AIDA NC1-1100 (2) E Manual [PDF]

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INSTRUCTION MANUAL



HY-FLEX PRESS



Be sure to read this Instruction Manual and fully understand the contents before using this machine. In addition, keep the manual near the machine, taking care not to misplace it, so that the operator can access it whenever necessary. This Instruction Manual is intended for the sole use of AIDA’s customers. The use of this manual in part or in whole by any third party is prohibited. Inst.Manual No.



e-22 3287 0911



北村真一郎作成



仕様 SPECIFICATIONS 標準（Ｂ仕様編参照） Section B, SPECIFICATION.)



ダイハイト Die height



450 mm



オプション一覧 OPTION LIST 下記が，貴社納入機に装備されているオプションです。



The following shows the options provided in the machine delivered to your site.



防振装置 メインモータ逆転装置 光線式安全装置 ｢連続」運転 主回路ノーヒューズブレーカ外部操作式



型式



製造番号



MODEL



SERIAL NO.



NC1-1100(2)E



Vibration absorber Main motor reversing device Presence-sensing device CONT. mode operation Externally operated circuit breaker



お問い合わせの際は，下記の製造番号をお知らせ下さい。



Please refer to this serial number when contacting AIDA.



C0411-0843,0844,0845,0846 DATE 07-2010 AIDA MANUFACTURING (M) SDN BHD



4



INTRODUCTION



INTRODUCTION Thank you for purchasing this AIDA product. We are confident that the technology that we have made constant efforts over decades to refine will contribute to the streamlining of your production system.



WARNING



AIDA



• Read this instruction manual before using this machine. Be sure to fully understand the descriptions contained in this instruction manual before starting operation, inspection, or maintenance of this machine. In particular, the press machine must be installed, operated, adjusted, and maintained by trained specialists or qualified personnel as directed in this instruction manual. If the press machine is operated by anyone other than a trained specialist or other qualified personnel, it can result in damage to the machine or personal injury or death. In such a case, the manufacturer of the machine shall be released from all responsibility and liability. • Any accidents or failures caused by users failing to follow the instructions contained in this instruction manual shall release the manufacturer of this machine from all responsibility and liability. • Keep this instruction manual in a specified place near the machine as a quick reference tool. Please keep this manual in good condition. • When this machine is transferred to another owner, this instruction manual must be transferred together with the machine.



5



INTRODUCTION



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



>



ＩＮ



AIDA



ＤＥ



Ｘ



First, open the GENERAL TABLE OF CONTENTS (pg. 7) to find out what section contains the item you want to see. Next, check the "Contents" of that section to locate the desired item. You may also be able to find the item using the INDEX located at the end of this instruction manual.



> When such a problem arises, contact the nearest AIDA Service Office (consult the list at the end of this instruction manual). When making inquiries, please be prepared to provide the machine serial number, model designation, the date of manufacture, and the instruction manual number (found on the lower left of the front cover).



© Copyright 2008 Aida Engineering, Ltd. ALL RIGHTS RESERVED. Reproduction of any part of this publication without the written permission of Aida Engineering, Ltd. is strictly prohibited.



6



GENERAL TABLE OF CONTENTS



GENERAL TABLE OF CONTENTS



A



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



B



Section B SPECIFICATIONS (pg. 45) Describes specifications, limitations of use, warranty, dimensions, and names of major components of the press machine.



C



Section C INSTALLATION (pg. 71) Describes preparations for press machine installation, for transportation, for installation, and preparation for test runs.



D



Section D OPERATION (pg. 83) Describes operation-related devices, routine inspection, operational procedures, adjustment operations, and die changes for the press machine.



E



Section E MAINTENANCE (pg. 185) Describes periodic inspection, lubrication, maintenance of units and components, troubleshooting, and provides drawings for the maintenance of the press machine.



APPENDIX INSTRUCTIONS FOR PRESS MACHINE USAGE LIST OF LUBRICANTS AVAILABLE ON THE MARKET TONNAGE MONITOR (made by AIDA) (option) INDEX Instruction Manuals for Peripheral Devices and Accessories (at the end of this instruction manual or in a separate binder)



7



GENERAL TABLE OF CONTENTS



CONTENTS SPECIFICATIONS, OPTION LIST .......................................................................3 MODEL, SERIAL NUMBER.................................................................................3 INTRODUCTION .................................................................................................5 GENERAL TABLE OF CONTENTS .....................................................................7



Section A SAFETY 1. WARNING DISPLAY .....................................................................................15 2. SAFETY PRECAUTIONS .............................................................................16 2.1 2.2 2.3 2.4



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



3. SAFETY DEVICES .......................................................................................19 3.1 3.2 3.3 3.4 3.5



ACTIONS TO PREVENT HAZARDS................................................................................................ 19 TWO-HAND RUN BUTTONS ........................................................................................................... 20 GUARDS (OPTION) ......................................................................................................................... 21 PRESENCE-SENSING DEVICE (OPTION) ..................................................................................... 22 IMPORTANT EQUIPMENT............................................................................................................... 23



4. USING THE PRESS MACHINE SAFELY .....................................................24 4.1 4.2 4.3 4.4 4.5 4.6



ESSENTIAL BASIC RULES ............................................................................................................. 24 ESSENTIAL USAGE ENVIRONMENT PRECAUTIONS .................................................................. 26 ESSENTIAL INSTALLATION PRECAUTIONS ................................................................................. 27 ESSENTIAL OPERATION PRECAUTIONS ..................................................................................... 28 ESSENTIAL MAINTENANCE PRECAUTIONS ................................................................................ 31 SAFETY PRECAUTIONS TO BE OBSERVED STRICTLY WHEN INSTALLING PRESENCESENSING DEVICE.......................................................................................................................... 32



5. SAFETY PROCEDURES DURING ADJUSTMENT .....................................33 6. WARNING PLATES ......................................................................................34 7. PAINTING ON HAZARDOUS AREAS ..........................................................43 8. GLOSSARY ..................................................................................................44



Section B SPECIFICATIONS



8



GENERAL TABLE OF CONTENTS



1. SPECIFICATIONS ........................................................................................47 1.1 1.2 1.3 1.4



STANDARD SPECIFICATIONS OF THE PRESS MACHINE........................................................... 47 DIE CUSHION SPECIFICATIONS (OPTION)................................................................................... 51 MECHANICAL KNOCKOUT SPECIFICATIONS (OPTION) ............................................................. 53 WARRANTY...................................................................................................................................... 54



2. CHARTS .......................................................................................................55 3. GENERAL DIMENSIONS .............................................................................60 4. NAMES OF MAJOR COMPONENTS ...........................................................63 5. ELEMENTS OF PRESSWORK ....................................................................66 5.1 5.2 5.3 5.4 5.5 5.6



TONNAGE CAPACITY (NOMINAL CAPACITY) ............................................................................... 66 TORQUE CAPACITY........................................................................................................................ 67 STROKE-TONNAGE CURVE........................................................................................................... 67 ENERGY CAPACITY (WORKING ENERGY)................................................................................... 68 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE ......................................... 68 CAUTIONS CONCERNING DIE CUSHION USAGE........................................................................ 69



6. SPECIFICATION PLATE...............................................................................70 6.1 PRESS MACHINE SPECIFICATION PLATE.................................................................................... 70 6.2 ELECTRICAL SPECIFICATION PLATE ........................................................................................... 70



Section C INSTALLATION 1. PREPARATION FOR INSTALLATION ..........................................................73 1.1 FOUNDATION WORK ...................................................................................................................... 73 1.2 INSTALLING SOLE PLATES ............................................................................................................ 73 1.3 PRELIMINARY INSTALLATION WORK ........................................................................................... 74



2. TRANSPORTATION AND INSTALLATION ...................................................75 2.1 INSTALLING WITH ANCHOR BOLTS.............................................................................................. 75 2.2 INSTALLING WITH VIBRATION ISOLATORS.................................................................................. 76



3. CONNECTING THE AIR SUPPLY ................................................................77 3.1 CONNECTING TO THE AIR SUPPLY.............................................................................................. 77 3.2 AIR CONSUMPTION ........................................................................................................................ 77



4. CONNECTING TO THE POWER SOURCE .................................................78 4.1 GROUNDING.................................................................................................................................... 78 4.2 CONNECTING TO THE POWER SOURCE AND GROUNDING..................................................... 79 4.3 WIRING CAPACITY.......................................................................................................................... 79



5. INITIAL LUBRICATION (OIL SERVICING) ...................................................80 6. POST-INSTALLATION CHECK.....................................................................81



9



GENERAL TABLE OF CONTENTS



Section D OPERATION 1. OPERATION DEVICES ................................................................................85 1.1 1.2 1.3 1.4



MAIN OPERATION PANEL............................................................................................................... 85 OPERATION BUTTON BOX............................................................................................................. 86 FUNCTION AND OPERATION......................................................................................................... 86 OPERATION OF KEY SWITCHES................................................................................................... 92



2. THE OPERATOR INTERFACE TERMINAL..................................................93 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8



SCREEN CONFIGURATION ............................................................................................................ 94 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS ...................................................... 95 DISPLAYS APPEARING IN WINDOWS........................................................................................... 97 THE RUN SCREEN .......................................................................................................................... 98 THE DATA SCREEN....................................................................................................................... 101 THE SET UP SCREEN................................................................................................................... 104 THE MAINTENANCE SCREEN...................................................................................................... 108 THE RECIPES (DATABANK) SCREEN.......................................................................................... 113



3. OPERATION ...............................................................................................118 3.1 3.2 3.3 3.4 3.5



PRE-WORK CHECK....................................................................................................................... 120 ROUTINE INSPECTION AND OPERATION .................................................................................. 121 OPERATION MODES..................................................................................................................... 125 SAFETY DEVICES AND OPERATION CONDITIONS ................................................................... 126 OPERATING GUARDS (OPTION).................................................................................................. 129



4. PROCEDURE WHEN COMPLETING WORK ............................................130 5. RESETTING FAULTS .................................................................................131 5.1 INTERLOCK INFORMATION MESSAGE LIST .............................................................................. 132 5.2 FAULT INFORMATION MESSAGE LIST........................................................................................ 137 5.3 HYDRAULIC OVERLOADS............................................................................................................ 142 5.4 OVERRUNS.................................................................................................................................... 146 5.5 WHEN THE EMERGENCY STOP BUTTON HAS BEEN PUSHED ............................................... 146 5.6 WHEN THE EXTERNALLY CONTROLLED BREAKER IS ACTUATED ........................................ 147 5.7 WHEN THE GROUND FAULT BREAKER IS ACTUATED ............................................................. 147 5.8 WHEN THE CLUTCH & BRAKE SOLENOID VALVE MONITOR IS ACTUATED........................... 147 5.9 WHEN A THERMAL RELAY HAS TRIPPED.................................................................................. 148 5.10 STICKING ..................................................................................................................................... 150



6. ADJUSTMENT ............................................................................................151 6.1 6.2 6.3 6.4 6.5 6.6



SLIDE ADJUSTMENT .................................................................................................................... 151 COUNTERBALANCE CAPACITY ADJUSTMENT ......................................................................... 154 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) (pg. 155) MECHANICAL KNOCKOUT ADJUSTMENT (OPTION)................................................................. 156 HOLP LOW PRESSURE SETTING DEVICE (OPTION) ................................................................ 157 SETTING TIMING SWITCHES....................................................................................................... 158



7. CHANGING DIES .......................................................................................161



10



GENERAL TABLE OF CONTENTS



7.1 7.2 7.3 7.4



WHEN USING AIDA EQUIPMENT................................................................................................. 163 WHEN USING PASCAL EQUIPMENT ........................................................................................... 170 MECHANICAL DIE LIFTER (OPTION) ........................................................................................... 177 WHEN USING A SHANK................................................................................................................ 178



8. OPERATION OF AUXILIARY EQUIPMENT ...............................................182 8.1 8.2 8.3 8.4 8.5 8.6



EJECTORS..................................................................................................................................... 182 SELECTING THE EXTERNAL OPERATION ................................................................................. 183 AUTOMATION DEVICES (OPTION) .............................................................................................. 183 SELECTING THE PRESET STOP POSITION (OPTION).............................................................. 184 DIE PROTECTION ......................................................................................................................... 184 MATERIAL END DETECTION DEVICE (OPTION) ........................................................................ 184



Section E MAINTENANCE 1. PERIODIC INSPECTION............................................................................187 1.1 1.2 1.3 1.4 1.5



MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION)......................................... 187 SEMI-ANNUAL INSPECTION (OR EVERY 1500 HOURS OF OPERATION)................................ 189 ANNUAL INSPECTION (OR EVERY 3000 HOURS OF OPERATION).......................................... 190 THREE YEAR INSPECTION (OVERHAUL)................................................................................... 191 PERIODIC INSPECTION OF PERIPHERAL DEVICES AND ACCESSORIES ............................. 192



2. LUBRICATION ............................................................................................193 2.1 2.2 2.3 2.4 2.5 2.6



FLUSHING...................................................................................................................................... 193 TYPES AND AMOUNTS OF OIL.................................................................................................... 194 OIL AND GREASE SERVICING POINTS ...................................................................................... 196 OIL AND GREASE SERVICING PROCEDURES .......................................................................... 196 OIL SERVICING OF HYDRAULIC OVERLOAD PROTECTOR ..................................................... 198 CHANGING CLUTCH AND BRAKE OIL ........................................................................................ 201



3. MAINTENANCE OF MECHANICAL COMPONENTS.................................204 3.1 3.2 3.3 3.4 3.5



MEASURING SLIDE GIB CLEARANCE......................................................................................... 204 V-BELT ADJUSTMENT................................................................................................................... 205 CHANGING V-BELTS ..................................................................................................................... 206 INSPECTING CLUTCH STROKE................................................................................................... 207 MAINTENANCE OF GUARDS (OPTION) ...................................................................................... 208



4. MAINTENANCE OF ELECTRICAL COMPONENTS ..................................209 4.1 4.2 4.3 4.4 4.5



MEGGER MEASUREMENT (INSULATION RESISTANCE MEASUREMENT).............................. 209 SERVICE LIFE OF ELECTRICAL COMPONENTS........................................................................ 210 INSPECTING THE GROUND FAULT BREAKER........................................................................... 211 REPLACING THE BUILT-IN PLC BATTERY .................................................................................. 212 OPERATOR INTERFACE TERMINAL MAINTENANCE................................................................. 214



5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS ....................217 5.1 5.2 5.3 5.4



AUTO-DRAIN FILTER..................................................................................................................... 217 THE CLUTCH AND BRAKE SOLENOID VALVE............................................................................ 219 AUTOMATIC GREASE PUMP........................................................................................................ 221 AUTOMATIC OIL PUMP (OPTION)................................................................................................ 223



11



GENERAL TABLE OF CONTENTS



5.5 MANUAL PUMP.............................................................................................................................. 224 5.6 MOTOR-DRIVEN OIL PUMP AND OIL FILTER ............................................................................. 225



6. TROUBLESHOOTING ................................................................................230 7. CONSTRUCTION DRAWINGS...................................................................232 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS ................................247 9. SPARE PARTS LIST (OPTION) ..................................................................259 10. LIST OF TOOLS PROVIDED WITH THE PRESS MACHINE...................261 11. DRAWINGS...............................................................................................265 (1)Mechanical Drawings (2)Electrical Drawings



APPENDIX INSTRUCTIONS FOR PRESS MACHINE USAGE LIST OF LUBRICANTS AVAILABLE ON THE MARKET TONNAGE MONITOR (made by AIDA) (option)



• INDEX • Instruction Manuals for Peripheral Devices (Option) > • Instruction Manuals for Accessories > • Sales offices and Service offices



12



SectionA SAFETY



A



Section SAFETY



1. WARNING DISPLAY ............................................................................................ 15 2. SAFETY PRECAUTIONS .................................................................................... 16 2.1 TO THE EMPLOYER...................................................................................................................... 16 2.2 INSTRUCTIONS FOR AUTHORIZED PERSONNEL AND QUALIFIED PERSONNEL................. 18 2.3 INSTRUCTIONS FOR DIE SETTERS AND OPERATORS............................................................ 18 2.4 INSTRUCTIONS FOR MAINTENANCE SPECIALISTS................................................................. 18 3. SAFETY DEVICES............................................................................................... 19 3.1 ACTIONS TO PREVENT HAZARDS.............................................................................................. 19 3.2 TWO-HAND RUN BUTTONS ......................................................................................................... 20 3.3 GUARDS (OPTION) ....................................................................................................................... 21 3.4 PRESENCE-SENSING DEVICE (OPTION) ................................................................................... 22 3.5 IMPORTANT EQUIPMENT ............................................................................................................ 23 4. USING THE PRESS MACHINE SAFELY............................................................. 24 4.1 ESSENTIAL BASIC RULES ........................................................................................................... 24 4.2 ESSENTIAL USAGE ENVIRONMENT PRECAUTIONS................................................................ 26 4.3 ESSENTIAL INSTALLATION PRECAUTIONS............................................................................... 27 4.4 ESSENTIAL OPERATION PRECAUTIONS ................................................................................... 28 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS.............................................................................. 31 4.6 SAFETY PRECAUTIONS TO BE OBSERVED STRICTLY WHEN INSTALLING PRESENCE-SENSING DEVICE ................................................................................................................................. 32 5. SAFETY PROCEDURES DURING ADJUSTMENT............................................. 33 6. WARNING PLATES.............................................................................................. 34 7. PAINTING ON HAZARDOUS AREAS.................................................................. 43 8. GLOSSARY.......................................................................................................... 44



13



Section A SAFETY



14



Section A SAFETY 1. WARNING DISPLAY



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



DANGER



This display indicates a serious situation where failure to heed the warning will cause death or serious injury.



WARNING



This display indicates a possible situation where failure to heed the warning may cause death or serious injury.



CAUTION



This display indicates a possible situation where failure to heed the warning may cause minor to medium level injury.



IMPORTANT



This display indicates a possible situation where failure to heed the warning may result in damage to the machine.



• Definition of symbols



This symbol indicates an act that is “prohibited”.



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



This mark is used to provide further information.



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



NOTE



• See Section A SAFETY, 8. GLOSSARY (pg. 44) for technical terms.



15



Section A SAFETY 2. SAFETY PRECAUTIONS



2. SAFETY PRECAUTIONS



WARNING • The employer, authorized personnel, qualified personnel, die setters, operators, and maintenance specialists must observe all regulations relating to labor safety. • If the regulations or safety precautions stated in this section are not followed, accidents causing injury, death or mechanical damage may occur. We will not bear any liability in such cases. The press machine is capable of performing a variety of operations. However, the actual procedure to operate the machine is at the discretion of the user. In general, press machine manufacturers cannot know or control the use of the press machine on a day-to-day basis. Like other press machine manufacturers, we cannot know what protection measures are required or suitable for your specific operation or application. Therefore, the user must establish and implement the most suitable safeguarding measures for the point of operation. The following shows the minimum safety precautions that are required to be observed. Be sure to perform all of these items.



2.1 TO THE EMPLOYER (1) Provide all employees with an employment contract and work place environment which ensures that no hazardous conditions exist that can result in the accidental death of or serious injury to an employee. (2) Implement safeguarding measures to protect operators and other employees from hazards including the point of operation, rotating parts, splashing objects, and sparks. (3) Confirm that the operators use safeguarding devices, which have been correctly installed and properly adjusted, for all press machine operations. Never allow anyone to modify or remove safeguarding devices. (4) Designate appropriate persons as authorized personnel, qualified personnel, die setters, operators, and as maintenance specialists for this machine. Authorized Personnel:



Qualified Electricians:



16



Personnel given the authority and responsibility by the employer to perform particular duties. These personnel must follow the instructions stated in 2.2 INSTRUCTIONS FOR AUTHORIZED PERSONNEL AND QUALIFIED PERSONNEL (pg. 18). The employer must designate appropriate employees who have special knowledge and experience associated with the hazards and safety measures of the press machine, handling and maintenance of the press machine, and handling of the presswork and dies as authorized personnel. It is recommended that authorized personnel be selected from company foremen, supervisors, or shop managers. Personnel who perform adjustment, inspection, and maintenance relating to the electrical systems according to applicable regulations. Select employees who have special knowledge of and experience with press machines and electrical systems. (Continued on the next page)



Section A SAFETY 2. SAFETY PRECAUTIONS



(Continued) Die Setters: Operators: Maintenance Specialists:



Personnel who perform die setups and adjustments needed to ensure that dies work properly and safely. Personnel who operate the press machine for presswork. Personnel involved in routine checks, inspections, and maintenance of the press machine. It is advisable that qualified personnel also serve as maintenance specialists.



(5) Give authorized personnel, qualified personnel, die setters, operators, and maintenance specialists training in safe operation before they start any kind of work. Also, ensure that the employees work according to proper operational procedures. (6) Based on this instruction manual, establish a training program about hazards, safe operation, setup, and maintenance of the press machine for the authorized personnel, qualified personnel, die setters, operators, and maintenance specialists. (7) Assure that the authorized personnel, qualified personnel, die setters, operators, and maintenance specialists are familiar with the recommended operation, setup, and maintenance procedures for the press machine. (8) In order to establish safe operation methods, prepare the following operation guides. Train the authorized personnel, qualified personnel, die setters, operators, and maintenance specialists to perform their operations in accordance with these operation guides. (a) Die setup and test operation (b) Press machine operation (presswork) (c) Lock-out procedures (d) Routine and periodic inspections (9) Establish and implement a proper and regular inspection program for the press machine and for guards and protective devices to confirm that all parts, auxiliary devices, guards, and protective devices are in good operating condition and that employees use them properly. Any defective conditions detected in the inspection should be immediately repaired. Inspection and maintenance records must be kept. (10)Inspect the press machine at least once a week. All the required maintenance and repair work must be completed before the press machine is returned to service. (11) Use dies and operational procedures which are designed to protect employees from hazards. (12)Ensure that all employees fully understand and follow the rule that if an abnormal condition occurs on the press machine that the press machine must be stopped immediately and the condition remedied before resuming production. The machine must never be restarted until the problem is resolved. (13)When there is a person who cannot read and understand this instruction manual due to language barriers or their educational level, either provide him/her with a translated version containing all of the necessary information, or interpret it to them. (14)Perform all other duties assigned on the employer by existing laws and regulations.



17



Section A SAFETY 2. SAFETY PRECAUTIONS



2.2 INSTRUCTIONS FOR AUTHORIZED PERSONNEL AND QUALIFIED PERSONNEL (1) Perform a pre-work check, a routine inspection, and a periodic inspection of the press machine, guarding, and safety devices. (2) When an abnormal condition is noted on the press machine, the guarding, or the safety devices, stop using the press machine immediately, report the condition to the employer, and take any necessary actions to repair the condition. (3) Control the keys for the key switches for the press machine and safety devices, etc. (4) Perform any other particular operations assigned by the employer.



2.3 INSTRUCTIONS FOR DIE SETTERS AND OPERATORS You must receive the following safety training in order to operate this machine. • Die Setter: Training for items relating to die setup, adjustment, and test running. In addition, you must receive the same training that the operator receives (as explained below). • Operator: Training related to press machine hazards and operation, usage and handling of the guards, safety devices and protective equipment, work procedures, pre-work check, routine inspection, emergency actions, and evacuation procedures in case an accident occurs.



2.4 INSTRUCTIONS FOR MAINTENANCE SPECIALISTS (1) Periodically inspect the press machine, guarding, and safety devices. (2) When an abnormal condition is found in the press machine, guarding, or a safety device, stop using the press machine immediately, report the condition to the employer, and take any necessary actions to repair the condition.



18



Section A SAFETY 3. SAFETY DEVICES



3. SAFETY DEVICES 3.1 ACTIONS TO PREVENT HAZARDS



WARNING • The employer must rigidly adhere to the following instructions prior to use of the machine. Part of someone’s body may enter the danger zone during operation, which may result in personal injury or death. (1) Safeguarding measures must be taken by the user for the point of operation that are the most appropriate for the user’s operation. (2) When installing material feeders (such as a coil line, a destack feeder, and/ or robot), product removal devices, or other peripheral devices, the user must provide safety fences or enclosures in accordance with applicable safety regulations and laws for that equipment. (3) This press machine has been manufactured based upon it being operated by one person at an operation position located in front of the press machine. When an assistant operator is involved, you must provide safeguarding measures so that no part of the body of the assistant operator can get inside the danger zone. (4) Confirm that sections related to safety, guarding, and safety devices are used in a way which is effective for the work of your company, and that they are always in use.



19



Section A SAFETY 3. SAFETY DEVICES



3.2 TWO-HAND RUN BUTTONS The two-hand RUN buttons are used in combination with the SINGLE mode operation. Pushing concurrently the two buttons with both hands will activate the slide. Releasing the button while the slide is in its down stroke, the slide will stop. The two-hand RUN buttons are mounted at a location that is well away from the point of operation to ensure safety. This means that the operator has to push the buttons with both hands while the slide is in its down stroke, thereby preventing his/her hands from entering the point of operation. Note that the two-hand RUN buttons are also used when any operation mode other than the SINGLE mode is selected. On a press machine having a bolster of 1300 mm wide or more, the two-hand RUN buttons have no capability of preventing danger. (See Section D OPERATION, 3.4 SAFETY DEVICES AND OPERATION CONDITIONS (pg. 126).) The above type of press machine therefore needs guards and a presence-sensing device as danger prevention measures.



WARNING • Never move the location of the two-hand RUN buttons since they have been installed at a location that assures the distance from the point of operation. • The front-rear dimension of the upper die must be equal to or less than that of the slide. Part of someone’s body may enter the danger zone during operation, which may result in personal injury or death.



WARNING • Never remove the access prevention ring from the stand-type operation button box (option). If the ring is removed, the distance between the two-hand RUN buttons and the point of operation will not be assured, and this could cause an accident resulting in personal injury or death. • The stand-type operation button box is portable. An access prevention ring may be provided depending on the specifications. The distance between two-hand RUN buttons and the point of operation is assured when the access prevention ring is in contact with the press machine.



Press side



Access prevention ring



20



Section A SAFETY 3. SAFETY DEVICES



3.3 GUARDS (OPTION) Closing the guard can prevent people from putting their hands into the point of operation. In operation modes other than the MICRO INCH and INCH, the slide cannot be started unless the guard limit switch detects that the guard is closed and locked. Note that, on the press machine having a bolster of 1300 mm wide or smaller, the SINGLE mode operation is possible using the two-hand RUN buttons with the guard opened. For the relationship between the guard condition and the operation mode, see Section D OPERATION, 3.4 SAFETY DEVICES AND OPERATION CONDITIONS (pg. 126).



WARNING • Do not operate the press machine with guard limit switches disabled. Disabling guard limit switches may cause guarding functions to be inoperable, and may thus result in personal injury or death. • If the transparent pane section of the guard breaks, replace it immediately. Injury or damage may be caused if a broken pane falls out of its frame.



21



Section A SAFETY 3. SAFETY DEVICES



3.4 PRESENCE-SENSING DEVICE (OPTION) The presence-sensing device detects interception of the light beam and outputs an Immediate Stop signal to the press machine. As long as the presence-sensing device operates normally, the slide will make an Immediate Stop if the light beam from the device is intercepted while the slide is in its down stroke in the SINGLE operation mode or while the slide is operating in the CONTINUOUS operation mode. See Section D OPERATION, 3.4 SAFETY DEVICES AND OPERATION CONDITIONS (pg. 126) for the relationship between the condition of the presence-sensing device and the operation mode. See 4.6 SAFETY PRECAUTIONS TO BE OBSERVED STRICTLY WHEN INSTALLING PRESENCE-SENSING DEVICE (pg. 32) .



WARNING • Never move the location of the presence-sensing device since they have been installed at a location that assures the distance from the point of operation. • Never remove the access prevention frame placed in front of the press machine. If it is removed, misuse may take place and personal injury or death can be caused. The access prevention frame is intended to prevent the presence of the operator or any other person in the area between the press machine and the light beam from the presence-sensing device. The installation depends on the specification of the machine. • The front-rear dimension of the upper die must be equal to or less than that of the slide. Part of someone’s body may enter the danger zone during operation, which may result in personal injury or death. • Before starting your work, be sure to carry out pre-work check of the presencesensing device following the steps of the procedure stated in the instruction manual for the device to verify that the device functions normally. If any fault is found, immediately prohibit the use of the press machine and repair the faulty part. If this rule is not strictly followed, an accident resulting in personal injury or death can be caused.



22



Section A SAFETY 3. SAFETY DEVICES



3.5 IMPORTANT EQUIPMENT The following equipment are not safety devices, but important equipment to avoid misuse. Be familiar with the functions and handle the equipment correctly. 3.5.1 CONTROL POWER Switch



This switch shuts off the control power source. By setting the switch to "O" (OFF) and removing the key, the slide and main motor start circuit will be disabled. (See pg. 33.) 3.5.2 Externally Controlled Breaker



When the externally controlled breaker located on the control panel door is set to the OFF position, the power supply to the press machine will be shut off. Set the circuit breaker to the OFF position before opening the control panel door. For the Safety Procedures During Adjustment, set the externally controlled breaker to the OFF position, then lock out the externally controlled breaker with a pad lock (to be prepared by the customer). (See pg. 33.) 3.5.3 Die Block (Option)



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



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



23



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



4. USING THE PRESS MACHINE SAFELY 4.1 ESSENTIAL BASIC RULES



WARNING • Do not modify the machine and do not modify or remove the control circuits. In particular, never modify, remove, or relocate the sections related to safety and safety devices. If modified, removed, or relocated, the machine or the safety device will no longer function properly, and there is a possibility that personal injury or death could be caused. • Do not use the press machine beyond the specified limits. Furthermore, do not use the machine under abnormal conditions, such as operating the machine in an inclined position, or using for hot working. If used under such circumstances, the machine and safety devices may not function properly, causing possible personal injury or death. • Avoid wearing loose clothes or accessories as they may be caught by the machine, resulting in personal injury or death. In addition, wear protective gear, such as a safety helmet, protection goggles, steel-toed shoes, a mask, or gloves, as necessary. • Operation and maintenance, etc., must be performed by operators or authorized persons who have received safety training. If undertaken by those who have no knowledge of the hazards or the correct operation of the press machine, there is a possibility that personal injury or death could result. • Perform installation, operation, and maintenance work of this machine according to this instruction manual. Unsafe usage of the machine or the performance of operation, service or maintenance tasks not specified in this manual could result in personal injury or death. • The design, manufacture, and use of dies are the responsibility of the user. Assess the hazards caused by dies and presswork, and implement necessary countermeasures. • The front-rear dimension of the upper die must be equal to or less than that of the slide. Otherwise, the press machine may be damaged or personal injury or death may occur. • If quick-drying, high-volatility material coating fluids are used in the material oil coating device, the customer is responsible for assuring that measures are implemented to prevent the spray, etc., from such coating fluids from coming into contact with the press and with peripheral devices. Quick-drying, high-volatility coating fluids can degrade press lubrication oil performance, as well as cause paint coatings, seals, hoses and the plastic coatings on wiring to harden, expand, and/or peel. There is a fire hazard risk from electrical short circuits resulting from wire or terminal block deterioration due to contact with such coating fluids. Take appropriate measures in accordance with the information provided on the coating fluid Material Safety Data Sheet. (Continued on the next page)



24



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



(Continued)



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



25



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



4.2 ESSENTIAL USAGE ENVIRONMENT PRECAUTIONS



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



WARNING • Do not use the machine under the following conditions, and do not operate the machine in such a way as to cause such conditions. Operating the machine under these conditions may damage electronic equipment or machine parts, or may cause a fire, electric shock, or a malfunction that could result in personal injury or death. (1) When the machine and the control panel are exposed to excessive airborne oil, water, or chemicals. (2) When excessive dust, minute particulates, and/or metal particles are present. (3) When corrosive gases are present. • Maintain the temperature inside the plant building between 5 and 40°C. (The allowable relative humidity is between 45 and 85%.) If the temperature is below this range, there is a possibility that the main motor will not start, or galling of the bushings or liners due to insufficient lubrication. If the temperature is above this range, there is a possibility of degradation of clutch and brake performance, or galling of the bushings or liners due to a degradation of the lubrication function. When it is anticipated that the temperature will be beyond the above range, consult with AIDA Service (listed at the end of this instruction manual). • Do not use the machine at a location higher than 1,000 meters (3,280 ft.) above sea level. If the machine is used at a location higher than 1,000 meters (3,280 ft.) above sea level, there is a possibility that the motor and other parts may overheat and cause a fire.



CAUTION • The machine must be installed in a plant building where there is adequate illumination and floor space for normal work. Otherwise, operation and inspection cannot be performed properly, and there is a possibility of injury or machine damage.



26



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



4.3 ESSENTIAL INSTALLATION PRECAUTIONS



WARNING • Transportation, hoisting, and installation of the machine requires special technical expertise. Use a contractor that specializes in such work or AIDA Service (listed at the end of this instruction manual) to perform such work. If such work is performed by unskilled workers, there is a possibility that the machine could be dropped, etc., and could result in personal injury or death. • Grounding and connection to the power source must be performed by qualified electricians according to the engineering standards for electrical equipment. (See Section C INSTALLATION, 4. CONNECTING TO THE POWER SOURCE (pg. 78). If such work is performed by an unauthorized person, there is a possibility of accidental electrical shock which could result in death.



27



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



4.4 ESSENTIAL OPERATION PRECAUTIONS



DANGER • Do not touch the knockout bar while the slide is moving or being adjusted. If touched, there is the danger of a hand being caught in the knockout bar.



WARNING • Do not engage the clutch while the press machine is under load and just before the press machine is put under load. If the clutch is engaged under such conditions, return the slide to the preset stop position by operating the main motor in reverse. Even if the presswork does not exceed the torque capacity shown on the stroketonnage curve, do not stop and then restart the press machine in the middle of the forming portion of the stroke. Such operations can result in the generation of excessive heat due to clutch slippage, and can lead to hazardous conditions such as clutch seizure and overruns. It can also result in personal injury. • Do not operate the machine with side covers or covers for rotating or moving areas removed or opened, including the flywheel cover. Operating the press machine with such covers removed could lead to a serious accident where a part of someone’s body could get caught in the running machine. • Do not put your hand or any other part of your body between the upper and lower dies while the slide is moving or being adjusted. Doing such could lead to your hand or other body part getting caught. • Keep away from the press machine while the slide is moving. Personal injury or death may be caused by approaching the machine and coming close to the point of operation. • Do not operate the machine with the presence-sensing device set to the OFF (DISABLE) position. If doing so, the slide may not be able to stop when light is intercepted, and personal injury or death may occur. • Do not operate the machine with the GUARD DISABLE•ACTIVE switch set to the DISABLE position. In this position, the guard function is not enabled, and personal injury or death may occur. (Continued on the next page)



28



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



(Continued)



WARNING • Control the keys for the key switches of the press machine and its safety devices, first making sure that the presence-sensing device is not disabled, and that the work methods and operational procedures are totally safe. Misuse may result in personal injury or death. (See Section D OPERATION, 1.1 MAIN OPERATION PANEL (pg. 85) and 1.2 OPERATION BUTTON BOX (pg. 86).) Keys: CONTROL POWER Switch GUARD DISABLE•ACTIVE Switch (option) PRE. SENSING DEVICE Switch (option) DATA WRITE Switch AH MASTER Switch (option) EXTERNAL•OFF•BUTTON Switch OPERATION SELECT Switch UNIT•LINE Switch (option) Presence-Sensing Device (see the instruction manual for the presencesensing device) Key Switches for Other Peripheral Devices • Before starting work, always perform pre-work checks and the Routine Inspection items (See pg. 120.) If any abnormal conditions are found, repair them immediately. Starting work without repairing such items may result in personal injury or death. • In cases where metal pieces or other chips may possibly fly out of the point of operation, install guards around the press machine and in front of operator. Flying metal may lead to personal injury or death. • Before starting operation, confirm that no personnel or obstructions are present in the vicinity of the press machine. It is strictly prohibited to place tools or parts on the bolster, as this could lead to the possibility of unintentional personal injury due to objects flying out of the press machine. • For the production using the hand-in die, operate the press machine in SINGLE mode using the two-hand RUN buttons. Do not operate the press machine in the INCH or CONTINUOUS modes. If any of these other modes is selected, there is the danger of a hand being caught in the die. When use of the foot switch is necessarily, take appropriate safety measures such as use of a presence-sensing device or safety fence that matches the work to be done, and operate the press machine in SINGLE mode. • Before using the EXTERNAL OPERATION receptacle, make sure first that the safety device employed functions normally. If the safety device is faulty, the slide may move even if the RUN buttons are not pushed. In this case, personal injury or death may be caused. (Continued on the next page)



29



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



(Continued)



WARNING • Operate the press machine at a speed that does not exceed the allowable number of intermittent strokes. If the allowable number of intermittent strokes is exceeded, the clutch and brake performance will be degraded, and personal injury or death may occur. • Use the MICRO INCH and INCH mode for die change or inspection only. If used for other operations, personal injury or death may be caused because safety devices, including guards, are disabled in the MICRO INCH and INCH modes. • When pushing the two-hand Run buttons, always push both of them at the same time using both hands. If you push one of the two Run buttons with some tool, etc., some part of your body may enter into the point of operation, and personal injury or death may occur. • When two or more people are involved in operating the press machine, each of them must use two-hand Run buttons. Misuse may result in personal injury or death. • If any problems occur while the slide is in operation, stop the slide immediately by pushing the EMERGENCY STOP button. Take troubleshooting action according to the instructions of authorized personnel. • Before removing scraps or troubleshooting, always perform steps (1) through (3) as described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33). Misuse of the press machine may cause personal injury or death. • Before putting your hand[s] between the upper and lower dies in order to change dies, make adjustments, or perform maintenance, always perform steps (1) through (5) as described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



30



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



4.5 ESSENTIAL MAINTENANCE PRECAUTIONS



WARNING • Be sure to conduct periodic inspections of the press machine and safety devices. Improper inspection and maintenance could result in the possibility of personal injury or death. For the inspection items, see Section E MAINTENANCE, 1. PERIODIC INSPECTION (pg. 187). • Adjustment and maintenance of electronic equipment must be performed by an electrician. If done by an unauthorized person, press machine malfunction or electric shock may occur, which could lead to personal injury or death. • Before opening a control panel door, etc., be sure to shut off the power supply from your power source. Otherwise, a fatal accident may be caused by electric shock when the insides of a control panel are touched. • Replace parts and components related to safety before they reach their standard service life even if they are working properly. (See Section E MAINTENANCE, 4.2 SERVICE LIFE OF ELECTRICAL COMPONENTS (pg. 210).) Replace failed parts--do not repair them. Personal injury or death may be caused by a malfunction. When replacing safety parts, such as RUN buttons, EMERGENCY STOP buttons, and a clutch and brake solenoid valve, etc., be sure to use replacement parts from the same manufacturer that have the same model or part number. (See Section E MAINTENANCE, 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS (pg. 247).) • Before performing maintenance, inspection, lubrication, and cleaning of the machine, be sure to follow all of the steps in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33). Otherwise, there is a possibility of personal injury or death owing to misuse. • When work is performed at a location that is 1.5m or higher above floor level, be sure to use a ladder and platform with safety features suitable for high lift work. Do not use part of the machine as a scaffold. Furthermore, when working at an high location, use a safety rope to prevent falls. Otherwise, there is a possibility of personal injury or death caused by falling down. • DIe maintenance must be performed after dies are removed from the press machine. Otherwise, an unexpected accident may occur.



31



Section A SAFETY 4. USING THE PRESS MACHINE SAFELY



4.6 SAFETY PRECAUTIONS TO BE OBSERVED STRICTLY WHEN INSTALLING PRESENCE-SENSING DEVICE



WARNING • When we install an optical presence-sensing device, which is fundamental safety device, it is done in accordance with the conditions mentioned in this paragraph. • When the user installs the optical presence-sensing device, please install it in accordance with the conditions mentioned in this paragraph. • The enterpriser must estimate the risk, and investigate and take measures to reduce the risk, in accordance with the "Guideline for research on risks and harmfulness." (The Ministry of Health, Labor and Welfare Ministerial Notification dated March 10, 2006) Refer to the "How to make risk assessment" on the home page of the Ministry of Health, Labor and Welfare. http://www.mhlw.go.jp/bunya/roudoukijun/anzeneisei14/dl/press1.pdf (This address is subject to change.) 4.6.1 Selection of a Presence-Sensing Device



(1) A qualified optical presence-sensing device that conforms to the "Standard for safety construction of presses or shears" (The Ministry of Health, Labor and Welfare Ministerial Notification No. 102) will be selected for use. (2) An optical presence-sensing device having redundancy that, in the event of failure of the device including the auxiliary light beams, can avoid an occurrence of a critical situation will be selected for use. 4.6.2 Scope of Safeguarding



The optical presence-sensing device will be so constructed that the operator's hand and other object will not reach the work area (danger zone) unless passing through the detection zone of the optical presence-sensing device. • There shall be no space between the side face of the bolster and the light beams so that passing through of a worker is not allowed. (Installation of auxiliary light beams or safeguard plates) • Entering of any part of the worker or any worker over the top light beam must be prevented. • Entering of any part of the worker or any worker through the right side or the left side opening must be prevented. (Installation of side guards) 4.6.3 Measures for the Case Where it is Possible that a Person Remains Inside the Safeguard Zone (Danger Zone)



(1) When the press machine is of a large size, there is a case where a person gets into the danger zone through the detection zone of the optical presence-sensing device and stays in the danger zone, or a case where a person stays in the danger zone cannot be detected. In such a case, a reset button that is to be pushed when it is confirmed that all persons have got out of the danger zone must be provided at the position from where the operator can look over the danger zone; and an electric circuit that make it impossible to start the press machine again unless the reset button is pushed. (2) If any hazardous situation owing to installation of the protection device, installation of the automation equipment, and temporary deactivation of the protection device at the time of setting of material or modification is foreseen, even if it is minor, the enterpriser must make a risk assessment. Further, the enterpriser must provide a reset button to confirm that no person remains in the danger zone in accordance with 4.6.3 (1).



32



Section A SAFETY 5. SAFETY PROCEDURES DURING ADJUSTMENT



5. SAFETY PROCEDURES DURING ADJUSTMENT



WARNING • Before an operator enters a hazardous area in order to perform adjustments, inspections, or maintenance, confirm that the following actions have been taken by qualified personnel. The keys that have been removed from the key switches must be held by the operator. If the press machine is misused, there is a possibility of personal injury or death. (1) Push the EMERGENCY STOP button. (2) Set the OPERATION SELECT switch to OFF, and remove the key from the key switch. (3) Set the CONTROL POWER switch to "O" (OFF), and remove the key from the key switch. (4) Visually confirm that the flywheel has stopped its rotation.



OFF



(5) Remove the die block plug. Insert the die block between the upper and lower dies. (Option) (6) Turn the externally controlled breaker to OFF, then lock out the circuit breaker using a padlock. (7) Shut off the power supply from your power source and lock out the power supply switch using a padlock. If the power supply switch cannot be locked out, put up a sign saying "DO NOT OPERATE" at locations requiring lock-out. (8) Close the air stop valve at the air supply port to the press machine, then lock-out the stop valve using a padlock. Next, relieve all residual air pressure in the press machine. See the system drawing for the method for relieving residual air pressure in each system. If lock-out is not possible, put up signs saying "DO NOT OPERATE" at locations requiring lock-out. (9) Prepare signs saying "DO NOT OPERATE," and put them up at easy to see locations.



NOTE



OFF DO NOT OPERATE



DO NOT OPERATE



DO NOT OPERATE



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



33



Section A SAFETY 6. WARNING PLATES



6. WARNING PLATES



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



NOTE



34



• Due to manufacturing requirements, the attachment location of warning plates may differ slightly. • Warning plate numbers may be different depending on the machine model. Check the plate number on the actual machine.



Section A SAFETY 6. WARNING PLATES



See the following pages.



35



Section A SAFETY 6. WARNING PLATES



1. Press Machine Usage Warnings (See pg. 15 ~ 33.)



PRECAUTIONS TO PREVENT ACCIDENTS In no event shall AIDA be liable for any damages due to an accident caused negligence in taking the following precautions. 1. Operate and maintain the press and the associated equipment according to description in the instruction manuals. 2. When the press is operated in the SINGLE, CONTINUOUS SINGLE, or CONTINUOUS mode, or when it is operated by a foot pedal switch, use all safety devices (such as the barrier guard and light curtain). 3. Before starting the press operation, do the START UP INSPECTION and ROUTINE CHECK as specified in the instruction manual. In particular, ensure the following, which directly affect the safety of operation. (1) Proper lubrication. (2) That the slide stops exactly in the preset stop position (within±10 o) (3) That the slide stops in the preset stop position even if the RUN buttons are kept depressed during SINGLE mode operation. 4. Do not operate the press with the safety device switch off except while the dies are being set. Do not operate the press with the barrier guard removed. 5. When the work is halted, turn off the operation selector switch. When the operator leaves the machine, turn off the main motor and depress the EMERGENCY STOP button. 6. When checking or repairing the dies or machine, do step 5 (above), and put up a "DO NOT OPERATE" sign on the operating panel. 7. Do not modify the machine or electric circuits and do not remove any component or them. Especially, never modify or remove any safety device or any component related to safety. 8. Do not adjust the rotary cam or the timing switch that controls the SINGLE mode operation, stopping the slide in the preset stop position, and non-repeat function. 9. Drain the sludge from the pneumatic system every day. 10.Do not operate the machine beyond the capacities and limits specified in the instruction manual. 11.The slide adjusting device cannot pre-load dies. If the device is not properly adjusted, the device may be overloaded and damaged. Use the slide adjusting device as explained in the instruction manual. 12.When starting the machine after a halt of more than 24 hours, operate the oil pump for five minutes or more before you start the main motor; this will prevent trouble due to poor lubrication. (This step is not required on a machine with oil bath lubricating system.) 13.Periodically measure the actual stroke length of the clutch/brake, and adjust the stroke to be within the allowable limits in accordance with the instruction manual. If the clutch/brake is used in excess of the allowable stroke limits, the performance of the clutch/brake will be deteriorated and it is detrimental to safety operation. Therefore, it is very dangerous. N2020e



38



Section A SAFETY 6. WARNING PLATES



3. Solenoid Valve Warning (See pg. 219.)



ATTENTION



8. Cautions when Disassembling the Counterbalance Disassembly of the counterbalance requires special skills. Be sure to contact AIDA Service (see the end of this instruction manual).



NEVER OPERATE MANUALLY SOLENOID VALVE FOR CLUTCH BRAKE DURING REVOLUTION OF FLYWHEEL. IF THE SOLENOID VALVE WERE OPERATED MANUALLY DURING REVOLUTION OF FLYWHEEL, IT WOULD BRING ABOUT ACCIDENT BY UNEXPECTED DESCENT OF SLIDE. N1556



CAUTION 4. Warning about Accessing the Press Machine from the Rear (See pg. 28.)



