time computation

• Computation of the blank lengths

• 2D collision monitoring

• High utilisation level of the machine, as it facilitates external

machine programming

Programming software Advantages of the PROFILE 3D programming software:

PROFILE 3D
• Contains the programming software capacity of PROFILE 2D

• 3D simulation
can be used for planning and tooling, as well as operator guidance
if complex parts are to be manufactured. This is recommended
when several tool stations are in use.

K006eng4 Description 4-23

 • 3D collision observance of the workpiece with the tool and the
machine
• Only one program is necessary for a 3D part
• High utilization level of the machine, as it facilitates external
machine programming

To convert DXF files in a 3D drawing you require the additional

TRUMPF option 3D graphic. Converting DXF files into a 3D drawing
requires the additional TRUMPF option: Programming Software DXF
Coonverter, ID.No. 846157.

4-24 Description K006eng4

 5.8 Operating station 2

Control panel 2 differs from control panel 1 in that neither of its key
switches Sick-light curtain nor its operational functions are present
(see chapter 5).

Depending on the key switch position in operating functions mode on

operating station 1 (see Chapter 5) there are the following options for
application:

Application in the case of Program-controlled switching (FD5=1) and monitoring in the safety
operation by one person control system makes it possible that the press bar (Y-axis) can
always be moved on one operating station only.
The functions on the keyboard can also be carried out, when the
operating station has not been activated.
This facilitates considerably faster tooling, specially if there are
several tool stations.

Application in the case of Operating mode 4-hand / 4-hand.

operation by two persons Monitoring the safety control system guarantees that in this operating
mode the press bar movement can only be activated if the two hand
pushbuttons of operating station 1 and operating station 2 are
actuated in view of the "simultaneousness".
Application e.g.: bending heavy or long pieces.
The functions on the keyboard can also be carried out if the
operating station has not been activated.

Application in the case of Operating mode 4-hand / foot.

4-hand / foot operation Monitoring the safety control system guarantees that in this operating
mode the press bar movement can only be activated if the two hand
pushbuttons of operating station 1 and operating station 2 are
actuated in view of the "simultaneousness". The foot switch of
operating station 2 is inactive during this operating mode.
From the MUTE point onwards the cycle ends if you actuate the foot
switch of operating station 1.
Application e.g.: bending heavy or long pieces.
The functions on the keyboard can also be carried out if the
operating station has not been activated.

Note on the Observe the permissible opening width.

4-hand / foot operation Vertical space of 8 mm between bottom edge of the machine
upperside and top edge of the machine lowerside. If the permissible
opening width is too small for bending sheets of a thickness of
> 6 mm, you may enlargen it by a maximum of the dimension of the
relevant sheet, as long as the width of the machine upperside does
not exceed the width of the workpiece or the parts of the tool
projecting over the workpiece width are covered.
This means that e.g. for a sheet thickness of 7 mm the maximum
permissible opening width is 15 mm.

K006eng4 Description 4-25

 Caution!

Observe the movement the work-

piece will perform in the course of
being bent.

3 1 Operating station 2

2 4 2 Keypad

3 Two-hand key

4 EMERGENCY STOP

5 Foot switch

The press bar is operated using the two-hand operating key or foot
switch depending on how the operating functions are set-up on
operating station 1 (see chapter 5).

4-26 Description K006eng4

 Operating panel and control elements on
operating station 2

Operating station 2 Front view:

TRUMPF

1 2

1 Keypad for various functions (description on the following page)

2 EMERGENCY STOP impact switch (pressing this button stops the

press brake immediately).

K006eng4 Description 4-27

 Explanation of control elements on operating
station 2

CONTROL ELEMENT EXPLANATION

Hydraulics OFF
This switch is used to turn the hydraulics system off. The pilot lamp
lights up to indicate that the hydraulics are switched off.

Hydraulics ON
This switch is used to turn the hydraulics system on. The pilot lamp
lights up to indicate that the hydraulics are switched on.

Error bridge button

If the hydraulics should switch off and the "Tilted press bar" fault
report is given then proceed as follows:
Press the error bridge and hydraulics ON button simultaneously and
the press bar will move to the upper end position and will be straight
again.

Upper die clamping device

This button releases or clamps the tool in the upper hydraulic die
clamping device. The lamp lights up to indicate that the upper die
clamping device has been released.

EMERGENCY RAISE button

When this button is pressed with "Hydraulics ON" the press bar
travels up to the upper dead center.
When this button is pressed with "Hydraulics OFF" the hydraulics
start first and then the press bar travels up to the upper dead center.
If operating station 2 has been selected, the lamp in the button lights
up if the START key is pressed.

Lower die clamping device

This button releases or clamps the tool in the lower hydraulic die
clamping device. The lamp lights up to indicate that the lower die
clamping device has been released.

Stop finger adjustment

Refer to section "Side adjustment of stop finger from the operators
side" chapter 5 / page 13 - 16.

4-28 Description K006eng4

 5.9 2nd foot switch

Function: The 2nd foot switch can be distinguished from operating station 2 by
the former only being able to trigger movement in the press bar. Other
functions cannot be affected.
The key switch on operating station 1 must be set to foot / foot mode
in order that the 2nd foot switch can be activated.

Employment of program-controlled switching and monitoring the

safety control system allow the press bar to be moved via just one
station.

FD5 = 0 Operating station 1 active

FD5 = 1 2nd foot switch active

If the lamp in the ON button on operating station 1 lights up, a stroke

can be triggered from this operating station.
If the lamp on the 2nd foot switch lights up, this indicates that the
press bar can from now on be moved via the foot switch.

NOTE: In addition to operating station 1, it is then only possible to use either

operating station 2 or the 2nd foot switch. The two may not be
employed together!

WARNING! The 2nd foot switch may only be used with one-man operation!

Advantages of the 2nd foot switch:

• flexible employment
• light
Indicator lamp

EMERGENCY STOP switch

Foot switch

K006eng4 Description 4-29

 5.10 Dies

The complete die and special die range is outlined in a die catalog.
• wide assortment of dies, short delivery times
• simple order procedure

As a standard feature, the work surfaces of all dies and the support
surfaces of all lower die clamping devices are hardened. The working
radii are laser hardened.
• long die life
• high level of machine repeatability

As a standard feature, all dies up to a length of 3.9 in (100 mm) are

supplied with a "Safety click".
• vertical change of the upper die is possible - fast and safe
• short set-up times

The dies are divided into various lengths.

• multiple die stations can be used
• time-optimized production
• flexible operation
• lower die costs

The upper dies can be accessed immediately.

4-30 Description K006eng4

 • lower die costs
• particularly cost saving for parting upper dies

Shoulder supporting dies can be used.

• Upper dies with high levels of utilization operate precisely
• Lateral stress that may occur during special shaping jobs
(for example, folding and compression jobs) does not adversely
affect the result.

Integrated safety lock that prevents the tool adapter from falling out.
The lock can be released by pushing a button.

K006eng4 Description 4-31

 5.11 SICK - LIGHT CURTAIN

5.11.1. Control panel 1 with optional Sick-light

curtain

Control panel 1 Front view:

ROBOT
TRUMPF

1 2 3 4

1 Key pad for various functions (description on page 5-5)

2 Key switch for selecting the individual operation modes of the

Sick-light curtain (description on page 5-5)

3 Key switch for selecting the individual operational functions

Hand / Foot, as well as combination possibilities (description on
pages 5-5 and 5-6)

4 Impact button E-STOP (When this button is pressed, the press

brake stops immediately).

4-32 Description K006eng4

 Description of the control elements on control panel 1

CONTROL ELEMENT DESCRIPTION

SICK-LIGHT CURTAIN:
Operating mode: 2-cycle.
(See chapter 4, 5.11)

SICK-LIGHT CURTAIN:
Operating mode: 1-cycle.
(See chapter 4, 5.11)

SICK-LIGHT CURTAIN:
! Operating mode: Protect mode.
(See chapter 4, 5.11)

SICK-LIGHT CURTAIN OFF

ROBOT Operating mode: Robot operation
(See chapter 4, 5.11)

4-hand / 4-hand operating mode

4-hand operation of rapid traverse and
work cycle

4-hand / 2-foot operating mode

4-hand operation of rapid traverse.
Work cycle operated by the foot
switches of control panel 1 and control
panel 2

Foot / foot operating mode

Rapid traverse and work cycle operated
by foot switch.

2-hand / 2-hand operating mode

2-hand operation of rapid traverse
and work cycle.

2-hand / foot operating mode

Rapid traverse by 2-hand switch, work
cycle by foot switch.

Setup mode is active!

Operating mode: Setup mode is active!
See chapter 7, part 3, point 1.2

K006eng4 Description 4-33

CONTROL ELEMENT EXPLANATION

"Pump not running"

Function "pump not running".

Hydraulics OFF
This switch is used to turn the hydraulics system off. The pilot lamp
lights up to indicate that the hydraulics are switched off.

Hydraulics ON
This switch is used to turn the hydraulics system on. The pilot lamp
lights up to indicate that the hydraulics are switched on.

Error bridge button

If the hydraulics should switch off and the "Tilted press bar" fault
report is given then proceed as follows:
Press the error bridge and hydraulics ON button simultaneously and
the press bar will move to the upper end position and will be straight
again.

Upper die clamping device

This button releases or clamps the tool in the upper hydraulic die
clamping device. The lamp lights up to indicate that the upper die
clamping device has been released.

EMERGENCY RAISE button

When this button is pressed with "Hydraulics ON" the press bar
travels up to the upper dead center.
When this button is pressed with "Hydraulics OFF" the hydraulics
start first then the press bar travels up to the upper dead center.
If operating station has been selected, the lamp in the key is lit up if
the start button has been pressed.

Bending aid
This switch turns the bending aid on.
See chapter 4 / 6.9. on how to program the bending aid.

Lower die clamping device

This button releases or clamps the tool in the lower hydraulic die
clamping device. The lamp lights up to indicate that the lower die
clamping device has been released.

Stop finger adjustment

Refer to section "Side adjustment of stop finger from the operators
side" chapter 5 / Page 13 - 16.

4-34 Description K006eng4

 5.11.2. Function description of Sick-light curtain

The Sick-light curtain is a protection device that works without

contact.

ROBOT
TRUMPF

ROBOT In this operation mode the Sick-light curtain is switched off so that it is
inactive and disconnected from the current.

Protect After switching off, the field of protection of the Sick-light curtain must
be interrupted once and acknowledged.
If the field of protection is free, a stroke can only be released again
when the Sick-light curtain has been acknowledged with the foot
switch of the selected control panel (1 or 2).

If the field of protection of the Sick-light curtain is interrupted during

the "rapid traverse" action of the press bar, the downward movement
of the press bar is stopped and the press bar is run up to the
uppermost dead point. Finally, acknowledge using the foot switch of
the selected control panel (1 or 2). Modes of operation can be set
using the press selection switch.

Note In foot/foot mode, the press bar stops on MUTE! Activating the foot
switch again completes the stroke.

Single cycle Whenever the mode of operation (Protect, Single cycle, Double cycle)
is changed, startup suppression is active. For this reason, the field of
protection must be interrupted once and reenabled. Subsequently, an
acknowledgement of the selected control panel must follow over the
foot switch, just as the Sick-light curtain must be acknowledged after
each time the machine is switched on.
If the field of protection is interrupted at the upper dead point and then
reenabled, the press bar starts automatically. If the field of protection is
interrupted during the "rapid traverse" motion of the press bar, the bar
will be stopped will return to the upper dead point. Finally, an
acknowledgement must be made using the foot switch of the selected

K006eng4 Description 4-35

 control panel (1 or 2).
From the point of MUTE, the foot switch must be used to proceed with
an operation.

Double cycle Whenever the mode of operation (Protect, Single cycle, Double cycle)
is changed, startup suppression is active. For this reason, the field of
protection must be interrupted once and reenabled. Finally, an
acknowledgement must be made using the foot switch from the
selected control panel. Subsequently, an acknowledgement of the
selected control panel must follow over the foot switch, just as the
Sick-light curtain must be acknowledged after each time the machine
is switched on.
If the field of protection is twice interrupted at the upper dead point and
then reenabled, the press bar starts automatically. If the field of
protection is interrupted during the "rapid traverse" motion of the press
bar, the bar will be stopped will return to upper dead center. Finally,
acknowledge using the foot switch of the selected control panel
(1 or 2).
From the point of MUTE, the foot switch must be used to proceed with
an operation.

Important! When using the Sick-light curtain with the support brackets (model
with Sick-light curtain) it is only functional in a vertical position.
When the Sick-light curtain is in a horizontal position, the support
bracket must be removed.

Pilot lamps Function of pilot lamps

a) Transmitter

LED Color Function

1 yellow Transmitter active
2 amber Operation indicator/voltage on

b) Receiver

LED Color Function

3 green Output active/protective area free
4 red Output inactive/protective area
broken
5 amber Dirt/fault
6 yellow Waiting for stroke
(only in conjunction with LCU-P)

4-36 Description K006eng4

 The light pulses (infrared) coded by the transmitter reach the receiver
where they are evaluated. The two FGS outputs are switched off to
shut down the machine when the protective area is broken by an
obstacle (> 14 mm). As soon as the protective zone is free the output
voltage is switched on again automatically.

Cleaning The transmitter and receiver windows are to be cleaned regularly

depending on local conditions. Otherwise the reflecting light can
become so weak due to dirt that this can lead to unintended shutdown
of the machine. Only soft and clean cloths should be used. Window
cleaning fluids such as Ajax are suitable.

Caution! The front window on the transmitter should only be cleaned with
mild substances. Do not use any substances which are
aggressive or cause abrasion! To prevent dirt forming again
quickly due to static charging the windows should not be
polished but just dried off.

K006eng4 Description 4-37

Alignment Alignment of transmitter and receiver
It is only guaranteed that the Sick-light curtain will function if the light
hits the receiver exactly. The light output received is reduced to such
an extent that when the light is too low an interruption is falsely
detected or even a small amount of dirt when there still sufficient light
has the same effect as an interruption.
Both result in a machine shutdown being triggered. To eliminate such
fault the transmitter and receiver must be aligned exactly with each
other.

Trimming Alignment
While a large degree of alignment is already given by the fixing
bracket, the mounting can be adjusted to give more trimming
freedom. This is to be done in the following way.
– Align the systems with each other
– Switch on power supply
– Turn the transmitter in both directions until the red LED on the
receiver lights up (green LED extinguishes). Take note of
position.
– Secure the transmitter in the middle of the swiveling range.
– Turn the receiver in both directions until the red LED on the
receiver lights up (green LED extinguishes). Take note of
position.
– Secure the receiver in the middle of the swiveling range.

When using the AR 60 laser alignment aid follow the procedure in the
accompanying manual.

Inspection! Daily inspection

The Sick-light curtain must be tested daily before production begins!
Before starting work, the testing rod supplied with the machine is to
be guided slowly within the protective area markings in the center
between the transmitter and receiving units and through the whole
protective area. Only the red pilot lamp should light up while this is
performed.

Important NOTE If the green or yellow pilot lamps light up at any point
then the machine must not be used any further.

4-38 Description K006eng4

Looking for faults Rectifying faults
The following table will help find and rectify faults. If this is not
successful then the TRUMPF Customer Services should be
consulted.

Acknowledgment: If the error has been corrected then it must be acknowledged with one
of the two-hand buttons (left or right button) on operating station 1,
see chapter 5, so that the command unit can be used to start the
system again.

Fault Possible cause Check and remedy

None of the LEDs on light up No voltage Connect voltage supply

Red LED lights up, yellow Transmitter does not transmit Test input open?
LED off after the supply voltage has
been connected

None of the LEDs on receiver No voltage Connect voltage supply

light up

Red LED on receiver lights System disaligned Check and possibly correct
up without protective area trimming
being interrupted or

Test input on transmitter open Close test input

or

Transmitter does not transmit Transmitter system fault

Dirt fault lights up constantly Fouling of transmitter and / or Clean front windows
on receiver receiver Check trimming

Flash interval 2x Transmitter fault

Flash interval 3x Receiver fault

Several LEDs flash System fault

simultaneously

K006eng4 Description 4-39

 5.12 ROBOT INTERFACE

NOTE The robot is connected to the press via the control system using the
same plug on the switch cabinet as that for the operating station with
foot switch. The operating station must be removed from the
press area.
Alternatively, a switchable robot interface is available, which remains
connected to the operating station.

Robot switch
in switch cabinet "0" The press bar travels with reduced speed in foot/foot mode.

Robot switch
in switch cabinet "1" The selector switch in the switch cabinet may only be switched to
position "1" when the press is operated by a robot.

The press must be specially secured when in robot mode, since there
is no two-hand operation. The press and the robot can for example be
secured with a fence. The responsibility for this falls to the user!

IMPORTANT! If these instructions are not observed, no liability will be

assumed for accidents or damage to the machine. Full respon-
sibility for this risk falls to the user (installer).

4-40 Description K006eng4

 6 Bending aid

6.1 Function description

The electromechanical bending aid supports the die during bending

operations by swivelling upwards according to the angle of bending.

The bending aid is employed to

- prevent the counter-bending effect when using thin sheets with

long limbs.
- relieve the operator of the load during bending operations,
especially where large or heavy loads are involved.

The bending aid is driven electromechanically. A CNC control unit is

used to provide exact co-ordination of the movements of the press
bar and bending aid. This results in a high repeatable accuracy.

K006eng4 Description 4-41

 6.2 Performance data

max. swivel angle 47°

max. weight of the die 100 kg

(with centre of gravity of die no more than 500 mm in
front of the bending line)

max. working speed approx. 45°/s

max. Y-speed with

Die width 6 mm approx. 2.5 mm/s
Die width 8 mm approx. 3.5 mm/s
Die width 10 mm approx. 4.0 mm/s
Die width 12 mm approx. 5.0 mm/s
Die width 18 mm approx. 6.5 mm/s
Die width 20 mm approx. 8.5 mm/s

Weight of bending aid per unit approx. 330 kg

6.3 Working ranges, dimensions

Possible dimensions of the lower dies

Adjustment range assuming lower die height of 100 mm:
-70 to +50 mm

Die height H min. 30 mm

max. 150 mm

Die width min. 6 mm

max. 70 mm

Supported limb length (standard) 1000 mm

Table width (standard) 275 mm

Max. workpiece mass in the front table length

extension area (with press bars) 10 kg

6.4 Additional apparatus

Standard The bending aid is provided as standard as the 1-arm version. The
addition of a second arm (2-arm version) can be carried out without
complications.
The bending aid is, in addition, fitted with side stops which are easily
activated.

4-42 Description K006eng4

 6.5 Centre of gravity of the bending aid

Centre of gravity

640

Xs

Machine type V85, V85S, V130 V170, V200

Xs 413 453

Mass per unit: approx. 330 kg

6.6 Transport and storage

A special device is provided for transportation and storage of the

bending aid.
CAUTION: The bending aid may not be transported without the transport device.
See point 6.5 for the centre of gravity of the bending aid.

K006eng4 Description 4-43

 6.7 Installing the bending aid

Mechanical a) Push the bending aid ( mounted on the assembly trolley ) to the
installation TrumaBend until the guide and rail are lined up with each other.
b) Secure the bending aid with 8 socket head screws (size 6) and lock
with Loctite 243 (torque: 24 Nm).
c) Remove the socket head screws (size 14) and push trolley away.

Note on setting (valid for initial assembly, maintenance and repair):

The two eccentric trunnion bearings (Pos. 2460) should be set in such
a way that all rollers always turn when the toothed quadrant moves
(Pos. 2240). The eccentric bearings must however not be set too
tightly. At standstill you should still be able to turn the rollers by hand.

Electrical installation d) Connect cables

The X12/13.1 and X12/13.2 (labelled) connectors lying loose at the

front of the machine (lower middle) as well as the two yellow
grounding wires (on a 2-pole terminal) are connected to the
bending aid as follows:

1-arm version:
- connect
X12/13.1 to X120.3
X12/13.2 to X120.5
- fit a PE conductor (yellow/green) on the PE terminal

2-arm version:
- connect
X12/13.1 to X120.3
X12/13.2 to X120.5
X120.4 to X130.4
X120.1/X120.2 to X130.1/X130.2
- fit the two PE conductors (yellow/green) on the PE terminal

Roll up any extra cable and attach to the front of the machine
(lower middle) using cable ties. Fit the cable cover.

e) Set the bending aid to the tool height (size 14)

6.8 Disassembly

Disassembly involves all steps under point 6.7 being carried out in
reverse order.

CAUTION: The bending aid may not be transported without the transport device.

4-44 Description K006eng4

 6.9 Control

If the bending aid is to be used as a support during bending

operations, this function must be selected via the DELEM control unit.
If working in automatic mode (when programming several working
steps), the operator must take into account the desired employment of
the bending aid.

Menu lines:

Bending aid.....PS = 0 (switched off)

1 (switched on)

See chapter 7 for appertaining program parameters.

In addition, the "Bending aid" button on operating station 1 must be pressed.

ROBOT
TRUMPF
Operating station 1
!

1 "BENDING AID" keypad on operating station 1

This switch is used to switch the bending aid on or off. The keypad
lights up when the aid is active.

Caution! The bending aid will only function when the bending aid is switched on
in the Delem control unit as well as on the keypad (operating
station 1)!
The bending aid cannot be controlled via operating station 2!

2-arm-version If a second arm is fitted it can be deactivated using the DELEM control
system:
01 bending aid arm 1 switched on, arm 2 switched off
11 bending aid arm1 and arm 2 switched on

The 2nd arm cannot be triggered on its own.

K006eng4 Description 4-45

 6.10 Adjusting the bending aid

Caution ! The bending aid must be adjusted to the height and die width of the
lower die - dial value (see (3) in 10.1). The dial value must correspond
to the die size.

The setting (dial scale) should be checked after each change of die.

6.10.1 Die width

2
3

1 - Adjusting spindle for die height

2 - Clamp mechanism for die height
3 - Adjusting head for die width
4 - Clamp mechanism for die width

4-46 Description K006eng4

 Adjustments are made by

- releasing the clamping mechanism (4)

- adjusting the die width on the adjusting head (3)

- tightening the clamping mechanism (4)

CAUTION! Ensure that the die width is not set too small!

6.10.2 Die height

Refer to picture from point 10.1

Adjustments are made by

- releasing the clamping mechanism (2) (tow screws)

- adjusting the height on the adjusting spindle (1).

Before carrying out checks, lay a ruler or flat sheet over the
table and lower die.

DANGER! When adjusting the height on adjusting spindle (1), you should on no
account reach between the dies. There is also a risk of injury from
potential collisions of the hand against the die. Ensure also that the
tool is removed after height adjustments have been made.

- Tightening clamping mechanism (4)

CAUTION! Ensure that both clamping screws are tightened securely.

K006eng4 Description 4-47

 6.10.3 Z-position
The Z-position is adjusted by shifting the bending aid by hand.
To do this:

- release clamping mechanism (2)

- push bending aid to the desired position

- tighten clamping mechanism (2).

DANGER! The bending aid may only be pushed and not pulled.

2 2

1 - Z-axis adjustment stop

2 - Z-axis adjustment clamping mechanism

4-48 Description K006eng4

 6.10.4 Side stop
The side stops can be retracted or extended by applying slight
pressure with the finger.

NOTE: To attain a higher angle accuracy, use stops as far apart as possible.

1 2

1 - activated

2 - deactivated

6.10.5 Park position (option)

To allow a corresponding clearance zone to be used in front of the
machine for a mounted bending aid (when the bending aid itself has
no use), it is possible to displace the bending aid 200 mm to the right.
This is made possible with the side installation of an additional
console.

K006eng4 Description 4-49

 6.10.5.1 Short park position

Console
Can be shifted up to 200 mm to the right

6.10.5.2 Park position

Can be shifted up to 920 mm to the right

4-50 Description K006eng4

 6.10.6 Table length extension /
table width extension
6.10.6.1 Table length extension (standard)

The front table length extension (with press bars) can be used as a
support for shorter limbs.

The front table length extension should be retracted after use.

DANGER! Ensure that the table length extension is not blocked. It should at all
times be able to swivel freely.

CAUTION! The front table length extension is provided exclusively for light
components with short limbs.

1 - Front table length

K006eng4 Description 4-51

 6.10.6.2 Table length extension /
table width extension (option)

Weight: a table length extension 4 kg

a table width extension 11 kg
combination 15 kg

4-52 Description K006eng4

 6.10.6.3 Option of machine table for bending
aid extension

4 clamping levers (two per side) for each machine table

Own weight of each machine table for bending aid extension: 13.5 kg

This is the weight the load capacity of the bending aid is reduced by
during application.

Assembly:
• Pull bending aid extension to the back until it reaches the back
stop.
• Fit machine table.
• Tighten machine table with all four clamping levers. Tighten by
pressing the clamping levers (in horizontal direction) and rotating
them at the same time.
• The clamping lever handles need to point downwards (pull out
and engage)
Disassemble in reverse order.

Note: Keep this option in its proper place outside the working range if you
are not using it - otherwise "Danger of Tripping".

K006eng4 Description 4-53

 6.11 Guide to safe operation

DANGER! When the bending aid is in use, the swivel movements of the table
can potentially cause damage through friction and thrusting forces.

The operator must ensure that the bending aid is in good working
order and that there is a sufficient clearance from the table.

The workpiece may slip towards the machine during upward

movement of the press bar.

6.12 Servo controller error indications

Display Ser.comm Malfunction

OU 1 Overvoltage. The D.C. link circuit voltage has exceeded

the maximum permitted level.

UU 2 Undervoltage. The D.C. link circuit voltage has fallen

below the minimum permitted level.

OC 3 Overcurrent. Current above 110 % of Ipk.

th 4 Excess temperature. Cooling element temperature

exceeds above maximum permitted level (95 °C).

rb 5 Resolver zero signal. Can also indicate a faulty connec-

tion or a wiring error.

lt 6 Drive operating within I²t range. When the integration

time has expired, the current output is temporarily
limited to Inom (output is not completely disabled).

PA 7 Temperature pre-alarm. Cooling element temperature

near to limit.

OS 8 Overspeed.

SC 9 Digital output short-circuit error. Reset by switching off

and on again.

Et 10 External trip element.

d0I 11 Drive operating incorrectly. Error can only be eliminated

by switching off and on. If this does not work please
consult TRUMPF customer service.

4-54 Description K006eng4

K006eng4
OPTIONS
In addition to the standard features, the machine can be equipped with the following options:

Variants with
V50 V85, V85S, V130, V170, V200 6-axis backgauge
Expanded machine equipment Expanded machine equipment Expanded machine equipment
Ambient conditioning package (oil/switch cabinet) Ambient conditioning package (oil/switch cabinet) Ambient conditioning package (oil/switch cabinet)
Speed-adjustable front support bracket Switch cabinet air conditioning (only with X versions) Switch cabinet air conditioning (only with X versions)
Work area lighting: Manual crowning, centrally adjustable Manual crowning, centrally adjustable
Additional 500 mm strip for support bracket CNC crowning CNC crowning
Connecting table for support brackets Height increase of up to 150 mm for installation and stroke Height increase of up to 150 mm for installation and stroke

7.
Tilt stop for front support bracket
Tool cabinet Expanded material handling Expanded material handling
Speed-adjustable front support bracket Speed-adjustable front support bracket
Expanded tool adapter and angular position measuring Front support, basic version with 1 arm Front support, basic version with 1 arm

Summary of options
system Table extension per front support arm, right or left Table extension per front support arm, right or left
"Modufix" hydraulic upper tool holder Table extension in X for basic table and additional tables Table extension in X for basic table and additional tables
Lower tool holder for single V dies with hydraulic clamp Work area lighting: Work area lighting:
Preparation for angle sensor system on the machine Additional 500 mm or 1000 mm strip for support bracket Additional 500 mm or 1000 mm strip for support bracket
ACB Connecting table for support brackets Connecting table for support brackets
Tilt stop for front support bracket Tilt stop for front support bracket
Configuration stages for stop system Tool cabinet Tool cabinet
Additional retractable gauge finger
CNC finger setting Z1/Z2 axis Expanded tool adapter and angular position measuring Expanded tool adapter and angular position measuring
Gauge finger with fine adjusting in X system system
Detachable finger for Z1/Z2 axis "Modufix" hydraulic upper tool holder "Modufix" hydraulic upper tool holder
Lower tool holder for single V dies with hydraulic clamp Lower tool holder for single V dies with hydraulic clamp
Configuration stages for operation Preparation for angle sensor system on the machine Preparation for angle sensor system on the machine
3D graphic control system DA69 with 12" VGA colour ACB ACB
display
Network card with BNC and RJ-45 connection Configuration stages for stop system Configuration stages for stop system
32 MB Flash additional memory Additional retractable gauge finger Additional retractable gauge finger
Second control panel, switchable with 4-hand backup CNC finger setting Z1/Z2 axis CNC finger setting Z1/Z2 axis
Additional foot switch Gauge finger with fine adjusting in X Gauge finger with fine adjusting in X
Description

Pivoting Sick-light curtain (not with front support) Detachable finger for Z1/Z2 axis Detachable finger for Z1/Z2 axis
Operation mode 1/2 cycle (only with Sick-light curtain)
Robot interface Configuration stages for operation Configuration stages for operation
3D graphic control system DA69 with 12" VGA colour 3D graphic control system DA69 with 12" VGA colour
display display
Network card with BNC and RJ-45 connection Network card with BNC and RJ-45 connection
32 MB Flash additional memory 32 MB Flash additional memory
Second control panel, switchable with 4-hand backup Second control panel, switchable with 4-hand backup
Additional foot switches Additional foot switches
4-55

Pivoting Sick-light curtain (not with front support) Pivoting Sick-light curtain (not with front support)
Operation mode 1/2 cycle (only with Sick-light curtain) Operation mode 1/2 cycle (only with Sick-light curtain)
Robot Interface Robot Interface
4-56 Description K006eng4
 Chapter 5

Operation

K006eng5 Operation 5-1

 Part 1: Control elements

1. Description of control elements

• Operating station 1
• Operating panel on operating station 1

1.1 Description of control elements on

operating station 1

1 Main switch
2 Operating station 1

5-2 Operation K006eng5

1 The power supply of machine and control system is switched on and
Main switch off with the main switch on the back wall of the press brake.

2 Control panel 1
with
two-hand switch and
3-position foot switch

1 Control panel 1
2 Key pad
3 Key switch optical safety device
4 Key switch operation mode selector
5 Impact button E-STOP
6 Two-hand switch
7 Foot switch with E-STOP function
8 E-STOP release

The beam is moved with the two-hand operation switch or with the
foot switch.
The 3-position foot switch has three positions: standstill, operation
and E-STOP.
The E-STOP function is released by pressing the foot switch at at
least 220 Nm (same function as with the impact button E-STOP).
The E-STOP function of the 3-position foot switch is released with the
button of the E-STOP release.

K006eng5 Operation 5-3

 1.2 Operating panel and control element on
the control panel 1

Control panel 1 Front view:

ROBOT
TRUMPF

1 2 3 4

1 Key pad for various functions (description on page 5-5)

2 Key switch for selecting the individual operation modes of the

optical safety device (description on page 5-5)

3 Key switch for selecting the individual operational functions Hand /

Foot, as well as combination possibilities (description on pages 5-5
and 5-6)

4 Impact button E-STOP (When this button is pressed, the press

brake stops immediately).

5-4 Operation K006eng5

 Explanation of control elements on operating
station 1

CONTROL ELEMENT EXPLANATION

OPTICAL SAFETY DEVICE

Operating mode: Protect mode.
(See chapter 4, 5.11)

OPTICAL SAFETY DEVICE OFF

ROBOT Operating mode: Robot operation
(See chapter 4, 5.11)

4-hand / 4-hand operating mode

4-hand operation of rapid traverse and
work cycle

4-hand / 2-foot operating mode

4-hand operation of rapid traverse.
Work cycle operated by the foot
switches of control panel 1 and control
panel 2

Foot / foot operating mode

Rapid traverse and work cycle operated
by foot switch.

2-hand / 2-hand operating mode

2-hand operation of rapid traverse
and work cycle.

2-hand / foot operating mode

Rapid traverse by 2-hand switch, work
cycle by foot switch.

Setup mode is active!

Operating mode: Setup mode is active!
See chapter 7, part 3, point 1.2

K006eng5 Operation 5-5

CONTROL ELEMENT EXPLANATION

"Pump not running"

Function "pump not running".

Hydraulics OFF
This switch is used to turn the hydraulics system off. The pilot lamp
lights up to indicate that the hydraulics are switched off.

Hydraulics ON
This switch is used to turn the hydraulics system on. The pilot lamp
lights up to indicate that the hydraulics are switched on.

Error bridge button

If the hydraulics should switch off and the "Tilted press bar" fault
report is given then proceed as follows:
Press the error bridge and hydraulics ON button simultaneously and
the press bar will move to the upper end position and will be straight
again.

Upper die clamping device

This button releases or clamps the tool in the upper hydraulic die
clamping device. The lamp lights up to indicate that the upper die
clamping device has been released.

EMERGENCY RAISE button

When this button is pressed with "Hydraulics ON" the press bar
travels up to the upper dead center.
When this button is pressed with "Hydraulics OFF" the hydraulics
start first then the press bar travels up to the upper dead center.
If operating station has been selected, the lamp in the key is lit up if
the start button has been pressed.

Bending aid
This switch turns the bending aid on.
See chapter 4 / 6.9. on how to program the bending aid.

Lower die clamping device

This button releases or clamps the tool in the lower hydraulic die
clamping device. The lamp lights up to indicate that the lower die
clamping device has been released.

Stop finger adjustment

Refer to section "Side adjustment of stop finger from the operators
side" chapter 5 / Page 13 - 16.

5-6 Operation K006eng5

 1.3 Operating panel DA65, DA69

1 11 2 12 3

?
13

0 I

10 9 7 8 4 6 5

1 Screen
2 Alphanumeric keyboard
3 Handwheel
4 Group operating modes
5 START pushbutton
6 STOP pushbutton
7 CURSOR keys
8 ON-LINE-HELP button
9 RETURN TO PREVIOUS PLANE key
10 SOFTKEYS
11 Delete key
12 Enter key and teach-in function
13 EMERGENCY-STOP pushbutton

A detailed description of all operating devices is to be found in

chapter 7 - operating instructions DA65, DA69 (chapter 1 operating
and indicator devices).

K006eng5 Operation 5-7

 Part 2: Work examples

2.1 Turning on and starting press brake

• Close or position all protective covers.

• Unlock EMERGENCY STOP button.

• Turn on compressed air supply.

• Turn on main switch.

• The fail-safe control carries out a safety check. After approx.

30 sec. the safety check is completed (signaled by the lamp in the
EMERGENCY STOP switch lighting up).

• Press the "Hydraulics ON" button on operating station 1, the

press bar is moved to the upper reverse point.

• Press the "I" key on the control.

All axes except Y1 and Y2 are calibrated automatically.

To avoid collisions the tools fitted have to correspond with the

currently programmed X-axis and R-axis position.

• Close upper and lower die clamping devices (see chapter 5,

page 5-6)

• Move the press bar up using the two-hand button or the foot switch
(depending on the operating mode).
The first upwards movement after the press brake is turned on is
used to calibrate the press bar. The message "Brake distance
O.K., press Start to continue" will appear.

5-8 Operation K006eng5

 2.2 Turning off the press brake

2.2.1 Turning off in emergencies

Lock EMERGENCY STOP impact button on the control unit or
operating station 1.

2.2.2 Turning off at end of work

Procedure:
• Put protective workpiece between the dies lower press bar:
approx. 7 mm

narrow sheetmetal strip as

off-time tool protection

• Press STOP button on the operating panel of the control

manufacturer.

• Turn hydraulic system off with HYDRAULICS OFF key.

• Turn main switch on rear of machine to "0" position.

K006eng5 Operation 5-9

 3. Fitting tools

The TrumaBend V series press brakes are equipped with a manual

die clamping device as standard. A hydraulic die clamping device is
available as an option.

Both versions of the die clamping device are self-centering, i.e. the
tool does not have to be aligned with an idle stroke.

The stop and the clamping surface of the tools must be clean.

Symmetrical TRUMPF lower dies have a marking on one side.

The die should be fitted so that this marking is at the front

1 Marking
2 Clamping shoulder

5-10 Operation K006eng5

 3.1 Manual die clamping

Conditions
• The machine is ready for operation
• The machine has a manual die clamping device

Procedure
• Loosen the inner hex screws on the clamping strip.
• Position the upper die by pushing it in vertically (tools with "Safety
Click") or pushing in the side to the required position.
• Fix the dies by tightening the inner hex screws.

Before press bar start-up, the operator must ensure that the dies
are securely fixed.

K006eng5 Operation 5-11

 3.2 Hydraulic die clamping device

Conditions
• The machine is ready for operation

• The machine is fitted with a hydraulic die clamping device

Procedure
• Open press bar using UP button on operating station 1 far enough
for the dies to be positioned easily.

• Open the die clamping device using upper or lower die clamping
device button. The lamp (upper die clamping or lower die
clamping) will indicate: clamp released.

• Move the dies into the required position in the die tool adapter.

• Press the upper or lower die clamping device button, the lamp
(upper die clamping or lower die clamping) will extinguish and
indicate: die clamped.

5-12 Operation K006eng5

 4. Z1/Z2-Axis

4.1 Adjustment of the stop finger with

manual Z1/Z2 axis

Conditions:
• The machine is ready for operation.

Procedure
• Press the stop finger adjustment switch and keep depressed. The
control automatically switches to STOP. On the control screen the
"stop finger adjustment active" message appears.

• Push START key. The press bar will move into the programmed
safety measurement position which depends on the dies. The rear
stop moves to a position where the stop fingers stick out of the
throat of the machine by 120 mm. The control switches to STOP
again.

• Release the stop finger adjustment key. The stop finger holder is
now open.

• Position the stop fingers.

• Press the START key. The pneumatic stop finger holder closes
and the rear stop moves to the programmed position.

When error messages "Conflict between R-axis and die" or

"Opening between the tools too small" appear, the rear stop will not
move to the programmed position. In this case, the operator must
compare the tools being used with the programmed parameters
and change them if necessary!

K006eng5 Operation 5-13


Caution!
The machine operator should make sure that the support
consoles including assembled accessories are at a sufficient
distance from the stop finger adjustment position.
Disregarding this requirement can seriously damage the
support consoles including accessories (side stop, tilt stop
with micrometer stops, bending aid) or the stop fingers.

Guideline
When using self-made or other types of stop finger which are
not original TRUMPF parts, the control executes no collision
observance procedure. TRUMPF assumes no liability in the
case of any collision, or injuries to personnel if this guideline
is disregarded. If a special product application requires the
stop finger to be modified, TRUMPF must confirm your
modification proposal in writing.

5-14 Operation K006eng5

 4.2 Adjusting stop fingers with CNC
controlled Z1/Z2 axes

The side adjustment of the stop fingers is not required if this option is
used.

The desired positions of the stop fingers must be programmed in the

control unit. The programming procedure is described in chapter 7
(operating manual of the control unit manufacturer).

4.3 Adjusting stop finger with 6-axis rear stop

It is not necessary to position the stop fingers manually in this case

either. All positioning movements can be programmed in the control
unit. the stop fingers can be positioned in all six axes independently
from one another (see ➤ chapter 7, part 3, 6-axis rear stop). A
collision is not possible.

4.4 Detachable stop finger with CNC

controlled Z axis at 4-axis rear stop

The detachable stop finger is installed with a 4-axis rear stop in

combination with a CNC Z axis system with every TrumaBend. The
simultaneous use of several stop fingers is possible. This can be used
if necessary.
When working with long and thin sheet metal it is particularly useful to
use the detachable stop finger to prevent the workpiece from sagging.

K006eng5 Operation 5-15

 Star grip clamp
release

Detach the stop finger by releasing the star grip. The star grip is
tightened until "unlock" after positioning to the desired location.

Important operating The detachable stop finger must be either positioned within the
instructions! motorised stop finger or removed before the machine is switched on
(main switch), as otherwise a reference error appears.

Safety! The stop finger must not be positioned at the front (in the centre
reached through in the pressure bar area).

Errors, cause and remedy

Error Possible cause Remedy

X1 axis not in Detachable stop finger posi- Switch off machine main switch. Remove
position tioned left of Z1 or right of detachable stop finger.
Z2 axis.