FOLLOW THE INSPECTION MANUAL IN CASE OF TAKING THIS PART INTO



DANGER Do not extend your hands or body beyond this point while the press is in operation



PIECES FOR INSPECTION AND ADJUSTMENT. N１１８ ８



PELIGRO No extienda las manos ni su cuerpo mas alla de este punto mientras la prensa este en funcionamiento. N2415es



12. Warning about the Number of Allowable Intermittent Strokes (See pg. 55, 68.) 11. Warning about the Access Prevention Ring (Option) (See pg. 20.)



WARNING NEVER REMOVE SAFETY GUARD BAR ATTACHED TO PEDESTAL.



Don't use the press beyond the allowable intermittent strokes per minute given in this chart. If the press is used beyond the limit, the brake may be deteriorated and a personal injury can be caused. ＡＤＶＥＲＴＥＮＣＩＡ No utilice la prensa a mas de las carreras intermitentes por minuto permitidas indicadas en el grafico. Si se utiliza por encima del limite, se puede deteriorar el freno con el consiguiente riesgo de causar lesiones personales. ALLOWABLE INTERMITTENT spm



9047Ne



ＷＡＲＮＩＮＧ



60 50 40 30 20 10 30



40



50



60



70



80



90



100



CONTINUOUS spm



(*1) (*1): The warning plate number differs between press machine models. See the warning plate attached to your press machine or the NAME PLATE MOUNTING drawing for the warning plate number.



39



Section A SAFETY 6. WARNING PLATES



13. Clutch and Brake Maintenance Instructions (See pg. 201.) MA I N T E N A N C E CO N T R O L O F C LU T C H & B R A K E UP



1. REFERENCE OIL IN USE : AIDAMATIC OIL VOLUME OF OIL : L gal TIME OF OIL EXCHANGE : EVERY 12 MONTHS



A OIL INLET(3/8B)



FLYWHEEL REVOLUTION



2. FILLING OF OIL 1. PUT THE OIL INLET A "UP" POSITION, AND LET THE LEVELGAUGE C HORIZONTAL, THEN TAKE OFF THE OIL INLET BY THE C OIL GAUGE PLUG A . 2. FILL THE OIL TO THE HORIZONTAL LINE OF LEVEL GAUGE C THROUGH OIL INLET A . 3. PUT ON THE PLUG AT THE OIL INLET A .



18. Die Clamper Cautions (Option) (See pg. 130, 161.)



ＣＡＵＴＩＯＮ DOWN



B CLUTCH STROKE



IN CASE OF CEASING SUPPLY OF PNEUMATIC POWER SCURCE MOR E T HA N TH RE E(3 ) HO URS , INCHING DOWN THE SLIDE(RAM) TO THE BOTTOM DEAD POSITION AND P RE VE NT FROM SKIDDING THE UPPER/LOWER DIE POSITIONS. NON -S UPP LY OF PNEUMATIC POWER MAY HAPPEN TO CA USE T HE RE DUC TI ON OF HYD RA ULIC PRESSURE ON DIE CLAMPER. N2116e



INSPECTION HOLE (1/8B)



LIST OF OIL INUSE



MAKER



OIL



MOBIL



ATF-220



TRANSMISSION OIL OR EQUIV.



3. DISCHRGE OF OIL 1. PUT THE OIL INLET A "DOWN" POSITION, AND TAKE OFF THE CLUTCH STROKE INSPECTION PLUG B 2. THEN TAKE OFF THE OIL INLET PLUG A , DISCHARGE THE OIL. 4. CLUTCH STROKE INSPECTION METHOD 1. PUT THE CLUTCH STROKE INSPECTION HOLE B AND TAKE OFF THE PLUG. 2. PUT A ROD DIA. 8mm X LENGTH 150mm INTO THE CLUTCH STROKE INSPECTION HOLE B 3. PUTTING THE ROD INTO THE INSPECTION HOLE AND TURN THE FLYWHEEL BY HANDS. 4. CHECK AND CONFIRM THE STROKE ALLOWANCE BY THE ROD BY 120mm (TOUCH TO THE PISTON) 5. LET THE CLUTCH ON-AND-OFF OPERATION AND INSPECT THE ROD STROKE ALLOWANCE.



(*1)



14. Changing the Clutch & Brake Oil (See pg. 201.) REPLACE OIL IN THE CLUTCH/BRAKE IN



.NEXT



TIME.



USE OIL SPECIFIED IN



THE INSTRUCTION MANUAL.



Ｎ９０３４e



15. Grease Pump Cautions (See pg. 221.)



注 意 CAUTION No,0



No,0(NLGI-0)のみ使用 Use only No,0 (NLGI-0)grease.



16. Do not Adjust the Regulator (See pg. 157, 198) This warning plate means that adjustment of the regulator is prohibited. In the event of accident caused by adjustment of a sealed regulator, AIDA disclaims any responsibility for the accident.



OK



グリース補給は，取扱説明書に従って下さい。



Refer to the INSTRUCTION MANUAL for approved greases to use.



9077N



（９０７６Ｎ）



(*1): The warning plate number differs between press machine models. See the warning plate attached to your press machine or the NAME PLATE MOUNTING drawing for the warning plate number.



40



Section A SAFETY 6. WARNING PLATES



20. Manual Pump Operation Cautions (See pg. 196.)



注　　意 CAUTION 給油操作は取扱説明書に 従って下さい。 Refer to the INSTRUCTION MANUAL for lubricating operation. 公嗟荷恬萩恆孚荷恬傍苧慕 序佩。 9153N



33. Die Cushion Usage Cautions (Option) (See pg. 69.)



WARNING



A B C D



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



40. Oil Filter Cautions (See pg. 225.) [Types (S)E, (1NL)E, and (2NL)E] CAUTION 1.WHEN HALF OF THE RED PORTION OF THE CLOGGED CONDITION INDICATOR OF THE LINE FILTER AND THE SUCTION FILTER APPEAR, CLEAN THE FILTER ELEMENT. 2.SEE THE INSTRUCTION MANUAL FOR REPLACEMENT AND CLEANING OF THE FILTER ELEMENT. 2745Ne



51. Megger Test of Electronic Parts (See pg. 209.)



CAUTION 1.No megger test is allowed for electronic device. 2.No megger test is allowed for proximity switch. 5412Pe



53. Warning (High Voltage) (See pg. 31.)



WARNING



Hazardous voltage can shock, burn or cause death. Turn off power before opening panel. 2620Ne



(2620Ne)



41



Section A SAFETY 6. WARNING PLATES



54. Mark Indicating a Grounding Terminal (See pg. 78.)



58. Warning Mark Indicating Points of Electricity This mark indicates a point of electricity. Turn off your power supply switch before opening a door or cover with this mark. If a person touches the inside components, death from electric shock can result.



Ｎ９０６４



（ＪＩＳ Ｂ６０１５）



55. Warning on Circuits Connected to External Power Supplies (Option) Control panels, etc., with the warning plate shown below contain circuits, such as interlock circuits, where power is supplied from other machines. Even if power to such machines is shut off, the orange wire circuits are live. When performing maintenance inside of control panels, etc., strictly adhere to the instructions on the warning plate.



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



42



Section A SAFETY 7. PAINTING ON HAZARDOUS AREAS



7. PAINTING ON HAZARDOUS AREAS Hazardous areas, such as moving sections, are painted yellow. This is done to call such areas to the attention of operators. Do not touch or approach these areas as they are hazardous during press machine operation. (3) Crank shaft arm



(8) End of automation power take-out shaft (option) To be attached to the right or left of the machine. It cannot be installed on Models (1NL)E and (2NL)E. Yellow PVC cover is used. (7) Knockout bar (option)



(2) Connecting rod



(5) Motor pulley



(1) Edge of underplate of slide For the slide that has a longer left-to-right dimension than the standard dimension, the part of top face of the slide that exceedes the standard (4) Flywheel dimension is painted. (6) Side cover



43



Section A SAFETY 8. GLOSSARY



8. GLOSSARY



44



(1) Point of Operation:



An area in which material is actually positioned and subjected to various press machine processes including shearing, stamping, forming, and assembling.



(2) Guard:



A barrier to prevent operator’s hands from entering the point of operation.



(3) Safety Device:



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



(4) Two-Hand RUN Buttons:



These are pushbuttons to start the slide and may be called RUN buttons or two-hand pushbuttons.



(5) Lock-Out:



Disables the machine by locking the power supply switch or air supply port in the OFF position. Lock-out prevents misuse or unintended operation by other operators.



Section B SPECIFICATIONS



B



Section SPECIFICATIONS



1. SPECIFICATIONS................................................................................................ 47 1.1 STANDARD SPECIFICATIONS OF THE PRESS MACHINE ........................................................ 47 1.2 DIE CUSHION SPECIFICATIONS (OPTION) ................................................................................ 51 1.3 MECHANICAL KNOCKOUT SPECIFICATIONS (OPTION)........................................................... 53 1.4 WARRANTY ................................................................................................................................... 54 2. CHARTS............................................................................................................... 55 3. GENERAL DIMENSIONS .................................................................................... 60 4. NAMES OF MAJOR COMPONENTS .................................................................. 63 5. ELEMENTS OF PRESSWORK............................................................................ 66 5.1 TONNAGE CAPACITY (NOMINAL CAPACITY) ............................................................................. 66 5.2 TORQUE CAPACITY...................................................................................................................... 67 5.3 STROKE-TONNAGE CURVE ........................................................................................................ 67 5.4 ENERGY CAPACITY (WORKING ENERGY)................................................................................. 68 5.5 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE....................................... 68 5.6 CAUTIONS CONCERNING DIE CUSHION USAGE ..................................................................... 69 6. SPECIFICATION PLATE ...................................................................................... 70 6.1 PRESS MACHINE SPECIFICATION PLATE ................................................................................. 70 6.2 ELECTRICAL SPECIFICATION PLATE ......................................................................................... 70



45



Section B SPECIFICATIONS



46



Section B SPECIFICATIONS 1. SPECIFICATIONS



1. SPECIFICATIONS 1.1 STANDARD SPECIFICATIONS OF THE PRESS MACHINE Special specifications are given on the page next to the cover. NC1-350



Model



(1)E



Press Machine Capacity



(kN)



(2)E



NC1-450 (S)E



350



(1)E



NC1-600 (2)E



(S)E



450



(1)E



600



Rated Tonnage Point (above bottom dead center)



(mm)



2.6



2.6



2.3



3.2



3.2



2.3



4



Slide Stroke



(mm)



70



120



50



80



120



55



90



(spm)



-



90



-



-



80



-



-



90 150



55 105



85 175



65 130



50 95



80 165



60 120



Number of Intermittent Strokes 53 per Minute (*2) (spm) (120) (At the shown number of strokes per minute)



62 (90)



49 (135)



25 (100)



39 (80)



50 (120)



45 (90)



Continuous Working Energy (*3) (At the shown number of strokes per minute)



1070 (90)



1250 (135)



1700 (100)



2250 (80)



1300 (120)



1900 (90)



250



250



250



270



270



270



Strokes Per Minute (No Load) (*1)



Fixed



Variable (spm)



(J)



760 (120)



Die Height (*4)



(mm) 200



Slide Adjustment



(mm)



50



60



70



Required Air Pressure



(MPa)



0.5



0.5



0.5



Ambient Temperature



(°C)



5 - 40



5 - 40



5 - 40



(kWxP)



5.5 x 4



5.5 x 4



5.5 x 4



70



66



132



Main Motor Max. Upper Die Weight



(kg)



(Continued on the next page) (*1): When “ - ” is shown in the “Fixed (spm)” box, the standard motor is a variable speed motor. When a numeric value is shown in the “Fixed (spm)” box, the standard motor is a fixed speed motor. In this case, a variable speed motor is available as an option. (*2): See Section B SPECIFICATIONS, 5.5 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE (pg. 68). (*3): Continuous working energy when the press machine uses a variable speed motor is indicated. (*4): The die height indicates the distance between the top of the bolster and the bottom of the slide, with the slide at bottom dead center and the slide adjustment at its upper limit.



47



Section B SPECIFICATIONS 1. SPECIFICATIONS



(Continued) Special specifications are given on the page next to the cover. NC1-800



NC1-600



Model



(2)E



Press Machine Capacity



(1)E (1NL)E



(kN) 600



Rated Tonnage Point (above bottom dead center)



(mm)



Slide Stroke



(mm) 140



4



(2)E (2NL)E (S)E



800



1100



3.2



5



5



5



5



3.2



60



100



100



160



160



70



(spm)



70



-



-



-



60



60



-



Variable (spm)



45 85



75 150



55 110



55 110



40 75



40 75



65 135



Number of Intermittent Strokes 50 per Minute (*2) (spm) (70) (At the shown number of strokes per minute)



60 (110)



53 (80)



33 (80)



60 (60)



42 (60)



50 (95)



Continuous Working Energy (*3) (At the shown number of strokes per minute)



2600 (70)



2000 (110)



2850 (80)



3340 (80)



3950 (60)



4850 (60)



3250 (95)



Die Height (*4)



(mm) 300



300



300



300



320



320



320



Slide Adjustment



(mm)



70



80



90



(MPa)



0.5



0.5



0.5



(°C) 5 - 40



5 - 40



5 - 40



(kWxP) 5.5 x 4



7.5 x 4



11 x 4



203



256



Strokes Per Minute (No Load) (*1)



Fixed



(S)E



NC1-1100



Required Air Pressure Ambient Temperature Main Motor Max. Upper Die Weight



(J)



(kg) 132



(*1): When " - " is shown in the "Fixed (spm)" box, the standard motor is a variable speed motor. When a numeric value is shown in the "Fixed (spm)" box, the standard motor is a fixed speed motor. In this case, a variable speed motor is available as an option. (*2): See Section B SPECIFICATIONS, 5.5 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE (pg. 68). (*3): Continuous working energy when the press machine uses a variable speed motor is indicated. (*4): The die height indicates the distance between the top of the bolster and the bottom of the slide, with the slide at bottom dead center and the slide adjustment at its upper limit.



48



Section B SPECIFICATIONS 1. SPECIFICATIONS



(Continued) Special specifications are given on the page next to the cover. NC1-1100 (1)E



(1NL)E



NC1-1500



(2)E



(2NL)E



(S)E



(1)E



1100



(1NL)E



NC1-2000 (2)E



(2NL)E



(S)E



1500



(1)E



2000



5



5



5



5



4



6



6



6



6



4



6



110



110



180



180



80



130



130



200



200



95



160



-



-



50



50



-



-



-



45



45



-



-



50 100



50 100



35 65



35 65



55 115



40 85



40 85



30 55



30 55



45 95



35 70



48 (70)



28 (70)



50 (50)



41 (50)



23 (90)



29 (65)



15 (65)



38 (45)



22 (45)



39 (70)



37 (50)



3200 (70)



5320 (70)



4600 (50)



5520 (50)



3800 (90)



5500 (65)



6370 (65)



7900 (45)



9900 (45)



6300 (70)



9300 (50)



320



320



350



350



350



350



350



400



400



410



410



90



100



110



0.5



0.5



0.5



5 - 40



5 - 40



5 - 40



15 x 4 (Fixed) / 11 x 4 (Variable)



15 x 4



290



1000



11 x 4



7.5 x 4 256



(Continued on the next page)



49



Section B SPECIFICATIONS 1. SPECIFICATIONS



(Continued) Special specifications are given on the page next to the cover. NC1-2000



Model



NC1-2500



(1NL)E (2)E (2NL)E (1)E



Press Machine Capacity



(kN)



Rated Tonnage Point (above bottom dead center)



(mm)



Slide Stroke



2000



2500



6



6



6.5



6.5



6.5



(mm) 160



250



250



170



300



300



(spm)



-



35



35



-



35



35



35 70



25 45



25 45



30 55



20 35



20 35



Number of Intermittent Strokes 23 per Minute (*2) (spm) (50) (At the shown number of strokes per minute)



35 (35)



35 (35)



36 (45)



23 (35)



17 (35)



Strokes Per Minute (No Load) (*1)



Fixed



Variable (spm)



Continuous Working Energy (*3) (At the shown number of strokes per minute)



(J)



6



(2)E (2NL)E



10690 13100 15740 15700 20750 27500 (50) (35) (35) (45) (35) (35)



Die Height (*4)



(mm) 410



450



Slide Adjustment



(mm)



110



120



Required Air Pressure



(MPa)



0.5



0.5



Ambient Temperature



(°C)



5 - 40



5 - 40



(kWxP)



15 x 4



22 x 4



(kg)



1000



1300



Main Motor Max. Upper Die Weight



450



450



540



540



(*1): When " - " is shown in the "Fixed (spm)" box, the standard motor is a variable speed motor. When a numeric value is shown in the "Fixed (spm)" box, the standard motor is a fixed speed motor. In this case, a variable speed motor is available as an option. (*2): See Section B SPECIFICATIONS, 5.5 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE (pg. 68). (*3): Continuous working energy when the press machine uses a variable speed motor is indicated. (*4): The die height indicates the distance between the top of the bolster and the bottom of the slide, with the slide at bottom dead center and the slide adjustment at its upper limit.



50



Section B SPECIFICATIONS 1. SPECIFICATIONS



1.2 DIE CUSHION SPECIFICATIONS (OPTION) 1.2.1 Bellows-Type Die Cushion



Press Machine Model (*1)



NC1-350



NC1-450



NC1-600



NC1-800



Die Cushion Model NCY- NCY- NCY- NCY- NCY- NCY- NCY- NCY- NCY- NCY(*2) 3-1S 3-1 4-1S 4-1 6-1S 6-1 6-2C 8-1S 8-1 8-2C 21 (26)



26



21 (26)



26



29 (35)



35



70



56 (63)



63



83



Stroke Length (mm) (*4)



60



60 (80)



60



60 (80)



70



70 (80)



70



70



70 (80)



70



Pad Dimensions LR x FB (mm)



285 x 240



Capacity (kN) (at 0.5 MPa) (*3)



Scrap Chute Diameter (mm)



100



Press Machine Model (*1)



335 x 205



-



100



335 x 235



-



NC1-1100



110



410 x 260



-



120



NC1-1500



-



NC12500



NC1-2000



Die Cushion Model NCY- NCY- NCY- NCY- NCY- NCY- NCY- NCY- NCY- NCY(*2) 11-1S 11-1 11-2C 15-1S 15-1 15-2C 20-1S 20-1 20-2C 25-1 Capacity (kN) (at 0.5 MPa) (*3) Stroke Length (mm) (*4)



71 (80)



80



126



88 (100)



100



159



130 (140)



140



198



140



80



80 (90)



80



80



80 (100)



80



100



100 (120)



100



100



Pad Dimensions LR x FB (mm) Scrap Chute Diameter (mm)



480 x 300 130



-



540 x 340 148



-



640 x 440 170



-



640 x 440 -



(*1): For the NC1-350, a die cushion can only be installed on the type(2) E. (*2): The model name followed by "S" indicates that the die cushion is equipped with a scrap chute. (*3): The numeric value shown in parentheses indicates the capacity value for the die cushion which the model name is followed by "SF" (i.e., with a front ejection scrap chute) or "SB" (i.e., with a back ejection scrap chute). (*4): The numeric value shown in parentheses indicates the stroke length of an increased stroke type, and the corresponding die cushion model name is followed by "H".



51



Section B SPECIFICATIONS 1. SPECIFICATIONS



1.2.2 Cylinder-Type Die Cushion φ 40h6



10



C1 0.



s



R



5



φd



5



Die Cushion Model



CA-120 CA-150 CA-180 CA-200 CA-230 CA-260 CA-300 CA-350



1 step (kN)



4



6



10



12



15



20



29



39



Capacity 2 step (kN) (at 0.5 3 step (kN) MPa) 4 step (kN)



8



12



20



24



31



39



57



78



12



18



30



36



47



59



86



117



16



24



40



48



63



79



115



156



5 step (kN)



20



30



50



60



79



99



144



195



Stroke Length s (mm)



50 100



60 110



60 120



60 130



80 130



80 140



100 150



100 150



Pad Diameter d (mm)



110



140



170



190



220



250



290



340



1.2.3 Dual Die Cushion φd1h6 φd2 φd3 φd4h6



s



9 1



24 25



Intermediate pad (will be provided by the user).



CA2120



CA2150



CA2180



CA2200



CA2230



CA2260



CA2300



CA2350



80



100



150



150



200



250



250



250



Stroke Length s (mm)



60 100



60 110



60 120



60 130



80 130



90 140



100 150



90 150



d1 (mm)



100



130



160



180



210



230



270



310



Pad Diame- d2 (mm) ter d3 (mm)



60



70



80



80



80



100



100



-



58



68



78



78



78



98



98



110



d4 (mm)



40



40



40



40



40



50



55



-



(kg)



1.4



2.2



3.4



4.7



6.3



7.6



11.7



14.9



Die Cushion Model Lift Capacity



Lifter Weight



52



(N)



Section B SPECIFICATIONS 1. SPECIFICATIONS



ａ



1.3 MECHANICAL KNOCKOUT SPECIFICATIONS (OPTION)



ｈ



ｄ



Press Machine Model



NC1450



NC1600



NC1800



NC11100



NC11500



NC12000



NC12500



Knockout Model



KM-4



KM-6



KM-8



KM-11



KM-15



KM-20



KM-25



(kN)



9



12



16



22



30



40



50



Stroke Length



a (mm)



45



50



60



65



70



90



100



Distance to the Bottom of Bar



h



(mm)



65



70



75



90



100



110



125



Hole Diameter



d (mm)



Capacity



As Shown on the Die Space Drawing



53



Section B SPECIFICATIONS 1. SPECIFICATIONS



1.4 WARRANTY This press machine is warranted in accordance with the "TERMS AND CONDITIONS" attached to the sales contract.



54



Section B SPECIFICATIONS 2. CHARTS



2. CHARTS The following charts are required in order to operate this press machine. An explanation of the charts and how they are to be used is contained in Section B SPECIFICATIONS, 5. ELEMENTS OF PRESSWORK (pg. 66). The authorized personnel must read this paragraph, understand the charts, and use the press machine within its capacity limits. An explanation of the allowable number of intermittent strokes per minute is contained in Section A, 4.4 ESSENTIAL OPERATION PRECAUTIONS (pg. 28). Please adhere to the precautions. (1) TONNAGE CURVE: See 5.3 STROKE-TONNAGE CURVE (pg. 67) for an explanation of the curve. (2) ALLOWABLE NUMBER OF INTERMITTENT S.P.M. DIAGRAM: See 5.5 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE (pg. 68) for an explanation of the diagram. The curve and diagrams are shown on the following pages.



55



Section B SPECIFICATIONS 2. CHARTS



>



See 5.3 STROKE-TONNAGE CURVE (pg. 67) for explanation of the curve.



Type (S)E



2000



NC1-2000(S)E



NC1-1500(S)E



Press capacity (kN)



1500



NC1-1100(S)E 1000



NC1-800(S)E NC1-600(S)E 500



NC1-450(S)E



0 40



30 20



10



0



Bottom dead center



Stroke (above bottom dead center) (mm)



Type (1)E, (1NL)E NC1-2500(1)E



Type (2)E, (2NL)E



NC1-2500(2)E (2NL)E



2000



NC1-2000(1)E (1NL)E



2000



NC1-2000(2)E (2NL)E



1500



NC1-1500(1)E (1NL)E



1500



NC1-1500(2)E (2NL)E



NC1-1100(1)E (1NL)E



1000



NC1-800(1)E (1NL)E NC1-600(1)E 500



NC1-450(1)E NC1-350(1)E



NC1-1100(2)E (2NL)E



1000



NC1-800(2)E (2NL)E NC1-600(2)E



500



NC1-450(2)E NC1-350(2)E



0



0 80



60



40



20



0



Bottom dead center



Stroke (above bottom dead center) (mm)



56



2500



Press capacity (kN)



Press capacity (kN)



2500



120 100 8 0



60



40



20



0



Bottom dead center



Stroke (above bottom dead center) (mm)



Section B SPECIFICATIONS 2. CHARTS



>



See 5.5 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE (pg. 68) for explanation of the curve. Type (S)E Allowable number of intermittent stokes (spm) 許容断続ストローク数(spm)



120



100



NC1 - 6 0 0,8 0 0 (S)E NC1 - 1 1 0 0 (S)E



80



NC1 - 1 50 0 (S)E



60



NC1 - 4 5 0 (S)E



40



20



NC1- 2 0 0 0 (S)E



0 0



20



40



60



80



100



120



140



160



180



200



Number of ス continuous strokes (spm) 連続 トロ ー ク 数 (spm ) Type (1)E



Allowable number of intermittent stokes (spm) 許容断続ストローク数(spm)



100 90 80



N C 1 - 8 0 0 (1 )E N C 1 - 1 1 0 0 (1 )E



70 60



N C 1 - 2 0 0 0 (1 )E



50



N C 1 - 3 5 0 (1 )E



40 30



N C 1 - 4 5 0 (1 )E



20



N C 1 - 6 0 0 (1 )E N C 1 - 2 5 0 0 (1 )E



10



N C 1 - 1 5 0 0 (1 )E



0 0



10



20



30



40



50



60



70



80



90



100 110 120 130 140 150 160 170



Number連of continuous strokes (spm) 続ス ト ロ ー ク 数 (sp m) (Continued on the next page)



57



Section B SPECIFICATIONS 2. CHARTS



(Continued) Type (1NL)E



Allowable number of intermittent stokes (spm) 許容断続ストローク数(spm)



80 70 60 NC1-1100(1NL)E



50 40 NC1-800(1NL)E



30 20



NC1-2000(1NL)E



10



NC1-1500(1NL)E



0 0



10



20



30



40



50



60



70



80



90



100



110



120



Number連続ストローク数(spm) of continuous strokes (spm) Type (2)E



Allowable number of intermittent stokes (spm) 許容断続ストローク数(spm)



90



80



70 N C 1 - 3 5 0 (2 )E



60 N C 1 - 8 0 0 (2 )E



50 N C 1 - 2 0 0 0 (2 )E



40



N C 1 - 4 5 0 (2 )E N C 1 - 2 5 0 0 (2 )E



30



N C1 - 1 1 0 0 (2 )E



20



N C 1 - 6 0 0 (2 )E



N C 1 - 1 5 0 0 (2 )E



10



0 0



10



20



30



40



50



60



70



80



90



100



110



連続 ト ロ ー ク 数 (spm ) Number of スcontinuous strokes (spm)



(Continued on the next page)



58



Section B SPECIFICATIONS 2. CHARTS



(Continued) Type (2NL)E



Allowable number of intermittent stokes (spm) 許容断続ストローク数(spm)



70



60



50



NC1-800(2NL)E



40 NC1-2000(2NL)E



30 NC1-1100(2NL)E



20



NC1-2500(2NL)E NC1-1500(2NL)E



10



0 0



10



20



30



40



50



60



70



80



Number連続ストローク数(spm) of continuous strokes (spm)



59



Section B SPECIFICATIONS 3. GENERAL DIMENSIONS



3. GENERAL DIMENSIONS The approximate dimensions of press machines with standard specifications are shown. There may be some variation between individual machines based on customer specifications.



AIDA



ｈ２



AIDA



ａ１ ａ３ ａ２



ｈ１



ｂ１ ｂ３ ｂ２



ａ４ ａ５ ａ６



ｂ４ ｂ５ ｂ６（*1） ｂ６（*2）



(*1): For NC1-2500 (*2): For NC1-350 to NC1-2000 (Continued on the next page)



60



Section B SPECIFICATIONS 3. GENERAL DIMENSIONS



(Continued)



Approximate Dimensions



Unit: mm NC1-350 NC1-450 NC1-600 Model (1)E (2)E (S)E (1)E (2)E (S)E (1)E (2)E Slide Dimensions a1xb1 380x300 380x300 410x340 410x340 410x340 480x400 480x400 480x400 Bolster a2xb2 730x310 730x380 810x360 810x360 810x440 870x400 870x400 870x520 Dimensions Bolster Thickness 100 100 110 110 110 130 130 130 Frame Gap b3 160 195 185 185 225 210 210 270 Inside Dimena3 458 458 499 499 499 560 560 560 sion of Frame Height of Top of Bolster 800 800 800 800 800 900 900 900 h1 above floor level Fixed Fixed 2295 2310 Overall Height h2 2195 2290 2275 2520 2505 2545 Variable Variable 2290 2355 Location of 720x 720x 745x 745x 745x 840x 840x 840x a4xb4 Anchor Bolts 845 905 910 910 950 1010 1010 1050 Installation 800x 800x 825x 825x 825x 940x 940x 940x a5xb5 Dimensions 1005 1065 1070 1070 1110 1175 1175 1215 Maximum 932x 932x 980x 980x 980x 1070x 1070x 1070x a6xb6 Dimensions 1365 1375 1490 1440 1430 1545 1545 1585 Approximate Machine 2.6t 2.6t 3.3t 3.3t 3.3t 4.2t 4.2t 4.2t Weight



Approximate Dimensions



Unit: mm NC1-800 NC1-1100 Model (S)E (1)E (1NL)E (2)E (2NL)E (S)E (1)E (1NL)E Slide Dimensions a1xb1 540x460 540x460 540x460 540x460 540x460 630x520 630x520 630x520 Bolster a2xb2 950x460 950x460 1000x460 950x600 1000x600 1070x520 1070x520 1100x520 Dimensions Bolster Thickness 140 140 140 140 140 155 155 155 Frame Gap b3 240 240 240 310 310 270 270 270 Inside Dimena3 624 624 640 624 640 666 666 666 sion of Frame Height of Top of Bolster 900 900 900 900 900 900 900 900 h1 above floor level Fixed Fixed 2755 2820 Overall Height h2 2695 2695 2810 2995 2995 3040 Variable Variable 2800 2860 Location of 920x 920x 980x 920x 980x 1040x 1040x 1070x a4xb4 Anchor Bolts 1160 1160 1210 1210 1290 1340 1340 1340 Installation 1020x 1020x 1060x 1020x 1060x 1140x 1140x 1150x a5xb5 Dimensions 1340 1340 1400 1390 1480 1550 1550 1560 Maximum 1150x 1150x 1243x 1150x 1243x 1270x 1270x 1343x a6xb6 Dimensions 1710 1710 1815 1760 1845 1920 1920 2050 Approximate Machine 8t 8t 9t 8t 9t 11t 11t 12.5t Weight



61



Section B SPECIFICATIONS 3. GENERAL DIMENSIONS



(Continued)



Approximate Dimensions



Unit: mm NC1-1100 NC1-1500 Model (2)E (2NL)E (S)E (1)E (1NL)E (2)E (2NL)E Slide Dimensions a1xb1 630x520 630x520 700x580 700x580 700x580 700x580 700x580 Bolster a2xb2 1070x680 1100x680 1170x600 1170x600 1250x600 1170x760 1250x760 Dimensions Bolster Thickness 155 155 165 165 165 165 165 Frame Gap b3 350 350 310 310 310 390 390 Inside Dimena3 666 666 726 726 766 726 766 sion of Frame Height of Top of Bolster 900 900 900 900 900 900 900 h1 above floor level Fixed Fixed 2955 3190 Overall Height h2 3025 3090 3090 3195 3280 Variable Variable 2995 3175 Location of 1040x 1070x 1140x 1140x 1200x 1140x 1200x a4xb4 Anchor Bolts 1440 1440 1560 1560 1640 1660 1740 Installation 1140x 1150x 1240x 1240x 1280x 1240x 1280x a5xb5 Dimensions 1650 1660 1800 1800 1890 1900 1990 Maximum 1270x 1343x 1370x 1370x 1503x 1370x 1503x a6xb6 Dimensions 2020 2025 2170 2170 2305 2270 2355 Approximate Machine 11t 12.5t 16t 16t 18.5t 16t 18.5t Weight



Approximate Dimensions



Unit: mm NC1-2000 NC1-2500 Model (S)E (1)E (1NL)E (2)E (2NL)E (1)E (2)E (2NL)E Slide Dimensions a1xb1 880x650 880x650 880x650 880x650 880x650 1100x730 1100x730 1100x730 Bolster a2xb2 1390x680 1390x680 1410x680 1390x840 1410x840 1750x760 1750x900 1780x900 Dimensions Bolster Thickness 180 180 180 180 180 180 180 180 Frame Gap b3 350 350 350 430 430 390 470 470 Inside Dimena3 906 906 906 906 906 1220 1220 1240 sion of Frame Height of Top of Bolster 1000 1000 1000 1000 1000 1100 1100 1100 h1 above floor level Overall Height



h2 3615



Location of a4xb4 Anchor Bolts Installation a5xb5 Dimensions Maximum a6xb6 Dimensions Approximate Machine Weight



62



3615



3710



3700



3795



4220



4375



4455



1360x 1890 1460x 2160 1590x 2530



1360x 1890 1460x 2160 1590x 2530



1360x 1890 1440x 2170 1763x 2585



1360x 2020 1460x 2290 1590x 2660



1360x 2020 1440x 2300 1763x 2665



1730x 1985 1850x 2275 1975x 2400



1730x 2135 1850x 2425 1975x 2550



1770x 2235 1890x 2525 2025x 2650



23t



23t



26.5t



23t



26.5t



28t



28t



33t



Section B SPECIFICATIONS 4. NAMES OF MAJOR COMPONENTS



4. NAMES OF MAJOR COMPONENTS The names of the major components are shown on the following pages.



63



Section B SPECIFICATIONS 4. NAMES OF MAJOR COMPONENTS



(Continued) • The layout of the components may vary by model, by options selected, and by user requirements. • When square brackets ([ ]) are shown below the name of a component, it is only applicable to the model given in the brackets. Check the actual press machine.



Cover of automation power take-out shaft hole [Types (S)E and (1)E] Slide gib Connecting rod



Hydraulic overload protector oil level gauge [NC1-350 and -450]



Die height indicator Slide knockout (option) Automatic grease pump



Reflector of presencesensing device (option)



AIDA



Phototransmitter/ photoreceiver (option)



Manual oil pump [For counterbalance (option, but, provided as standard on models (S)E and NC1-2500) and for cylinder-type die cushion (option)] [NC1-350~2000] [NC1-2500] Automation device (option)



Self-supporting operation panel (option)



Operation button box [NC1-350~2000]



Die cushion pressure gauge (option) Die cushion regulator (option)



Die cushion manual valve (option)



Operation button box [NC1-2500]



Ejector air connector



(Continued on the next page)



64



Section B SPECIFICATIONS 4. NAMES OF MAJOR COMPONENTS



(Continued)



Encoder for TCS (option)



Counterbalance Gear box oiling port (on the top of frame)



Suspension point oil level gauge



Frame Gear box oil level gauge



Slide Side cover



Operation panel Control panel Die protection receptacle (option) Balancer regulator [NC1-2000 and -2500] Balancer pressure gauge [NC1-2000 and -2500]



Bolster



Encoder for press machine (for detecting crank angles) [Types (S)E, (1)E and (2)E] Die cushion (inside the machine body) (option)



Main motor Clutch and brake



Clutch and brake solenoid valve Clutch pressure gauge [Types (S)E, (1)E and (2)E] Electric oil pump [Types (1NL)E and (2NL)E] Encoder for automatic slide adjustment (option)



Encoder for press machine (for detecting crank angles) [Types (1NL)E and (2NL)E] (To be installed on the back sida of flywheel)



Flywheel Clutch pressure gauge [Types (1NL)E and (2NL)E] Lubricating oil pressure gauge [Types (1NL)E and (2NL)E]



Hydraulic overload protector air pump Externally controlled breaker



Auto-drain filter



Electric oil pump [Type (S)E] Regulator Drain cock



65



Section B SPECIFICATIONS 5. ELEMENTS OF PRESSWORK



5. ELEMENTS OF PRESSWORK



IMPORTANT • The employer must observe the following before using and during use of the press machine. (1) Use the press machine within the specified tonnage capacity. When performing blanking, use the press machine with a pressing force lower than the value in “Limitation of the tonnage capacity for blanking” mentioned bellow. If used beyond the capacity, the slide, connecting rod, crankshaft, frame, and other parts can be damaged. (2) Use the press machine within the limits of the maximum allowable load indicated on the stroke-tonnage curve. If used beyond its allowable load, the slide drive-related parts, the clutch, and other components may break. (3) Use the press machine within its specified energy capacity (working energy). If used beyond its specified energy capacity, the main motor and other components may break. This press machine is used for the cold working of metal (including bending, drawing, and blanking). Be familiar with the three elements of the press machine capacity (tonnage capacity, torque capacity, and energy capacity) and the allowable number of intermittent strokes, so that you can perform press machine operations within the limits of the machine capacity. Follow the instructions given in Section A SAFETY, 4.4 ESSENTIAL OPERATION PRECAUTIONS (pg. 28) for the allowable number of intermittent strokes per minute.



5.1 TONNAGE CAPACITY (NOMINAL CAPACITY) The tonnage capacity of the press machine is the maximum allowable pressing force that can be generated by the press machine during presswork with the slide at a position lower than the nominal capacity generating point. However, in consideration of the following, the working load shall be lower than the tonnage capacity with an adequate margin. (1) Variation in thickness of the material. (2) Variation in tensile strength of the material. (3) Wear of cutting edges of the punch and die. (4) Change in the die lubrication condition. (5) Whether or not a stripper is provided on the die and the type when provided. When the presswork involves blanking, which can cause an impact load owing to breakthrough, the working load shall be lower than the value in “Limitation of the tonnage capacity for blanking” mentioned below. Limitation of the tonnage capacity for blanking Models NC1-(S)E, -(1)E, and (1NL)E .....70% of the tonnage capacity Models NC1-(2)E and (2NL)E ................60% of the tonnage capacity See INSTRUCTIONS FOR PRESS MACHINE USAGE in the appendix for countermeasures for breakthrough. The tonnage capacity has been calculated on the assumption that the load is uniformly distributed in an area consisting of 60% of the bolster area, and located in the center of the bolster. Avoid concentration of a heavy load in a small area, or off-center loading (the center of the resultant load is not aligned with that of the press machine). If excessive concentration of a load, or off-center loading is anticipated, contact our sales office shown on the last page of this instruction manual.



66



Section B SPECIFICATIONS 5. ELEMENTS OF PRESSWORK



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



5.3 STROKE-TONNAGE CURVE The stroke-tonnage curve shows the relationship between the slide position above bottom dead center of the strokes and the generated pressure (torque capacity). The example below indicates that a press machine having a capacity of I is capable of blanking work (1), but bending work (2) would exceed the capacity. Therefore, a press machine of the torque capacity shown by the curve I cannot perform the bending work (2). Note that the hydraulic overload protector works against the overload described in 5.1 TONNAGE CAPACITY (NOMINAL CAPACITY) (pg. 66) and does not work against the overload of torque capacity. When using a tonnage monitor as a torque capacity overload detector, consult our sales office (see the list at the end of this instruction manual).



(2)



Press capacity



Ⅰ



(1) Bottom dead center



Stroke (above bottom dead center)



Presswork and stroke-tonnage curve The above diagram is only an example. See 2. CHARTS (pg. 55) for the actual chart for your machine.



67



Section B SPECIFICATIONS 5. ELEMENTS OF PRESSWORK



5.4 ENERGY CAPACITY (WORKING ENERGY) Energy capacity represents the energy that can be used in one cycle of operation. The energy available in a single cycle is limited by the inertial energy of the flywheel, and the output of the main motor. Energy capacity specifications are given in the continuous working energy field in Section B SPECIFICATIONS, 1. SPECIFICATIONS (pg. 47). Calculate the working energy necessary for the presswork from the force needed for the work and the work stroke. Then, check that the calculated working energy is not more than the specified value. In particular, perform your presswork in full consideration of energy capacity when deep drawing or forming with the press machine rotated at a low speed. For further information about energy capacity, contact our sales office (see the end of this instruction manual).



5.5 ALLOWABLE NUMBER OF INTERMITTENT STROKES PER MINUTE



Allowable number of intermittent strokes (s.p.m.)



The allowable number of intermittent strokes per minute is the maximum number of strokes per minute at which the press machine can be run and stopped intermittently in the ONE STROKE operation, SINGLE operation, or INCH operation mode. The chart shown below is an example. In this example, when the press machine is set to continuous strokes of 81 spm and operated at intermittent strokes exceeding 50 spm, the clutch and brake performance will be degraded and personal injury or death can occur.



100 80 60 40 20 0



0



20



40



60



80



100



120



Number of continuous strokes (s.p.m.) Number of continuous strokes and allowable number of intermittent strokes The above diagram is only an example. See 2. CHARTS (pg. 55) for the actual chart for your machine.



68



Section B SPECIFICATIONS 5. ELEMENTS OF PRESSWORK



5.6 CAUTIONS CONCERNING DIE CUSHION USAGE



IMPORTANT • When the press machine is equipped with a die cushion (bellows type), the authorized personnel must use the press machine according to the following instructions. (1) Do not use the die cushion under an eccentric load. When the die cushion is used under an eccentric load, the die cushion pad will incline, and not only the accuracy of products and dies are adversely affected, but it can also cause excessive vibration, degradation of presswork accuracy, and die cushion breakage during presswork. As a countermeasure for eccentric loads, Top view of cushion pad divide the pad into four blocks--A, B, C and D-around the center of the pad as shown in the illustration on the left, and place one or more Ａ Ｂ cushion pins in each block. Determine the number of cushion pins to be used according to the working conditions, such as shape and Ｃ Ｄ size of products and load. Center in the direction of leftto-right and front-to-back.



(2) Do not use presswork oil and die coolant oils that fall under category (a) or (b) below. Oil resistance has been taken into consideration in the design of the bellows of the die cushion. The bellows, however, can break if certain kinds of oil or chemicals adhere to them. Referring to the following list, select suitable presswork oil and die coolant oil. (a) Adhesion of the following oils and chemicals must be strictly avoided Kerosine, oleic acid, xylene, methyl ethyl ketone, benzol, carbon tetrachloride, thinner, ether, and toluene (b) Oils and chemicals that need to be wiped off immediately after adhesion Diesel oil, paraffin, gasoline, turbine oil, machine oil, nitric acid (10%), acetone, turpentine, and grease (c) Adhesion of the following oils and chemicals causes no adverse affect Crude oil, silicon oil, brake oil, citric acid, glacial acetic acid, acetic acid, ammonia water (10%), caustic soda (10%), ethyl alcohol, methyl alcohol, hydrochloric acid (10%), and sulfuric acid (10%) Note that the above-mentioned categories of applicability may vary with operating conditions. Contact AIDA Service (see the end of this instruction manual) for details. (3) Close the die-cushion pin holes that are not in use with die-cushion pin hole covers. Otherwise, scraps may drop through the die cushion pin holes, causing the die cushion to break.



69



Section B SPECIFICATIONS 6. SPECIFICATION PLATE



6. SPECIFICATION PLATE 6.1 PRESS MACHINE SPECIFICATION PLATE The specification plate to the right is attached to the press machine. Check the description on the actual specification plate on your press machine. See Section A SAFETY, 6. WARNING PLATES (pg. 34) for the location of the specification plate.



AI DA AIDA ENGINEERING,LTD. SERIAL NO. JAPAN



MODEL CAPACITY SLIDE STROKE



kN mm spm mm mm mm mm kW MPa kg



STROKES PER MINUTE : NO LOAD



DIE HEIGHT SLIDE ADJUSTMENT SLIDE AREA : L.R×F.B BOLSTER AREA : L.R×F.B MAIN MOTOR REQUIRED AIR PRESSURE MAX. UPPER DIE WEIGHT



× ×



6.2 ELECTRICAL SPECIFICATION PLATE The electrical specification plate is attached to the control panel door. Check the description on the actual specification plate on your press machine.



CONTROL ENCLOSURE SOURCE



Φ



W A.C



V



A



Φ



W A.C



V



A



FREQUENCY CONTROL VOLTAGE A.C SERIES No.



Hz V D.C



AIDA ENGINEERING, LTD



70



V



MFD. 2715Se



Section C INSTALLATION



C



Section INSTALLATION



1. PREPARATION FOR INSTALLATION.................................................................. 73 1.1 FOUNDATION WORK .................................................................................................................... 73 1.2 INSTALLING SOLE PLATES.......................................................................................................... 73 1.3 PRELIMINARY INSTALLATION WORK ......................................................................................... 74 2. TRANSPORTATION AND INSTALLATION .......................................................... 75 2.1 INSTALLING WITH ANCHOR BOLTS............................................................................................ 75 2.2 INSTALLING WITH VIBRATION ISOLATORS ............................................................................... 76 3. CONNECTING THE AIR SUPPLY ....................................................................... 77 3.1 CONNECTING TO THE AIR SUPPLY ........................................................................................... 77 3.2 AIR CONSUMPTION...................................................................................................................... 77 4. CONNECTING TO THE POWER SOURCE ........................................................ 78 4.1 GROUNDING ................................................................................................................................. 78 4.2 CONNECTING TO THE POWER SOURCE AND GROUNDING .................................................. 79 4.3 WIRING CAPACITY........................................................................................................................ 79 5. INITIAL LUBRICATION (OIL SERVICING) .......................................................... 80 6. POST-INSTALLATION CHECK ............................................................................ 81



71



Section C INSTALLATION



72



Section C INSTALLATION 1. PREPARATION FOR INSTALLATION



1. PREPARATION FOR INSTALLATION 1.1 FOUNDATION WORK



IMPORTANT • Be sure to take the bearing capacity of the soil into account prior to foundation work. Otherwise, the press machine may partially sink. • Be sure to reinforce the concrete of the base section on which the press machine is to be installed with reinforcing bars. Otherwise, the foundation concrete may be broken. (1) Have a specialist to conduct foundation work in advance according to the foundation drawings provided by AIDA. (2) When the ground is soft, use reinforcing bars. Also, strengthen concrete accordingly by increasing the thickness, etc. (3) For the weight of the press machine, see the foundation drawings submitted by AIDA.



1.2 INSTALLING SOLE PLATES 1.2.1 Installation Using Anchor Bolts



See (pg. 74). At least 15 days before the press machine is brought to the installation site, install the sole plates according to the following procedure: (1) Place sole plates (3) on the specified positions indicated in the foundation drawing. (2) Screw leveling bolts (4) into the sole plates. (3) Adjust the sole plates with the leveling bolts so that the installation accuracy is within the tolerances shown below. Levelness



0.5mm or less per m



Height difference between plates 3mm or less (4) Inject a type of mortar that will not shrink (non-shrinkage grout) (7) under the sole plates. Be sure to throw mortar so that it is in good contact with the bottom face of the sole plates. (5) Check the installation accuracy of the sole plates again. 1.2.2 Installation Using Vibration Isolators



See Section C INSTALLATION, 1.3.2 Installing with Vibration Isolators (pg. 74).



NOTE



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



73



Section C INSTALLATION 1. PREPARATION FOR INSTALLATION



1.3 PRELIMINARY INSTALLATION WORK 1.3.1 Installing with Anchor Bolts



(1) Remove the concrete forms mounted on foundation hole for the anchor bolt (1). (2) Cut leveling bolt (4) at sole plate (3) so that the bolt does not project from the top face of the plate.



(1) Anchor bolt (foundation bolt) (option) (2) Shim (3) Sole plate (to be provided by customer) (4) Leveling bolt (to be provided by the user) (5) Press machine frame foot (6) Mortar (non-shrink grout) (Pour mortar after leveling the press machine.) (7) Mortar for sole plate (non-shrink grout) (8) Mortar at the time of installation (non-shrink grout) (9) Concrete before installation



1.3.2 Installing with Vibration Isolators



The schematic drawing illustrates an installation using a standard vibration isolator (option). Check whether or not the sole plates are required by the foundation drawing. (1) Smooth the concrete at the location where the vibration isolator or sole plates are to be installed. Differences in height between the sole plates at four installing locations must not exceed 4 mm. (2) Place the sole plates on top of the smoothed concrete. The drawing illustrates the standard vibration isolator. When you need further information on the vibration isolator, contact our sales office (see the end of this instruction manual).



(4) Bolt (3) Nut (2) Washer (1) Vibration isolator



74



Section C INSTALLATION 2. TRANSPORTATION AND INSTALLATION



2. TRANSPORTATION AND INSTALLATION For transportation, lifting, and installation, follow the precautions described in Section A SAFETY, 4.3 ESSENTIAL INSTALLATION PRECAUTIONS (pg. 27).



IMPORTANT • Place anchor bolts perpendicularly. If the anchor bolt is set in an inclined position, poor tightening or chipping of the bolt can result.



2.1 INSTALLING WITH ANCHOR BOLTS See (pg. 74). (1) Unpack the press machine and wash the machined surfaces with mineral cleaning oil to remove the rust inhibitor. Also clean the bottom of the frame foot. (2) Install the press machine at the predetermined location. (3) Attach a washer and double nut to the anchor bolt (1). Insert them into the foundation hole through the hole in the frame foot (5) of the press machine. (4) Place a shim plate (2) between the frame foot of the press machine and the sole plate (3) to adjust the accuracy of installation of the press machine as described below: Levelness of the bolster top face



0.03mm or less per m



(5) Pour mortar (non-shrink grout) (8) into the foundation hole. At this time, confirm that the anchor bolt does not tilt from the perpendicular position. (6) When the mortar (non-shrink grout) has set to a sufficient hardness, tighten the double nut of the anchor bolt. Fully tighten the lower nut of the double nut first. Then, tighten the upper unit and lock the double nut. (7) Recheck the accuracy of installation of the press machine. (8) Mound the mortar (non-shrink grout) (6) on the frame foot of the press machine so that the shim plate does not protrude through the surface of the mortar.



NOTE



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



75



Section C INSTALLATION 2. TRANSPORTATION AND INSTALLATION



2.2 INSTALLING WITH VIBRATION ISOLATORS See (pg. 74). (1) Unpack the press machine and wash the machined surfaces with mineral cleaning oil to remove the rust inhibitor. Also clean the bottom of the frame foot. (2) Install the vibration isolator (1) at the predetermined location. At this time, remove the bolt (4) from the vibration isolator. (3) Place the press machine on the vibration isolator. (4) Insert the bolt that has been removed in the above-mentioned step (2) through the hole in the frame foot of the press machine, and screw in the vibration isolator. (5) Further, screw in the bolt to adjust the accuracy of the installation of the press machine as described below: Levelness of the bolster top face



0.03mm or less per m



After the adjustment, confirm that there is no clearance between the press machine and the vibration isolators at the four locations (i.e., that they support the press machine). (6) Fully tighten nut (3). (7) Recheck the accuracy of the installation of the press machine. (8) If the press machine moves out of position due to presswork, take appropriate measures to prevent it.



76



Section C INSTALLATION 3. CONNECTING THE AIR SUPPLY



3. CONNECTING THE AIR SUPPLY



CAUTION • Supply dry and clean compressed air that contains no dust or sludge. If air containing dust or sludge is used, the solenoid valve may malfunction or rust may accumulate in the cylinder, leading to an accident. • Examine the air consumption of the ejector, automation equipment (option), and other equipment, and then determine the capacity of your compressed air source by adding the above-mentioned air consumption to the air consumption stated in this instruction manual. If the supply of compressed air is inadequate, problems with the press machine may occur.



3.1 CONNECTING TO THE AIR SUPPLY (1) Close the stop valve on the air supply inlet. Connect the air supply inlet to your air line. Supply air pressure: 0.5 - 0.7 MPa (2) When the length of piping between the air source and the press machine exceeds 5 m, use 3/4B pipe.



Stop valve Air supply inlet size 1/2B



3.2 AIR CONSUMPTION NC1-350 NC1-600 NC1-800 NC1-1100 NC1-1500 NC1-2000 NC1-2500 NC1-450



Press Machine Model Balance Tank Capacity Air Consumption



(L)



5.1



10.6



16.6



33.2



47.2



98.8



226



(L/min.)



3.9



5



6



5



7.3



7.3



16.5



Air Compressor Capacity (kW)



NOTE



1.5



• The air consumption amounts given above indicate air consumption when the supplied air pressure is 0.5 MPa. • The air consumption and compressor capacity amounts given above indicate the values when only the clutch has been taken into account during operation at the allowable number of intermittent strokes.



77



Section C INSTALLATION 4. CONNECTING TO THE POWER SOURCE



4. CONNECTING TO THE POWER SOURCE 4.1 GROUNDING



CAUTION • Ground the machine properly by using a specialized contractor or other suitable means. Do not connect grounding cables to the steel frames or the steel props of the building as an alternative means of grounding. • Connect a grounding cable to each component as shown below in the "Good example." Do not connect grounding cables to a common cable as shown below in the "Bad example." Control panel A



Control panel B



Grounding



Good example



Control panel C



Control panel A



Control panel B



Control panel C



Grounding



Bad example



• The grounding position should be as near to the control panels as possible. If the above-mentioned caution is not followed, noise can be generated in the signal wires or the accessories, and as a result, improper operation or failure of the machine can be caused. Further, an injury to or death of the operator can be caused as a result of unexpected erroneous operation of the machine or by electric shock.



78



Section C INSTALLATION 4. CONNECTING TO THE POWER SOURCE



4.2 CONNECTING TO THE POWER SOURCE AND GROUNDING



IMPORTANT • If the L1 (R), L2 (S), and L3 (T) phases are wired incorrectly, the flywheel will rotate in the opposite direction of that shown on the nameplate. • On an inverter-controlled press machine, the direction of rotation of the flywheel will not change even if the wiring of the L1 (R), L2 (S), and L3 (T) phases is reversed. However, please be aware that the direction of rotation of the other motors will be reversed. (1) Follow Section A SAFETY, 4.3 ESSENTIAL INSTALLATION PRECAUTIONS (pg. 27). (2) Provide a power source switch in your plant to turn the power to this press machine on and off. When a ground fault breaker is used with an inverter-controlled press machine, use a ground fault breaker that is compatible with the inverter to prevent malfunctions due to harmonic leakage current. This power source switch is hereafter referred to as your power source. (3) Turn your power source OFF. (4) Install a power supply cable from your power source to the terminal block of the press machine. Be sure to connect the L1 (R), L2 (S), and L3 (T) phases correctly. When the press machine is equipped with a fuseless circuit breaker (option) in the main circuit, connect the power supply cable to the primary terminal for the fuseless circuit breaker on the main circuit located in the lower left inside the control panel. (5) Connect your factory grounding wire to the grounding terminal of the press machine. Power source to the press machine



Control panel Power source connecting opening for the machine that has a fuseless breaker for main circuit



R S T



Terminal block



Terminal block Power supply connector



Grounding terminal



To your power source



4.3 WIRING CAPACITY -NC1Main Motor Capacity



(kW) 5.5



Power Sup- Current When Main (A) 40 ply Voltage Motor is Fully Loaded 200 V Grounding Wire (mm2) 5.5 Power Sup- Current When Main (A) 22 ply Voltage Motor is Fully Loaded 400 V Grounding Wire (mm2) 3.5



7.5



11



15



22



30



37



45



60



75



100



135



160



8



14



14



22



22



22



25



30



37



50



67



85



5.5



5.5



8



14



14



14



Main Breaker Capacity Capacity is described on the electrical circuit drawings The above-mentioned values are for a press machine of standard specifications and subject to change according to the actual specifications. See the electrical circuit drawings for details.



79



Section C INSTALLATION 5. INITIAL LUBRICATION (OIL SERVICING)



5. INITIAL LUBRICATION (OIL SERVICING)



CAUTION • Service the press machine and equipment with lubricating oil, hydraulic fluid, and grease before operating them. Operating the press machine before oil servicing may cause seizure or breakage of the press machine. • In order to ensure safe handling of lubricating oils, hydraulic fluid, grease, etc., obtain the product safety data sheets prepared by the lubrication manufacturer from the lubrication supplier. Take proper measures in accordance with the information on the data sheets. Particularly, pay attention to first-aid action and actions in case of fire and spillage of these materials. • Be careful not to spill oil. Wipe up spilled oil immediately. If oil comes in contact with the control equipment, malfunctions may be caused due to poor insulation. • Be sure to use a ladder and platform with enhanced safety when working at high elevations to supply oil to the gear box oil bath and the slide point. Do not use any part of the press machine as a scaffold. In addition, be sure to use a hook-type safety device (such as a lifeline) to prevent falls when working at high elevations. After installation, perform initial oil servicing (oil supply) at the following points. Prepare the appropriate oil in advance (refer to Section E MAINTENANCE, 2.2 TYPES AND AMOUNTS OF OIL (pg. 194)). Lubrication Procedure



Reference Page



Gear Box Oil Bath



Remove the rubber cap from the oiling port on the top of the frame. Refill with fresh oil through the oiling port until the oil level reaches the middle level of the oil gauge attached to the side face of the frame.



196



Slide Suspension Point



Remove the plastic plug from the oiling port in the slide. Refill with fresh oil through the oiling port until the oil level reaches the middle level of the oil gauge attached to the side face of the slide.



196



Manual Oil Pump (option, but, provided as standard on models (S)E and NC1-2500)



Open the lid of the oil pump and refill with fresh oil until the oil level reaches the upper limit of the pump.



196 224



Die Lifter Oil Reservoir (option) which is also used as a die clamper oil reservoir (option)



Remove the cover from the oil reservoir unit and detach the plastic plug from the oiling port on the top face of the oil reservoir. Refill with fresh oil through the oiling port until the oil level reaches the upper level of the oil gauge attached to the side face of the oil reservoir.



196



Automatic Grease Pump



Refill the grease pump with AIDA standard grease no. 0.



221



Initial Oil Servicing Point



For any options other than those described above, see the applicable instruction manual.



80



Section C INSTALLATION 6. POST-INSTALLATION CHECK



6. POST-INSTALLATION CHECK The following items must be checked by a technician after installation. After making sure that all the check items meet the evaluation criteria, proceed to the Pre-Work Check (See pg. 120.) and the Routine Inspection (See pg. 121.) explained in Section D OPERATION. Items to be Checked after Installation 1 Check the oil level of the: • Gear box oil bath • Slide suspension point section • Manual oil pump (option, but, provided as standard on models (S)E and NC1-2500) • Connecting rod oil-tight (*1) • Hydraulic overload protector (*1) • Die lifter oil reservoir (option) • Die clamper oil reservoir (option) • Clutch and brake (*1) • Automatic grease pump (*1): Delivered with oil filled and shielded and requiring no initial lubrication. 2 Check the supplied air pressure Slowly open the stop valve on the air supply inlet. • Check the clutch pressure gauge needle: It should remain in the white (or green) zone of the scale. 3 Check the power supply (to be done by an electrician). • Check if the grounding conductor has been wired. Turn your power source ON. • Confirm that the supply power voltage matches the value stamped on the SOURCE column in the electrical specification plate. • Confirm that the POWER light on the operation panel comes on.



Evaluation Criteria



Action



It is within the specified range indicated on the oil level gauge or container.



Service with oil. Operate the manual oil pump for 10 strokes after checking the items listed to the left.



It is within the speci- Supply air presfied zone of the scale. sure must be 0.5 - 0.7 MPa.



Visual check



Do the wiring.



To be as stated in the Examine and electrical specificainspect the power tion. supply. Visual check



81



Section C INSTALLATION 6. POST-INSTALLATION CHECK



82



Section D OPERATION



D



Section OPERATION



1. OPERATION DEVICES. . . . . . . . . . . . . . 85 1.1 MAIN OPERATION PANEL . . . . . . . . . . . . . . . . . 85 1.2 OPERATION BUTTON BOX. . . . . . . . . . . . . . . . . 86 1.3 FUNCTION AND OPERATION. . . . . . . . . . . . . . . 86 1.4 OPERATION OF KEY SWITCHES. . . . . . . . . . . . 92 2. THE OPERATOR INTERFACE TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 2.1 SCREEN CONFIGURATION . . . . . . . . . . . . . . . . 94 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 2.3 DISPLAYS APPEARING IN WINDOWS. . . . . . . . 97 2.4 THE RUN SCREEN . . . . . . . . . . . . . . . . . . . . . . . 98 2.5 THE DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . 101 2.6 THE SET UP SCREEN. . . . . . . . . . . . . . . . . . . . 104 2.7 THE MAINTENANCE SCREEN . . . . . . . . . . . . . 108 2.8 THE RECIPES (DATABANK) SCREEN . . . . . . . 113 3. OPERATION . . . . . . . . . . . . . . . . . . . . . 118 3.1 PRE-WORK CHECK. . . . . . . . . . . . . . . . . . . . . . 120 3.2 ROUTINE INSPECTION AND OPERATION . . . 121 3.3 OPERATION MODES. . . . . . . . . . . . . . . . . . . . . 125 3.4 SAFETY DEVICES AND OPERATION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 3.5 OPERATING GUARDS (OPTION) . . . . . . . . . . . 129 4. PROCEDURE WHEN COMPLETING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 5. RESETTING FAULTS . . . . . . . . . . . . . . 131 5.1 INTERLOCK INFORMATION MESSAGE LIST . 132 5.2 FAULT INFORMATION MESSAGE LIST . . . . . . 137 5.3 HYDRAULIC OVERLOADS . . . . . . . . . . . . . . . . 142 5.4 OVERRUNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 5.5 WHEN THE EMERGENCY STOP BUTTON HAS BEEN PUSHED. . . . . . . . . . . . . . . . . . . . . . . . . . 146 5.6 WHEN THE EXTERNALLY CONTROLLED BREAKER IS ACTUATED. . . . . . . . . . . . . . . . . . 147



5.7 WHEN THE GROUND FAULT BREAKER IS ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 5.8 WHEN THE CLUTCH & BRAKE SOLENOID VALVE MONITOR IS ACTUATED . . . . . . . . . . . . . . . . . 147 5.9 WHEN A THERMAL RELAY HAS TRIPPED. . . 148 5.10 STICKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150



6. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 151 6.1 SLIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 151 6.2 COUNTERBALANCE CAPACITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 6.4 MECHANICAL KNOCKOUT ADJUSTMENT (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 6.5 HOLP LOW PRESSURE SETTING DEVICE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 6.6 SETTING TIMING SWITCHES . . . . . . . . . . . . . 158 7. CHANGING DIES. . . . . . . . . . . . . . . . . . 161 7.1 WHEN USING AIDA EQUIPMENT . . . . . . . . . . 163 7.2 WHEN USING PASCAL EQUIPMENT . . . . . . . 170 7.3 MECHANICAL DIE LIFTER (OPTION) . . . . . . . 177 7.4 WHEN USING A SHANK. . . . . . . . . . . . . . . . . . 178 8. OPERATION OF AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 8.1 EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 8.2 SELECTING THE EXTERNAL OPERATION . . 183 8.3 AUTOMATION DEVICES (OPTION) . . . . . . . . . 183 8.4 SELECTING THE PRESET STOP POSITION (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 8.5 DIE PROTECTION . . . . . . . . . . . . . . . . . . . . . . 184 8.6 MATERIAL END DETECTION DEVICE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184



83



Section D OPERATION



84



Section D OPERATION 1. OPERATION DEVICES



1. OPERATION DEVICES • The following illustrations show the operation panel layout under standard configuration. The layout for your operation panel may be different due to customer requests, etc. See the operation panel layout drawings in Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings for the location of the switches related to any optional devices that are installed on your machine that are not shown in the illustrations given below. • The numbers shown in the illustrations correspond to the explanation numbers used in 1.3 FUNCTION AND OPERATION (starting on page 86).



1.1 MAIN OPERATION PANEL



1



5



2



3



4



6 7 REV.



8



13



12



9



11



10



14 AIDA



ENGINEERING,LTD.



85



Section D OPERATION 1. OPERATION DEVICES



1.2 OPERATION BUTTON BOX



21



22



23



AH MASTER OFF SLIDE ADJUST OFF ON EXTERNAL BUTTON OFF ON



25



30



26



27



24



INCH



31



21



OFF SINGLE



28



29



1.3 FUNCTION AND OPERATION Before beginning press machine operation, gain a thorough understanding of the contents of sections 3. OPERATION (pg. 118) through 8. OPERATION OF AUXILIARY EQUIPMENT (pg. 182) in Section D OPERATION. 1.3.1 Main Operation Panel



1



86



Crank Angle Indicator



• Displays the crank angle. 0° corresponds to top dead center and 180° corresponds to bottom dead center.



2



POWER Light (White) • When your power source is turned on, this light comes on to indicate that the power is supplied to the control circuits and power circuits.



3



MAIN MOTOR RUN Light (Green) • Lights up while the main motor is running in the “FWD.” operation mode. It flashes while the main motor is running in the “REV.” operation mode.



4



RUN OK Light (Green) • It lights up to indicate that the press machine is ready to run. The slide can be operated by pushing the RUN buttons.



Section D OPERATION 1. OPERATION DEVICES



5



DIE AREA LIGHT Switch (Option) • When the switch is set to "|" (ON), the lights go on.



6



LUBRICATING OIL Button (Green Light) [Types (S)E, (1NL)E, and (2NL)E] • When this button is pushed, the lubricating oil pump is activated and the light comes on. The main motor cannot be started unless this button has been pushed. • If the press machine power is turned on again, the pump cannot be started until the lubricating oil pressure drops to the predetermined level. Wait for approximately ten seconds, then restart the pump.



7



CONTROL POWER Key Switch • When the switch is set to "|" (ON), the press machine can be operated using the switches on the operation panel and operation button box. In addition, the automatic grease pump operates for approximately ten seconds. • When the control power source is turned off while the main motor is rotating, turn the power on again after visually confirming that the flywheel has stopped its rotation. If the power is turned on again immediately after turning it off, an inverter fault may be caused. In this case, push the RESET button to reset. • When the switch is set to "O" (OFF), the key can be removed. If the key is removed from the key switch it should be controlled by authorized personnel.



8



Guard “O” (DISABLE)•“|” (ACTIVE) Key Switch (Option) • Used to switch the status of the front guard as a safety device between DISABLE and ACTIVE. Set the switch to “|” (ACTIVE) under normal circumstances. • Operating conditions vary depending on the status of the switch. See Section D OPERATION, 3.4 SAFETY DEVICES AND OPERATION CONDITIONS (pg. 126) for details. • The key can be removed anywhere. If the key is removed from the key switch it should be controlled by authorized personnel.



9



" " (PRESET STOP POSITION)•" " (TOP DEAD CENTER) Stop Position Switch (Option) • Used to change the preset stop position. See Section D OPERATION, 8.4 SELECTING THE PRESET STOP POSITION (OPTION) (pg. 184) for details.



87



Section D OPERATION 1. OPERATION DEVICES



10



(OFF) REV.



(REV.)



(FWD.)



Main Motor REV.•OFF•FWD. Switch (Option) “REV.”: Set the switch in this position to unstick the slide, etc. See Section D OPERATION, 5.10 STICKING (pg. 150) for details. “OFF”: Set the switch to this position to keep the main motor at rest. “FWD.”: Set the switch to this position for normal operation of the press machine.



11



MAIN MOTOR START Button • When the button is pushed, the main motor starts. When the button is released while the main motor is rotating in the reverse direction, the power to the main motor is turned off and rotates by inertia. • If the slide is not activated for approximately 15 minutes while the main motor is running, the power to the main motor is automatically turned off and the main motor speed decreases until the motor stops.



12



MAIN MOTOR STOP Button • Used to stop the main motor.



13



Data Write “O” (OFF)•“|” (ON) Key Switch • When the switch is set to “|” (ON) (i.e., enabled), data such as timing switch angle settings and databank settings can be inputted. • See Section D OPERATION, 2.5 THE DATA SCREEN (pg. 101) and 2.8 THE RECIPES (DATABANK) SCREEN (pg. 113) for an explanation of data writing. • When the switch is set to "O" (OFF), the key can be removed. If the key is removed from the key switch it should be controlled by authorized personnel.



14 Operator Interface Terminal



15 ~20



• See Section D OPERATION, 2. THE OPERATOR INTERFACE TERMINAL (pg. 93). • The operator interface terminal shows information required for operation. Data is programmed through the operator interface terminal. (Spares)



1.3.2 Operation Button Box



21 RUN Buttons



88



• When the two RUN buttons are pushed simultaneously with both hands, the slide starts in the selected operation mode.



Section D OPERATION 1. OPERATION DEVICES



22 TOP STOP (PRESET STOP) Button (Option)



23 EMERGENCY STOP Button



24 RESET Button



25



• Push this button during operation to immediately stop slide motion. • When the slide has stopped due to a fault, correct the cause of the fault and then push this button. • If the press machine is equipped with optional optical presence-sensing devices or guards, in some cases pushing this button will reset these devices as well.



AH MASTER OFF ON



AH MASTER Switch (Option) • When the switch is set to ON, the press machine slide is started by a start signal from the AH (auto-hand). • The key can be removed anywhere. If the key is removed from the key switch it should be controlled by authorized personnel.



OFF



EXTERNAL•OFF•BUTTON Switch • Used to select how to start the press machine, i.e., external operation or RUN buttons. See 8.2 SELECTING THE EXTERNAL OPERATION (pg. 183). • The key can be removed anywhere. If the key is removed from the key switch it should be controlled by authorized personnel.



26 EXTERNAL



27



• When this button is pushed while the press machine is running in CONT. mode, the slide will stop at the preset stop position.



BUTTON



SLIDE ADJUST OFF ON



28 INCH



OFF SINGLE



SLIDE ADJUST Switch • Set this switch to ON to select the slide adjustment mode. (See 6.1 SLIDE ADJUSTMENT (pg. 151).) The SLIDE ADJUSTMENT screen will be displayed on the operator interface terminal (See pg. 105.). Press machine operation is disabled in the slide adjustment mode. • This switch is enabled only on the RUN screen and SET UP screen. OPERATION SELECT Key Switch • Used to select the operation mode. (See pg. 125.) • When the switch is set to OFF, the slide will not activate even if the RUN buttons are pushed. • See 1.4 OPERATION OF KEY SWITCHES (pg. 92) for an explanation of key switch operation. If the key is removed from the key switch it should be controlled by authorized personnel.



89



Section D OPERATION 1. OPERATION DEVICES



29



Left Button (Green Light): • UP/UNCLAMP/RET. Button • CONT. ARMING Button (Option) • Ejector and Automation Device (Option) TEST Button Right Button (Orange Light): • DOWN/CLAMP/ADV. Button • Automation Device (Option) TEST RESET Button • Flashing Light: The operation is enabled. (When the button is pushed, the corresponding device is activated) Steadily Lit: The operation has been completed. • These buttons are used for various operations such as slide adjustment (See pg. 151.) and die clamper or die lifter (option) operation (See pg. 161.). • When the OPERATION SELECT switch is set to CONT. (option), the UP/UNCLAMP/RET. button (green) located at the left flashes. When the button is pushed, the light turns on. When the two RUN buttons are pushed simultaneously with both hands within five seconds after the light is steadily lit, CONT. mode operations will be activated. If CONT. mode operations are not activated within five seconds after the light is steadily lit, the light will begin flashing again. Push the button again to make the button light be steadily lit.



90



30



BUTTON BOX INTERLOCK Receptacle (This is not provided on press machines with a stand-type operation button box.) • With the operation button box placed in the standard position (i.e., attached to the front face of the bolster), insert the plug into the receptacle. Press machine operation is disabled unless the plug is properly inserted into the receptacle. • When rotating the operation button box, be sure to first remove the plug.



31



EXTERNAL OPERATION Receptacle • To perform external operation, set the EXTERNAL•OFF•BUTTON switch to EXTERNAL and use the receptacle. • When the external operation is not performed, insert the cap into the receptacle.



32 ~40



(Spares)



Section D OPERATION 1. OPERATION DEVICES



1.3.3 Optional Switches



See the operation panel layout drawings in Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings or the actual machine for the location of the switches shown below.



41



42



43



PRE. SENSING DEVICE OFF ON



PRE. SENSING DEVICE Key Switch (Option) • Turns the presence-sensing device ON (i.e., enabled) and OFF (i.e., disabled). Set the switch to ON (i.e., enabled) under normal circumstances. • Operating conditions vary depending on the status of the switch. See Section D OPERATION, 3.4 SAFETY DEVICES AND OPERATION CONDITIONS (pg. 126) for details. • When ON/OFF switch is not provided on the operation panel of the optical presence sensing device (as in the case of a device manufactured by RIKEN OPTIC RPH4*N), this switch is provided on the side face of the control panel or on the operation panel. • The key can be removed anywhere. If the key is removed from the key switch it should be controlled by authorized personnel.



MATERIAL END OFF ON



MATERIAL END Switch (Option) • Turns the material-end detection device ON and OFF. See Section D OPERATION, 8.6 MATERIAL END DETECTION DEVICE (OPTION) (pg. 184).



EJECTOR 3 OFF ON



EJECTOR 4 OFF ON



EJECTOR Selector Button (If the press machine is equipped with three or more ejectors.) • When this selector ring is set to ON, air blows out of the ejector air connector in synchronization with the slide stroke. (See 8.1 EJECTORS (pg. 182)) • See Section D OPERATION, 2.4 THE RUN SCREEN (pg. 98) for selecting modes of the EJECTOR 1 and EJECTOR 2.



91



Section D OPERATION 1. OPERATION DEVICES



1.4 OPERATION OF KEY SWITCHES The keys for key switches must be stored and controlled by authorized personnel. (See Section A SAFETY, 4.4 ESSENTIAL OPERATION PRECAUTIONS (pg. 28).) 1.4.1 OPERATION SELECT Switch



(1) If the key is turned counterclockwise, the key can be removed. The set position of the switch cannot be changed after the key is removed. (2) If the key is inserted and turned clockwise, the key cannot be removed. You can change the selected position of the switch. （１）



（２）



1.4.2 CONTROL POWER Switch



（１）



NOTE



92



（２）



(1) If the key is turned counterclockwise to "O" (OFF), the key can be removed. The switch cannot be set to "|" (ON) after the key is removed. (2) If the key is inserted and turned clockwise to "|" (ON), the key cannot be removed.



• Two keys are provided for each switch. If you lose a key, contact AIDA Service (see the end of this instruction manual) and inform them of the switch model.



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2. THE OPERATOR INTERFACE TERMINAL



IMPORTANT • Do not press down hard on the operator interface terminal or press it with hard objects such as a pen. Doing so could break the liquid crystal display. The operator interface terminal is a touchscreen system which is operated by lightly pressing the screen with your fingers. The operator interface terminal displays information relating to interlocks, and displays data, on-screen touchbuttons for selecting modes, a numeric keypad for setting data, and onscreen touchbuttons for changing screens. Operations such as starting and stopping which are directly related to press machine actions are not performed using the on-screen touchbuttons, but rather performed by operating the buttons arranged on the operation panel or the operation button box. In such cases, the functions of these buttons will be displayed on the operator interface terminal. The information shown on the screens contained in this instruction manual, such as numeric values, messages, etc., are provided as examples. The actual screens on your press machine may be different.



93



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.1 SCREEN CONFIGURATION Initial screen



Displayed for five seconds. Then the screen changes over to the RUN screen. When turning the SLIDE ADJUST switch ON / OFF. SLIDE ADJUSTMENT



RUN (p.98)



AUTO. SLIDE ADJUSTMENT*



COUNTER SETTING D.H. SET TARGET VALUE* EJECTOR, AUTOMATION DEVICE*, DIE PROTECTION ON/OFF



DATA (p.101) CAM 1~8



CAM 1~8 CHANGE



CAM 9~16



CAM 9~16 CHANGE



CAM 17~24



CAM 17~24 CHANGE (*1)



GAIN CAM 5~8



GAIN CAM 5~8 CHANGE



GAIN CAM 9~12



GAIN CAM 9~12 CHANGE



DIE PROTECTION



DIE PROTECTION CHANGE



D.H.: Die height



Go to the RUN screen (*1): Cam setting changes may be disabled when the cam setting is manufacturer-designated. *: Option



When turning the SLIDE ADJUST switch ON / OFF. SLIDE ADJUSTMENT



SET UP (p.104) SET UP 1



AUTO. SLIDE ADJUSTMENT*



UPPER DIE CLAMPER*



D.H. SET TARGET VALUE *



LOWER DIE CLAMPER*



Go to the RUN screen



DIE LIFTER*



SET UP 2



:Press machine operation is enabled.



FEED BAR CLAMPER* DIMENSION*



:Press machine operation in only the MICRO INCH and INCH modes is enabled.



FEED BAR JOINT*



MAINTENANCE (p.108)



CL&BR S.V. TEST MAINTENANCE COUNTER & HOUR METER MPC I/O MONITOR



Go to the MAINTENANCE screen



MPC DATA MONITOR



ADDRESS ENTRY WINDOW



DIAGNOSIS/FAULT LIST



FAULT HISTORY



OPTION SET UP



RECIPES (DATABANK) (p.113)



:Set the Data Write “O” (OFF)•“|” (ON) Key Switch (pg. 88) to "|" (ON).



PRODUCT LIST p1•p2 UPLOAD DATA COPY



MPC: Multiprocessing press controller EDIT DATA p1~p7 CLEAR DATA EDIT NAME p1•p2 DOWNLOAD



94



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS The operation and display elements found on all screens is described below: (3) (2)



(4)



(5)



(6) (1) (1) Function Touchbuttons These function touchbuttons are used to change the screen mode. The currently active mode is highlighted. RUN (Operation): ...........Used to run the press machine. (See 2.4 THE RUN SCREEN (pg. 98).) DATA (Settings): ............Used to set data on cams 1 to 24 and the gain cam, and to make die protection settings. (See 2.5 THE DATA SCREEN (pg. 101).) SET UP (Setup): ...........Used to perform slide adjustment and operate die clampers (option), die lifters (option), and the feed bar and related devices (option). (See 2.6 THE SET UP SCREEN (pg. 104).) MAINT. (Maintenance): ..Used to activate various monitoring functions and to display fault and error histories. (See 2.7 THE MAINTENANCE SCREEN (pg. 108).) RECIPES (Databank): ..Used to make and transfer databank data settings, etc. (See 2.8 THE RECIPES (DATABANK) SCREEN (pg. 113).) (2) Currently Selected Mode Display The screen mode that is currently selected is displayed. (3) Operation Selection Display (a) Displays the selected starting method and location. Display Specifics: EXTERNAL, OFF, RUN BTNS (RUN buttons). (b) Displays the mode selected on the OPERATION SELECT switch. (c) If the press machine is equipped with TCV or TCV-T, it displays the clamp/unclamp status. If the press machine is equipped with a feeder, it displays the selected master. (Option) (d) If the press machine is equipped with TCV-T, it displays the selected 2-dimension or 3-dimension setting., and for a press machine equipped with TCE or AH, it displays the selected master. (Option)



a



b



c



d



(Continued on the next page)



95



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) (4) Production Die Number and Product Name Display Displays the production die number (hereafter referred to as the “die number”) and product name stored in the databank. (5) Fault Detection Display A wrench-shaped mark is shown when a fault is detected. When this mark is displayed, see the > (pg. 110) screen. (6) Interlock Information Display Displays information relating to machine operation. (See Section D OPERATION, 5.1 INTERLOCK INFORMATION MESSAGE LIST (pg. 132).)



96



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.3 DISPLAYS APPEARING IN WINDOWS Messages and corrective actions to be taken in response to the press machine status that are displayed because of operations performed on the operator interface terminal, and the status of communication between the press machine and the MPC (multiprocessing press controller) are described below: Data settings are outside of the specified range.



Setup has been successfully completed.



The press machine is currently downloading.



Communication with the MPC for downloading has not been completed within the specified time limit. Check the data on the current die to ascertain if all of the data has been downloaded. Also check the data itself. If any problems are found, download the data again. A failure has occurred in the communication with the MPC. Power interruption occurred while the data was being written (e.g., the timing data). Check the data that is being changed. If data is outside of the specified range, set the data again.



Power interruption occurred while the data was being downloaded. Check the data on the current die to ascertain if all of the data has been downloaded. Also check the data itself. If any problems are found, download the data again. Set the Data Write “O” (OFF)•“|” (ON) Key Switch (pg. 88) on the operation panel to "|" (ON, i.e., PERMIT).



The die number to be uploaded is outside of the 1 to 20 range.



97



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.4 THE RUN SCREEN Press machine operation is controlled on this screen. On this screen, the counter setting and press machine speed setting can be made, and the use of ejector, automation devices (option) and die protection can be set.



(3) (1)



(4)



(5) (2)



(1) Preset Counters and Production Counters The press machine has three different ON/OFF touchbutton ("0" indicates counters. Counters can be turned on and OFF, and "1" indicates ON.) off by pressing the ON/OFF touchbutton. Displays the Whether a counter can be used as a preset current value counter or a production counter depends on whether the inputted target setting is "0" or Displays the a numeric quantity. target setting • Using a Counter as a Preset Counter: A counter will function as a preset counter Pressing this when a number other than 0 (zero) is section changes entered. When the quantity on the counter the screen to Used to clear the the counter setreaches the target setting, the press current value machine stops at the preset stop position. ting screen Up to a 6-digit quantity can be inputted. • Using a Counter as a Production Counter: A counter functions as a production counter when "0" is entered as the target setting. • Counter 3 has a function that outputs a "count completed" signal when the preset number is reached. (See 2.7.6 Setting Up Options (pg. 110).) This signal is outputted for 0.5 seconds when "Preset Auto Reset" has been selected.



Used to clear the current value



Ten-key pad 0 to 9........ Numeric keys CLR ......... Used to clear an inputted numeric value. SET.......... Used to enter an inputted numeric value. "↑" "↓" ... Used to move the cursor. END ......... Used to return to the RUN screen (Continued on the next page)



98



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) (2) Die Height Indicator Displays the current die height value on press machines equipped with an automatic slide adjusting function (option). (3) Selection of MICRO INCH Operation To operate the press machine in the MICRO INCH mode, set the OPERATION SELECT switch to INCH, and then press this touchbutton. The touchbutton is highlighted. (When the MICRO INCH is OFF, characters are black on a white background; when the MICRO INCH is ON, characters are white on a black background.) MICRO INCH mode operations cannot be performed unless the OPERATION SELECT switch is set to INCH. To operate the press machine in a mode other than MICRO INCH, turn the MICRO INCH mode off. See 3.3 OPERATION MODES (pg. 125) for details about MICRO INCH mode operation. (4) Digital Press Machine Speed Meter For variable speed press machines, the desired speed can be set. If the set speed falls outside the specified range, the entire display flashes. For fixed speed press machines, only the speed is indicated, and LIMIT, TARGET and the speed setting keys (a), (b), and (c) are not displayed on the screen.



ON (Select)



Data setting range Indication of current value Indication of target setting



a



b



c



(a) Increase Speed Key:



Used to increase the target setting in increments of 1. (When the key (b) is highlighted, the target setting is increased in increments of 10.) (b) Fast Mode Key: Pressing key (b) will highlight key (b). If key (a) or (c) is pressed while (b) is highlighted, the target setting is increased/decreased in increments of 10. Pressing key (b) again removes the highlighting. (c) Decrease Speed Key: Used to decrease the target setting in increments of 1. (When key (b) is highlighted, the target setting is decreased in increments of 10.) (Continued on the next page)



99



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) (5) Ejectors, Automation Devices (Option), and Die Protection Pressing section (5) will display the screen on which On/Off selection of ejectors, automation devices, and die protection is performed. To switch between OFF and ON, press the touchbutton corresponding to OFF or ON. The selection will be highlighted. To perform testing, press the TEST touchbutton. The TEST touchbutton will be highlighted, indicating that the test mode is ON. Perform testing procedures by pushing the UP/UNCLAMP/RET. button or the DOWN/CLAMP/ADV. button located on the operation button box. Used to return to the previous page See 8.1 EJECTORS (pg. 182), (when the TEST key is OFF). 8.3 AUTOMATION DEVICES (OPTION) (pg. 183), and 8.5 DIE PROTECTION (pg. 184) for details. If the press machine is not equipped with optional ejector 2 and optional automation devices 1 and 2, they are not displayed on the screen.



100



Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.5 THE DATA SCREEN Press the DATA setting function touchbutton to go to the DATA screen. MONITOR 1..Timing switch setting (pg. 101), cams 1 to 8 MONITOR 2..Timing switch setting, cams 9 to 16 MONITOR 3..Timing switch setting, cams 17 to 24 (*1) MONITOR 4..Gain setting (pg. 102), cams 5 to 8 MONITOR 5..Gain setting, cams 9 to 12 MONITOR 6..Die protection setting (pg. 102), die protection 1 and 2 (*1): For cams 17 through 24, cam setting changes may be disabled if the cams are factoryset by the cam manufacturer. Even when cam settings changes are disabled, it is possible to monitor the cams. 2.5.1 Timing Switch Setting Monitor Screen



Displays the data of timing switches that are currently selected. The press machine will continue to run even if you switch from the RUN screen to the DATA screen. See Section D OPERATION, 6.6 SETTING TIMING SWITCHES (pg. 158).



Go to the CHANGE screen See 2.5.4 The CHANGE Screen (pg. 103). Change-over of pages among monitors 1 to 6



"ON"..............ON angle "OFF" ............OFF angle "TIMER" ........After the cam is turned ON, the timer turns OFF after the preset time has elapsed. The setting on the timer takes precedence over the "OFF angle" setting. If the TIMER is set to "0" (zero), it is rendered inoperable. The timer setting range is from 0.1 to 9.9 seconds. It can be set in increments of 0.1 seconds. Note that the cam cannot be turned OFF within a single cycle if the timer setting is increased excessively. For example, a cam which requires one second for one cycle cannot be turned OFF when the timer is set to one second or higher.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.5.2 Gain Setting Monitor Screen



See Section D OPERATION, 6.6 SETTING TIMING SWITCHES (pg. 158).



Go to the CHANGE screen See 2.5.4 The CHANGE Screen (pg. 103). Go to the next page for monitors 1 to 6



"ON GAIN" ....Used to advance the ON angle. "OFF GAIN" ..Used to advance the OFF angle. 2.5.3 Die Protection Setting Monitor Screen



See Section D OPERATION, 8.5 DIE PROTECTION (pg. 184). When die protection 1 and 2 are turned ON, they perform error detection according to the settings explained below. See 2.4 THE RUN SCREEN (pg. 98) for the procedure for turning die protection ON and OFF. Go to the CHANGE screen See 2.5.4 The CHANGE Screen (pg. 103). Go to the next page for monitors 1 to 6 "MODE" .... 0: The press machine makes an Immediate Stop when the input signal is turned ON within the programmed window. 1: The press machine makes an Immediate Stop when the input signal is turned OFF within the programmed window. 2: The press machine makes an Immediate Stop at the end-of-detection angle when no input signal (an input signal changing from ON to OFF) is detected. (*1) (*3) 3: The press machine makes an Immediate Stop at the end-of-detection angle when no input signal (an input signal changing from OFF to ON) is detected. (*2) (*3) "ON".......... The detection start angle "OFF" ........ The detection stop angle "FILTER" ... The input signal is ignored during the input sensor filter set time, which ranges from 0 to 0.10 seconds (minimum unit: 0.01 seconds). (*1): For MODE 2, if the signal does not stay OFF longer than the setting for the filter time, the ON-to-OFF signal cannot be detected and a fault is generated. (*2): For MODE 3, if the signal does not stay ON longer than the setting for the filter time, the OFF-to-ON signal cannot be detected and a fault is generated. (*3): The stopping angle may exceed the end-of-detection angle because the stopping angle varies in relation to the press machine speed.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.5.4 The CHANGE Screen



Press the CHANGE touchbutton on the monitor screen to display the CHANGE screen. Be sure to set the OPERATION SELECT switch to OFF. To change data, insert the key into the Data Write “O” (OFF)•“|” (ON) Key Switch (pg. 88) and set the switch to "|" (ON; PERMIT). See Section D OPERATION, 6.6 SETTING TIMING SWITCHES (pg. 158). Lower limit



Go to the RUN screen



Upper limit



Input value



Used to scroll between pages 1 to 6



Ten-key pad 0 to 9........ Numeric keys CLR ......... Used to clear an inputted numeric value. SET.......... Used to enter an inputted numeric value. "←" "→" ... Used to move the cursor. END ......... Used to return to the monitor screen



Lower limit ....Displays the lower input limit. Upper limit ....Displays the upper input limit. Input value ....Displays the value entered with the ten-key pad. The screen shown above is an example of the timing switch CHANGE screen that is displayed when the CHANGE touchbutton on the timing switch DATA screen is pressed. Pressing the CHANGE touchbutton on the die protection DATA screen displays the die protection CHANGE screen.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.6 THE SET UP SCREEN Press the SET UP touchbutton to display the mode selection screen where upper die clamper or other operations can be selected. >



Go to each mode screen



Go to the SET UP 2 screen



>



Go to the SET UP 1 screen



>



• Pressing a touchbutton displays the corresponding mode operation screen as mentioned below. • If your system is provided with optional operation modes, touchbuttons for these modes will also be displayed on the screen. • A touchbutton to select the slide adjustment mode (See pg. 105.) is displayed if the SLIDE ADJUST switch (See pg. 89.) is set to ON when the SET UP or RUN screen is displayed. • Press machine operation is possible only in the INCH mode. If the SET UP AUTO. SPEED REDUCTION (MIC) has been set to the option setting (See pg. 110.) when the SET UP screen is displayed, the press machine speed is automatically reduced. When you change to another screen (for example, the RUN screen), the press machine speed returns to the original spm setting. "UPPER DIE CLAMPER" (Option) ....Upper die clamper operation (p.106) "LOWER DIE CLAMPER" (Option) ....Lower die clamper operation (p.106) "DIE LIFTER" (Option) .......................Die lifter operation (p.106) "F.B. CLAMPER" (Option) ..................Feed bar clamp/unclamp operation (p.107) "DIMENSION SELECT" (Option) .......Selecting two or three dimensions(p.107) "F.B. JOINT" (Option) .........................Feed bar separation and joining (p.107)



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.6.1 Manual Slide Adjustment



When the RUN or SET UP screen is displayed with the SLIDE ADJUST switch (See pg. 89.) set to ON, the manual slide adjustment screen is displayed.



SLIDE ADJUST OFF ON



If the press machine is equipped with automatic slide adjustment (option), the screen shown on the left will be displayed when MANUAL SLIDE ADJUSTMENT is selected. Under standard configuration, the screen shown on the right will be displayed. (See Section D OPERATION, 6.1.1 Manual Slide Adjustment (pg. 152).)



Die height CURRENT VALUE



Die height TARGET VALUE The value entered in DIE HEIGHT field on 2.8.4 Edit Data (pg. 115) is shown. These buttons indicate the functions of the UP/UNCLAMP/RET. button (green) and the DOWN/CLAMP/ADV. button (orange), which are arranged on the front face of the operation button box. In this illustration, the green button (“G”) indicates UP and the orange button (“O”) indicates DOWN.



2.6.2 Automatic Slide Adjustment (Option)



The die height is automatically adjusted to the height specified in the TARGET VALUE box. (See Section D OPERATION, 6.1.2 Automatic Slide Adjustment (Option) (pg. 153).) To change the die height TARGET VALUE, press this touchbutton to display the 2.6.3 Die Height Setup Screen (Option) (pg. 106). These buttons indicate the functions of the UP/UNCLAMP/RET. button (green) and the DOWN/CLAMP/ADV. button (orange), which are arranged on the front face of the operation button box. The illustration to the left shows that the green button (“G”) indicates START and the orange button (“O”) indicates STOP.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.6.3 Die Height Setup Screen (Option)



Ten-key pad 0 to 9 ....... Numeric keys CLR ......... Used to clear an inputted numeric value. SET ......... Used to enter an inputted numeric value. END ......... Used to return to the AUTO. SLIDE ADJUSTMENT screen.



2.6.4 Die Clamper (Option) These screens are used to operate the upper and lower die clampers. (See Section D OPERATION, 7. CHANGING DIES (pg. 161).)







These buttons indicate the functions of the UP/UNCLAMP/RET. button (green) and the DOWN/CLAMP/ADV. button (orange), which are arranged on the front face of the operation button box. The above illustration shows that the green button (“G”) indicates UNCLAMP and the orange button (“O”) indicates CLAMP. 2.6.5 Die Lifter (Option) This screen is used to operate the die lifter. (See Section D OPERATION, 7. CHANGING DIES (pg. 161).)



These buttons indicate the functions of the UP/UNCLAMP/RET. button (green) and the DOWN/CLAMP/ADV. button (orange), which are arranged on the front face of the operation button box. The illustration to the left shows that the green button (“G”) indicates LIFT and the orange button (“O”) indicates DOWN.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.6.6 F. B. (Feed Bar) Clamper (Option) When equipped with TCV, TCV-T:



These buttons indicate the functions of the UP/UNCLAMP/RET. button (green) and the DOWN/CLAMP/ADV. button (orange), which are arranged on the front face of the operation button box. The illustration to the left shows that the green button (“G”) indicates UNCLAMP and the orange button (“O”) indicates CLAMP.



2.6.7 Dimension Selection (Option) When equipped with TCV-T:



These buttons indicate the functions of the UP/UNCLAMP/RET. button (green) and the DOWN/CLAMP/ADV. button (orange), which are arranged on the front face of the operation button box. The illustration to the left shows that the green button (“G”) indicates 3D FEED and the orange button (“O”) indicates 2D FEED.