Pressure bar does Z1 or Z2 CNC stop finger Stop machine (press stop button of the
not move down cannot reach the program- control)
med position, as it is Push detachable stop finger out of the
stopped by the detachable collision area.
stop finger. Move Z1 or Z2 into desired position.

5-16 Operation K006eng5

 4.5 Gauge finger with micrometer
adjustment

There are three different models of gauge finger with micrometer

adjustment. They are described in the following.

They can be used only with the 4-axis backgauge system!

Simultaneous use of several gauge fingers is possible. They can be
used as needed.

They are ideal for processing sheet metal with indentations. The
traversing distances are limited to +/- 15 mm.

minus direction plus direction

8
9
15 10 5 0 5 10 15 0
1
2

position display micrometer screw

one increment line one increment line
= 1 mm = 0,05 mm

15 10 5 0 5 10 15
To set the millimetres (millimeters),
bring the increment line of the scale
even with the white mark

marker for zero position or

VIEW X
plus/minus adjustment turned 90°

Turn the micrometer screw Turn the micrometer screw

to the left to the right
The gauge finger is adjusted The gauge finger is adjusted
in the minus direction in the plus direction

Positioning the gauge finger and turning the micrometer screw can
only be done from the rear of the machine and never from the front
(by reaching into the press bar area)!

K006eng5 Operation 5-17

 4.5.1 Micrometer gauge finger for
CNC Z1/Z2 axis
This gauge finger cannot be clamped on vertically.
Exact adjustment by a service technician is required for retrofitting!

Error messages, causes and remedy

Error (message) Cause Remedy

Gauge finger Possible causes: Move back to the initial position with the
collides with X axis.
lower die Gauge finger was placed Then either place the micrometer finger
too far forward. in the zero position or move the R axis
into the positive range.
R axis is in negative range. After a collision, the set position of the
micrometer screw must be checked and
the lower die must be loosened and then
re-tightened.

I axis not in position Possible causes: Move back to position 1 with the I axis.
Then either place the micrometer finger
Gauge finger was placed in the zero position or move the R axis
too far forward. into the positive range.
R axis is in negative range. After a collision, the set position of the
micrometer screw must be checked and
Traversing of the I axis from the lower die must be loosened and then
position 1 to position 2. re-tightened.

5-18 Operation K006eng5

 4.5.2 Clamp-on micrometer gauge finger for
CNC Z axis
Important comment regarding Before the machine is switched on (main switch), the clamp-on micro-
the operation of the machine! meter gauge fingers must either be positioned inside the motorised
(motorized) gauge finger or be removed, or else a referencing error
occurs.

Star handle clamp

loosen

Clamp on the gauge finger by loosening the star handle.

After positioning at the desired position, the star handle is tightened
until it "unlocks".

Error messages, causes and remedy

Error (message) Cause Remedy

X1 axis not in Clamp-on gauge finger Switch off main machine switch.
position positioned to the left of Z1 Remove clamp-on gauge finger.
or to the right of Z2 axis.

K006eng5 Operation 5-19

 Error (message) Cause Remedy

Press bar does not Z1 or Z2 CNC gauge finger Stop machine (press stop button of the
move downwards cannot reach the control system).
programmed position Push clamp-on gauge finger out of the
because it is stopped by the collision area.
clamp-on gauge finger. Move Z1 or Z2 to the desired position.

Gauge finger Possible causes: Move back to the initial position with the
collides with X axis.
lower die Gauge finger was placed Then either place the micrometer finger
too far forward. in the zero position or move the R axis
into the positive range.
R axis is in negative range. After a collision, the set position of the
micrometer screw must be checked and
the lower die must be loosened and then
re-tightened.

I axis not in position Possible causes: Move back to position 1 with the I axis.
Then either place the micrometer finger
Gauge finger was placed in the zero position or move the R axis
too far forward. into the positive range.
R axis is in negative range. After a collision, the set position of the
micrometer screw must be checked and
Traversing of the I axis from the lower die must be loosened and then
position 1 to position 2. re-tightened.

5-20 Operation K006eng5

 4.5.3 Micrometer gauge finger for manual
Z axis
Assembly note The micrometer gauge finger is pushed on the left side of the machine
onto the guide rail (Z axis). For assembly, the finger stop sheet must
be loosened and turned to the side. The micrometer gauge finger can
then be pushed onto the guide rail. The finger stop sheet must then be
re-mounted. Otherwise there is a danger of collision!
Important When pushing on and removing the micrometer gauge finger, the
plastic insert in the guide carriage must be used or else the guide
carriage will be damaged.
Use is possible in any combination because the micrometer gauge finger
can be mounted either to the side or between the standard fingers.

Error messages, causes and remedy

Error (message) Cause Remedy

Gauge finger collides Possible causes: Move back to the initial position with the
with lower die X axis.
Gauge finger was placed Then either place the micrometer finger
too far forward. in the zero position or move the R axis
into the positive range.
R axis is in negative range. After a collision, the set position of the
micrometer screw must be checked and
the lower die must be loosened and then
re-tightened.

I axis not in position Possible causes: Move back to position 1 with the I axis.
Then either place the micrometer finger
Gauge finger was placed in the zero position or move the R axis
too far forward. into the positive range.
R axis is in negative range. After a collision, the set position of the
Traversing of the I axis from micrometer screw must be checked and
position 1 to position 2. the lower die must be loosened and then
re-tightened.

K006eng5 Operation 5-21

 4.6 1000 mm gauge finger

These gauge fingers enable the maximum stop range to be increased

from 860mm (see Chapter 4.1 page 4-3) to 1000 mm.

Note After installation, the control system parameters in menu 11 must be

modified in programming mode, as laid out in Chapter 7, Part 2/9.5,
Gauge finger measurements.

Important Stop position 2 cannot be used with these gauge fingers, since it is an
inclined plane which cannot however be represented in the control
system.

1000 mm
Standard
Parameter backgauge
finger
finger

Stop positions 3 4
Put on default 1 1
Stop R offset 0 0
Finger breadth 76 mm 76 mm
Finger height 8 mm 8 mm
Finger length 30 mm 30 mm
Gauge height H1 25 mm 25 mm
Gauge height H2 0 mm 0 mm
Gauge height H3 53 mm 54 mm
Gauge length L2 260 mm 136 mm
Gauge height H4 Not applicable 63 mm
Gauge length L3 Not applicable 400 mm

5-22 Operation K006eng5

 5. Avoiding collisions

In the following diagram the gray shadowed region of the press table
is not collision monitored by the control:

Y
x SN

1 Workpiece SN Safety X-axis

2 Die X Die / press bar gap
3 Press table Y Stop finger safety gap
4 Stop finger

If a negative R-axis position is required for a bend then a safety gap is

has to be programmed into the control (see ➤ chapter 7, 3.4 Drawing
lower dies, changing lower die data, page 2-18 until 2-25).

Caution!
If you disregard this instruction, TRUMPF assumes no
liability for any damages that result from collision.

K006eng5 Operation 5-23

 Collisions can occur when bending operations are performed with
lower tools that have a narrow V groove:

Caution!
If you disregard this instruction, TRUMPF assumes no
liability for any damages that result from collision.

5-24 Operation K006eng5

 6. Crowning

6.1 Manual crowning

Condition:
• The machine is ready for operation.
• The machine has a manual crowning device with central
adjustment.

Crowning value indicator

Procedure:
Adjust the crowning device by turning the crank. One turn increase or
reduces the height of the crowning curve by the following
measurement depending the machine type:

Machine type Crowning curve height

V85, V85X, V85S 0.024 mm
V130, V130X 0.036 mm
V170 0.060 mm
V200 0.090 mm

K006eng5 Operation 5-25

 6.2 Crowning curve height

Condition:
• The machine is ready for operation.
• The machine has a CNC crowning device.

Drive

Procedure:
❏ For machines with CNC control, the required crowning value is
calculated automatically (see ➤ chapter 7, Machine parameters,
page 2-94)
❏ If required, correct the proposed value by overwriting the
suggested value. For control units DA65 and DA69, the crowning
value BM is read off on menu page 1 in manual operation or on the
programming mode menu.

5-26 Operation K006eng5

 7. Flattening

A wide range of folded products can be produced with the available

accessories for flattening from Trumpf (see Trumpf tool catalogue)
and the I axis.

Possible tool arrangements

for flattening A B C

The drawing above shows the principal possibilities and functions.

A folding is produced in two working steps. In the first operating cycle
an angle of 30° is edged. The I axis then moves in the flattening
position. The flattening is carried out in the second working step.
The Trumpf accessories for flattening can be used in a variety of
ways.
Version A Untreated and stainless steel up to 2 mm thick
Products with long limbs
(long support area)

Version B Untreated and stainless steel up to 1 mm thick

Flattening with low capital expenditure
(Waste of tool support)

Version C Untreated and stainless steel up to 2 mm thick

Products with a special geometry

Example for "version C"

Advantage of flattening method C:

Flattening of workpieces with several edges and a special geometry

K006eng5 Operation 5-27

 7.1 Setting various translation paths for
the I axis

1 2 31
1 Fixed stop set at the factory 3 Spacer
2 Swivelling piece

The appropriate spacer must be set up for each size of single V die used:

Tool Spacer
EV001 30 mm
EV002 30 mm
EV003 30 mm
EV004 27.5 mm
EV005 25 mm
EV006 22.5 mm
EV007 20 mm

"Changeover of I axis working range"

procedure

Initial position

Spacer can be exchanged if In this position the workpiece can

necessary be edged with an angle of 30°.
Swivelling piece setting:
"rear flattening":

5-28 Operation K006eng5

 Release swivelling piece

Initial position for "swivelling The workpiece can be flattened

piece" change of position. with the "rear flattening" method in
this position.

Swivelling piece swivels

up 90°

Tools can be changed

Release and remove spacer

Apply swivelling piece

Tools for "front flattening" are set.

K006eng5 Operation 5-29

 Apply spacer

Move I axis in the direction The workpiece can be edged with

of the pressure bars an angle of 30° in this position

I axis up to stop
Move spacer

The workpiece can be flattened

with the "front flattening" method in
this position.

7.2 Programming with the DA65 and DA69

control

There are 2 bending methods available for flattening.

1. "Flattening"
2. "Flattening with bottoming"

The press bar control is path-dependent for the "flattening" method of

bending.
The control of the press bar (lower stop point of the upper die) takes
place with the help of the programmed force of pressure for the
"flattening with bottoming" method of bending.

5-30 Operation K006eng5

 • No flattening offset [OF] can be programmed with the "flattening
with bottoming" method of bending.

OF
OP

OP Flattening opening
OF Flattening offset

Creating program for "flattening bending method"

The flattening offset and the flattening opening can be programmed in

menu 11, menu page 11.3.

A side spacing can be programmed with the flattening offset

parameter.
The parameter flattening opening is only an active second stop point
of the press bar with the flattening function.

• First stop point: ............... switch from rapid reverse in work cycle
• Second stop point:.......... before start of flattening

DATEN

11.3

K006eng5 Operation 5-31

 The programming of single working steps (edges) takes place in
menu 3 or modifications in menu 4. Hand operation occurs in the
same way. However the programming steps are not carried out in
menu 3 or 4 but in the hand operation mode.

Bend 1 is programmed as a normal 30° air bend.

Programming for the I axis position:
Version A,B ("rear flattening") 2
Version C ("front flattening") 1

Bend 2 is programmed with the parameter flattening method, BM=10.

The symbol (flattening) appears next to the Y position parameter.
Programming for the I axis position:

Version A,B ("rear flattening") 1

Version C ("front flattening") 2

10

BIEGEPOSITION Y 300

PROGRAMMEINGABE

3.3

5-32 Operation K006eng5

 Program creation for "flattening with bottoming" method of bending.

The flattening opening is programmed in menu 11, menu page 11.3.

The desired bottoming force [BF] is programmed in menu page 11.3
as well.

The programming of single working steps (edges) takes place in

menu 3 or modifications in menu 4. Hand operation occurs in the
same way. However the programming steps are not carried out in
menu 3 or 4 but in the hand operation mode.
Bend 1 is programmed as a normal 30° air bend.
Programming for the I axis position:
Version A,B ("rear flattening") 2
Version C ("front flattening") 1

Bend 2 is programmed with the parameter flattening method, BM=11.

The symbol (bottoming) appears next to the Y position parameter.
Programming for the I axis position:
Version A,B ("rear flattening") 1
Version C ("front flattening") 2

Caution

FH
FH

Observe that the parameter FH is programmed in menu 7 (upper die)

and in menu 8 (lower die).

K006eng5 Operation 5-33

 8. Programming instructions for
coining
Coining short workpiece lengths
The minimum press force of the press brake is 10 % of the maximum
press force and cannot be less than this.
Example: TrumaBend V170: press force 170 t, minimum press
force: 17 t

When coining, it must be ensured that the calculated coining force is

greater than the minimum force of the press brake. If this is not the
case (for example with short bending lengths), the following
procedure must be carried out:

Apply the penetration depth (Y position) calculated by the control

system and reduce this by the sheet thickness of +0.3 mm. This is
possible in the programme change or in automatic mode as Y-axis
correction.
Check the angle that is created by this setting and increase the Y-axis
corrective value to 0.05 mm steps if necessary, until the desired angle
accuracy has been reached.

Adapting the penetration

depth in the programme
change

5-34 Operation K006eng5

 Adapting the penetration
depth in automatic mode

K006eng5 Operation 5-35

 9. Additional comments regarding the
operation of the machine

9.1 Loosening of the hydraulic upper die

clamping device in case of error

During normal operation of the machine, the 2/2 way valve (pos. 30)
releases the hydraulic upper tool clamping device by emptying the
hydraulic accumulator (location see chapter 6-5, pos. 10). (The dia-
grammatic view of the hydraulic system can be found at the end of
this chapter.)

If the valve pos. 30 does not open due to a fault then the hydraulic
accumulator can be emptied, or the hydraulic upper die clamping
device be released, by turning the safety valve hand wheel (pos. 70):

The hand wheel should be turned back fully after the fault has been
corrected.

5-36 Operation K006eng5

 9.2 "Swivel downwards" the bending aid
when the ACB® angle sensor is used
®
If workpieces are bent while using the ACB angle sensor and the
bending aid, the following must be observed:
®
If the sensing disks of the ACB angle sensor are gripping and the
bending aid swivels into the start position, it can damage the sensing
disks.

For this reason the bending aid swivels into the start position in two
steps when swivelling (swiveling) downwards. The first step takes
place automatically. The bending aid swings back to a programmed
(e.g. 12°) safety angle and stops. The operator can then check visually
whether continuing the swivelling (swiveling) motion can damage the
®
sensing disks of the ACB angle sensor. The swinging down
procedure is continued by:

Operating mode Operating procedure

2 hand / 2 hand Press 2 hand buttons

2 hand / foot Press 2 hand buttons
foot / foot Press foot button

Entering the Switch main switch on.

safety angle
Change to the machine parameter menu (menu 19).

Enter supplementary code (14753).

Select point 2 (auxiliary axes) in the machine parameter menu.

Call up auxiliary axis 9 and press the "Other parameters" softkey.

Enter an angle between 0° and 24° in the parameter "Safety stop

angle" (menu page 19.91). The value 11° has proven itself in practice.

K006eng5 Operation 5-37

 9.3 Error message "Filter dirty, hydraulics
stopped"

If the error message "Filter dirty" appears on the screen of the control
system, the machine switches off after 30 minutes. The message
"Filter dirty, hydraulics stopped" appears.
• Switch off the main switch of the machine and secure it against
unauthorised (unauthorized) restarting.
• The filter element of filter HH 98 00 C20 KNSBM must be changed
and the filter housing and bypass valve must be checked.

Filter HH 98 00 C20 KNSBM

Attention! It is not allowed to clean the element. It must be replaced.

A detailed description of the procedure for filter element replacement

can be found in the appendix of this Operator's Manual.

• The press brake can be restarted by switching the main switch off
and then on.

5-38 Operation K006eng5

 Chapter 6

Maintenance

K006eng6 Maintenance 6-1

 1. General Guidelines
Proper maintenance is required to maintain the quality of the
machine. It prevents machine failures and their consequences. It is
important to observe the following maintenance guidelines.

Prior to start-up Before start-up, lubricate the machine carefully according to the
lubrication plan. If the machine is not run for an extended period (for
example during overseas transportation), you must check the entire
machine for lubrication. Remove any hardened oil from all lubrication
points and hoses.

Cleaning instructions Clean the entire unit at regular intervals. Sweep, or vacuum off any
rough dirt with an industrial vacuum.

The cylinder pistons must be lubricated when cleaning the machine.

Lubrication is also necessary if a whistling noise is heard. Remove the
acrylic cylinder cover and move the press bar to the lower end
position. A suitable grease can be obtained from TRUMPF (order
no. 822847).

Lubrication instructions The lubrication plan, and the descriptions accompanying the plan,
apply to machine lubrication. We recommend the following points:

· Make sure that filling and draining seals are not open longer than
necessary. Keep all filling and draining seals clean.
· Use only lint-free cleaning cloths for cleaning oil spaces and
lubrication points. Never use steel wool, petroleum or Benzol. Use
a thin, liquid spindle oil (cleaning oil).
· Drain old oil only when it is warm from operation.
· Make sure that old oil is removed and disposed of correctly.

Safety instructions Switch off using the main switch and secure the machine before any
maintenance work is undertaken, unless the operating manual states
otherwise.
The safety instructions (chapter 1) must be strictly observed to avoid
accidents.

6-2 Maintenance K006eng6

 2. Maintenance Overview

MAINTENANCE LOCATION PROCEDURE INTERVAL hrs

2 hydraulic-oil level indicator check oil level 8

3 hydraulic-oil filter observe text message on 8

control display

4 safety switch on the protective covers check functioning 8

5 air pressure filter with water separator drain condensate 40

6 tool adapter, upper and lower clean 40

7 fixing strip on stop finger adjustment clean 40

(Z-axis)

8 support console guide clean 40

16 gear rack/pinion (X and Z axes) clean and oil 40

9 tapped rod lower tool adjustment (I-axis) oil 500

hydraulic – oil filter
3 oil filter change 500

10 hydro accumulator-upper tool clamping check pre-pressure 500

(Modufix)

11 control (operator's panel) clean filter 500

12 ballscrew unit on X axis lubricate 500

13 ballscrew unit on R axis lubricate 500

14 ballscrew unit on Z axis lubricate 500

15 ball lead screw lubricate 500

17 R axis toothed belt check 500

18 X axis stop (not necessary for 6-axis visually inspect position 500
rear stop)

K006eng6 Maintenance 6-3

MAINTENANCE LOCATION PROCEDURE INTERVAL hrs

21 brake sheet – stop finger (only with manual lubricate 500

finger positioning on the Z axis)

19 hydraulic hoses inspect 2000

3 hydraulic oil filter oil filter change 5000

oil analysis

3 hydraulic oil filter oil filter change 10000

oil analysis

20 X axis drive and Z axis drive oil change 10000

3 hydraulic oil filter oil filter change 15000

oil analysis

3 hydraulic oil filter oil filter change 20000

oil analysis

1 hydraulics oil change 20000

22 Fail safe control system PSS 3056 Battery change 3 years

23 DA control system Battery change 3 years

Lubrication chart – Explanation of Symbols

Lubrication interval data in operating hours Monitor oil level, if necessary

fil to proper level

Read lubrication and access

position descriptions in the Check oil level
operators manual descriptions

Empty container here:

Lubrication via grease gun (oil gun)
drain condensate separator

General lubrication via oil can Exchange container contents

or spray can

Fig. 4541

6-4 Maintenance K006eng6

 3. Lubrication and Maintenance Plan

40

5 4 4 1 10 9 6 8 11

Fig. 600

K006eng6 Maintenance 6-5

6-6 Maintenance K006eng6
 TRB V50, V85, V130, V170

K006eng6 Maintenance 6-7

 TRB V50, V85

6-8 Maintenance K006eng6

 TRB V130, V170

K006eng6 Maintenance 6-9

 Option Z1, Z2 CNC-controlled at V50 / V85

6-10 Maintenance K006eng6

K006eng6
10000

14 16 20 14 13 20 15 16 13 16 12 20 16

6-axis rear stop

Maintenance
6-11
 4. LUBRICATION PRODUCT TABLE

NO. LUBRICATION QUAN- RECOMMENDED LUBRICANT * DESIGNATION VISCOSITY

POINT TITY

1 hydraulics Aral Vitam DE 46 CL, HL, HLP, ISO VG 46

BP Energol HLP-D46 HLPD
V50 80 l Castrol Hysping AWH-M 46 (for initial
fill-up)
V85 200 l ELF Elfolna HMD 46
V85S 200 l Esso HLPD-Oil 46
V130 250 l Fuchs Renolin MR 15
V170 350 l Mobil-Hydraulikoil HLPD 46
V85 with extended 200 l SHELL Tellus Oil DO 46
installation height

9 tapped rod for lower ARAL Degol BG 220 CG, CLP, CGLP ISO VG 220
tool shift (I axis) ARAL Deganit B 220
BP Energol GR-XP 220
BP Maccurat 220 D
CASTROL Alpha SP 220
21 brake sheet-finger CASTROL Magna CTH 220
stop (only with ELF Reductelf SP 220
manual finger ELF Moglia 220
adjustment of the ESSO Spartan EP 220
Z axis, not with CNC ESSO Febis K 220
control) FUCHS Renep Compound 106
FUCHS Renep 220 K
MOBIL Mobilgear 630
MOBIL Vactra Oil Nr. 4
MOBIL Bettbahnöl 220
16 gear rack, SHELL Omala Oil 220
pinion SHELL Tonna Oil T 220

15 ball lead screw SHELL Alvania EP2 KP2K – 20 NLGI 2

BP MOBIL Mobilux-EP2
12 ballroom axis for
X axis
13 ballroom axis for
R Axis
14 ballroom unit for
Z axis
20 X and Z axis drives 0.075 l Fuchs RENODIOL PGP 68 PG68 ISO VG 68
Castrol Alphasyn T68 Synthetic oil

ELF Syntherma P55

20 X and Z-axis gear 0.035 l Fuchs RENOLIN PG 220 PG220 ISO VG 220
V130 and V170 All Aral Degol GS 220 Synthetic oil
6-axes backgauges BP Energol SG-XP 220
Klüber Klübersynth GH 6-220
Mobil Glygoyle 30 / Glygoyle HE220
Molyduval Syntholube G 220 EP
Optimol Optiflex 220
Shell Tivela Öl WB (PG220) 220
Tribol 800/220

6-12 Maintenance K006eng6

 This table gives a list of quality lubricants. We recommend the use of those
products listed, or other lubrication products of equal quality from other
mineral oil companies for lubricating the machine.
Do not mix different kinds of oil!

F Caution!
A double ladder must be used for maintenance work
where a ladder is required.
The oil temperature may be up to 80 °C if oil change
or other maintenance work is performed immediately
after machine operation.

K006eng6 Maintenance 6-13

 5. Notes on the Lubrication and
Maintenance Plan

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE

NO. (OPERATING INSTRUCTIONS
HOURS)

1,2 8 check oil level

Hydraulics oil level must be between the upper and lower
markings on the oil level indicator

5000 oil analysis by oil service dept. of mineral oil

company

20000 oil change

perform oil change

· attach a hose to the drain port to allow oil to
be collected in a container
· only refill with the same oil brand just used
· in order to pump new hydraulic oil from the oil
container to the oil tank, TRUMPF supplies an
optional oil pump with integrated filter. This
pump is operated with the help of a drilling
machine.

Caution!

When hydraulic oil is filled into the oil tank, it

must first be pre-filtered with a filter rating
level of 0.003 mm.

Oil that is not pre-filtered can destroy the

hydraulic unit!
All warranty agreements are then null and
void!

Only refill with the same brand of oil just used.

For more information, see: Maintenance of

hydraulic machine components.

6-14 Maintenance K006eng6

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

2 8 check oil level

oil level indicator For a hydraulic unit which is switched on, the oil
level must be between the upper and lower
markings of the oil level indicator.

3 8 checking the dirt indicator

oil filter · after plain text data on the control display,
change the oil filter.

500 oil filter change

2500
5000 · after the first 5000 hours of operation and
10000 after each 5000 interval, the oil filter should
15000 be changed, and the hydraulic oil of the
20000 corresponding mineral oil company should be
analyzed. If it is unsuitable for further use, the
oil should be changed. This also applies when
the hydraulic oil becomes very dirty because
of some type of failure.

4 8 checking for function

Safety switch on the
protective covers · The machine is supplied with safety covers, as
a standard feature (left, right and rear).
All protective covers are provided with safety
switches, that trigger the hydraulics OFF
function when the protective grille is open.
These safety switches engage during every
operating mode of the machine.

Caution!
Prior to turning the machine on again, the
operator must be certain that no one is in the
danger area.

5 The air pressure filter with water separator

air pressure filter with water cleans dampness, hard particles such as dust,
separator ash and rust from the air supply.

K006eng6 Maintenance 6-15

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

Fig. 2108

1 filter cartridge
2 inspection glass
3 drain screw

40 Draining condensate

· activate drain screw (3)

· drain condensate

when dirty Removing & cleaning the inspection glass:

· close air feed

· remove inspection glass (2)
· clean inspection glass with water only, then:

Cleaning the filter cartridge

· remove filter cartridge (1)

· wash out filter cartridge with gasoline or
petroleum, and dry from the inside with
compressed air
· insert filter cartridge
· insert inspection glass (2)

6 40 clean with an oil-dampened cloth

upper, lower die adapter

6-16 Maintenance K006eng6

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

7 40 clean with an oil-dampened cloth

fixing strip stop finger shift
(Z axis)
8 40 clean with an oil-dampened cloth
support console guide nut
9 500 lightly oil
tap rod on lower die shift
(I axis)
10 500 check available pre-pressure in both hydro
hydro accumulator upper die accumulators
adapter (Modufix)
required pre-pressure Pv:
· 609 psi (42 bar) for the upper die adapter.

The required pre-pressure Pv is noted on each

accumulator.

The diagram shows the hydro accumulator

assembly.

Fig. 2121

1 locking screw
2 membrane/bubble
3 gas space/nitrogen
4 closing button
5 fluid space
6 steel container

The pressure container of the hydro accumulator

is subdivided into a gas and fluid space through
an elastic separating wall (membrane/bubble).
The pressure container stores pressurized
hydraulic fluid.

K006eng6 Maintenance 6-17

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

The gas space may only be filled with nitrogen.

The pre-pressure in the gas space, given in the

hydraulic plan, is a basic condition for the
smooth working of the upper tool clamping
device (Modufix); it is essential to check this on a
regular basis.

Caution!
Only trained personnel may perform
maintenance work on hydro accumulators.

Training is the responsibility of the company.

Compare with pressure container regulations

(for Germany)

Hydro accumulators must undergo inspections

They must undergo a pressure inspection every
ten years.

The relevant national safety regulations must be

conformed to and observed.

Refilling nitrogen in the gas space of the

hydro accumulator

If too little pre-pressure is available in the gas

space, nitrogen must be added.

To do this:
· Switch on machine until the hydraulic
operating pressure has built up.
· Turn off hydraulic unit (emergency stop button
should be activated and the main switch
should be off).
· Unscrew the filling and checking device on the
hydro accumulator to be filled, and read the
available pre-pressure Pv and fill until the
required pre-pressure Pv is reached.

6-18 Maintenance K006eng6

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

Using a filling and checking device for the

hydro accumulator*

When using a filling and checking device the use

of a pressure reducer is recommended when
filling in front of the hydro accumulator to protect
it.

The prescribed pre-pressure for the gas space of

the corresponding hydro accumulator should be
set on the pressure reducer.
The shut-off valve on the nitrogen bottle should
be opened carefully, to allow the gas to flow out
slowly.

The filling device should be fitted with a class 1.6

manometer. A H 1/4 B (Festo) return valve
should be used instead of the one installed when
filling. After opening the shut-off screw, set the
pre-pressure Pv in the hydro accumulator to the
right value.

Operator's instruction for filling and testing

device for the hydro accumulator

Fig. 1483

1 transition piece
2 shut-off valve
3 torque wrench
4 return valve
5 valve head
6 exhaust valve
7 connection piece
8 hydro accumulator

K006eng6 Maintenance 6-19

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

Connecting the filling device:

· accumulator shut-off screw should be

loosened with an inner hex nut wrench
· tighten the high pressure hose transition piece
on the nitrogen bottle
· screw the filling device on the hydro
accumulator, paying careful attention that the
O ring slots into its groove.

Filling the hydro accumulator:

· close exhaust valve

· open the shut-off valve on the nitrogen tank
slightly. The shut-off valve should be closed at
specific intervals to read the gas pressure on
the manometer. After the required gas
pressure is reached, a temperature
equalization should take place in the
accumulator within a few minutes. The gas
pressure can change slightly during this time.
· Close shut-off valve on the nitrogen bottle. If
the gas pressure is too high, the exhaust valve
on the filling device can be opened to equalize
it.
· Tighten the accumulator locking screw.
· Release all of the air from the filling device via
the exhaust valve and remove.
· Caution!
Now tighten the accumulator locking screw
with the torque wrench to 30 Nm.

* The TRUMPF order no. for the filling and checking device is 053198.

11
Control (operator's panel) 500 Clean the filter netting on the back of the
operator panel

6-20 Maintenance K006eng6

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

12 500 Lubricate the nipple with the grease gun. To

ballscrew unit for X axis guarantee equal lubrication of all roller parts, one
must relubricate in four axis positions. Travel the
axis in 30 mm (1.18 in) steps each time. After
approaching an axis position, all lubrication
points on the corresponding axis should be
lubricated. For each location, only a small
amount of grease should be applied, so that
grease does not exude out through the stripper.

13 500 Lubricate the nipple with the grease gun. To

ball circulation unit for R axis guarantee equal lubrication of all roller parts, one
must relubricate in four axis positions. Travel the
axis in 30 mm (1.18 in) steps each time. After
approaching an axis position, all lubrication
points on the corresponding axis should be
lubricated. For each location, only a small
amount of grease should be applied, so that
grease does not exude out through the stripper.

14 500 Lubricate the nipple with the grease gun. To

ball circulation unit for Z axis guarantee equal lubrication of all roller parts, one
must relubricate in four axis positions. Travel the
axis in 30 mm (1.18 in) steps each time. After
approaching an axis position, all lubrication
points on the corresponding axis should be
lubricated. For each location, only a small
amount of grease should be applied, so that
grease does not exude out through the stripper.

K006eng6 Maintenance 6-21

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

15 500 Lubricate the nipple with the grease gun. To

Ball lead screw guarantee equal lubrication of all roller parts, one
must relubricate in four axis positions. Travel the
axis in 30 mm (1.18 in) steps each time. After
approaching an axis position, all lubrication
points on the corresponding axis should be
lubricated. For each location, only a small
amount of grease should be applied, so that
grease does not exude out through the stripper.

16 500 Lubricate using an oil can or spray can.

gear rack Caution! Clean dirty pinions or gear racks, with
X, Z axis pinion a paint brush and petroleum prior to oiling. We
recommend applying oil to the gear rack using a
paint brush.

17 Check belt tension; the toothed belts should be

Toothed belt of the R-axis mounted so that they are diverted from the
straight line under the test load Fv after half the
trunk length s/2.

500 At V50 and V85

10.000 At V130 and V170

6-22 Maintenance K006eng6

Lubrication Location No. Interval Procedure/ Maintenance Instructions
Operation
hours

Fv = 4N (0,882 lb)
Illustration right:
applies only to V50 and V85

Justing force: Fv = 4N (0,882 lb)

axis distance: s = 301,6 mm (11,87 in)

belt deviation: s/50 = 6±1mm (0,24±0,0394 in)

Illustration below:
(applies at V130 and V170
4-axes backgauge

K006eng6 Maintenance 6-23

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

18 500 The fixing screws for the fixed stops must be

fixed stop for X axis tightened with a torque wrench (8 Nm). The fixed
(applies only to V50 and V85 stops must be assembled so that they can be
without 6-axes backgauge) slid from the center of the adjustment path
outward. When the X axis unit is moved, the
fixed stop must be able to move. If this happens,
the fixed stop must be corrected according to the
data given in the diagram on pages 6-8 pos. 18.

6-24 Maintenance K006eng6

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)

19 2000 The hydraulic hoses should be checked by a

hydraulic hoses trained technician to ensure safe conditions.
This check should be performed prior to the
machine start-up.

Examples of potential defects in hydraulic hoses:

1. Outer layer damage all the way through to the

insert (for example shower spots, cuts or
tears).

2. Brittle outer layer (tearing of hose material).

3. Bends, that do not correspond to the natural

shape of the hose, either in no-pressure, or
pressurized condition; or bends, for example
layer separations, bubble formations, crimps,
bends.

4. Unsealed portions

5. Requirements not observed during assembly.

6. Hose comes away from the fittings

7. Damages or deformations to the fittings, that

minimize the function and tightness of the
fittings, or the hose/fittings connection.

8. Fittings corrosion that reduces function and

strength.

9. Storage times and usage periods exceeded

(according to ZH 1/74).

Further to this data, the safety regulations for

hydraulics hoses (order no. ZH 1/74), and the
relevant national safety regulations should be
adhered to and observed.

K006eng6 Maintenance 6-25

LUBRICATION POINT INTERVAL PROCEDURE/MAINTENANCE
NO. (OPERATING INSTRUCTIONS
HOURS)
* Publisher:
Hauptverband der gewerblichen
Berufsgenossenschaften e.V.
(Central Union of Commercial Trade
Associations)
Postfach 2052

Sales:
Carl Heymanns Verlag KG
Luxemburger Str. 449
5000 Köln 1

20 10000 The drives are virtually maintenance free.

Getriebe der X und Z-Achse However, we do recommend, even with synthetic
oils, changing the oil every 8000 – 10000
operating hours. The friction causes the oil to
become dirty, creating more wear.

21 500 Remove brake sheet, oil thoroughly and

Brake sheet, stop finger reassemble.

22 3 years We recommend changing the battery every 3

Battery change on years.
Fail-Safe Control
PSS 3056 If the battery voltage goes below 2.5 V, the CPU
indicates the error message "S-04". The battery
must be changed.

CR 2032 3V Lithium (Varta)

Pilz Art.No. 374 125
Trumpf Id.No. 842 352

23 3 years We recommend changing the battery every 3

Battery change on years.
DA Control
Lithium – Battery (3V)
Type: 2A25H CRAA
Trumpf Id.No. 839 170

6-26 Maintenance K006eng6

 6. BENDING AID

Maintenance is carried out according to the lubrication and

maintenance plan below.

40 8

2000 1 2 6

4000 3 4 5 7

K006eng6 Maintenance 6-27

6-28 Maintenance K006eng6
User’s guide

DA-65, DA-69
User’s guide

DA-65, DA-69
Control systems for the CNC-press brakes for
the TrumaBend V-series

Edition 02/2000
 Please state title of document, desired language and date of
Ordering Information edition.

TRUMPF GmbH + Co. KG

D-71254 Ditzingen
Johann-Maus-Straße 2
Telefon (07156)303-0
Telefax (07156)303-309, Telex 7245201
Internet: http://www.trumpf.com
e-mail: [email protected]

This document was compiled by the Technical Documentation Dept. of TRUMPF

GmbH + Co. KG.

All rights, in particular the right to reproduce, distribute or translate this

documentation, are reserved to TRUMPF GmbH + Co. KG, even in case of patent
and industrial rights applications. No part of this documentation may be reproduced,
processed, duplicated or distributed by means of electronic systems in any form
whatsoever without the prior written consent of TRUMPF GmbH + Co. KG. Subject
to errors and technical changes.

 TRUMPF GmbH + Co. KG

TRUMPF GmbH + Co. KG cannot be held responsible for possible mistakes in this
documentation. Any warranty for direct and indirect damages, arising in connection
with the delivery or the use of this documentation, is excluded, as far as this is in
conformity with the law.
 Before You Proceed...

The DA-65 and DA-69 control systems control the machine

functionality of the TrumaBend series V press brakes from
TRUMPF. CNC programs can be programmed directly or are
calculated and saved on the basis of graphically created product
drawings.

DA-65 The DA-65 control system can be used to create two-dimensional

product drawings, freely select tool and machine outlines and
determine bend sequences. The display is presented on-screen in
’Gray scales’.

DA-69 The DA-69 control system can be used to create three-dimensional

product drawings as well. The on-screen display is in color.

Extended length Included in the two-dimensional programming is the calculation of

the extended length of a bend section.

Automatic bending The control sytems also include the automatic bend sequence
sequence calculation calculation function for graphically programmed products.

Production time calculation The control systems include a production time calculation equation
in which manual processing time can be also be taken into account.

Viewing collision Using the graphical depiction of the section, the tools and the
CNC-controlled gauge finger in 1:1 scale any possible collisions of
workpiece and tools are visualised on the screen.

Automatic dimensioning Tools and products are always fully displayed by the control system
regardless of size.

B294e0.doc Table of Contents 0-5

 The operating manual consists of 5 parts:

Chapter 1 Chapter 1 describes all the application related operating and

display elements of the control systems.

Chapter 2 In chapter 2 the actual programming is described: From the product

drawing on paper to the completed CNC-program.

Chapter 3 In chapter 3 you will learn everything required to run a completed

program.

Chapter 4 Chapter 4 contains a selection of practice tasks which are designed

to increase your understanding of the programming and of how to
optimise bending programs.

Chapter 5 Chapter 5 acts as a reference. Use the index at the back of the
book to find specific information.

0-6 Table of Contents B294e0.doc

 Format

Certain formats and terms are used consistently in the text. Make
yourself familiar with the conventions of formatting and language.

CAPITAL LETTERS MENU BLOCKS, FUNCTIONS and PARAMETERS are always

printed in capital letters.

"..." Messages are always in inverted commas, e.g.: "Message".

<...> Keys which are specifically assigned are in pointed brackets, e.g.:
<ENTER>

[...] Inputs which must be made are indicated by square brackets.

refer to ‘. . .’ Refers to the cross reference whose title appears in quotation

marks.

Paragraphs indicated with this symbol contain information which is

especially important.

This symbol indicates hints and tips for practical usage.