2.6.8 F. B. (Feed Bar) Joint (Option) When equipped with TCV, TCV-T:



These buttons indicate the functions of the UP/UNCLAMP/RET. button (green) and the DOWN/CLAMP/ADV. button (orange), which are arranged on the front face of the operation button box. The illustration to the left shows that the green button (“G”) indicates UNCLAMP and the orange button (“O”) indicates CLAMP.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.7 THE MAINTENANCE SCREEN Pressing the MAINT. touchbutton changes the screen to the mode selection screen, which is used for selecting DIAGNOSIS and other modes.



Go to each mode screen



> “CL&BR SV TEST” ...............Clutch & brake solenoid valve test mode (p.108) “MAINT.CTR.HOUR MTR.”...Display of maintenance counter and operation hours (p.108) “MPC I/O MONITOR”............Display of MPC I/O status monitoring result (p.109) “MPC DATA MONITOR” .......Display of MPC internal memory monitoring result (p.109) “DIAGNOSIS” .......................Display of MPC fault history and current fault monitoring results (p.110) “OPTION SET UP”................Additional option-related settings (p.110) 2.7.1 Clutch and Brake Solenoid Valve Test



This screen is used to perform clutch & brake solenoid valve tests. In this mode, a faulty condition is created intentionally in order to check the monitoring function of the clutch and brake solenoid valves. When the RUN buttons are pushed in this mode, the message CL&BR SOL.VALVE MONITOR is displayed in the interlock information field. See Section E MAINTENANCE, 5.2.2 Clutch and Brake Solenoid Valve Monitor Function Test (pg. 220). 2.7.2 Maintenance Counter & Hour Meter



The maintenance counter displays the total number of strokes of the press machine. The hour meter displays the amount of time that the clutch has been engaged.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.7.3 The MPC I/O Monitor Screen This screen is used to check the I/O status during operation adjustments, etc. This screen indicates the input and output status of the MPC (Multiprocessing Press Controller). For details of the display, see the “MPC I/O monitor list” (included in Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings). > MPC bit information



2.7.4 The MPC Data Monitor Screen This screen is used for checking data, as required, during maintenance or service when a problem occurs. This screen displays the internal data specified by the MPC. Pressing KEY IN on the MPC DATA MONITOR screen displays “Address entry window.” On this screen, input an address to be read in the MPC. To return to the MPC DATA MONITOR screen, press KEY IN again. > MPC register information



Press this touchbutton to display or hide "Address entry window".



> Enter read address in this screen.



0 to F ....... Numeric keys (hexadecimal) CLR ......... Used to clear an inputted numeric value. SET ......... Used to enter an inputted numeric value.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.7.5 Fault Diagnosis The screens shown below are displayed when the DIAGNOSIS touchbutton is pressed on the MAINTENANCE screen. These screens indicate information about current MPC faults and the fault history. The FAULT HISTORY screen shows only relatively serious faults in the entire fault history. For a description of messages and how to reset faults, see Section D OPERATION, 5.2 FAULT INFORMATION MESSAGE LIST (pg. 137). > Displays current faults.



> Displays the eight most recent MPC faults.



Go to the FAULT HISTORY screen



Go to the FAULT LIST screen



2.7.6 Setting Up Options



WARNING • When the optional settings and the wiring of optional devices have been completed, be sure to check the devices for proper operation before starting production. Incorrect settings and/or wiring may lead to unexpected operation, resulting in an accident causing personal injury or death. When the OPTION SET UP touchbutton is pressed on the MAINTENANCE screen, the following screen is displayed. Complete the setup by press> ing the SET touchbutton. > Press to select.



(option) Press the desired touchbutton enclosed by a rectangle " " (the upper half of the touchbutton will turn black), then press the SET touchbutton to complete the setting (the entire touchbutton will turn black). (Continued on the next page)



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) >



The user can set the following modes. “PX1” COUNTER 1 AUTO. RESET



When the preset quantity is reached on Counter 1, the current value is automatically reset to zero (0) without pressing the RESET touchbutton.



“PY1” The press machine normally stops when a preset quanCOUNTER 1 AUTO STOP:OFF tity is reached on Counter 1, but in this mode the press machine continues to run without stopping. “PX2” COUNTER 2 AUTO. RESET



When the preset quantity is reached on Counter 2, the current value is automatically reset to zero (0) without pressing the RESET touchbutton.



“PY2” The press machine normally stops when a preset quanCOUNTER 2 AUTO STOP:OFF tity is reached on Counter 2, but in this mode the press machine continues to run without stopping. “PX3” COUNTER 3 AUTO. RESET



When the preset quantity is reached on Counter 3, the current value is automatically reset to zero (0) without pressing the RESET touchbutton.



“PY3” The press machine normally stops when a preset quanCOUNTER 3 AUTO.STOP:OFF tity is reached on Counter 3, but in this mode the press machine continues to run without stopping. “MIC” SET UP AUTO. SPEED REDUCTION (Option)



When you go to the SET UP screen, the current press machine speed is automatically reduced. When you go into any other screen, it returns to the original speed. (This function is not provided for fixed-speed motors.)



“PZ3” COUNTER 3 OUTPUT SET: UP-OFF



The Counter 3 preset quantity output signal logic is selectable. When not selected: The output is turned ON when Counter 3 reaches the preset quantity. When selected: The output is turned OFF when Counter 3 reaches the preset quantity.



*: For further details about counters, see page 98. Counter 3 has the function of outputting a signal to notify that a preset quantity has been reached. (Continued on the next page)



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) >



“ZE” CHANGE LANGUAGE



The language used on the operator interface terminal can be switched between English and Japanese.



The customer can install the following devices as options by enabling the following settings and performing the necessary wiring (refer to the section that includes optional symbols (such as UDC and LF1) in the electrical circuit drawings in Section E MAINTENANCE, 11. DRAWINGS (pg. 265)). The corresponding touchbuttons will be displayed on the SET UP screen, etc. “UDC” UPPER DIE CLAMPER



Enabling this setting will allow you to install non-AIDA upper die clampers. (See page PM-023xx of the electrical circuit drawings.)



“UDCX” MOVABLE UPPER DIE CLAMPER



Enabling this setting will allow you to install movable upper die clampers. (See page PM-023xx of the electrical circuit drawings.)



“LDC” LOWER DIE CLAMPER



Enabling this setting will allow you to install non-AIDA lower die clampers. (See page PM-023xx of the electrical circuit drawings.)



“DL” DIE LIFTER



Enabling this setting will allow you to install non-AIDA die lifters. (See page PM-023xx of the electrical circuit drawings.)



“LF1” FEEDER 1



Enabling this setting will allow you to install feeders primarily made by AIDA. (See page PM-025xx of the electrical circuit drawings.)



“LF2” FEEDER 2



Enabling this setting will allow you to install non-AIDA feeders. (See page PM-025xx of the electrical circuit drawings.)



* : Based on the specifications of your press machine, you may not be able to attach some devices. Referring to the instruction manual for the device and the electrical circuit drawings in this manual, perform a feasibility study.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



2.8 THE RECIPES (DATABANK) SCREEN > A databank system (hereafter referred to as the “databank”) is built into this press machine as a standard item to assist in presswork productivity. The databank links the press machine data settings for dies (hereafter referred to as "die data"), which can vary from die to die, with die numbers that are stored in the databank. Data for up to 20 different dies can be stored. When performing a setup change (die change) operation, select the desired DIE NO. in the PRODUCT LIST to DOWNLOAD the data. This will automatically change the setting of the press machine. > Data entry for 20 dies Upload Data copy Product name entry Clear data Download > Die height (Die height will automatically be set to a target value only when the press machine is equipped with optional automatic slide adjustment.) Press machine speed (for variable speed motors) Counter preset value setting Memo Cams 1 to 16 ON/OFF angle setting Cams 5 to 12 gain (advance) setting Die protection setting



When the RECIPES (Databank) touchbutton is pressed, a mode selection screen is displayed on which you can select modes such as PRODUCT LIST. Go to each mode screen • To change data, insert the key into the Data Write “O” (OFF)•“|” (ON) Key Switch (pg. 88) and select the “|” (ON) position.



> “PRODUCT LIST” ...Pressing this touchbutton changes the screen to a screen that displays a product list. You can edit the data on this list. Display this screen in order to DOWNLOAD (p.114). “UPLOAD” ..............Selecting this mode allows the current press machine settings to be uploaded into the databank. The die data stored in the databank is changed accordingly (p.114). “DATA COPY” .........This allows you to copy die data from one die number to another (p.115).



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.8.1 The Product List Screen



Product names already entered are listed in a table. After selecting a die number on this screen, change the screen to another screen such as the EDIT DATA screen. Go to each sub mode screen



Go to the RECIPES (DATABANK) screen



Select the die number data which is to be edited.



Pressing this touchbutton changes the screen over to another screen to indicate product names for dies 11 to 20.



> “EDIT DATA” ...........To edit die height and other die data. (p.115) “CLEAR DATA” .......To clear die data. (p.116) “EDIT NAME”..........To change and edit product names. (p.116) “DOWNLOAD” ........To download the die data settings of the selected die number to the press machine. (p.117)



2.8.2 The Upload Screen This function uploads the current press machine settings into the databank, and changes the saved die data.



Pressing this touchbutton initiates uploading.



The die number and product name to be uploaded are indicated here.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.8.3 Data Copy This function copies the die data of a die to a different die number. Where to copy from (source) and where to copy to (destination) is specified on this screen.



Ten-key pad 0 to 9........ Numeric keys CLR.......... Used to clear an inputted numeric value. SET.......... Used to enter an inputted numeric value. END ......... Used to return to the RECIPES screen



Press these touchbuttons to select the die number to be entered.



Pressing this touchbutton executes data copy. 2.8.4 Edit Data The following screen is displayed when a die number is selected and then the EDIT DATA touchbutton is pressed on the PRODUCT LIST screen (p.114).



Lower limit



Page change



Upper limit



Entered value



Ten-key pad 0 to 9........Numeric keys CLR..........Used to clear an inputted numeric value. SET..........Used to enter an inputted numeric value. "↑" "↓" ...Used to move the cursor. END .........Used to return to the PRODUCT LIST screen



For description of: • cams 1 to 16 angle settings; • cams 5 to 12 gain settings, and; • die protection settings, on the following pages, see 2.5 THE DATA SCREEN (pg. 101) and 2.5.4 The CHANGE Screen (pg. 103).



“DIE HEIGHT”............. If the press machine is not equipped with optional automatic slide adjustment, die height data is stored as a memo. In this case, the value entered in this step is shown in TARGET VALUE field on the (pg. 105) screen of 2.6.1 Manual Slide Adjustment. “spm” .......................... This setting is not required for fixed speed motors. “COUNTER OFF/ON” . A value “0” indicates OFF, and “1” indicates ON. “MEMO” ...................... 8-digit data entry is allowed. Data for the feeder and other devices can be recorded here.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.8.5 Clear Data This function clears the die data of a selected die number. The following screen is displayed when a die number is selected and then the CLEAR DATA touchbutton is pressed on the PRODUCT LIST screen (p.114).



Pressing this touchbutton clears the data.



A die number and product name for which data is to be cleared are shown here.



2.8.6 Edit Product Names This screen is used to enter product names. Since there is not enough space on a single screen to display an entire keyboard, KEY 1 and KEY 2 touchbuttons are provided to change the screen between two keyboard sections. The following screens are displayed when a die number is selected and then the EDIT NAME touchbutton is pressed on the PRODUCT LIST screen (p.114). A product name can consist of up to 13 characters including uppercase alphabetic characters, numerals, and hyphens (“-”).



A product name input is displayed here.



Change between KEY 1 and KEY 2 screens " ← " " → "......Used to move the cursor. CLR ...............Used to clear entered characters. BS..................Backspace SET................Used to fix entered characters. KEY 1 ............Displays a keyboard with “1” to “H” keys. KEY 2 ............Displays a keyboard with “I” to “Z” keys.



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Section D OPERATION 2. THE OPERATOR INTERFACE TERMINAL



(Continued) 2.8.7 Downloading Press machine settings change automatically to the die data of the selected die number. The following screen is displayed when a die number is selected and then the DOWNLOAD touchbutton is pressed on the PRODUCT LIST screen (p.114).



Press this touchbutton to execute downloading.



The die number and product name to be downloaded are shown here. When the DOWNLOAD ENTER touchbutton is pressed, the die data stored in the databank (die height (*1), press machine speed (*2), counter settings, cams 1 to 16 ON/OFF angle settings, cams 5 to 12 gain settings, and die protection settings) are automatically set in the press machine. (*1): Set a numeric value for the die height "target value". (Just pressing the touchbutton alone will not activate the slide adjust motor.) To automatically adjust the die height, follow the procedure described in 6.1.2 Automatic Slide Adjustment (Option) (pg. 153). If your press machine is not equipped with optional automatic slide adjustment, manually adjust the die height based on the value given in the DIE HEIGHT box while watching the die height indicator. (See 6.1.1 Manual Slide Adjustment (pg. 152).) (*2): If your press machine is equipped with a variable speed motor, acceleration and deceleration are performed automatically.



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Section D OPERATION 3. OPERATION



3. OPERATION



CAUTION • Do not perform presswork in the MICRO INCH and INCH modes. The clutch can be damaged or stick due to insufficient torque (incomplete engagement of the clutch). • When operating the press machine for the first time, operate the machine only after performing all of the actions described in Section C INSTALLATION. If the press machine is operated without adequate preparation, there is a possibility of injury or death due to press machine damage or malfunction. • Before starting work and after every 8 hours of operation, conduct an inspection according to the procedure described in 3.2 ROUTINE INSPECTION AND OPERATION (pg. 121). If the procedure sequence is ignored or inspections are omitted, there is a possibility of injury or death due to press machine damage or malfunction. • If abnormal sounds, smells, smoke, or other abnormalities occur during press machine operation, stop the operation immediately and investigate and remove the cause. If the cause cannot be identified, contact AIDA Service (see the end of this instruction manual). • Be sure to perform the steps described below before starting work after press machine operation has been halted for 24 hours or more in order to prevent an accident resulting from lubricating oil shortages. (1) Perform the procedure given in 3.2 ROUTINE INSPECTION AND OPERATION (pg. 121). However, note that the manual oil pump should be pumped for 10 strokes as described in item 3. (2) Perform run-in for five minutes or more. (Continued on the next page)



118



Section D OPERATION 3. OPERATION



(Continued)



CAUTION • Be sure to perform the steps described below before restarting the press machine after press machine operation has been halted for an extended period of time (approximately one week). (1) Perform the procedure given in 3.2 ROUTINE INSPECTION AND OPERATION (pg. 121). However, note that the following steps should be added to the procedure: (a) Operate the manual oil pump for 10 strokes as described in item 3, and; (b) Set the CONTROL POWER switch to “O” (OFF) and “|” (ON) positions four or five times at about 20 seconds intervals in order to ensure adequate grease supply. (2) Perform the monthly inspection. (See pg. 187.) (3) Remove the dies and perform run-in for 30 minutes or more to check for unusual sounds, heat, or abnormal vibration.



Before beginning operation, review and follow the instructions given in Section A SAFETY. If the press machine is equipped with a presence-sensing device (option), read the instruction manual for the presence-sensing device (the manual is contained in the Instruction Manuals for Accessories in a separate binder or provided at the end of this instruction manual) before operation. Do not start operation until you read through the instruction manual.



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Section D OPERATION 3. OPERATION



3.1 PRE-WORK CHECK The following pre-work check items must be performed by the employer, authorized personnel, and qualified personnel. (1) Clutch and brake function check • In the INCH operation mode, confirm that the slide only moves when the RUN buttons are held down and immediately stops when the buttons are released. (2) Check the bolts on the crankshaft, flywheel, slide, connecting rod, and connecting screw, making sure they are all secure. (3) Single stroke mechanism function check • In the SINGLE operation mode, confirm that the press machine is allowed to operate in the INCH mode from the preset stop position up to approximately 165° (for more information, see the electrical circuit drawings contained in Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings), and that after approximately 165° that the press machine always stops at the preset stop position whether the RUN buttons are held down or released. (4) Immediate Stop and Emergency Stop function check • Confirm that the slide immediately stops when the EMERGENCY STOP (Immediate Stop) button is pushed during operation. • Confirm that slide movement is disabled when the EMERGENCY STOP (Immediate Stop) button is pushed and then released. (5) Slide and/or die safety mechanism function check (a) Guard (option) • Confirm that your hand cannot enter into the point of operation when the guard is closed. • Confirm that slide movement is disabled unless the guard is closed and locked when in the SINGLE operation mode. (A press machine with a bolster width of 1,300mm or less should be confirmed in any mode other than MICRO INCH, INCH, and SINGLE.) (b) Presence-sensing device (option) • Confirm that slide movement is disabled with beams interrupted. • Confirm that the slide immediately stops when beams are interrupted during slide descending stroke in the SINGLE and CONTINUOUS modes. (c) Two-hand RUN buttons • Confirm that the slide does not move unless the two RUN buttons are pushed with both hands simultaneously (except in the MICRO INCH and INCH modes). (6) Press machine die and bolster condition check • Confirm that no tools or parts are lying on the die or bolster.



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Section D OPERATION 3. OPERATION



3.2 ROUTINE INSPECTION AND OPERATION For the location of operation switches and equipment, see Section B SPECIFICATIONS, 4. NAMES OF MAJOR COMPONENTS (pg. 63) and Section D OPERATION, 1. OPERATION DEVICES (pg. 85). The items marked with an asterisk (*) must always be conducted by qualified personnel.



1



Clean up the area around the press machine and the floor to keep them neat and organized.



* 2



Confirm that the oil is above the lower limit line of the oil gauge of each oil reservoir or within the specified range of the container. If the oil level is low, add oil. (See pg. 194.) Also check for any leakage.



3



Move the lever of the manual oil pump (option, but, provided as standard on models (S)E and NC1-2500) up and down 3~5 times. If the press machine is equipped with a cylinder-type die cushion, move the lever up and down 10 times.



4



Check whether the auto drain filter is dirty. If dirty, clean the filter. Periodic cleaning (every week) is recommended. (See pg. 217.)



5



Check that the clogged oil filter indicator on Model (S) E press machines is green. If the indicator is red, clean or change the filter element (See pg. 225.).



6



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



7



Raise the die cushion (option), and then supply 1 to 2 grams of grease to the cushion guide grease fitting. (See pg. 155 and pg. 194.)



* 8



9



*10



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



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



Turn your power source ON. Set the externally controlled breaker to ON. Confirm that the POWER light comes on. (Continued on the next page)



121



Section D OPERATION 3. OPERATION



(Continued)



* 11



Insert the key into the CONTROL POWER switch, and turn it clockwise to “|” (ON). Confirm that the key cannot be removed when in this position. Push the LUBRICATING OIL button (provided on Models (S)E, (1NL)E, and (2NL)E) to start the lubricating oil pump.



*12



Conduct tests to monitor the function of the clutch and brake solenoid valve. (See pg. 220.)



*13



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



*14



Insert the key into the EXTERNAL•OFF•BUTTON switch, and turn it clockwise to the BUTTON position. When a key is removed it from a key switch it must be held by authorized personnel.



*15



Confirm that the devices and switches are set as follows. In addition, set all of the safety devices so that they work effectively. When a key is removed it from a key switch it must be held by authorized personnel. • GUARD DISABLE•ACTIVE key switch (option)............... ACTIVE • PRE. SENSING DEVICE key switch (option) .................. ON (ACTIVE) • PRESET STOP POSITION•TOP DEAD CENTER stop position switch (option)............. PRESET STOP POSITION or TOP DEAD CENTER • Die lifters (option)............................................................. DOWN (The arms should be closed.) • Upper and lower die clampers (option) ............................ CLAMP • Main motor REV.•OFF•FWD. switch (option)................... FWD. • Die protection receptacles (option) .................................. The plugs are inserted.



*16



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



17



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



*18



Push the two RUN buttons with both hands simultaneously, and release them to check that the clutch and brake solenoid valve produces crisp exhaust noise and that the muffler does not continue exhausting. (The exhaust noise must be listened to by qualified personnel standing close to the clutch and brake solenoid valve.)



19 *20



122



Set the OPERATION SELECT switch to OFF.



Set the press machine speed to minimum (zero) using the digital spm meter on the operator interface terminal (for variable speed motors). (Continued on the next page)



Section D OPERATION 3. OPERATION



(Continued)



21 *22



Push the MAIN MOTOR START button to activate the main motor. Check that the MAIN MOTOR RUN light turns on.



Using the digital spm meter on the operator interface terminal, set the number of noload continuous strokes to a desired value stated in the specifications (for variable speed motors). Check the direction of flywheel rotation from the back of the press machine. The proper direction is indicated by an arrow on the nameplate. Also, check that the V belts do not emit slipping sounds or abnormal vibrations.



23



Set the OPERATION SELECT switch to INCH. Check that the RUN OK light turns on.



24



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



25



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



26



Move the slide to the preset stop position.



*27



Set the OPERATION SELECT switch to SINGLE, then confirm the following items: (a) Confirm that the RUN OK light turns on. (b) Confirm that the RUN OK light turns off and that the slide does not start when only one of the two RUN buttons is pushed. (c) Push the RUN buttons simultaneously with both hands to activate the slide. Confirm that the slide stops (in the INCH mode) when the RUN buttons are released in the range from the preset stop position to approximately 165° (see Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings for details), and that after approximately 165° that the press machine always stops at the preset stop position whether the RUN buttons are held down or released. (d) Run the press machine several times in the SINGLE mode, and confirm that the variation of the stopping position is 10° or less. (e) Push and release the EMERGENCY STOP button when the RUN OK light is lit, and confirm that slide movement is disabled. (f) Push the EMERGENCY STOP button while the press machine is in operation and confirm that the slide immediately stops. < Restart Procedure > • Reset the EMERGENCY STOP button (by turning it). • Using the INCH mode, inch the slide to the preset stop position. (g) Confirm that the RUN OK light turns off and that the slide movement is disabled with beams interrupted. (h) Confirm that the slide immediately stops when the beam is interrupted during slide descending stroke. (Continued on the next page)



123



Section D OPERATION 3. OPERATION



(Continued)



*28



If the press machine is equipped with a guard (option), perform the following inspection in the SINGLE mode. For a press machine with a bolster width of 1,300 mm or less, however, perform the inspection in any mode other than MICRO INCH, INCH, and SINGLE. (a) Confirm that the press machine point of operation is out of reach when the guards are closed. (b) Confirm that the RUN OK light does not go on and that slide movement is disabled unless the guard is closed and locked. (c) Confirm that the slide immediately stops when the guard locking device (pin, etc.) is removed while the press machine is in operation.



*29



If CONTINUOUS or other operation modes (option) can be selected, check the slide movement in each of the operation modes described in 3.3 OPERATION MODES (pg. 125). Also, perform check items (e) to (h) in Step * 27 and (a) to (c) in Step * 28 for each operation mode.



*30



Perform the pre-work check of the presence-sensing device according to the instruction manual of the device.



*31



Perform the check specified in Section D OPERATION, 3.1 PRE-WORK CHECK (pg. 120).



*32



If the press machine is equipped with a die block, check that slide movement is disabled and the main motor cannot be started in all operation modes when the die block plug is disconnected.



*33



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



*34



If you have changed the stop position during operation, perform check items (a) to (d) in Step * 27 before resuming operation.



This completes the inspection. To supply oil during regular operation, operate the manual oil pump (option, but, provided as standard on models (S)E and NC1-2500) lever 3 to 5 times (or 10 times if the press machine is equipped with a cylinder-type die cushion) every four hours.



124



Section D OPERATION 3. OPERATION



3.3 OPERATION MODES This section describes the operation modes that can be selected using the OPERATION SELECT key switch. (See pg. 89.) In the following descriptions, “push or release the buttons” means to “push or release the two RUN buttons simultaneously using both hands.” To operate the press machine in a mode other than MICRO INCH, turn the MICRO INCH mode off. (See pg. 99.)



INCH



OFF SINGLE



RUN screen (pg. 98)



INCH



OFF SINGLE



RUN screen (pg. 98) OFF SINGLE



INCH



OFF SINGLE



INCH



OFF SINGLE



CONT. SINGLE



INCH



CONT. ONCE



OFF INCH



SINGLE



MICRO INCH Operation Mode • The slide moves at a micro-speed as long as the buttons are held down. The micro-speed is a set speed that is lower than the lowest speed in the INCH mode. • This mode is used for adjusting dies. Trial presswork cannot be performed in the MICRO INCH mode. • See page 99 for the procedure for selecting the MICRO INCH operation mode. INCH Operation Mode • The slide moves as long as the buttons are held down, and immediately stops when the buttons are released. • This mode is used when performing inspections or for inserting or removing dies.



SINGLE Operation Mode • The slide moves in the same manner as it moves in the INCH mode within the range from the preset stop position to approximately 165° (see the electrical circuit drawings contained in Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings for details). From approximately the 165° position and beyond, the slide stops at the preset stop position regardless of whether the RUN buttons are held down or released. CONTINUOUS SINGLE Operation Mode (Option) • The slide moves continuously from the preset stop position only while the buttons are being pushed. When the slide is moving between the preset stop position and approximately the 165° point, the slide immediately stops when the buttons are released (see Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings for details). When the buttons are released after approximately the 165° position, the slide completes the current stroke and stops at the preset stop position. CONTINUOUS ONCE Operation Mode (Option) • The slide runs continuously from the preset stop position only while start signals are given by the feeder. When the start signal is interrupted, the slide completes the current stroke and stops at the preset stop position.



CONT.



CONTINUOUS Operation Mode (Option) • When the buttons are pushed within five seconds of pushing the CONT. ARMING button (See pg. 90.), the slide moves continuously. The slide continues moving even if the RUN buttons are released. When the TOP STOP (PRESET STOP) button is pushed, the slide stops at the preset stop position.



125



Section D OPERATION 3. OPERATION



3.4 SAFETY DEVICES AND OPERATION CONDITIONS The tables below show the relationship between the status of safety devices (option) under standard AIDA configuration and the operation modes. The relationship may be different from the following table if the specifications have been changed due to a customer request. In such cases, refer to the electrical circuit drawings contained in Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings. 3.4.1 When a FRONT GUARD DISABLE•ACTIVE Key Switch is not Provided:



MICROINCH SINGLE CONT. SINGLE INCH



CONT. ONCE



CONT.



Preset Stop Position



Guard Open



○



○ (*1) × (*2)



×



×



×



Guard Closed



○



○□△



○□



□△



○



Presence-Sensing Device DISABLE



○



○ (*1) × (*2)



×



×



×



Presence-Sensing Device ACTIVE



○



○□△



○□



□△



○



○



○ (*1) × (*2)



×



×



×



○



○□△



○□



□△



○



Other positions than top dead center are allowed.



○



○□△



○□



□△



○



Other positions than top dead center are allowed.



○



○□△



○□



□△



○



Other positions than top dead center are allowed.



Presence-Sensing Device DISABLE and Guard Open Presence-Sensing Device DISABLE and Guard Closed Presence-Sensing Device ACTIVE and Guard Open Presence-Sensing Device ACTIVE and Guard Closed × □ ○ △



Only top dead center for the SINGLE mode Other positions than top dead center are allowed. Only top dead center for the SINGLE mode. Other positions than top dead center are allowed. Only top dead center for the SINGLE mode.



: : : :



Operation is disabled. Operation using the foot switch is enabled. Operation using two-hand RUN buttons is enabled. Operation with start signals sent from a feeder or other device is enabled. (In some cases, operation is started by pushing the two-hand RUN buttons.) : Where the preset stop position is top dead center, it is the standard setting to disable the danger preventive function of the presence-sensing device during slide ascending stroke. However, it is the standard setting to enable the presence-sensing device all around if the press machine is equipped with a material feeder or other related device. (See the instruction manual of the presence-sensing device.) (*1): If the bolster area is 1,300 mm or less (*2): If the bolster area exceeds 1,300 mm NOTE



126



• To set the preset stop position to any point other than the top dead center, a stop position change device (option) is necessary. • If you are implementing safety measures, please reference the above table. • The above table is not intended as a recommendation for a work system. (Continued on the next page)



Section D OPERATION 3. OPERATION



(Continued) 3.4.2 When a FRONT GUARD DISABLE•ACTIVE Key Switch is Provided:



Guard Open



Guard Open



Guard Closed



Guard ACTIVE Selected Guard DISABLE Selected Guard ACTIVE Selected



Presence-Sensing Device DISABLE and Guard Open Presence-Sensing Device DISABLE and Guard Open



Guard ACTIVE Selected Guard ACTIVE Selected Guard DISABLE Selected



Presence-Sensing Device DISABLE and Guard Closed



Guard ACTIVE Selected



Presence-Sensing Device DISABLE and Guard Closed Presence-Sensing Device ACTIVE and Guard Open



Guard DISABLE Selected Guard ACTIVE Selected



Presence-Sensing Device ACTIVE and Guard Open



Guard DISABLE Selected



Presence-Sensing Device ACTIVE and Guard Closed



Guard ACTIVE Selected



Presence-Sensing Device ACTIVE and Guard Closed



Guard DISABLE Selected



Guard Closed



MICRO -INCH INCH



SINGLE



×



×



×



×



×



○



○ (*1) × (*2)



×



×



×



Only top dead center for the SINGLE mode Other positions than top dead center are allowed.



CONT. CONT. CONT. SINONCE GLE



Preset Stop Position



○



○□△



○□



□△



○



○



○ (*1) × (*2)



×



×



×



×



×



×



×



×



○



○ (*1) × (*2)



×



×



×



Only top dead center for the SINGLE mode Other positions than top dead center are allowed.



○



○□△



○□



□△



○



○



○ (*1) × (*2)



×



×



×



×



×



×



×



×



○



○



○



○□△



○□△



○□△



○□



○□



○□



□△



□△



□△



○



Other positions than top dead center are allowed.



○



Other positions than top dead center are allowed.



○



Other positions than top dead center are allowed.



(Continued on the next page)



127



Section D OPERATION 3. OPERATION



(Continued) × □ ○ △



: : : :



Operation is disabled. Operation using the foot switch is enabled. Operation using two-hand RUN buttons is enabled. Operation with start signals sent from a feeder or other device is enabled. (In some cases, operation is started by pushing the two-hand RUN buttons.) : Where the preset stop position is top dead center, it is the standard setting to disable the danger preventive function of the presence-sensing device during slide ascending stroke. However, it is the standard setting to enable the presence-sensing device all around if the press machine is equipped with a material feeder or other related device. (See the instruction manual of the presence-sensing device.)



(*1): If the bolster area is 1,300 mm or less (*2): If the bolster area exceeds 1,300 mm



128



Section D OPERATION 3. OPERATION



3.5 OPERATING GUARDS (OPTION)



WARNING • Do not operate the press machine with guard limit switches disabled. Disabling guard limit switches may cause guarding functions to be inoperable, and may thus result in personal injury or death. • If the transparent pane section of the guard breaks, replace it immediately. Injury or damage may be caused if a broken pane falls out of its frame. Operate the swing-type guard following the steps of the procedure described below: 3.5.1 Opening the Guard



1



Push the EMERGENCY STOP button.



2



Set the OPERATION SELECT switch to OFF and remove the key from the key switch.



3



Pull the pin out.



4



Unlatch the locking hardware.



5



Holding the guard handle, slowly raise the guard to its upper limit.



6



Connect the fall prevention chain to the guard.



7



When it is necessary to put your hands or any other part of your body inside the guard, strictly follow the instructions given in Section A SAFETY, 4. USING THE PRESS MACHINE SAFELY (pg. 24).



3.5.2 Closing the Guard



To close the guard, reverse the procedure described above in 3.5.1 Opening the Guard.



129



Section D OPERATION 4. PROCEDURE WHEN COMPLETING WORK



4. PROCEDURE WHEN COMPLETING WORK



CAUTION • When stopping the air supply from the source for three hours or longer while die clampers are in use, lower the slide to bottom dead center to prevent misalignment between the upper and lower dies. In order to prevent the dies from striking directly or sticking, use the slide adjustment feature to raise the slide up 2 to 3 mm. Otherwise, the upper die may become misaligned with the lower die due to a decrease in die clamper hydraulic pressure. Perform the following operation when press machine operations have been completed or before halting press machine operation. The items marked with an asterisk (*) must always be performed by authorized personnel.



1 * 2 3 * 4



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



Push the MAIN MOTOR STOP button to stop the main motor.



Set the CONTROL POWER switch to “O” (OFF) and remove the key. Also, set the EXTERNAL•OFF•BUTTON switch to OFF and remove the key. Removed keys must be controlled by authorized personnel.



5



Turn the power source OFF.



6



Drain the sludge in each air line. Also drain the sludge in your air compressor.



7



Close the air supply port stop valve at the press machine.



8



Remove dust and dirt on the rod surface of the gas spring of the guard (option) by wiping it with a dry, clean cloth. Perform cleaning and maintenance of the other parts.



* 9 10



130



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



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



Clean up the area around the press machine and the floor to keep them neat and organized.



Section D OPERATION 5. RESETTING FAULTS



5. RESETTING FAULTS



CAUTION • Faults are to be reset under the supervision of qualified personnel. • Investigate and eliminate the causes of slide stoppage, and confirm that no more faults exist before restarting slide operation. If you cannot reset a fault because the cause of the fault is unclear, contact AIDA Service (see the end of this instruction manual). • All operations involving electrical equipment must be performed by a qualified electrician, or contact AIDA Service (see the end of this instruction manual).



Before eliminating a fault, read and follow the instructions given in Section A SAFETY. (Continued on the next page)



131



Section D OPERATION 5. RESETTING FAULTS



5.1 INTERLOCK INFORMATION MESSAGE LIST The interlock information message list gives the details of the interlock messages that are displayed on the operator interface terminal, and they are arranged in the order of the message numbers. Find a message by using the message number displayed on the operator interface terminal. Note that this list may include messages that are not displayed on your system due to the options of your press machine. Interlock information No.



200



Interlock Message



INITIAL / E-STOP BUTTON RELEASE



236 MODE SELECTOR: OFF



The system is being initialized. Wait about five seconds. However, the initialization process cannot be completed in any of the following cases. If one of these occurs, perform the applicable reset procedure and take the proper remedial action. • The EMERGENCY STOP button has been pushed. • The operation button box [NC1-350~NC1-2000, NS1(option)] is not located in its home position. • The Emergency Stop line is being interrupted by another device. During press machine operation: Set the OPERATION SELECT switch to some position other than OFF. During set up: Set the OPERATION SELECT switch to OFF.



241



FRONT GUARD SW. ACTIVE (ON)



242



REAR GUARD SW. ACTIVE The slide cannot be operated unless the rear guard is enabled (ON). Enable (turn ON) the rear guard. (ON)



243



PRESENCE SENSING DEVICE



The slide cannot be operated unless the front guard is enabled (ON). Enable (turn ON) the front guard.



The presence-sensing device’s light beam has been interrupted. Reset the device to its normal state.



244 FRONT GUARD CLOSE



The slide cannot be operated unless the front guard is closed and enabled. Close the front guard.



245 REAR GUARD CLOSE



The slide cannot be operated unless the rear guard is closed and enabled. Close the rear guard.



247



248



249



132



Description & Resetting Method



INNER PRESENCE SENS. DEVICE



The presence-sensing device’s light beam has been interrupted. Reset the device to its normal state. After performing the fault reset procedure, push the RESET button.



EMERGENCY STOP (BUTTON)



The EMERGENCY STOP button has been pushed (including the cases where the button box is located at its home position and where the system has normal monitoring result outputs). Follow the fault reset procedure. The Emergency Stop function also actuates when the EMERGENCY STOP button is pushed so lightly that the button does not lock. In this case, fully push the button again to ensure that the button is locked, then reset the button. (See 5.5 WHEN THE EMERGENCY STOP BUTTON HAS BEEN PUSHED (pg. 146).)



CL&BR SOL.VALVE MONITOR



The clutch and brake solenoid valve monitor has been activated. This message is displayed when testing the clutch and brake solenoid valve. (See Section E MAINTENANCE, 5.2.2 Clutch and Brake Solenoid Valve Monitor Function Test (pg. 220).) After performing the fault reset procedure, push the RESET button.



250 MAIN MOTOR



Start the main motor. However, for press machines equipped with a lubricating oil pump, start the main motor only after starting the pump.



251 SUPPLY AIR PRESSURE



The clutch and brake or counterbalance air pressure is abnormal. Check the pressure gauge. Check your air supply pressure and perform an air leakage inspection. After eliminating the cause of the fault, push the RESET button.



252 OVERLOAD



A hydraulic overload has occurred. Clear the hydraulic overload. (See 5.3 HYDRAULIC OVERLOADS (pg. 142).)



Section D OPERATION 5. RESETTING FAULTS



No.



Interlock Message



Description & Resetting Method



253 EXT. IMMEDIATE STOP



The slide has I-Stopped due to an external I-Stop signal. After eliminating the cause of the fault, push the RESET button.



254 EXT. LINE INTERLOCK



The necessary conditions for external line operation have not been met. After eliminating the cause of the fault, push the RESET button.



255



PERIPHERAL EMERGENCY STOP



The slide has been E-Stopped by an E-Stop signal sent from an external source.



256 LUBRICATING OIL



There is insufficient lubrication from the electric oil pump. If the oil level is low, replenish with oil. Check whether the filter is clogged, the piping has oil leakage, or the thermal relay for the oil pump has tripped. (See 5.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 148).) Repair defects, if any. After eliminating the cause of the fault, push the RESET button.



257 LUB.CYCLE CHECK



There is insufficient lubrication from the automatic grease pump. If the grease level is low, add grease and turn the control power source ON again. If a circuit breaker has tripped, turn the breaker ON. For any other cases, contact AIDA Service (see the end of this instruction manual).



slide has stopped due to an external preset stop signal. After 258 EXTERNAL PRESET STOP The eliminating the cause of the fault, push the RESET button.



259



OPERATING SELECTOR SET UP



The selected operation mode (such as INCH and SINGLE) is incompatible with the selected control (such as BUTTON, EXTERNAL, and LINE). Check which operation mode and control has actually been selected. When any control other than BUTTON has been selected, always select SINGLE (CONT. ONCE) mode. When TCS is provided: The setting by UNIT•LINE switch on operation button box and that by OPERATION SELECT switch are not in concordance. When the UNIT is selected, select other position than the CONT. by OPERATION SELECT switch.



260



SLIDE PRESET STOP POSITION



Move the slide to the preset stop position in the INCH mode.



261 ADD.1 GUARD CLOSE



The slide cannot be operated unless the additional Guard 1 is closed and enabled. Close the additional Guard 1.



262 ADD.2 GUARD CLOSE



The slide cannot be operated unless the additional Guard 2 is closed and enabled. Close the additional Guard 2.



263 F.PRESENCE SENS.D.ON



The slide cannot be operated unless the front presence-sensing device is activated. Turn the front presence-sensing device on. If a front guard is used, close the guard.



264 R.PRESENCE SENS.D.ON



The slide cannot be operated unless the rear presence-sensing device is activated. Turn the rear presence-sensing device on. If a rear guard is used, close the guard.



265 PRESET STOP BUTTON



The TOP STOP (PRESET STOP) button has been pushed.



266 TWO-HAND OPERATION



The two RUN buttons have not been pushed simultaneously. Push these two buttons simultaneously with both hands.



267



ADD.TWO-HAND OPERATION



The two RUN buttons have not been pushed simultaneously. Push these two buttons simultaneously with both hands.



OPERATION READY 268 CONT.ARMING G



Push the CONT. ARMING button and then the RUN buttons. CONT. mode operations can then be performed.



269 RUNNING



The slide is running.



270 ROBOT START POSITION



The slide cannot be operated because the robot is not located in its home position.



271 OPERATION READY



Operation in the selected mode is possible.



272



OPERATION BUTTON ANTIREPEAT



There is a faulty start signal setting. Cut off the start signal once, and perform the restart operation. If the message still remains, check the start signal.



273 DIE PROTECTION 1



Die Protection 1 has detected a fault. After performing the fault reset procedure, push the RESET button.



274 DIE PROTECTION 2



Die Protection 2 has detected a fault. After removal of the fault, push the RESET button.



133



Section D OPERATION 5. RESETTING FAULTS



No. 276



Interlock Message MAIN MOTOR STOP DETECT



Description & Resetting Method The main motor has not stopped yet. Wait a moment before starting the main motor.



277 MAIN MOTOR STARTING



The main motor is starting. Wait a moment.



278 ENERGY SAVING TIMER



The energy saving timer was activated to stop the main motor. To restart, push the RESET button, then push the start button.



MAIN MOTOR THERMAL TRIP



The main motor thermal relay has tripped. (See 5.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 148).) After eliminating the cause of the fault, push the RESET button.



279



280 INVERTER



There are inverter problems. Eliminate the cause of the problem as instructed in the inverter instruction manual. After eliminating the problem, push the RESET button. Inverter problems may also arise when you turn the power ON immediately after you turn the control power source OFF with the main motor still running (see the section of CONTROL POWER Key Switch (pg. 87)). In such a case, push the RESET button to restore the press machine. Turn the power on again after visually confirming that the flywheel has stopped its rotation.



281 OVERLOAD: INCH-RESET



A hydraulic overload has occurred. (See 5.3 HYDRAULIC OVERLOADS (pg. 142).)



282



OVERLOAD IS RESETTING / LOAD ANALYZER



The hydraulic overload protector is recovering its original hydraulic pressure level. Or, reset the load analyzer (tonnage monitor).



283 UPPER DIE CLAMPER



The upper die clampers have not clamped. Check whether the upper die clampers are clamped properly.



284 LOWER DIE CLAMPER



The lower die clampers have not clamped. Check whether the lower die clampers are clamped properly.



285 DIE LIFTER DOWN



The die lifter has moved up (the hydraulic pressure has increased) or die lifter UP has been selected. Move the die lifter down.



286 DIMENSION SELECT



The dimensional setting of the transfer equipment has not been made. Set the dimension again.



287 MISGRIP



The transfer equipment has detected a misgrip. Return the material to the proper position, then push the FEED BAR RESET button.



288 FEED BAR OVERLOAD



The transfer equipment feed bar has detected an overload. Return the feed bar to its proper position, then push the FEED BAR RESET button.



289 FEED BAR LIFT POSITION



The transfer equipment feed bar has not been lifted. Return the feed bar to its proper position, then push the FEED BAR RESET button.



290 PRESET STOP SELECT



Set the PRESET STOP POSITION•TOP DEAD CENTER stop position switch to PRESET STOP POSITION.



291 MISGRIP SELECTOR ON



Set the transfer equipment MISGRIP switch to ON.



292 TCS IMMEDIATE STOP



The slide has stopped immediately upon receiving an Immediate Stop signal from the transfer.



slide has stopped immediately upon receiving an Immediate Stop 293 FEEDER IMMEDIATE STOP The signal from the feeder.



294 ROBOT IMMEDIATE STOP



The slide has stopped immediately upon receiving an Immediate Stop signal from the robot.



295 OVER MICRO SPM



The press machine speed limit for the MICRO INCH operation has been exceeded. Wait a moment until the speed is reduced to within the limits. The press machine speed limit for the INCH and SINGLE operation of



296 OVER INCH.&SINGLE SPM the transfer equipment has been exceeded. After adjusting the speed



to an appropriate level below the speed limit, push the RESET button.



134



297 OVER 3DIMENSION SPM



The three-dimension operation speed limit of the transfer equipment has been exceeded. After adjusting the speed to an appropriate level below the speed limit, push the RESET button.



298 FEED BAR CLAMP



Clamp the transfer equipment feed bar.



299 COUNT UP STOP 1



Preset stop Counter 1 has reached the preset quantity. Reset the counter to zero.



300 COUNT UP STOP 2



Preset stop Counter 2 has reached the preset quantity. Reset the counter to zero.



Section D OPERATION 5. RESETTING FAULTS



No.



Interlock Message



Description & Resetting Method



301 COUNT UP STOP 3



Preset stop Counter 3 has reached the preset quantity. Reset the counter to zero.



302 TCS PRESET STOP



The slide has been stopped by a preset stop signal from the transfer.



303 FEEDER PRESET STOP



The slide has been stopped by a preset stop signal from the feeder.



304 ROBOT PRESET STOP



The slide has been stopped by a preset stop signal from the robot.



305



MODE SELECTOR OFF (MICRO.)



The press machine cannot be operated unless the OPERATION SELECT switch is set to OFF (MICRO INCH).



306 BOTTOM DEAD CENTER



The press machine cannot be operated unless the slide is positioned at bottom dead center.



307 DIE LIFTER DOWN



The die lifter has moved up (the hydraulic pressure has increased) or die lifter UP has been selected. In order to start the selected operation, move the die lifter down.



308 LOWER DIE UNCLAMPED



CLAMP has been selected for the lower die clampers. In order to start the selected operation, unclamp the lower die clampers.



309 SLIDE ADJUSTMENT OFF



The press machine cannot be operated unless the SLIDE ADJUST switch is turned off.



311 DIE HEIGHT UPPER LIMIT



The slide has reached its upper limit during slide adjustment. No further upward adjustments can be made.



slide has reached its lower limit during slide adjustment. No fur312 DIE HEIGHT LOWER LIMIT The ther downward adjustments can be made.



313 TESTING EJECTOR 314



TESTING AUTOMATION EQUIPMENT



315 FAULT DETECTED



The ejector is in the test mode. To perform other operations, reset the test mode. The automation device is in the test mode. To perform other operation, reset the test mode. A fault has been detected. Identify the fault on the DIAGNOSIS screen on the MAINTENANCE screen. After pushing the LUBRICATING OIL button, wait a moment (approx-



OIL PUMP START / JUST A imately 10 seconds). If the oil pump does not reset even after waiting, 316 the oil quantity is low. Reset the fault as explained in message MOMENT description No. 256 LUBRICATING OIL.



LUBRICATING - PLEASE WAIT (1 MIN.)



If the message does not change after a short time, the lubricating oil quantity is low. Reset the fault as explained in message description No. 256 LUBRICATING OIL.



323 MODE SELECTOR: INCH



The MICRO INCH operation mode has been selected. Set the OPERATION SELECT switch to INCH. To operate the press machine in a mode other than MICRO INCH, turn the MICRO INCH mode off. (See (3)Selection of MICRO INCH Operation (pg. 99).)



324 FEED BAR JOINT CLAMP



The transfer equipment feed bar joint has been unclamped. Clamp the feed bar joint, then push the FEED BAR RESET button. Or, the feed bar has been locked. Clamp the feed bar joint.



317



325



FEED BAR JOINT UNCLAMP



CLAMP has been selected for the transfer equipment feed bar joint. To execute the selected operation, unclamp the feed bar joint.