Input menus are outlined in the left-hand margin in ITALICS

INPUT CAPITALS and are framed.
MENU

Menu blocks are outlined in the left-hand margin in CAPITALS and

MENU are framed.
BLOCKS

B294e0.doc Table of Contents 0-7

 Table of Contents

Chapter 1 Operating and display elements

1. Operating panel.............................................................. 1-2

2. Overview of operating elements................................... 1-3

3. Interactive input with control system .......................... 1-5

3.1 Entering numbers ............................................................. 1-5
3.2 Entering letters ................................................................. 1-5
3.3 Entering angles with the cursor-keys ............................... 1-6
3.4 Additional functions .......................................................... 1-6

4. Structure of the operating surface ............................... 1-7

5. Group operating modes ................................................ 1-8

Chapter 2 Programmed operation

1. Menu overview ............................................................... 2-4

2. Input menu...................................................................... 2-5

3. Programming tools ........................................................ 2-7

3.1 Menu block overview........................................................ 2-7
3.2 The cursor in two-dimensional programming ................... 2-8
3.3 Punches ........................................................................... 2-9
3.4 Dies ................................................................................ 2-17
3.5 Machine upper- and lowerside ....................................... 2-25

4. Graphical programming in the two-dimensional

display ........................................................................... 2-29
4.1 Menu block overview...................................................... 2-29
4.2 Defining product parameters .......................................... 2-30
4.3 Drawing bend section..................................................... 2-33

0-8 Table of Contents B294e0.doc

 4.4 Assignment..................................................................... 2-41
4.5 From the two-dimensional graphics to the CNC-
program .......................................................................... 2-48

5. Graphical programming in the three-dimensional

display ........................................................................... 2-60
5.1 Menu block overview...................................................... 2-61
5.2 Defining product parameters .......................................... 2-62
5.3 Drawing product ............................................................. 2-63
5.4 From the three-dimensional graphics to the CNC-
program .......................................................................... 2-69

6. Generating CNC-programs without graphic

support .......................................................................... 2-84
6.1 Defining basic parameters.............................................. 2-84
6.2 Programming bend sequence ........................................ 2-86
6.3 Program backup ........................................................... 2-100

7. Editing programs ....................................................... 2-101

7.1 Editing graphics program ............................................. 2-101
7.2 Editing CNC-Programs................................................. 2-106

8. Product selection ....................................................... 2-107

8.1 Loading or deleting product.......................................... 2-108
8.2 Expanding directory...................................................... 2-109

9. Program constants .................................................... 2-111

9.1 General parameters ..................................................... 2-112
9.2 Machine constants ....................................................... 2-113
9.3 Serial interface ............................................................. 2-119
9.4 Backgauge speed......................................................... 2-120
9.5 Gauge finger dimensions ............................................. 2-121
9.6 Production time calculation .......................................... 2-122
9.7 Machine upperside speeds .......................................... 2-123

10. External management of tools, program and machine

constants .................................................................... 2-124
10.1 Product backup ............................................................ 2-124
10.2 Reading tools from diskette.......................................... 2-127
10.3 Tool backup.................................................................. 2-128

11. Machine parameters .................................................. 2-129

B294e0.doc Table of Contents 0-9

 Chapter 3 Manual operation, automatic operation and
step-by-step operation

1. Manual operation ........................................................... 3-2

2. Automatic and step-by-step operation ........................ 3-7

2.1 Graphically visualising bend sequence .......................... 3-12

3. Set-up mode ................................................................. 3-14

Chapter 4 Practice examples

1. Programming punch ...................................................... 4-3

2. Programming die............................................................ 4-5

3. Programming in the two-dimensional display ............ 4-7

4. Programming in the three-dimensional display.......... 4-9

Index

0-10 Table of Contents B294e0.doc

 Chapter 1

Operating and display

elements
1. Operating panel.............................................................. 1-2

2. Overview of operating elements................................... 1-3

3. Interactive input with control system .......................... 1-5

3.1 Entering numbers ............................................................. 1-5
3.2 Entering letters ................................................................. 1-5
3.3 Entering angles with the cursor-keys ............................... 1-6
3.4 Additional functions .......................................................... 1-6

4. Structure of the operating surface ............................... 1-7

5. Group operating modes ................................................ 1-8

B294e1.doc Operating and display elements 1-1

 1. Operating panel

1 2 3

A B C D E F
- +
7 8 9
G H I J K L

4 5 6
M N O P Q R

1 2 3
S T U V W X

. 0 
Y Z

11
?

0 I
S1 S2 S3 S4 S5 S6 S7 S8 END

10 9 8 7 4 6 5

1 Screen 6 STOP pushbutton

2 Keyboard 7 CURSOR-keys
3 Handwheel 8 ON-LINE HELP pushbutton
4 GROUP OPERATING MODE 9 END pushbutton
pushbuttons
10 Softkeys
5 START pushbutton
11 EMERGENCY STOP (OFF)
impact switch

Operating panel Fig. 12418

1-2 Operating and display elements B294e1.doc

 2. Overview of operating elements

Operating element Prerequisite Description

START EMERGENCY STOP not Actuating this pushbutton activates

I triggered the control system. All CNC-axes
automatically position themselves
according to the selected program.
Operation of the machine with the
2-HAND/FOOT PUSHBUTTON is
enabled.

A program interrupted by STOP

can be continued.

There is an indicator lamp in the

pushbutton which indicates active
operation.

STOP Pressing the STOP key interrupts

0 all machine activity. As long as
STOP is activated back gauge
system movements can be
accomplished by means of the
handwheel in setup mode only.

There is an indicator lamp in the

pushbutton which indicates active
status.

With GROUP OPERATING MODE

keys, select the respective control
system operating mode. (Refer to
"5. Group operating modes").

There is an indicator lamp in each

GROUP
pushbutton which indicates active
OPERATING
operation.
MODE

B294e1.doc Operating and display elements 1-3

Operating element Prerequisite Description

SOFTKEYS A menu block is assigned to

S1 every softkey on the screen in
the same sequence. The 1st
to menu block corresponds to the
1st softkey going from the left.

S8 Even unassigned menu blocks

are displayed.

END key By actuating this key you return

END
to the previous screen.

HELP With this key you can call up

integrated on-line help On-line
? help. If on-line help is available,
this is indicated by the < ? > on
the right-hand side of the dialogue
input field.

CURSOR-keys The Cursor is positioned on the

screen with this key.
The bend sequence graphical
display can be scaled up, scaled
down or rotated in PROGRAM-
MED OPERATION.
With graphical programming the
bend angle can be displayed with
the CURSOR-keys as multiples
of 45°.
With alphanumeric inputs indivi-
dual letters or numbers can be
deleted with the < ← > key.

HANDWHEEL Group operating mode MANUAL All CNC-controlled axes with the
- + exception of the machine upper-
OPERATION and STOP for all
CNC-controlled axes with the side are traversed manually.
exception of the Y-axis.
The machine upperside is
MANUAL OPERATION, START
traversed manually in the positive
and depressed foot switch for
direction starting at the mute point.
the Y-axis.

1-4 Operating and display elements B294e1.doc

 3. Interactive input with control system

Interactive input with the control system is conducted via the

alphanumeric keyboard:

A B C D E F

7 8 9
G H I J K L

4 5 6
M N O P Q R

1 2 3
S T U V W X

. 0 
Y Z

Alphanumeric keyboard Fig. 12509

3.1 Entering numbers

Numbers are entered directly by actuating the numbered keys.

.
The full stop serves as a decimal point.

With < ± > the sign of a numerical input can be changed.

±

3.2 Entering letters

Entering letters firstly as numbers. By actuating the function

ALPHANUMERIC a number is changed into the letter depicted on
ALPHANUM.
the key. Note:

❑ Actuating ALPHANUM. once activates the top left-hand letter on

a key.
❑ Actuating ALPHANUM. twice activates the top right-hand letter
on a key.

If you have the possibility of an alphanumeric input, the < ± > key
is assigned with a < - >, the < . > key is assigned with a < / >.

B294e1.doc Operating and display elements 1-5

 3.3 Entering angles with the cursor-keys

Angles can be directly programmed with the Cursor-keys as

multiples of 45°:

A    135°

B   45°

C  -90°

D  90°

A Input of 135° with the adjacent cursor-key

B Input of 45° with the adjacent cursor-key
C Input of -90° with the adjacent cursor-key
D Input of 90° with the adjacent cursor-key

Entering angles with the < cursor >-keys> Fig. 12508

3.4 Additional functions

With the < ENTER >-key you can quit and save inputs in the
Dialogue input fields.

By actuating the < DELETE >-key complete entries in the input

fields can be deleted.

1-6 Operating and display elements B294e1.doc

 4. Structure of the operating surface

The operating surface consists of 4 areas:

1 2

TRUMPF V 2.6 E

4 3

1 Header line
2 Display area
3 Dialogue input field
4 Menu bar

Structure of the operating surface Fig. 12426E

B294e1.doc Operating and display elements 1-7

 5. Group operating modes

The control system operates in 4 different group operating modes:

❑ Group operating mode MANUAL OPERATION:

You program all the parameters of an individual bend. After the
START-key has been pressed all the CNC-controlled axes
move into position. The bend can be executed.

❑ Group operating mode PROGRAMMED OPERATION:

Bend sequences are created, edited and managed in the form
of graphics or CNC-programs.
You can create, edit and manage press tools.
You can define machine, bend and operation specific
parameters.

❑ Group operating mode AUTOMATIC OPERATION:

In this operating mode, you can run a program selected in
PROGRAMMED OPERATION.

❑ Group operating mode STEP-BY-STEP OPERATION:

A program selected in PROGRAMMED OPERATION is run
step-by-step. After the completion of each bend, the control
system switches to STOP. To carry out the next bend the
control system must be activated with the START-key.

1-8 Operating and display elements B294e1.doc

 Chapter 2

Programmed operation
1. Menu overview ............................................................... 2-4

2. Input menu...................................................................... 2-5

3. Programming tools ........................................................ 2-7

3.1 Menu block overview........................................................ 2-7
3.2 The cursor in two-dimensional programming ................... 2-8
3.3 Punches ........................................................................... 2-9
Drawing punches ...................................................... 2-12
3.4 Dies ................................................................................ 2-17
Drawing dies ............................................................. 2-19
3.5 Machine upper- and lowerside ....................................... 2-25
Drawing machine upper- and lowerside.................... 2-27

4. Graphical programming in the two-dimensional

display ........................................................................... 2-29
4.1 Menu block overview...................................................... 2-29
4.2 Defining product parameters .......................................... 2-30
4.3 Drawing bend section..................................................... 2-33
Adding lines............................................................... 2-34
Deleting lines and angles .......................................... 2-36

B294e2.doc Programmed operation 2-1

 Adding angle to existing section................................ 2-37
Precision ................................................................... 2-38
Bumping .................................................................... 2-39
4.4 Assignment..................................................................... 2-41
4.5 From the two-dimensional graphics to the CNC-
program .......................................................................... 2-48
Selecting tools ........................................................... 2-49
Changing position of actual bend .............................. 2-52
Manually programming gauge finger position ........... 2-53
Turning workpiece..................................................... 2-54
Saving manual changes ............................................ 2-55
Automatic bend sequence calculation....................... 2-57
Display bending sequence ........................................ 2-58
Saving bend sequence.............................................. 2-59

5. Graphical programming in the three-dimensional

display ........................................................................... 2-60
5.1 Menu block overview...................................................... 2-61
5.2 Defining product parameters .......................................... 2-62
5.3 Drawing product ............................................................. 2-63
Adding surfaces ........................................................ 2-64
Positioning cursor...................................................... 2-65
Changing side length ................................................ 2-66
5.4 From the three-dimensional graphics to the CNC-
program .......................................................................... 2-69
Selecting tools ........................................................... 2-69
Dies ........................................................................... 2-74
Machine upper- and lowerside .................................. 2-74
Bend simulation......................................................... 2-75
Translating product under the tool set....................... 2-77
Manually changing bend sequence........................... 2-78
Programming CNC-controlled backgauge fingers
manually.................................................................... 2-81
Saving bend sequence.............................................. 2-83

6. Generating CNC-programs without graphic

support .......................................................................... 2-84
6.1 Defining basic parameters.............................................. 2-84
6.2 Programming bend sequence ........................................ 2-86
Positioning backgauge .............................................. 2-89
Machine parameters ................................................. 2-94
Bending sequence overview ..................................... 2-99
6.3 Program backup ........................................................... 2-100

7. Editing programs ....................................................... 2-101

7.1 Editing graphics program ............................................. 2-101

2-2 Programmed operation B294e2.doc

 Editing 2D-graphics program .................................. 2-102
Editing 3D-graphics program .................................. 2-104
7.2 Editing CNC-Programs................................................. 2-106

8. Product selection ....................................................... 2-107

8.1 Loading or deleting product.......................................... 2-108
8.2 Expanding directory...................................................... 2-109

9. Program constants .................................................... 2-111

9.1 General parameters ..................................................... 2-112
9.2 Machine constants ....................................................... 2-113
9.3 Serial interface ............................................................. 2-119
9.4 Backgauge speed......................................................... 2-120
9.5 Gauge finger dimensions ............................................. 2-121
9.6 Production time calculation .......................................... 2-122
9.7 Machine upperside speeds .......................................... 2-123

10. External management of tools, program and machine

constants .................................................................... 2-124
10.1 Product backup ............................................................ 2-124
10.2 Reading tools from diskette.......................................... 2-127
10.3 Tool backup.................................................................. 2-128

11. Machine parameters .................................................. 2-129

B294e2.doc Programmed operation 2-3

 1. Menu overview

Menu Block Overview PROGRAMMED Operation

1 2 3 4 5 6 7 8 9 10 11 12
PRODUCT PRODUCT DATA DATA PRODUCT PRODUCT BOTTOM MACHINE MACHINE PROGRAM TOOL
DRAWING EDIT PREPARATION EDIT SELECTION BACKUP PUNCHES DIES UPPERSIDE LOWERSIDE CONSTANTS BACKUP

Tool programming, Operator-specific settings

internal tool management

Product parameter

Two-dimensional Threeidimen- CNC Internal External program and

graphic sional programming programmanagement tool management
programming graphic
programming

Menu overview for programmed operation Fig. 12591E

Programming rules ❑ All inputs, which are entered in interactive mode, must be
confirmed with the < ENTER >-key.

❑ You leave an interface with the < END >-key.

❑ All machine and tool outlines are considered from the right-
hand side of gauge. In 3D-programming the viewing direction
can be changed by rotating with the cursor keys.

Y1 Y2

DA-65
DA-69

View from the right-hand side of gauge Fig. 15595

2-4 Programmed operation B294e2.doc

 2. Input menu

To access group operating mode PROGRAMMED OPERATION,

actuate the adjacent pushbutton. The input screen appears:

Input menu for PROGRAMMED OPERATION Fig. 15557E

You access the desired interfaces by entering the assigned menu

numbern:

In the menu 1 PRODUCT DRAWING a product section is

1 graphically programmed and its bend sequence is determined. On
PRODUCT
this basis the control system calculates a CNC-program for your
DRAWING
press brake.

In the menu 2 PRODUCT EDITING a graphically created bending

2 program can be edited. Changes are possible both in the product
PRODUCT
section and in the bend sequence.
EDITING

In the menu 3 DATA PREPARATION, you can create a bend

3 sequence as a CNC-program without graphical support.
DATA PRE-
PARATION

In the menu 4 DATA EDIT you can edit the parameters of a CNC-
4 program.
DATA EDIT
It is also possible to edit CNC-programs which were
computed by the control system on the basis of graphical
programming.

B294e2.doc Programmed operation 2-5

 In the menu 5 PRODUCT SELECTION, all the saved programs are
5 managed. You can call up the complete program directory, have a
PRODUCT
graphic program list displayed and load and delete programs.
SELECTION
A total of up to 2500 bendings can be saved.

In the menu 6 PRODUCT BACKUP, programs can be read from or

6 be saved on a diskette.
PRODUCT
BACKUP

In the menu 7 PUNCHES, punches can be created, edited and

7 managed. You receive an overview catalogue of all programmed
PUNCHES
punches. You can read in or save punches from or onto diskette.

In the menu 8 DIES, dies can be created, edited and managed.

8 You receive an overview catalogue of all programmed dies. You
DIES
can read in or save dies from or onto diskette.

In the menu 9 MACHINE UPPERSIDE, the machine upperside of

9 your press brake can be created or edited and managed. At the
MACHINE
same time you can save several forms.
UPPERSIDE

In the menu 10 MACHINE LOWERSIDE, you can create or edit

10 machine lowerside. At the same time you can save several forms,
MACHINE
e.g. machine lowerside with part support and machine lowerside
LOWERSIDE
without part support. Similar to punches and dies the machine
lowerside can be managed by means of diskette.

In the menu 11 PROGRAM CONSTANTS you can define machine-

11 specific settings for the control system and press brake. You can
PROGRAM
read in or save program constants.
CONSTANTS

In the menu 12 TOOL BACKUP you can import and save complete
12 tool directories from or onto a diskette. At the same time machine
TOOL
parameters are read in or out in software versions < V2.1. Starting
BACKUP
at software version level V2.1 you have the option of saving or
reading in machine parameters separately.

2-6 Programmed operation B294e2.doc

 3. Programming tools

3.1 Menu block overview

Menu Block Overview TOOLS

Example MACHINE UPPERSIDE

7
MACHINE
UPPERSIDE

EDIT
PREVIOUS NEXT
CALCU-
PAGE PAGE
LATION

AUTO. EDIT DELETE DELETE EDIT

PROD. HEIGHT LINE DRAWING DATA

Tools menu block overview with punches as example Fig. 12594E

Tools are programmed in the two-dimensional display. Select the

desired tool type in the input menu.

Rules for tool programming ❑ The tools are drawn from the functional side (die opening or
punch tip) to the tool adapter.
❑ The final section of a tool side should be finished using the
AUTOFINISH function (see ’Drawing punches’ on page 2-12).
❑ The shortest programmable side length is 1.1 mm.
❑ Tool radii can only be numerically programmed with the specific
tool constants.

B294e2.doc Programmed operation 2-7

 3.2 The cursor in two-dimensional
programming

In two-dimensional graphical programming the cursor appears in

the form of a circle:

The cursor in 2D-graphical programming Fig. 12559

From the position of the cursors it is apparent whether the length or

angle dimensions must be entered:

❑ Enter a length dimension when the cursor is centered on a line.

In the dialogue input field you are asked the side length.
❑ Enter an angle dimension when the cursor is positioned at the
end of a line. In the dialogue input field you are asked to enter
the angle.

With the cursor-keys < ↑ >, < ↓ >, < ← > and < → > you can
locate the cursor at any addressable position on the marked line.

2-8 Programmed operation B294e2.doc

 3.3 Punches

Enter menu number 7 for the menu PUNCHES. A data overview of

7 the punches stored in the control system.
PUNCHES
Up to 30 different punches can be stored.

PUNCHES menu - data overview Fig. 15401E

Reading from left to right you will receive the following information:

❑ Punch number
The punch in the bend sequence is programmed via the
punch number.

❑ Angle at the punch tip

❑ Punch height without punch adapter (working height)
❑ Radius at the punch tip
❑ Alphanumeric tool name (punch code)

B294e2.doc Programmed operation 2-9

 Functions

With PREVIOUS PAGE and NEXT PAGE you can scroll pages in
PREVIOUS the punch directory.
PAGE

NEXT
PAGE

Using DELETE TOOL you can delete the tool marked by the
DELETE cursor.
TOOL
In the dialogue input field you are asked: "Are you sure 1/0?"
1 Product is deleted.
0 The delete procedure is aborted.

Using DISKETTE individual tools or the complete tool directory can

saved onto diskette or read in to the control system from diskette
DISKETTE
(see Point ’10.3 Tool backup’ on page 2-128).

With the function GRAPHICAL DIRECTORY you obtain a graphical

GRAPHICAL overview of all punches. Angle, radius, height, punch number and
DIRECTORY
punch code are listed for each punch.

GRAPHIC DIRECTORY - Punches Fig. 15402E

2-10 Programmed operation B294e2.doc

 With the function HEEL, all punches with programmed heel,
including heel dimensions are listed. For tools without heel the
HEEL
message "Heel not programmed" appears.

HEEL Fig. 15403E

Heel tools are depicted graphically in three-dimensional

programming (see page 2-72).

Functions

The DATA function returns you to the GRAPHIC DIRECTORY

interface.
DATA

Use NEXT PAGE to scroll between screen pages.

NEXT PAGE

B294e2.doc Programmed operation 2-11

 Drawing punches

Use the cursor keys < ↑ > and < ↓ > to select an unassigned tool
number.

Actuate the softkey for the function EDIT DRAWING. The message
EDIT "not programmed" appears.
DRAWING

You are asked in the dialogue input field for the start constants for
the punch. You reply in interactive mode:

❑ Punch height without punch adapter (working height)

❑ Angle dimension at the punch tip

The punch tip is graphically displayed on the screen. The angle and
tool height appear as well:

DRAWING A PUNCH Fig. 15648E

With the cursor-keys position the cursor at the place where you can
input the next dimension. You will be asked in the dialogue input
field for this dimension. Input the desired value. After the value has
been entered the cursor jumps automatically to the next position to
be defined.

2-12 Programmed operation B294e2.doc

 To draw a punch start at the punch tip first in the clockwise then in
the counterclockwise direction. If possible complete the sides using
the AUTOFINISH function.

120.0

86.0 86.0 86.0

1 2 3

1 Display following angle input 3 Display following AUTOFINISH

The cursor jumps automatically to
2 Display following length input
the other side.

Programming a punch Fig. 15594

Asymmetric angles are depicted with the aid of an intermediate line

with a length of 1,1 mm:

80° 1,1 mm

40°

Programming an asymmetric angle Fig. 12584

B294e2.doc Programmed operation 2-13

 Functions

With the AUTOFINISH function the punch is made to the defined

AUTO overall height in accordance with the last line input.
FINISHING

With CHANGE HEIGHT you change the overall height of a punch,

CHANGE whether the punch has already been made or not.
HEIGHT

With DELETE LINE the marked line is deleted.

DELETE
LINE

To delete a complete drawing press the softkey which corresponds

DELETE to the function DELETE DRAWING.
DRAWING
In the dialogue entry field you will be asked "Are you sure 1/0?"
1 Drawing is deleted
0 The delete procedure is aborted

2-14 Programmed operation B294e2.doc

 Punches data

Using the function EDIT CONSTANTS you can define or edit

EDIT specific punch constants.
CONSTANTS

PUNCH DATA interface Fig. 12530E

You define the following parameters:

❑ CODE CX
Alphanumeric tool name up to a max. of 20 characters.
The programming is not absolutely necessary.
❑ RESISTANCE R
Maximum punch loading in kN per mm tool length.
❑ LENGTH L
Length of the punch in the Z-position; the maximum can be
programmed into the bending sequence. Generally this will be
the complete fold length of your bending machine.

CNC-controlled ❑ Z-POSITION Z
Z1/Z2 axis Value for the offset from the middle of the punch and the middle
of the machine upperside. (Default value = 0 mm).
The control system extrapolates the Z-position of the gauge
fingers from the length of the bend line and the Z-position of the
workpiece (and hence from the position of the tool). Using a
Z-Offset value the control system shifts the position of the
gauge fingers in relation to the middle of the machine
upperside.
Positive value: The Z-axis shifts to the right (viewed from
the front)
Negative value: The Z-axis shifts to the left
The programming of the Z-axis has a higher priority than
the Z-POSITION Z in the CNC-program.

B294e2.doc Programmed operation 2-15

 ❑ RADIUS RA
Radius at the punch tip.
You need to define this value!

❑ FLATTENING HEIGHT FH
The control system requires the flattening height for calculating
the Y-axis position when flattening with a flattening tool. If you
do not define this parameter the control system will select the
tool height as a default value.

Double sheet thickness, FLATTENING OFFSET and

FLATTENING OPENING from the menu PROGRAM
CONSTANTS are taken into account when calculating the
flattening height (refer to ‘9.2 Machine constants' on
page 2-113).

1 Tool height 2 Flattening height

Flattening height Fig. 12585

Programming the heel In three-dimensional graphic programming (DA-69) the heel tool
can be programmed separately and depicted graphically (see
'Selecting tools' on page 2-49).

2-16 Programmed operation B294e2.doc

 3.4 Dies

Enter menu number 8 for the menu DIES. A directory of all the
8 stored dies appears on the display screen.
DIES
Up to 60 different dies can be stored.

DIES menu - data overview Fig. 15404E

You obtain the following information from the directory reading from
left to right:

❑ Die number
A die in the bend sequence is programmed via the die
number.

❑ Die width
❑ Opening angle of the die
❑ Die height without die adapter (working height)

B294e2.doc Programmed operation 2-17

 Functions

With PREVIOUS PAGE and NEXT PAGE you can scroll through
PREVIOUS pages in the tool list.
PAGE

NEXT PAGE

The GRAPHIC DIRECTORY function provides a graphic overview

GRAPHIC of the machine upperside or lowerside. Die width, die angle, die
DIRECTORY height, die number and die code are listed for each die.

GRAPHICAL DIRECTORY - Dies Fig. 15405E

Using DELETE TOOL you can delete the tool marked by the
DELETE cursor.
TOOL
In the dialogue entry field you will be asked "Are you sure 1/0?"
1 Drawing is deleted.
0 The delete procedure is aborted.

Using the DISKETTE function tools can saved onto diskette or read
into the control system from diskette (see Point ’10.3 Tool backup’
DISKETTE
on page 2-128).

2-18 Programmed operation B294e2.doc

 Drawing dies

Use the cursor keys < ↑ > and < ↓ > to select an unassigned tool
number in the data overview.

Actuate the softkey for the function EDIT DRAWING. The message
EDIT "not programmed" appears.
DRAWING

You are asked in the dialogue input field for the specific die start
constants for the new die. You reply in interactive mode:

❑ Tool height without die adapter

❑ Opening angle of the die
❑ Die width
❑ Radius of the angle between the V-opening and the die top
edge.

The die opening is graphically displayed on the screen. Likewise

angle size, tool height, die width and radius are stated:

DRAWING DIES Fig. 15649E

With the cursor-keys position the cursor at the place where you can
input the next dimension. You will be asked in the dialogue input field
for the corresponding dimension. You reply in interactive mode.

After the value has been entered the cursor jumps automatically to
the next position to be defined.

B294e2.doc Programmed operation 2-19

 Draw a die starting at the die opening first in the counterclockwise
then in the clockwise direction. If possible complete the sides using
the AUTOFINISH function.

1 2 3
25.6 25.6
2.50

86.0 86.0 86.0

100.0
1 Display following angle input 3 Display following AUTOFINISH
The cursor jumps automatically to
2 Display following length input
the other side.

Programming the die Fig. 15596

Functions

With AUTOFINISH the die is automatically made to the defined

AUTO overall height in accordance with the last line input.
FINISHING

With CHANGE HEIGHT the overall height of a die is edited

CHANGE
HEIGHT

With DELETE LINE you erase a line.

DELETE
LINE

To delete a complete drawing, press the softkey for the DELETE

DELETE DRAWING function.
DRAWING
In the dialogue entry field you will be asked "Are you sure 1/0?"
1 Drawing is deleted.
0 The delete procedure is aborted.

2-20 Programmed operation B294e2.doc

 Dies data

In the menu CHANGE DATA you can define or edit the specific
CHANGE constants for a die:
DATA
❑ CODE
Alphanumeric tool name up to a max. of 20 characters.

❑ X-SAFETY NORMAL SN
Safety offset beween the gauge finger and the die. Although
this value is calculated automatically by the control system it
can be changed manually as well. The control system
calculates the
X-safety by means of the following equation:

SN = 1/2V + FS

V Die width
FS Right-hand side of die top edge

V FS

V Die width FS Right-hand side of die top edge

X-Safety Fig. 15658

With the collision analysis the control system does not take the
machine lowerside in the minus area of the R-axis into account
(Fig. 12374). In this case program the safety zone manually
according to the following formula:

Safety = SN + X + A

SN X-SAFETY
X Offset die - machine lowerside front edge
A Safety value of 0.5 mm, to avoid the gauge finger
coming into contact with the machine lowerside.

B294e2.doc Programmed operation 2-21

 A
SN X

1 Workpiece SN X-safety
2 Die X Offset die -
3 Machine lowerside machine lowerside front edge
4 Gauge finger A Safety offset

Safety for the R-axis in the negative range Fig. 12374

Please make certain that the programmed safety zone is also

valid in the positive range of the R-axis. If the same die with
different safety zones is required within one bending sequence
then reprogram this die under a different tool number.

❑ X-SAFETY TURNED (NEGATIVE) ST

Safety offset between the gauge finger and the die as
calculated by the control system, reverse installed. For
symmetric dies this value is identical to the value of the X-
SAFETY NORMAL SN.

2-22 Programmed operation B294e2.doc

 ❑ MUTE M
Height of the punch tip above the workpiece, when the
changeover from rapid traverse to work cycle takes place.
The mute point can be a maximum of 8 mm. Generally it
is programmed with a value of 4 mm.

❑ FLATTENING HEIGHT FH
The flattening height generally corresponds to the working
height of the die.

❑ I-AXIS ID
The die adaptor is disengaged or engaged at the I-axis (die
offset), e.g. during flattening at the front or back with pre-edging
at a tool station.
1 I-axis in front position
2 I-axis in rear position

1 Pre-edging: I-axis in position 1

2 Flattening: I-axis in position 2

Flattening front view (schematic diagram) Fig. 15558

B294e2.doc Programmed operation 2-23

 The mechanical setting of the translation path for the I-axis is found
in Chapter 5 of the Operating manual for TrumaBend series V.

❑ The I-axis positions defined here appear automatically in the

CNC program of a bending sequence. Should you require a
different position for a bend, program this value manually in the
CNC program. If an error indication should appear it can be
deleted.
Achange is made in the CNC program has no effect on the
I-axis ID parameter in the die data.

2-24 Programmed operation B294e2.doc

 3.5 Machine upper- and lowerside

The machine upper- and lowerside are programmed identically. For

this reason both machine components are dealt with in the same
chapter.
The dimensions of the machine upper- and lowerside are
programmed by TRUMPF specifically for each machine. As a
rule you have only one possible choice for each.
Exceptions to this are built-on accessories to the machine
upperside or lowerside, e.g. part support on the machine
lowerside. In this case reprogram the machine press tool
outlines including part support under a different tool number.

Enter menu number 9 for the MACHINE UPPERSIDE menu or

9 menu number 10 for the MACHINE LOWERSIDE menu. The
MACHINE
machine upperside or lowerside directory appears on the screen:
UPPERSIDE

10
MACHINE
LOWERSIDE

MACHINE UPPERSIDE interface - overview Fig. 15406E

You can obtain the following information from the catalogue:

❑ Machine press tool number
The tools are programmed in the bend sequence via the
numbers.

B294e2.doc Programmed operation 2-25

 ❑ Height
Machine upperside:
Height of machine upperside up to the tool adapter.
Machine lowerside:
Height from the tool adapter up to the level of installation
surface.

❑ Tool adapter
Alphanumeric tool name up to a max. of 20 characters.

Functions

Using DELETE TOOL you can delete the tool marked by the
DELETE cursor.
TOOL
In the dialogue entry field you will be asked "Are you sure 1/0?"
1 Drawing is deleted.
0 The delete procedure is aborted.

Using the DISKETTE function tools can saved onto diskette or read
into the control system from diskette (see Point ’10.3 Tool backup’
DISKETTE
on page 2-128).

The GRAPHICAL DIRECTORY function provides you with a

GRAPHICAL graphic overview of the machine upperside or lowerside. The
DIRECTORY
appropriate height is stated for each tool.

GRAPHICAL DIRECTORY - Machine upperside Fig. 15407E

2-26 Programmed operation B294e2.doc

 Drawing machine upper- and lowerside

Use the cursor keys < ↑ > and < ↓ > to select an unassigned tool
number in the data overview.

Actuate the softkey for the function EDIT DRAWING. The message
EDIT "not programmed" appears.
DRAWING

You will be asked in the dialogue input field for the height of the
machine upper and lowerside. You reply in interactive mode.

The functional side is graphically displayed on the screen. The

height of the machine press tool is stated:

DRAW MACHINE UPPERSIDE interface - overview Fig. 12535E

Position the cursor with the cursor-keys at the location where you
can input the next dimension. You will be asked in the dialogue
input field for the corresponding dimension. Input the desired value.
After the input, the cursor jumps to the next position, which you
again define.

B294e2.doc Programmed operation 2-27

 Functions

With the function AUTO FINISHING, you can make the machine
upperside or lowerside to the defined overall height in accordance
AUTO FINISH
with the last line input.

With CHANGE HEIGHT the overall height of the machine

CHANGE upperside or lowerside is edited.
HEIGHT

With DELETE LINE you can erase a line.

DELETE
LINE

To delete a complete drawing, press the softkey for the function

DELETE DELETE DRAWING.
DRAWING
In the dialogue entry field you will be asked "Are you sure 1/0?"
1 Drawing is deleted.
0 The delete procedure is aborted.

2-28 Programmed operation B294e2.doc

 4. Graphical programming in the two-
dimensional display

The bend section can be programmed in a two-dimensional

graphical display with all control systems.

Enter menu number 1 for the menu PRODUCT PROGRAMMING.

1
PRODUCT
PROGRAMMING

4.1 Menu block overview

Menu block overview PRODUCT DRAWING

2D programming

1
PRODUCT
DRAWING

Product parameter
2D-programming

PRECISION
CHANGE BEND
DELETE DATA ASSIGNM. SEQUENCE
CLOSE DIM. 3D programming

INSERT BUMPING

2D DRAWING

Tool configuration

PREVIOUS NEXT LOAD SAVE

PAGE PAGE DEFAULTS DEFAULTS

ASSIGNMENTS

GAUGE CHECKS BEND

UNBEND BEND ADJUSTM. SWAP ON / OFF CALCULATE SAVE SEQUENCE

BEND SEQUENCE

Menu block overview 2D-programming Fig. 12592E

B294e2.doc Programmed operation 2-29

 4.2 Defining product parameters

Before you can begin with the graphical programming of a product,

the control system requests several product parameters which you
must enter in interactive mode:

PRODUCT INPUT - Product parameter Fig. 15504E

❑ 2D/3D DRAWING SELECTION DS

2 Programming in the two-dimensional display.
DA-69 3 Programming in the three-dimensional display.

❑ PRODUCT NUMBER PN
Numerical product number up to a max. of 7 figures.

❑ DRAWING NUMBER DN
Alphanumeric product name up to a max. of 20 characters.
This entry is not absolutely necessary.

2-30 Programmed operation B294e2.doc

 The control system switches automatically to the next display
screen page.

PRODUCT INPUT - Product parameter Fig. 15505E

❑ THICKNESS BS
Sheet thickness.

❑ MATERIAL M
Material type specified by tensile strength and E-modulus in
Menu 11 PROGRAM CONSTANTS (see ’9. Program
constants’ on page 2-111). There are six material types to
select from:
1 Steel (mild steel)
2 Aluminium
3 Zinc
4 Stainless steel / special steel
5 Material 5 (user-defined material)
6 Material 6 (user-defined material)

❑ LENGTH L (only for 2-D products)

Length of the workpiece in the direction of the Z-axes.
The control system requires L to calculate the bending
pressure.

B294e2.doc Programmed operation 2-31

 ❑ DIMENSIONS OUT/INSIDE 0/1
Dimensions with which the product is drawn
0 Outside dimension
1 Inside dimension

A Inside dimension B Outside dimension

Types of measurements Fig. 12424

2-32 Programmed operation B294e2.doc

 4.3 Drawing bend section

After all the product parameters have been entered, the control
system switches to the interface PRODUCT INPUT - Draw:

PRODUCT INPUT - Draw interface Fig. 12513E

You are asked in the dialogue input field for the length of the base
line. You reply in interactive mode. the cursor positions itself auto-
matically on the base line. Finally the cursor is automatically
positioned at the end of the base line where a bending angle can
be entered.

The cursor functions are explained in detail in the programming

manual for dies (refer to "3.2 The cursor in two-dimensional
programming" on page 2-8).

B294e2.doc Programmed operation 2-33

 Adding lines

You can enter the desired angle size in the dialogue input field or
decide the direction of a new line with the cursor-keys as multiples
of 45°.

A    135°

B   45°

C  -90°

D  90°

A Input of 135° with the adjacent cursor-key

B Input of 45° with the adjacent cursor-key
C Input of -90° with the adjacent cursor-key
D Input of 90° with the adjacent cursor-key

Entering angles with the <CURSOR>-keys Fig. 12508

After the angle is entered the new line appears with the cursor
positioned at its center. The control system asks for the line length
in the dialogue input field. You reply in interactive mode.

Line programming Fig. 15426E

2-34 Programmed operation B294e2.doc

 You can also define the length with its Projection dimension,
instead of as a direct length:

2
1

① Direct side length 1 Bend section

② Vertical projection 2 Cursor

③ Horizontal projection

Direct lengths and projection dimensions Fig. 12421

Programming projection Horizontal projection:

❑ Enter the new angle.
❑ Enter the horizontal projection dimension.
❑ Press < ← > or < → >.
The message "horizontal projection" appears in the dialog input
field.
❑ Press < ENTER >.
The new side length appears on the dialog input field.

Or:

Vertical projection:
❑ Enter the vertical projection dimension.
The message "vertical projection" appears in the dialog input
field.
❑ Press < ↑ > or < ↓ >
❑ Press < ENTER >.
The new side length appears in the dialog input field.

B294e2.doc Programmed operation 2-35

 Deleting lines and angles

Use DELETE to remove a line when the cursor is positioned at the

middle or end of a line open at least one end. An angle is removed
DELETE
when the cursor is positioned on it.

Deleting a line The overall length of the section being displayed is shortened after
a line has been deleted. (Fig. 12422, b).
A line closed at both ends cannot be deleted using this
function.

Deleting an angle The side of the deleted angle is joined to another line. This means:
the length of both sides are added together. The overall length of
the section stays the same (Fig. 12422, c).

2 1

a Original bend section

b Bend section after deletion of side 1
c Bend section after deletion of angle 2 of the original bend section

Deleting lines and angles of a bend section Fig. 12422

2-36 Programmed operation B294e2.doc

 Adding angle to existing section

The function INSERT is integrated in the the same softkey as the

function DELETE. INSERT is introduced when the cursor is located
INSERT
in the centre of a line which is closed at both ends.

Insert angle Actuate INSERT and enter the desired angle size.
The individual lines at an angle which has been added each
have the same length as the original line. The overall length
of the bend section is increased (Fig. 12425, b).

1
a

1 2

a Bend section before addition of angle 1

b Bend section after addition of angle 1 (angle 2 is translated sidewards)

Insert angle Fig. 12425

B294e2.doc Programmed operation 2-37

 Precision

The function PRECISION offers the possibility of bending one or

more sides without the sum of all tolerances. PRECISION can be
PRECISION
activated only when the cursor is at the center of a line.

Precision Fig. 15427E

High precision Actuate the softkey once to program the active line in the automatic
bending sequence calculation without the sum of all tolerances. The
control system tries to position the backgauge for every bend so
that the gauge finger does not contact this side. If this does not
succeed, the control system delivers the message "Doesn’t comply
with high precision" on completion of the automatic bend sequence
calculation.

Closing dimension Actuate the function PRECISION twice to define the sum of all
tolerances of the whole workpiece for this side. If this does not
succeed, the control system delivers the message "Closing
dimension not considered" upon completion of the automatic bend
sequence calculation.

2-38 Programmed operation B294e2.doc

 Bumping

With BUMPING you program a radius for an angle in the bend

section. BUMPING is only active when the cursor is located at an
BUMPING
angle. This function is an ON/OFF function. To activate press the
softkey once. When pressed a second time the function is
deactivated.

You will be asked in the dialogue input field for the following values:
❑ Bumping radius
❑ Segments:Number of bends which you intend to use the
production of a cylindrical curve. The control system attempts to
implement this number in the bending sequence.
The greater the number of segments the rounder the radius
will be.

BUMPING interface - Programming radius Fig. 15410E

BUMPING interface - Programming segments Fig. 15408E

B294e2.doc Programmed operation 2-39

 You should select a die width that is small enough to insure that an
existing segment bend will not be located at the die for the next
bend. The contol system calculates the maximum die width for a
segement bend and displays it on the screen:

BUMPING interface Fig. 15409E

The maximum value of a radius must correspond to the smallest

adjacent side length:

R L1

L1
R 1

L2

R Radius 1 Bend section

L1 Side length 1
L2 Side length 2

Bumping Fig. 12375

2-40 Programmed operation B294e2.doc

 4.4 Assignment

With ASSIGNMENT you can alter the proportion of bending

sequence and production time for automatic bending sequence
ASSIGNMENT
calculation.

ASSIGNMENT interface Fig. 15411E

❑ OPTIMILISATION DEGREE OD
Number of alternative bend sequences checked by the control
system during the calculation sequence of the optimalised CNC
program.
Input a number between 1 and 5.
The higher the number of alternative bend sequences the
more time that the control system needs to calculate the
bend sequences.

❑ FRONT EXTEND RATIO FR

The proportion of workpiece length in front of the machine
upperside to the overall workpiece length during the bending
procedure (in the direction of the X-axis).
Define a value between 0.01 and 1.
0.3 means, for example: The control system calculates the
bending sequence in such a way that at least 30 % of the
workpiece length is located in front of the machine when a bend
is made.

B294e2.doc Programmed operation 2-41

 ❑ FRONT EXTEND RATIO ACCEPT FA
0 If FRONT EXTEND RATIO cannot be maintained because
of the product geometry, the control system calculates a
bend sequence ignoring this setting.
1 The control system does not calculate a bend sequence if
the FRONT EXTEND RATIO setting cannot be fulfilled. The
control system displays the message: "No bending
sequence possible".

❑ BACKSTOP AGAINST SHARP ANGLE ALLOWED SA

You define whether a gauge finger may contact a bend with an
angle of < 90° during automatic bending sequence calculation.
0 Stop is allowed.
1 Stop is not allowed.