326 FEED BAR UNCLAMP



CLAMP has been selected for the transfer equipment feed bar. To execute the selected operation, unclamp the feed bar.



327 DIMENSION: 2DIM.



The three-dimension setting for the transfer equipment is selected. To execute the selected operation, select the two-dimension (2 DIM.) setting for the transfer equipment.



328



329



SLIDE PRESET STOP POSITION



Operation cannot be executed unless the slide is positioned at the preset stop position.



PRESS PRIOR ACTION/OIL PUMP START



Push the LUBRICATING OIL button. The message changes to LUBRICATING - PLEASE WAIT (1 MIN.). If the message does not change after a short time, the quantity of lubricating oil is low. Reset the fault as explained in message description No. 256 LUBRICATING OIL.



330 DECK INTERLOCK



After making sure it is safe, close the door. The press machine cannot be operated unless the deck door is closed and locked.



135



Section D OPERATION 5. RESETTING FAULTS



No.



Interlock Message



331 OVER 2 DIMENSION SPM



Description & Resetting Method The two-dimension operation speed limit of the transfer equipment has been exceeded. After adjusting the speed to an appropriate level below the speed limit, push the RESET button.



332



FEED BAR TAKE OUT POSITION



Move feed bar to the take-out position.



333



FEED BAR ESCAPE POSITION



Move feed bar to the escape position.



334 CUSHION CLAMPER



Clamp the die cushion.



335



FORNT INNER PRESENCE The front presence-sensing device’s light beam has been interrupted. Reset the device to its normal state. After eliminating the cause of the SENS. DEVICE fault, push the RESET button.



336



REAR INNER PRESENCE SENS. DEVICE



The rear presence-sensing device’s light beam has been interrupted. Reset the device to its normal state. After eliminating the cause of the fault, push the RESET button.



337



FRONT AUX. PRESENCE SENS. DEVICE



The front auxiliary presence-sensing device’s light beam has been interrupted. Reset the device to its normal state.



338



REAR AUX. PRESENCE SENS. DEVICE



The rear auxiliary presence-sensing device’s light beam has been interrupted. Reset the device to its normal state.



339



PRESS TOP DEAD CENTER SELECT



Set the PRESET STOP POSITION•TOP DEAD CENTER stop position switch to TOP DEAD CENTER.



340



ROBOT UNIT ADJUSTMENT



A signal to tell that robot (AUTOHAND) is under adjustment in the UNIT mode is being fed. When AH MASTER switch is turned ON, the press machine cannot be operated. The press machine becomes operable in the UNIT mode by turning off the AH MASTER switch.



341



AUX. PRESENCE SENS. DEVICE



The auxiliary presence-sensing device’s light beam has been interrupted. Reset the device to its normal state.



342 REAR COVER



The press machine rear cover is opened. Close the cover.



343 LUB. PARAMETER CHECK The parameter setting is faulty. Contact AIDA Service. 344



TORQUE RELEASER IS ACTIVATED



Overload on the transfer equipment drive shaft caused disengagement of the coupling. Return the feed bar to its proper position, then push the FEED BAR RESET button.



345



PLEASE INITIALISE RECIPE'S DATA



The databank has not been cleared. You may continue the operation without taking any action. When you are going to reset, however, contact AIDA Service.



346



OIL COATING THERMAL TRIP



The oiling device thermal relay has tripped. (See 5.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 148).)



347



OIL COATING OIL SHORTAGE



The quantity of oil in the oiling device is low. Replenish the oil. After replenishing the oil, push the RESET button.



LOOP STRETCH 348 (STRAIGHTENER) 349



DIE COOLING THERMAL TRIP



350



DIE COOLING OIL SHORT- The quantity of oil in the die cooling device is low. Replenish the oil. After replenishing the oil, push the RESET button. AGE



351 STRAIGHTENER LINE



136



The state of the slack of the loop is improper, or operation of the straightener is improper. See the instruction manual for the straightener found at the end of this instruction manual or in a separate binder. The die cooling device thermal relay has tripped. (See 5.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 148).)



When the OPERATION SELECT switch is set to CONT., select the LINE operation mode on the straightener.



Section D OPERATION 5. RESETTING FAULTS



5.2 FAULT INFORMATION MESSAGE LIST The fault information message list shows various fault messages that are displayed on the MAINTENANCE screen on the operator interface terminal explained in 2.7.5 Fault Diagnosis (pg. 110), and they are arranged in the order of the message numbers. Find a message by using the message number displayed on the operator interface terminal. Note that this list may include messages that are not displayed on your system due to the options of your press machine.



Fault information



When the message FAULT DETECTED is displayed in the interlock information field during operation and a wrench symbol is displayed, see 2.7.5 Fault Diagnosis (pg. 110). No.



Fault Information Message



Description & Resetting Method



20



OPERATING SELECTOR FAILURE



The OPERATION SELECT switch signal is faulty. Check the switch, and replace it if necessary.



21



OPERATING SELECTOR FAULT



The OPERATION SELECT switch signal is faulty. Check the switch, and replace it if necessary.



22



EXTERNAL-BUTTON SELECTOR FAULT



The EXTERNAL•OFF•BUTTON switch signal is faulty. Check the switch, and replace it if necessary.



24



MASTER SELECTOR FAIL- Set the master selecting signal (press machine/feeder) to the proper position. URE



25



MASTER SELECTOR FAULT



The master selecting signal (press machine/feeder) is faulty. Check the selector, and replace it if necessary.



26 PSDI SELECTOR FAILURE Set the PSDI selector switch signal to the proper position. 27 PSDI SELECTOR FAULT



The PSDI selector switch signal is faulty. Check the switch, and replace it if necessary.



28



F.PRESENCE SENS.D.SW.FAILURE



The front presence-sensing device selector switch signal is faulty. Check the switch, and replace it if necessary.



29



F.PRESENCE SENS.D.SW.FAULT



The front presence-sensing device selector switch signal is faulty. Check the switch, and replace it if necessary.



30



PRESENCE SENS.D.OUTPUT FAULT



A failure has been detected in the presence-sensing device. Stop using the press machine immediately, and contact AIDA Service (see the end of this instruction manual).



31



R.PRESENCE SENS.D.SW.FAILURE



The rear presence-sensing device selector switch signal is faulty. Check the switch, and replace it if necessary.



32



R.PRESENCE SENS.D.SW.FAULT



The rear presence-sensing device selector switch signal is faulty. Check the switch, and replace it if necessary.



33



I.PRESENCE SENS.D.OUT- The internal presence-sensing device has faulty outputs. Check the device, and replace it if necessary. PUT FAULT



34



FRONT GUARD LIMIT SWITCH FAULT



The guard limit switch signal is faulty. Check the switch, and replace it if necessary.



35



REAR GUARD LIMIT SWITCH FAULT



The guard limit switch signal is faulty. Check the switch, and replace it if necessary.



137



Section D OPERATION 5. RESETTING FAULTS



No.



Fault Information Message



Description & Resetting Method



36



ADD.1 GUARD LIMIT SWITCH FAULT



The guard limit switch signal is faulty. Check the switch, and replace it if necessary.



37



ADD.2 GUARD LIMIT SWITCH FAULT



The guard limit switch signal is faulty. Check the switch, and replace it if necessary.



38



TWO-HAND RIGHT BUTTON FAULT



The RUN button switch signal is faulty. Check the switch, and replace it if necessary.



39



TWO-HAND LEFT BUTTON The RUN button switch signal is faulty. Check the switch, and replace it if necessary. FAULT



40



ADD.TWO-HAND R.BUTTON FAULT



The RUN button switch signal is faulty. Check the switch, and replace it if necessary.



41



ADD.TWO-HAND L.BUTTON FAULT



The RUN button switch signal is faulty. Check the switch, and replace it if necessary.



42



EXTERNAL RUN SIGNAL FAULT



The external start signal is faulty. Check and replace it if necessary.



43



EXTERNAL RUN SIGNAL FAILURE



The external start signal is faulty (where an external starter is connected). Cut off the start signal once, and perform the restart operation. If the message still remains, check the external start signal. When an external starter is not connected, this message is displayed when the EXTERNAL•OFF•BUTTON switch is placed in EXTERNAL and OFF or SINGLE mode is selected. In this case, select BUTTON on the EXTERNAL•OFF•BUTTON switch. (See 8.2 SELECTING THE EXTERNAL OPERATION (pg. 183).)



44



MASTER RUN SIGNAL FAULT



The Autohand / TCS master start signal is faulty. Check, and replace if necessary.



45



MASTER RUN SIGNAL FAILURE



The Autohand / TCS master start signal is faulty. Cut off the start signal once, and perform the restart operation. If the message still remains, check the autohand / TCS master start signal.



46



FEEDER MASTER RUN SIGN.FAULT



The feeder master start signal is faulty. Check, and replace if necessary.



47



FEEDER MASTER RUN SIGN.FAILURE



The feeder master start signal is faulty. Cut off the start signal once, and perform the restart operation. If the message still remains, check the feeder master start signal.



48



PRESET STOP POS.SELECTOR FAILURE



Set the PRESET STOP POSITION•TOP DEAD CENTER stop position switch to the proper position.



49



PRESET STOP POS.SELECTOR FAULT



The PRESET STOP POSITION•TOP DEAD CENTER stop position switch is faulty. Check the switch, and replace it if necessary.



50 CPU 5VDC FAULT



The 5 V power supply voltage inside the press controller is faulty. Contact AIDA Service.



51 CPU 24VDC FAULT



The 24 V power supply voltage being supplied to the press controller is faulty. Check and adjust the power voltage.



MPC CONTROLLER NORMAL OUTPUT



A controller normal output contact weld fault has been detected. Check whether the Emergency Stop wiring has a short.



56 PARAMETER SUM FAULT



A backup error has occurred in the parameters stored in the press controller. Set the parameters of the faulty block again.



57



LOADING DATA SUM FAULT



A backup error has occurred in the loading data stored in the press controller. Contact AIDA Service.



58



ANALOGUE SETTING DATA SUM FAULT



A backup error has occurred in the analog setting data stored in the press controller. Contact AIDA Service.



55



A write error has occurred in the press controller’s internal memory



59 EEPROM WRITE IN FAULT (EEPROM). Turn the power on again. If this error occurs repeatedly, contact AIDA Service.



60 DPRAM READ OUT FAULT



138



A read error has occurred in the press controller’s internal memory (DPRAM). Push the RESET button. If this error occurs repeatedly, contact AIDA Service.



Section D OPERATION 5. RESETTING FAULTS



No.



Fault Information Message



Description & Resetting Method



61 CL&BR CONTROL FAULT



An inconsistency has been detected in the press controller’s internal dual processing. Turn the power on again. If this error occurs repeatedly, contact AIDA Service.



62 CL&BR OUTPUT FAULT



Failure has been detected in the press controller’s internal clutch & brake output circuit. Push the RESET button. If this error occurs repeatedly, contact AIDA Service.



63



CL&BR OUTPUT FUSE CUT OFF



It has been detected that the press controller’s internal clutch & brake output circuit has a blown fuse. Push the RESET button. If this error occurs repeatedly, contact AIDA Service.



64



CL&BR SOL.VALVE MONITOR DETECT



The clutch & brake solenoid valve monitor has been activated. (See 5.8 WHEN THE CLUTCH & BRAKE SOLENOID VALVE MONITOR IS ACTUATED (pg. 147).)



65 INPUT SIGNAL FAULT



A faulty signal has been inputted to the press controller. Check the switch and other devices, and replace if required. This message represents all input signal failures shown in the fault list.



66 OVERRUN DETECT (MPC) An overrun has occurred. (See 5.4 OVERRUNS (pg. 146).) 68



PLC COMMUNICATION FAILURE



69 PLC BREAKDOWN



A communication data error has occurred between the PLC and MPC. Check the communication cable. Communication between the PLC and MPC has been interrupted. Check the communication cable.



70



ENCODER CONVERTER BREAKDOWN



A failure has been detected in the encoder converter. After checking the cable between the encoder and the encoder converter, reset the converter.



71



CRANK ENCODER BIT WRONG



Data loss has been detected in the crank angle data. Check the crank motion detector for proper installation and the cable connection.



72



CRANK MOTION MONITOR DETECT



A crank motion detector problem has been detected. Check the crank motion detector for proper installation and the cable connections. If the press machine is being operated at a speed level lower than the specified range, increase the speed.



73



TIMING SWITCH CAM SIG- The cam signal and motion detection proximity switch pattern is faulty. The motion detection proximity switch is faulty. Check the NAL (MPC) installation and wiring.



74



MOTION DET. PROXIMITY SW. (MPC)



75



DIE HEIGHT ENCODER BIT Data loss has been detected in the die height data. Check the die height detector for proper installation and the cable connections. WRONG



76



SLIDE ADJUSTMENT THERMAL TRIP



77



SLIDE ADJ.MOTION MONI- The slide adjusting device is faulty. Check that there are no obstructions in the slide. TOR



78



DIE HEIGHT COUNTER LIMIT SWITCH



The limit switch in the die height indicator is faulty. Check the limit switch, and replace it if necessary.



79



AUTO.SLIDE ADJ.OUT OF TARGET



Slide adjustment has not been done successfully. Confirm that there are no obstructions in the slide. Check the target value, and adjust the slide again.



80



PC COMMUNICATION FAILURE



A communication error has occurred between the MPC and the personal computer. Check the communication cable connection.



81



RECEIVE PARAMETER OUT OF AREA



Data outside of the preset range has been entered. Check the correct data to be entered and where it is to be entered. Then, re-enter the data.



82



PARAMETER BLOCK 0 FAULT



Data (a die number) outside of the preset range has been entered or the data is corrupt. Check the data and where it is supposed to be entered, and then re-enter the data.



83



PARAMETER BLOCK 1 FAULT



Data (cam angle data for cams 1 to 8) outside of the preset range has been entered or the data is corrupt. Check the data and where it is supposed to be entered, and then re-enter the data.



The motion detection proximity switch is faulty. Check the installation and wiring.



The thermal relay for the slide adjust motor has tripped. (See 5.9 WHEN A THERMAL RELAY HAS TRIPPED (pg. 148).)



139



Section D OPERATION 5. RESETTING FAULTS



No.



Fault Information Message



Description & Resetting Method



84



PARAMETER BLOCK 2 FAULT



Data (die protection data) outside of the preset range has been entered or the data is corrupt. Check the data and where it is supposed to be entered, and then re-enter the data.



85



PARAMETER BLOCK 3 FAULT



Data (cam angle data for cams 9 to 16) outside of the preset range has been entered or the data is corrupt. Check the data and where it is supposed to be entered, and then re-enter the data.



86



PARAMETER BLOCK 4 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact AIDA Service.



87



PARAMETER BLOCK 5 FAULT



Data (die height) outside of the preset range has been entered or the data is corrupt. Check the data and where it is supposed to be entered, and then re-enter the data.



88



PARAMETER BLOCK 6 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact the AIDA Service.



89



PARAMETER BLOCK 7 FAULT



Data (cam angle data for cams 17 to 24) outside of the preset range has been entered or the data is corrupt. Check the data and where it is supposed to be entered, and then re-enter the data.



90



PARAMETER BLOCK 8 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact AIDA Service.



91



PARAMETER BLOCK 9 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact AIDA Service.



92



PARAMETER BLOCK 10 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact AIDA Service.



93



PARAMETER BLOCK 11 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact AIDA Service.



94



PARAMETER BLOCK 12 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact AIDA Service.



95



PARAMETER BLOCK 13 FAULT



Data (data set by the manufacturer) outside of the preset range has been entered or the data is corrupt. Contact AIDA Service.



96 PLC BATTERY FAILURE



The PLC built-in battery has not been installed or has low voltage. Confirm that the battery is properly installed. If the battery has been depleted, replace it. (See Section E MAINTENANCE, 4.4 REPLACING THE BUILT-IN PLC BATTERY (pg. 212).)



97



MPC-PLC COMMUNICATION FAILURE



Communication between the PLC and MPC has been interrupted. Check the communication cable connection.



98



MPC-PLC COMMUNICATION FAILURE



Communication between the PLC and MPC has been interrupted. Check the communication cable connection.



99 OVERRUN DETECT (PLC)



An overrun has occurred. (See 5.4 OVERRUNS (pg. 146).)



101



MOTION DET.PROXIMITY SW. (PLC)



103



TIMING SWITCH CAM SIG- A timing switch cam signal failure on the PLC side has been detected. Check the switch, and replace it if necessary. NAL (PLC)



105



OPE.SELECTOR AUTOHAND MASTER



A motion detection proximity switch fault on the PLC side has been detected. Check the switch, and replace it if necessary.



The AH MASTER switch signal is faulty. Check the switch, and replace it if necessary.



UNIT•LINE switch signal is faulty. Check the switch, and replace 106 OPE.SELECTOR UNIT-LINE The it if necessary.



140



107



PLC SYSTEM SET UP AREA



A faulty setting has been found in the PLC system setting. Contact AIDA Service.



108



PLC SYSTEM SET UP AREA



A faulty setting has been found in the PLC system setting. Contact AIDA Service.



109



PLC SYSTEM SET UP AREA



A faulty setting has been found in the PLC system setting. Contact AIDA Service.



Section D OPERATION 5. RESETTING FAULTS



No.



Fault Information Message



Description & Resetting Method The PLC program process (scan) time has exceeded 100 ms. Turn



110 PLC SCAN TIME MONITOR the power on again. If this failure occurs repeatedly, contact AIDA Service.



111 100VAC,24VDC FAILURE



The 24V power supply voltage supplied to the press controller is faulty. Check and adjust the power supply voltage.



112 100VAC,24VDC FAILURE



Activation of the controller has not been confirmed. Check the communication cable connection, or check the controller power supply. This message is also displayed for Emergency Stops. Referring to interlock message No. 200 INITIAL / E-STOP BUTTON RELEASE (pg. 132) included in 5.1 INTERLOCK INFORMATION MESSAGE LIST, reset the Emergency Stop.



115 PLC USER PROGRAM



Data cannot be transferred normally between the PLC unit and the memory cassette.



116 PLC USER PROGRAM



Data cannot be transferred normally between the PLC unit and the memory cassette.



117 PLC USER PROGRAM



Data cannot be transferred normally between the PLC unit and the memory cassette.



118 PLC USER PROGRAM



Data cannot be transferred normally between the PLC unit and the memory cassette.



PLC-MPC INTERLOCK WIRE



Interlock wiring between the PLC and MPC is faulty. Check the wiring.



119



wiring for clutch & brake output monitoring signals of the PLC is 120 CLUTCH&BRAKE OUTPUT The faulty. Check the wiring. MPC>PLC NORMAL PULSE The wiring for MPC > PLC normal pulse signals is faulty. Check the 121 wiring. WIRE



122 MPC CPU STOP 123



The PLC has detected that the CPU of the MPC has stopped. Turn the power on again. If this failure occurs repeatedly, contact AIDA Service.



MPC DUAL CPU COMPARI- The MPC dual CPU comparison has detected an inconsistency. Turn the power on again. If this failure occurs repeatedly, contact AIDA SON Service.



124 PLC NORMAL OUTPUT



A weld fault has been detected in the PLC normal output contact. Check whether the Emergency Stop circuit wiring has shorted.



125



MAIN MOTOR REV.FWD.SELECTOR



The main motor REV.•OFF•FWD. switch signal is faulty. Check the switch, and replace it if necessary.



126



OPE.SELECTOR OFF SIGNAL FAULT



The OPERATION SELECT switch PLC input signal is faulty. Check the switch, and replace it if necessary.



127 LUB.CHECK SENSOR



The oil pump pressure switch signal is faulty. Check the switch, and replace it if necessary.



141



Section D OPERATION 5. RESETTING FAULTS



5.3 HYDRAULIC OVERLOADS When the press machine is overloaded, the hydraulic overload protector actuates, the message OVERLOAD is displayed in the interlock information field, and the slide immediately stops. (1) When the slide stop position is past bottom dead center, see 5.3.1 When the Slide Stop Position is Past Bottom Dead Center. When the slide stop position is before bottom dead center, see 5.3.2 When the Slide Stop Position is Before Bottom Dead Center. When the slide stop position is before bottom dead center, the overload reset procedure cannot be performed if you use the INCH mode with FORWARD rotation. (2) In either case, raise the slide to top dead center to release the overload. Then, perform the reset procedure described in 5.3.3 Resetting Overloads. 5.3.1 When the Slide Stop Position is Past Bottom Dead Center



1



Set the OPERATION SELECT switch to INCH, and push the RESET button.



2



Push the MAIN MOTOR STOP button to stop the main motor.



3



In the INCH mode, raise the slide to top dead center using the inertial rotation of the flywheel.



5.3.2 When the Slide Stop Position is Before Bottom Dead Center When a > is not provided and a > or > is used:



1



Push the MAIN MOTOR STOP button to stop the main motor.



2



Perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



Switch the L1 (R) phase and L3 (T) phase of the three-phase power supply to the main motor electromagnetic switch (located inside the control panel). This enables reverse rotation of the main motor. After clearing the overload, be sure to reconnect the L1 (R) phase and L3 (T) phase to their original positions.



4



Reverse the steps of the Safety Procedures During Adjustment performed in step 2 above. Go behind the press machine and visually confirm that the flywheel has stopped.



5



Set the OPERATION SELECT switch to INCH, and push the RESET button. (Continued on the next page)



142



Section D OPERATION 5. RESETTING FAULTS



(Continued)



6



Push the MAIN MOTOR START button. Check the direction of motor rotation and confirm that the MAIN MOTOR RUN light is flashing. After checking these items, push the MAIN MOTOR STOP button.



7



In the INCH mode, raise the slide to top dead center using the inertial rotation of the flywheel.



When a > is not provided and an is used:



1



Push the MAIN MOTOR STOP button to stop the main motor.



2



Perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



Remove the terminal cover of the programmable logic controller terminal box (located in the control panel), and switch the terminals “Y100” and “Y101”. This enables reverse rotation of the main motor. After clearing the overload, be sure to reconnect “Y100” and “Y101” to their original locations.



Y1 0 1 Y101



Y1 00 Y100



Y1 0 0 Y100



Y1 01 Y101



4



Reverse the steps of the Safety Procedures During Adjustment performed in step 2 above. Go behind the press machine and visually confirm that the flywheel has stopped.



5



Set the OPERATION SELECT switch to INCH, and push the RESET button.



6



Push the MAIN MOTOR START button. Check the direction of motor rotation and confirm that the MAIN MOTOR RUN light is flashing. After checking these items, push the MAIN MOTOR STOP button.



7



In the INCH mode, raise the slide to top dead center by using the inertial rotation of the flywheel. (Continued on the next page)



143



Section D OPERATION 5. RESETTING FAULTS



(Continued) When a > is provided:



1



Push the MAIN MOTOR STOP button to stop the main motor.



2



Go behind the press machine and visually confirm that the flywheel has stopped. After confirming this, set the main motor REV.•OFF•FWD. switch to REV.



3



Set the OPERATION SELECT switch to INCH, and push the RESET button.



4



Push and hold down the MAIN MOTOR START button for about five to ten seconds. (When the button is released, the flywheel rotates using its own inertia.)



5



In the INCH mode, raise the slide to top dead center by using the inertial rotation of the flywheel.



5.3.3 Resetting Overloads



1



When the overload is cleared, the hydraulic overload protector pneumatic pump will operate for approximately one minute to restore the hydraulic pressure to its normal level. The pneumatic pump will stop when the hydraulic pressure reaches the predetermined level. Stop the slide at top dead center; and if the pump does not stop after three minutes, see Section E MAINTENANCE, 2.5 OIL SERVICING OF HYDRAULIC OVERLOAD PROTECTOR (pg. 198).



144



2



Perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



The following inspection must be performed by qualified personnel. Repair work on dies must be performed according to Section A SAFETY, 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS (pg. 31). (1) Confirm that the specified tonnage capacity has not been exceeded. (2) Check whether the dies have failed (including seizure, breakage, double-blank stamping, misalignment, loose bolts, and improper installation).



4



When a main motor REV.•OFF•FWD. switch is not provided: Reconnect the switched wires as originally positioned. When a main motor REV.•OFF•FWD. switch is provided: Set the switch to FWD.



5



Reverse the steps of the Safety Procedures During Adjustment performed in step 2 above. Go behind the press machine and visually confirm that the flywheel has stopped. (Continued on the next page)



Section D OPERATION 5. RESETTING FAULTS



(Continued)



6



Push the MAIN MOTOR START button. Check that the MAIN MOTOR RUN light goes on.



7



If required by the die configuration, use the slide adjust function to raise the slide by about 3 mm. (See pg. 151.)



8



Operate the slide in INCH mode for two or three strokes to confirm that there are no faults.



9



Operate the slide in SINGLE mode for two or three strokes to confirm that there are no faults.



145



Section D OPERATION 5. RESETTING FAULTS



5.4 OVERRUNS When an overrun is detected during operation, the slide immediately stops and a wrench symbol is displayed on the operator interface terminal. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) When you access the 2.7.5 Fault Diagnosis (pg. 110) screen, the message OVERRUN DETECT (MPC) or OVERRUN DETECT (PLC) is displayed. In either case, immediately stop press machine operations and stop the main motor. Then perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33) and consult with AIDA Service (see the end of this instruction manual).



5.5 WHEN THE EMERGENCY STOP BUTTON HAS BEEN PUSHED When the EMERGENCY STOP button is pushed while the slide is in motion, the slide immediately stops and the message EMERGENCY STOP (BUTTON) is displayed in the interlock information field. Follow the procedure described below to reset the machine.



146



1



Push the MAIN MOTOR STOP button to stop the main motor.



2



Perform steps (2) through (3) described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



Eliminate the causes that led to the EMERGENCY STOP button being pushed.



4



Reverse the steps of the Safety Procedures During Adjustment performed in step 2 above.



5



Push the MAIN MOTOR START button. Check that the MAIN MOTOR RUN light goes on.



6



Turn the EMERGENCY STOP button in the reset (arrow) direction.



7



Set the OPERATION SELECT key switch to INCH and inch the slide to the preset stop position.



Section D OPERATION 5. RESETTING FAULTS



5.6 WHEN THE EXTERNALLY CONTROLLED BREAKER IS ACTUATED



SE



T



TR



IP



ON



RE



When the externally controlled breaker is actuated, the slide immediately stops and the POWER light goes out. If this occurs, immediately stop press machine operations and find the cause. Follow the resetting procedure described below. • Turn the handle once from TRIP to RESET, and then return it to ON.



5.7 WHEN THE GROUND FAULT BREAKER IS ACTUATED When the ground fault breaker is actuated, the slide immediately stops and the POWER light goes out. If this occurs, immediately stop press machine operations and find the cause. If the cause remains unknown after troubleshooting, contact AIDA Service (see the end of this instruction manual). Follow the resetting procedure described below:



1



Perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Open the control panel door.



3



Move the ground fault breaker handle down once to OFF, then return it to ON. (See pg. 211.)



4



Close the control panel door.



5



Reverse the steps of the Safety Procedures During Adjustment performed in step 1 above.



5.8 WHEN THE CLUTCH & BRAKE SOLENOID VALVE MONITOR IS ACTUATED When the clutch and brake (CL & BR) solenoid valve monitor has detected an abnormal condition during operation, the slide immediately stops, and a wrench symbol is displayed on the operator interface terminal. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) When you access the 2.7.5 Fault Diagnosis (pg. 110) screen, the message CL&BR SOL.VALVE MONITOR DETECT is displayed. In this case, immediately stop press machine operations and stop the main motor. Then, perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33), and contact AIDA Service (see the end of this instruction manual).



147



Section D OPERATION 5. RESETTING FAULTS



5.9 WHEN A THERMAL RELAY HAS TRIPPED



IMPORTANT • The rated current of the thermal relays are preset at the factory before shipment. Any additional adjustment is strictly prohibited. • If motors are frequently started and stopped, the thermal relay can trip. Avoid such frequent starting/stopping operations. On NC1-2000 and NC1-2500 press machines or press machines with upgraded counterbalance capacities (option), the thermal relay may trip due to improper adjustment of the counterbalance capacity. Be sure to adjust the counterbalance capacity properly. (See 6.2 COUNTERBALANCE CAPACITY ADJUSTMENT (pg. 154).) When the thermal relay for the main motor trips, the slide immediately stops and the message MAIN MOTOR THERMAL TRIP is displayed in the interlock information field (if a fixed speed motor or VS motor is used). When the thermal relay for the oil pump trips, the oil pump stops, and the message LUBRICATING OIL is displayed in the interlock information field. When the thermal relay for the slide adjust motor trips, the slide adjustment feature is disabled. At the same time, a wrench symbol is displayed on the operator interface terminal. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) When you access the 2.7.5 Fault Diagnosis (pg. 110) screen, the message SLIDE ADJUSTMENT THERMAL TRIP is displayed. Reset the fault by following the procedure described below. In addition, if a thermal relay on an option has been tripped, perform the applicable fault resetting procedure. See the electrical circuit drawings shown in Section E MAINTENANCE, 11. DRAWINGS (pg. 265) for details.



1



Push the MAIN MOTOR STOP button to stop the main motor.



2



Perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



Open the control panel door.



4



Push the thermal relay reset button located on the lower side of the electromagnetic switch. The relay will make a clicking sound when it is reset.



5



Close the control panel door.



6



Reverse the steps of the Safety Procedures During Adjustment performed in step 2 above. (Continued on the next page)



148



Section D OPERATION 5. RESETTING FAULTS



(Continued)



7



If the thermal relay trips again, one of the mechanical parts may be faulty. In this case, be sure to immediately stop press machine operations and perform troubleshooting. If you cannot ascertain the cause of the problem, contact AIDA Service (see the end of this instruction manual). Electromagnetic switch for the main motor



Electromagnetic switch for oil pump



Electromagnetic switch for slide adjusting motor



Thermal relay reset button Rated current setting scale (For fixed-speed or VS motors)



Thermal relay reset button Rated current setting scale



• The actual shape of the electromagnetic switch may differ slightly.



149



Section D OPERATION 5. RESETTING FAULTS



5.10 STICKING Sticking is a condition where the upper and lower dies ram into each other in the vicinity of bottom dead center, causing the clutch to slip and preventing slide movement. The wrench symbol will be displayed on the operator interface terminal. When you access the 2.7.5 Fault Diagnosis (pg. 110) screen on the MAINTENANCE screen, the message CRANK MOTION MONITOR DETECT will be displayed. When unsticking the press machine, follow the instructions described in Section A SAFETY, 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS (pg. 31).



IMPORTANT • Be sure to follow the procedure described below when performing unsticking operations. Never use the slide adjustment device to attempt to unstick the press machine. This can damage the slide adjustment mechanism.



150



1



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Relieve the hydraulic pressure in the hydraulic overload protector by loosening the hydraulic pressure release bolt on the pneumatic pump (located on the back side of the slide) approximately one turn. Once the hydraulic pressure is relieved, retighten the bolt. (See Section E MAINTENANCE, 2.5 OIL SERVICING OF HYDRAULIC OVERLOAD PROTECTOR (pg. 198).)



Hydraulic overload protector pneumatic pump Air bleed bolt



Hydraulic pressure release bolt



3



Reverse the steps of the Safety Procedures During Adjustment performed in step 1 above.



4



Stop the slide at top dead center according to the procedure in Section D OPERATION, 5.3 HYDRAULIC OVERLOADS (pg. 142). Confirm that the hydraulic overload protector builds up to the normal hydraulic pressure.



5



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33) again. Eliminate the cause of sticking.



6



Perform steps 3 through 9 of the resetting procedure explained in Section D OPERATION, 5.3.3 Resetting Overloads (pg. 144).



Section D OPERATION 6. ADJUSTMENT



6. ADJUSTMENT Complete the inspection and operation described in Section D OPERATION, 3.2 ROUTINE INSPECTION AND OPERATION (pg. 121) before performing adjustments.



6.1 SLIDE ADJUSTMENT



WARNING • When the press machine is equipped with a mechanical knockout (option), raise the strike pin to the top or remove the pin before adjusting the slide upward. Otherwise, the knockout bar may hit the strike pin and cause breakage or failure, and may result in personal injury or death.



IMPORTANT • Do not use the slide adjustment device for any purpose other than slide adjustment. The slide adjustment device has no pre-loading capability to press the upper and lower dies together. If the slide adjustment device is used for performing presswork or for pressing the upper and lower dies together, the motor can overheat or slide adjustment components can be broken. The die height indicator (see Section B SPECIFICATIONS, 4. NAMES OF MAJOR COMPONENTS (pg. 63)) displays the distance between the top of the bolster and the bottom of the slide when the slide is at bottom dead center. Slide adjustment must be performed by qualified personnel according to the procedure described below.



151



Section D OPERATION 6. ADJUSTMENT



6.1.1 Manual Slide Adjustment



Perform the following procedure to manually adjust the die height:



1



Set the OPERATION SELECT key switch to OFF and remove the key from the key switch.



2



Confirm that there are no other operators present in the point of operation.



3



Confirm that the operator interface terminal shows the RUN or SET UP screen. Set the SLIDE ADJUST switch to ON. (See pg. 89.) The MANUAL SLIDE ADJUSTMENT screen will be displayed. (See Section D OPERATION, 2.6.1 Manual Slide Adjustment (pg. 105).)



4



Confirm that the message OPERATION READY is displayed in the interlock information field. If any other message is shown, reset the applicable interlock according to Section D OPERATION, 5.1 INTERLOCK INFORMATION MESSAGE LIST (pg. 132).



5



Push the flashing green UP/UNCLAMP/RET. button or the orange DOWN/CLAMP/ADV. button, which are located on the front of the operation button box. The slide then moves up or down. Releasing the button stops the slide. Adjust the slide while viewing the die, the knockout bar, and the die height indicator. The flashing light changes to a steadily lit state when the slide reaches the upper or lower end of the slide adjustment and cannot be moved any more.



6



(DOWN)



After adjustment, set the SLIDE ADJUST switch to OFF. The screen will return to the previous screen.



NOTE



152



(UP)



• Die conditions permitting, AIDA recommends that slide adjustments be performed with the slide at the preset stop position.



Section D OPERATION 6. ADJUSTMENT



6.1.2 Automatic Slide Adjustment (Option)



The slide is automatically adjusted to the preset die height “target value”.



1



Set the OPERATION SELECT key switch to OFF and remove the key from the key switch.



2



Confirm that there are no other operators present in the point of operation.



3



Confirm that the operator interface terminal shows the RUN or SET UP screen. Set the SLIDE ADJUST switch to ON. (See pg. 89.) The MANUAL SLIDE ADJUSTMENT screen will be displayed. (See Section D OPERATION, 2.6.1 Manual Slide Adjustment (pg. 105).)



4



Press the AUTO. SLIDE ADJUSTMENT touchbutton to display the AUTO. SLIDE ADJUSTMENT screen. (See Section D OPERATION, 2.6.2 Automatic Slide Adjustment (Option) (pg. 105).)



5



Set to the desired “target value” of die height. Press the SET TARGET VALUE touchbutton on the AUTO. SLIDE ADJUSTMENT screen to display the DIE HEIGHT SETTING screen (see 2.6.3 Die Height Setup Screen (Option) (pg. 106). Enter the target value on this screen. After entering the target value, return to the AUTO. SLIDE ADJUSTMENT screen.



6



Confirm that the message OPERATION READY is displayed in the interlock information field. If any other message is shown, reset the applicable interlock according to Section D OPERATION, 5.1 INTERLOCK INFORMATION MESSAGE LIST (pg. 132).



7



Push the flashing green UP/UNCLAMP/RET. button located on the front face of the operation button box. The slide then moves up or down and stops at the “target value”. To stop the slide halfway during the automatic adjustment, push the orange DOWN/CLAMP/ADV. button. Before making slide adjustments, confirm that there is no interference with the dies or knockout bar. (Note that the “current value” (actual slide stop position) may be slightly different from the “target value” due to brake slippage or other reasons.)



8



(START)



(STOP)



After adjustment, set the SLIDE ADJUST switch to OFF. The screen will return to the previous screen.



153



Section D OPERATION 6. ADJUSTMENT



6.2 COUNTERBALANCE CAPACITY ADJUSTMENT Counterbalance capacity adjustments are required on NC1-2000 and NC1-2500 press machine models, and on press machines with upgraded counterbalance capacities (option). For any other configurations (standard specifications), no adjustment is necessary.



WARNING • Before operating the machine or adjusting the slide, properly adjust the counterbalance capacity to the level that matches the upper die weight. The adjustment of the counterbalance capacity must be done according to the RELATIONSHIP OF UPPER DIE WEIGHT TO BALANCER AIR PRESSURE instruction plate. If the counterbalance capacity does not match the upper die weight, the slide may descend, leading to an accident causing personal injury or death. Position the slide at top dead center, then adjust the counterbalance air pressure according to the following procedure. For the location of the counterbalance air pressure regulator and pressure gauge, see Section B SPECIFICATIONS, 4. NAMES OF MAJOR COMPONENTS (pg. 63).



1



Loosen the regulator lock nut.



2



To Increase Capacity: Turn the handle of the regulator clockwise to set the air pressure to the required level indicated on the RELATIONSHIP OF UPPER DIE WEIGHT TO BALANCER AIR PRESSURE instruction plate.



3



To Decrease Capacity: Turn the handle of the regulator counterclockwise to decrease the air pressure to a level lower than the required air pressure displayed on the RELATIONSHIP OF UPPER DIE WEIGHT TO BALANCER AIR PRESSURE instruction plate. Next, turn the handle clockwise to gradually increase the air pressure to the required level.



4



When the required air pressure is reached, tighten the regulator lock nut.



NOTE



154



• When the counterbalance air pressure is set to the minimum operating pressure indicated on the RELATIONSHIP OF UPPER DIE WEIGHT TO BALANCER AIR PRESSURE instruction plate, the pressure switch interlock may actuate due to a pressure gauge indication error or some other cause, thereby making the press inoperable. In this case, first adjust the counterbalance air pressure to a level approximately 0.05 MPa higher than the required pressure. Next, slowly turn the handle of the regulator counterclockwise to reach the required pressure level.



Section D OPERATION 6. ADJUSTMENT



6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) The die cushion capacity can be set by adjusting the operating air pressure in accordance with the information given on the DIE CUSHION CAPACITY - AIR PRESSURE instruction plate. The operating air pressure must be adjusted by qualified personnel according to the following procedure. For devices related to the operation of the die cushion air pressure, see Section B SPECIFICATION, 4. NAMES OF MAJOR COMPONENTS (pg. 63).



1



Slowly turn the handle of the manual die cushion valve clockwise (in the "IN" direction).



2



Loosen the regulator lock nut.



3



To Increase Capacity: Turn the handle of the regulator clockwise to set the air pressure to the required pressure level indicated on the DIE CUSHION CAPACITY - AIR PRESSURE instruction plate.



4



To Decrease Capacity: (1) Turn the handle of the regulator counterclockwise. (2) Turn the handle of the manual die cushion valve counterclockwise (in the "EXH" direction) to decrease the air pressure to a level lower than the required air pressure displayed on the DIE CUSHION CAPACITY - AIR PRESSURE instruction plate. (3) Next, turn the handle of the manual die cushion valve clockwise (in the "IN" direction). (4) Turn the handle of the regulator clockwise to gradually increase the air pressure to the required level.



5



When the required air pressure is reached, tighten the regulator lock nut.



>



ＩＮ Setting the knob to this position will allow air to be supplied to the die cushion, thereby raising the die cushion.



ＥＸＨ ＥＸＨ Setting the knob to this position will allow air to be exhausted from the die cushion, thereby lowering the die cushion.



ＩＮ



155



Section D OPERATION 6. ADJUSTMENT



6.4 MECHANICAL KNOCKOUT ADJUSTMENT (OPTION)



DANGER • Do not touch the knockout bar while the slide is moving or being adjusted. If touched, there is the danger of a hand being caught in the knockout bar. This adjustment is to be done after the procedure described in Section D OPERATION, 7.1.1 Die Loading (when Using AIDA Equipment) (pg. 163), is completed. The adjustment must be done by qualified personnel according to the following procedure after the slide is positioned at top dead center.



1



Perform steps (1) through (4) described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Loosen the bracket hex bolts.



3



Adjust the position of the strike pin against the knockout bar so that the gap between the tip of the strike pin and the top face of the knockout bar is approximately 10 mm. Adjust both sides to ensure that the same gap is created on both sides.



4



Retighten the hex bolts.



5



Reverse the steps of the Safety Procedures During Adjustment performed in step 1 above.



NOTE



156



１０ｍｍ



• Some models come with a T-wrench designed specifically for the hex bolts. (See pg. 247.)



Section D OPERATION 6. ADJUSTMENT



6.5 HOLP LOW PRESSURE SETTING DEVICE (OPTION)



IMPORTANT • Do not adjust the hydraulic overload protector (HOLP) regulator located on the back of the slide. Adjusting the regulator may damage the slide, connecting rod, crankshaft, frame, etc. • Do not set the capacity and/or air pressure to a level below the specified range shown on the PRESS CAPACITY / AIR PRESSURE instruction plate. If it is set below the specified range, the hydraulic pressure switch will be actuated and press machine operation will be disabled. • When you do not use the hydraulic overload protector (HOLP) low pressure setting device, set the HOLP SET switch to NORMAL. The following setting procedure must be performed by qualified personnel. The PRESS CAPACITY / AIR PRESSURE instruction plate shows the relationship between press machine capacity and air pressure.



1



Set the HOLP SET switch to RELEASE. The hydraulic overload protector (HOLP) drops to a level lower than the set level.



2



Unlock the regulator knob (2) by pulling the regulator locking ring (1) outwards (away) from the regulator. This will enable adjustments.



3



Set the HOLP SET switch to LOW.



4



Turn the regulator (2) clockwise or counterclockwise to set the air pressure to the required pressure indicated on the PRESS CAPACITY / AIR PRESSURE instruction plate.



5



Push the locking ring back in. Confirm that the regulator is locked by trying to lightly turn the regulator knob. Instruction plate Pressure gage (1)



HOLP SET switch (2)



Regulator



LOW NORMAL RELEASE



Left side of frame



157



Section D OPERATION 6. ADJUSTMENT



6.6 SETTING TIMING SWITCHES



WARNING • Timing switch settings must be performed by qualified personnel in cooperation with a qualified electrician. Settings made by unqualified personnel may lead to an accident causing personal injury or death. • Except for ejector and automation device (option) data, do not change the data settings made by AIDA. If changed, personal injury or death can be caused due to unexpected actuation and motion. • AIDA will not be held liable for any accidents resulting in personal injury or death nor for any damages to the press machine that are caused by entering data that is different from the preset data entered by AIDA at the time the press machine was shipped from the factory, or by the usage of data entered by the user on a user-furnished device without consulting AIDA. • Be sure to set the OPERATION SELECT switch to OFF before operating the timing switch. Otherwise, the slide or other related devices may inadvertently start, leading to an accident causing personal injury or death.



6.6.1 What is a Timing Switch?



A timing switch is used to synchronize ejectors, automation devices (option), and other equipment with the press machine. For instance, if you require an ejector to actuate at a press machine crank angle of 10° and stop at 20°, you can set this operational sequence using a timing switch. In this case, you would set the ON angle to 10° and the OFF angle to 20°. This machine is equipped with an ejector as standard equipment. You can use “CAM 1" to make ejector settings. For other options, see 6.6.4 Cam Allocation List (pg. 160). To change the timing switch settings, set the Data Write “O” (OFF)•“|” (ON) Key Switch (pg. 88) to “|” (ON). To make data settings using the operator interface terminal, see Section D OPERATION, 2.5 THE DATA SCREEN (pg. 101).



6.6.2 Types of Timing Switch Cams > A cam that turns on at a preset ON angle and turns off at a preset OFF angle. > A cam that turns on at an ON angle and turns off when a preset time has elapsed. No OFF angle is used for timer cams. The time can be set between 0.1 to 9.9 seconds in increments of 0.1 seconds. When a cam is not used as a timer cam (i.e., the TIMER is set to “0”), the cam will function as a regular cam and will simply operate according to the ON and OFF angles.



(Continued on the next page)



158



Section D OPERATION 6. ADJUSTMENT



(Continued) > These cams allow the ON and OFF angles to gain (advance) in proportion to the press machine speed (spm). The gain angle settings are made by specifying the maximum gain angle for the maximum press machine speed (spm). When a cam is not used as a gain angle cam (i.e., the ON GAIN and OFF GAIN are set to “0”), the cam will function as a regular cam and will simply operate according to the ON and OFF angles. ON GAIN .........Sets the gain angle for the ON angle. OFF GAIN........Sets the gain angle for the OFF angle. 6.6.3 About the Automatic Gain Angle Function



The gain angle function automatically adjusts the signaling timing for equipment actuation (for example, the timing of peripheral device ON and OFF signals) in relation to changes in the press machine speed. If the gain angle function is not used (i.e., no gain angle is set), devices synchronized with the press machine operation will lag behind press machine motions as the press machine speed increases. When comparing operation at two different press machine speeds, for example at 30 spm and at 100 spm, the responsiveness of press machine peripheral devices would lag more at 100 spm than at 30 spm. In this scenario, although the actuator is actuating at 50° when the press machine is running at 30 spm, at 100 spm it would be actuating at 70°, etc. To compensate for such time delays, the gain angle function can be effectively used to offer better responsiveness to increases in press machine speed. > The gain angle settings for ON GAIN and OFF GAIN should be set by specifying the maximum gain angle at the maximum press machine speed (spm). Calculate the maximum gain angle (the setting value) at the maximum press machine speed (spm) by using the formula below, which is based on your actual press machine speed (spm) and the desired gain angle. If the maximum press machine speed (spm) equals the actual press machine speed (spm), or the motor used is a fixed-speed type, the desired gain angle value becomes the setting value. The maximum speed (spm) of your press machine is shown on the specification plate.



Desired gain angle Gain setting value "A" = Example)



Actual speed



× Max. spm



Actual press machine speed = 65 spm, Desired gain angle = 10°, Max press machine speed = 75 spm. 10 × 75 = 11.5 → 11 65 Therefore, the setting would be “11”.



When you want to individually set the ON GAIN and OFF GAIN, determine each setting value separately. NOTE



• AIDA recommends that the ON GAIN and OFF GAIN be set to the same value. • If the ON GAIN and OFF GAIN are set to different values, it is very important that the gain OFF ANGLE does not precede the gain ON ANGLE. Otherwise, the cam outputs may be reversed.



159



Section D OPERATION 6. ADJUSTMENT



6.6.4 Cam Allocation List



Note that your actual cam allocation may be different from the allocation pattern shown in this list due to differences in options, etc. To confirm your actual cam allocation, see the electrical circuit drawings in Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings. Cam 1



Standard Ejector



-



Option 2



Cam Type



-



Timer cam



2



-



Ejector 2



-



Timer cam



3



-



Automation 1



-



Timer cam



4



-



Automation 2



-



Timer cam



5



Reserved



-



-



Gain angle cam



6



Reserved



-



-



Gain angle cam



7



Reserved



-



-



Gain angle cam



8



Reserved



-



-



Gain angle cam



9



-



LF work roll release ORII LF timing



Gain angle cam



10



-



LF release



AF release



Gain angle cam



11



-



LF feed 1



AF feed



Gain angle cam



12



-



LF feed 2



AF zigzag



Gain angle cam



13



-



Misfeed detection



-



Regular cam



14



-



Pass-through detection



-



Regular cam



15



-



Scrap detection



-



Regular cam



16



-



Tonnage monitor



-



Regular cam



17



-



TCV 3-dimension



NCAH preset stop position



Regular cam



18



-



TCV misgrip



NCAH top dead center



Regular cam



19



-



TCV return



NCAH feedbar down



Regular cam



20



-



TCV FB separation



NCAH feedbar down confirmation



Regular cam



21



-



SHO start



NCAH lap operation 1



Regular cam



22



-



AH top dead center



NCAH lap operation 2



Regular cam



23



-



AH lap operation



NCAH lap operation 3



Regular cam



24



-



AH synchronization NCAH operation detection check



NOTE



160



Option 1



Regular cam



• Four cams are reserved as standard spares. • Four or eight cams can be added as an option. • In some cases, cams 17 to 24 are reserved for use by the manufacturer.



Section D OPERATION 7. CHANGING DIES



7. CHANGING DIES



WARNING • When it is necessary to place your hand between the upper and lower dies in order to change or adjust dies, or for maintenance or repairs, first be sure to perform steps (1) through (5) described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33). • When you have lifted up the die lifter arms or installed the removable extension rails, be sure to shake the die lifter arms or the removable extension rails to verify that they are securely fixed. If any of them are not securely fixed, the dies can drop out of position, causing personal injury or death.



CAUTION • Avoid jolting the die lifter arms or rails when placing a set of dies. The arms or rails can break as a result of jolting. • Perform die changes under the direct supervision of authorized personnel. • Die hoisting work must be performed by qualified personnel in compliance with applicable laws and regulations. If the die hoisting work is performed by any unqualified person, the dies can drop out of position. • When lowering the slide to bottom dead center after putting dies in position, operate the slide while visually confirming that the knockout pin and the shank of the dies, etc., that protrude above the top face of the die do not come in contact with the bottom of the slide. • Before removing dies, use the slide adjust device to separate the slide from the upper die. Otherwise, the upper die could possibly remain attached to the bottom of the slide, and when the slide is raised it could also be lifted and then subsequently fall. • When removing dies, be sure to swing out the die lifter arms or attach the extension rails in position before performing the operation to raise the die lifters. Otherwise, the dies can drop out of position. • When stopping the air supply from the source for three hours or longer while die clampers are in use, lower the slide to bottom dead center to prevent misalignment between the upper and lower dies. Otherwise, the upper die may be misaligned with the lower die due to a decrease in die clamper hydraulic pressure.



161



Section D OPERATION 7. CHANGING DIES



Gain a full understanding of Section A SAFETY and follow those instructions before changing dies. In addition, perform the procedure given in Section D OPERATION, 3.2 ROUTINE INSPECTION AND OPERATION (pg. 121) before changing dies. The die loading and die removal procedures described in this chapter apply to configurations where the following devices (option) are provided: • 7.1 WHEN USING AIDA EQUIPMENT (pg. 163) AIDA upper die clampers (swing-type), AIDA lower die clampers, and AIDA hydraulic die lifters (horizontal swing-type extension arms). • 7.2 WHEN USING PASCAL EQUIPMENT (pg. 170) PASCAL upper die clampers, PASCAL lower die clampers, and PASCAL hydraulic die lifters (removable extension rails). • 7.3 MECHANICAL DIE LIFTER (OPTION) (pg. 177) AIDA mechanical die lifters. This section describes the important precautions and operation procedures for mechanical die lifters. • 7.4 WHEN USING A SHANK (pg. 178) Punch holder (provided as standard on Models NC1-350 to NC1-800) If your press machine uses equipment in a different combination or from a different manufacturer than those listed above, follow the procedure described in section 7.2 (pg. 170) while referring to the manufacturer’s Instruction Manuals for Accessories, which is contained in a separate binder (or found at the end of this instruction manual). In addition to this Instruction Manual, it is recommended that the customer prepare and utilize an operation standard that takes into consideration the most suitable safe operating procedures for your work. Note that this chapter does not cover accessories such as spacers, which are supplied by the customer.



NOTE



• The table below shows the relationship between each clamping state of the upper and lower die clampers and INCH mode operations. Note that upper die clampers made by AIDA are swing-type clampers. Manufacturer Switch Position Upper Die Clamper Lower Die Clamper × : Not allowed



162



AIDA



PASCAL, KOSMEK, Etc.



Unclamp



Clamp



Unclamp



Clamp



○



○



×



○



○



×



○



× ○ : Allowed



Section D OPERATION 7. CHANGING DIES



7.1 WHEN USING AIDA EQUIPMENT The upper and lower die clampers made by AIDA use hydraulic cylinders to clamp dies to the slide and bolster. The hydraulic die lifters make die changes easier by using lifter rails in the bolster to raise the dies. 7.1.1 Die Loading (when Using AIDA Equipment)



1



If the press machine is equipped with a die cushion (option), lower the die cushion. (See Section D OPERATION, 6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) (pg. 155).)



2



Using the INCH mode, bring the slide to bottom dead center, then turn the OPERATION SELECT switch to OFF.



3



Press the SET UP function touchbutton on the lower section of the operator interface terminal screen. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) The SET UP screen will be displayed. (See Section D OPERATION, 2.6 THE SET UP SCREEN (pg. 104).) Press the UPPER DIE CLAMPER touchbutton on the SET UP screen to display the UPPER DIE CLAMPER screen. (See Section D OPERATION, 2.6.4 Die Clamper (Option) (pg. 106).) Push the appropriate button to unclamp the upper die clampers. Visually confirm that the upper die clampers are unclamped. Next, press the END function touchbutton.



4



Set the OPERATION SELECT key switch to INCH. Inch the slide to top dead center.



5



Adjust the slide height so that the distance (the readout on the die height indicator) between the bottom of the slide when at bottom dead center and the top of the bolster exceeds the height of the dies to be loaded by approximately 10 mm. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



6



Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. (See Section D OPERATION, 2.6.4 Die Clamper (Option) (pg. 106).) Push the appropriate button to unclamp the lower die clampers. Press the END function touchbutton.



7



Push the EMERGENCY STOP button. (Continued on the next page)



163



Section D OPERATION 7. CHANGING DIES



(Continued)



8



9



Swing out the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Pull the plug out of the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle. (2) Turn the handle located in the center of the underside face of the operation button box clockwise to release the box. (3) Swing the operation button box out.



Pull out on the die lifter arm lock pins and swing out the arms. Confirm that the arms are locked in the correct position.



10 Reset the EMERGENCY STOP button (by turning it). 11 Press the DIE LIFTER touchbutton on the SET UP screen to display the DIE LIFTER screen. (See Section D OPERATION, 2.6.5 Die Lifter (Option) (pg. 106).) Push the appropriate button to raise the die lifters. Confirm that the rails on the bolster have been raised. Press the END function touchbutton.



12 Push the EMERGENCY STOP button. 13 Hoist the dies using a crane, etc., and gently place them on the arms. Push the dies into their proper position and locate them.



14 Reset the EMERGENCY STOP button (by turning it). 15 Push the appropriate button to lower the die lifters according to the DIE LIFTER screen (see 2.6.5 Die Lifter (Option) (pg. 106)). Confirm that the rails in the bolster are lowered, that the dies are placed directly on the bolster, and that they do not move. Press the END function touchbutton.



16 Push the EMERGENCY STOP button. 17 Pull out on the die lifter arm lock pins, and close the arms. (Continued on the next page)



164



Section D OPERATION 7. CHANGING DIES



(Continued)



18 Swing in the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Swing the operation button box in. (2) Turn the handle located in the center of the underside face of the operation button box counterclockwise, and confirm that the handle is locked. (3) Insert the plug into the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle.



L-block



19 Clean the clamping areas on the dies. Insert lower die clamper L-blocks into the clampers located in the notched section of the bolster.



Clamper



20 Reset the EMERGENCY STOP button (by turning it). 21 Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. Push the appropriate button to clamp the lower die clampers. Visually confirm that the lower die clampers have clamped properly. Press the END function touchbutton.



22 Set the OPERATION SELECT key switch to INCH. Inch the slide to bottom dead center. 23 Using the slide adjustment feature, lower the slide close to the top face of the upper die, so that there is a clearance of approximately 0.1 to 1 mm between the top face of the upper die and the bottom of the slide. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



24 Push the EMERGENCY STOP button. 25 Visually confirm that the U-shaped machined part on the upper die fastening area is aligned with the upper die clamper rod.



26 Clean the clamping areas on the dies. 27 Reset the EMERGENCY STOP button (by turning it). (Continued on the next page)



165



Section D OPERATION 7. CHANGING DIES



(Continued)



28 Press the UPPER DIE CLAMPER touchbutton on the SET UP screen to display the UPPER DIE CLAMPER screen. Push the appropriate button to clamp the upper die clampers. Visually confirm that the upper die clampers have clamped properly. Press the END function touchbutton.



29 On NC1-2000 and NC1-2500 press machines or press machines with upgraded counterbalance capacities (option), perform the following steps: (1) Press the RUN function touchbutton located in the lower section of the operator interface terminal. Insert the key into the OPERATION SELECT switch and select the INCH mode. (2) Inch the slide to top dead center. (3) Set the OPERATION SELECT switch to OFF and remove the key. (4) Adjust the counterbalance capacity. (See Section D OPERATION, 6.2 COUNTERBALANCE CAPACITY ADJUSTMENT (pg. 154).)



30 If the dies cannot be test-run without material being present, use the slide adjustment feature to raise the slide by the required amount. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



31 Insert the key into the OPERATION SELECT switch and select the INCH mode. Stroke the slide two or three times in the INCH mode to confirm that no faults exist. Then move the slide to the preset stop position.



32 Adjust the die height setting while performing a test run (trial stamping) in the SINGLE mode.



• Gradually adjust the slide downward while performing a test run. The readout on the die height indicator that is displayed when the desired product is produced will become the die height setting. It is recommended that this die height setting be recorded for future reference.



• Perform presswork according to your operation standards.



166



Section D OPERATION 7. CHANGING DIES



7.1.2 Die Removal (when Using AIDA Equipment)



1



If the press machine is equipped with a die cushion (option), lower the die cushion. (See Section D OPERATION, 6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) (pg. 155).)



2



If your dies require some clearance between the upper and lower dies when the slide is positioned at bottom dead center, use the slide adjustment feature to raise the slide by only the required amount. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



3



Set the OPERATION SELECT key switch to INCH. Inch the slide to bottom dead center.



4



Lower the slide using the slide adjustment feature until the upper and lower dies come in light contact with each other. At this time, be sure to not forcefully press the dies together.



5



Press the SET UP function touchbutton located on the lower part on the operator interface terminal. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) The SET UP screen will be displayed. (See Section D OPERATION, 2.6 THE SET UP SCREEN (pg. 104).) Press the UPPER DIE CLAMPER touchbutton on the SET UP screen to display the UPPER DIE CLAMPER screen. (See Section D OPERATION, 2.6.4 Die Clamper (Option) (pg. 106).) Push the appropriate button to unclamp the upper die clamper. Visually confirm that the upper die clampers are unclamped. Press the END function touchbutton.



6



Raise the slide by 3 to 5 mm using the slide adjustment feature, and confirm that the top face of the upper die is fully separated from the bottom of the slide. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



7



Inch the slide to top dead center. After reaching top dead center, set the OPERATION SELECT switch to OFF.



8



Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. Push the appropriate button to unclamp the lower die clampers. Press the END function touchbutton. (Continued on the next page)



167



Section D OPERATION 7. CHANGING DIES



(Continued)



9



Push the EMERGENCY STOP button.



10 Remove the lower die clamper L-blocks by pulling them out, and store them. L-block



11 Swing out the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Pull the plug out of the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle. (2) Turn the handle located in the center of the underside face of the operation button box clockwise to release the box. (3) Swing the operation button box out.



12 Pull out on the die lifter arm lock pins and swing out the arms. Confirm that the arms are locked in the correct position.



13 Reset the EMERGENCY STOP button (by turning it). 14 Push the appropriate button to raise the die lifters according to the DIE LIFTER screen (see 2.6.5 Die Lifter (Option) (pg. 106)). Confirm that the rails on the bolster have been raised.



15 Push the EMERGENCY STOP button. 16 After removing the dies from the die space, hoist them using a crane, etc.



17 Reset the EMERGENCY STOP button (by turning it). 18 Push the appropriate button to lower the die lifters according to the DIE LIFTER screen (see 2.6.5 Die Lifter (Option) (pg. 106)). Press the END function touchbutton. (Continued on the next page)



168



Section D OPERATION 7. CHANGING DIES



(Continued)



19 Push the EMERGENCY STOP button. 20 Pull out on the die lifter arm lock pins, and close the arms. 21 Swing in the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Swing the operation button box in. (2) Turn the handle located in the center of the underside face of the operation button box counterclockwise, and confirm that the handle is locked. (3) Insert the plug into the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle.



22 Clean the notched bolster areas where the lower die clamper L-blocks are to be inserted, making sure they are free of scrap and other foreign objects.



23 Reset the EMERGENCY STOP button (by turning it). 24 Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. Push the appropriate button to clamp the lower die clampers. Press the END function touchbutton.



169



Section D OPERATION 7. CHANGING DIES



7.2 WHEN USING PASCAL EQUIPMENT Read the PASCAL die clamper and die lifter instructions found at the end of this instruction manual. Do not start operation until you have gained a full understanding of the contents. 7.2.1 Die Loading (when Using PASCAL Equipment)



1



If the press machine is equipped with a die cushion (option), lower the die cushion. (See Section D OPERATION, 6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) (pg. 155).)



2



Set the OPERATION SELECT key switch to INCH. Inch the slide to top dead center.



3



Adjust the slide height so that the distance (the readout on the die height indicator) between the bottom of the slide when at bottom dead center and the top of the bolster exceeds the height of the dies to be loaded by approximately 10 mm. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



4



Press the SET UP function touchbutton on the lower section of the operator interface terminal screen. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) The SET UP screen will be displayed. (See Section D OPERATION, 2.6 THE SET UP SCREEN (pg. 104).) Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. (See Section D OPERATION, 2.6.4 Die Clamper (Option) (pg. 106).) Push the appropriate button to unclamp the lower die clampers. Press the END function touchbutton.



5 6



7



Push the EMERGENCY STOP button.



Swing out the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Pull the plug out of the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle. (2) Turn the handle located in the center of the underside face of the operation button box clockwise to release the box. (3) Swing the operation button box out.



Set the removable extension rails in position. Confirm that the rails are securely affixed.



(Continued on the next page)



170



Section D OPERATION 7. CHANGING DIES



(Continued)



8



Reset the EMERGENCY STOP button (by turning it).



9



Press the DIE LIFTER touchbutton on the SET UP screen to display the DIE LIFTER screen. (See Section D OPERATION, 2.6.5 Die Lifter (Option) (pg. 106).) Push the appropriate button to raise the die lifters. Confirm that the rails on the bolster have been raised. Press the END function touchbutton.



10 Push the EMERGENCY STOP button. 11 Hoist the dies using a crane, etc., and gently place them on the arms. Push the dies into their proper position and locate them.



12 Reset the EMERGENCY STOP button (by turning it). 13 Push the appropriate button to lower the die lifters according to the DIE LIFTER screen (see 2.6.5 Die Lifter (Option) (pg. 106)). Confirm that the rails in the bolster are lowered, that the dies are placed directly on the bolster, and that they do not move. Press the END function touchbutton.



14 Push the EMERGENCY STOP button. 15 Remove the extension rails. 16 Swing in the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Swing the operation button box in. (2) Turn the handle located in the center of the underside face of the operation button box counterclockwise, and confirm that the handle is locked. (3) Insert the plug into the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle. (Continued on the next page)



171



Section D OPERATION 7. CHANGING DIES



(Continued)



17 Clean the areas of the die that are to be clamped. Place the lower die clampers in position.



18 Reset the EMERGENCY STOP button (by turning it). 19 Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. Push the appropriate button to clamp the lower die clampers. Visually confirm that the lower die clampers have clamped properly. Press the END function touchbutton.



20 Set the OPERATION SELECT key switch to INCH. Inch the slide to bottom dead center. 21 Using the slide adjustment feature, lower the slide close to the top face of the upper die, so that there is a clearance of approximately 0.1 to 1 mm between the top face of the upper die and the bottom of the slide. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



22 Press the UPPER DIE CLAMPER touchbutton on the SET UP screen to display the UPPER DIE CLAMPER screen. Push the appropriate button to unclamp the upper die clampers.



23 Push the EMERGENCY STOP button. 24 Clean the areas of the die that are to be clamped. Place the upper die clampers in position.



25 Reset the EMERGENCY STOP button (by turning it). 26 Push the appropriate button to clamp the upper die clampers. Visually confirm that the upper die clampers have clamped properly. Press the END function touchbutton. (Continued on the next page)



172



Section D OPERATION 7. CHANGING DIES



(Continued)



27 On NC1-2000 and NC1-2500 press machines or press machines with upgraded counterbalance capacities (option), perform the following steps: (1) Press the RUN function touchbutton located in the lower section of the operator interface terminal. Insert the key into the OPERATION SELECT switch and select the INCH mode. (2) Inch the slide to top dead center. (3) Set the OPERATION SELECT switch to OFF and remove the key. (4) Adjust the counterbalance capacity. (See Section D OPERATION, 6.2 COUNTERBALANCE CAPACITY ADJUSTMENT (pg. 154).)



28 If the dies cannot be test-run without material being present, use the slide adjustment feature to raise the slide by the required amount. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



29 Insert the key into the OPERATION SELECT switch and select the INCH mode. Stroke the slide two or three times in the INCH mode to confirm that no faults exist. Then move the slide to the preset stop position.



30 Adjust the die height setting while performing a test run (trial stamping) in the SINGLE mode.



• Gradually adjust the slide downward while performing a test run. The readout on the die height indicator that is displayed when the desired product is produced will become the die height setting. It is recommended that this die height setting be recorded for future reference.



• Perform presswork according to your operation standards.



173



Section D OPERATION 7. CHANGING DIES



7.2.2 Die Removal (when Using PASCAL Equipment)



1



If the press machine is equipped with a die cushion (option), lower the die cushion. (See Section D OPERATION, 6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) (pg. 155).)



2



If your dies require some clearance between the upper and lower dies when the slide is positioned at bottom dead center, use the slide adjustment feature to raise the slide by only the required amount. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



3



Set the OPERATION SELECT key switch to INCH. Inch the slide to bottom dead center.



4



Lower the slide using the slide adjustment feature until the upper and lower dies come in light contact with each other. At this time, be sure to not forcefully press the dies together.



5



Press the SET UP function touchbutton located on the bottom of the operator interface terminal. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) The SET UP screen will be displayed. (See Section D OPERATION, 2.6 THE SET UP SCREEN (pg. 104).) Press the UPPER DIE CLAMPER touchbutton on the SET UP screen to display the UPPER DIE CLAMPER screen. (See Section D OPERATION, 2.6.4 Die Clamper (Option) (pg. 106).) Push the appropriate button to unclamp the upper die clampers.



6



Push the EMERGENCY STOP button.



7



Remove the upper die clampers.



8



Reset the EMERGENCY STOP button (by turning it).



9



Push the appropriate button to clamp the upper die clampers. Press the END function touchbutton. (Continued on the next page)



174



Section D OPERATION 7. CHANGING DIES



(Continued)



10 Raise the slide by 3 to 5 mm using the slide adjustment feature, and confirm that the top face of the upper die is fully separated from the bottom of the slide. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



11 Inch the slide to top dead center. After reaching top dead center, set the OPERATION SELECT switch to OFF.



12 Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. Push the appropriate button to unclamp the lower die clampers. Press the END function touchbutton.



13 Push the EMERGENCY STOP button. 14 Remove the lower die clampers.



15 Swing out the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Pull the plug out of the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle. (2) Turn the handle located in the center of the underside face of the operation button box clockwise to release the box. (3) Swing the operation button box out.



16 Place the removable extension rails in place. Confirm that the rails are securely fixed.



17 Reset the EMERGENCY STOP button (by turning it). 18 Push the appropriate button to raise the die lifters according to the DIE LIFTER screen (see 2.6.5 Die Lifter (Option) (pg. 106)). Confirm that the rails on the bolster have been raised.



19 Push the EMERGENCY STOP button. (Continued on the next page)



175



Section D OPERATION 7. CHANGING DIES



(Continued)



20 After removing the dies from the die space, hoist them using a crane, etc.



21 Reset the EMERGENCY STOP button (by turning it). 22 Push the appropriate button to lower the die lifters according to the DIE LIFTER screen (see 2.6.5 Die Lifter (Option) (pg. 106)). Press the END function touchbutton.



23 Push the EMERGENCY STOP button. 24 Remove the extension rails. 25 Swing in the operation button box by performing the following procedure (this is not applicable to a stand-type operation button box): (1) Swing the operation button box in. (2) Turn the handle located in the center of the underside face of the operation button box counterclockwise, and confirm that the handle is locked. (3) Insert the plug into the BUTTON BOX INTERLOCK (the button box’s standard position) receptacle.



26 Reset the EMERGENCY STOP button (by turning it). 27 Press the LOWER DIE CLAMPER touchbutton on the SET UP screen to display the LOWER DIE CLAMPER screen. Push the appropriate button to clamp the lower die clampers. Press the END function touchbutton.



176



Section D OPERATION 7. CHANGING DIES



7.3 MECHANICAL DIE LIFTER (OPTION) The mechanical die lifter raises or lowers the rails in the bolster by mechanically operating the die lifter arms.



WARNING • Confirm that the support bar is adequately supported by the stopper after the mechanical die lifter arm is raised. (1)



(2)



○ Support bar Stopper When the support bar is positioned such as shown in diagram (2) above, the dies may drop, and personal injury or death may occur.



CAUTION • When the dies are located on the bolster, take measures to prevent the dies from shifting before raising or lowering the die lifter arms. When the rails are mechanically raised or lowered, the dies sitting on the rails may shift due to rail movement, which could cause them to drop.



Block Die T nut Front



Bolster



An example of a die shift prevention method. > When the die lifter arms are raised, the support bar moves on top of the stopper, and the die lifter arms are supported by the stopper. At the same time, the rails on the bolster are mechanically raised. > Slightly lift up the die lifter arm, then move the die lifter arm down while pulling the support bar toward you. The rail on the bolster will be lowered and the die will come in contact with the bolster.



177



Section D OPERATION 7. CHANGING DIES



7.4 WHEN USING A SHANK The upper die can be installed on the slide by attaching a shank to the punch holder located in the lower section of the slide. The punch holder is optional for NC1-1100 ~ NC1-2000 models. (A punch holder is not available on NC1-2500 press machines.)



CAUTION • Only use shank lock bolts manufactured by AIDA. AIDA is not responsible for any accidents resulting in personal injury or physical damage when a non-AIDA shank lock bolt is used. • Select a shank of an appropriate diameter, taking into consideration the fit standards in relation to the hole size. (5) Shank retaining bolt



(3) Shank



(5) Shank retaining bolt



(4) Holder Ａ



(2) Shank hole (5) Shank retaining bolt (1) Shank lock bolt (1) Shank lock bolt



Punch holder cross section



Installation and removal of the upper die must be conducted by authorized personnel in accordance with the following procedure: 7.4.1 Installation



178



1



Set the OPERATION SELECT key switch to INCH. Inch the slide to top dead center.



2



Adjust the slide height so that the distance (the readout on the die height indicator) between the bottom of the slide when at bottom dead center and the top of the bolster exceeds the height of the dies to be loaded by approximately 10 mm (0.39 in). (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



3



Perform steps (1) through (4) described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



4



Turn the right and left shank retaining bolts (5) counterclockwise approximately two or three turns to loosen the holder (4). (Continued on the next page)



Section D OPERATION 7. CHANGING DIES



(Continued)



5



Loosen the center shank lock bolt (1). After loosening it, confirm that the shank lock bolt does not protrude into the shank hole (2) (area "A" of the shank lock bolt (1) shown in the above illustration).



6



Place the dies on the bolster.



7



Reverse the steps of the Safety Procedures During Adjustment performed in step 3 above. Using the INCH mode, gradually lower the slide. Stop the slide just before the shank (3) enters into the shank hole.



8



While ensuring that the shank does not interfere with the shank hole, use the slide adjust function to lower the slide to where the shank has entered the shank hole by about 3 to 5 mm. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



9



Confirm that the die height indicator reading is still higher than the post-slide adjustment die height setting.



10 Set the OPERATION SELECT switch to INCH. Inch the slide to a position slightly beyond bottom dead center (180° to 185°).



11 Lower the slide using the slide adjustment feature until the lower face of the slide comes in light contact with the upper face of the die. Do not forcefully push the dies together.



12 Perform steps (1) through (4) described in Section A SAFETY, 5.



SAFETY PROCE-



DURES DURING ADJUSTMENT (pg. 33).



13 Tighten the right and left shank retaining bolts alternately and evenly until the tightening torque reaches the value described below. Model



NC1-350, NC1-450



NC1-600~NC1-2000



Tightening torque



120 N•m



240 N•m



14 Tighten the shank using the center shank lock bolt until the tightening torque reaches the value described in step 13.



15 Reverse the steps of the Safety Procedures During Adjustment performed in step 12 above. Using the slide adjustment feature, raise the slide about 3 to 5 mm. This is to prevent the upper die from gouging into the lower die.



16 Utilizing the T-slots in the slide, use upper die clampers, T-bolts, etc., to install the upper dies.



17 Confirm that the upper and lower dies are properly aligned, then confirm that all bolts are securely tightened.



179



Section D OPERATION 7. CHANGING DIES



7.4.2 Removal



CAUTION • Confirm that the upper die is completely separated from the slide when the shank lock bolt is loosened. If you raise the slide when the upper dies are not yet completely separated, the dies could drop.



1



If the press machine is equipped with a die cushion (option), lower the die cushion. (See Section D OPERATION, 6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) (pg. 155).)



2



If your dies require some clearance between the upper and lower dies when the slide is positioned at bottom dead center, use the slide adjustment feature to raise the slide by only the required amount. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



3



Set the OPERATION SELECT key switch to INCH. Inch the slide to bottom dead center.



4



Lower the slide using the slide adjustment feature until the upper and lower dies come in light contact with each other. At this time, be sure to not forcefully press the dies together.



5



Perform steps (1) through (4) described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



6



Remove the upper die clampers and T-bolts.



7



Loosen the center shank lock bolt (1).



8



Loosen the right and left shank retaining bolts (5) alternately and evenly.



9



Reverse the steps of the Safety Procedures During Adjustment performed in step 5 above.



10 Raise the slide by 3 to 5 mm (0.12 to 0.2 in) using the slide adjustment feature, and confirm that the top face of the upper die is fully separated from the bottom of the slide. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).) (Continued on the next page)



180



Section D OPERATION 7. CHANGING DIES



(Continued)



11 Inch the slide to top dead center. After reaching top dead center, set the OPERATION SELECT switch to OFF.



12 Perform steps (1) through (4) described in Section A SAFETY, 5.



SAFETY PROCE-



DURES DURING ADJUSTMENT (pg. 33).



13 Remove the lower die clampers and T-bolts, and remove the dies.



181



Section D OPERATION 8. OPERATION OF AUXILIARY EQUIPMENT



8. OPERATION OF AUXILIARY EQUIPMENT See Section B SPECIFICATIONS, 4. NAMES OF MAJOR COMPONENTS (pg. 63) and Section D OPERATION, 1. OPERATION DEVICES (pg. 85) for the location of operating switches and devices.



8.1 EJECTORS Ejectors are used to blow air to remove product and scraps from the dies.



CAUTION • Provide guarding between the operator and the dies to prevent blown items from hitting the operator. Be sure to use personal protective equipment such as goggles to protect your eyes.



182



1



Turn all ejectors OFF on the operator interface terminal. (See Section D OPERATION, 2.4 THE RUN SCREEN (pg. 98).) In addition, if the press machine is equipped with three or more ejectors, set all of the EJECTOR button selector rings (option) arranged on the operation panel or the operation button box to OFF.



2



Perform steps (1) through (3), (8) and (9) described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



Connect your air hose to the ejector air connector. Confirm that no hazards are created by the air blow.



4



Reverse the steps of the Safety Procedures During Adjustment performed in step 2 above.



5



Pressing the TEST touchbutton on the operator interface terminal, turning it ON and pushing the UP/UNCLAMP/RET. button will cause the ejector to eject air regardless of slide movement. (See Section D OPERATION, 2.4 THE RUN SCREEN (pg. 98).) After completing the test, press the TEST touchbutton to turn the test mode off.



6



If the press machine is equipped with three or more ejectors, set the EJECTOR button selector ring (option) arranged on the operation panel or the operation button box to ON. Pushing the button will cause the ejector to eject air regardless of slide movement.



7



Turn the desired ejectors ON.



8



Using the INCH mode, check the air ejection timing. Adjust the timing as directed in Section D OPERATION, 6.6 SETTING TIMING SWITCHES (pg. 158).



Section D OPERATION 8. OPERATION OF AUXILIARY EQUIPMENT



8.2 SELECTING THE EXTERNAL OPERATION In addition to the RUN buttons, the press machine can be operated by external starting signals. The external operation shall be selected by a qualified person. When selecting the external operation, safety measures described in Section A SAFETY shall be taken without fail. "EXTERNAL" : The press machine can be operated by external starting signals other than the RUN buttons. "OFF" : Operation is disabled. "BUTTON" : The press machine can be operated by the RUN buttons.



8.3 AUTOMATION DEVICES (OPTION) Automation devices consist of 4-way solenoid valves and timing switches which are used to actuate air actuators furnished by the customer. Automation devices are used to actuate customer-furnished air actuators in synchronization with press machine operation.



1



Turn OFF all automation devices. (See Section D OPERATION, 2.4 THE RUN SCREEN (pg. 98).)



2



Perform steps (1) through (3), (8) and (9) described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



There are two automation air connectors, designated A and B. Connect your air hoses to them. Confirm that the actuation of the customer-furnished air actuators do not create hazards. Examples of actuation timings for A and B are given below: Crank angle indicator Slide stroking position Timing switch setting Connector A Connector B



0° (360°) 180° 360° Top dead center Bottom dead center Top dead center OFF ON OFF Supplies air Vents air Supplies air Vents air Supplies air Vents air



4



Reverse the steps of the Safety Procedures During Adjustment performed in step 2 above.



5



Turn the automation devices ON. To verify operation of the air actuators, press the TEST touchbutton to turn it ON and push the UP/UNCLAMP/RET. button. This switches the solenoid valve and actuates the air actuator in the reverse direction regardless of slide movement. (See Section D OPERATION, 2.4 THE RUN SCREEN (pg. 98).) After completing the test, push the DOWN/CLAMP/ADV. button to restore the actuator to its normal state. Then press the TEST touchbutton to turn the test mode OFF.



6



Using the INCH mode, check the air ejection timing. Adjust the timing as directed in Section D OPERATION, 6.6 SETTING TIMING SWITCHES (pg. 158).



183



Section D OPERATION 8. OPERATION OF AUXILIARY EQUIPMENT



8.4 SELECTING THE PRESET STOP POSITION (OPTION) The preset stop position of the slide in the SINGLE and CONT. operation modes can be changed. This procedure must be performed by qualified personnel.



1



Using the INCH mode, stop the slide at the desired preset stop position.



2



Set the " " (PRESET STOP POSITION)•" " (TOP DEAD CENTER) stop position switch to one of the following positions: " " (PRESET STOP POSITION): A position corresponding to a crank angle such as 60° or 90°. The most suitable position is determined by the peripheral devices being used. " " (TOP DEAD CENTER): The 0° crank angle position (top dead center)



3



Using the SINGLE mode, confirm that the slide stops at the selected preset stop position. Cycle the machine several times to verify that variation in the stopping position is 10° or less.



8.5 DIE PROTECTION Die protection is a function that stops the press machine immediately when material feed errors and product (or scrap) conveyance errors, etc., are detected. To perform misfeed detection (for detecting material feed errors) or conveyance detection (for checking the removal of product or scrap), connect the customer-furnished and installed detectors on the dies, etc., to the die protection terminals located inside the control panel. Two circuits are installed in the control panel. See Section E MAINTENANCE, 11. DRAWINGS (pg. 265), (2)Electrical Drawings for the location of the connection terminals. • See 2.4 THE RUN SCREEN (pg. 98) for the procedure for turning die protection ON and OFF. • See 2.5.3 Die Protection Setting Monitor Screen (pg. 102) for a detailed description of how to set die protection. • Two additional die protection receptacles can be provided as an option. See Section B SPECIFICATIONS, 4. NAMES OF MAJOR COMPONENTS (pg. 63) for the receptacle locations.



8.6 MATERIAL END DETECTION DEVICE (OPTION) This device stops the slide at the preset stop position when it detects the end of the material. ON : The material end detection function is enabled. The device stops the slide at the preset stop position when it detects the end of the material. OFF : The material end detection function is disabled.



184



MATERIAL END OFF ON



Section E MAINTENANCE



E



Section MAINTENANCE



1. PERIODIC INSPECTION . . . . . . . . . . . 187 1.1 MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION) . . . . . . . . . . . . . . . . . . . . . . . . 187 1.2 SEMI-ANNUAL INSPECTION (OR EVERY 1500 HOURS OF OPERATION) . . . . . . . . . . . . . . . . . 189 1.3 ANNUAL INSPECTION (OR EVERY 3000 HOURS OF OPERATION) . . . . . . . . . . . . . . . . . . . . . . . . 190 1.4 THREE YEAR INSPECTION (OVERHAUL). . . . 191 1.5 PERIODIC INSPECTION OF PERIPHERAL DEVICES AND ACCESSORIES. . . . . . . . . . . . . 192



5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS . . . . . . . . . . . . . . . . 217 5.1 AUTO-DRAIN FILTER . . . . . . . . . . . . . . . . . . . . 217 5.2 THE CLUTCH AND BRAKE SOLENOID VALVE 219 5.3 AUTOMATIC GREASE PUMP. . . . . . . . . . . . . . 221 5.4 AUTOMATIC OIL PUMP (OPTION). . . . . . . . . . 223 5.5 MANUAL PUMP . . . . . . . . . . . . . . . . . . . . . . . . 224 5.6 MOTOR-DRIVEN OIL PUMP AND OIL FILTER 225



2. LUBRICATION. . . . . . . . . . . . . . . . . . . . 193 2.1 FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 2.2 TYPES AND AMOUNTS OF OIL . . . . . . . . . . . . 194 2.3 OIL AND GREASE SERVICING POINTS . . . . . 196 2.4 OIL AND GREASE SERVICING PROCEDURES196 2.5 OIL SERVICING OF HYDRAULIC OVERLOAD PROTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 2.6 CHANGING CLUTCH AND BRAKE OIL . . . . . . 201



7. CONSTRUCTION DRAWINGS . . . . . . . 232



3. MAINTENANCE OF MECHANICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 204 3.1 MEASURING SLIDE GIB CLEARANCE. . . . . . . 204 3.2 V-BELT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 205 3.3 CHANGING V-BELTS . . . . . . . . . . . . . . . . . . . . . 206 3.4 INSPECTING CLUTCH STROKE. . . . . . . . . . . . 207 3.5 MAINTENANCE OF GUARDS (OPTION) . . . . . 208



6. TROUBLESHOOTING . . . . . . . . . . . . . . 230



8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . 247 9. SPARE PARTS LIST (OPTION) . . . . . . . 259 10. LIST OF TOOLS PROVIDED WITH THE PRESS MACHINE . . . . . . . . . . . . . . . . . 261 11. DRAWINGS . . . . . . . . . . . . . . . . . . . . . 265 (1)Mechanical Drawings (2)Electrical Drawings



4. MAINTENANCE OF ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 209 4.1 MEGGER MEASUREMENT (INSULATION RESISTANCE MEASUREMENT) . . . . . . . . . . . . . . . . . 209 4.2 SERVICE LIFE OF ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 4.3 INSPECTING THE GROUND FAULT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 4.4 REPLACING THE BUILT-IN PLC BATTERY . . . 212 4.5 OPERATOR INTERFACE TERMINAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214



185



Section E MAINTENANCE



186



Section E MAINTENANCE 1. PERIODIC INSPECTION



1. PERIODIC INSPECTION • Conduct the pre-work check and routine inspection procedures as explained in Section D OPERATION, 3.2 ROUTINE INSPECTION AND OPERATION (pg. 121). • The periodic inspection items listed below are the minimum requirements necessary for the safe use of the press machine over a long period of time. Add other inspection items as appropriate according to the operating conditions and environment of your company. • For periodic inspection relating to lubrication (servicing and changing oil, etc.), see Section E MAINTENANCE, 2. LUBRICATION (pg. 193). • The inspection leader and the inspectors who conduct periodic inspections must follow the instructions regarding periodic inspections explained in Section A SAFETY, 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS (pg. 31). The inspection leader is to take appropriate actions for any problems found.



1.1 MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION) Inspect the following items once a month. Be sure to repair any problems found during the inspection. Inspection Item



1



Auto-Drain Filter • Check for cracks or other breakages in plastic parts such as the bowl. (See pg. 217.)



Action to be Taken • Replace.



2



V-Belts (1) Check the belts for proper tension (amount (1) Adjust the tension. of deflection). (See pg. 205.) (2) Check the belts for cracks or damage. (2) Replace. (See pg. 206.)



3



Clutch and Brake Solenoid Valve (1) Check if the coil makes a humming noise. (1), (3) Contact AIDA Service. (2) Check the muffler for damage. (3) Check if the muffler is leaking excessive (2) Replace. (See pg. 219.) sludge or oil. (4) Conduct function tests of the monitors. (See pg. 220.)



4



Hydraulic Overload Protector Pneumatic Pump • Check whether pump operation can be • Contact AIDA Service. heard every 30 minutes~2 hours under noload conditions.



5



Pushbuttons and Switches (1) Check for oil and dust accumulation. (1) Clean them and their surroundings (2) Confirm proper operation and smooth so that symbol marks and characters movement of the selector switches and are clearly legible. pushbuttons. (2), (3) Replace. (3) Check for damage and cracks. (Continued on the next page)



187



Section E MAINTENANCE 1. PERIODIC INSPECTION



(Continued) Inspection Item



6



Ground Fault Circuit Breaker • Check that the circuit breaker turns off when the TEST button is pushed. (See pg. 211.)



Action to be Taken • Contact AIDA Service.



7



Relays (1) Check for vibration. (1) ~ (3), (6), (7) (2) Check the contacts and coils for significant Contact AIDA Service. discoloration or burning. (3) Check the cases for damage. (4) Check for loose screws. (4) Tighten. (5) Check the remaining service life. (See pg. (5) Replace. 210.) Receptacles for Plugs, etc. (6) Check the bent pins. (7) Check soldered areas for separation.



8



Electrical Wires in Moving Areas, and External Wires for the Operation Button Box. Wires Connected to the EXTERNAL OPERATION Receptacle. (1) Check for wire cover damage. (1), (2) Replace. (See pg. 191.) (2) Check wires for damage.



9



Guards (Option) (1) Check for loose screws. (1), (3) Tighten. (2) Check gas spring capacity deterioration. (2) Contact AIDA Service. (See pg. 208.) (3) Check wire clip for looseness.



10 Check the oil filter element (on the delivery side) for clogging or damage. [Types (S)E, (1NL)E and (2NL)E]



• Clean or replace. (See pg. 226.)



11 Check the control panel air fan filter for clogging or damage.



188



• Clean or replace.



Section E MAINTENANCE 1. PERIODIC INSPECTION



1.2 SEMI-ANNUAL INSPECTION (OR EVERY 1500 HOURS OF OPERATION) Inspect the following items and the items described in 1.1 MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION) every six months. Be sure to repair any problems found during the inspection. Inspection Item



Action to be Taken



1



Instruments (1) Crank angle indicator (1), (2) Contact AIDA Service. Displays 180 degrees when slide is at bottom dead center. (2) Die height indicator The displayed value is correct (*1). (3) Air pressure gauges (3) Replace. (See Section E MAINTEThe pressure gauge needles return to 0 NANCE, 8. LIST OF COMMER(zero) after air is totally exhausted. CIALLY AVAILABLE PRODUCTS (pg. 247).)



2



Megger Measurement (Insulation Resistance Measurement) • Check that the megger measurement value • Contact AIDA Service. is appropriate. (See pg. 209.)



3



Clutch and Brake Solenoid Valve Air Leakage • Air leakage from the main unit when sending • Contact AIDA Service. and cutting off electrical signals to the solenoid valve.



4



Service Life of Electrical Components • Check the remaining service life of electrical components. (See pg. 210.)



• Replace.



(*1): Actually measure the distance from the bottom of the slide to the top of the bolster when the slide is at bottom dead center. (See Section D OPERATION, 6.1 SLIDE ADJUSTMENT (pg. 151).)



189



Section E MAINTENANCE 1. PERIODIC INSPECTION



1.3 ANNUAL INSPECTION (OR EVERY 3000 HOURS OF OPERATION) Inspect the following items and the items described in 1.1 MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION) (pg. 187) and 1.2 SEMI-ANNUAL INSPECTION (OR EVERY 1500 HOURS OF OPERATION) (pg. 189) every year. Be sure to repair any problems found during the inspection. Inspection Item



1 2 3 4 5



• Contact AIDA Service.



Replace Oil in the Gear Box Oil Bath, Slide • Replace. (See pg. 193.) Suspension Point, and the Clutch and Brake. Clutch Stroke • Check that the stroke is not larger than the proper stroke value. (See pg. 207.)



• Contact AIDA Service.



Rubber Hoses Attached to Moving Parts • Check the rubber hoses for deterioration and damage.



• Replace.



Press Machine Installation Accuracy • Check that the top face of the bolster is level.



• Contact AIDA Service.



6



For Type (S)E Press Machines: Replace the oil filter’s paper filter element (on the delivery • Replace. (See pg. 225.) side)



7



For Types (S)E, (1NL)E and (2NL)E Press Clean or replace. Machines: Check the oil filter (Suction Side)



8



190



Slide Gib Clearance • Check for proper slide gib clearance. (See pg. 204.)



Action to be Taken



All Solenoid Valves Other than the Clutch and Brake Solenoid Valve • Check and correct the solenoid valves in the same manner as the clutch and brake solenoid valve. (See the inspection in 1.1 MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION) (pg. 187).)



Section E MAINTENANCE 1. PERIODIC INSPECTION



1.4 THREE YEAR INSPECTION (OVERHAUL) Inspect the following items and the items described in 1.1 MONTHLY INSPECTION (OR EVERY 250 HOURS OF OPERATION) (pg. 187) and 1.2 SEMI-ANNUAL INSPECTION (OR EVERY 1500 HOURS OF OPERATION) (pg. 189) every three years. Be sure to repair any problems found during the inspection. 1.4.1 Comprehensive Inspection



The inspections described below require the disassembly (overhaul) of the press machine. Therefore, contact AIDA Service (see the end of this instruction manual) when any of the inspections stated below are necessary. (1) Press machine accuracy inspection and check (2) Check of ball cup, adjusting screw, worm wheel, and chains (3) Check of drive shaft bearings and other bearings, gear tooth surfaces, and gear backlash. (4) Check of sliding surfaces of slide gibs and plain bearings (5) Check of gaskets, O-rings and seals (6) Check of clutch and brake 1.4.2 Replacing Rubber Hoses and Electrical Wiring



(1) Replace the rubber hoses between the clutch and brake solenoid valve and the flywheel once every three years whether the hoses are damaged or not. Model: MID-25, Manufacturer: The Yokohama Rubber Co., Ltd. (2) The material in rubber hoses and electrical wiring used with moving parts is likely to deteriorate over time. It is therefore necessary to replace them with new ones every five years whether they are damaged or not. Contact AIDA Service (see the end of this instruction manual) for the technical specifications of the replacement parts.



191



Section E MAINTENANCE 1. PERIODIC INSPECTION



1.5 PERIODIC INSPECTION OF PERIPHERAL DEVICES AND ACCESSORIES Inspect the peripheral devices (option) and the accessories periodically. For periodic inspection details, refer to the Instruction Manuals for Peripheral Devices found at the end of this instruction manual or in a separate binder, or the Instruction Manuals for Accessories. In particular, the units listed below can cause personal injury or death, or damage to the press machine if inspection or service is not properly performed. Be sure to repair any problems found during the inspection. Be sure to perform inspection and service for units other than those listed below according to the relevant Instruction Manuals. Periodic Inspection Cycles Frequency of Inspection Name



Daily



1 Main Motor



●



AG Brake Motor 2 (Slide Adjust Device)



●



Weekly Monthly ●



3 6 Months Months



●



●



Yearly



3 years



●



●



●



Inverter (Not provided 3 in the case of a fixed speed motor.)



●



◎ 4 VS Controller



●



Presence-Sensing ◎ 5 Device



●



●



●



◎ 6 Die Clampers



●



●



●



●



●



◎ 7 Die Lifter



●



●



●



●



●



●



●



●



● : Inspection is necessary. ◎ : Optional devices. See the page following the front cover of this Instruction Manual for a list of optional devices that have been provided specifically for your press machine.



192



Section E MAINTENANCE 2. LUBRICATION



2. LUBRICATION Perform oil and grease servicing in accordance with the instructions in Section A SAFETY, 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS (pg. 31).



CAUTION • Use only No. 0 (NLGI-0) grease. If any other type of grease is used, the grease will not be supplied properly, causing wear on bearing surfaces, etc. • Use only the type of oil specified, and do not mix different types of oil or old and new oil. If mixed, there is a possibility that the lubricating qualities of the oil could be lost, resulting in damage to bearing surfaces, etc. • In order to assure safe handling of lubricating oils, hydraulic oils, and grease, etc., obtain the manufacturer’s product safety data sheet from your oil supplier, and take appropriate actions in accordance with the safety data sheet. Pay special attention to first aid measures, measures in case of fire, measures in case of leakage, and precautions related to storage and disposal. • Take special care when handling lubricants, and wear protective gear such as protective goggles and gloves. Particularly, the oil temperature may be high immediately after press machine operation is stopped. To avoid burns, allow some cooling time before starting any tasks. • Contact AIDA Service (see the end of this instruction manual) if the drained oil (waste oil) contains metal chips or foreign matter as this may indicate that there are broken internal parts. • Wipe up spilt oil immediately. If oil penetrates into control devices, there is a possibility of malfunctions due to poor insulation. • For the cautions concerning material coating fluids, refer to Section A SAFETY, 4.1 ESSENTIAL BASIC RULES (pg. 24).