1
3

1 Gauge finger ① Acute angle

2 Die
3 Workpiece
4 Punch

Stop at a point angle Fig. 12378

2-42 Programmed operation B294e2.doc

 ❑ BACKSTOP DIE INTERMEDIATE ANGLE IB
You define whether a gauge finger may contact a side at a
intermediate angle during automatic bending sequence
calculation.
0 Stop is allowed
1 Stop is avoided with lower priority
2 Stop is only allowed when not avoidable
3 Stop is not allowed

3
1

1 Gauge finger ① Intermediate angle

2 Die
3 Workpiece
4 Punch

Stop at an intermediate angle Fig. 12380

B294e2.doc Programmed operation 2-43

 ❑ EDGE TOLERANCE ET
You define the size of obtuse angle still allowed by the
backgauge stopping the product during automatic bending
sequence calculation.
You give this value as a tolerance between 0° and 90° in the
horizontal direction.

2
3 1

1 Gauge finger ① Bend angle

2 Die ② Edge tolerance
3 Workpiece
4 Punch

Edge tolerance Fig. 12379

❑ 90 DEGREE TOLERANCE CT
You define the maximum deviation from a 90° bend with which
the gauge finger may still make contact during automatic
bending sequence calculation.
You give this value as a tolerance between 0° and 90° in the
vertical direction.

2-44 Programmed operation B294e2.doc

 4

3 1

1 Gauge finger ① 90° Tolerance

2 Die
3 Workpiece
4 Punch

90° tolerance Fig. 12384

B294e2.doc Programmed operation 2-45

 ❑ LAY ON BACKSTOP LIMIT BL
Workpiece length in X-direction (starting at the center of the
die) starting at which the control system programs the gauge
fingers in such a way that the workpiece can be placed onto the
gauge fingers (② is greater than BL).

A
3

1
1

B
3

2
1

1 Gauge finger A ① is smaller than limit value BL

2 Die B ② is larger than limit value BL
3 Workpiece

Limit value for stop or positioning Fig. 12381

❑ RADIUS FACTOR EXTENDED LENGTH RF

Correction factor for the inside radius of a bend to compensate
for bend shortening during bending of the workpiece (extended
length).
This factor only refers to the calculation of the extended
length. It has no effect on the position of the backgauge.

2-46 Programmed operation B294e2.doc

 ❑ RADIUS FACTOR X-AXIS AF
Correction factor for the position of the X-axis calculated by the
control system to compensate for bend shortening during
folding of the workpiece.

RF- and AF-factors are determined with a single bend on a test

workpiece of known length. The deviation of the measured side
lengths from the nominal value help to establish both factors.

❑ MIN. Y-OPENING YM
Opening of the machine upperside after bending.
The control system automatically calculates a value for
the minimum opening of the machine upperside. The
value of YM is added to the mute point.

❑ X TOLERANCE DIN XA
Method used for calculating extended length.
0 Calculation according to a formula from DELEM
Formula is applicable especially for bends ≥ 90°.
1 Calculation according to DIN 6935
Formula is applicable especially for bends ≤ 90°.

Functions

With PREVIOUS PAGE and NEXT PAGE you can scroll between
PREVIOUS screen pages.
PAGE

NEXT
PAGE

With SAVE AS DEFAULTS you can save the current assignment

LOAD data and after editing, call-up again with LOAD DEFAULTS.
DEFAULTS

SAVE AS
DEFAULTS

B294e2.doc Programmed operation 2-47

 4.5 From the two-dimensional graphics to
the CNC-program

After the bend section has been drawn, the bending sequence is
defined. The bending sequence can be calculated by the control
system or programmed manually.

The BEND SEQUENCE interface is accessed by pressing the

BEND S5 softkey.
SEQUENCE

PRODUCT INPUT interface Fig. 15412E

2-48 Programmed operation B294e2.doc

 Selecting tools

In the dialogue input field you will be asked to select the bending
sequence for individual tools. Enter the corresponding tool number
(see also ’3. Programming tools’ beginning on page 2-7).
When < ENTER > is pressed the programmed tool is displayed on
the screen. At the same time you will be asked to designate the
next tool to be programmed in the dialogue field:

Selecting tools Fig. 15414E

An existing tool configuration can still be changed. The control

system switches within the dialogue entry field between tools which
can be programmed with a new tool number when < ENTER > is
pressed.

You can set up several different punches or several different

dies simultaneously within one bending sequence. Make
certain that the different tools have the same tool heights!

B294e2.doc Programmed operation 2-49

 The function GRAPHICAL DIRECTORY provides a graphic
GRAPHICAL overview of the current tool directory, from which you can choose
DIRECTORY
the desired tool. For example, dies:

GRAPHICAL DIRECTORY interface - Dies Fig. 15415E

A tool can be programmed from the graphical directory in exactly

the samre way as from the overview directory.

Selecting dies Die width is determined by the sheet thickness. To insure that the
maximum load on the die is not exceeded the following equation is
used to determine die width:

V ≥ 6 to 8 x BS

V Die width
BS Sheet thickness in mm

2-50 Programmed operation B294e2.doc

 Programming turned tools All tools are viewed from the right-hand gauge side on the screen. If
you want to install a tool reversed, enter the negative tool number in
the dialogue input field. For punch No. 1 enter therefore "-1".

1 2

1 Tool No. 1 from right-hand side of gauge (standard)

2 Tool No. -1 from left-hand side of gauge (reversed)

Programming turned tools Fig. 12386

After you have programmed all the tools, the tools and the
programmed product are depicted on the screen in their actual
dimensions. The last bend is located between the punch and die:

BENDING SEQUENCE interface Fig. 15492E

B294e2.doc Programmed operation 2-51

 Changing position of actual bend

All bends which could be implemented without collision as possible

alternatives to the bend currently shown are marked with a large
circle (see Fig. 15492 on page 2-51).

If you would like to change the position of the last bend, move the
product using the cursor keys < ← > and < → > between the tools
to the desired position.

A B C

3 1

1 2

3 2

2 1 3

① Bend possible (marked with circle) A bend ② suggested by the control system

② current bend B bend ① selected with the < → > key

③ bend not possible C bend ③ not possible without collision

(display possible only when has been deactivated)

Changing position of current bend Fig. 12423

A manual change is stored to the bending sequence only by

manual unbending (see UNBEND function on page 2-55).

2-52 Programmed operation B294e2.doc

 Manually programming gauge finger
position

With the function SHIFT GAUGE you can program the position of
SHIFT the backgauge finger so that the workpiece lies on the gauge finger
GAUGE
or can be stopped at the gauge finger.

The function SHIFT GAUGE is only active when the setting of the
parameter LAY ON BACK STOP LIMIT has been complied with.
(refer to "4.4 Assignment" 2-41). If you would like to place a
workpiece with a shorter side as BL on the gauge finger then you
must define a smaller value for BL in the ASSIGNMENTS.

1 2 3

1 Gauge position suggested by the control system

2 Possible gauge position if the BACKSTOP DIE INTERMEDIATE ANGLE IB is permitted in the ASSIGNMENT menu
3 Possible gauge position when workpiece placed on the gauge position

Positioning gauge fingers Fig. 15428

A manual is stored to the bending sequence by manual

unbending only (see UNBEND function on page 2-55).

B294e2.doc Programmed operation 2-53

 Turning workpiece

With aid of the ROTATE function program the rotation of the

workpiece underneath the punch within the bending sequence.
ROTATE
A rotation can become necessary if the original workpiece position
leads to a collision. The rotation is visualised on the screen:

A B

A Bending without collision is not possible

B Bending after rotation of workpiece possible

Rotating workpiece Fig. 12587

A manual change is stored to the bending sequence only by

manual unbending (see UNBEND function on page 2-55).

2-54 Programmed operation B294e2.doc

 Saving manual changes

The control system can store manual changes to the bending

sequence to the CNC program only if said changes have been
UNBEND
previously straightened manually using the UNBEND function.

This means: Each individual bend which includes a manual change

must be fixed using UNBEND.

Each straightened-out angle is marked on the product drawing with

a small circle:

BENDING SEQUENCE interface Fig. 15508E

With the function BEND you rebend an angle which has been
straightened.
BEND

Collision safeguard The control system has a collision safeguard which prevents
programming of bends with collision. In this case the message
SAFEGUARD "Collision safeguard on" appear in the header bar. This function
ON / OFF can be switched off using SAFEGUARD ON / OFF.

If the collision safeguard is switched off the control system

will allow a bend to be programmed although the collision is
displayed on the screen!

B294e2.doc Programmed operation 2-55

 Bend sequence display With each unbending step the associated clamping direction
appears on the bottom left of the screen. The sequence of bending
displays how many bends have been straightened so far and how
often the workpiece must be rotated during processing.

After you have straightened out the last bend, the overall pro-
cessing time (refer to "10.6 Production time calculation" on
page 2-122) calculated by the control system will be displayed:

t = x sec.

1
1
2

3
3

1 to 4 Bend No. 1 to 4 ① Top-bottom rotation

② Front-rear rotation
③ Combination of ① and ②

Bend sequence display Fig. 12388

2-56 Programmed operation B294e2.doc

 Automatic bend sequence calculation

With the function COMPUTE the control system automatically

creates a bending sequence for a designated product. All that
COMPUTE
remains for you to do is to select the tools.

You can have the automatic bend sequence carried out for all
bends. You can also however fix a section of the bends manually
and calculate the remaining bends with the function COMPUTE:

A B

1 1

2 2

3 3

4 4

5 * 5

6 6
*
A Automatic bend sequence calculation for all 6 bends
B Automatic bend sequence calculation for bends 1 to 4

Fig. 12589

You cancel the automatic bend sequence calculation by pressing

ABORT the softkey for the function ABORT COMPUTATION, the menu
COMP.
block for which appears during the calculation.

B294e2.doc Programmed operation 2-57

 Display bending sequence

The function BENDING SEQUENCE can be used to display a

BENDING graphic overview of the individual steps of the bending sequence,
SEQUENCE
provide that the product has been completely straightened.

Bending sequence graphic overview Fig. 15430E

Functions

Use these functions to enlarge or reduce the size of the on-screen

display.
ENLARGE

REDUCE

2-58 Programmed operation B294e2.doc

 Saving bend sequence

After you have optimised your bend sequence press the softkey for
the function STORE. The control system creates the associated
STORE
CNC-program with all the required machine settings.

During the calculation the message "Postprocessing" appears,

subsequently the extended product length is stated.

Extended length Fig. 15429E

The completed program is filed in the program catalogue under the

allocated product number and can be called up at any time (refer to
"8. Product selection" on page 2-107).

B294e2.doc Programmed operation 2-59

 5. Graphical programming in the three-
dimensional display

The DA-69 control system can also be used to graphically program

three-dimensional product drawings. The main difference between
3D-programming and 2D-programming is that areas rather than line
segments are added in 3D-programming.

Enter menu number 1 in the dialogue input field for PRODUCT

1
PRODUCT
PROGRAMMING. You access the graphics programming input
PROGRAMMING interface (refer to "4.2 Defining product parameters" on page 2-30).

2-60 Programmed operation B294e2.doc

 5.1 Menu block overview

Menu Block Overview PRODUCT DRAWING

3D programming

1
PRODUCT
DRAWING

Product parameter
3D programming

2D programming
PREVIOUS NEXT NEXT CHANGE DELETE FLAT/ BEND
SURFACE SURFACE SIDE LENGTH SURFACE BEND SEQUENCE

3D DRAWING

Tool configuration

SHIFT MANUAL TOOLS/ TOOL

UNBEND BEND GAUGE SELECT MACHINE CONFIG. STORE

3D BEND SEQUENCE SHIFT

PRODUCT

JUMP JUMP SWAP SWAP TOOLS/ NO

LEFT RIGHT LEFT RIGHT MACHINE CHANGE ACCEPT

SHIFT PRODUCT

SELECT CHANGE SHIFT SHIFT TOOLS/ ON NO

FINGER SIDE LEFT RIGHT MACHINE FINGER CHANGE ACCEPT

SHIFT GAUGE

PREVIOUS NEXT NEXT NO

SURFACE SURFACE SIDE SWAP CHANGE ACCEPT

MANUAL DETERMINATION OF BEND SEQUENCE

Menu block overview for 3D-programming Fig. 12593E

B294e2.doc Programmed operation 2-61

 5.2 Defining product parameters

Before you can display a product graphically, you are asked by the
control system to provide several product parameters which you
enter in interactive mode:

❑ 2D/3D DRAWING SELECTION DS

2 Programming in the two-dimensional display
3 Programming in the three-dimensional display

When programming in the two-dimensional display, the

parameter LENGTH L appears. This is the length of the
workpiece in the direction of the Z-axes. The control system
requires the length for 2D-programming in order to calculate
the bending pressure.

❑ PRODUCT NUMBER PN:

Numerical product number up to a max. of 7 figures.

❑ DRAWING NUMBER DN
Alphanumeric product name up to a max. of 20 characters.

❑ THICKNESS BS
Sheet thickness.

❑ MATERIAL M
Material type specified by tensile strength and E-modulus in
Menu 11 PROGRAM CONSTANTS (see ’9. Program
constants’ on page 2-111). There are six material types to
choose from:
1 Steel (mild steel)
2 Aluminium
3 Zinc
4 Stainless steel / special steel
5 Material 5 (user-defined material)
6 Material 6 (user-defined material)

❑ DIMENSIONS OUT/INSIDE 0/1

Type of dimension with which the product is marked
(see Fig. 12424 on page 2-32).
0 Outside dimension (standard)
1 Inside dimension

2-62 Programmed operation B294e2.doc

 5.3 Drawing product

After you have defined all product parameters, you access the
interface 3D DRAW. The base surface will be displayed.

3D-drawing interface Fig. 15462E

You define the dimensions of the base surface in the dialogue input
field. You first program the length of the first side, then the length of
the second side in the dialogue field.
The base surface cannot be deleted!

B294e2.doc Programmed operation 2-63

 Adding surfaces

After you have have specified the dimensions of the base surface,
the graphics programming menu bar appears. The cursor marks
one side of the base surface.

Adding surfaces Fig. 15464E

Header bar In the header bar you can see the way in which you can continue
processing the product. The position of the cursor determines the
possibilities.

❑ Adding surfaces
You can add a surface to the activated side of the base
surface.
❑ Rotate product
With the cursor-keys < ↑ >, < ↓ >, < ← > and < → > you
can rotate the product display.

In the dialogue input field you program the size of the bend angle
on the active side. You can simultaneously read the length of the
active side in the dialogue input field (see Fig. 15464).

You enter either the size of the bend angle or decide the direction
of the bordering surface with the < CURSOR >-keys as multiples of
45° (refer to Chapter 1: "3.3 Entering angles with the cursor-keys").
A surface can only be added to an open side!

2-64 Programmed operation B294e2.doc

 In the dialogue input field you program the length of the new
surface:

Programming side length Fig. 15465E

You can program a maximum of 26 surfaces within one

product.

Positioning cursor

With NEXT SIDE you move the cursor clockwise along the sides of
NEXT a surface.
SIDE

With the functions PREVIOUS SURFACE and NEXT SURFACE

PREVIOUS you position the cursor on an adjacent surface. The originally
SURFACE
activated side is deactivated.

Moving the cursor to an adjacent surface is only possible if it

NEXT has been previously positioned with NEXT SIDE on the
SURFACE associated bend line.

B294e2.doc Programmed operation 2-65

 Changing side length

With the function CHANGE SIDE LENGTH you can change the
CHANGE shape of a surface. The drawing appears in a separate window:
LENGTH

3D-DRAWING - Changing side length Fig. 15560E

Functions

Use PREVIOUS SIDE and NEXT SIDE to select the of the active
PREVIOUS surface which you wish to change.
SIDE

NEXT
SIDE

Use NEXT PART to select part of the active side (see example in
NEXT Fig. 15621 on the following page).
PART

2-66 Programmed operation B294e2.doc

 In the dialogue input field, the current length of the active side is
displayed. Enter the new length:
❑ For a new length enter a positive value.
❑ If you would like to reduce the original length, enter the value to
be subtracted with a negative sign.

100 -20 -20 60

1 2 3

-40 60

B
4 5 6

-40 60

7 8 9

A Reduce length on the entire side

1 The entire side is activated with the cursor
2 Input of -40
3 Result

B Reduce length of righthand section of side

4 NEXT SECTION: The righthand section is activated with the cursor
5 Input of -40
6 Result

C Reduce length of lefthand sectionof the side

7 The lefthand side is activated with the cursor
8 Input of -40
9 Result

Reducing side length Fig. 15621

B294e2.doc Programmed operation 2-67

 Side lengths with two adjacent surfaces cannot be changed! Side
lengths with only one adjacent surface can be changed by selecting
the open side using NEXT SECTION:

1 Change is not possible 3 Change is possible

2 Change is not possible
Changing a line with adjacent surface Fig. 15622

2-68 Programmed operation B294e2.doc

 5.4 From the three-dimensional graphics
to the CNC-program

With the function BEND SIMULATION it is possible to move from the

BEND
interface 3D-DRAWING to the interface TOOL CONFIGURATION.
SIMULATION

Selecting tools

In the interface TOOL CONFIGURATION the control system

assigns the saved tool configuration of the most recently created
product. e.g.:

TOOL CONFIGURATION interface - stored configuration Fig. 15467E

Use the function NEW CONFIGURATION to select a new tool

NEW configuration.
CONFIG.
In the dialogue input field you will be asked: "Are you sure 1/0?"

1 yes
0 no

B294e2.doc Programmed operation 2-69

 The last tool configuration is deleted. You reprogram all tools:

TOOL CONFIGURATION - new configuration Fig. 15466E

Define the tools in the dialogue input field by entering their tool
numbers (refer to ’Selecting tools’ on page 2-49).

The function SHOW LIBRARY provides a graphic overview of the

SHOW stored tools (see Fig. 15402 on page 2-10). You can also program
LIBRARY
tools in this interface.

2-70 Programmed operation B294e2.doc

 The selected tool is considered from the right-hand side of the
gauge, displayed in a separate window. For example, punches:

TOOL CONFIGURATION interface Fig. 15468E

Using the < ↑ > and < ↓ > keysyou can toggle between tools. The
current tool is marked by a colored border. The selected tool is
designated in the dialogue input field.

The maximum and minimum tool lengths for the programmed

drawing appear in the bottom right of the display area.

When programming a box the tool length needs to be programmed

at least 1 mm smaller than the length of the line of the bend.
Otherwise an error indication will appear.

Punches

In the dialogue input field you input the number of the required
punch. The control system positions the selected tool automatically
onto the whole length of the machine upperside (siehe Fig. 15468).
For tools installed in reverse you program the punch with a
negative sign (refer to ‘Programming turned tools’ on
page 2-51).

B294e2.doc Programmed operation 2-71

 Functions

If you have input heel dimensions for a tool in the Punch Constants
(refer to ‘Drawing punches’ on page 2-12), these dimensions can
HEEL
be activated via the function HEEL. You will be asked in the
dialogue input field by the control system for the Heel type. You
reply in interactive mode:

0 No heel tool
1 Heel dimensions on the right-hand side of gauge
-1 Heel dimensions on the left-hand side of gauge
2 Heel dimensions on both gauge sides

Heel tools are used when a standard punch would cause a lateral
collision with the workpiece:

1 Heel tool 2 Workpiece

Heel tool in operation (schematic diagram) Fig. 12420

With CHANGE POSITION you program a translation of the tool on

CHANGE the machine upperside. In the dialogue input field, you define a
POSITION
position (entries in [mm]) for the left-hand side of the tool gauge.
The left-hand side of the machine upperside is defined with 0 mm.

A tool set cannot be longer than the machine upperside itself.

If you do not want to assign the whole length of the machine

CHANGE upperside with one punch, select the function CHANGE LENGTH.
LENGTH
In the dialogue input field enter the required length. The tool length
is visualised on the screen proportional to the length of the
machine upperside.

2-72 Programmed operation B294e2.doc

 With ADD you can program additional tools on the machine
upperside, providing space is available. Enter the number and
ADD
length of the new punch in the dialogue input field.

Different tools on the same machine upperside must have

the same height!

The control system suggests a position for the centre of the second
punch marked with a yellow arrow. With the cursor-keys < ← >
and < → > you change the suggested position.

Adding a punch Fig. 15469E

Due to the limits of the machine frame the gauge fingers in

Z-direction cannot be moved completely to the zero or end position
of the press brake. For smaller parts the tool must be programmed
mounted inwards.

With DELETE you can remove one of several punches from the
configuration. The respective tool marked with a coulored border
DELETE
will be deleted.

This function cannot be carried out if there is only one punch

in the configuration.

B294e2.doc Programmed operation 2-73

 Dies

With the exception of the function Heel, the programming of the

dies is analgous to the programming of punches and can be carried
out correspondingly.

Machine upper- and lowerside

Program the number of the machine upperside and lowerside from

the stored directory.

After all tools have been programmed the function BEND

SIMULATION (softkey S8) appears in the menu header bar. With
this function you move to the interface 3D-drawing where the
bending sequence is defined.

2-74 Programmed operation B294e2.doc

 Bend simulation

In the BENDING SIMULATION interface you define the bending

BEND sequence for the designated product. The bent product is displayed
SIMULATION
on the screen:

3D-bending simulation interface Fig. 15489E

In order for the bending sequence to be calculated automatically

you must straighten out the product step by step. Only when the flat
product is depicted on the screen can the control system calculate
the CNC-program. In 3D-programming the system does not support
an automatic bending sequence calculation.

B294e2.doc Programmed operation 2-75

 Functions

With the function UNBEND you straighten the bend located

beneath the work station. The alteration is visualised on the screen.
UNBEND
At the same time the backgauge fingers are displayed at the stop
position selected by the control system:

3-D simulation following UNBEND Fig. 15471E

With UNBEND a manual change is accepted in the bending

sequence.

Use the function NEXT BEND to select the next bend to be

straightened. This bend too will first be suggested by the control
NEXT
system.

2-76 Programmed operation B294e2.doc

 Translating product under the tool set

With SHIFT PRODUCT you change the position of the tool on the
SHIFT Z-axis. The interface MANUAL PRODUCT POSITION appears in a
PRODUCT
separate window.

SHIFT PRODUCT interface Fig. 15486E

You can rotate the display of product and tools using the < ← >,
< ↑ >, < → > and < ↓ > keys.

Functions

With JUMP LEFT and JUMP RIGHT you implement the current
JUMP bend on one (left-hand or right-hand) adjacent tool station if you
LEFT
have programmed multiple tool stations. The current tool station is
displayed on the screen.
JUMP
RIGHT

With the functions SHIFT PRODUCT TO LEFT and SHIFT

SHIFT PRODUCT TO RIGHT move the work piece at the current tool
LEFT
station a defined length to the left or to the right.
You define this distance in the dialogue entry field. The minimum
SHIFT value is 0.01 mm.
RIGHT If one of these functions is actuated repeatedely the work piece
moves the programmed distance each time.

B294e2.doc Programmed operation 2-77

 With the function NO CHANGE the interface is quitted without
NO change.
CHANGE

With ACCEPT a manual change is accepted in the bending

sequence. Should this change cause conflicts in the bending
ACCEPT
sequence a corresponding error indication will appear.

With UNBEND a manual change is accepted in the bending

sequence.

Manually changing bend sequence

With MANUAL SELECTION you can change one of the bend

MANUAL sequences suggested by the control system.
SELECTION
When the MANUAL EDITING softkey is actuated the product
drawing appears in a separate window:

MANUAL EDITING interface Fig. 15472E

The bend between tools currently selected by the control system is

marked by the cursor (here: light gray). The light gray surface
shows the part of the workpiece which is located at the front of the
folding press.

You can rotate the display of product and tools using the < ← >,
< ↑ >, < → > and < ↓ > keys.

2-78 Programmed operation B294e2.doc

 Functions

Use the functions PREVIOUS SURFACE and NEXT SURFACE to

PREVIOUS set which of the two workpiece sides which border the active cursor
SURFACE
is located on the contact side or in front of the machine.

In practice this means: When changing to the adjacent surface the

NEXT workpiece is rotated underneath the tools; the bend itself remains
SURFACE the same.

1 Bend suggested by the control system (contact on short side)

2 Manual surface change (the short, light gray side is located in front of
the machine during bending)

Example for the function NEXT SURFACE Fig. 15485

With the function NEXT PAGE you position the cursor at a different
bend that is to be selected as the current bend in the bending
NEXT PAGE
sequence.

The cursor must border the surface onto which you want to switch.
With NEXT PAGE you can set the cursor at this position.

B294e2.doc Programmed operation 2-79

 When a product is constructed in such a way that two sides are
COMBI- located inside a bend line the control system will suggest that the
NATIONS
two bends are made simultaneously with one stroke.
The function COMBINATIONS appears on the menu bar with
which you can accept both bends in the bend sequence
individually.
Press 1x: The first bend is selected as the current bend.
Press 2x: The second bend is selected as the current bend.
Press 3x: Both bends are accepted simultaneously in the
bending sequence (starting position).

MANUAL SELECTION - Combinations Fig. 15484E

You can rotate the display of product and tools using the < ← >,
< ↑ >, < → > and < ↓ > keys.

With the function SWAP PRODUCT you program a rotation of the

product underneath the tools. The bend remains the same (see
SWAP
also Fig. 15485 on page 2-79).

With the function NO CHANGE the interface is quitted without

NO adoption of a manual change.
CHANGE

With the ACCEPT function a manual change is accepted in the

bending sequence. Should this change cause conflicts in the
ACCEPT
bending sequence a corresponding error indication will appear.

With UNBEND a manual change is accepted in the bending

sequence.

2-80 Programmed operation B294e2.doc

 Programming CNC-controlled backgauge
fingers manually

With the function SHIFT GAUGE you program the position of the
SHIFT gauge finger manually.
GAUGE

Adjusting fingers interface (here: Six-axis backgauge fingers) Fig. 15487E

You can rotate the display of product and tools using the < ← >,
< ↑ >, < → > and < ↓ > keys.

Functions

With SELECT FINGER the gauge finger to be positioned is

SELECT activated. The activated gauge finger is highlighted in light green,
FINGER
the deactivated gauge finger in dark green.

A new possible stop side of the product can be selected using the
CHANGE CHANGE SIDE function.
SIDE

With the functions SHIFT LEFT and SHIFT RIGHT move the
SHIFT activated backgauge finger a defined distance to the left or to the
LEFT
right.
You define this distance in the dialogue entry field. The minimum
SHIFT value is 0.01 mm.
RIGHT If one of these functions is actuated repeatedly the workpiece
moves the programmed distance each time.

B294e2.doc Programmed operation 2-81

 Six-axis backgauge, You can program the CLAMP function if your brake press has a
DA-69 six-axis backgauge. The workpiece is clamped between the gauge
fingers by means of the geometric form. The resulting lateral
contact provides a particularly stable hold:
CLAMP

CLAMP function with six-axis backgauge Fig. 15488E

There are two possible selections for clamping:

❑ Select CLAMP when the workpiece makes contact with the
gauge fingers:
The workpiece is clamped between the lower sections of the
gauge fingers (see Fig. 15488).
❑ Select CLAMP when the workpiece is lying on the gauge
fingers:
The workpiece is clamped between the upper sections of the
gauge fingers.
The function CLAMP is an on/off function. Pressing once activates
the function, pressing twice deactivates it again.

2-82 Programmed operation B294e2.doc

 Using the fuction LAY ON FINGER you can place the workpiece
LAY ON onto the gauge finger.
FINGER
This function is an on/off function. Pressing once activates the
function, pressing twice deactivates it again.

This function can only be carried out when the conditions of

the assignment LAY ON BACKSTOP LIMIT BL have been
fulfilled (refer to "4.4 Assignment" on page 2-41).

With NO CHANGE you quit the interface without accepting the

NO changes in the bend sequence.
CHANGE

With ACCEPT you quit the interface without accepting the change
in the bend sequence.
ACCEPT

With UNBEND a manual change is accepted into the

bending sequence.

Saving bend sequence

With the STORE function, a complete bend sequence is stored in

the memory. The control system computes the associated CNC-
STORE
program, the message "Postprocessing" appears. Product graphics
and CNC-program are saved and can be called up from the menu
PRODUCT SELECTION (refer to "8. Product selection" on page 2-
107).

B294e2.doc Programmed operation 2-83

 6. Generating CNC-programs without
graphic support

With the DELEM-control systems CNC-programs can be pro-

grammed without graphical support.

Enter menu number 3 in the dialogue input field for the function
3
DATA PREPARATION. In this menu all the program steps are
DATA
PREPARATION entered in interactive mode

6.1 Defining basic parameters

On the first page of the interface DATA PREPARATION you define

the parameters which apply for all bends in a program.

DATA PREPARATION Fig. 15490E

2-84 Programmed operation B294e2.doc

 ❑ Y-INPUT mα

0 absolut
Program the bending angle by entering the y-axis position
as an absolute value in [mm].
1 α
Program the bending angle in degrees.

❑ THICKNESS BS
Sheet thickness. Values between 0.05 mm and 99.99 mm are
possible.

❑ MATERIAL M
Material type specified by tensile strength and E-modulus in
Menu 11 PROGRAM CONSTANTS (see ’9. Program
constants’ on page 2-111). There are six material types to
choose from:
1 Steel (mild steel)
2 Aluminium
3 Zinc
4 Stainless steel / special steel
5 Material 5 (user-defined material)
6 Material 6 (user-defined material)

❑ EXTENDED LENGTH L
Overall workpiece length in X-direction after all bends have
been carried out.

❑ CONNECT CN
Number of an available program that is to be connected with
the current program.

Before a combined program series can be run, both

individual programs must be respectively connected with
each other!
The currently loaded program will be run first!

You connect two CNC-programs into a combined program series if,

for example, you want to bend a product in two axial directions.
Each program corresponds to an axial direction.

B294e2.doc Programmed operation 2-85

 6.2 Programming bend sequence

After you have defined all basic parameters access the interface in
which individual bends are programmed. In the header bar the
number of the current bend is displayed.

DATA PREPARATION - Programming bend sequence Fig. 15502E

❑ PUNCH UP
Number of required punch from the punch directory.

❑ DIE UN
Number of the required die from the die directory.

2-86 Programmed operation B294e2.doc

 ❑ BEND METHOD BM
0 Air bending
The machine upperside moves with the calculated pressure
to the absolute y-axis position or the y-axis position
programmed using the bending angle.
If the pressure is insufficient (e.g. because incorrect
material constants have been programmed) the machine
upperside remains stationary at the point of equilibrium.
1 Bottom bending
The machine upperside moves with the calculated pressure
downwards until it ceases movement for 0.3 s or until it has
reached the programmed y value. During bottom bending
the y value is generally located approx. 2 mm below the die
opening.
10 Flattening
11 Flattening with bottoming. The control system automatically
computes the required pressing force for flattening with
bottoming.

ACB® angle sensor 3 Bending method when making a bend using the ACB®
angle sensor in Identification or Control mode.
4 Bending method when making a bend using the ACB®
angle sensor in Learned bend mode.
Additional information about the ACB® angle sensor is
found in the Operating manual for the ACB® angle
sensor.

For each bend an individual bend method can be programmed. If

you do not define a bend method, the control system selects air
bending automatically.
The bend method is one of the parameters which the control
system requires for calculating the pressing force. You should
therefore check the bend method selected for each bend.

B294e2.doc Programmed operation 2-87

 Length of the bend line ❑ LENGTH BL
Length of the workpiece in the Z-direction.
This parameter is consulted by the control system when
calculating the required pressing force.

Defining bend angle Depending on the type of angle input which you have selected
(refer to "6.1 Defining basic parameters" on page 2-84), you will be
asked by the control system for the bend position of the machine
upperside or for a direct angle input.

❑ BEND POSITION Y
Lowest position of the machine upperside during bending.
This parameter can be programmed as an alternative to
ANGLE α.

❑ ANGLE α
Bend angle in [°].
The control system calculates the position of the machine
upperside and the required pressing force using angle, material
constants and bending method.

If the bending angle selected does not correspond to the

programmed tool a message will appear, for example: "Angle
too small for V opening, check using S3".
When the S3 softkey is pressed, the control system switches
to the graphical directory of the corresponding tool to allow
you to select an appropriate tool.

❑ OPENING DY
Opening of the machine upperside after a bend. DY is the
distance above the mute point.

2-88 Programmed operation B294e2.doc

 Positioning backgauge

❑ BACKGAUGE X
Position of the X-axis during bending.
Always enter values for the X-axis as positive values. The
(theoretical) value [0] corresponds to the front end of the
gauge finger on the line from the center of the die. For safety
reasons the minimum permissable value for the x-axis is
stored as 3 mm in the control system.

x=0
1

1 Gauge finger x=0 theoretical zero point

2 Die

Zero point of X-axis Fig. 12377

If an edge diagram is available and the product is to be program-

med using the outside measurements subtract the sheet thickness
or the half allowance value from the side measurement to get the
correct x-position.

B294e2.doc Programmed operation 2-89

 Six-axis backgauge If the cursor is positioned on the parameter BACKGAUGE X (X2)
DA-69 the function GAUGE FUNCTION appears in the menu bar.

In GAUGE FUNCTION a separate window appears in which all

GAUGE gauge positions are listed in overview.
FUNCTION

CNC-programming - Gauge functions Fig. 15559E

The explanation for gauge positions GL and GR can be found in

Menu 11 PROGRAM CONSTANTS in which the gauge functions
are defined (see ’9.5 Gauge finger dimensions’ on page 2-121).

2-90 Programmed operation B294e2.doc

 ❑ OPENING DX
Retraction of the X-Axis before a bend with programmed
pinching point (refer to parameter CODE CX, next page).

For certain workpiece shapes (e.g. Z-edge) the x-axis must retract
in front of a bend in order to avoid a collision with the back gauge.

1 Gauge finger 3 Punch

2 Die 4 Workpiece

Bend sequence with pinching point Fig. 12370

B294e2.doc Programmed operation 2-91

 ❑ CODE CX
The CODE defines the point at which the next bend will be
active:
00 Next bend becomes active on completion of pressure
release.
01 Next bend becomes active when mute point is passed
while press bar is raised.
02 Next bend becomes active when the machine upperside is
located at upper dead point (largest opening).
03 Next bend becomes active at upper dead point. The control
system switches to STOP.
04 Next bend becomes active when the UP-key on the
2-hand/foot control panel is activated and the machine
upperside is at rest. If the machine upperside moves, the
X-axis does not perform a retract function.
05 Next bend becomes active when the UP-key on the
2-hand/foot control panel is activated and is at the upper
dead point.

Pinching point 1X The combination of the previously described codes with a 1

at the start causes the acceptance of a pinching point into
the CNC-program. The machine upperside waits at the
pinching point until the X-axis is positioned at the
programmed value.
The workpiece is fastened between the tools by means of a
clamp so that it does not change position when the back
gauge retracts.

2-92 Programmed operation B294e2.doc

 ❑ DELAY TX
Delay of 0 to 30 secs between two bends.

❑ R-AXIS R
Position of the R-Axis during a bending process.

The values for the R-axis can be positive (above the die top
edge) or negative (below the die top edge). By entering the
value [0] you program the lower side of the gauge finger to
the height of the die top edge.
This means: The zero point of the R-axis corresponds to the
height of the die!

R=0

1 Gauge finger 2 Die

Zero position of the R-axis Fig. 12376

B294e2.doc Programmed operation 2-93

 Machine parameters

All the parameters calculated by the control system are annotated

with the message "Computed" after confirmation with the
< ENTER >-key. You can however a program in a value which you
yourself have selected.

CNC-controlled Deflection ❑ DEFLECT BM

The control system computes the corrected value inde-
pendently. The limits are determined by machine type.
0 Deflection is not active.

❑ REPETITION CY
Number of repetitions of an equal bend in the bending
sequence.
0 While the program is running, the control system ignores
this bend.
99 Maximum number of repetitions.

❑ SPEED V
The maximum speed of the machine upperside during the work
cycle depends on the machine type. It is between 11 and
13 mm/sec.

❑ PRESSURE P
Pressing force in [kN] or [t] (depending on the unit selected in
the machine parameters) during bending. The pressing force is
calculated by the control system automatically when you press
< ENTER >.

❑ DWELL TIME T
Time which the machine upperside remains with the computed
presssing force at the lowest bend point.

❑ BACKPR. SPEED BS
Working speed with which the machine upperside retracts from
the workpiece to the mute point after bending.
This parameter may not exceed 11 mm/s when bends are
made using the ACB angle sensor.

2-94 Programmed operation B294e2.doc

 ❑ DECOMPRES. DC
Path along which the machine upperside retracts after bending
workpiece. The control system computes the required value
automatically.
This parameter may not exceed 11 mm when bends are
made using the ACB angle sensor.

❑ PARALLEL Y2
Parallelism of the Y-axis below the mute point.
The parallelism is controlled via the Y2-axis.
Positive value: Y2-axis (right-hand axis when viewed from
the front) is lower.
Negative value: Y2-axis is higher.

I-axis ❑ I-AXIS ID
Engages or disengages the die adapter (e.g during folding with
pre-edging at a tool station. See also page 2-23f.).
1 I-axis in disengaged position
2 I-axis in engaged position
The mechanical setting of the translation path for the I-axis is
found in Chapter 5 of the Operating manual for TrumaBend
series V.

Second foot switch ❑ ON / OFF FD

Switches second foot switch on or off.
0 Second foot switch is deactivated.
1 Second foot switch is activated.

B294e2.doc Programmed operation 2-95

 CNC-controlled Z1/Z2-axis ❑ Z1-AXIS Z1
Z2-AXIS Z2
Position of the left gauge finger side (viewed from the front).

Due to limits imposed by the machine frame the gauge fingers

cannot be programmed to the outermost position of the
machine lowerside. The software limit is different for each type
of gauge.
You can find out the software limit of your machine by entering
[0] for the Z1-axis and [5000] for the Z2-axis in CNC-
programming. When these values are confirmed with
< ENTER > the control sytem will display the minimum value for
Z1 and the maximum value for Z2.

Part support... ❑ Part support PS

Switches part support on or off.
...with 1 arm 0 Part support is deactivated.
1 Part support is activated.
...with 2 arms 00 Part support is deactivated.
01 Arm 1 is activated, Arm 2 is deactivated
11 Both arms are activated.
Direct deflection of the part support is carried out via operating
station 1 (see chapter 5; operating manual)

❑ MACHINE UPPERSIDE M1
Number of machine upperside in the Machine upperside
catalogue.

❑ MACHINE LOWERSIDE M2
Number of machine lowerside in the Machine lowerside
catalogue.

2-96 Programmed operation B294e2.doc

 Programming sequence of It is not absolutely necessary to define this parameter.
bends
❑ ANGLE NUMBER AN
Number of a bend in a product drawing, counting from left to
right (Fig. 12590).

❑ BACKGAUGE XN
Number of the backgauge position on the product drawing
going from left to right (Fig. 12590).

For putting the workpiece onto the gauge finger enter [1] and
[gauge number].

0 1

1 4 5

4
2 3
2 3

① bis ④ Bend angle numbers

0 to 5 Possible backgauge

Way of counting Fig. 12590

B294e2.doc Programmed operation 2-97

 Programming additional After you have entered all parameters for the first bend the control
bends system will ask: "New bend 1/0?"
0 no new bend
1 new bend
The control system first copies all the parameters for the
previous bend to the next bend. You must match the
parameters for the new bend individually and confirm by
pressing < ENTER >.

Functions

With PREVIOUS BEND and NEXT BEND, you can scroll between
PREVIOUS two bends
BEND
In the header line the number of the current bend is displayed.

NEXT
BEND

With PREVIOUS PAGE and NEXT PAGE (the softkey is double

PREVIOUS assigned) you can scroll between the pages of a bend.
PAGE

NEXT
PAGE

2-98 Programmed operation B294e2.doc

 Bending sequence overview

Use ALL BENDS to get an overview of the most important settings

ALL in the bending sequence:
BENDS

DATA PREPARATION - All bends Fig. 15503E

Beside material type and thickness the following are displayed from
left to right:

❑ Number of the bend.

❑ Number of bend repetitions.
❑ Tool number of the programmed tool from the tool directory:
left-hand side: punch
right-hand side: die
❑ Length of the bend line.
❑ Bend angle or absolute position of the machine upperside.
❑ X(1)-axis position during the bend.
❑ Position of the X2-axis during bending (Six-axis back gauge).
CNC-controlled R-axis ❑ R1 (R2)-axis position during bending.
(can be selected using the function NEXT PAGE)
CNC-controlled deflection ❑ Setting of CNC-controlled deflection.