2.1 FLUSHING Flushing is a means of preventing the mixture of foreign particles or old oil with fresh oil when replacing oil. If flushing is instructed in the procedure for oil replacement, take the following steps or consult the oil supplier or AIDA Service (listed at the end of this instruction manual). To flush the clutch and brake (See pg. 201.), pour the specified quantity of oil into the clutch and brake, start the main motor, and turn the flywheel for about 20 to 30 minutes. Then drain the oil. (1) Before oil servicing, remove foreign particles or old oil remaining inside the oil supply pump before pumping fresh oil. In cases where an oil supply device other than a pump is used, clean the insides in a similar manner. (2) When flushing, drain the old oil from the oil bath, etc., then fill it with the same type of oil as that to be used in the lubrication device. Operate a circulation-type hydraulic device for 20 to 30 minutes for internal cleaning. (3) After cleaning, drain the oil.



193



Section E MAINTENANCE 2. LUBRICATION



2.2 TYPES AND AMOUNTS OF OIL During servicing oil, watch the oil level gauge to check the quantity of the serviced oil. When the oil level gauge shows that the quantity of oil is still short after servicing oil, add oil. For the location of the oil level gauge and the meaning of the indication of the oil level gauge, see 2.3 OIL AND GREASE SERVICING POINTS and 2.4 OIL AND GREASE SERVICING PROCEDURES. The quantity of oil given in the table shown below is an approximate value for press machines of the standard specifications. For press machines of special specifications, the quantity may be different. The lubrication table given below is based on eight hours of operation per day. If daily operation time exceeds eight hours, increase the frequency of service according to the increase of daily use. If the daily operation time is less than eight hours, use the frequency given in the table below. In addition to the lubrication points in the table below, apply grease to sliding portions, screws, chains, etc. as necessary. For lubrication of accessories and peripheral devices other than those listed below, refer to the manual provided for that device. Unit: L Amount of Oil Point of Type of Lubrication No. Lubrication Oil (*1) NC1- NC1- NC1- NC1- NC1- NC1- NC1- NC1Frequency Type (S)E



AIDA Standard Oil No.1



Type (1)E



Gear 1 Box Oil Type Bath (1NL)E AIDA Standard Type Oil No.3 (2) E Type (2NL)E Slide 2 Suspension Point Section



450



600



800 1100 1500 2000 2500



-



13



17



20



37



50



60



(*2) 13



17



20



37



50



60 109 Change oil every 12 months. 66 - (Change after first 3 months.)



-



-



-



-



22



41



54



13



13



19



20



37



50



-



-



-



34



67



78 119 117



64 106



0.5 0.5 1.0 1.2 2.0 3.0 3.0 4.0



Change oil every 12 months.



3



AIDA Connecting Rod Standard Oil-Tight Oil No.3



Check and replenish. Change oil at the 0.1 0.12 0.15 0.25 0.33 0.33 0.82 0.95 time of overhaul (once every three years).



4



Clutch and Brake



6.8



Hydraulic 5 Overload Protector



194



AIDA Standard Oil No.3



350



MOBIL ATF220 AIDA Standard Oil No.1



9



9



9



9



15



15



15



Change oil every 12 months.



Check and replenish. Change oil at the 0.9 0.9 1.8 1.8 2.9 3.0 4.0 10.0 time of overhaul (once every three years). (Continued on the next page)



Section E MAINTENANCE 2. LUBRICATION



(Continued) Unit: L No.



Point of Lubrication



Amount of Oil Type of Oil NC1- NC1- NC1- NC1- NC1- NC1- NC1- NC1(*1) 350



450



Manual Oil Pump (Option, but, AIDA provided as Standard Oil 6 standard on No.3 models (S)E and NC12500) Automatic 7-1 Grease Pump



AIDA Standard Grease No.0



600



Lubrication Frequency



800 1100 1500 2000 2500



0.4 (tank capacity)



Operate the handle 3 to 5 times (or 10 times if the press machine is equipped with a cylinder-type die cushion) every four hours. Replenish tank with oil as required.



400 g (or 1000 g) (tank capacity)



Replenish as required.



Automatic Oil MOBIL DTE 7-2 Pump Oil HH (Option) (*3)



1 (tank capacity)



Replenish as required.



Die Lifter/Die Clamper Oil AIDA Reservoir 8 Standard Oil (For AIDA No.1 hydraulic unit) (Option)



4



Cushion Guide AIDA 9 Grease Fitting Standard Grease No.0 (Option)



1 to 2 g per grease fitting



Change oil every 12 months.



Once a day



Slide 10 Adjustment Chain



AIDA Standard Grease No.0



Rod



AIDA Standard Grease No.0



3 to 4 g per unit Apply grease to [Except for the press machine is equipped the rod section with a manual oil pump for counterbalance] once every month.



KLUBERSYNTH GE46-1200 manufactured by: NOK KLUBER



Seal on the top of piston at the time 50 g per unit [Except for the press machine is equipped of overhaul (once with a manual oil pump for counterbalance] every three years)



Counter11 balan Top Face ce of Piston 12 Main Motor



Apply grease once every six months.



1 to 2 g



See the instruction manual for the main motor (in the Instruction Manuals for Accessories) and name plate of the main motor.



(*1): A list of lubricating oils available on the market which are equivalent to AIDA standard oil and MOBIL oil is provided in APPENDIX-4. Be sure to use the brand of the manufacturers listed there. (*2): For the gear box oil bath of NC1-350(1)E, refer to the table shown below. Point of Press Machine Strokes Per Minute No. Type of Oil Amount of Oil Lubrication Model (No Load) Gear Box 1 Oil Bath



NC1-350(1)E



200 spm (Special specifications)



AIDA Standard Oil No.1



13 L



90 - 150 spm AIDA Standard (Standard specifications) Oil No.3



13 L



(*3): An automatic oil pump (option) is installed per customer request.



195



Section E MAINTENANCE 2. LUBRICATION



2.3 OIL AND GREASE SERVICING POINTS Oil and grease servicing points may vary depending on the model of press machine, optional devices, and customer requests. (11) Counterbalance [Except for the press machine is equipped with a manual oil pump for counterbalance] Rod section Top surface of piston (5) Hydraulic Overload Protector [for NC1-350, 450] Oil servicing port Oil level gauge Drain port (6) Manual Oil Pump (option, but, provided as standard on models (S)E and NC1-2500) [NC1-350~2000] [NC1-2500]



(7)-1 Automatic Grease Pump (7)-2 Automatic Oil Pump (Option) (*3)



(1) Gear Box Oil Bath Oil servicing port Drain port Oil level gauge (*2)



(3) Connecting Rod Oil-Tight (Oil servicing) Oil level gauge



AIDA



(12) Main Motor (4) Clutch and Brake Oil servicing port Oil level gauge



(2) Slide Suspension Point Section Oil servicing port Oil level gauge (*1) Drain port



(5) Hydraulic Overload Protector Oil servicing port [For NC1-600 or larger] (8) Die Lifter / Die Clamper Oil Reservoir (Option)



(10) Slide Adjustment Chain Oil Recovery Reservoir (Option) (*4) (9) Cushion Guide Grease Fitting (Option)



[Type (S)E] Suction-Side Oil Filter



Auto-Drain Filter [Type (S)E] Delivery-Side Oil Filter



(*1): For NC1-450, the oil gauge is located on the front face. (*2): For NC1-350 and -450, the oil gauge is located on the left side face. (*3): The automatic oil pump (option) will be installed instead of an automatic grease pump if requested by the customer. (*4): The oil recovery reservoir is installed on press machines that are equipped with an automatic oil pump (option). For NC1-350 and -450, the oil recovery reservoir is located inside the frame. To replenish the automatic oil pump (option) with oil, be sure to discard the oil remaining in the oil recovery reservoir. If not, the reservoir will overflow. In addition, never reuse the old oil. Reusing old oil can damage the press machine.



2.4 OIL AND GREASE SERVICING PROCEDURES (1) Gear Box Oil Bath Loosen the drain port valve located on the underside of the oil bath inside the frame to drain oil remaining inside the oil bath. Flush the system. Remove the rubber plug from the oil servicing port located on the top of the press machine. Pour fresh oil through the oil servicing port until the oil level reaches the middle level of the oil gauge located on the side of the frame. (Continued on the next page)



196



Section E MAINTENANCE 2. LUBRICATION



(Continued) (2) Slide Suspension Point Section Remove the plug from the drain port located on the side face of the slide to drain oil remaining inside the slide. Flush the system. Remove the plastic plug from the oil servicing port located inside the slide. Pour fresh oil through the oil servicing port until the middle level of the oil gauge placed on the side of the slide is reached. (3) Connecting Rod Oil-Tight The oil servicing port is located on the connecting rod (above the oil level gauge). Lower the slide to bottom dead center with the slide adjuster at the upper end. Pour oil through the oil servicing port until oil overflows from the oil servicing port. (4) Clutch and Brake See Section E MAINTENANCE, 2.6 CHANGING CLUTCH AND BRAKE OIL (pg. 201). (5) Hydraulic Overload Protector See Section E MAINTENANCE, 2.5 OIL SERVICING OF HYDRAULIC OVERLOAD PROTECTOR (pg. 198). (6) Manual Oil Pump (option, but, provided as standard on Models (S)E and NC1-2500) A manual oil pump is used for oiling counterbalance (option, but, provided as standard on Models (S)E and NC1-2500) and for oiling cylinder-type die cushion (option). Pumping the handle feeds oil to the press machine. Pump the handle for 3 to 5 strokes (or for 10 strokes if the press machine is equipped with a cylinder-type die cushion) before starting operation. Then, perform the same procedure once every four hours. See Section E MAINTENANCE, 5.5 MANUAL PUMP (pg. 224) for the procedure to replenish the tank with oil. (7) -1 Automatic Grease Pump See Section E MAINTENANCE, 5.3 AUTOMATIC GREASE PUMP (pg. 221). (7) -2 Automatic Oil Pump (Option) See Section E MAINTENANCE, 5.4 AUTOMATIC OIL PUMP (OPTION) (pg. 223). (8) Die Lifter/Die Clamper Oil Reservoir (Option) Remove the cover from the oil reservoir unit. Remove the plug from the drain port located on the underside of the oil reservoir to drain the oil remaining in the reservoir. Flush the system. Remove the plastic plug from the oil servicing port located on the top of the oil reservoir. Pour fresh oil through the oil servicing port until the upper level of the oil gauge on the side of the oil reservoir is reached. See the Instruction Manual for non-AIDA accessories (in a separate binder or provided at the end of this instruction manual). (9) Cushion Guide Grease Fitting (Option) Raise the die cushion, and then supply the specified quantity of grease using the grease gun furnished as an accessory. (See Section D OPERATION, 6.3 DIE CUSHION CAPACITY ADJUSTMENT (OPTION) (pg. 155), and Section E MAINTENANCE, 5.3.4 Grease Gun (pg. 222).) (10)Slide Adjustment Chain Apply grease directly onto the chain with a brush, etc. (11) Counterbalance [Except for the press machine is equipped with a manual oil pump for counterbalance] Rod Section: With the slide positioned at bottom dead center, apply grease directly onto the counterbalance rod. Top Face of Piston: Open the lid and apply grease directly to the sliding part on the top face of the piston. (12)Main Motor See the instruction manual for the main motor given at the end of this instruction manual (or in a separate binder).



197



Section E MAINTENANCE 2. LUBRICATION



2.5 OIL SERVICING OF HYDRAULIC OVERLOAD PROTECTOR



CAUTION • Do not adjust the hydraulic overload protector regulator located on the rear face of the slide. If the regulator is adjusted, the slide, connecting rod, crankshaft, frame, and other related components can be damaged. • Exercise added caution to the following when working on the hydraulic overload protector. (1) Be sure to wear safety goggles when loosening the pneumatic pump air bleed bolt and the regulator air bleed plug. Loosening the bolt or plug could cause air to blow out or oil to splash out. (2) Bleeding the air will cause the pneumatic pump to actuate and the piston to move. Do not touch the pump and piston. (3) When removing the regulator air bleed plug, the plug may be forcefully propelled out because of the residual pressure in the hydraulic overload protector tank. Confirm that there is no residual pressure remaining before fully loosening the plug.



198



Section E MAINTENANCE 2. LUBRICATION



2.5.1 Bleeding Air from the Hydraulic Overload Protector



In cases where the hydraulic overload protector is actuated repeatedly over a short period of time, air bubbles may form in the hydraulic overload protector’s hydraulic oil. In such cases, reaching the required hydraulic pressure may not be possible even if the pneumatic pump is actuated. If this problem occurs, perform the following procedure to bleed the air and restore the normal hydraulic pressure.



1



Stop the slide at bottom dead center. Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Loosen locknut (1), and then gradually loosen the air bleed bolt (2) by about one turn. Do not remove the air bleed bolt (2). Otherwise, the parts can spring out or oil can spout out.



Piston (1) Locknut Air pump



(2) Air bleed bolt



(Rear face of the slide)



3



Slowly open the air stop valve on the air supply inlet. The air pump piston will be actuated. After 5 to10 seconds, close the air stop valve on the air supply inlet.



4



Tighten air bleed bolt (2), and fix it by tightening locknut (1).



5



If the hydraulic pressure does not return to its normal pressure when the pneumatic pump actuates after the air has been bled, the following may be possible causes. • Air still remains in the hydraulic overload protector: Perform air bleeding procedure again. • The oil quantity is low: Replenish the tank with oil according to the following procedure.



199



Section E MAINTENANCE 2. LUBRICATION



2.5.2 Replenishing Hydraulic Overload Protector Oil



Replenish the hydraulic overload protector with oil according to the procedure described below. For NC1-350 and NC1-450, however, remove the plug (see 2.3 OIL AND GREASE SERVICING POINTS (pg. 196)) from the oil servicing port inside the slide to replenish the oil tank with oil. Furthermore, change oil at the time of the three-year inspection (during overhaul).



1



Stop the slide at bottom dead center. Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Loosen the air bleed plug’s lock nut (1), then slowly turn the air bleed plug (2) until air begins to escape. Loosening the air bleed bolt will allow air-laden hydraulic oil to escape through the bolt threading.



3



Once residual air pressure is relieved, remove the air bleed plug.



4



Add oil through the air bleed plug hole. Continue to add oil until oil begins to overflow. For convenience, we recommend using an oilcan to add oil.



5



Insert and tighten the air bleed plug, then securely tighten the lock nut. AG brake motor for slide adjustment



(1) Locknut



Regulator Pneumatic pump



Rear face of the slide



200



(2) Air bleed plug (commonly used as oil servicing port)



Section E MAINTENANCE 2. LUBRICATION



2.6 CHANGING CLUTCH AND BRAKE OIL



WARNING • When manually turning the flywheel, be sure to turn it slowly and be aware of the V-belts. Otherwise, your hand may be caught between the flywheel and V-belts.



IMPORTANT • An instruction plate that indicates the date for changing the clutch and brake oil is attached to the rear face of the control panel. Perform the initial periodic change of oil at the date indicated on the instruction plate. After changing the oil, enter the date for the next clutch and brake oil change on a new instruction plate, and attach it on the control panel in place of (or over) the old instruction plate. New instruction plates are available from AIDA Service (see the end of this instruction manual).



REPLACE OIL IN THE CLUTCH/BRAKE IN , NEXT TIME. USE OIL SPECIFIED IN THE INSTRUCTION MANUAL.



N9034e



The oil changing procedure varies by press machine model and tonnage. See the following pages for the procedure applicable to your press machine.



201



Section E MAINTENANCE 2. LUBRICATION



2.6.1 Oil Changing Procedure [for NC1-350]



WARNING • Be sure to replace the rear cover to its original position. Operating the press machine without replacing the rear cover can cause personal injury or death.



1



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Remove the rear cover.



3



Turn the flywheel by hand and position it so that the Oil level gage Oil servicing port oil drain port is positioned at the lowest point. Air vent The oil level line (red) on the oil level gage will be horizontal.



Oil drain port



4



Place an oil pan under the flywheel, then remove the plugs from the oil drain port and the air vent. Oil will drain from the drain port. When all the oil has been drained, insert and tighten the plug in the drain port hole. If the drained oil is excessively contaminated (the oil is black and tar-like), it is possible that a problem such as internal lining wear exists. In this case, immediately contact AIDA Service (see the end of this instruction manual).



5



Flush the system. (See 2.1 FLUSHING (pg. 193).)



6



Remove the plug from the oil servicing port and insert oil through the oil servicing port until the oil reaches the middle (the red line) of the oil level gauge. Insert and tighten the plugs in the oil servicing port and the air vent.



7



202



Replace the rear cover.



Oil servicing port Air vent



Air vent



Oil drain port



Section E MAINTENANCE 2. LUBRICATION



2.6.2 Oil Changing Procedure [for NC1-450~NC1-2500]



WARNING • Be sure to replace the rear cover to its original position. Operating the press machine without replacing the rear cover can cause personal injury or death.



1



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Remove the rear cover.



3



Turn the flywheel by hand and position it so that the oil drain port is positioned at the lowest point.



Oil servicing port Oil level gage



Air vent



The oil level line (red) on the oil level gage will be horizontal. Oil drain port



4



Place an oil pan under the flywheel, then remove the plugs from the oil drain port and the air vent. Oil will drain from the drain port. When all the oil has been drained, insert and tighten the plug in the drain port hole. If the drained oil is excessively contaminated (the oil is black and tar-like), it is possible that a problem such as internal lining wear exists. In this case, immediately contact AIDA Service (see the end of this instruction manual).



5



Flush the system. (See 2.1 FLUSHING (pg. 193).)



6



Air vent Remove the plug from the oil servicing port and insert oil through the oil ser- Oil servicing port vicing port until the oil reaches the mid- Oil level gage dle (the red line) of the oil level gauge. Insert and tighten the plugs in the oil servicing port and the air vent.



7



Replace the rear cover.



Air vent



Oil drain port



203



Section E MAINTENANCE 3. MAINTENANCE OF MECHANICAL COMPONENTS



3. MAINTENANCE OF MECHANICAL COMPONENTS When performing maintenance on mechanical components, follow the instructions in Section A SAFETY 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS (pg. 31).



3.1 MEASURING SLIDE GIB CLEARANCE



IMPORTANT • If the measured slide gib clearance value falls outside the specified value, immediately contact AIDA Service (see the end of this instruction manual). AIDA technical staff will adjust the clearance, and then check the accuracy of the press machine. If you continue using a press machine with improper gib clearance, product accuracy and/or die life may be adversely affected and it may result in gib galling or seizure.



1



Remove the dies from the press machine (see Section D OPERATION, 7. CHANGING DIES (pg. 161)) and stop the slide at bottom dead center.



2



Perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



3



Using a space gauge, measure clearances (1) through (6). The measurement should be made at the upper and lower ends of the gibs, but because the clearance at those ends has been made slightly larger, the space gauge must be inserted to a depth of at least 30 mm to obtain an accurate measurement. Take the maximum value as the measured clearance. After measuring, adequately apply grease onto the gibs.



(1) (3)



(4) (6)



(2)



(5)



Slide • The gib structure varies between press machine models.



* Gib clearance should be 0.07 mm or less, with the total of that clearance plus the opposing gib clearance ((1)+(2), (4)+(5), and (3)+(6)) being from 0.03 to 0.14 mm.



204



Section E MAINTENANCE 3. MAINTENANCE OF MECHANICAL COMPONENTS



3.2 V-BELT ADJUSTMENT



1



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Check the V-belts for proper tension. To obtain the proper tension, adjust them so that the V-belts deflect by approximately 16 mm per meter when the middle part of the belt is pressed with a load F (see the table below). Model NC1-350~NC1-1500



Span Ｆ



V-belt



Load F Approx. 27 N



Amount of deflection



NC1-2000, NC1-2500 Approx. 20 N



3



Motor pulley



Flywheel



If the V-belt tension is incorrect, adjust the V-belt tension. Loosen the lock bolts (2) and locknuts (4). Turn the four adjusting bolts (3) equally to lift the motor. This will put tension on the V-belts (1). Adjust the V-belt tension while checking that height h values, in the illustration given below, are equal at all four places. Below are some examples of adjustment bolt configurations used on different models. Visually confirm your press machine to determine the type being used.



(2) (1)



①



①



②



(3)



②



③



(4)



④ h



NC1-350 NC1-450 NC1-600 NC1-800



④ ③



h



NC1-1100 NC1-2000 NC1-2500



h



NC1-1500



The shape of the motor on your press machine may be different from that shown above.



4



After the adjustment, apply LOCTITE NO. 242 to the lock bolts (2) and locknuts (4) to prevent them from loosening. Then, fully tighten the four lock bolts and locknuts.



NOTE



• It is recommended that a tension gauge be used to check the tension. To ascertain which tension gauge would be the most appropriate, consult the V-belt dealer or AIDA Service (see the end of this instruction manual).



205



Section E MAINTENANCE 3. MAINTENANCE OF MECHANICAL COMPONENTS



3.3 CHANGING V-BELTS



IMPORTANT • Change all V-belts at the same time. Even if the belts have the same nominal length, the actual lengths may be different. It is therefore necessary to measure the actual length of each V-belt and use the ones that are the same in measured length. Otherwise, a matched set of V-belts should be purchased. If used belts and new belts are used together or belts of different lengths are used in combination, the elongation of the belts as well as the tension of each V-belt will be different. This will decrease the life of the V-belts. • Confirm that no oil or grease is allowed into the V-grooves in the flywheel. Oil or grease in the V-grooves can cause the belts to slip. • It takes approximately three days for new V-belts to settle into the grooves. Three days after changing the V-belts, be sure to re-adjust the tension properly. • Spare V-belts should be stored in a dry, cool place, away from exposure to direct sunlight, and should be kept free from oil. Perform the following procedure to replace V-belts.



206



1



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Loosen the V-belts using the procedure explained in 3.2 V-BELT ADJUSTMENT (pg. 205).



3



Loosen and remove the hose clamp (1) on the clutch and brake side and remove the hose clamp. Next, remove the bracket for the clutch and brake solenoid valve together with the solenoid valve and hose.



(2) Hose



Solenoid valve



Clutch and brake



(1)



4



Replace the old V-belts with new V-belts.



5



Replace the clutch and brake solenoid valve bracket to its original position. Connect the hose to the clutch and brake and tighten it with a hose clamp.



6



Adjust the V-belts to their proper tension following the procedure explained in 3.2 V-BELT ADJUSTMENT (pg. 205).



Section E MAINTENANCE 3. MAINTENANCE OF MECHANICAL COMPONENTS



3.4 INSPECTING CLUTCH STROKE



WARNING • In cases where the measured stroke exceeds the specified range, immediately contact AIDA Service (see the end of this instruction manual). If the press machine is used in this state, clutch and brake performance may deteriorate, and could cause personal injury or death. • When manually turning the flywheel, be sure to turn it slowly and be aware of the V-belts. Otherwise, your hand may be caught between the flywheel and V-belts. • Before manually operating the clutch and brake solenoid valve, lower the slide to bottom dead center and perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33). Otherwise, the slide may fall, and personal injury or death could be caused. • After completing the measurement, be sure to remove the rod and tighten the inspection plug. If the press machine is operated without the rod being removed, the clutch and brake can break and personal injury or death could be caused.



1



Lower the slide to bottom dead center and stop it there. Perform all the steps except step (8) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33). Confirm that the clutch and brake area has cooled sufficiently. This area remains very hot after the press machine has been stopped.



2



Turn the flywheel by your hands to bring stroke inspection plug (1) to the highest point. Remove the stroke inspection plug.



(1)



3



Insert a rod (φ8 mm x 150 mm to be prepared by the customer) into the stroke inspection hole.



4



Turn the flywheel slowly by hand while pushing the rod into the hole, until the rod can be inserted about 120 mm (where it comes in contact with the piston).



5



Simultaneously press the two manual operation pins on the clutch and brake solenoid valve to activate the clutch. Now, measure the stroke of the rod. * The proper stroke is 1.5 to 3.0 mm.



Approx. 120 mm



Manual operation pins



1.5 to 3.0 mm



207



Section E MAINTENANCE 3. MAINTENANCE OF MECHANICAL COMPONENTS



3.5 MAINTENANCE OF GUARDS (OPTION) Perform maintenance of the gas spring of the swing guard (option) as described below.



IMPORTANT • Do not oil the gas spring. Oiling the rod part will damage the seal, causing leakage of gas or oil from the cylinder. This can degrade the function of the gas spring.



3.5.1 Inspection



1



Open the guard.



2



With the guard near its upper limit, confirm that the guard does not fall down under its own weight.



3



If the guard falls down under its own weight, replace the gas spring with a new one. If you have any problems while replacing it, contact AIDA Service (see the end of this instruction manual).



3.5.2 Disposal



CAUTION • Do not incinerate the gas spring. The nitrogen gas sealed inside the gas spring is not combustible. However, if thrown into a fire, the gas spring seal can deteriorate to the point where the oil or gas sealed inside the cylinder can burst out. • Do not disassemble the gas spring. Nitrogen gas is sealed inside the gas spring in a pressurized condition. If disassembled, parts of the gas spring may burst out. • Discard the gas spring after the purging gas. Drill a of 2 to 3 mm diameter hole into the used gas spring removed from the guard at a location 20 mm above the lower end of the cylinder to purge the gas. Be sure to wear safety goggles during this procedure, since oil or chips may be blown out. Drill the hole with the gas spring situated in a horizontal position.



208



２０mm



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



4. MAINTENANCE OF ELECTRICAL COMPONENTS When performing maintenance on electrical components, follow the instructions in Section A SAFETY, 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS (pg. 31).



CAUTION • After replacing any component or part, perform a pre-work check (routine inspection) (See pg. 120.) and run tests to verify that there are no errors before resuming press machine operations. • If an inductive load, such as a solenoid valve, is added, surge absorbers or other noise countermeasures are required. Otherwise, there is a possibility that the press machine could malfunction due to noise. • While performing maintenance on electrical parts and components, confirm that they are protected from dust, oil, and water. Furthermore, be sure to close the control panel door except when you are doing maintenance inside the control panel. Dust, oil, and/or water can reduce the lifespan of electrical parts and components. Furthermore, there is also a possibility that the press machine could malfunction.



4.1 MEGGER MEASUREMENT (INSULATION RESISTANCE MEASUREMENT)



CAUTION • Never take a megger measurement with the terminals of electronic devices and proximity switches connected. The electronic devices may be damaged. • Megger measurements and maintenance of electrical parts and components, such as inspection and adjustment, must be conducted by a qualified electrician. The following is an example of a megger measurement of a control circuit.



1



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Disconnect all wires from the input terminals of electronic devices and proximity switches, and disconnect all grounding wires of the control circuit transformer.



3



Connect the ground side of the megger to the earth plate (1) inside the control panel, and touch the probe side to the terminal (2) to which the common wire (wire no. RC) of the control circuit is connected. * If the megger measurement is 5MΩ or higher, it is normal. If the measurement is less than 5M Ω, contact AIDA Service (see the end of this instruction manual).



(1)



５ＭΩ



(2)



209



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



4.2 SERVICE LIFE OF ELECTRICAL COMPONENTS The service life of electrical components is described below. Be sure to replace components before they reach their standard service life even if the component is operating properly. Furthermore, when replacing it with a new one, use a component made by the same manufacturer with the same type or model number. Clutch and brake solenoid valve replacement requires special skills. Contact AIDA Service (see the end of this instruction manual) when you need to replace the clutch and brake solenoid valve with a new one. The service life of electrical components is a nominal value given by the manufacturer. It may vary depending on the frequency of use and environmental conditions. See Section E MAINTENANCE, 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS (pg. 247) for details regarding the manufacturers and model numbers of components. Component Name



Standard Service Life



Electromagnetic Switch



Fuji Electric



5 years



Auxiliary Relay



OMRON, Fuji Electric



2 years



Terminal Relay



OMRON



1 year



Push Buttons



IDEC



5 years



Limit Switch



Yamatake, etc.



5 years



Clutch and Brake Solenoid Valve



Toyooki Kogyo



5 years



NOTE



210



Manufacturer



• If a relay vibrates, there is a possibility that dust is present on the contact.



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



4.3 INSPECTING THE GROUND FAULT BREAKER



DANGER • When inspecting the ground fault breaker, do not touch anything inside the control panel other than the ground fault breaker. Touching anything else could cause an electric shock resulting in death. The illustrations below show the ground fault breakers for the control circuit and for the main circuit (option).



(3) Handle



ON



(2) Ground fault indicator button



OFF



ON



OFF



(1) TEST button



Ground fault breaker for control circuit



1



Ground fault breaker for main circuit



Push the TEST button (1).



2



Check that the ground fault breaker operates as described below: • The ground fault indicator button (2) is sticking out. • The handle (3) moves to the neutral position.



3



After confirming operation, reset the ground fault breaker following the procedure described below: • Push the handle down to OFF once. Then, push it up to ON. • This will return the ground fault indicator button to its original position and reset the ground fault breaker.



4



If the ground fault breaker will not operate when the TEST button is pushed, abort the inspection and investigate the cause of the trouble. If the cause remains unknown, contact AIDA Service (see the end of this instruction manual).



211



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



4.4 REPLACING THE BUILT-IN PLC BATTERY When a wrench symbol is displayed on the operator interface terminal and the message PLC BATTERY FAILURE is displayed on the DIAGNOSIS screen (see Section D OPERATION, 2.7.5 Fault Diagnosis (pg. 110)), it indicates that the programmable logic controller (PLC) data back-up battery is almost depleted. When this occurs, immediately replace the battery with a new one.



IMPORTANT • Replace the battery with a new one within one week after the appearance of the above message. If you continue to use the almost-depleted battery, there is the possibility that stored data may be lost, and that press machine operation may be disabled. • Energize the PLC control power source for at least five minutes before replacing the battery with a new one. This supplies power to the capacitor that maintains the existing data while the battery is being changed. If the control power source is not energized for at least five minutes, the capacitor will not store sufficient power to maintain the data. As a result, the data may be lost while the battery is being changed. • Remove the used battery after energizing the control power source for at least five minutes, then load a new battery within five minutes. If the PLC is left without a battery for longer than five minutes, the existing data can be lost. • Prepare a spare battery in advance. A new battery may not be obtainable before the battery is totally depleted even if it is ordered when the message PLC BATTERY FAILURE has been displayed. • The service life of the battery is approximately five years. Change the battery after five years even if the battery is still operational. • Do not incinerate the old battery. • The battery is not rechargeable. Do not disassemble the battery. • The disposal of batteries may be restricted by local governments. Discard batteries in accordance with applicable local governmental regulations.



(Continued on the next page)



212



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



(Continued) 4.4.1 PLC Built-In Battery Model Information



Product Name Battery Set



Model Type CPM2A-BAT01



Manufacturer OMRON



4.4.2 Replacing the PLC Built-In Battery



1



Set the CONTROL POWER switch to "O" (OFF), then remove the key from the key switch. If the press machine has not been energized for at least five minutes, energize it first, then set the switch to "O" (OFF).



2



Turn your power source OFF.



3



Open the control panel door.



4



You will find the programmable logic controller (PLC) in the upper area inside the control panel. Open the cover of the battery case. Disconnect the connector of the used battery loaded inside the PLC case and pull out the battery. Load a new battery within five minutes. Battery



Connector



5



Close the battery case cover and the control panel door.



213



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



4.5 OPERATOR INTERFACE TERMINAL MAINTENANCE



WARNING • Do not disassemble or touch the insides of the unit while it is energized. Turn off the control power source and your power source before removing the panel from the operation panel. If not, electric shock hazards can occur.



CAUTION • When you have removed the panel from the press machine operation panel, do not suspend the panel using the cables connected to the panel as a support. If suspended by the cabling, the wiring cable can be damaged, and discontinuity or short-circuits can be caused. It is recommended that two persons perform the above work so that one person can remove the panel while the other supports it. • Do not touch printed circuit boards with bare hands. Do not disassemble printed circuit boards.



4.5.1 Service Life of the Backlight



Contact AIDA Service (see the end of this instruction manual) when the brightness of the backlight of the operator interface terminal has decreased to the point where the displays on the operator interface terminal are hard to recognize. AIDA technical staff will replace the operator interface terminal with a new one. The standard service life of the backlight is approximately ten years.



214



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



4.5.2 Replacing the Operator Interface Terminal Built-In Battery



When the “RUN” LED located on the left side of the operator interface terminal has turned red or orange (it is normally green), it indicates that the operator interface terminal memory backup battery has died. In this case, replace the battery with a new one.



IMPORTANT • Do not incinerate the old battery removed from the operator interface terminal. • The battery is not rechargeable. Do not disassemble the battery. • Replace the battery with a new one within five days after the above message has been displayed. If you continue to use the almost-depleted battery, the data stored in the memory can be lost. • Energize the control power source for at least five minutes before replacing the battery with a new one. Then remove the used battery and load a new battery within five minutes after removing the used one. If the operator interface terminal is left without a battery for longer than five minutes, the data stored in the memory will be lost. • Prepare a spare battery in advance. (The service life of the battery is approximately five years.) A new battery may not be obtainable before the battery is totally depleted even if it is ordered when the “RUN” LED has changed to red or orange. • The disposal of batteries may be restricted by local governments. Discard batteries in accordance with applicable local governmental regulations.



Model Type C500-BAT08



Manufacturer OMRON



(Continued on the next page)



215



Section E MAINTENANCE 4. MAINTENANCE OF ELECTRICAL COMPONENTS



(Continued)



1



Set the CONTROL POWER switch to "O" (OFF), then remove the key from the key switch. If the press machine has not been energized for at least five minutes, energize it first, then set the switch to "O" (OFF).



2



Turn your power source OFF.



3



The panel is affixed with screws. Remove the screws to remove the panel from the press machine operation panel. The panel has many wires. Take care to not damage any of them.



4



Fit the tip of a flat tip screwdriver into the upper end of battery cover located in the upper left area of the rear side of the operator interface terminal, and pull the battery cover towards you until it opens.



Battery cover



216



5



Remove the battery secured to the inside of the battery cover. Pull the connector straight towards you until it comes off. Replace the used battery with a new one within five minutes after pulling out the connector. Remove the used battery located inside the cover.



6



Connect the connector of the new battery and affix the battery to the inside of the cover. When connecting the connector, push it until it will go no further, with the projection of the connector facing toward you.



7



Close the battery cover, taking care that the battery cable is not pinched by the cover.



8



Reinstall the panel to the press machine operation panel.



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS When performing maintenance on pneumatic and hydraulic units, follow the instructions in Section A SAFETY, 4.5 ESSENTIAL MAINTENANCE PRECAUTIONS (pg. 31).



5.1 AUTO-DRAIN FILTER



CAUTION • When the quantity of drained sludge is excessive (the auto-drain filter is actuated several times a day), install an air dryer or the like at the air source to supply dry air. Using air containing sludge can cause the solenoid valve to malfunction or rust to form inside the cylinder. This can lead to an accident. 5.1.1 Specifications



Model



1137, 1138



Proof Pressure



1.5 MPa



Working Pressure



1.0 MPa max.



Allowable Temperature



5 to 65 ℃



Fluid to be Filtrated



Compressed air



Filter Rating



5 μm



Manufacturer



CKD Co., Ltd.



5.1.2 Construction (1) Clamp ring



(2) Bowl guard



(7) Tab (6) Filter element



(3) Bowl (5) Baffle (4) Flexible drain



5.1.3 Manually Draining the Auto-Drain Filter



Lightly push the flexible drain (4) to the side with your finger. Sludge will drain as long as the flexible drain remains pushed to the side. (Continued on the next page)



217



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued) 5.1.4 Disassembling, Cleaning, and Replacing the Auto-Drain Filter



Refer to 5.1.2 Construction on the previous page.



IMPORTANT • Never clean the bowl (3) of the auto-drain filter with an organic solvent such as thinner or alcohol. Because the bowl is made of plastic, if it is immersed in an organic solvent cracks will be made, the transparency of the bowl will be impaired, and air leakage may be caused.



218



1



Shut off the shop air supply, then release any air remaining in the pneumatic system of the machine.



2



Lightly push the flexible drain (4) to the side to drain sludge and release remaining air. When the sludge and air have drained completely, release the flexible drain.



3



While pressing the tab (7), turn the clamp ring (1) approximately 30°. (Align the △ mark on the tab with the IN ▽ mark (away from the LOCK ▽ mark) on the clamp ring.)



4



Pull down on bowl guard (2) and bowl (3) together until they come off.



5



Turn the baffle (5) counterclockwise and remove it along with the filter element (6).



6



Immerse the filter element (6) in kerosene for five to ten minutes. Then, clean it with neutral detergent and blow air inside the element to clean it.



7



Clean the bowl (3) and baffle (5) with a neutral detergent.



8



Place the washed element or a new element in the bowl and reassemble the auto-drain filter by reversing the disassembly procedure.



9



Confirm that tab (7) is locked (i.e., the △ mark on the tab is aligned with the LOCK ▽ mark on the clamp ring) before supplying air.



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



5.2 THE CLUTCH AND BRAKE SOLENOID VALVE



WARNING • Do not press the manual operation pin while the flywheel is in motion. Pressing the pin when the flywheel is in motion may cause the slide to drop suddenly, and personal injury or death can be caused. Before pressing the manual operation pin, lower the slide to bottom dead center and perform all the steps except step (8) (relieving the air) of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33). In addition, the manual operation must be conducted by authorized personnel and the manual operation pin must not be pressed in any case other than for the purpose of checking. • Do not place anything within 20 cm of the muffler that might obstruct the exhaust air from the solenoid valve. Interference with the exhaust air could cause a malfunction, and personal injury or death can be caused. • In the event of air or oil leakage, or solenoid valve malfunction, immediately prohibit the use of the press machine and contact AIDA Service (see the end of this instruction manual). Failure of the clutch and brake solenoid valve can cause personal injury or death. 5.2.1 Solenoid Valve Specifications



Model



AD-04104* to AD-08104* (24 VDC) with monitor



Operating Pressure



0.2 to 0.8 MPa



Operating Temperature



5 to 50 ℃



Manufacturer



Toyooki Kogyo Co., Ltd.



The asterisk (*) shown above denotes the number designated by Toyooki Kogyo Co., Ltd. as a control number, and it is subject to change without notice. When a new solenoid valve is needed for replacement or maintenance purposes, place an order without using the asterisk (e.g., AD-04104).



219



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



5.2.2 Clutch and Brake Solenoid Valve Monitor Function Test



Test the monitoring function according to the procedure described below:



220



1



Stop the slide at the preset stop position.



2



Press the MAINT. touchbutton located on the lower half of the operator interface terminal. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) The MAINTENANCE screen will be displayed. (See Section D OPERATION, 2.7 THE MAINTENANCE SCREEN (pg. 108).)



3



Press the CL & BR SV TEST on the MAINTENANCE screen to change the screen to the CLUTCH & BRAKE SOL. VALVE TEST screen. (See Section D OPERATION, 2.7.1 Clutch and Brake Solenoid Valve Test (pg. 108).)



4



Confirm that the message OPERATION READY is displayed in the interlock information field. If any other message is displayed, reset it according to Section D OPERATION, 5.1 INTERLOCK INFORMATION MESSAGE LIST (pg. 132).



5



Set the OPERATION SELECT switch to INCH. Check that the RUN OK light goes on.



6



Push the two RUN buttons simultaneously with both hands. The clutch and brake solenoid valve will produce exhaust noise, the RUN OK light will go out, and the message CL&BR SOL.VALVE MONITOR will be displayed in the interlock information field.



7



Press the END touchbutton and then the RUN touchbutton to return to the RUN screen.



8



The wrench symbol will be displayed on the operator interface terminal. (See Section D OPERATION, 2.2 COMMON OPERATION AND DISPLAY SCREEN ELEMENTS (pg. 95).) Change the screen to the 2.7.5 Fault Diagnosis (pg. 110) screen, check that the message CL&BR SOL.VALVE MONITOR DETECT is displayed on the screen. As long as this message is displayed on the screen, the monitoring functions of the solenoid valve are normal. If the above message is not displayed on the screen, the monitor may not be functioning normally. In this case, contact AIDA Service (see the end of this instruction manual).



9



After completing the test, push the RESET button.



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



5.3 AUTOMATIC GREASE PUMP See 5.4 AUTOMATIC OIL PUMP (OPTION) (pg. 223) if your machine is equipped with an automatic oil pump (option) instead of the automatic grease pump.



IMPORTANT • Do not replenish grease by removing the lid (1) (see the illustration shown below). If the lid is removed, air or dust may enter inside. Be sure to add grease to just the upper limit of the tank, making sure that the quantity is neither too much nor too little. If air or dust enters the grease, the grease may not be supplied properly, causing overheating, galling, or damage to the bushings or gibs.



ＯＫ



• Do not adjust the relief valve (5) (see the illustration below). Adjusting the valve will change the grease supply pressure, resulting in the faulty supply of grease, and cause overheating, galling, or damage to the bushings or gibs. 5.3.1 Specifications



Model Tank Capacity Delivery Pressure



(1) Lid



SK505BMA-04



SK505BMA-1



400 cm3 14.7 MPa



1000 cm3



13 cm3 / min. Ishikawajima Hanyouki Manufacturer Service Co., Ltd. Type of Grease AIDA Standard Grease No.0 Capacity



(9) Motor



(2) Floor plate (3) Tank (4) Grease inlet (5) Relief valve (6) Air bleed valve (7) Check valve (8) Discharge opening



5.3.2 Replenishing Grease



Replenish the tank (3) with no. 0 grease before the grease level in the tank reaches the lower limit (the line marked “Low”). Open the grease servicing port (4) and supply grease using a grease gun (furnished with the press machine as a standard accessory) or a grease pack (option) into the tank until the grease level reaches the upper limit (the line marked “High”). Do not use excessive force when connecting the grease gun to the grease servicing port. Doing so may damage the plastic case. See 5.3.4 Grease Gun (pg. 222) or 5.3.5 Grease Pack (Option) (pg. 222). 5.3.3 Bleeding Air



If the grease contains a large quantity of air, the grease distributor valve will not operate and the press machine cannot be operated. To vent air from the grease, open air bleed valve (6) and then turn on the control power source to actuate the automatic grease pump. When air in the grease is bled from the air bleed valve and grease begins to be discharged from the valve, close the valve. (Continued on the next page)



221



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued) 5.3.4 Grease Gun



IMPORTANT • Do not remove the cartridge while grease is being delivered, otherwise air will enter the grease. • Only use genuine AIDA grease cartridges. Contact AIDA Service (see the end of this instruction manual), because this grease is not commercially available. If any grease other than the above grease (AIDA Standard Grease) is used, the grease may not be delivered properly. A grease gun (an AIDA genuine product) of the following specifications is furnished with the press machine as a standard tool. Replenish grease using the AIDA grease gun by placing a grease cartridge in the grease gun. Model



CH-650SP



Delivery Pressure



25 MPa max.



Capacity



1.7 cm3 / stroke



The illustrations below indicate how to place the grease cartridge in the grease gun. Lever



Main unit Cap



Grease Install the oil pipe in Cartridge position. Unlock the Detach the main unit Draw the chain to Remove the cap from chain and house it in the oil pipe with form the oil pipe. lock it in the slit in the the cartridge grease contracted. This oil pipe. and screw it in the completes the loading. main unit. Main unit



Oil pipe



Oil pipe



5.3.5 Grease Pack (Option)



Grip



Approx. 390 mm



The grease pack is intended to be used when replenishing the tank with grease from a grease can (2.5-kg or 16-kg can). When the grease pack is used, the grease will not be exposed to the air, thereby preventing debris such as dust from entering the grease. Connect the quick-coupling joint to the grease servicing port, then insert the tip of nylon hose installed at the grip into the joint. Now, operate the handle to feed the grease. The main grease pack specifications are given below:



Handle



φ22



Inlet port (Continued on the next page)



222



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued) Model (Product Code)



SGP-16 (RK701000)



Capacity



45 cm3 / stroke 1 MPa Ishikawajima Hanyouki Service Co., Ltd.



Delivery Pressure Manufacturer



If you need detailed information about the grease pack, contact the AIDA office in your area (see the end of this instruction manual) or the dealer. Dealer: Ishikawajima Hanyouki Service Co., Ltd.



Grease inlet



Grease can



5.4 AUTOMATIC OIL PUMP (OPTION) An automatic oil pump (option) is provided instead of an automatic grease pump.



IMPORTANT • Only use the specified type of oil. • Discard the oil remaining in the oil recovery reservoir before adding oil, otherwise the oil may overflow from the reservoir. • Never reuse the recovered oil. Using such oil can damage the press machine. • Carefully prevent any dust from entering the tank while replenishing the oil. 5.4.1 Specifications



(1) Lid Model Tank Capacity Delivery Pressure Capacity Manufacturer Type of Oil



SK-505BMAL-1 1L 5.9 MPa 13 mL/min. Ishikawajima Hanyouki Service Co., Ltd. MOBIL DTE Oil HH (or equivalent)



5.4.2 Replenishing Oil



(8) Motor (2) Tank (3) Filter (4) Relief valve (5) Air bleed valve (6) Check valve (7) Discharging opening



Add oil to the tank (2) before the oil level reaches the lower limit (the line marked “Low”) of the tank. Open the lid (1) and replenish the tank with oil until the oil level reaches the upper limit (the line marked “High”) of the tank. 5.4.3 Bleeding Air



If the oil contains a large quantity of air, proper lubrication cannot be performed. To bleed the air, open the air bleed valve (5) and then turn on the control power source to actuate the automatic oil pump. Actuate the pump until the air contained in the oil begins to be bled from the air bleed valve. When the oil begins to be discharged, close the air bleed valve.



223



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



5.5 MANUAL PUMP A manual oil pump is used for oiling counterbalance (option, but, provided as standard on Models (S)E and NC1-2500) and for oiling cylinder-type die cushion (option). A manual grease pump (option) may be used for greasing peripheral devices.



IMPORTANT • If the pump handle becomes too heavy to operate, the oil (grease) pipe may be damaged (crushed) or the distributor valve may be clogged. In this case, immediately check and repair the problem. If the press machine is used without repairing the problem, moving parts may be damaged because of inadequate oiling (greasing). 5.5.1 Specifications



Manual Pump Model



SKA-214L (for Oil)



SKA-214 (for Grease)



Type of Oil and Grease



AIDA Standard Oil No. 3



AIDA Standard Grease No. 0



Tank Capacity



400 cm3



Capacity



1cm3 / stroke



Manufacturer



Ishikawajima Hanyouki Service Co., Ltd.