B294e2.doc Programmed operation 2-99

 Functions

With the function INSERT BEND you add on a new bend.

INSERT
BEND With the cursor-keys < ↑ > and < ↓ > you mark the bend which
the inserted bend should follow. The control system displays the
message "Save bend - press Enter". On pressing the < ENTER >-
key the added bend appears as a copy of the marked bend. With
the < END >-key you return to the marked bend in the previous
level.

With DELETE BEND a bend is deleted which was previously

DELETE marked with a cursor.
BEND

Use the functions PREVIOUS PAGE and NEXT PAGE to scroll

PREVIOUS between pages.
PAGE

NEXT
PAGE

6.3 Program backup

To save the new program press the < END >- or the < ENTER >-
key. You will be asked to allocate a numerical product number and
an alphanumeric drawing number.
The input of a product number is absolutely essential!

After you have confirmed the inputs with < ENTER >, you return
automatically to the input menu.

2-100 Programmed operation B294e2.doc

 7. Editing programs

You can make changes to an existing program if it has been loaded

(see ’8. Product selection’ on page 2-107). Depending on the type
of program you have two editing options:
❑ Edit graphics program, reset bending sequence and compute
CNC-program.
❑ Edit CNC-programs
Changes to the CNC-program cannot be transferred to the
graphic display of the graphics programming!

7.1 Editing graphics program

Enter menu number 2 for PRODUCT EDITING and press

2 < ENTER >. The interface is strcutured analogously to PRODUCT
PRODUCT
INPUT:
EDITING

copy
drawing
product

PRODUCT EDITING - Product parameters Fig. 15506E

B294e2.doc Programmed operation 2-101

 Functions

With COPY PRODUCT you can save the existing program under
COPY an additional product number.
PRODUCT

Editing 2D-graphics program

Using the DRAW function you access the existing product drawing.
The functions for editing graphics are the same as for intial
DRAW
programming in the PRODUCT PROGRAMMING menu (see ’4.3
Drawing bend section’ beginning on page 2-33).

PRODUCT EDITING - Draw Fig. 15507E

2-102 Programmed operation B294e2.doc

 Functions

With the BENDING SEQUENCE function the control system asks

BENDING whether you want to start a completely new bending sequence or
SEQUENCE
work using the existing bending sequence:

Changing bending sequence Fig. 15509E

With NEW the control system switches to the PRODUCT CONFI-

GURATION interface. You reprogram all tools (see ’Selecting tools’
NEW
on page 2-49) and define a new bending sequence.

The control system assigns the edited product to the most recently
saved bending sequence. You can also make changes here.
RESTORE
Finally the CNC program must be recalculated (see page 2-57).

Possibly the existing bending sequence and and the edited

drawing no longer match. If this is the case the following
message appears: "Invalid program. Press S1 to restart the
bend sequence". In this case it is not possible to save the
existing CNC-program.

If you edit the bending sequence existing α- and X-corrections are

deleted in STEP-BY-STEP or AUTOMATIC OPERATION (see
Chapter 3).

B294e2.doc Programmed operation 2-103

 Editing 3D-graphics program

You access the interface EDIT 3D DATA in which product

parameters can be confirmed or edited.

Using the DRAW function you access the existing product drawing.
The functions for editing graphics are the same as for intial
DRAW
programming in the PRODUCT PROGRAMMING menu (see ’5.3
Drawing bend section’ beginning on page 2-63).

PRODUCT EDITING - Drawing 3D Fig. 15510E

With the function BEND SIMULATION the control system first

BEND switches to the TOOL CONFIGURATION interface (for additional
SIMULATION
procedures see ’Selecting tools’ on page 2-69).
❑ Press NEW CONFIGURATION if you want to reprogram all
tools.
❑ Press BEND SIMULATION if you want to define the bending
sequence.

2-104 Programmed operation B294e2.doc

 The control system asks whether you want to start a completely
new bending sequence or work using the existing bending
sequence:

The control system switches to the interface 3D BEND

SIMULATION. The bend last suggested by the control system is
NEW
located among the tools. You define a new sequence as described
on page 2-75 under ’Bend simulation’.

The control system assigns the edited drawing to the most recently
saved bending sequence. You can also make changes here.
OLD
After editing it is possible that the old CNC-program no
longer corresponds to the product drawing. If this is the case
the following message appears: "Stored bending sequence
will be deleted. Continue?"
0 ancel: the bending sequence must be redefined.
1 Continue: the control systems saves the CNC-program
of the existing bending sequence in spite of the error
indication.

B294e2.doc Programmed operation 2-105

 7.2 Editing CNC-Programs

In Menu 4 PROGRAM EDIT you edit a CNC-program regardless

4 whether the program has been programmed graphically or in the
DATA EDIT
CNC-program.
The parameters in PROGRAM EDIT are identical to those for initial
programming in the DATA PREPARATION (see ’6. CNC-programs
without graphic support’ beginning on page 2-84).

Functions

With FIRST BEND you call up the first side of the first bend. The
FIRST CNC-program is processed in the same way as for creating a
BEND
program (refer to "6.2 Programming bend sequence" on page 2-86).

With PREVIOUS PAGE and NEXT PAGE (the softkey is double

PREVIOUS assigned) you can scroll between the pages of a bend.
PAGE

NEXT
PAGE

2-106 Programmed operation B294e2.doc

 8. Product selection

In the menu 5 PRODUCT SELECTION all the programs saved in

5 the control system are listed:
PRODUCT
SELECTION

PRODUCT OVERVIEW - compressed overview Fig. 15536E

The following information can be derived from the product

designation, e.g. 2 P2D:
❑ 2 Product number
❑ P A CNC-program is available.
❑ 2D A two-dimensional product drawing is available.
❑ 3D product drawing is available.
❑ − Product drawing / CNC-program is not available.

Functions

With PREVIOUS PAGE and NEXT PAGE (the softkey is double

PREVIOUS assigned) you can scroll between the pages of a bend.
PAGE

NEXT
PAGE

B294e2.doc Programmed operation 2-107

 With this alternating function you can call up products using either
DRAW NO. the drawing number or the product number.
PROD. NO.

This function is only active in conjunction with the function

DRAWING NUMBER. It is required in order to enter letters (see
ALPHANUM.
Chapter 1: ’3.2 Entering letters’).

8.1 Loading or deleting product

Loading product A product can be loaded immediately by switching to PRODUCT

OVERVIEW (’Select product’ appears in the dialogue input field):
❑ Enter the product or drawing number.
❑ Press < ENTER >.
The product is now loaded and can be edited or executed.

Deleting product The DELETE function appears in the menu field when the LOAD
function is active and vice versa.
DELETE
Use DELETE to delete an existing product (’delete product’
LOAD appears in the dialogue input field: The control system asks: "Are
you sure 1/0?"

1 The product is deleted.

0 The delete procedure is aborted.

Delete all products The function DELETE ALL deletes all products from the memory.
The control system asks: "Are you sure 1/0?" In addition the
DELETE message appears "Press 1 to delete all programs".
ALL
1 The product is deleted.
0 The delete procedure is aborted.
In addition the following message appears: "Press 1 to delete all
programs".

2-108 Programmed operation B294e2.doc

 8.2 Expanding directory

With the function DIRECTORY EXPAND you can extend the

DIRECTORY directory for the saved products:
EXPAND

PRODUCT SELECTION - expanded directory Fig. 15537E

You receive the following information:

❑ Product number
❑ Drawing number
❑ Number of bends (when a CNC-program is available)
❑ Program type
❑ Connection with other programs (refer to "6.1 Defining Basic
parameters" on page 284)
❑ Directory number of the punch or die used in the first bend.

With DIRECTORY COMPRESS you return to the compressed

DIR. directory.
COMPRESS

B294e2.doc Programmed operation 2-109

 The function GRAPHICAL DIRECTORY appears in the menu bar
GRAPHICAL in the expanded directory. You are given a graphic overview of all
DIRECTORY
products when a product drawing exists:

PRODUCT OVERVIEW - graphical directory Fig. 15538E

2-110 Programmed operation B294e2.doc

 9. Program constants

In menu 11 PROGRAM CONSTANTS you define operator specific

11 parameters.
PROGRAM
CONSTANTS

PROGRAM CONSTANTS - Input screen Fig. 15539E

Functions

With PREVIOUS PAGE and NEXT PAGE you can scroll between
PREVIOUS pages
PAGE

NEXT
PAGE

B294e2.doc Programmed operation 2-111

 9.1 General parameters

❑ INCH / MM 1/0 IS
You define the desired dimensions:
0 All lengths are programmed in [inches].
1 All lengths are programmed in [mm].

❑ TON / kN selection 1/0 TS

0 Pressing force calculated in [t].
1 Pressing force calculated in [kN].

❑ LANGUAGE LA
The various language versions are listed on the screen. Input
the digits for the desired language.

❑ MATERIAL TENSILE STRENGTH S, E-MODULUS E

Although materials 1 to 4 are defined by the manufacturer the
numerical values can be changed. You can define materials 5
and 6 yourself.

PROGRAM CONSTANTS - material constants Fig. 15540E

1 Steel
2 Aluminium
3 Zinc
4 Stainless steel
5 User defined
6 User defined

2-112 Programmed operation B294e2.doc

 9.2 Machine constants

PROGRAM CONSTANTS - machine constants Fig. 15546E

❑ PRESSURE CORRECTION (SAFETY FACTOR) FF

You program a factor which raises the required closing
pressure for a bend. The standard value is 120%, i.e. the
control system computes a closing pressure for each bend
increased by 20 %.

❑ TURN PAGE DELAY PD

Time in which a screen page is turned over.

❑ REDUCTION 1/0 BA
X-axis correction in relation to the extended length when
creating a bend sequence without graphic support (refer to "6.
Creating CNC-program without graphical support" on
page 2-84).
0 Correction not active
1 Correction active

B294e2.doc Programmed operation 2-113

 CNC-controlled Z1/Z2 axis ❑ Z-OFFSET ZD
Minimum offset of the gauge fingers from the lateral edge of the
workpiece when the control system calculates a bending
sequence:

A 1 A

1 Gauge finger A Z-OFFSET

2 Workpiece

Z-OFFSET Fig. 12385

❑ BOTTOMING PRESSURE CORRECTION BF

factor multiplied to the pressing force of an air bend during a
bottom bending. Depending on the material being used this
value should be between 3 and 8.
The maximum value for this factor depends on the tool selected
and the properties of the material being used.
The load bearing capacity of the punch and the die is defined in
the parameter RESISTANCE R in the tool constants in kN per
1 mm of tool length.
For a bottom bend on a length of 100 mm using a tool with
resistance R = 1.3 kN the maximum permissable pressing force
for this bend is calculated in the following manner:

1.3 kN/mm x 100 mm = 130 kN

2-114 Programmed operation B294e2.doc

 ❑ CLAMPING CORRECTION CC
Correction of the calculated ’punch to top of ram’ at the
clamping point (see ’Positioning backgauge’ on page 2-89).
Positive value: clamping point is lower.
Negative value: clamping point is higher.

❑ FLATTENING OFFSET OF
Offset between the flattened workpiece sides (Fig. 12387,
item 1) during flattening.

❑ FLATTENING OPENING FOP

Gap between the flattening surface of the punch and the
flattening surface of the die. This value determines the machine
upperside dwell point during flattening (Fig. 12387, item 2).

A B

A FLATTENING OFFSET 1 Punch

B FLATTENING OPENING 2 Die
3 Workpiece

Flattening parameters Fig. 12387

B294e2.doc Programmed operation 2-115

 PROGRAM CONSTANTS - machine constants Fig. 15547E

❑ PARALLEL OFFSET PO
Difference (inclination) between the Y1 nd Y2 axes during
machine upperside stroke below th mute point.
The control system uses the value defined here as the base
value for all programs and bends.
Should you program an inclination for individual bends using
PARALLEL Y2 in the CNC-program the inclination is the sum
of PO + Y2.

❑ AUTO BEND CHANGE MODE (STEP) CS

Here you define an automatic mode step change within a bend
sequence in the group operating mode STEP-BY-STEP
OPERATION.

0 No automatic automatic mode step change takes place in

STEP-BY-STEP OPERATION. The next bend must
selected first.
1 The control system loads the next bend parameters
automatically. After activating the START-key the axes
move into position.

2-116 Programmed operation B294e2.doc

 Six-axis backgauge ❑ X1X2 DIFFERENCE PROGRAMMING XX
Method by which you can program the proportion of the X1 axis
to the X2 axis in the CNC-program.
0 Program the proportions in projection dimension.
1 The function is not supported by the system.

❑ DEFAULT X-AXIS CODE XC

Default setting for the point at which the transition of the x-axis
to the next bend occurs.

0 Boundary with next bend at bend point (default

configuration).
1 Boundary with next bend at mute point after a bend.
2 Boundary with next bend at upper dead point of machine
upperside axis.
The control system attempts within the framework of the
assignments (refer to "4.4 Assignment" on page 2-41) to
compute the shortest processing time for a bend sequence.
As a consequence the boundary with the next bend is
activated at the bend point by default. With the DEFAULT X-
AXES CODE you can program another boundary as the
default boundary.

❑ DEFAULT X-TIME XT:

Default setting for the dwell time before the next bend is
activated.

❑ X REFERENCE CORRECTION XR:

You define a correction value for the X1 axis reference point.
If the current position of the x-axis does not match the value
calculated and displayed by the control system you can make
an override correction e.g.
displayed value: 250 mm
actual value: 252 mm
reference correction XR: - 2 mm
This means: Following the correction the x-axis moves to the
position 250 mm and displays this value in the control system.

B294e2.doc Programmed operation 2-117

 Six-axis backgauge ❑ X2 REFERENCE CORRECTION XR:
Correction value for the reference point of the X2 axis as in the
preceding parameter.

❑ SETTING-UP AUTO.CALC.AC
Automatic recalculation of material dependent parameters after
the material constants of a bend have been modified in a CNC-
program.
0 Material dependent parameters remain unmodified.
1 Material dependent parameters are recalculated after you
have pressed < ENTER >.
Material constants are: material type
material thickness
bending length

modified are: pressure

release path
CNC-controlled deflection
CNC Z-axes (for bending length)

2-118 Programmed operation B294e2.doc

 9.3 Serial interface

It is possible to program the control system from an external PC

with the PROFILE-software. For this purpose all control systems
have a serial interface. On screen page 11.5 of the program
constants you specify the transmission parameters.

PROGRAM CONSTANTS - serial interface Fig. 15548E

❑ MACHINE NUMBER MN:

Number for indentifying a machine in the PROFILE-software.
The default number is 1.
It is essential to indentify individual machines if you are
programming several machines with the PROFILE-software.

❑ STOP BITS 1/2 SB:

Transmission parameter with default value of 2.

❑ PARITY ODD/EVEN 1/0 PA:

Transmission parameter with default value of 0.

❑ BAUD RATE BR:

Transmission parameter with default value of 5.

B294e2.doc Programmed operation 2-119

 9.4 Backgauge speed

The following parameters are releant for calculating production time

only (see also ’9.6 Production time calculation’ on page 2-120).
They have no influence on the actual working speed of the axes.

PROGRAM CONSTANTS - back gauge speed Fig. 15549E

❑ X-AXIS SPEED BS:

Working speed of the X-axis.

❑ R-AXIS SPEED RS:

Working speed of the R-axis.

2-120 Programmed operation B294e2.doc

 9.5 Gauge finger dimensions

PROGRAM CONSTANTS - gauge finger dimensions Fig. 15550E

The dimensions of the gauge finger are preset by TRUMPF. The

following basic data can be altered as required:

❑ GAUGE POSITIONS GN
Number of possible gauge positions.
Marked as 0, 1 and 2 i the illustration above.

❑ DEFAULT INDEX POSITION GD

Position given preference by the control system in calculating
the bending sequence.

❑ Finger dimensions:
• FINGER WIDTH FW
• FINGER HEIGHT FH
• FINGER LENGTH FL
• GAUGE LENGTH L2
• GAUGE HEIGHT H

Please note that the control system calculates the translation

path from the R- and X-axis and any possible collision
between product and backgauge with the finger dimensions.
Incorrect adjustments at this point could result in damage to
your press brake.

B294e2.doc Programmed operation 2-121

 9.6 Production time calculation

The control systems have a production time calculation available

with the graphics programming, including the time to turn a
workpiece taking into account its spatial dimensions.

PROGRAM CONSTANTS - Production time calculation Fig. 15551E

❑ BOUNDARIES B1 to B3
Workpiece dimensions as limit values that define the boundary
to an increased handling time in production time calculation.

With the following parameters you establish the time interval for a
workpiece rotation which are valid for the previously programmed
length interval:

❑ TOP BOTTOM TURN T1 to T4

The time intervals refer to a rotation of the workpiece about the
X-axis, i.e. the previously defined length intervals apply to the
length of the workpiece in the Z-direction.

❑ FRONT BACK TURN F1 to F4

The time intervals refer to a rotation of the workpiece about the
Z-axis, i.e. the previously defined length intervals apply to the
length of the workpiece in the X-direction.

❑ COMBINATION TURN C1 to C4
The time intervals refer to a rotation of the workpiece about the
Z-axis, combined with a rotation about the X-axis. The
previously defined length intervals apply to the size of the
workpiece in the X- and Z-direction.

2-122 Programmed operation B294e2.doc

 9.7 Machine upperside speeds

The Y-axis working speeds defined here are required for the
production time calculation. They have no influence on the actual
working speed of the axes:

PROGRAM CONSTANTS - machine upperside Fig. 15552E

In each case you define the average movement speeds:

❑ CLOSING SPEED CS
Closing speed of the machine upperside in rapid traverse.

❑ PRESSING SPEED PS
Speed of the machine upperside in work cycle.

❑ OPENING SPEED OS
Opening speed of the machine upperside in rapid traverse.

B294e2.doc Programmed operation 2-123

 10. External management of tools,
program and machine constants

We recommend that you always make a backup copy of all

saveable parameters.

Diskette format Diskettes for the DA-65 and DA-69 control systems must have the
following format:
❑ 3½" HD/2HD
Diskettes with the 3½" DS/DD can only be read by the
control systems.

10.1 Product backup

In the PRODUCT BACKUP menu programs can be read from

6 diskette or be transmitted from the control system onto diskette.
PRODUCT
BACKUP

PRODUCT BACKUP Fig. 15554E

Use this function to format a diskette.

INIT
All data saved on the diskette is deleted during formatting!
DISKETTE

2-124 Programmed operation B294e2.doc

 Use this function to save all products and programs onto diskette.
PRODUCT
BACKUP All products will be listed.

Product backup on diskette Fig. 15555E

If you would like to save an individual program on diskette, enter

the required product number in the dialogue input field and confirm
the input with the < ENTER >-key.

If you do not have the storage medium or it has not been

correctly inserted or if the storage medium does not
correspond to the correct format, the control systems reports
"Diskette incorrectly inserted". Check the diskette and the
disk drive and repeat the command.

B294e2.doc Programmed operation 2-125

 Functions

With PREVIOUS PAGE and NEXT PAGE you can scroll between
PREVIOUS program pages.
PAGE

NEXT PAGE

Use ALL PRODUCTS to save all products onto diskette.

ALL
PRODUCTS The control system gives the message "Data could be overwritten.
Are you sure? 1/0".

1 The data is saved

0 The saving procedure is aborted
Programs stored with the same number in the control system
program memory and on diskette are overwritten i.e. deleted.

The programs can be loaded according to either the product

DRAW number or the drawing number.
NUMBER

PRODUCT
NUMBER

2-126 Programmed operation B294e2.doc

 10.2 Reading tools from diskette

Use this function to read in products and programs into the control
PRODUCT system from diskette.
RESTORE
All programs stored on the diskette will be listed.

Programs in the control system or on diskette with identical

product numbers are written over when saved and therefore
deleted.

If you would like to save an individual program from diskette in the

control system, you enter the required product number in the
dialogue input field and confirm the entry with the < ENTER >-key.
The end of this procedure is reported with the message "finished".

Functions

With PREVIOUS PAGE and NEXT PAGE you can scroll between
PREVIOUS program pages.
PAGE

NEXT PAGE

The loading of all programs from a diskette is carried out by

ALL activating the function ALL PRODUCTS.
PRODUCTS

Programs which are available to the control system under the

same product number on diskette or in the program memory
are overwritten and therefore deleted.

With the DA-65 control system the programs can be loaded

DRAW according to the product number or the drawing number.
NUMBER

PRODUCT
NUMBER

B294e2.doc Programmed operation 2-127

 10.3 Tool backup

The layout of the menu interface 12 TOOL BACKUP corresponds

12 to the layout of the menu interface 6 PROGRAM BACKUP.
TOOL
BACKUP

TOOL BACKUP Fig. 15556E

You can save tool constants on diskette and copy from diskette into
the control system memory.

Up to software level < V2.1 the machine parameters are also

stored during tool backup. The same is true when tools are
read into the control system. This means: existing tool
constants will be overwritten!

2-128 Programmed operation B294e2.doc

 11. Machine parameters

Starting with control system software V2.1 machine parameters can

be read in from diskette or stored onto diskette separately from
tools. You must confirm all entries by pressing < ENTER >.

❑ Enter menu number 19 in the input menu.

❑ Enter access code "14753".
❑ Select Menu 5 MACHINE PARAMETERS.
The following interface appears:

STORING MACHINE PARAMETERS Fig. 15660E

Use this function to format a diskette.

FORMAT
DISKETTE All data saved on the diskette is deleted during formatting!

B294e2.doc Programmed operation 2-129

2-130 Programmed operation B294e2.doc
 Chapter 3

Manual operation,
automatic operation and
step-by-step operation
1. Manual operation ........................................................... 3-2

2. Automatic and step-by-step operation ........................ 3-7

2.1 Graphically visualising bend sequence .......................... 3-12

3. Set-up mode ................................................................. 3-14

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-1

 Chapter 3 describes the group operating modes in which bending
programs run: MANUAL OPERATION, STEP-BY-STEP OPERA-
TION and AUTOMATIC OPERATION.

1. Manual operation

In group operating mode MANUAL OPERATION you program all

parameters for an individual bend separate from the loaded
program. The parameters are active after the START key has been
pressed. All CNC-controlled axes move into position, the bend can
now be made.

Select group operating mode MANUAL OPERATION. The following

interface appears:

Group operating mode MANUAL OPERATION Fig. 15624E

You program the following parameters:

❑ PUNCH UP
Punch number from the punch directory.
❑ DIE UN
Die number from the die directory.

3-2 Manual operation, automatic operation and step-by-step operation B294e3.doc

 ❑ MATERIAL MA
In the menu PROGRAM DATA, material type defined by tensile
strength and E-module (see Chapter 2: "9. Program data" on
page 2-120). There are six material types to choose from:
1 steel (mild steel)
2 aluminum
3 zinc
4 stainless steel / special steel
5 Material 5 (user-defined material)
6 Material 6 (user-defined material)

❑ THICKNESS TH
Sheet thickness. Possible values between 0.05 mm and
99.99 mm.

❑ LENGTH BL
Length of the workpiece in Z- direction.
This parameter is required by the system in order to calculate
the bending pressure.

❑ BEND METHOD BM
0 Air bending
1 Bottom bending
10 Flattening
11 Flattening with bottoming

ACB® angle sensor 3 Bending method when making a bend using the ACB
angle sensor in Identification or Control mode.
4 Bending method when making a bend using the ACB®
angle sensor in Learned bend mode.
Additional information about the ACB® angle sensor is
found in the Operating manual for the ACB® angle
sensor.

❑ CORRECTION Cα
SENSORCORRECTION Sα
Correction value for the current bend angle.
In order for a correction to become active, the Y measurement
must be confirmed one more time by pressing < ENTER >.

A negative input increases the angle, i.e. the bend angle opens
wider with correction in comparison to the uncorrected angle. A
positive degree input reduces the angle, the angle getting smaller
on correction.

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-3

 ❑ ANGLE α
Bend angle in [°].

❑ Y-AXIS Y
Lowest position of the machine upperside during bending.

❑ MUTE M
Boundary between rapid transverse and work cycle. The offset
from the die to the workpiece surface is calculated.
This parameter is as a rule defined as 4 mm.

❑ DECOMPRESSION BP
Distance by which the upper beam retracts after the bending of
the workpiece.

This parameter may not exceed 11 mm when bends are

made using the ACB angle sensor.

❑ PRESSURE P
Closing pressure during bending.

❑ X-AXIS X
Position of the X-axis during bending.

❑ OPENING DY
Opening of the machine upperside after a bend above the mute
point.

❑ SPEED S
Closing speed of the machine upperside in work cycle.

❑ BACKPR. SPEED BS
Speed with which the machine upperside after bending retracts
from the workpiece in work cycle.
This parameter may not exceed 11 mm/s when bends are
made using the ACB angle sensor.

❑ D-TIME T
Dwell time of the machine upperside at lower dead point of the
machine upperside. Maximum possible dwell time is 9.9 s.

3-4 Manual operation, automatic operation and step-by-step operation B294e3.doc

 ❑ PARALLELISM Y2:
Inclination of the machine upperside below the mute point. The
maximum possible difference between Y1 and Y2 is 10 mm.
The inclination is controlled via the Y2-axis.
The following definition applies to TRUMPF default settings for
machine parameters:
Positive value: Y2-axis (right-hand axis, viewed from the
front) is lower.
Negative value: Y2-axis is higher.

❑ R-AXIS R
Position of the R-axis during bending.

Six-axis backgauge ❑ X-AXIS X1

Position of the X1-axis during bending.

❑ X2-AXIS X2
Position of the X2-axis during bending.

❑ R1-AXIS R1
Position of the R1-axis during bending.

❑ R2-AXIS R2
Position of the R2-axis during bending.

❑ Z1-AXIS Z1
Position of the Z1-axis during bending.

❑ Z2-AXIS Z2
Position of the Z2-axis during bending.

Part support ❑ PART SUPPORT PS

Activates the part support. For functional details, refer to the
TrumaBend operator’s manual (p. 4-39).

Parameter G-corr Gp
The final position of the part support can be corrected using this
parameter. The value is entered in degrees. A positive value
results in a larger final angle of the part support to the
horizontal line. A negative value decreases the angle to the
horizontal line.

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-5

 Functions

The function SEQUENCER DEBUG is a service function for

SEQUENCER service technicians. It is not important for the operation of the
DEBUG
control system.

Axes not displayed on the first page of the display screen will be
found on the following screen page. Use NEXT PAGE to scroll to the
NEXT PAGE
following screen page.

PREVIOUS
PAGE

By actuating the function MACRO all current settings of the

MACRO CNC-controlled axes are displayed in upper case making them
easy to read, even for an operator standing at a distance.

X2 = Z1 = 500.0
BM = Z2 = 900.0
ID = R1 = 1500.0
FD = R2 = 1900.0

MANUAL OPERATION - Macro Fig. 15625E

Position all CNC-controlled axes with the handwheel using the

MANUAL MANUAL POSITIONING function (see §3. Set-up mode" on
POSITIONING
page 3-14).

3-6 Manual operation, automatic operation and step-by-step operation B294e3.doc

 2. Automatic and step-by-step operation

The interfaces for the group operating modes AUTOMATIC

OPERATION and STEP-BY-STEP OPERATION are identical and
are therefore not dealt with separately.

In AUTOMATIC OPERATION you run the program called up in

PROGRAMMED OPERATION. You can undertake angle corrections
or corrections directly on the X-axis, without having to leave the
interface.

In STEP-BY-STEP OPERATION you run a program activated in

PROGRAMMED OPERATION. After each bend the control system
switches to STOP. The next bend must be reactivated by means of
the START-key. You can also undertake angle corrections or
corrections directly on the X-axis without leaving the interface.

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-7

 Select the group operating mode AUTOMATIC OPERATION or
STEP-BY-STEP OPERATION. The following interface appears:

AUTOMATIC OPERATION (here: six axis backgauge) Fig. 15626E

In the upper section of the screen information about the current

positions of the Y- and X-axes and an overview of the most
important program constants. You cannot however do any editing
here.

You receive information about the following program constants:

Axis parameters ❑ Bend angle

❑ Opening of the Y-axis
❑ Punch number from the punch catalogue
❑ Die number from the die catalogue
❑ Fold length
❑ Position of X-axes
❑ Retraction of X-axes during bending.
❑ Code which defines the boundary with the next bend
❑ Delay between two bends
❑ Positions of other CNC-axes (not illustrated)

3-8 Manual operation, automatic operation and step-by-step operation B294e3.doc

 With the double assigned softkey FUNCTIONS / AXES you can
FUNCTIONS
toggle between axes parameters and progam parameters.
AXES

Program parameters ❑ Speed of the machine upperside in work cycle before bending.
❑ Maximum closing pressure during bending.
❑ Dwell time of machine upperside during bending.
❑ Speed of the machine upperside in work cycle after bending.
❑ Path along which the machine upperside retracts after bending
in work cycle.
❑ Parallelism of the Y-axes below the pinching point.
❑ Thickness of the material to be folded.
❑ Material type
❑ Bend angle
❑ Part support activated (if applicable)

The correction possibilities for bend angle, X-axis position and

angle of the part support (if applicable) are displayed in the lower
section of the screen. Here you can mark the positions to be
changed by using the cursor keys < ↑ > and < ↓ >, and define
corrections in the dialog input field. The corrections have no effects
on the CNC program from programmed operation.

❑ BEND NO. BN
Number of bend in in the bending sequence at which you would
like to undertake a correction.

❑ CORRECTION α Cα
Correction of bend angle at the selected bend

❑ CORRECTION X CX
Correction of the X(1)-axis at the selected bend.

Six-axis backgauge ❑ CORRECTION X2 CX

Correction of the X2-axis at the selected bend.

❑ SELECT ST
Number of repetitions of a program. After quitting, each
program cycle is subtracted from the number of program cycles
currently available.

❑ G-CORRECTION Gα
Correction of bend angle of the current program

❑ G-CORRECTION GX
Correction of the X(1)-axis of the current program

Six-axis backgauge ❑ G-CORRECTION X2 GX

Correction of the X2-axis of the current program

Part support Parameter G-corr Gp

Total correction of the part support for all bendings of the current
program.

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-9

 ❑ For the angle correction:
A negative angle dimension reduces the bending angle, i.e. the
angle constricts on correction. A positive angle dimension
enlarges the bending angle, i.e. the angle expands on correction.

❑ For correction of the X-axis:

A negative value positions the gauge fingers further to the front
towards the operator. A positive value positions the gauge
fingers further back in the throat of the machine.

Part support For correction of the part support:

The value is entered in degrees. A positive value results in a larger
final angle of the part support to the horizontal line. A negative
value decreases the angle to the horizontal line.

®
ACB angle sensor

Sens. S Prebend . . . . . . .P =

AUTOMATIC OPERATION with the ACB® angle sensor Fig. 15650E

When a bend is made with the aid of the angle sensor the
parameter PREBEND Pα also appears in the lower portion of the
display screen; this parameter is required in order to identify the
prebend angle. The prebend angle is stored in the machine
parameters (see Operating manual for the ACB® angle sensor).
In spite of this it can be corrected here.

3-10 Manual operation, automatic operation and step-by-step operation B294e3.doc

 Functions

With PREVIOUS BEND and NEXT BEND you can scroll between
PREVIOUS the individual bends.
BEND

NEXT BEND

Position all CNC-controlled axes with the handwheel using the

MANUEL MANUAL POSITIONING function (see page 3-14).
POS.

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-11

 2.1 Graphically visualising bend sequence

With the function GRAPHIC VISUALISATION a bend sequence

GRAPHIC created in graphics programming is graphically visualised while the
VISUAL.
program is running. The depiction of product and tools is identical
to their depiction in graphical programming:

AUTOMATIC OPERATION - Graphic visualisation Fig. 15627E

The respective current bend is depicted. You can recognise the

bend by the bend number in the header line and the asterisk-
marked bend in the bend sequence (refer to Chapter 2: "Bending
sequence" on page 2-57).

3-12 Manual operation, automatic operation and step-by-step operation B294e3.doc

 Functions

With PREVIOUS BEND and NEXT BEND you can scroll between
PREVIOUS the individual bends.
BEND

NEXT BEND

With the function PROGRAM VALUES you return to the input

PROGRAM screen.
VALUES

With TOOLS / MACHINE you insert/mask out tools and machine

TOOLS / parts on the screen.
MACHINE

By actuating the function MACRO all current settings of the CNC-

MACRO controlled axes are displayed in upper case making them easy to
read, even for an operator standing at a distance.

Use the function 3D visualisation to convert the current 2D display to

3D a three-dimensional display. This function can be activated only if the
VISUAL.
2D program is not connected to another program.

Position all CNC-controlled axes with the handwheel using the

MANUAL MANUAL POSITIONING function (see page 3-14).
POSITIONING

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-13

 3. Set-up mode

Within all three group operating modes you can position all CNC-
MANUAL controlled axes with the handwheel using the MANUAL
POSITIONING
POSITIONING function during set-up mode.

Set the lower keyswitch on the 2-hand/foot control panel to set-up

mode:

1 Symbol for set-up mode

Lower keyswitch on 2-hand/foot control panel Fig. 15630

Set-up mode is displayed in the display area at lower right The

current axis position is shown at the left, the programmed axis
position at the right:

Set up

MANUAL POSITIONING Fig. 15629E

3-14 Manual operation, automatic operation and step-by-step operation B294e3.doc

 Functions

Use PREVIOUS PAGE and NEXT PAGE to scroll to additional

PREVIOUS CNC-axes.
PAGE

NEXT
PAGE

Backgauge axes ❑ Select the desired axis using the cursor keys < ↑ > and < ↓ >.
❑ Switch on the hydraulic system.
❑ Set the control system to STOP.
❑ Rotate the handwheel until the desired position has been
reached.
❑ The current position can be saved to the CNC program by
pressing < ENTER >.

Y axis ❑ Select the Y axis using the cursor keys < ↑ > and < ↓ >.
❑ Switch on the hydraulic system.
❑ Activate the control system by pressing the START key.
❑ Move the machine upperside to the mute point.
❑ Hold down the foot pedal.
❑ Rotate the handwheel until the desired position has been
reached.
❑ The current position can be saved to the CNC program by
pressing < ENTER >.
It is possible to move the Y axis using the handwheel below
the mute point only. If the Y axis is moved to a position
above the mute point the machine upperside will move back
to the upper dead point automatically.

B294e3.doc Manual operation, automatic operation and step-by-step operation 3-15

3-16 Manual operation, automatic operation and step-by-step operation B294e3.doc
 Chapter 4

Practice examples
1. Programming punch ...................................................... 4-3

2. Programming die............................................................ 4-5

3. Programming in the two-dimensional display ............ 4-7

4. Programming in the three-dimensional display.......... 4-9

B294e4.doc Practice examples 4-1

 In Chapter 4 the operating and programming instructions for control
systems are supplemented with selected practice examples.

Programming the DELEM-control system should be practised with

these practice exercises so increasing the ability to optimize the
bend programs.

Note Each practice exercise contains one or more remarks, which are
marked with the term note. These remarks are especially geared to
the set task and should be closely observed.

4-2 Practice examples B294e4.doc

 1. Programming punch

Program the punch OW 210 illustrated in Fig. 12602.

10

10
13
5°

,5
25

25
,5

- 1 35

35 °
° -1

42

62,5
9
0°

140
-9
0°

11
166°
66

50,6

166°
28°
4,1

Fig. 12602

B294e4.doc Practice examples 4-3

 Note ❑ Tools are programmed without tool adapters.
❑ The programming of tools with the function AUTOFINISHING is
finished first in the clockwise then in the anti-clockwise
direction.
❑ Unsymmetrical angles are depicted with a intermediate lines
with a length of at least 1.1 mm.
❑ Punch radii are programmed in the menu punch constants.

There are more punches in the TRUMPF-punch catalogue which

you can use for practising programming:

Type Name Angle (vertex) Height [mm] Radius [mm]

Deer foot tools OW200 86.0° 120 1.0
OW200/S 86.0° 220 1.0
OW201 86.0° 120 1.0
OW201/S 86.0° 220 1.0
Pointed tool with OW202 28.0° 120 1.0
extension OW202/S 28.0° 220 1.0
Symmetrical tool OW203 60.0° 120 4.0
OW203/S 60.0° 220 4.0
Flattening tool OW210 28.0° 120 1.0
OW210/S 28.0° 220 1.0
Bottoming tool OW211 89.6° 120 1.0
OW211/S 89.6° 220 1.0

4-4 Practice examples B294e4.doc

 2. Programming die

Program the die illustrated in Fig. 12603.

5,7 5,7
16,5

6
1,
R
30°

100

Fig. 12603

Note ❑ Tools are programmed without tool adapters.

❑ The programming of tools is finished with the function AUTO-
FINISHING.

B294e4.doc Practice examples 4-5

 There are more dies in the TRUMPF-die catalogue which you can
use for practising programming:

Type Name Die width [mm] Angle [mm] Height [mm]

1) 2)
Air bending EV001(/H )-W6/30 6.2 30.0° 100 (150 )
EV002(/H1))-W8/30 8.4 30.0° 100 (1502))
EV003(/H1))-W10/30 10.4 30.0° 100 (1502))
EV004(/H1))-W12/30 12.4 30.0° 100 (1502))
EV005(/H1))-W16/30 16.6 30.0° 100 (1502))
EV006(/H1))-W20/30 20.8 30.0° 100 (1502))
EV007(/H1))-W24/30 25.0 30.0° 100 (1502))

EV020(/H1))-W6/86 6.3 86.0° 100 (1502))

EV021(/H1))-W8/86 8.5 86.0° 100 (1502))
EV022(/H1))-W10/86 10.6 86.0° 100 (1502))
EV023(/H1))-W12/86 12.6 86.0° 100 (1502))
EV024(/H1))-W16/86 17.0 86.0° 100 (1502))
EV025(/H1))-W20/86 21.2 86.0° 100 (1502))
EV026(/H1))-W24/86 25.5 86.0° 100 (1502))
EV027(/H1))-W30/86 31.8 86.0° 100 (1502))

1)
Insert when effective tool height 150 mm
2)
Effective tool height 150 mm

4-6 Practice examples B294e4.doc

 3. Programming in the two-dimensional
display

Program the trough illustrated in Fig. 12600. Optimize the bend

sequence so that the workpiece lays on as many gauge fingers as
possible during folding.

35 35

°
90

90
°
R
30
50

50
30
R

110

Fig. 12600

Details ❑ Thickness: 1.0 mm

❑ Material: Steel
❑ Dimension: outside
❑ Length: 100 mm

❑ Radius made of 5 segments

Note ❑ Select a narrow punch to avoid collisions.

B294e4.doc Practice examples 4-7

 U folds Program the profile illustrated in Fig. 15651. Set the bending
sequence by unbending manually. Optimise the bend sequence in
such a way that you are able to place the workpiece onto the gauge
fingers as often as possible during folding.

50

50
Fig. 15651

Details ❑ Thickness: 1.0 mm

❑ Material: steel
❑ Dimension: outside
❑ Length: 500 mm

Note ❑ Select a heel tool. Note that the punch can also be
programmed when turned.
❑ Select a punch that has a die width of 6 mm.

4-8 Practice examples B294e4.doc

 4. Programming in the three-dimensional
display

Program the box with recess illustrated in Fig. 12611. The sheared
blank is illustrated in Fig. 12601. Only select a die type.

Fig. 12611

200 25
25
65
100
25
25

180 25

Fig. 12601

Details ❑ Thickness: 2.0 mm

❑ Material: Steel
❑ Dimension: outside

B294e4.doc Practice examples 4-9

 Note ❑ In three-dimensional programming the maximum bend length is
1 mm less than the value computed by the control system.
❑ The length of the die must be at most 3-4 mm shorter than the
bend line length on each side.

4-10 Practice examples B294e4.doc

Index
Bend simulation.................................2-69,2-104
Bending sequence............................2-58,2-103
Bending sequence from program ...2-103,2-105
Bending simulation ..................................... 2-75
2D/3D Drawing selection DS..................... 2-62 Bottom bending ....................................2-87,3-3
3D Visualisation ......................................... 3-12
Bottoming pressure correction BF ............ 2-114
90 Degree tolerance CT............................. 2-44
Boundaries B1 to B3................................. 2-122
Bumping ..................................................... 2-39

Abort computation..................................... 2-57

ACB® angle sensor.............................. 2-87,3-3 Change data.............................................. 2-21
Accept ................................................ 2-78,2-80
Change height ............................2-14,2-20,2-28
Access code............................................. 2-129
Change length ............................................ 2-72
Add............................................................. 2-73
Change position.......................................... 2-72
Air bending ........................................... 2-87,3-3
Change side ............................................... 2-81
All Bends .................................................... 2-99
Change side length..................................... 2-66
All products .............................................. 2-126
Changeover from rapid traverse
Alphanumeric ............................................... 1-5
to work cycle.......................................... 2-23
Alphanumeric keyboard ............................... 1-5
Clamp ......................................................... 2-82
Aluminium ................................................ 2-112
Clamping correction CC ........................... 2-115
Angle α ................................................. 2-88,3-4
Clamping direction...................................... 2-56
Angle at the punch tip .................................. 2-9
Closing dimension ...................................... 2-38
Angle correction ......................................... 3-10
Closing speed CS..................................... 2-123
Angle entry with the cursor-keys ................ 2-34
Code...................................................2-15,2-21
Angle number AN....................................... 2-97
Code CX..................................................... 2-92
Assignment ................................................ 2-41
Collision analysis ........................................ 2-21
Asymmetric angles with tools ..................... 2-13
Combination turn C1 to C4....................... 2-122
Auto bend change mode (step) CS.......... 2-116
Compute..................................................... 2-57
Auto finishing.............................................. 2-28
Connect CN................................................ 2-85
Autofinish ..................................... 2-7,2-14,2-20
Control.......................................................... 3-3
Automatic operation ............................... 1-8,3-7
Copy product ............................................ 2-102
Axis .............................................................. 3-9
Correction Cα ............................................... 3-3
Cursor........................................................... 1-4
Cursor-keys ............................................1-4,1-6

Backgauge X............................................. 2-89

Backgauge XN ........................................... 2-97
Backpr. speed BS ................................ 2-94,3-4 Data........................................................... 2-11
Backstop against sharp angle
Decompres. DC.......................................... 2-95
allowed SA ............................................ 2-42
Decompression BP....................................... 3-4
Backstop die intermediate angle IB............ 2-43
Default Index Position GD ........................ 2-121
Backup copy............................................. 2-124
Default X-axis code XC ............................ 2-117
Base line .................................................... 2-33
Default X-time XT ..................................... 2-117
Baud rate BR............................................ 2-119
Deflect BM .................................................. 2-94
Bend method BM ................................. 2-87,3-3
Deflection.................................................... 2-94
Bend number.............................................. 2-99
Delay TX..................................................... 2-93
Bend position Y .......................................... 2-88
Delete .........................................1-6,2-73,2-108
Bend repetitions ......................................... 2-99
Delete all................................................... 2-108
Bend sequence .......................................... 2-48
Delete bend .............................................. 2-100
Bend sequence display .............................. 2-56

B294e5.doc Index 5-1

Delete drawing ................................... 2-20,2-28 Functions ...................................................... 3-9
Delete line .......................................... 2-20,2-28
Delete tool .................................................. 2-10
Dialogue input field....................................... 1-6
Die directory ............................................... 2-17
Die height ................................................... 2-17
Gauge function .......................................... 2-90
Gauge height H ........................................ 2-121
Die number........................................... 2-17,3-2
Gauge positions GN ................................. 2-121
Die UN.................................................. 2-86,3-2
Graphical Directory..................................... 2-10
Die width .................................... 2-17,2-19,2-21
Graphical directory products..................... 2-110
Dimensions Out/Inside 0/1 ......................... 2-32
Group operating mode ................................. 1-8
Directory cmpress .................................... 2-109
Directory expand ...................................... 2-109
Diskette ...................................................... 2-10
Draw............................................... 2-102,2-104
Drawing number DN........................... 2-30,2-62 Handwheel .................................................. 1-4
Drawing selection DS................................. 2-30 Heel ....................................................2-11,2-72
D-Time T ...................................................... 3-4 Heel dimensions ......................................... 2-72
Dwell time T ............................................... 2-94 High precision............................................. 2-38
Horizontal projection................................... 2-35

E modulus ................................................. 2-62

Edge tolerance ET ..................................... 2-44 I-Axis ID .............................................2-23,2-95
Edit 3D-data ............................................. 2-104 Identification ................................................. 3-3
Edit drawing ....................................... 2-12,2-19 Inch/mm 1/0 IS ......................................... 2-112
Emergency stop ..................................... 1-2,1-3 Insert .......................................................... 2-37
E-Modules E............................................. 2-112 Insert bend ............................................... 2-100
End-key .................................................. 1-4,2-4 Inside dimension......................................... 2-32
Enlarge....................................................... 2-58
Entering letters ............................................. 1-5
Enter-key...................................................... 1-6
Extended length ......................................... 2-59
Extended length L ...................................... 2-85
Jump left.................................................... 2-77
Jump right................................................... 2-77

Finger height FH ..................................... 2-121 Key-operated switch for set-up mode ....... 3-13
Finger length FL ....................................... 2-121
Finger width FW ....................................... 2-121
First bend ................................................. 2-106
Fixing bending sequence ........................... 2-76
Flattening ............................................. 2-87,3-3 Language LA ........................................... 2-112
Flattening height FH........................... 2-16,2-23 Lay on backstop limit BL............................. 2-46
Flattening offset.......................................... 2-16 Learned bend ............................................. 2-87
Flattening offset OF.................................. 2-115 Learning bend .............................................. 3-3
Flattening opening...................................... 2-16 Length and angle entry................................. 2-8
Flattening opening FO.............................. 2-115 Length BL .............................................2-88,3-3
Flattening with bottoming ..................... 2-87,3-3 Length L .....................................2-15,2-31,2-62
Fold length ................................................... 3-8 Library ........................................................ 2-70
Format Diskette.............................. 2-124,2-129 Load ......................................................... 2-108
Front back turn F1 to F4........................... 2-122 Load defaults .............................................. 2-47
Front extend ratio accept FA...................... 2-42
Front extend ratio FR ................................. 2-41

5-2 Index B294e5.doc

Machine lowerside M2 .............................. 2-96
Machine number MN................................ 2-119
Machine upperside M1............................... 2-96 Parallel Y2 ................................................. 2-95
Macro ................................................... 3-6,3-12 Parallelism Y2............................................... 3-5
Manual operation ......................................... 1-8 Parity odd/even 1/0 PA............................. 2-119
Manual Positioning............................... 3-6,3-13 Part support PS .......................................... 2-95
Manual selection ........................................ 2-78 Pinching point ............................................. 2-92
Material M .................................. 2-31,2-62,2-85 Postprocessing ...................................2-59,2-83
Material MA .................................................. 3-3 Prebend Pα ................................................ 3-10
Material tensile strength S........................ 2-112 Precision..................................................... 2-38
Maximum punch loading ............................ 2-15 Pressing force............................................. 2-87
Menu block................................................... 1-4 Pressing speed PS ................................... 2-123
Menu Data edit............................................. 2-5 Pressure correction (Safety factor) FF ..... 2-113
Menu Data preparation ................................ 2-5 Pressure P............................................2-94,3-4
Menu Dies .................................................... 2-6 Pressure release ........................................ 2-92
Menu Machine lowerside ............................. 2-6 Previous surface......................................... 2-65
Menu Machine upperside............................. 2-6 Product backup......................................... 2-125
Menu number ............................................... 2-5 Product number PN............................2-30,2-62
Menu Product drawing ................................. 2-5 Program catalogue ..................................... 2-59
Menu Product editing ................................... 2-5 Programmed operation...........................1-8,2-5
Menu Produkt backup .................................. 2-6 Programming turned tools .......................... 2-51
Menu Produkt selection................................ 2-6 Projection dimension .................................. 2-35
Menu Program constants .............................. 2-6 Punch code................................................... 2-9
Menu Punches ............................................. 2-6 Punch height.........................................2-9,2-12
Menu Tool backup........................................ 2-6 Punch number ........................................2-9,3-2
Min. Y-opening YM..................................... 2-47 Punch radius................................................. 2-9
Mute M ................................................. 2-23,3-4 Punch start constants ................................. 2-12
Mute point .................................................. 2-92 Punch UP .............................................2-86,3-2

New ......................................................... 2-103 R1-Axis R1 .................................................. 3-5

New bending sequence............................ 2-103 R2-Axis R2 ................................................... 3-5
New configuration ...................................... 2-69 Radius factor extendet length RF ............... 2-46
Next side .................................................... 2-65 Radius factor X-Axis AF ............................. 2-47
Next surface ............................................... 2-65 Radius RA .................................................. 2-16
No change.................................................. 2-80 R-Axis R ...............................................2-93,3-5
R-Axis speed RS ...................................... 2-120
Read products .......................................... 2-127
Reduce ....................................................... 2-58
Reduction 1/0 BA...................................... 2-113
On/off FD .................................................. 2-95 Repetition CY ............................................. 2-94
On-line help.................................................. 1-4
Resistance R .............................................. 2-15
Opening angle of the die .................... 2-17,2-19
Right-hand side of gauge ............................. 2-4
Opening DX................................................ 2-91
Rotate......................................................... 2-54
Opening DY.......................................... 2-88,3-4
Rotate product............................................ 2-64
Opening speed OS................................... 2-123
Rules for tool programming .......................... 2-7
Operating panel............................................ 1-2
Operating surface......................................... 1-7
Optilimisation degree OD ........................... 2-41 Safeguard On / Off .................................... 2-55
Outside dimension ..................................... 2-32 Save as Defaults ........................................ 2-47
Overall processing time.............................. 2-56 Segments ................................................... 2-39

B294e5.doc Index 5-3

Select gauge .............................................. 2-81
Sequencer debug......................................... 3-6
Service function............................................ 3-6
Setting-up auto. calc. AC ......................... 2-118
Unbend...................................................... 2-55
UP-key........................................................ 2-92
Shift gauge ......................................... 2-53,2-81
Shift left ...................................................... 2-81
Shift product ............................................... 2-77
Shift product to left ..................................... 2-77
Shift product to right ................................... 2-77 Vertical projection ...................................... 2-35
Shift right .................................................... 2-81
Shortest programmable side length ............. 2-7
Softkey ......................................................... 1-4
Specific die constants......................... 2-19,2-21
Speed S ....................................................... 3-4
X-Axis X................................................3-4, 3-5
X Reference correction XR....................... 2-117
Speed V ..................................................... 2-94
X Safety turned (Negative) ST ................... 2-22
Stainless steel .......................................... 2-112
X Tolerance DIN XA ................................... 2-47
Start-key....................................................... 1-3
X1X2 Difference programming XX ........... 2-117
Steel ......................................................... 2-112
X2- Axis X2................................................... 3-5
Step-by-step operation........................... 1-8,3-7
X-axis correction....................................... 2-113
Stop bits 1/2 SB ....................................... 2-119
X-Axis speed BS....................................... 2-120
Stop key ....................................................... 1-3
X-Safey normal SN..................................... 2-21
Store................................................... 2-59,2-83
Swap product ............................................. 2-80

Y-axis........................................................... 1-4
Tensile strength......................................... 2-62 Y-Axis Y........................................................ 3-4
The cursor in 3D-dimensional Y-input mα .................................................. 2-85
programming......................................... 2-63
Thickness BS ............................. 2-31,2-62,2-85
Thickness TH ............................................... 3-3
Ton / kN-selection 1/0 TS......................... 2-112 Z1-Axis Z1 ................................................... 3-5
Tool adapter ............................................... 2-26 Z1/Z2-axis .................................................. 2-96
Tool configuration....................................... 2-69 Z2-Axis Z2 .................................................... 3-5
Tool constants.......................................... 2-128 Z-edge ........................................................ 2-91
Tool radii ...................................................... 2-7 Zinc........................................................... 2-112
Top bottom turn T1 to T4 ......................... 2-122 Z-Offset ZD............................................... 2-114
Turn page delay PD ................................. 2-113 Z-Position Z ................................................ 2-15
Turning time ............................................. 2-122

5-4 Index B294e5.doc

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 DNI-06

Instruction manual
Version 2 GB

Edition 07/00

Ethernet instruction manual 8-1

 FOREWORD

This manual describes the employment of the Ethernet option in

the type DA-65 and DA-69 control systems. It is intended for
operators who have been trained in all aspects of operation of the
entire machine.

Only authorised persons should be in a position to alter the

settings. The control system is therefore assigned an access code
in the interests of preventing unauthorised programming.

The Ethernet option is only available for the control systems from
the DA-60 series of the DA-65 and DA-69 system types. The
description of the Ethernet option can be used as a separate
manual or inserted as a chapter in the standard instruction
manual.

8-2 Ethernet instruction manual

 Contents

PAGE

FOREWORD .................................................................................................................. 2

1. Introduction .......................................................................................................... 5

2. Loading products ................................................................................................. 5

3. Loading tools and machine forms ........................................................................ 5

4. Product and tool backup .................................................................................... 11

Product backup (menu 6) ........................................................................ 11

Tool backup (menu 12) ........................................................................... 14

5. Notes for the system administrator .................................................................... 15

5.1 Introduction ....................................................................................................... 15

5.2 Display the connectors in the machine and on network..................................... 15

5.3 Preconditions on the NFS-Server ...................................................................... 18

5.4 Parameter settings for network cards in the DA control system ........................ 19

Explanation of parameters ...................................................................... 20

5.5. Error indications ................................................................................................. 25

Ethernet instruction manual 8-3

8-4 Ethernet instruction manual
 Option Network card

1. Introduction

This chapter deals with the Modification of the programming

options, in case you work with the network option (Ethernet).
This chapter is a supplement to the standard operating manual of the
DA-65 and DA-69 control systems.

2. Loading products

In the standard scenario, the products are located in the main

memory of the control system. Only these products can be selected
(menu 5: ‘Product selection’). The selected product is activated and
can therefore then be executed.

The Ethernet option gives you access to a much greater number of

products: products which are on the server. These products cannot,
however, actually be executed while they are on the server. These
products cannot be selected via menu 5. You must therefore first load
the products from a network directory on the server into the main
memory of the control system. The loading of prodcuts from the
network can be compared with loading products from a disk.

These products are loaded (or ‘restored’) via menu 6, ‘Product

backup’, in the main menu of the programming mode. See also
section 4.

3. Loading tools and machine forms

This paragraph is a supplement to the full operating manual

DA65/DA69 and refers to menus 7, 8, 9 and 10 of the programming
mode.

Ethernet instruction manual 8-5

 The ‘load from and save to’ functionality of this menu applies only to
the transfer of tools from and to an external medium, e.g. disk or
network. The process with the network option is the same for all four
menu options: upper tools (menu 7), lower tools (menu 8), machine
top (menu 9) and machine bottom (menu 10). The machine forms are
also treated as tools here.

The difference between the transfer of files from and to a network and
a disk is that the user is able to open/delete a specific tool directory
when working with a network.

Softkeys:

Disk Select disk transfer (save tools and load tools)

Network Select network transfer (save tools and load tools)

8-6 Ethernet instruction manual

 Network transfer

Select S7 (‘Network’) in menu 7.11

Softkeys:

Save tools Save tools from the control system in a

network directory.

Load tools Load tools from a network subdirectory

into the control system.

Ethernet instruction manual 8-7

 If you select S2 (‘Load tools’), the message "NO TOOLS" will appear.
This means that no network subdirectory was selected, from which
tools are to be loaded.

Softkeys:

Network For selecting the network subdirectory from which the

tools are to be loaded

If you select S7 (‘Network’), the following appears:

8-8 Ethernet instruction manual

 Softkeys:

Open subdir. Add a new subdirectory. The name of the subdirectory can
be any alphanumeric string of up to 8 characters. Do not use
slash marks (‘/’). You are only able to open a subdirectory if
you have authorisation from your network system manager
(see user rights, par. 12.5).

Delete Delete a subdirectory. If the subdirectory is not subdirectory

empty, the message ‘SUBDIRECTORY CANNOT BE
DELETED’ appears. It is only possible to delete an empty
subdirectory if you have appropriate authorisation from your
network system manager (see user rights, pt. 5).

Ethernet instruction manual 8-9

 Softkeys:

All Load all punches from the selected network

subdirectory.

Code Select a code instead of a number.

Network dir. Select another network directory. Open subdirectory

or delete (empty) subdirectory.

Expand subdirectory
Tool overview. Switchover function between expand
directory/graphic directory/normal directory.

The process for menus 8, 9 and 10 is the same.

8-10 Ethernet instruction manual

 4. Product and tool backup

This section is a supplement to the operating manual DA65/DA69

and refers to menus 6 and12 of the programming mode.

The functionality of these menus regarding 'Restore (load) from' and

'backup (save) on' applies only to the transfer of product/tool files
‘from and to’ an external medium, e.g. disk or network. The upper
menu bar shows the active local subdirectory, should you have a hard
disk available.

Product backup (menu 6)

Option for loading (restoring) one, several or all products from a

network directory in the main memory or in a specified local directory
instead of a hard disk. The functions of the save (backup) option are
reversed.

Softkeys:

Product backup From the main memory or local subdirectory

(only with hard disk option) to the selected
network directory.

Ethernet instruction manual 8-11

 Restore product From the selected network subdirectory to the
main memory or to a local subdirectory (only
with hard disk option).

Disk Switchover function between disk and network

backup.

You can use the network option to gain access to the network
directories on the server. You must select the specific network
directory from which the products are to be restored. These network
directories are found in the path directory ‘...\PRODDIR’ mounted to
the server. The text in the top line of the screen specifies the source
(‘from’).
The procedure for making a backup copy or restoring products from
disk was not subjected to modifications to that for the standard
scenario.

Use S7 and the cursor keys to select a specific network directory and
confirm your selection with the Enter key.

8-12 Ethernet instruction manual

 Softkeys:

All Load all products.

Drawing no. Switchover between drawing number/product number

Network dir. Modify, create or delete network subdirectory.

Expand dir. Product overview. Switchover function between

expand directory/graphic directory/normal directory.

The product subdirectories on the network server are accessible to all

connected DA control systems.

Ethernet instruction manual 8-13


Tool backup (menu 12)

This option is used to load (restore) or save (backup) all tools at

once. It is not possible to select a specific tool, as in menus 7, 8, 9
and 10. For a backup of the tools, all tools in the control system are
saved in a specific network directory or on a disk. The machine
constants are not included in this backup.

The tools, i.e punches, dies, machine top, machine bottom, program
constants and the machine parameters are always located in one
single network backup directory for each control system. This
subdirectory is identical to the user name of the control system (menu
11.11). This directory is created automatically on the server when the
tool backup option is executed. This machine-specific tool backup
directory cannot be created or modified manually.

8-14 Ethernet instruction manual

 5. Notes for the system adminstrator

5.1 Introduction

The Ethernet Option for the DA65/69 provides a means for the
control system to function as an NFS client in an Ethernet
based network. In order to make use of this option your network
system must have at least one NFS server. The NFS server
must fulfil the following criteria:

- NFS Server Version two with TCP/IP Protocol. The NFS

server itself should be loaded on User Datagram Protocol
(UDP).

- Mount Service Version one must run on your server.

- Your server must have a Portmap Service Version two.

- Your server must have a protocol which is compatible with

RPC Version two.

In order for your control system to communicate with your

server you must precondition your NFS server for use with DA
control systems and you must enter the Ethernet settings in the
control system (Menu 11.11 of the program constants).

5.2 Display the connectors in the machine

and on network

The Network Card Option can be cabled using one of two

cabling systems.

• Twisted pair (RJ45)

• Coax cable (BNC)

Ethernet instruction manual 8-15

 Twisted pair cabling:

The required connectors on the network card are marked in the

following Fig.
• Plug in the jumper (Pos 2) in accordance with the circuit
diagram
• Plug in the twisted pair cable

1
RJ45
2
3 BNC

1 Twisted pair connector 2 Jumper 3 BNC connector

The second cable end piece - twisted pair - (for location see
Figure page 17 / Pos. 6) must be connected to the Ethernet
network with the aid of coupling ID No. 845171.

Coax cable (BNC):

The required connectors on the network card ID No. 844891

are marked in Fig. page 17.

• Plug in the distributor with terminal resistor at the BNC

connector.
• Plug in the jumper (Fig. page 17 / Pos 2) in accordance with
the circuit diagram.
• Plug the coax cable into the T distributor.

The second coax cable end piece (switching cabinet side / for
location see Fig. page 17 / Pos. 6) must be connected to the
Ethernet network.

If multiple machines are to be connected to the server via coax

cable the terminal resistor at the T distributor must be removed.
The connection to the next machine can be established by
means of an additional coax cable. The terminal resistor must
be attached to the end machine - see page 8: cable options
circuit diagram.

8-16 Ethernet instruction manual

 3
1
2
4

5
6

1 ........ID No. 844891 Network card

2 ........50 Ohm resistor (Component ID No. 844891)
3 ........Connector ID No. 845170 Twisted pair
4 ........Possible connector ID No. 845169 or ID No. 846391 Coax cable
..........(Pos 2 must be removed if this connector is used)
5 ........Possible connector ID No. 845169 or ID No. 846391 Coax cable
6 ........Cable end pieces ID No. 845170 incl. ID No. 845171 coupling + ID No. 845169 + ID No. 846391
7 ........Installation of the cable loom on the side wall of the switch cabinet by means of self-adhesive pads
and cable ties

The picture shows the cable following installation and electronic

components.
Twisted pair (RJ45) is connected. The optional variant coax
cable (BNC) is marked.

Ethernet instruction manual 8-17

 5.3 Preconditions on the NFS server

In order to make use of the network options at the work station

several preconditions must be implemented on the NFS server.

Step 1:

Provide a path on the server for the control systems

connected to the network. To prevent problems during
configuration of the control system it is advisable to make
this path available to all users (this is usually a special option
on NFS servers). Afterwards, when the system is set up and
running, user access to the NFS server can be restricted if
necessary. These user rights are different from the user
rights that can be programmed in Control System Menu
11.11. User rights that you assign to the server have higher
priority than user rights that are programmed in the control
system (local rights).

Step 2:

If these user rights are to be restricted to read-only for the

path exported to the DA control systems then several
directories must be created manually. This applies to the
"TOOLDIR" and "PRODDIR" directories. Otherwise these
directories are created automatically during the intialization
phase of the control system with the server. It is not possible
to create these directories in the control system.

The PRODDIR and TOOLDIR directories are available for all

DA control systems in the network system. At the same level
automatically a BACKUP directory is created when one of the
control systems (if permissable) implements a Tool backup
(Menu 12 in the programmed operation). Within this BACKUP
directory each control system has its own directory for the
backup of Tools. The directory name corresponds to the unique
user name assigned to each control system (see Menu 11.11).

8-18 Ethernet instruction manual

 5.4 Parameter settings for network
cards in the DA control system

Ethernet settings are found in Menu 11.11 in programmed

operation. These Ethernet settings must be entered in order to
make possible communication between the control system and
the server.

Example of a parameter entry in Menu 11.11

Function keys:

S7 Unblock page
Ethernet settings are saved by means of a numerical
identifier word. Modifying a parameter can have considerable
effect on the network performance of the control system.
Access to Ethernet parameters is possible when the
'Unblock page' key is pressed and the identifier word is
entered. If a correct password has been entered the user
has the option of changing the password by pressing the key
again and entering a new password. Following initial
installation the password is '0'.

Ethernet instruction manual 8-19

 S8 Check server
As soon as the server and client addresses have been
entered, the interaction between the server and the client
(control system) can be checked by pressing this key.

Explanation of parameters

Server Internet address

This address is the Internet address (IP address) of the
NFS server in your network. The four digits are interpreted
as decimals.

Client Internet address

This address is the Internet address which will be used by
the control system during communication within the
network. It is important that this address appears only once
within your network system. No other client or server may
use the same address. For this reason the client address
for each control system should be definitive.

It is best to avoid using zeroes in the fields for the server and client
Internet addresses. As soon as both Internet addresses have been
entered it is possible to check these settings. The existance of the
server and the validity of the control system address can be checked
by pressing the 'Check server' key (S8).

8-20 Ethernet instruction manual

 It is likely that the 'Path mount not possible' or 'Cannot localize
NFS port' error message will appear but this is irrelevant at this
point. If the 'Ping' test fails you should check your network
connection and the validity of the Internet addresses which you
have assigned. If this test has been completed successfully you
should return to the previous page by pressing the 'END' key
and moving the cursor onto the 'MOUNT PATH' parameter.

Mount Path

The Mount Path is the path in your NFS server which

should be made available to the control system clients.
This means that this path should be exported to your NFS
server.

When the cursor is moved onto the ‘MOUNT PATH’ parameter

the ‘Scroll’ key lights up. In order to use this function it is
important that the Internet address for both the server and the
client have been entered correctly. In addition your server must
have a Mount Service.

When this key “S5” is pressed a field appears with path names
which are being exported by the NFS server. See illustration
below.

Ethernet instruction manual 8-21

 If no entries appear in this field you should check the names of
the paths being exported by your NFS server. If no field
appears it is possible that this function is not supported by your
server. In this case use the operator’s panel at the front to enter
the path. An additional reason why this field does not appear
could be that the NFS server does not exist (an NFS server is
not required to complete the ‘Ping’ test successfully). In this
case it is advisable to check whether an NFS server which
corresponds to that of the ‘SERVER INTERNET ADDRESS’ is
running on the machine.

If a path is selected by pressing the ‘ENTER’ key, the ‘LOG-ON’

parameter will be selected. The ‘USER NAME’ cannot be
changed and the value is set by means of the ‘UID’ parameter.

“NFS NAME CONVERSION.....NC =”.

With this parameter you can select whether the DA control
system reads/writes in upper or lower case.
The default setting for this parameter is “0”. Upper case
letters are used. If the parameter is activated (NC = 1), the
softkey S5 = modify appears and upper/lower case can be
changed.
The first line (File/directory create) is how the files from the
control system are to be stored and the second line
(File/directory find) is how they are stored on the server. A
“1” indicates upper case letters, a “0” indicates lower case
letters. The settings have no effect on numbers.

Log-on
This parameter determines how the control system
identifies itself to the server. It is advisable to set this
parameter to ‘UNIX’ log-on. In the rare case that your
server supports only a ‘NONE’ log-on you should set this
parameter to zero.

UID (User ID) and GID (Group ID) are used to identify the
control system to the server (for UNIX certification) and to
identify the user when a file is being created/written (not all
servers support the latter option). It is advisable to complete this
parameter even if the system seems to function troublefree
without valid values.

8-22 Ethernet instruction manual

 Uid
This parameter identifies the user. It should be a value that
appears only once in your system. A value between 1 and
60000 can be selected.

Gid
This parameter defines the group to which the user
belongs. This value is valid for multiple users / clients.
Possible values are between 0 and 60000.

User rights

This parameter was added to provide a means by which control

system rights can be limited on user side rather than on the
server side. In practice this means that you can limit the
administration on your server side to a minimum (for example,
by providing all clients with read/write access only). All file
actions to the server can be checked at the control system and
compared with user rights. This parameter can have the
following values:

-0 read-only:

Only ‘read’ actions are permitted in the control system. It is not

possible to write onto the server or to damage files on the
server by overwriting them. In addition it is not possible to
create or delete directories on the server.

-1 read / write once:

‘Read’ and ‘write’ actions are permitted. Only new files can be
created on the server; it is not possible to overwrite existing
files.
It is possible to create and delete directories (directories can be
deleted only if they are empty).

-2 read / write / modify:

All actions described above are permitted; in addition, it is

possible to overwrite existing files on the server.

Ethernet instruction manual 8-23

 CAUTION: If these actions are permitted, users in the control system are
able to modify products/Tools locally and overwrite existing
products/ Tools with the same number on the server!!!

It is now possible to check the interaction between the server

and the control system by pressing the ‘Check server’ key. At
least ‘Find directory’ test must be completed successfully in
order for the control system to be put into operation. If the other
tests fail the server will not permit the control system to write
onto the server. Rights from the ‘USER RIGHTS’ field are not
used during this check.

The illustration above shows an overview of the mode in which

communication has been established between the control
system and the server.

The illustration (next side) shows an overview of possible

settings for a control system within a network system.

8-24 Ethernet instruction manual

 5.5 Error indications

During normal operation only a general error indication is used:

Network error:
This error indication indicates that an error occurs when the
control system attempts to communicate with the server.
A more specific error indication can be obtained by going to
the Program constants menu and running a Check server
test.

The following error indications may appear in the Program

constants menu:

Log-in failure:
The server does not accept the control system as a user.
Check the settings on your server.

Ethernet instruction manual 8-25

 'RPC version does not correspond':
The RPC protocol versions being used in the control
system and on the server do not correspond to each other.
You need a server which supports a Version 2 RPC
protocol.

'MOUNT version does not correspond':

The MOUNT protocol versions being used in the control
system and on the server do not correspond to each other.
You need to use a server which supports a Version 1
Mount protocol.

'NFS version does not correspond':

The NFS protocol versions being used in the control
system and on the server do not correspond to each other.
You need to use a server that supports a Version 2 NFS
protocol.

'Cannot localize NFS port':

This error appears when the control system cannot identify
the UDP port being used by the NFS server. There may be
several reasons for this:
- Your server does not respond to queries form the control
system. Make certain that the 'Ping' test runs successfully.
- Your server does not have an NFS Service. Check your
server.
- No Portmap Service. In order to receive the UDP port
being used by the server the control system sends a query
to the Portmap Service. This indication appears when no
Portmap Service is available. Make certain that the
Portmapper runs on your server.

'Cannot find MOUNT port':

This error indication appears when the control system
cannot find the UDP port number for the MOUNT service.
Make certain that the MOUNT service runs correctly on
your server.

8-26 Ethernet instruction manual

 'NFS-Server does not respond':
The control system has succeeded in finding the UDP port
numbers for the NFS and MOUNT service but the NFS
server does not repond to the queries being sent by the
control system. Check whether your NFS server is running
correctly.

'Path mount not possible':

The Mount path entered is not being exported by the server
or is not available to this user. Check the paths which your
server exports.

'Permission denied':
The control system is attempting to perform an action on
the server which it is not permitted to do. Check control
system rights on the server.

Ethernet instruction manual 8-27

8-28 Ethernet instruction manual
Installation-
and Operating-
Manual

Flash Disk Card

DFD

Id.Nr. 855204

Version: 12/98
2 DFD – Flash Disk
 TABLE OF CONTENTS

TABLE OF CONTENTS.......................................................................... 3

1. PREFACE ......................................................................................... 5

2. INSTALLATION MANUAL ................................................................. 6

2.1 INTRODUCTION.......................................................................6

2.2 SOFTWARE INSTALLATION....................................................7

2.3 HARDWARE INSTALLATION ...................................................9
3. OPERATING MANUAL ................................................................... 11
3.1 INTRODUCTION.................................................................... 11

3.2 SELECTION OF PRODUCTS ................................................ 11

3.3 SELECTIONS OF TOOLS AND MACHINE MOULDS............ 15

3.4 PRODUCT AND TOOL BACKUP........................................... 16

DFD - Flash Disk 3

4 DFD – Flash Disk
 1. PREFACE

This manual describes the installation and operation of the

flash disk (memory expansion) card option in DELEM
controllers of type DA-65 and DA-69. It is intended for
operators who have been instructed in operating the total
machine.

Only authorized persons should be able to change the

settings. The controller therefore has an access code to
prevent unauthorized programming.

The flash disk option is available only for DA-60 series

controllers of type DA-65 and DA-69 in combination with
controller software Version 3.1 or higher.

DFD - Flash Disk 5

 2. INSTALLATION MANUAL

2.1 Introduction

The CNC DA-60 series controllers of Type DA-65 and DA-69

support a flash disk card which can be integrated in the
controller. The flash disk provides extended memory capacity.
In order to use the flash disk you must first carry out two
procedures: one procedure for installing the hardware, and a
second procedure for installing the software.

6 DFD – Flash Disk

 2.2 Software installation

Before installing and initializing the flash disk you must make
a backup copy of all the products and all the tools of your
controller. Once the flash disk is installed it will no longer be
possible to access the products in RAM. The RAM is
subsequently used only for storing machine parameters and
applications software. The flash disk is used only for storing
the products and tools.

Warning! Backup copy of products and Tools

DO NOT FORGET THE FIRST TWO STEPS, OTHERWISE
THE PRODUCTS AND TOOLS WILL BE LOST. THESE
STEPS ARE ABSOLUTELY ESSENTIAL!

Step 1:
Select Menu 6 (Product Backup) and backup all products to a
floppy disk.

Step 2:
Select Menu 12 (Tool Backup) and backup all tools to a
floppy disk.

Step 3:
Select Menu 19 (Machine Parameters), type the access code
14753 and make a backup copy of the machine parameters
(Submenu 5). Unlike Steps 1 and 2, this step is not essential.
Steps 1, 2 and 3 create a complete backup copy of the
controller before you install the flash disk.

Step 4:
Switch off the controller power supply.

Installation of the flash disk

Step 5:
Install the flash disk in accordance with the instructions (see
Chapter 2.3). Do not install the flash disk until after you have
completed Steps 1 to 3.

DFD - Flash Disk 7

 Initialization of the flash disk

Step 6:
Switch on the controller power supply.

Step 7:
Select Menu 19 in programming mode.

Step 8:
Enter the access code 14753.

Step 9:
Select number 8 (Options).

Step 10:
Select option Number 4 (flash disk).

Step 11:
Enter the access code for enabling the flash disk. This code
can be obtained from TRUMPF. The option number which
appears on the monitor after Step 9 is also needed.

Step 12:
Exit the Installation Menu option with the END key.

Step 13:
Initialization of the controller begins automatically. The flash
disk is automatically initialized. Initialization of the controller
requires a certain amount of time.

Do NOT switch off the power while initialization is taking

place.

Step 14:
The working directory is created automatically (not visible). A
standard product directory with the name ‘PRODUCTS’ is
also automatically created.

Restoration of the products and tools

Step 15:
You can now restore the tools with Menu 12. The products
can be restored either in the standard ‘PRODUCTS’ directory
or in any other directory.

8 DFD – Flash Disk

 2.3 Hardware installation

Warning!
The mains power supply must be switched off before the
controller is opened. (Switch off at main switch).

Software version
Installation of the optional network card requires controller
software Version 3.1 or higher.
Instructions for installing the software are given in the
respective Software Installation Manual.

Mainboard type
The mainboard type must enable controller software Version
3.1 or higher to run. The following mainboards are therefore
suitable for the flash disk option: D7404-001, D7404-004 and
D7404-007 for DA65; D7404-005 and D7404-008 for DA69.

Installation of Flash Disk ID No. 854527 in the controller

To illustrate the installation of the individual components, Fig.

01 shows Flash Disk Card ID No. 854527 already fitted in the
DA controller.

Flash disk

Fig. 01

DFD - Flash Disk 9

 Important!
It is recommended that the flash disk be installed as the
lowest printed circuit board.

Fitting the flash disk card

Step 1:
Remove the options already in place (CAN bus, network
card).

Step 2:
Connect the flash disk card to the PC-104 connection of the
mainboard (see Fig. 02; a network card expansion is shown
as an example).
Insulation plate
Of the network card

Mainboard Memory expansion Network card option

option connector DFD-32 DNI-05 RB

Fig. 02

Step 3:
Fix the flash disk card in place with the screws provided.

Step 4:
Replace and fix the option boards previously removed.

Step 5:
Close the controller.

10 DFD – Flash Disk

 3. Operating Manual

3.1. Introduction

This chapter describes the extended programming

possibilities when you have the flash disk installed inside
your controller. The flash disk expands the storage capacity
of the main memory (RAM) compared with the standard
situation. You can store up to 28000 files on a flash disk card.
The products and tools are stored on the flash disk. As with a
hard disk inside a computer you can create the required
product directory structure (one level). The machine
parameters and other application software are stored in RAM.
The expansion refers to the standard Operating Manual for
the DA series controller types DA-65 and DA-69.

3.2 Selection of products

This section describes the modifications to Chapter 7: DA

Controller Operating Manual, Item 2.8 Product overview.

Fig. 03

DFD - Flash Disk 11

 During the installation of the flash disk the default
‘PRODUCTS’ directory is created automatically. This
directory can be used for storage of the products. The active
local directory name is displayed in the title bar.

Via ‘local directory’ you get an overview of the manually

created product directory structure.

Fig.04

The cursor keys are used to move the highlighted bar to

another subdirectory. Pressing the Enter key selects the
subdirectory with the products. Only products in the active
local directory can be loaded.

12 DFD – Flash Disk

 Fig. 05

Make or remove a subdirectory

In this menu it is also possible to remove existing

subdirectories (only if empty) and to make new
subdirectories. Press ‘make subdir’ and enter the new name.

Subdirectories are called subdirectories because they reside

in the local directory ‘C:\PRODUCTS’. In the figure below the
full path name of subdirectory CLIENT1 is therefore
‘C:\PRODUCTS\CLIENT1'.

DFD - Flash Disk 13

 Fig. 06

Function keys:

make subdir.................................Add a new subdirectory. The name

of the subdirectory can be any alphanumeric string
containing no more than 8 characters. (Avoid the use of
slashes ‘/’).

remove subdir .............................Delete a subdirectory. If the

subdirectory is not empty the controller returns the
message ‘UNABLE TO REMOVE DIRECTORY’. An empty
subdirectory is deleted without warning. The default
directory ‘PRODUCTS’ can also be deleted. When all the
subdirectories have been removed the controller
automatically creates the default directory

Cursor key Up/Dn........................Select another subdirectory.

It is not possible to copy products from one subdirectory to another

subdirectory. A product must be restored in a subdirectory via Menu
6, Product Backup. You cannot change the name of the
subdirectory.

14 DFD – Flash Disk

 When you leave Menu 5 the controller remembers the active
subdirectory and the active product (if a product was selected) until
a different directory or product is selected.

3.3 Selection of tools and machine moulds

This section is the extension to Chapter 7, Item 2.3 of the

complete Operating Manual, Programming of tools and
machine moulds, and refers to Menus 7,8, 9 and 10 of the
programming mode.

Fig. 07

The ‘load from’ and ‘save to’ functions of these menus is

concerned only with the transfer of tool files from and to an
external device, i.e. floppy disk or network. The local directory
has only one directory for the tools and machine moulds (here
also considered as tools). This ‘tools directory’ is
automatically created and can not be deleted. In fact it is the
same as in the standard situation.

DFD - Flash Disk 15

 3.4 Product and tool backup

This section is the extension to Chapter 7, Product and tool

backup, and refers to Menus 6 and 12 of the programming
mode.

The ‘restore (load) from’ and ‘backup (save) to’ functions of

these menus only concern the transfer of product/tool files
‘from and to’ an external device, i.e. floppy disk or network.
The active local subdirectory is displayed in the upper menu
bar.

Product Backup (Menu 6)

Option to load (restore) one, several or all products from

floppy disk into a local subdirectory of the flash disk. The save
(backup) option functions vice versa.

Fig. 08

16 DFD – Flash Disk

 Function keys:

Backup Products....................from a selected local

subdirectory to a floppy disk. Note that for a complete
backup of all products you have to backup all the
products in each local subdirectory!

Restore Products ...................from a floppy disk to a selected

local directory.

Format Disk ...........................Formatting of a floppy disk. All

data will be lost.

If you want to make a backup of the products, you first have

to select the local subdirectory. A backup is made only of the
selected subdirectory. The text in the title bar on the screen
indicates the source (‘from’) and the destination (‘to’).

Fig. 09

DFD - Flash Disk 17

 If the destination is a floppy disk the products are
automatically copied to the directory ‘A:\PRODUCTS’ on the
floppy disk. The floppy disk has only one directory for the
products. If the floppy disk is full the operator is requested to
insert another floppy disk. The copying process is then
continued after a key is pressed.
If you want to restore products from a floppy disk you must
first select the destination subdirectory on your local flash
disk. Then select the products you wish to restore from the
floppy disk.

Fig. 10

When you leave Menu 6 the situation before entering Menu 6

is restored. If this is not possible (directory deleted) then the
default directory ‘PRODUCTS’ is loaded.

18 DFD – Flash Disk

 Tool Backup (Menu 12)

Option to load (restore) or to save (backup) all the tools at

once. There is no possibility of selecting a specific tool as for
Menus 7, 8, 9 and 10. During the backup of the tools all the
tools of the controller are saved to a specific network directory
or to a floppy disk. The machine constants are not included in
this backup. Please contact your machine supplier if you want
to make a backup of the machine constants too.

The tools, i.e. punches, dies, machine upper side and

machine lower side are always put in the same directory
‘C:\TOOLS’ of the local flash disk. This directory is
automatically created when you initialize the flash disk. This
directory can not be manually created or deleted. Neither is it
possible to add or remove a subdirectory for the tools.

DFD - Flash Disk 19

20 DFD – Flash Disk
 Manual

Bar code reader

Version 1.0

Edition: 02/00
ID no.: 863046

Manual Bar code reader Version 1.0 1

Ordering information Please give the title of the document, the language desired and
the date of issue.

TRUMPF Ltd.
President Way
Airport Executive Park
Luton, Beds. LU 9NL
England
Telephone: **44/1582-25335
Telefax: **44/1582-399260

TRUMPF Inc.
Farmington Industrial Park
Farmington, CT. 06032
USA
Telephone: 860-677-9741
Telefax: 860-677-4928

TRUMPF GmbH + Co
Johann-Maus-Straße 2
D-71254 Ditzingen
Telephone: **49/07156-303-0
Telefax: **49/07156-303-309

The document was written by the Technical Documentation department of

TRUMPF Maschinen Austria.
All rights reserved, particularly those concerning the duplication, distribution and
translation of this documentation, even in the event of property right registration. No
part of this documentation may be reproduced or electronically processed,
duplicated or distributed without the prior written consent of TRUMPF. Subject to
errors and technical changes.

© TRUMPF Maschinen Austria GmbH & Co KG

TRUMPF GmbH & Co. accepts no liability for any errors in this documentation.
Claims for direct or indirect damages arising from the delivery of the use of this
documentation are, within the bounds of the law, excluded.

2 Manual Bar code reader Version 1.0

 Before reading any further

Contents This Handbuch for the Strichcodeleser is addressed to all operators of the
TrumaBend V -series. It must be accessible to the operators at all times.

This manual documents the:

usable bar code type

operation of the control system

retrofitting Strichcodeleser in Chapter 3

Prerequisites
TrumaBend V-series with a Fail-Safe SPS, DA65 or DA69 control

system and software version V3.4 or above

Reference guides
Operating manual for TrumaBend V-series

Instruction manual for DA-control system



Installation manual for V3.4 software

Manual Bar code reader Version 1.0 3

 Table of contents

1 General information............................................................................. 5

2 Operation.............................................................................................. 6

2.1. Syntax of the bar code................................................................... 6

2.2 Using the bar code reader option ................................................... 7
2.3 Display of the user interfaces on the screen .................................. 8
2.4 Controller messages..................................................................... 15
2.5 Loading the product not possible ................................................. 16

3 Installation.......................................................................................... 17

4 Testing instructions .......................................................................... 21

4 Manual Bar code reader Version 1.0

 1 General information
The Strichcodeleser consists of
ID no.
863249 bar code reading device DLC-7070
863044 internal cable for the Strichcodeleser
863217 spiral cable for the Strichcodeleser
864666 holder for the Strichcodeleser
863046 Handbuch Strichcodeleser

Bar code components Bar code symbols convey information by means of the relative widths
of the bars and the gaps between them. There are various types of
codes which are the result of specific developments and require-
ments. Each code consists of a start character, the data characters,
occasionally test characters and a stop character. Below the code,
the information is often stated in writing. An example of a bar code:

1234567
The Strichcodeleser enables the user to activate or load a particular
product simply by scanning the bar code. Of course, the selected
product needs to be contained in the memory of the control system or
be loadable via the network.
Bar code printer The bar codes are generated by means of a bar code printer or a
software program which is able to generate bar codes. You can
obtain the BAR-ONE Lite demo software for generating bar codes
from the Internet at www.zebra.com.
Note The bar code reading device is programmed so that it will be able to
read the codes Code39, Code93, Code128, Interleaved2/5 and EAN8
immediately after installation. Therefore, it is not necessary to carry
out any configurations.
Code types The alphanumeric Code39 works with up to 30 characters (this
means the drawing number may comprise 17 characters when using
network names)!
Example: N-/VZEICHNS/$12345678901234567 (see also
Chapter 1.12.1)

Manual Bar code reader Version 1.0 5

 The two alphanumeric codes Code93 and Code128 enable full
functional capacity (20digit drawing number and network).
The Interleaved2/5 code permits numeric characters only and
therefore only the selection of product numbers. Furthermore, its
syntax requires the usage of a square number of digits (2, 4 or 6)
only.
The EAN8 code requires precisely 7 numerals plus a test numeral
which is not needed for the product number. In other words, all
products need to be stored as 7 digits when using this code.

2 Operation

2.1. Syntax of the bar code

The syntax of the bar code depends on the location of the product
and if you want to select the product via its product number or
drawing number: The product can be in three different locations:
• local (in the controller memory);
• another local directory (only possible with Flash disk option);
• network (only possible with Ethernet option).

Syntax principle
The general syntax of the bar code is as follows:
[N-] [/directory name/] <product number/$drawing number>
Remark:
• components between brackets [..] are optional.
• [N-] corresponds with the mount path on the server.
Depending on the product location and the way of product selection
the syntax uses one, two or three components.
Local:
<product number>
<$drawing number>
Example:
• product number: 1, 1234567, 5800;
• drawing number: $EXAMPLE, $1234, $ABC.

Another local directory:

</path/><product number>

6 Manual Bar code reader Version 1.0

 </path/><$drawing number>
Example:
• product number: /directory name/1;
• drawing number: /directory name/$EXAMPLE.

Network:
<N-></directoryname/><product number>

<N-></directoryname/><$drawing number>

Example:
• product number: N-/123/1, N-/client/1234567;
• drawing number: N-/123/$EXAMPLE, N-/123/$1234.

Also the following points should be taken into account before

generating bar codes:

Please note • ASCII characters lower than 32 and higher than 127 are ignored
(they are usually part of the pre- and post ambles). This also applies
to the network paths.
• Case sensitivity. The path in the bar code has to correspond with
the case (upper case, lower case or combined) of the path on the
server (or controller). For example: when you have made the path
‘CLIENT’ (all upper case letters) on the server then the bar code must
also have ‘CLIENT’ in the path name and not ‘Client’. Read also the
manual of the Ethernet option.
• The letters in the drawing number must always be upper case.
• The path name uses forward slashes ‘/’ as in UNIX-style paths.
• Drawing numbers must directly be proceeded by the dollar-sign ‘$’.
• Products that reside on the network should be of the standard DLC-
type (generated with Profile or the controller itself).
• A product network can only be selected if the corresponding
program file is available on the network.
• </directory name/>. Make sure the level of the search path is fully
compatible with the Ethernet functionality, otherwise you will not find
the product.

2.2 Using the bar code reader option

The bar code reader is only active in the ‘product selection’ menu.
The ‘product selection’ menu is selected in the programming mode of
the controller (menu 5). When a bar code is scanned with the
controller in this state, the product number and/or drawing number of

Manual Bar code reader Version 1.0 7

 the scanned product will be displayed in a message box on the
screen.
After you acknowledge (‘continue 1/0’), an attempt is made to load
the product.

Loading a product from Scanning a product number or drawing number which resides in the
the memory current local directory is comparable to the ‘load product’ function in
the standard situation. When the product resides in another local
directory the product is loaded and this directory will automatically
become the current local directory.
Loading a product from A product which resides in a network directory is first of all copied to
the network the current local directory. Does the product exist in this current local
directory an additional warning is given that the product will be
overwritten. If you acknowledge (‘contine 1/0’), then the product will
automatically be copied to the current directory of the controller and
automatically loaded.
The next section gives an overview of the user interface screens
when using the bar code reader option.

2.3 Display of the user interfaces on the screen

Go to the ‘product selection’-menu (fig. 1). Besides the standard

selection method of typing the product by using the frontpanel keys,
the bar code reader can also be used to load a product.

Fig. 1: Product selection menu

8 Manual Bar code reader Version 1.0

 Scan the bar code of the product you want to load.
e.g.:

1
After you have scanned the bar code a message box appears with
the source location of the product, the product number and drawing
number of the product (if present).

Fig. 2: Read in product 1?

Manual Bar code reader Version 1.0 9

 This scanned product is only loaded after confirmation (‘continue ?
1/0’). Typ ‘1’ to continue.

Fig. 3: Product loaded

You can also load a product by scanning the drawing number instead
of the product number.
In fig. 4 the drawing number ‘ABC’ has been scanned in stead of
product number ‘200’, but the result will be the same.
e.g.:

$ A B C

10 Manual Bar code reader Version 1.0

 Fig. 4: Load drawing?

After confirmation the product (drawing and program) has been

loaded.

Fig. 5: Drawing loaded

Manual Bar code reader Version 1.0 11

 In case the product is in another local directory this local directory will
automatically be changed into the current local directory and the
scanned product will be the active product.

/ 4 5 6 / 1

Fig. 6: Load product from different directory?

In fig. 6 product number ‘1’ with drawing number ‘1234’ from local
directory ‘456’ will be loaded after confirmation.

12 Manual Bar code reader Version 1.0

 Fig. 7: Product loaded from directory
After confirmation the local directory has been changed into ‘456’and
the product has been loaded. See also the header in fig. 7.
In case the product is a network product first of all this product will be
copied to the current (local) directory. If you are familiar with the
Ethernet option you will recognize this procedure: it is the same
principle. However, with the bar code reader option the product is
copied and loaded automatically. You only have to confirm the scan
action.

N - / 1 2 3 / 1

Manual Bar code reader Version 1.0 13

 Fig. 8: Load product from the network?
When this product already exists in this current directory then an
additional message is given that the product will be overwritten, if you
continue. In this case you have to confirm twice.

Fig. 9: Overwrite product?

14 Manual Bar code reader Version 1.0

 Fig. 10: Product loaded from the network
Remark on network Please remember that scanning network products requires a certain
products amount of free storage capacity on your control system. You will
need as much capacity as is required to copy the product into the
memory. Make sure these products are never deleted automatically.

2.4 Controller messages

The next specific bar code reader messages can occur while using
the bar code reader:

2.4.1 Error messages

‚Too many characters in bar code’

Cause: The bar code you have scanned contains too many
characters.
‚Syntax error in bar code input’
Cause: The syntax of the information in the bar code is not
correct.
‚Ethernet option not available’
Cause: A network path has been defined in the bar code, but there
is no network option available in this controller.
‚Product not found’

Manual Bar code reader Version 1.0 15

 Cause: The product specified in the bar code is not present in the
controller or on the network.

2.4.2 Message
‚Machine number mismatch’
Cause: machine number of the product you want to select is not
the same as the machine number of the controller you are using.
This is the same message that appears when you are copying
files from one controller to another. When you acknowledge then
the product is loaded. Do you press abort then the product will not
be loaded.

2.5 Loading the product not possible

Scanning the bar code does not load the product, nor does the
control system display an error code, or scanning the bar code loads
the wrong product. In this case, please check the bar code reader.
Refer to Chapter 4.

16 Manual Bar code reader Version 1.0

 3 Installation

• Switch machine off.

• Remove recessed head screws on the rear panel and open the
control system.
• Remove dummy plug from the rear panel.
• From the outside, insert internal cable 863044 through the recess
in the rear panel.
• Fasten 5 channel plug to rear panel with retaining ring.
• Plug cable into "serial keyboard" plug on mainboard, as shown on
diagram.

• Close the housing.

Manual Bar code reader Version 1.0 17

 • Remove the right-hand front countersunk head screws M5x20
using the Allan key.
• Screw holder for the Strichcodeleser with the head screws M5x20
onto the side of the housing as shown on the photo below.

• Push Strichcodeleser into holder and switch on machine.

• In programming mode, select menu '19'.

• Enter code '14753'.
• Select menu '8', option codes.
• Select code '7', bar code reader, and enter code.
• Restart control system by repeatedly pressing the 'END' key.

18 Manual Bar code reader Version 1.0

 • Reprogram the bar code reader:

<4xPiep>

<1xPiep=Ok>

<1xPiep=Ok>

<1xPiep=Ok>

<1xPiep=Ok>

<1xPiep=Ok>

<1xPiep=Ok>

<1xPiep=Ok>

<1xPiep=Ok>

Manual Bar code reader Version 1.0 19

 <4xPiep>

• Carry out testing check as described in Chapter 4 .

20 Manual Bar code reader Version 1.0

 4 Testing instructions

• Enable option code

• Push bar code reading device into holder
• In programming mode, switch to menu '5'

If the product or the drawing is not available, the error message

stating that they are not available is correct for this test.
• Scan code

1234567
Product is read in.
• Scan code

$TESTPRODUKT
Drawing number is read in.
• Scan code

N- / TESTVERZ/ $ABC
A drawing number is read in from the network. If there is no network
available, the following error is displayed: Option not available.

Manual Bar code reader Version 1.0 21

22 Manual Bar code reader Version 1.0
Operational manual

Robot Interface
Operational
Manual

Robot Interface

Version 1.1

Edition: 09/01
ID no.: 856365
Ordering Please state the title of the document, the language desired,
information and the date of issue.
TRUMPF Maschinen, Austria
GmbH & Co KG
Industriepark 24
A-4061 Pasching
Telephone: ++43 (0)7221 / 603 - 0
Fax: ++43 (0)7221 / 603 - 50

This document was written in the Technical Documentation Department of TRUMPF

Maschinen, Austria.
All rights to this documentation, especially the rights of reproduction and distribution
as well as that of translation are retained by TRUMPF, even in the case of
notifications of protective privilege. No part of this documentation may be in any way
copied or processed using electronic systems, reproduced or distributed without the
prior written consent of TRUMPF. Errors and technical changes are excepted.

© TRUMPF Maschinen Austria GmbH & Co KG

TRUMPF is not liable for any errors in this documentation. Liability for direct and indirect
damage or injury resulting from the delivery or use of this documentation is excluded, in so far
as this is legally permissible.

2 Operational Manual Robot Interface

 Before reading any further ...

About the contents The Operational Manual for the Robot Interface is directed to all service
personnel, robot programmers, owners and operators. It has to be available
to these people and be carefully read before the installation work and initial
putting into operation.

This manual describes:

r Interface and connection

r Software configuration and parameterization

r Signal paths

Prerequisite r TrumaBend V-series with a fail-safe SPS, DA65 or DA69 control

system and a software version which is larger or the same as a
V 5.4 with V25 sequencer.
Supplimentary r Operating manual for TrumaBend V series
literature
r Instruction manual for DA control system
r Service manual, TrumaBend V series
r Software installation V5.4 - a brief description
®
r Instruction manual ACB
r Retrofitting manual Robot Interface

Operational Manual Robot Interface 3

 Contents
1 General information..................................................................5

1.1 The operating mode switch.........................................................6

2 Description of the hardware ....................................................7

2.1 Specifications for plugs XS7 and XS8 ........................................8

2.2 Plug signals for XS7 and XS8 for robot A...................................9

2.3 Specifications for plug XS3 .......................................................12

2.4 Signals at plug XS3 for robot B.................................................14

2.5 Signals of the plug XS7 for robot B...........................................16

2.6 Emergency stop circuits............................................................17

2.7 Error acknowledgment ..............................................................18

2.8 The key switches ......................................................................18

2.9 DM04 module signals ...............................................................18

3 Machine parameters ...............................................................19

4 The flags ..................................................................................20

4.1 Activate robot ............................................................................20

4.2 TrumaBend passive/active........................................................20

4.3 Bending aid ...............................................................................20

4.4 Loading regulation at the sheet clamping point ........................21

4.5 Activating the robot interface ID No. 856364 ............................21

®
4.6 Using ACB ...............................................................................21

4.7 Signal „First bending operation active” ....................................22

4.8 Programming withdrawals.........................................................23

4.9 Flattening or hemming ..............................................................23

5 The signal sequence...............................................................23

®
5.1 Signal course without ACB ......................................................25

4 Operational Manual Robot Interface

 ®
5.2 Signal course with ACB ...........................................................28

1 General information

Note This is the description of the optionally available Robot Interface, as it

was mentioned in Operational Manual 4 Descriptions Chapter 5.12
Robot interfaces.
This Robot Interface is arranged for operation with TrumaBend
V-Series with one or two robots. It is possible to manually operate the
TrumaBend V-Series from the control panel (under consideration of
safety regulations according to the respective norms of the country in
question and its laws as well as the additional safety information in
this manual).
The robot interface has two 24-pole plug outputs for robot A, a
48-pole plug output for the control panel or for robot B, a DM04
module (digital input/output module) for the control system signal, a
switching panel with relay and an additional key switch with two
positions on the rear of the switch cabinet. The entire Robot Interface
consists of
ID no.
856282 Robot interface connection cable
841436 HSB connection cable
841052 CAN bus card
856365 Operational Manual
858369 Robot operating mode sign
845365 2 Phillips securing screws

Important! This Robot Interface replaces the description in Robot Interface,

which is in the manual on pages 4-36. There, only one robot can be
connected or the control panel disconnected.
For this Robot Interface, the control panel must remain connected
only for operation with robot A.
Operating mode: In this documentation, a difference is made between "TrumaBend
without robot" operation and "TrumaBend with robot".
TrumaBend without
robot - For operation without robot, the is manually fed. To do this, the press
TrumaBend with robot brake is controlled with the control panel. This tooling status corresponds
to the one described in the operation manual (see page 4-36).
During operation with the robot, the robot feeds the press brake. In the
"TrumaBend with robot A" operating mode, the control panel is not
removed, but the TrumaBend cannot be moved with the control panel.

Operational Manual Robot Interface 5

 When you are in "TrumaBend with robot" operation, the internal key
switch S57 in the switch cabinet makes it possible for you to select
between slower or faster rapid traverse speed.

Important note for the Only authorized personnel are allowed to select the "TrumaBend
owner of the TrumaBend with robot in fast rapid traverse" operating mode. The responsibility
for this rests entirely with the owner of the TrumaBend.

1.1 The operating mode switch

The external operating mode switch can be used normally to select

between manual feeding or control system of the TrumaBend with
control panel and robot feeding by robot A. The control panel remains
connected during this.
If the TrumaBend is reconfigured for two robots, it is then possible to
select between action by robot A or robot B.

The operator is to assure that the robot is not put into operation
while he is in the danger zone of the robot. For this reason, it is
recommended that you set up a parking position for the robot
for "Stand-Alone-Operation" (TrumaBend without robot).
TrumaBend with robot A If you select "TrumaBend with robot A" operating mode, the first control
panel is partially inactive; i.e. the foot switch, the left two-hand switch and
the operation mode switch will not function. It is therefore not possible in
robot operation A to trigger a beam movement with the control panel.
Note: If the control panel is disconnected, the E-STOP is active; i.e. the
E-STOP switch is completely operative. The following keys are
operative for the control panel: punch holder/lower tool holder, front
support on/off, Z-offset, motor on/off, the bypass key, the emergency
open switch, the E-STOP switch, the right two-hand switch and the
selector switch for the light curtain.
TrumaBend with robot B Robot B is connected instead of the first control panel. You should
therefore remove the first control panel from the working range and
securely store it. The following switch signals have to be realized from
robot B: punch holder/lower tool holder, front support on/off, Z-offset,
motor on/off, the bypass key, a two-hand switch (for acknowledging
errors), a foot switch, foot/foot front operation mode and the
emergency open switch.
Robot A is inactive in this mode. Its emergency stop signal is not
engaged. However, the emergency stop circuit for robot A is open
and robot A can therefore not be put into operation.

6 Operational Manual Robot Interface

 Note about wiring Correct and trouble-free operation with the TrumaBend with robot can
only be assured if robot A is wired as indicated in Chapter 2.2 and
robot B is wired as indicated in Chapter 2.4. Because robot B is
connected instead of the first control panel, you should remove the
control panel from the working range and securely store it. Robot B is
the master which triggers the stroke.
Second operating station/ On the "TrumaBend with robot B" operation modes, disconnect and
second foot switch remove the second operating station/foot switch, as is the case with
the first operating station.
Second operating station/ In the "TrumaBend with robot A" operating mode, the same applies
foot switch with robot A as applied above for the first control panel. The E-STOP circuit is
engaged. The following switches also function: punch holder/lower
tool holder, front support on/off, Z-offset, motor on/off, the bypass key
and the emergency operation switch. The second control panel/foot
switch is therefore not to be disconnected.

2 Description of the hardware

The plugs in the switch cabinet are to be placed as follows:

XS3
XS8

XS7

The 48-pole plug XS3 is for the control panel or robot B. The two
24-pole plugs XS7 and XS8 are for robot A. Plug XS7 can, however,
also take on signals for robot B (see Chapter 2.5).

Operational Manual Robot Interface 7

 2.1 Specifications for plugs XS7 and XS8

Both plugs are configured as socket inserts (F) (Figure 2). They are
coded with filled-in circles with barring bolt (ID no. 09 30 000 990)
(Figure 5) to eliminate confusion. The connection blocks are installed
in attachment housings (Figure 1). For this reason, plug inserts such
as those in the drawing are to be used as opposing plugs (M). It is
suggested to use the pin inserts (ID no. 09 33 024 2601) (Figure 3)
with the grommet housing (ID no. 09 30 024 0440) (Figure 4) from the
Harting company. Alternatively, you can also connect other grommet
housing shapes (cable output on the side, low shape, flat connector
output, output for more narrow cable). In addition, the two plugs with
barring bolts (ID no. 09 30 000 990) have to be correctly coded
according to Figure 5.
It is also a good idea to use the special cable screw connection (ID no.
09 00 000 5106) and the simple washer (ID no. 09 00 000 5024).
You can also order the opposing plug from TRUMPF Machines,
Austria, using the ID no. 860801. Please note that you need two of
these.

Figure 1: Attachment housing type HAN 24 E

Figure 2: Socket insert type HAN E

8 Operational Manual Robot Interface

 Figure 3: Pin insert type HAN E

Figure 4: Grommet housing type HAN 24 E

Figure 5: Coding of inserts XS7 and XS8 (look from cable

connection)

2.2 Plug signals for XS7 and XS8 for robot A

Signals at plug XS7 The signals of the 24-pole plug XS7 are connected with DM04.
So, the arrangement is:
1 Start release
2 Upper dead point
3 Sheet clamping point

Operational Manual Robot Interface 9

 4 Lower dead point
®
5 ACB -bend
6 Required angle reached
7 ACBâ bend 3.3 (identification)
9 ACBâ tilting +
10 ACBâ tilting -
11 ACBâ stop
12 Permission condition 1
13 First bend active
14 Permission condition 2
15 Approach LDP
16 Approach UDP
17 Approach clamping point
18 TRB active for robot B
19 TRB passive for robot A
20 Control panel (robot B) has been selected
21 Carry out beam movement
The pins 1 to 6, 9 to 11 and 13 are outputs. The remaining pins are
inputs. All 24 pins are wired for future extensions.
The XS7/15-17 press bar is guided towards the required points (CP,
LDP, UDP). However, it is also possible to carry out the beam
movement sequentially using the XS7/21 pin. In robot mode,
however, only one beam movement is carried out when the
permission conditions 1 and 2 (robot permission switch) have been
fulfilled.

Signals on the XS8 plug The XS8 also has 24 pins. Its configuration is
1 Sensor stop finger signal 1
2 Sensor stop finger signal 2
3 Sensor stop finger signal 3
4 Sensor stop finger signal 4
5 Reserve
6 0 V for TrumaBend
7/8 Emergency stop circuit 1 for TrumaBend
9/10 Emergency stop circuit 2 for TrumaBend
11/12 Emergency stop circuit 1 for robot A
13/14 Emergency stop circuit 2 for robot A

10 Operational Manual Robot Interface

 15 24 V of the TrumaBend, switched on when TrumaBend is in
robot mode
16 Emergency-opening or bending step relay (C input)
17 0 V from the robot
18 24 V from the robot
19 (Tableau in resting position 1)
20 (Tableau in resting position 2)
21 Reserve
22 Reserve
23 Reserve
24 Reserve
Note: If the bending step alteration is carried out using the robot, the bend
must be programmed using code 4 or 5 and a short impulse (200 to
250 ms) must be defined on the XS8/16 pin. If the signal is longer
than 200ms, the press bar travels to (emergency stop function) for
as long as the signal is present.
The signals (besides 11/12 and 13/14) are not potential-free. For this
reason, the potential separation is to be done on the robot side (see
Figure 6). The lamps shown (H1 to H6 and H19 and H21) can, for
example, be connected to the coils of relays. They correspond to the
above-mentioned pins XS7/1 to XS7/6 and XS7/19 and XS7/21.
Switch S16 is a two-channeled emergency-stop-switch at robot A.
Switch S17 is the two-channeled emergency stop relay A360 in
TrumaBend. The button S18 is an emergency open button.

Operational Manual Robot Interface 11

 Figure 6: Wiring in robot A

2.3 Specifications for plug XS3

The plug consists of two 24-pole socket inserts (see Figure 2). They
are coded with filled-in circles with barring bolt (ID no. 09 30 000 990)
(Figure 9), to eliminate confusion. The connection blocks are installed
in attachment housings (Figure 7). For this reason, plug inserts such
as those in the drawing are to be used as opposing plugs (M). It is
suggested to use the pin inserts (ID no. 09 33 024 2601 and ID no.
09 35 024 2611) (Figure 3) with the grommet housing (ID no.
09 30 048 0440) (Figure 8) from the Harting company. Alternatively,
you can also connect other grommet housing shapes (cable output
on the side, low shape, flat connector output, output for more narrow
cable). In addition, the two plugs with barring bolts (ID no.
09 30 000 990) have to be correctly coded according to Figure 9.
It is also a good idea to use the special cable screw connection (ID no.
09 00 000 5106) and the simple washer (ID no. 09 00 000 5024).
You can order the grommet housing, including the special screw
connection using the ID number 838400 and the pin insert using the
ID number 825318 from TRUMPF Machines, Austria.

12 Operational Manual Robot Interface

 Figure 7: Attachment housing type HAN 48 E

Figure 8: Grommet housing type HAN 48 E

Operational Manual Robot Interface 13

 Figure 9: Coding of plug XS3 (look from cable connection)

2.4 Signals at plug XS3 for robot B

Signals at plug XS3 The 48-pole plug XS3 corresponds almost to a control panel. So, the
arrangement is:
1/2 Emergency stop circuit 1 for TrumaBend
3/4 Emergency stop circuit 2 for TrumaBend
5/6 Bypass for beam inclined position
7 Hydraulic system start
8 24 V for Signal 7 and 9
9 Hydraulic system stop
10 Hydraulic system is running
11 0 V for press
12 Hydraulic system is not working
13/14 Open foot switch
15/16 Open the right two-hand switch
19 Open contact, foot switch
20 Open contact, right two-hand switch
26 Emergency open switch together with 39
27 UT release/clamp

14 Operational Manual Robot Interface

 28 24 V for press
29 LT release/clamp
30 UT released
31 LT released
32-35 Light curtain
36 Activate Z-offset
37/38 Resistance is necessary so that the Fail Safe recognizes
that the robot is present
39 Emergency open together with 26
40 Bending aid on
43/44 Emergency stop circuit 1 for robot B
45/46 Bracket for recognition of robot B (switch on key switch S57!)
47/48 Emergency stop circuit 2 for robot B

As for the connection the plugs XS7 and XS8, the potential sepa-
ration is also to be done at the robot side, as can be seen in the
Figure 10 and Figure 11. The switches have the same designation as
in the wiring diagram. This information is as follows:
S21 Two channel emergency stop switch
S25 Cross bridge button (this is needed for the inclined position
of the press bar)
S30.1 Hydraulic system start button
S30 Hydraulic system stop button
H33 Hydraulic system started lamp
H34 Hydraulic system stopped lamp
S42 Close-open contact foot switch
S42.1 Close-open contact right two-hand switch
S32 Two-channeled normally open contact emergency-open
S111 Clamp/release upper tool
S116 Clamp/release lower tool
H113 Upper tool holder released lamp
H116.1 Lower tool holder released lamp
S41.1 Light curtain selector switch
S281 Activate Z-offset button
H37 Robot B active lamp
S120 Bending aid on button
S27 Two channel emergency stop switch

Operational Manual Robot Interface 15

 Figure 10: Wiring in robot B part 1

Figure 11: Wiring in robot B part 2

2.5 Signals of the plug XS7 for robot B

Signals at plug XS7 The signals of the 24-pole plug XS7 are connected with DM04.
So, the arrangement is:
1 Start release
2 Upper dead point
3 Sheet clamping point
4 Lower dead point
®
5 ACB -bend
6 Required angle reached
7 ACBâ bend 3.3 (identification)
9 ACBâ tilting +

16 Operational Manual Robot Interface

 10 ACBâ tilting -
11 ACBâ stop
12 Permission condition 1
13 First bend active
14 Permission condition 2
15 Approach LDP
16 Approach UDP
17 Approach clamping point
18 TRB active for robot B
19 TRB passive for robot A
20 Control panel (robot B) has been selected
21 Carry out beam movement
The pins 1 to 6, 9 to 11 and 13 are outputs. The remaining pins are
inputs. All 24 pins are wired for future extensions. A stroke is always
released with the S42 foot switch (see chapter 2.4). The XS7/15-17
or 21 inputs are only required for the press bar to continue traveling
when in active mode.

2.6 Emergency stop circuits

The press brake requires two emergency stop circuits which are
independent from each other. The robots also have to have their
emergency stop signals available in two paths. Furthermore, these
signals have to be potential-free and normally closed contacts. Robot A
is linked via plug XS8, pin 7/8 and pin 9/10 to the emergency stop circuit
of the TrumaBend. There are also two potential-free and normally closed
contacts from the TrumaBend for robot A at pins 11/12 and 13/14 of plug
XS8 in order to link the emergency stop circuit of the robot.
Robot B is linked via plug XS3, pin 1/2 and pin 3/4, which is
connected instead of the control panel. There are also two potential-
free and normally closed contacts from the TrumaBend for robot B at
pins 41/42 and 43/44 of plug XS3 in order to link the emergency stop
circuit of the robot.
Attention! In the "TrumaBend without robot" operating mode, the emergency
stop switches for the robots are not engaged in the emergency stop
circuits of the press. Since the robot has to be in a parking position,
the two systems are only minimally connected in the "TrumaBend
without robot" operating mode.
In the "TrumaBend with robot B" operating mode, the emergency
stop switches for robot A are not engaged in the emergency stop
circuits of the press. Since robot A is in a "slave function", the
emergency stop switch in the robot B circuit has to be connected so
that TrumaBend can switch it off. Robot A is only minimally connec-
ted with the TrumaBend in this operating status.

Operational Manual Robot Interface 17

 2.7 Error acknowledgment

The zero position of the valves is checked at the upper dead point. If
this zero position is not reached in time, the Fail-Safe SPS
recognizes a valve error. This can be acknowledged with a two-hand
switch. Then work can proceed with the TrumaBend. This is done in
all operation modes with a two-hand switch.

2.8 The key switches

There is a key switch in the switch cabinet to switch between faster
and slower rapid traverse speed for "TrumaBend with robot".
A key switch with two positions is installed at the back of the switch
cabinet. This is used to select between operation with robot A or
without robot or, as the case may be, with robot B. The control panel
is required for operation with robot A. The control panel is used for
the following: tool clamping, activating the bending aid, switching the
hydraulic system on and off, valve error acknowledgment (see
Chapter 2.7) and the Z-offset (if available). For "TrumaBend without
robot" operation, the TrumaBend moves in foot/foot operation in rapid
traverse only with the bending speed.

2.9 DM04 module signals

I/O-Layout at the DM04 The I/O signals from the DM04 module are wired directly to plug XS7.
module With the LEDs of the module, you can see which signals are present.
1 Start release
2 Upper dead point
3 Sheet clamping point
4 Lower dead point
®
5 ACB -bend
6 Required angle reached
7 ACBâ bend 3.3 (identification)
8 Valve drive
9 ACBâ tilting +
10 ACBâ tilting +
11 ACBâ stop
12 Permission condition 1
13 First bend active
14 Permission condition 2
15 Approach LDP
16 Approach UDP

18 Operational Manual Robot Interface

 17 Approach clamping point
18 TRB active for robot B
19 TRB passive for robot A
20 Control panel (robot B) has been selected
21 Carry out beam movement
The pins 1 to 11 and 13 are outputs. The remaining pins are inputs.
The XS7/15-17 press bar is guided towards the required points (CP,
LDP, UDP). However, it is also possible to carry out the beam
movement sequentially using the 21 signal. In robot mode, however,
only one beam movement is carried out when the permission
conditions 1 and 2 (robot permission switch) have been fulfilled.

3 Machine parameters

Activating the Steps to activate the DM04 module

DM04 module
· Changing into programming mode (symbol next to the hand)
· Enter '19' and press 'ENTER'
· Enter the code '14753' and press 'ENTER'
· Select menu '3'
· Switch to axis 13
· Enter box number '40'
· Enter the ID number of the module (on the underside of the
module)
· Select the axis and change to 'IO1' using the 'S6' softkey
· Quit axis configuration with 'END'
· Select menu '1'
· On the last page, replace 19.10 with 'S2'
· Now the flags can be changed as described below.
· Then press the 'END' key until the control system reboots.

Operational Manual Robot Interface 19

 4 The flags

Changing the parameters Each parameter (numbered from 123 to 130) consists of four flags. So
if you want to change flag number 5, you have to select parameter 124.
Then you can change the four flags 8-5. The left bit is the most
significant bit. In parameter 124, this stands for flag 8. This means you
do not have to change the first three bits. The first three bits are
entered in the same way and only the last bit in a changed form.
Do not change any bit which is marked with an 'X'. Proceed as
described above for the entry.

4.1 Activate robot

When using a robot, the signals with flag 1 of parameter 123 will be
activated. For this reason, 'XXX1' is to be entered there.

4.2 TrumaBend passive/active

TrumaBend is active when flag 9 is present. Therefore, parameter 125

is to be changed to 'XXX1'. You can, then, have a passive TrumaBend
with 'XXX0'.
TrumaBend TrumaBend is passive. That means that the robot serves the
passive/active TrumaBend like a servant. If robot A takes away the start signal
(pin 21 for robot A; release foot switch for robot B), then the
TrumaBend will stop after reaching the mute point in the press
operation and will start moving again with the start signal.
TrumaBend active TrumaBend is active. That means that when the TrumaBend receives
an increasing start signal flank, it will move up to the sheet clamping
point and automatically stop there until a new start flank is received.
The next time, the TrumaBend will stop at the lower dead point. The
TrumaBend will only move again after a new start flank.
Note: If TrumaBend is operated when active, bends with the code 10, 11,
12, 13, or 15 are not permitted. This is also not necessary, since
when it is active, TrumaBend and the robot will adhere to the
clamping point of their own accord.

4.3 Bending aid

Normally, the bending aid also moves along when activated after the
sheet clamping point. However, if you want a new start flank to be
required for the bending aid to move along, then set flag 10. The
bending aid will then only start to move when a new start flank after
or at the sheet clamping point. This is could be especially useful for
the active TrumaBend mode.
Parameter 125 is to be set to 'XX1X'. Please note that the bending
aid has to be switched on using the control panel (for the description
of the switches and buttons, see the operation manual, page 5-6).

20 Operational Manual Robot Interface

 ®
If an ACB bend is done, then the bending aid will stay at the safety
angle when it is withdrawn. This exists so that the sensor disks of the
®
ACB tool will not be damaged. The TrumaBend will wait for a new start
signal until it moves the bending aid downwards into the initial position.

4.4 Loading regulation at the sheet clamping point

Note: If the TrumaBend is operated in active mode, it can be that the sheet
clamping point signal will be at a low state for a short period of time
after the start release signal is taken away. This occurs because of
the spring-back effect of the sheet metal.
Remedy: You can switch this off by activating flag 11 by setting parameter 125
on 'X1XX'.
The valves can then be controlled at the sheet clamping point, but a
start flank is needed for further movement. Furthermore, set the
parameter 10 TANDEM I/O to '2'. This can be found a few pages
before in the machine parameters (softkey S1, page 19.2).

4.5 Activating the robot interface ID No. 856364

Flag 12 in parameter 125 is used to activate the signals for this robot
interface. Set parameter 125 to '1XXX'.
Note: The combination '1001' is not possible! That is, the selection of a new
interface in active mode but without loading regulation is not possible
for technical reasons.

4.6 Using ACB®

®
Before using ACB with a robot, you have to acquaint yourself with
® ®
the way ACB -bendings work with the ACB Operational Manual.
This will enable you to do the connections and the robot programming
correctly.
®
To activate the sensor signals (ACB in use No. 5, required angle
reached No. 6), you have to do changes at the sensor settings. To do
this, you have to do the following:
· Change to menu 19.
· Enter the code '14753'.
· Select menu '2'.
· Press the softkey 'S8'.
· Select parameters 10 and enter '64'.
· Leave the menu with the 'END' key.

Operational Manual Robot Interface 21

 ®
Configuring the robot The signal 'ACB in use' (pin 5 of the XS7 or also output 4005 of the
program DM04 module) has to be inquired about at the upper dead point. In this
case, the bending cycle is only complete when the required angle signal
has been reached and not when the lower dead point has been reached.
This is because something is moving upwards after the bending of the
beam and then the angle will be measured. For this reason, signal
®
4006 (pin 6 XS7) has to be inquired about for ACB bendings.
In case an identification is necessary, the beam moves upwards again.
'Required angle reached' will be shown for a second time. Whether the
bending is complete can be linked with the upper dead point.
After the required angle has been reached, the TrumaBend has to
stop. Either TrumaBend will stop itself or, in the case of passive
TrumaBend, by the robot. A new start flank may only be set after
100 ms at the earliest.
Tilt angle After stopping, the robot should take the sheet. Be sure that the robot
holds the sheet within the tilt angle. Otherwise, the beam will not
move up. The tilt angle can also be deactivated. To do this, sensor
parameter 9 on the second page has to be set to 1 (as described in
®
the ACB instruction manual on page 20). Even if an identification is
done, the robot has to be able to take up the sheet movement, which
can take place in the Y as well as the X direction.
®
Pay attention to the sensor disks for ACB bendings. It is possible
that the robot has to remove the sheet and, for this reason, will follow
the upwards movement of the beam.

4.7 Signal „First bending operation active”

In the bending program of TRB, the FD output 1 (right = least

significant bit) must be set to 1 (XXXX1) for the first bending
operation in order for the output XS7/13 to be set to "First bending
operation active". All other bits are not allowed to be modified.
Caution This FD output is also used for the fault management of ACBâ
bending and must therefore be programmed at the first bending
operation.

Note If the on/off FDs are not active, they must be activated as follows.
· Move to menu 19.
· Enter the code '32157'.
· Select menu 2.
· Change to the axis with the 'FD' type.
· Press the softkey 'S5'.
· Set the number of FD outputs to min. 1 (max. 5).
· Set the LsFD output to '1'.

22 Operational Manual Robot Interface

 · Exit the menu with 'END'.

4.8 Programming withdrawals

If a withdrawal of the backgauges is programmed when TrumaBend
has been activated and when the robot interface is active, bends with
code 10, 11, 12, 13, or 15 are not permitted. This is also not
necessary, since when it is active, TrumaBend, together with the
robot, will adhere to the clamping point of its own accord.
Note: During the withdrawal, the "Start release" signal (pin 1 of the SX7 or
output 1 of the DM04 module) is triggered. If the withdrawal has been
completed, the "Start release" signal is again given.

4.9 Flattening or hemming

If the bend needs to be hemmed, the bending machine should be set to
passive mode for this bend using the XS7/19 signal "Robot A passive".
Before the part is loaded, the beam movement must be triggered by the
XS7/21 signal, "Carry out beam movement". The TRB stops at mute
point 2 (opening before flattening) and releases the XS7/3 signal "Sheet
clamping point". Only then can the XS7/21 signal be canceled and the
part be loaded. Flattening starts when the XS7/21 signal is redefined.
Note: Since the TRB is passive during flattening, it does not automatically
remain on the lower dead point. However, by resetting the XS7/21
signal "Carry out beam movement", the movement on the lower dead
point can be stopped.

5 The signal sequence

Brief description of the First of all, the TrumaBend is in status 1. The speed is at zero and
bending cycle the beam is at the upper dead point.
After a stroke has been triggered with the foot switch, two-hand
switch, or robot signal, the beam will move to the mute point ‚ with
rapid traverse speed  (except foot/foot operation with the control
panel). The TrumaBend is in status 2.
Then the press will move at bending speed ƒ for the work cycle
(status 3). This ends at the lower dead point. The sheet has reached
the final angle.
In status 4, the beam waits for the entered dwell time at the lower
dead point.
Then the decompression follows in status 5. The beam will be moved
upwards with the decompression speed along the decompression path.
Once the end of the decompression has been reached, the beam
moves with maximum reverse speed in status 6 to the upper dead
point. Then the TrumaBend is in status 1 again and waits for a new

Operational Manual Robot Interface 23

 start flank.
The beam moves after the mute point at a bending speed of no more
than 10 mm/s.

Press bar movement with Since robot B replaces the control panel, or is fitted in the same
robot B position as the control panel, the foot switch must be placed there. In
other words, when nothing particular is shown on the following pages,
robot B refers to the foot pedal for the "Approach upper dead point",
"Approach lower dead point", "Approach clamping point" or "Carry out
beam movement" signal procedure.
The Figure 12 to Figure 18 shows each signal sequence as affected
by the option flag 125.

24 Operational Manual Robot Interface

 5.1 Signal course without ACB®
STATUS

1 2 3 4 5 6 1
a (Oberer Totpunkt)

1
9

2 3
4 5
b (Mutepunkt)
c (Klemmpunkt)
7 8
6
d (Unterer Totpunkt)

A (Oberer Totpunkt XS7/

2)

B (Klemmpunkt XS7/3)

C (Unterer Totpunkt
XS7/4)

D (Startfreigabe XS7/1)

E (Balkenbewegung
durchführen XS7/21)

a Upper dead point B Clamping point XS7/3

b Mute point C Lower dead point XS7/4
c Clamping point D Start release XS7/1
d Lower dead point E Carry out beam movement XS7/21
A Upper dead point XS7/2
Figure 12: Passive mode

In passive mode (flag 125=“XXX0“), the TrumaBend reacts in the same way as
in "TrumaBend without robot". In active mode (flag 125=“XXX1), the same
reaction can be triggered for robot A by defining signal XS7/19. As soon as the
input signals XS7/15 or 21 are no longer present when using robot A or when
releasing the foot switch when using robot B to trigger an action in the press
operation ƒ, the TrumaBend will stop „. Only after the XS7/15 or 21 (E)
movement signal is present, or when the foot switch signal has been pressed,
will the TrumaBend continue to travel . In rapid traverse, the press bar will be
withdrawn if the signal is absent. The "Lower dead point" signal is only halted
at the end of the decompression (after position ˆ). If the XS7/16 or 21 (E)
movement signal is removed or if the foot switch is released during decom-
pression ‡, the press bar does not move. The simplest way of triggering the
passive TrumaBend is to use the XS7/21 (E) signal, since only one signal then
needs to be taken into account.

Operational Manual Robot Interface 25

 STATUS

1 2 3 4 5 6 1
a (Oberer Totpunkt)

1
9

2 3
4 5
b (Mutepunkt)
c (Klemmpunkt)

7 8
6
d (Unterer Totpunkt)

A (Oberer Totpunkt XS7/

2)

B (Klemmpunkt XS7/3)

C (Unterer Totpunkt
XS7/4)

D (Startfreigabe XS7/1)

E (Klemmpunkt anfahren
XS7/17)

F (Unteren Totpunkt
anfahren XS7/15)

G (Oberen Totpunkt
anfahren XS7/16)

a Upper dead point C Lower dead point XS7/4

b Mute point D Start release XS7/1
c Clamping point E Approach clamping point XS7/17
d Lower dead point F Approach lower dead point XS7/15
A Upper dead point XS7/2 G Approach upper dead point XS7/16
B Clamping point XS7/3
Figure 13: Active mode for robot A

Flag 9 in parameter 125 has to be on "1" (i.e. 125="XXX1") so that the

TrumaBend will be operated active mode. It is not possible with this robot
interface to move without loading regulation in active mode (for this reason,
flag 125 is to be set to "11X1" for active mode). The TrumaBend will stop at the
sheet clamping point (c). The TrumaBend only travels further after a new start
edge at the XS7/15 (F) or 21 input. At the lower dead point (d) (see position †),
the TrumaBend stops again. If the dwell time programmed at the control
system is shorter than the new start flank ‡, the beam will move immediately.
If the dwell time is longer than the time between the reaching of the lower dead
point and the start flank, the beam will wait for the remainder of the dwell time
and then start moving up without a new start flank.

26 Operational Manual Robot Interface

 STATUS

1 2 3 4 5 6 1
a (Oberer Totpunkt)

1
9

2 3
4 5
b (Mutepunkt)
c (Klemmpunkt)

7 8
6
d (Unterer Totpunkt)

A (Oberer Totpunkt XS7/

2)

B (Klemmpunkt XS7/3)

C (Unterer Totpunkt
XS7/4)

D (Startfreigabe XS7/1)

E (Balkenbewegung
durchführen XS7/21)

F (Fusstaster
XS3/19
XS3/13/14)

a Upper dead point B Clamping point XS7/3

b Mute point C Lower dead point XS7/4
c Clamping point D Start release XS7/1
d Lower dead point E Carry out beam movement XS7/21
A Upper dead point XS7/2 F Foot switch XS3/19 XS3/13/14
Figure 14: Active mode for robot B

Operating robot B is similar. You can set the input signal XS7/18 next to flag
125="XXX1". If it is not set, then the press is passive in robot operation B. This
procedure is necessary so that it is possible for the servant to continue to
operate in the usual fashion when using the control panel. Input XS7/21 (E) is
on also high before the stroke. The raising flank of the foot switch triggers the
stroke. That means that the normally open contact XS3/19 (F) closes and the
normally closed contacts XS3/13 (F) and XS3/14 open at the same time. The
TrumaBend moves to the sheet clamping point „. Further movement is done
only after a new increasing flank at signal XS7/15 or 21 (E) . The foot switch
remains actuated during this entire time. This behavior also applies for the
lower dead point (d). During the withdrawal (status 6) or the before the next
stroke, release the foot switch.

Operational Manual Robot Interface 27

 5.2 Signal course with ACB®
Besides the ACB declaration, you must also have understood chapter 5.1 before
working with the ACB sensors in robot operation. In particular, the information
about the flags is also relevant here. Basically, only the difference to the last
chapter will be explained here.

STATUS

1 2 3 4 5 6 1
a (Oberer Totpunkt)
100ms
1
7

2
6
3
b (Mutepunkt)
c (Klemmpunkt)
5

4
d (Unterer Totpunkt)

A (Oberer Totpunkt XS7/

2)

B (Klemmpunkt XS7/3)

C (Unterer Totpunkt XS7/

4)

D (Startfreigabe XS7/1)

E (ACB in Verwendung
XS7/5)

F (Sollwinkel erreicht XS7/

6)

G (Balkenbewegung
durchführen XS7/21)

a Upper dead point C Lower dead point XS7/4

b Mute point D Start release XS7/1
c Clamping point E ACB in use XS7/5
d Lower dead point F Required angle reached XS7/6
A Upper dead point XS7/2 G Carry out beam movement XS7/21
B Clamping point XS7/3
Figure 15: Passive mode with ACB®
At the upper dead point (a), you have to inquire output XS7/5 (E) so that the
®
robot knows that the following bend will be done with ACB angle
measurement. It is also always possible here, as in Figure 12, to bring the
beam to a stop by taking the movement signal (G) away after the mute point.
This is, however, not drawn in here. The robot has to take the sheet after
receiving the signal "Required angle reached" (XS7/6) (F) . The signal "Beam
movement" (G) † is to be taken away at the same time and may only be resent
after 100 ms at the earliest. The withdrawal ‡ is done.

28 Operational Manual Robot Interface

 STATUS

1 2 3 4 5 6 1
a (Oberer Totpunkt)

9
2 3 100ms 100ms

b (Mutepunkt)
c (Klemmpunkt)
5 6 8

4 7

d (Unterer Totpunkt)

A (Oberer Totpunkt XS7/

2)

B (Klemmpunkt XS7/3)

C (Unterer Totpunkt
XS7/4)

D (Startfreigabe XS7/1)

E (ACB in Verwendung
XS7/5)

F (ACB 3.3 Identifikation

XS7/7)

F (Sollwinkel erreicht
XS7/6)

G (Balkenbewegung
durchführen XS7/21)

a Upper dead point C Lower dead point XS7/4

b Mute point D Start release XS7/1
c Clamping point E ACB in use XS7/5
d Lower dead point F ACB 3.3 Identification XS7/7
A Upper dead point XS7/2 G Required angle reached XS7/6
B Clamping point XS7/3 H Carry out beam movement XS7/21
Figure 16: Passive mode with ACB® with identification
First of all, the identification of the signal course the same as in Figure 15. Post
bending ‡ will occur after the rising edge "Carry out beam movement" (H) †.
Whether the bend is really complete or whether a post bending is to be done
®
because of the identification, can be seen with the help of the signal "ACB in
use" (E). As long as it does not disappear, the beam is not in withdrawal. For
an identification, the signal "Required angle reached" (G) is sent a second
time ˆ. If the bend is complete and an upwards movement ‰ of the beam is
done, no signal is present anymore at XS7/5 (E).

Operational Manual Robot Interface 29

 STATUS

1 2 3 4 5 6 1
a (Oberer Totpunkt)

1
9

2 3
4 5
b (Mutepunkt)
c (Klemmpunkt)
7 8
6
d (Unterer Totpunkt)

A ( berer Totpunkt XS7/2)

B (Klemmpunkt XS7/3)

C (Unterer Totpunkt
XS7/4)

D (Startfreigabe XS7/1)

F (ACB in Verwendung
XS7/5)

G (Sollwinkel erreicht
XS7/6)

H (Klemmpunkt anfahren
XS7/17)

I (Unteren Totpunkt
anfahren XS7/15)

J (Oberen Totpunkt
anfahren XS7/16)

a Upper dead point D Start release XS7/1

b Mute point E ACB in use XS7/5
c Clamping point F Required angle reached XS7/6
d Lower dead point G Approach clamping point XS7/17
A Upper dead point XS7/2 H Approach lower dead point XS7/15
B Clamping point XS7/3 I Approach upper dead point XS7/16
C Lower dead point XS7/4
Figure 17: Active mode with ACB®

In active mode, the TrumaBend stops automatically at the sheet clamping point (c)
„. After a renewed start edge of XS7/15 (H) or 21 , the press bar will continue to
travel. The dwell time occurs in the lower dead point †. After the required angle
has been reached (F) ‡, the press bar will stop again. An edge at XS7/16 (I) or
21 ˆ completes the bend ‰.
Here, the same procedures again apply in relation to the "Press bar movement"
signals for using robot B as for Figure 14, i.e. the foot switch is responsible for
triggering the stroke and signal XS7/15, 16 or 21 for the onward travel, while the
input signal XS7/18 always has to be set.

30 Operational Manual Robot Interface

 STATUS

1 2 3 4 5 6 1
a (Oberer Totpunkt)

11
2 3 100ms
4 5
b (Mutepunkt)
c (Klemmpunkt)
7 10
8
6 9

d (Unterer Totpunkt)

A (Oberer Totpunkt XS7/

2)

B (Klemmpunkt XS7/3)

C (Unterer Totpunkt
XS7/4)

D (Startfreigabe XS7/1)

E (ACB in Verwendung
XS7/5)

F (ACB 3.3 Identifikation

XS7/7)

G (Sollwinkel erreicht
XS7/6)

H (Klemmpunkt anfahren
XS7/17)

I (Unteren Totpunkt
anfahren XS7/15)

J (Oberen Totpunkt
anfahren XS7/16)

a Upper dead point D Start release XS7/1

b Mute point E ACB in use XS7/5
c Clamping point F ACB 3.3 Identification XS7/7
d Lower dead point G Required angle reached XS7/6
A Upper dead point XS7/2 H Approach clamping point XS7/17
B Clamping point XS7/3 I Approach upper dead point XS7/15
C Lower dead point XS7/4 J Approach upper dead point XS7/16
Figure 18: Active with ACB® with identification

For identification, the course is initially the same as in Figure 17. After the
movement signal ˆ bending will occur ‰ and "Required angle reached" (G) Š is
again issued. Bending is complete and the press stops again Š. The upwards
movement towards the upper dead point is then triggered again by the signal
XS7/16 (J) or 21.

Operational Manual Robot Interface 31

Operational Manual

TRUMPF BendGuard
Operational
Manual

TRUMPF BendGuard
Edition: 03/2002
ID no.: 874806
 Chapter 14

TRUMPF BendGuard
(optional)
1. Description ................................................................... 14-3
1.1 Overview of the optional TRUMPF BendGuard ............. 14-3
1.2 Control programming ..................................................... 14-8
1.3 Functions of the magnetic plate ..................................... 14-9
1.4 Indicator lamp on the transmitter ................................. 14-10
1.5 Safety information ........................................................ 14-10

2. Installation .................................................................. 14-12

2.1 Mounting the BendGuard ............................................. 14-12
2.2 Resetting the laser beam ............................................. 14-15

3. Operation .................................................................... 14-17

3.1 Activating BendGuard .................................................. 14-17
3.2 Referencing the machine ............................................. 14-17
3.3 Defining the mute point ................................................ 14-19
3.4 Bending workpieces ..................................................... 14-20
Bending BendGuard mode 1 and 3 ........................ 14-20
Bending in the BendGuard mode 2 and 4
(Nest bending mode) .............................................. 14-22

B172EN14.DOC TRUMPF BendGuard (optional) 14-1

 3.5 Working with and without BendGuard.......................... 14-23
3.6 Laterally changing the upper tool................................. 14-24

4. Error messages .......................................................... 14-25

4.1 Acknowledging messages on the screen..................... 14-25
4.2 Error messages on the evaluation unit ........................ 14-26

14-2 TRUMPF BendGuard (optional) B172EN14.DOC

 1. Description

1.1 Overview of the optional TRUMPF

BendGuard

Background In practice, TrumaBend press brakes are normally loaded by hand.

In accordance with the valid safety regulations, the following
concepts of operation exist to avoid the risk of accident:
• Two-hand operation at rapid speed. Disadvantage: the part
must be laid down to approach the bending position.
• Foot operation at working speed. Disadvantage: larger clock
cycles.
• Operation with light curtain at rapid speed. Disadvantage:
applicable only to certain shapes of parts.

New safety concept TRUMPF BendGuard enables you to work at a reduced rapid
speed in foot mode without jeopardizing the safety of the operating
personnel. The section underneath the punch is constantly
monitored by two moving strips made of three visible, red laser
beams. If the light beams are interrupted, the downward movement
of the beam is stopped.
TRUMPF BendGuard is a contactless protection device (BWS)
Type 4 according to EN954 with integrated follow-on control
device. Protection according to EN12622 (2001) 5.3.2(f) is
achieved.

B172EN14.DOC Description 14-3

 Principle Three parallel laser beams shine in front of the punch at a distance
of 4 mm (laser light A) and 14 mm (laser light B) under the upper
tool tip and serve as hand and finger protection. The effective width
of the laser lights being 20 mm before and end 20 mm behind the
upper tool tip.

1 2 3 4 5 6

1 Transmitter 4 Lower tool holder

2 Laser light A 5 Upper tool
3 Laser light B 6 Receiver
Principle of the TRUMPF BendGuard Fig. 30830

The altogether 40 mm wide laser lights are divided into three

separate beams:
• 20 mm wide laser light before the upper tool tip.
• Laser beam with circular cross-section exactly under the upper
tool tip.
• 20 mm wide laser light behind the upper tool tip.

In this way BendGuard knows if the light interruption should be

before, exactly under or behind the upper tool tip. If the laser light
is interrupted, the beam is stopped.

14-4 Description B172EN14.DOC

 3

4
4

1 5
10

40
2 6
7

1 Laser light before the upper tool 5 Laser light behind upper tool tip
tip (laser light A) (laser light A)
2 Laser light before the upper tool 6 Laser light behind the upper tool
tip (laser light B) tip (laser light B)
3 Upper tool 7 Stop finger
4 Laser beam with circular cross- 8 Laser beam with circular cross-
section (laser light A) section (laser light B)
9 Lower tool
Laser beam and tools Fig. 31003

B172EN14.DOC Description 14-5

 Other functions In addition to light beam interruption, TRUMPF BendGuard also
monitors the beam speed in rapid and working speed, the beam
springback and the mute point position.

Attaching to the machine TRUMPF BendGuard is clamped onto the upper tool holder and
can therefore be easily removed for upper tool replacement or
complete disassembly; the upper tool holder can then be
reinstalled.
With lateral upper tool replacements and when working with
dismounted BendGuard units, put them down carefully. For this
reason, both a holding device on the switch cabinet and on the
cartridge are mounted of the right protection door:

Holding device for BendGuard Fig. 29743

14-6 Description B172EN14.DOC

 Length of bend The maximum length of bend is reduced by 100 to 150 mm by
installing BendGuard in the upper tool holder.
A gooseneck tool that evens out the loss of length via an
asymmetric form can be used to increase the length of bend.

Bend length [mm]

without BendGuard with BendGuard with BendGuard
and gooseneck tool
V 50 1275 1125 1185
V 85 2050 1940 2000
V 85 S 2550 2450 2510
V 130 3060 2960 3020
V 170 4080 3980 4040
V 200 4080 3980 4040
V 230 3060 2960 3020
V 320 4080 3980 4040
Tab. 14-1

These gooseneck tools are standard equipment in the tool sets

starting from September 2001 and can be reordered for previously
existing sets using the same ID number.

Use full bend length ½ Work without BendGuard.

B172EN14.DOC Description 14-7

 1.2 Control programming

Starting with control version V5.1 or higher, the functions for

TRUMPF BendGuard are integrated in an additional command
line. The softkey S5 is available for confirming messages from the
BendGuard system. The softkey S6 is used to define and redefine
the mute point.

BendGuardModus LM=1: Normal mode

LM=2: Nest bending mode
LM=3: Normal mode, stop at the mute point
LM=4: Nest bending mode, stop at the
mute point

In BendGuard modes 3 and 4, the press bar stops at the mute

point. The bending process is completed by operating the foot
switch again.

BendGuard mode 1 is automatically stored in the machine when

calling up existing programs that are programmed without
BendGuard. If need be, this mode can be changed afterwards and
be adjusted to the product.

14-8 Description B172EN14.DOC

 1.3 Functions of the magnetic plate

The included plate is magnetic. There are two functional sections

on the black backside:
• Wide, white box.
• Millimeter scale from 0 to 20 mm.

Magnetic plate Fig. 29676

Position of the laser beam With the magnetic plate, the position of the laser beam is checked
under the punch. To do this, the millimeter scale is printed on the
magnetic plate.

Simulation of the sheet When determining the mute point, the magnetic plate will be
thickness pushed up by the sheet thickness. To do this, the millimeter scale
is printed on the magnetic plate.

Laser beam shielding after TRUMPF BendGuard demands and monitors the correct definition
mute point of the mute point. The laser beam must be interrupted after
reaching the mute point. Otherwise, the bending cycle can not be
completed.
This interruption is caused by laterally placing the magnetic plate
on the die. This hinders the laser beam from shining through the
die width.

B172EN14.DOC Description 14-9

 1.4 Indicator lamp on the transmitter

A red indicator lamp is located on the BendGuard transmitting unit.

Constant illumination The indicator lamp illuminates continuously after reaching the mute
point or when the laser beam has been interrupted.

Slow blinking In the nest bending mode (BendGuard modes 2 and 4) the
indicator lamp blinks slowly until the mute point has been reached
or until the laser beam has been interrupted.

Quick blinking The indicator lamp blinks quickly during malfunctions or screen
messages.

Indicator lamp in the robot The indicator lamp blinks quickly for mounted though switched off
operation BendGuard units (operation without protection function).

1.5 Safety information

Danger of injury!
Do not touch live parts.
½ Never open parts of the TRUMPF BendGuard.
Caution

Class 1 lasers
Risk of eye injury.
½ Never look directly into the laser beam.
Caution
½ The laser light is harmless to the body surface.

Checking functionality Every work day the TRUMPF BendGuard should be checked that it
before work commences is running perfectly. Do not trust the setting without first checking
yourself.

1. Interrupt the laser beam with an object during the closing

motion in rapid speed.
The downward motion of the beam must stop.
2. Check or define mute point.

14-10 Description B172EN14.DOC

 Avoiding contamination ½ Keep the sender and receiver window free of dust, dirt and oil.
½ Avoid scratches in the beam area.
½ Only clean window with a soft, slightly damp cotton cloth.

Safety after the mute point TRUMPF BendGuard demands and monitors the correct definition
of the mute point. The laser beam must be interrupted after
reaching the mute point. Otherwise, the bending cycle can not be
completed.
This interruption is caused by laterally placing the magnetic plate
on the die. This hinders the laser beam from shining through the
die width during the bending cycle.
From the mute point on, it can not differentiate between loading
your finger or a metal sheet, as the laser beam is switched to mute
mode. If the mute point has been correctly defined though, it
should not be possible to jam your finger in the narrow gap
between upper tool and die.

Working without BendGuard If TRUMPF BendGuard is switched off using the optical safety
control key switch on the operating station 1 (key switch set to
ROBOT), every mode of operation can be selected using the select
operation mode key switch. However, there is not optical safety
devices available.
½ Only use this operation mode if it is absolutely necessary.

Remaining risks TRUMPF BendGuard has been designed for operations where
workpieces are held by hand or fingers. Slight jamming incidents
can occur when the manual operation in the gap between tool and
workpiece is carried out at high speed shortly before closing.
½ Inform the operators about proper use of the BendGuard.

B172EN14.DOC Description 14-11

 2. Installation

2.1 Mounting the BendGuard

Attaching BendGuard to the 1. Loosen the upper tool clamp:

machine – Manual upper tool clamp: Loosen the socket head screw
on the clamping shoulder.
– Hydraulic upper tool clamp: Press the UPPER TOOL
CLAMP button on the operating station 1.
2. Switch off the machine in the correct manner and switch off the
MAIN SWITCH.
3. Remove the dummy plug from the back side of the upper tool
clamp.
The plugs for the BendGuard transmitter and receiver will
become visible:

Plugs for BendGuard Fig. 29609

4. Connect the transmitting unit and receiver unit laterally into the
upper tool clamp:

Transmitting unit; receiver unit Fig. 29606; 29607

14-12 Installation B172EN14.DOC

 Adjusting the BendGuard

BendGuard height adjustment screw Fig. 29608

1. Read the workpiece height on the employed upper tool:

1 Workpiece height
Upper tool Fig. 30199

2. Adjust workpiece height on the BendGuard using the height

adjustment screw.
3. Tighten the adjusting screw.

Note
The adjusting screw is controlled by a limit switch. A badly
tightened screw would mean a standstill for the machine.

B172EN14.DOC Installation 14-13

 Checking the laser beam After every tool change and in regular intervals, you have to check
that the laser beam A is positioned 4 mm underneath the upper
tool tip:

Field of tolerance for laser adjustment Fig. 29676

Checking the laser beam Fig. 29675

½ Hold the platelet centered under the tool tip.

The red laser light A is located 4 mm under the upper tool tip.

This positional test must be applied to the whole length of the

machine.

14-14 Installation B172EN14.DOC

 Note
The laser beam A must be located exactly 4 mm (±0.5 mm) under
the upper tool tip.

If the laser beam A is above 4 mm, the machine no longer

stops within the braking distance.
Possibility of severe injury leading to amputation of body
Caution parts.
½ Reset the laser beam.

2.2 Resetting the laser beam

The BendGuard units set at the factory are coordinated to one

another at a 5 m distance. When you start up the machine for the
first time, the laser beam should be in the correct position. Due to
vibrations during transport or unprofessional handling, the laser
beam may be located under or over 4 mm.

2
1

1 Adjusting screw for height and 2 Adjusting screws on

angle adjustment compensation plate, fixed
completely to the top
Fig. 29677

B172EN14.DOC Installation 14-15

 Adjusting the transmitter 1. Take off the transmitter’s covering cap.
2. Remove the bellows from the Velcro fastener.
3. Set the height of the laser beam on all three screws (1 and 2).
4. The laser beam A 4 mm is fixed to screws (2) under the upper
tool tip with a compensation plate 6.4. If the distance is larger
or smaller than 4 mm, use thinner or several compensation
plates.
5. Set the slope of the laser beam with a separate screw (1).
The laser beam meets the receiver field.

Factory settings for the adjusting screws:

Screw (see Fig. 29677) Thread overhang of nut [mm]

1 10
2 fixed on the compensation plate
Tab. 14-2

Adjusting the receiver The laser beam is somewhat wider than the receiver field.
Therefore the receiver setting does not have to be exact. Even
small vibrations (e.g. by stopping the beam) are smoothed out.
Note
The receiver only has to be set if the laser beam does not meet the
receiver field even after setting the sender for height, inclination
and parallelism.

1. Take off the receiver’s covering cap.

2. Remove the bellows from the Velcro fastener.
3. Open both front adjacent screws.
4. Set the receiver so that the laser beam meets the receiver
field.

14-16 Installation B172EN14.DOC

 3. Operation

3.1 Activating BendGuard

!
Protect mode; foot mode Fig. 29578; 29584

1. Set the optical safety device key switch to protect mode.

2. Set the select operation mode key switch to foot mode.

3.2 Referencing the machine

When you switch the machine on, the reference program is

augmented by the following sequence of operations when using
BendGuard:

Note
The reference program must be performed in the BendGuard
mode 1.
Other messages could appear on the screen besides the itemized
messages. Ignore them.

Switching the machine on 1. Turn on the main switch.

The machine control system starts up.
2. Press the HYDRAULICS ON at the operating station 1.
or
½ Press EMERGENCY OPEN at operating station 1.
3. Press START at the control system.
All axes reference automatically with the exception of the
Y1/Y2 axis.
The message "BG - perform BendGuard safety check" appears
on the control system.
4. Press the softkey S5.

There is now a 3-fold recognition of the safety system:

• Has a safety system been installed?
• Which safety system has been installed?
• Enabling the safety system.

B172EN14.DOC Operation 14-17

 Referencing BendGuard 1. Interrupt the laser beam once.
The message "BG - unexpected laser beam interruption during
definition" appears on the control system.
2. Press the softkey S5.
3. Activate the foot switch.

4. Interrupt the laser beam once.

The message "BG - unexpected laser beam interruption during
definition" appears on the control system.
5. Press the softkey S5.
6. Activate the foot switch.

7. Interrupt the laser beam once.

The message "BG - unexpected laser beam interruption during
definition" appears on the control system.
8. Press the softkey S5.
9. Activate the foot switch until the beam stops.
The hydraulic system switches off.
10. Press the HYDRAULICS ON at the operating station 1.
or
½ Press EMERGENCY OPEN at operating station 1.
11. Press START at the control system.

Carrying out the brake 1. Release the stoke with the foot switch.
distance check The message "Brake distance O.K., press Start to continue"
appears on the control system.
2. Press START on the control system.

Defining the mute point 1. Attach magnetic plate laterally on the die to cover the die
width.
2. Push the magnetic plate upwards by sheet thickness.
3. Activate the foot switch.
The beam moves downwards.
The beam stops by the first interruption of the laser beam. This
is the mute point.
"BG - Confirm mute point" appears.
4. Press the softkey S6.

14-18 Operation B172EN14.DOC

 3.3 Defining the mute point

The laser beam B is located 14 mm underneath the upper tool tip.

The beam needs 4 to 5 mm springback to stop after a laser beam
interruption. Therefore the upper tool remains 9 to 10 mm over the
workpiece to be bent. This is the mute point.

The mute point must be redefined when calling up a new program,

changing the thickness of the sheet to be bent or for a tool change.
The message "BG - Define the mute point" appears.

Defining the mute point 1. Attach magnetic plate laterally on the die to cover the die
width.
2. Push the magnetic plate upwards by sheet thickness.
3. Activate the foot switch.
The beam moves downwards.
The beam stops at the first interruption of laser beam B. This is
the mute point.
"BG - Confirm mute point" appears.
4. Press the softkey S6.

Did the beam stop because of an unwanted interruption?

For example, because of object or body parts in the way.
½ Press EMERGENCY OPEN at operating station 1.
Beam moves to upper dead point.
½ Begin again with Step 1.

Redefine Mute point itself 1. Press the softkey Continue>> to get to the second screen side.
2. Press the softkey Define mute point.
The message "BG - Define the mute point" appears.
3. Attach magnetic plate laterally on the die to cover the die
width.
4. Push the magnetic plate upwards by sheet thickness.
5. Activate the foot switch.
The beam moves downwards.
The beam stops by the first interruption of the laser beam. This
is the mute point.
"BG - Confirm mute point" appears.
6. Press the softkey S6.

B172EN14.DOC Operation 14-19

 Defining a mute point for For products with sides < 20 mm, the mute point must not be
products with short sides defined at the upper edge of the gauge finger to avoid premature
interruption of the laser beam by the gauge finger.

1. Drive the gauge fingers to the rear.

2. Attach magnetic plate laterally on the die to cover the die
width.
3. Push the magnetic plate upwards by sheet thickness.
4. Activate the foot switch.
The beam moves downwards.
The beam stops at the first interruption of laser beam B. This is
the mute point.
"BG - Confirm mute point" appears.
5. Press the softkey S6.

Tip
In Production, use BendGuard mode 3 for products with sides
< 20 mm.

3.4 Bending workpieces

Bending BendGuard mode 1 and 3

The laser beams are active in rapid speed during the upward beam
motion. If the laser light is interrupted, the beam is stopped.

Bending in mode 1 ½ Activate the foot switch.

The beam moves the mute point without stopping if the laser beam
is not interrupted.

Bending in mode 3 1. Activate the foot switch.

The beam moves with rapid speed to the mute point and
remains there.
2. Restart beam with foot switch.
The beam will continue to move in a slower working speed.

14-20 Operation B172EN14.DOC

 Bending simple nests Simple nests can be bent in the BendGuard mode 1 or 3.

1. Activate the foot switch.

The beam moves downwards until a previously laterally bent
nest side interrupts the laser beam.
2. Press the foot switch twice (foot switch must be opened at
least 0.3 s).
The beam moves to the mute point in a slower working speed
and remains there.
3. Restart beam with foot switch.

Use BendGuard mode 3 with the nest side to be bent last:

1. Do not insert the workpiece.

2. Activate the foot switch.
The beam moves to the mute point and remains there.
3. Insert workpiece and stop.
4. Restart beam with foot switch.

Switching between All four different BendGuard modes can be used in a program.
the modes 1/3 and 2/4 1. Wait 5 seconds.
2. Press the softkey S5.

Note
For technical reasons, you have to wait 5 seconds until the
execution of the program can be continued.
For this reason, program products in a mode (1/3 or 2/4) if
possible. There are no delays here.

B172EN14.DOC Operation 14-21

 Bending in the BendGuard mode 2 and 4
(Nest bending mode)

Note
In the nest bending mode the indicator lamp blinks slowly until the
mute point has been reached or until the laser beam has been
interrupted.

First the entire laser light is active. The machine stops at the first
interruption of the laser light (e.g. through a nest side wall). The
front and rear laser light is no longer monitored from this point. The
laser beam with circular cross-section directly under the upper tool
tip may not, however, be interrupted.
All laser beams are active again after starting up the beam.

Bending in mode 2 ½ Activate the foot switch.

The beam moves the mute point without stopping if the laser beam
is not interrupted.

Beam moves to the upper dead point after bending and remains
there.

Bending in mode 4 1. Activate the foot switch.

The beam moves with rapid speed to the mute point and
remains there.
2. Restart beam with foot switch.
The beam continues to move in a slower working speed (1 to
10 mm/s).
Beam moves to the upper dead point after bending and
remains there.

Bending nests 1. Activate the foot switch.

The beam moves downwards until a nest side previously bent
to the side interrupts the laser beam.
2. Press the foot switch (foot switch must be opened at least 0.3 s).
The beam moves to the mute point in a slower working speed
and remains there.
3. Restart beam with foot switch.

14-22 Operation B172EN14.DOC

 Switching between All four different BendGuard modes can be used in a program.
the modes 1/3 and 2/4 1. Wait 5 seconds.
2. Press the softkey S5.

Note
For technical reasons, you have to wait 5 seconds until the
execution of the program can be continued.
For this reason, program products in a mode (1/3 or 2/4) if
possible. There are not delays here.

3.5 Working with and without BendGuard

Working with mounted without BendGuard function:

BendGuard units
1. Select robot mode with the optical safety devices key switch on
operating station 1.
All optical safety devices are switched off.
2. Press the softkey S5.
3. Select the desired operation mode with the select operation
mode key switch.

with BendGuard function:

1. Select protect mode with the optical safety devices key switch
on operating station 1.
2. Press the softkey S5.
3. Press EMERGENCY OPEN on operating station 1.
Beam moves to upper dead point.
4. Release stroke with the foot switch.
After the first interruption of the laser beam, the message
"BG - Confirm mute point" appears on the control system.
5. Press the softkey S6.

B172EN14.DOC Operation 14-23

 Working with dismounted BendGuard must be removed for processing products that need to
BendGuard units be bent along the lateral side of the beam. The BendGuard must
also be removed when using a robot.
Note
When installing or deinstalling the BendGuard units, the main
switch must be switched off and then on again.

1. Remove the BendGuard transmitter and receiver.

2. Insert dummy plug into plug behind the upper tool holder.
3. Select robot mode with the optical safety devices key switch on
operating station 1.
All optical safety devices are switched off.
4. Select the desired operation mode with the select operation
mode key switch. All operation modes are possible.

Remounting the See page 14-12.

BendGuard units

3.6 Laterally changing the upper tool

1. Remove the BendGuard units.

®
2. Take the tool without Safety-Click to be change out of the
upper tool clamp laterally.
3. Load new upper tools.
4. Load BendGuard units. The laser beam has to be reset.
5. Check the position of the laser beam.

Note
You can immediately begin to work again after the transmitter unit
has been unloaded and reloaded again. The mute point must be
redefined after unloading and reloading the receiver unit.

14-24 Operation B172EN14.DOC

 4. Error messages

4.1 Acknowledging messages on the

screen

Messages on the screen Acknowledge the error message

#9060# BG - BendGuard information: ½ Wait a short time.
Wait a short time.
#9061# BG - Carry out safety check 1. Press the softkey S5.
BendGuard 2. Reference BendGuard
(see page 14-16).
#9062# BG - BendGuard mode ½ Press the softkey S5.
modified
#9071# BG - Define the mute point ½ Activate the foot switch.
#9063# BG - Unexpected laser beam ½ Press the softkey S5.
interruption during definition
#9064# BG - Confirm mute point ½ Press the softkey S6.
#9065# Sensor received wrong light Malfunction due to ambient light
or break in power supply
½ Press the softkey S5.
#9066# Start time exceeded ½ Press the softkey S5.
#9067# BG - No magnetic plate after ½ Attach magnetic plate laterally
the mute point on the die
#9068# BG - Brake distance too 1. Switch off the machine.
large 2. Switch the machine back on.
3. Begin the reference cycle again.
#9072# Five seconds to switch-over ½ Wait 5 seconds.
normal/nest bending mode
Tab. 14-3

B172EN14.DOC Error messages 14-25

 4.2 Error messages on the evaluation unit

Error messages are displayed on a two-digit display of the signal

processor in the switch cabinet or on the back side of the beam.

First display on the signal In the normal display mode, a two-digit hexadecimal number is
processor displayed on the signal processor:
• First position: 1. Secondary display
• Second position: 1. Primary display

For example: 19

Displaying second display ½ Press the relay K422.

A two-digit hexadecimal number is displayed:
• First position: 2. Secondary display
• Second position: 2. Primary display

For example: 39

Primary error code The primary error code is made up of the first primary display and
the second primary display.
In the example above: 99:
"Contact SEC2 does not close - Error on
the relay or on the contact recognition."

Primary error code Description

8\1 Working speed too fast - the machine has
exceeded the speed of 10 mm/s at the mute point.
8\2 Stopping distance exceeded - the stopping dis-
tance was exceeded during the secondary stop
check by 10 mm or the stopping distance was
exceeded by 8.5 mm when defining the mute
point.
8\3 Stopping distance exceeded - the stopping dis-
tance has exceeded 8.5 mm during normal mode,
or the machine has moved on by more than
8.5 mm without the foot switch being operated.
8\4 Stopping distance exceeded - the stopping dis-
tance was exceeded by 8.5 mm during normal
mode, or the machine has moved on by more than
8.5 mm without the foot switch being operated
within an area of 2 mm from the mute point.
9\1 to 9\6 Internal malfunction
9\7 Contact EN1 does not close - Error on the relay or
on the contact recognition.
9\8 Contact EN1 does not open - Error on the relay or
on the contact recognition, or no current supply via
EN2 when BendGuard switches off the relay
9\9 Contact SEC2 does not close - Error on the relay
or on the contact recognition.

14-26 Error messages B172EN14.DOC

 Primary error code Description
A\1 Error function on the receiver alignment - wiring on
the receiver unit has become crossed or has short
circuited.
B\1 Internal malfunction
B\2 Counter overrun - the encoder has counted more
than 1750 mm upwards
B\3 Counter underrun - the encoder has counted more
than 1750 mm downwards
B\4 Internal malfunction
C\1 Internal malfunction
C\2 Error in muting lamp - wiring to muting lamp has
short circuited or is broken.
D\1 Internal malfunction
E\1 and E\2 Internal malfunction
E\3 Invalid dip switch setting; the dip switches on the
processor console are set to an invalid position
E\4 Invalid operation mode - the press brake or the
protection device has performed an invalid or
unexpected operation mode.
F\1 Shut down - the secondary processor was
switched off by the primary processor
Tab. 14-4

Secondary error code The secondary error code is made up of the first primary display
and the second primary display.
In the example above: 13:
"High working speed when bending - the
speed has exceeded 10 mm/s at the
unimpeded mute point."

Secondary error code Description

1\1 to 1\2 Internal malfunction
1\3 High working speed when bending - the speed has
exceeded 10 mm/s at the unimpeded mute point.
1\4 High working speed - the speed has exceeded
12 mm/s at forced working speed.
1.\1 Shut down - the secondary processor was
switched off by the primary processor
2\1 Internal malfunction
2.\1 Internal malfunction
3\1 Internal malfunction
3.\1 Internal malfunction
4\1 Counter overrun - the encoder has counted more
than 1750 mm upwards
4.\1 Internal malfunction
4.\2 Counter underrun - the encoder has counted more
than 1750 mm downwards

B172EN14.DOC Error messages 14-27

 Secondary error code Description
5\1 Internal malfunction
5\2 Internal malfunction
6\1 Internal malfunction
6.\1 Internal malfunction
7\1 Internal malfunction
7.\1 Internal malfunction
9\1 Stopping distance exceeded - the stopping dis-
tance has exceeded 8.5 mm in normal mode
9.\1 Stopping distance of the secondary stopping check
exceeded by 10 mm
A\1 Internal malfunction
A.\1 Internal malfunction
A\2 Contact EN2 does not close - Error on the relay or
on the contact recognition.
A.\3 Contact EN2 does not open - Error on the relay or
on the contact recognition, or no current supply via
EN2 when BendGuard switches off the relay
B\1 Contact SEC1 does not close - measuring error or
relay error.
B\2 Contact SEC1 does not open - Measuring error or
relay error or there is no tension on SEC1 when
the second stopping test is carried out.
B.\1 Internal malfunction
C\1 Internal malfunction
C.\1 Error function in middle receiver - receiver error
D\1 Error function in receiver alignment
D.\1 Error function in side receiver - receiver error
E\1 Internal malfunction
E.\1 Internal malfunction
F\1 to F\6 Internal malfunction
F.\1 to F.\5 Internal malfunction
Tab. 14-5

Remedy error message ½ Replace signal processor.

"Inner malfunction"

14-28 Error messages B172EN14.DOC