(1) Lid (2) Filter Floor plate (5) Handle (3) Tank (4) Air bleed



(6) Grease inlet



5.5.2 Replenishing Manual Oil Pump Oil



Add oil to the tank (3) before oil level reaches the lower limit (the line marked "Low") of the tank. Open the lid (1) and replenish the tank with oil until the oil level reaches the upper limit (the line marked “High”) of the tank. 5.5.3 Replenishing Manual Grease Pump (Option) Grease



IMPORTANT • Do not replenish grease by removing the lid (1) (see the illustration shown above). If the lid is removed, air or dust may enter inside. Be sure to add grease to just the upper limit of the tank, making sure that the quantity is neither too much nor too little. If air or dust enters the grease, the grease may not be supplied properly, causing overheating, galling, or damage to the bushings or gibs. Add grease to the tank (3) before the grease level reaches the lower limit of the tank. Open the grease servicing port (6) and replenish the tank with grease using the grease gun or a grease pack until the grease level reaches the upper limit of the tank. See 5.3.4 Grease Gun (pg. 222) or 5.3.5 Grease Pack (Option) (pg. 222) for details. (Continued on the next page)



224



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued) 5.5.4 Bleeding Air



When the quantity of oil in the tank (3) is reduced, air is drawn into the tank and handle (5) operation can become light or spongy. In this case, replenish the tank with oil or grease, then open the air bleed (4), and operate the handle (5) to bleed air from the tank. When oil or grease begins to come out, stop handle operation and close the air bleed.



5.6 MOTOR-DRIVEN OIL PUMP AND OIL FILTER A motor driven oil pump and oil filter is furnished on Types NC1-(S)E, -(1NL)E and -(2NL)E.



IMPORTANT • Do not adjust the oil pump relief valve. • If the pressure switch has detected a drop in lubricating oil pressure, the probable cause is oil leakage from the suction pipe or a clogged filter on the suction side. Inspect the suction pipe and clean or replace the filter element. 5.6.1 Electric Oil Pump Specifications



Press Machine Model



NC1-(S)E



NC1-(1NL)E and -(2NL)E



Pump Model



TOP-1ME100-12MAVB



TOP-1ME100-11MA



Capacity (Under No Load Conditions)



50 Hz: 3.7 L / min. 60 Hz: 4.5 L / min.



50 Hz: 2.2 L / min. 60 Hz: 2.7 L / min.



Pressure



0.5 MPa max.



Manufacturer



Nippon Oil Pump Co., Ltd. (Continued on the next page)



225



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued) 5.6.2 Suction-Side Oil Filter



(2) Bolt Press Machine NC1-(S)E Model Filter Model



VN-04A-40W



Flow Rate



30 L / min.



Filter Rating



40 Mesh (Filter Material: Wire Mesh)



Manufacturer



Taisei Kogyo Co., Ltd.



(4) Reset button (1) Clogging indicator (5) Discharge opening



(3) Cover



(6) Drain plug



(7) Suction port



As the element gradually becomes clogged, the green display on the clogging indicator (1) will change to red. When the element becomes clogged, the clogging indicator turns completely red. Before the indicator turns completely red, clean the element or replace it with a new one according to the procedure described below: Reset button



226



Green indication



Red indication



Element is clean.



Element is clogged.



1



Close the stop valve on the suction side.



2



Remove the bolt (2) and remove the cover (3).



3



The element is now visible. Pull up on the element until it comes off.



4



Clean the element with cleaning solvent. Then blow air from the inside of the element to blow off the cleaning solvent.



5



Check the O-ring and packing inside the filter.



6



Put the clean element in position, close the cover (3) and fully tighten the bolt (2).



7



Push the reset button (4) to reset the clogging indicator (1) to green.



8



Open the stop valve on the suction side.



9



If the filter element cannot be cleaned (i.e., the clogging indicator does not reset to green when the cleaned filter element is reinserted), or the filter element is broken, replace it with a new one. (Continued on the next page)



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued) 5.6.3 Delivery-Side Oil Filter [Type (S)E]



Press Machine NC1-(S)E Model Filter Model



LND-06-40μ



Flow Rate



30 L / min.



Filter Rating



40 μm (Filter Material: Filter Paper)



Manufacturer



Taisei Kogyo Co., Ltd.



(2) Cover



(1) Nut



Note that the filter uses a paper filter element that cannot be cleaned and reused. Be sure to replace the element with a new one.



1



Close the stop valve on the suction side.



2



Loosen the nut (1) and remove the cover (2).



3



Pull down on the element until it comes off.



4



Check the O-ring and packing inside the filter.



5



Install a new element in the correct position.



6



Replace the cover (2) and tighten the nut (1).



7



Open the stop valve on the suction side. (Continued on the next page)



227



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued) 5.6.4 Delivery-Side Oil Filter [Type (1NL)E and (2NL)E]



Press Machine Model



NC1-(1NL)E and -(2NL)E



Model



UL-03A-40UW-IK



Filter Rating



40 μm (Filter Material: Wire Mesh)



Manufacturer



Taisei Kogyo Co., Ltd.



(1) Clogging indicator (3) Bolt



(4) Cover



(2) Drain plug



As the element gradually becomes clogged, the green display on the clogging indicator (1) will change to red. When the element becomes clogged, the clogging indicator turns completely red. Before the indicator turns completely red, clean the element or replace it with a new one according to the procedure described below: Green indication



Red indication



Element is clean.



Element is clogged.



1



Perform all the steps of the procedure described in Section A SAFETY, 5. SAFETY PROCEDURES DURING ADJUSTMENT (pg. 33).



2



Remove the drain plug (2) and drain the remaining oil.



3



Remove the bolt (3) and lift up the cover (4). The filter element will be lifted up together with the cover. Remove the filter element from the cover.



4



Clean the filter element with a light oil such as kerosene. Then blow air from the inside of the element to remove the cleaning solvent.



5



Check the O-ring and packing inside the filter. (Continued on the next page)



228



Section E MAINTENANCE 5. MAINTENANCE OF PNEUMATIC AND HYDRAULIC UNITS



(Continued)



6



After attaching the cleaned filter element to its original position, put the cover back into place and securely bolt it. During assembly, check the arrow mark on the cover to confirm that the flow direction from the suction side to the delivery side is correct.



7



Reverse the steps of the Safety Procedures During Adjustment performed in step 1 above.



8



If the filter element cannot be cleaned (i.e., the clogging indicator turns red soon after it is cleaned and reused), or the filter element is broken, replace it with a new one.



229



Section E MAINTENANCE 6. TROUBLESHOOTING



6. TROUBLESHOOTING No power to the press machine.



Status



Cause



Remedy (page to be referred to)



Electrical power supply in your plant has failed. The POWER light does not come on.



The ground fault breaker has tripped.



See page 147



The externally controlled breaker has tripped.



See page 147



Contact AIDA Service.



Other unknown cause.



The slide does not move.



Status



Cause



The main motor does not start.



The lubricating oil pump is not operating (if your press machine is equipped with this pump). The main motor thermal relay has tripped.



An interlock information message is displayed on the operator interface terminal.



A wrench symbol is displayed on the operator interface terminal.



The RUN OK light does not come on.



Start the oil pump.



See page 148



Check the message number displayed on the operator interface terminal and see the list of messages contained in the Instruction Manual to find an explanation of the message. Follow the resetting procedure explained in the message. See page 132 Switch to the DIAGNOSIS screen. Check the message number displayed on the screen and see the list of messages contained in the Instruction Manual to find an explanation of the message. Follow the resetting procedure explained in the message. See page 137 Operating requirements are not being met to enable the slide to operate in the selected mode.



Other unknown cause.



230



Remedy (page to be referred to)



Perform the procedure described in 3.2 ROUTINE INSPECTION AND OPERATION (pg. 121). Contact AIDA Service.



Section E MAINTENANCE 6. TROUBLESHOOTING



The slide has stopped during operation.



Status



Cause



Remedy (page to be referred to)



An interlock information message is displayed on the operator interface terminal.



Check the message number displayed on the operator interface terminal and see the list of messages contained in the Instruction Manual to find an explanation of the message. Follow the resetting procedure explained in the message. See page 132



A wrench symbol is displayed on the operator interface terminal.



Switch to the DIAGNOSIS screen. Check the message number displayed on the screen and see the list of messages contained in the Instruction Manual to find an explanation of the message. Follow the resetting procedure explained in the message. See page 137



The upper and lower dies are stuck together.



The upper and lower dies are stuck together because of insufficient torque.



See page 150



Contact AIDA Service.



Other unknown cause.



The press machine is out of order.



Status



Cause



Remedy (page to be referred to)



V-belts emit slipping noise or other abnormality.



The V-belts have worn out or have insufficient tension.



See page 205 See page 206



Product accuracy is inconsistent.



Bottom dead center accuracy is not consistent due to insufficient lubrication, improper guide post clearance, etc.



Contact AIDA Service.



There are unusual noises, odors, or vibrations, and the cause is unknown.



Lubrication is not sufficient or internal parts have broken.



Contact AIDA Service.



Other unknown cause.



Contact AIDA Service.



231



Section E MAINTENANCE 7. CONSTRUCTION DRAWINGS



7. CONSTRUCTION DRAWINGS



CAUTION • Do not modify or remove any mechanical structural components. AIDA shall not be liable for any failure or problems caused by any such modification or removal. See the following pages.



232



(5)



(8)



Section E MAINTENANCE 7. CONSTRUCTION DRAWINGS



246



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS Manufacturer and model names may vary according to availability or other reasons.



8.1 MECHANICAL PARTS



Bearings



Item



Part Number



Manufacturer Q’ty NC1350 (Material)



NC1450



NC1600



NC1800



NC11100



NC11500



NC12000



-



-



-



-



-



-



B-008-1 NTN



2



-



B-016-1



2



6206 30x62x16



B-016-2



1



-



C-016-1



2



C-014-1



1



C-019-1



1



C-019-2



1



KD-010-1



18



7207A 35x72x17



-



-



-



6932-ACO 160x220x28 22219-C160 95x170x43 7218B 90x160x30



-



SAR4-30 (*1) Inside the slide -(*2)



Motor driven 6207 adjust35x27x12 (*1) able worm shaft -(*2)



6948-ACO 240x320x38 23030-C160 150x225x56 7228B 140x250x42



Clutch



6301 ZZ 12x37x12 6201 ZZ 12x32x10 6302 ZZ 15x42x13 6302 ZZ 15x42x13



KD-002-1



Oil Seals



-



Remarks



6005ZZ 25x47x12



Standard KD-024-1 Part



KD-009-1



6



B-016-2



2



B-018-2



2(*1) 1(*2)



-



-



B-022-2



1



-



-



C-012-1 C-013-3 C-014-3



1 1 2



Mitsubishi Cable C-021-1 Industries, Ltd. C-023-2 Standard Part



-



NC12500



SB SB 30508 30508



-



-



Hydraulic die lifter



Mechanical die lifter



-



-



-



-



SB 355508 - (*1)



Motor driven adjustable worm shaft



SB 355508 (*2) IS 28032020 ISR 15018014



ISR 18022015 IS 13016014 IS 9511513



Clutch 1



1



DRS-25H



-



-



-



-



-



IS 16019014



(*1): Applies to Models NC1-(S)E, -(1)E and -(2)E. (*2): Applies to Models NC1-(1NL)E and (2NL)E. (Continued on the next page)



247



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



(Continued)



O-Rings



Item



Part Manufacturer Q’ty NC1Number (Material) 350 A-141-2



1



A-155-2



1



B-002-2 Standard Part



1



-



NC1450



-



NC1600



-



NC1800



NC11100



- (*1)



- (*1)



- (*1) G-420 G-460 519.3x (*2) 530.7x (*2) 5.7(*2)



NC12000 - (*1) 574.3x 585.7x 5.7(*2)



G-145 -



-



-



-



-



-



1



B-009-2



1



B-009-3 Standard Part B-013-1 (11-9010)



1 1



-



-



G-165



B-013-2



1



-



-



-



B-013-3



1



G-120



-



G-110



Standard B-015-1 Part (11-9010)



1



-



-



P-5



P-5



P-5



P-5



B-015-2



1



G-45



G-45



G-45



G-45



G-45



G-45



B-015-3



1



-



-



-



-



B-015-4



1 2(*1) 1(*2)



-



-



-



-



G-65



G-65



G-65



G-65



G-105 G-115 G-210 175.6x 184.4x 169.4x 190.6x G-130 3.1 3.1 G-150 -



Standard Part



-



289.3x 300.7x 329.3x 369.3x G-250 5.7(*1) 340.7x 380.7x 5.7 5.7 G-290(*2) G-150(*1) G-175(*1) G-200(*1) 254.3x 265.7x G-165(*2) G-195(*2) G-230(*2) 5.7 G-195(*1) G-230(*1) G-265(*1) G-280 G-180(*2) G-210(*2) G-250(*2) 269.4x 275.6x 3.1 169.4x175.6x3.1(*1) 174.4x 204.4x 244.4x 180.6x 210.6x 250.6x 3.1(*2) 3.1(*2) 3.1(*2)



B-009-1



B-018-1



NC12500



Remarks



- (*1) Rear 744.3x eccentric 755.7x boss 5.7(*2) Front G-160 cover for drive shaft G-210 Connecting rod G-450



G-315 Inside the G-335 slide 329.4x 335.6x 3.1 P-18(*1)



Standard B-018-2 Part



2



B-022-1



P-7(*1) P-7(*1) - (*2) - (*2) -



-



G-55(*1) G-55(*1)



-



-



-



-



- (*2)



- (*2)



1



-



-



B-203-1



2



G-60



G-70



G-85



B-203-1



2



G-70



G-85



G-95 G-120 G-135 G-150



- (*1) - (*1) - (*1) - (*1) G-65(*2) G-65(*2) G-65(*2) G-65(*2) G-95 G-120 G-135



(*1): Applies to Models NC1-(S)E, -(1)E and -(2)E. (*2): Applies to Models NC1-(1NL)E and (2NL)E.



248



NC11500



P-5



- (*2)



- (*1) G-45 P-18(*2) Overload (11-9010) joint P-18(*1) - (*2) G-35 G-65



G-65



Motor driven adjustable worm - (*1) - (*1) shaft G-65(*2) G-65(*2) G-190 G-240 Counterbalance Counterbalance diameter is increased by one rank.



(Continued on the next page)



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



(Continued) Item



Part Manufacturer Q’ty NC1Number (Material) 350



NC1450



NC1600



NC1800



NC11100



NC11500



NC12000



NC12500



B-203-2



2



P-29



P-31



P-35



P-35



P-35



P-35



P-49



B-203-2 Standard Part



2



P-31



P-35



P-35



P-35



P-35



P-41



-



P-55 Counterbalance Counterbalance diameter is increased by one rank.



C-001-1 C-013-2



1 1



G-95 429.4 x 440.6 x 5.6



G-145 589.4 x 600.6 x 5.6



1



-



AS 568-273



2 1



G-200 G-85



G-260 G-135



O-Rings



Mitsubishi C-013-4 Cable Industries, Ltd. C-014-2 Standard C-019-3 Part Mitsubishi C-021-2 Cable Industries, Ltd. Standard KN-003-1 Part Standard KN-003-5 Part (11-9010) Standard KN-004-2 Part KN-004-3 NOK Standard KN-008-1 Part (11-9010) KN-012-2 NOK KN-013-1 Standard Part KN-020-1 (11-9010) KN-020-3 NOK Standard KN-021-1 Part KN-025-1 NOK



Standard Part



1



AS 568-030



1



G-85



1



P-12 (1B)



1



P-10



1



CO-0546A (S-70)



1



P-22A (1B)



1 1



CO-0501A (S-4) P-3 (1B)



1



P-9 (1B)



1



CO-0601



1



P-7



1



CO-0501A



Clutch



Overload protector



1



-



-



P42



P42



-



-



-



-



1



-



-



P20 (1B)



P20 (1B)



-



-



-



-



1



-



-



-



-



P21 (1B)



P21 (1B)



P21 (1B)



Standard KD-105-1 Part (14-7010)



1



-



-



-



-



-



-



Standard KD-105-2 Part (11-9010)



1



-



-



-



-



-



-



KD-101-2 KD-101-3



Standard Part KD-103-1 (11-9010)



P36 (4D) (provided with a backup ring) P20 (1B)



P20 (1B)



Remarks



Upper die clamper (DC-150-1.5)



P21 Upper die (1B) clamper (DC-150-2) Upper die clamper (DC-150-1.5)



(*1): Applies to Models NC1-(S)E, -(1)E and -(2)E. (*2): Applies to Models NC1-(1NL)E and (2NL)E. (Continued on the next page)



249



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



(Continued)



GRS Seals



V-Rings



O-Rings



Item



Part Manufacturer Q’ty NC1Number (Material) 350



NC1600



NC1800



NC11100 P21 (1B)



KD-106-1 Standard Part KD-106-2 (11-9010)



1



-



-



-



-



1



-



-



-



-



KD-108-1



1



-



-



P21



P21



KD-111-1



1



-



-



-



-



KD-130-1



1



-



-



Standard KD-130-2 Part (11-9010)



1



-



-



KD-131-2



1



-



-



A-107-4



1



A-121-1 Sansho



1



P42 (1B) P-10A (1B) P-22 (1B) - (*1) AV-16 (*2) AV-16 (*1) - (*2)



P42 (1B) P-10A (1B) P-22 (1B) - (*1) AV-16 (*2) AV-16 (*1) - (*2)



A-401-1



1



-



-



-



-



C-016-3 Siegling (Japan)



1



-



-



-



-



A-001-3



1



-



-



Standard Part



Sansho A-103-1



1



B-002-3



1 NOK



Packing



NC1450



B-003-2



1



B-204-1



2 Sakagami



B-204-1



2



- (*1) - (*1) AV-16 AV-16 (*2) (*2) AV-16 AV-16 (*1) (*1) - (*2) - (*2)



GRS- GRS95 105 -



-



GRS- GRS125 145 -



-



-



-



NC11500



NC12000



NC12500



P21 P21 P21 (1B) (1B) (1B) Upper die clamper P44 (1B) (DC-150-2) (provided with a backup ring) Upper die clamper (DC-150-1.5) Upper die P21 P21 P21 P21 clamper (DC-150-2) P42 P42 P42 P42 (1B) (1B) (1B) (1B) Lower die P-10A P-10A P-10A P-10A clamper (1B) (1B) (1B) (1B) (DC-150-2) P-22 P-22 P-22 P-22 (1B) (1B) (1B) (1B) - (*1) Encoder AV-16 drive (*2) AV-16 AV-16 AV-16 AV-16 (*1) (*1) (*1) (*1) Crankshaft - (*2) - (*2) - (*2) - (*2) - (*1) - (*1) - (*1) Encoder AV-16 AV-16 AV-16 drive (*2) (*2) (*2) V-28A (*1) Clutch - (*2) GRS- GRS- GRS- GRS165 185 215 250 Crankshaft -



-



-



-



ISI 200x 220x12 (*1)



- (*2) - (*1) ISI ISI ISI ISI ISI ISI ISI 70x80 80x90 95x 112x 130x 150x 170x ISI 200x x6 110x9 125x9 145x9 165x9 185x9 220x12 x6 (*2) GLY-55PGY- PGY- PGY- PGY- PGY1K701 GLY-65 GLY-80 100 125 140 200 250 GLY-65 GLY-80 PGY100



PGY125



Remarks



PGY140



PGY160



-



-



Connecting rod



Counterbalance Counterbalance diameter is increased by one rank.



(*1): Applies to Models NC1-(S)E, -(1)E, and -(2)E. (*2): Applies to Models NC1-(1NL)E and (2NL)E. (Continued on the next page)



250



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



(Continued) Item



Part Manufacturer Q’ty NC1Number (Material) 350 B-207-1



NC1450



NC1600



NC1800



NC11100



NC11500



NC12000



NC12500



2



PNY-16 PNY-18 PNY-20 PNY-20 PNY-20 PNY-20 PNY-30 PNY-35



B-207-1



2



PNY-16 PNY-20 PNY-20 PNY-20 PNY-20 PNY-25



C-002-1 Sansho C-019-4 (Fluorine) KN-002-1 Sakagami Sakagami KN-003-2 (Fluorine)



1 1 1



D.P 285 x 300 x 9 D.P 80 x 92 x 6.3 PGY-63



1



KY-2403-8 (provided with a backup ring)



B-009-4 Sansho



1



Backup Rings



Packing



Sakagami



-



G-150A (*1)



-



B-015-3 Standard Part



1



-



-



-



-



-



-



-



-



-



-



-



-



3V-900 3V-900 3V-1060 3V-1250 3V-1320 B-153 2 pcs. 2 pcs. 3 pcs. 3 pcs. 3 pcs. 5 pcs.



3V-850 3V-900 3V-900 3V-1060 3V-1250 3V-1320 2 pcs. 2 pcs. 2 pcs. 3 pcs. 3 pcs. 3 pcs.



-



-



-



Counterbalance Counterbalance diameter is increased by one rank.



D.P 410 x 425 x 9 Clutch D.P 133 x 145 x 6.3 Overload protector



-



- (*2)



-



V-Belts



-



Remarks



3V-1120 3V-1250 3V-1400 3 pcs. 3 pcs. 3 pcs.



Inside the slide



For P-18 Overload joint



Model (S)E B-153 B-178 Model 5 pcs. 7 pcs. (1)E B-158 Model 5 pcs. (1NL)E



3V-850 As shown (50 Hz) 3V-850 3V-850 3V-1060 3V-1180 3V-1320 B-156 Standard A-201-1 at the 3V-800 2 pcs. 2 pcs. 3 pcs. 3 pcs. 3 pcs. 5 pcs. Part right (60 Hz) 2 pcs.



-



-



Model (2)E Fixed speed (spm)



Model 3V-850 3V-900 3V-900 3V-1120 3V-1250 3V-1320 B-160 B-178 (2)E 2 pcs. 2 pcs. 2 pcs. 3 pcs. 3 pcs. 3 pcs. 5 pcs. 7 pcs. Variable speed (spm)



Die Studs Chains Timing Belts



-



A-405-1 Standard Part



1



1



B-015-4 Mitsubishi Cable IndusC-002-3 tries, ltd.



4 8



-



3V-1120 3V-1180 3V-1400 B-158 B-178 Model 3 pcs. 3 pcs. 3 pcs. 5 pcs. 7 pcs. (2NL)E



390L0 427L0 436L0 75 75 75 (*1) (*1) (*1) - (*2)



B-020-1 Standard Part



-



- (*2)



Encoder drive



-



- (*2) Motor driven slide adjust device



RS-40 DS-1H-6



DS-1H-8 DS-1H-6



-



Overload joint Clutch



(*1): Applies to Models NC1-(S)E, -(1)E, and -(2)E. (*2): Applies to Models NC1-(1NL)E and (2NL)E.



251



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



8.2 PNEUMATIC PARTS Item / Part Number Globe Valve F-0001-1 Auto-Drain Filter F-0001-2 Regulator F-0001-3 Regulator Unit F-0001-4 Regulator F-0001-4



Manufac- Q’ty NC1turer 350



NC1450



NC1600



NC1800



1



HM10K-SG 1/2B



CKD



1



1137-4C-S310 1/2B



1



RV2-400-06-K50 1/2B



TACO



1 1



-



-



RV2-400-04 -K00



-



-



-



1



DU1/4x60x1MPa



Muffler F-0001-6



SMC



1



AN500-06 3/4B



Pressure Switch F-0001-9



UEDA As shown at the right



Self-Sealing Coupling Nitto F-0001-12



2



Regulator F-0001-13



1



Regulator F-0001-15 Regulator F-4001-4 Air Valve KN-017-2



TACO



CKD



NC12500



Remarks



Air inlet



-



Overload protector -



Clutch, counterbalance, die cushion Clutch



PS-102 (0.35MPa) 1/4B 1 pc. (*1) PS-102 2 pcs. PS-102 (0.35MPa) 1/4B 1 pc. (*2) (*2) NSV303 Clutch, 3 pcs. counterNSV- (*1) balance 303 NSV-303 3/8B 1 pc. 2 pcs. NSV303 2 pcs. (*2) Ejector TW-30SM,30PF 3/8B pneumatic tool RV2-400 RV2RNLB 40M Counter-05 RNLB balance



1



1



NC12000



C17-0050



Air Pressure Yamamoto Gauge F-0001-5



Regulator F-0001-13



NC11500



Hitachi



Safety Valve TACO F-0001-11



RV2-400-RNLB-05 1/2B



-



-



-



-



-



1



RV2-40M-RNLB 1/2B



1



MM-08-FL-105658



(*1): Applies to Models NC1-(S)E, -(1)E, and -(2)E. (*2): Applies to Models NC1-(1NL)E and (2NL)E.



252



NC11100



-



For counterbalance capacity upgrade RV2-400 RV2-400 Clutch and 06-K50 06-K50 brake Die cushion Overload protector



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



8.3 LUBRICATION SYSTEM PARTS Item / Manufac- Q’ty NC1Part Number turer 350 Grease Pump 1 G-0001-1 Grease Distributor Valve 1 G-0001-2



Grease Distributor Valve G-0001-3



Oil Pump G-0001-13



NC11500



NC12000



NC12500



(See 8.4.1 Motors)



-



-



-



-



-



-



U-4R



-



VN-04A-40W



-



1



-



LND-06-40μ



-



1



Oil Pump G-0002-1



1 IHI



1



Remarks



Automatic grease pump



Model (S)E Models UUUUUUU12MA 12MA 12MA 12MA 12MA 12MA 12MA U-8R (1)E, (1NL)E Models UUU-8MA U-8MA U-8MA U-8MA U-8MA 12MA U-8R (2)E, 12MA (2NL)E Automatic U-8MA grease pump Motor driven pump for Models (See 8.4.1 Motors) (S)E, (1NL)E and (2NL)E Manual SKA- pump for SKA-214L (for oil) (option) 214L counterbalance Manual pump for SKA-214L (for oil) Model (S)E Motor driven pump for U-4RL (option) U-4RL Models (S)E, (1NL)E and (2NL)E



1



1



Oil Pump G-0001-21



Line Filter G-2001-3 Line Filter G-2001-17



NC11100



-



1



Oil Distributor Valve G-0001-23/ G-0002-2



NC1800



U-8MA U-8MA U-8MA U-8MA U-8MA U-8MA



1



NOP



NC1600



-



IHI



Grease Distributor Valve G-0001-4



NC1450



Taisei



Model (S)E



253



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



8.4 ELECTRICAL PARTS 8.4.1 Motors Item



Main Motor (kWxP)



Slide Adjust Motor (kWxP) Grease Pump Motor



Code



Manufac- Q’ty NC1turer 350



1IM



1



1IM Yaskawa



1



17D IHI M



1



Oil Pump Motor



NC1450



NC11100 (S)E, (1)E, (1NL)E 5.5x4 5.5x4 5.5x4 7.5x4 11x4 (2)E, (2NL)E 7.5x4



Oil Pump Motor



-



IHI



NC1800



UAAGE-5TX (UAAGE-5-15FTS) 0.2x4



NC11500



NC12000



NC12500



15x4



Variable speed or 22x4 motor fixed speed motor



Fixed 15x4 Variable 11x4



UAAGE-5TX (UAAGE-5-20FTS) 0.75x4



Remarks



AG brake motor



SK- Automatic 505BM grease A-1 pump Motor driven TOP-1ME100-12MAVB pump for Model (S)E Motor driven pump for TOP-1ME100-11MA Models (1NL)E, (2NL)E Automatic SK-505BMAL-1 oil pump (option) SK-505BMA-04



1



-



1



-



1IM NOP Oil Pump Motor



NC1600



-



1



8.4.2 Parts Inside the Control Panel Item



Code Manufac- Q’ty NC1turer 350



NC1450



NC1600



NC1800



NC11100



NC11500



NC1-(S)E, (1)E, (1NL)E



(Fixed)



NC12000



NC12500



Remarks Fixed



speed SW-N2S SW-N3 (SC-N3) (SC-N2S) SW-N1 SW-N1 SW-N1 SW-N2 SW-N3 SW-N5 motor or



(SC-N3) (SC-N5) VS motor (option) (2NL)E For 200V, SW-N2 SW-N2S 220V (SC-N2) (SC-N2S)



(SC-N1) (SC-N1) (SC-N1) (SC-N1) NC1-(2)E, Electromagnetic Switch for 18M01 (18M03) Fuji Main Motor 18TH01 .



1



NC1-(S)E, (1)E,(1NL)E



(VS)



(Fixed)



Fixed



speed SW-N1 SW-N2S (SC-N2S) motor or SW-N1 SW-N1 SW-N1 SW-N1 (SC-N1) SW-N2S SW-N2S



(SC-N2S) (SC-N2S) VS motor (option) For 380V SW-N2 SW-N1 ~415V (SC-N2) (SC-N1) The model name of electromagnetic switch shown in parentheses applies to the motor provided with a reversing device.



(SC-N1) (SC-N1) (SC-N1) (SC-N1) NC1-(2)E, (2NL)E



(VS)



(Continued on the next page)



254



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



(Continued) Item



Code



Manufac- Q’ty NC1turer 350



NC1450



NC1600



NC1800



NC11100 NC1-(S)E, (1)E, (1NL)E



SC-4-0 SC-4-0 SC-4-0 SC-5-1



Electromagnetic Switch for Main Motor 18M05



SC-N1 NC1-(2)E, (2NL)E



SC-5-1



1



NC1-(S)E, (1)E,(1NL)E



SC-4-0 SC-4-0 SC-4-0 SC-4-0



SC-5-1 NC1-(2)E, (2NL)E



SC-4-0 SW-ORM/G TH 1.4~2.2A



Electromagnetic Switch for 11M13 11M14 Slide 11TH13 Adjust Motor



1



Ground Fault Breaker



1



SW-ORM/G TH 0.8~1.2A



1ELB21 Fuji



Breaker for Slide 1NFB14 Adjust Motor



1



Grease Pump Cir- 17CPB cuit Protec- 21 tor



1



Electromagnetic 22M22 Switch for Oil Pump 22TH22 Motor



Fuji OMRON



CR



Terminal Relay



CR OMRON



Inverter Motor Con- 1VS04 trol Unit VS Motor Control Unit



NC12000



NC12500



Remarks



Inverter SC-N1 SC-N2S SC-N3 motor For 200V, 220V Inverter SC-5-1 SC-N2 SC-N2S motor For 380V ~415V



SW-ORM/G TH 4~6A



Motor driven slide adjust device For 200V, 220V



SW-ORM/G TH 2.3~3.4A



Motor driven slide adjust device For 380V ~415V



EA33/10



Motor driven slide adjust device



EG 32F/5 Sensitivity current 30mA



EA33/5



CP31D/1



Automatic grease pump



SW-0 TH 0.48~0.72A coil 100V AC



Motor driven pump for Models (S)E, (1NL)E, (2NL)E For 200V, 220V



SW-0 TH 0.24~0.36A coil 100V AC



Motor driven pump for Models (S)E, (1NL)E, (2NL)E For 380V ~415V



1



Auxiliary Relay



NC11500



HH52P-FL/DC24V MY2N-D2/DC24V G6B-47BND(DC24V) 1



CIMR-G5, CIMR-G7



Variable (inverter)



1



CVSR-404GP



(Option)



Yaskawa



(Continued on the next page)



255



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



(Continued) Item 24 VDC Power Source



Code



Manufac- Q’ty NC1turer 350



3DP17 OMRON



NC1450



NC1600



1



S82J-10024D-602



Controller 2CU01 AIDA 1



1



MPC



Controller 3PC02 AIDA 2



1



PLC



NC1800



NC11100



NC11500



NC12000



NC12500



Remarks



8.4.3 Operation Panel and Operation Button Box Item POWER Light MAIN MOTOR RUN Light RUN OK Light



Code ManufacQ’ty Common to NC1 turer 1PL21 1 HW1P-1H2W 17PL10 1 HW1P-1Q4G 10PL11 1 HW1P-1Q4G



1



HW1L-M111H2G



17PL05



1



HW1L-MF210Q4G



17PL07



1



HW1L-MF210Q4A



1SS20 15SS10



1 1



HW1K-2B10-1H HW1K-2B10



15SS07



1



HW1S-3T20



8SS10 Fuji



1 1 1 1 1



RC310-1-J-A2-C4-N44 (L45) HW1B-M110B HW1B-M201R HW1B-M110B HW1B-V502R HW1B-M511B (provided with rubber cover (AXH285-B) and guard ring (AHX284))



LUBRICATING OIL Button (Light) 22PL22



UP/UNCLAMP/RET. Button (Light) DOWN/CLAMP/ADV. Button (Light) CONTROL POWER Switch DATA WRITE Switch Main Motor REV.•OFF•FWD. Switch OPERATION SELECT Switch MAIN MOTOR START Button MAIN MOTOR STOP Button RESET Button EMERGENCY STOP Button RUN Button TOP STOP (PRESET STOP) Button EXTERNAL•OFF•BUTTON Switch SLIDE ADJUST Switch GUARD DISABLE•ACTIVE Switch Crank Angle Indicator Operator Interface Terminal Operator Interface Terminal Protection Sheet



256



Remarks



For Models (S)E, (1NL)E and (2NL)E



IDEC



15PB06 16PB01 9PB16 4EM04 8PB01 8PB04



2 IDEC



9PB17



1



HW1B-M301Y



9SS04



1



HW1K-3A20-2H



15SS14



1



HW1S-2T10



10SS04



1



HW1K-2A11



3CRK20



1 1



-



1



-



30D10 -



AIDA



Continuous



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



8.4.4 Others Item



Code



Overload Detection Limit Switch



Yamatake 1



Overrun Detection Proximity Switch



Angle Detecting Encoder



ManufacQ’ty turer



1



VRE-P062SAC



Keio



2



RT25-GR3F•GP3M•RC



Option



1



AD-04104* DC24V (See Section E MAINTENANCE, 5.2 THE CLUTCH AND BRAKE SOLENOID VALVE (pg. 219).)



1



MVS-2203M-17



1



524-300-2000



1



524-300-2100



1



#3220 #3222R



Toyooki



Ejector Solenoid Valve TACO



Automation Solenoid Valve



Receptacle for 100-V Tools Receptacle for 200-V Tools Pressure Switch Pressure Switch for Oil Pump



1 (2) PE1-CS5Q/276



1



American 1 Electric 1 1



16PS03A



22PS21



SL1-H100



NSD



2EN01 SUMTAK



Clutch Solenoid Valve



Remarks



Provided with a stop position change device Crank angle detector Option For TCS



Fuji



Angle Detecting Encoder Receptacle for Die Protection



Common to NC1



Ueda



1



AE-074-0720(NC1-350 ～ 2000) AE-063-0720(NC1-2500)



#7110GD #7112GR, #7110GHDZ



Without regulator With regulator 2P, double type



#4220 #4222R PS-102A



PS-102A



For Models (S)E, (1NL)E and (2NL)E



257



Section E MAINTENANCE 8. LIST OF COMMERCIALLY AVAILABLE PRODUCTS



8.5 PARTS ONLY FOR MODEL NC1-(S)E



Die Studs



O-Rings



Oil Seals



Item



258



Part Manufacturer Q’ty Number (Material)



NC1450



NC1600



NC1800



NC11100



NC11500



NC12000



Remarks



ISR ISR IS IS ISR ISR 13016014 15018014 17020015 19522515 21524515 25531525 Crankshaft ISR ISR ISR IS ISR ISR 10513514 12515514 14517514 16519515 18521515 21524515



A-113-2



2



A-175-2 Standard Part



1



B-002-1



2



ISR ISR ISR IS IS ISR Connect16019014 18521515 21024515 24027015 27031020 32038025 ing rod



Mitsubishi Cable IndusA-175-3 tries, ltd.



1



A568-163 A568-166 A568-169 152.07x 171.12x 190.17x 2.62 2.62 2.62



1 B-005-2 Standard Part



2



B-005-3



2



MitsubA-116-2 ishi Cable Industries, ltd.



4



-



-



-



196.8x 200.6x 1.9 221.8x 225.6x 1.9



221.8x 225.6x 1.9 246.8x 250.6x 1.9



248.3x 244.5x 1.9 275.6x 271.8x 1.9



DS-1H-12



219.4x 225.6x 3.1 276.8x 280.6x 1.9 301.8x 305.6x 1.9



239.4x 245.6x 3.1 316.8x 320.6x 1.9 341.8x 345.6x 1.9 DS-1H-16



Crankshaft



269.4x 275.6x 3.1 386.8x 390.6x 1.9 Connect411.8x ing rod 415.6x 1.9 Crankshaft



Section E MAINTENANCE 9. SPARE PARTS LIST (OPTION)



9. SPARE PARTS LIST (OPTION) If your machine order includes spare parts (option), see the next page. If your machine order does not include spare parts, the list of spare parts will not be contained in this instruction manual.



259



Section E MAINTENANCE 9. SPARE PARTS LIST (OPTION)



260



Section E MAINTENANCE 10. LIST OF TOOLS PROVIDED WITH THE PRESS MACHINE



10. LIST OF TOOLS PROVIDED WITH THE PRESS MACHINE See the next page.



261



Section E MAINTENANCE 10. LIST OF TOOLS PROVIDED WITH THE PRESS MACHINE



262



Section E MAINTENANCE 10. LIST OF TOOLS PROVIDED WITH THE PRESS MACHINE



264



Section E MAINTENANCE 11. DRAWINGS



11. DRAWINGS See the following pages for the drawings listed below. (1)Mechanical Drawings • GENERAL VIEW (Option) • FOUNDATION (Option) • SLIDE DIE SPACE and BOLSTER DIE SPACE • PNEUMATIC DIAGRAM, HYDRAULIC DIAGRAM, and Other Drawings • LUBRICATION DIAGRAM • Other Drawings (Option) (2)Electrical Drawings • OPERATION PANEL LAYOUT and Other Drawings • CIRCUIT DIAGRAM • PARAMETER LIST • Listing of MPC IO Monitors



265



Section E MAINTENANCE 11. DRAWINGS



(1) Mechanical Drawings See the following pages for the drawings listed below. They include the "Technical Documents" which have already been submitted to the customer. • GENERAL VIEW (Option) • FOUNDATION (Option) • SLIDE DIE SPACE and BOLSTER DIE SPACE • PNEUMATIC DIAGRAM, HYDRAULIC DIAGRAM, and Other Drawings • LUBRICATION DIAGRAM • Other Drawings (Option)



(1) Mechanical Drawings



Section E MAINTENANCE 11. DRAWINGS



(2) Electrical Drawings



CAUTION • Do not modify or remove any electrical circuits. AIDA shall have no liability for any failure or problems caused by such a modification or removal. Contact AIDA Service (see the end of this instruction manual) whenever it is necessary to change any of the electrical circuits after the delivery of the press machine in order to install a peripheral device provided by you on the press machine. See the following pages for the drawings listed below. • OPERATION PANEL LAYOUT and Other Drawings • CIRCUIT DIAGRAM • PARAMETER LIST • Listing of MPC IO Monitors



(2) Electrical Drawings



Section E MAINTENANCE 11. DRAWINGS



(2) Electrical Drawings



2004/2/3



LIST OF MPC_IO MONITOR (IN THE ORDER OF PLC ADDRESS INDICATED ON THE DISPLAY) This list shows the data in reference to "Controller I/O monitor" function of the display (on the MAINTENANCE screen)



PLC Address Wire No



Name



Name



1211 1212 1213 1214



PRESS MASTER Select FEEDER MASTER Select Front guard Close 1 Rear guard Close 1



DM28-0 DM28-1 DM28-2 DM28-3 DM28-4 DM28-5 DM28-6 DM28-7 DM28-8



410 411 1314 1315



C&B solenoid valve monitor 1 (NO) C&B solenoid valve monitor 2 (NC) Slide adjustment Upper end Slide adjustment Lower end



DM25-14 808 Operation selector OFF



DM28-9



1308



DM25-15 809 Operation selector INCH DM26-0 1003 Front guard ineffective Select



DM28-10 1309 Front presence sensing device Beam is intercepted. DM28-11 1310 Rear presence sensing device ON DM28-12 1311 Rear presence sensing device OFF



DM26-1 1004 Rear guard ineffective Select



DM28-13 1312



DM26-2 DM26-3 DM26-4 DM26-5 DM26-6



810 811 901 902 903 904 905 906 801 802 804 805 806 807



1201 1202 1203 1204 1205



DM26-7 1206 DM26-8 DM26-9 DM26-10 DM26-11 DM26-12 DM26-13 DM26-14 DM26-15



907 908 909 910 911 912 1001 1002



Operation selector SINGLE Operation selector CONT. Operation selector CONT. SINGLE Operation selector MICRO-INCH Control selector BUTTON Control selector EXTERNAL AUTOHAND MASTER OFF AUTOHAND MASTER ON RUN button, left Start RUN button, left Restart auxiliary RUN button, right Start RUN button, right Restart auxiliary External start signal External start auxiliary signal



PLC Address Wire No



DM27-12 DM27-13 DM27-14 DM27-15



DM25-0 DM25-1 DM25-2 DM25-3 DM25-4 DM25-5 DM25-6 DM25-7 DM25-8 DM25-9 DM25-10 DM25-11 DM25-12 DM25-13



Additional RUN button, left Start Additional RUN button, left Restart auxiliary



Front guard Close 2 Rear guard Close 2 Additional guard 1 Close 2, or Front aux. presence sens. device pass 2 Additional guard 2 Close 2, or Rear aux. presence sens. device pass 2 PSDI Protect PSDI Break Button with green lamp Button with orange lamp RESET button TOP STOP button Stop position Top dead center Stop position Preset stop position



DM27-0 1215 Additional guard 1 Close 1, or Front aux. presence sens. device pass 1 DM27-1 1216 Additional guard 2 Close 1, or Rear aux. presence sens. device pass 1 DM27-2 1301 UP ineffective OK DM27-3 1303 Station selection Standard DM27-4 1304 Robot Home position DM27-5 X002 External Emergency stop signal DM27-6 1305 Slide adjustment Thermal relay DM27-7 1306 Front presence sensing device ON DM27-8 1207 Additional RUN button, right Start DM27-9 1208 Additional RUN button, right Restart auxiliary DM27-10 1209 FEEDER MASTER Start DM27-11 1210 FEEDER MASTER Restart auxiliary



1307 Front presence sensing device OFF Front presence sensing device Beam is not intercepted.



Inner presence sensing device Beam is not intercepted.



DM28-14 1313 Inner presence sensing device Beam is intercepted. DM28-15 406 Emergency stop Y000 PLC immediate stop Y001 PLC CONT. stop



DM29-0 DM29-1 DM29-2 DM29-3 DM29-4 DM29-5 DM29-6 DM29-7 DM29-8 DM29-9 DM29-10 DM29-11 DM29-12 DM29-13 DM29-14 DM29-15



702 705 X000 X001 -



DM30-0 DM30-1 DM30-2 DM30-3 DM30-4 DM30-5 DM30-6 DM30-7 DM30-8 DM30-9 DM30-10



501 502 503 504 506 507 508 509 511 512 513



Die protection sensor 1 Die protection sensor 2 Motion detector proximity sw (Top dead center) Motion detector proximity sw (Preset stop position)



C&B 1 fuse has blown. C&B 1 Monitor C&B 2 fuse has blown. C&B 2 Monitor



CAM 1 (Output) CAM 2 (Output) CAM 3 (Output) CAM 4 (Output) CAM 5 (Output) CAM 6 (Output) CAM 7 (Output) CAM 8 (Output) CAM 9 (Output) CAM 10 (Output) CAM 11 (Output)



920-06900e.xls (1 / 4) ORDER OF PLC ADDRESS



2004/2/3



LIST OF MPC_IO MONITOR (IN THE ORDER OF PLC ADDRESS INDICATED ON THE DISPLAY) This list shows the data in reference to "Controller I/O monitor" function of the display (on the MAINTENANCE screen)



PLC Address Wire No



DM30-11 DM30-12 DM30-13 DM30-14 DM30-15



514 516 517 518 519



DM31-0 601 DM31-1 602 DM31-2 603 DM31-3 604 DM31-4 606 DM31-5 607 DM31-6 608 DM31-7 609 DM31-8 DM31-9 DM31-10 X101 DM31-11 DM31-12 X015 DM31-13 X014 DM31-14 DM31-15 DM32-0 X008 DM32-1 X012 DM32-2 X013 DM32-3 X007 DM32-4 1104 DM32-5 1107 DM32-6 1106 DM32-7 1101 DM32-8 1102 DM32-9 1103 DM32-10 415 DM32-11 414 DM32-12 DM32-13 DM32-14 DM32-15 DM33 DM34 DM35 DM36 DM37 DM38 DM39



Name



CAM 12 (Output) CAM 13 (Output) CAM 14 (Output) CAM 15 (Output) CAM 16 (Output) CAM 17 Output CAM 18 Output CAM 19 Output CAM 20 Output CAM 21 Output CAM 22 Output CAM 23 Output CAM 24 Output Die protect CAM 1 Die protect CAM 2 Bottom dead center CAM Top dead center/Preset stop position CAM



SINGLE CAM Home positions stop CAM Bottom dead center stop CAM



CPU 1 normal pulse C&B immediate stop C&B stop at Preset stop position Operation ready Slide adjustment UP Slide adjustment DOWN Prior action (Indicator lamp) Emergency stop (Spare 1) Guard close (Spare 2) Spare 3 (Presence sensing device effective, normal)



C&B solenoid valve 1 (PNP) C&B Solenoid valve 2 (NPN)



Crank angle Real data Die height Real data Die height Real data Analog input real data MPC version (Model & Specifications) MPC version 2 digits



920-06900e.xls (2 / 4) ORDER OF PLC ADDRESS



2004/2/3



LIST OF MPC_IO MONITOR (IN THE ORDER OF WIRE NUMBER) This list shows the data in reference to "Controller I/O monitor" function of the display (on the MAINTENANCE screen) Wire No



406 410 411 414 415 501 502 503 504 506 507 508 509 511 512 513 514 516 517 518 519 601 602 603 604 606 607 608 609 702 705 801 802 804 805 806 807 808 809 810 811 901 902 903 904 905 906 907 908 909 910 911 912



Name



Emergency stop C&B solenoid valve monitor 1 (NO) C&B solenoid valve monitor 2 (NC) C&B solenoid valve 2 (NPN) C&B solenoid valve 1 (PNP) CAM 1 (Output) CAM 2 (Output) CAM 3 (Output) CAM 4 (Output) CAM 5 (Output) CAM 6 (Output) CAM 7 (Output) CAM 8 (Output) CAM 9 (Output) CAM 10 (Output) CAM 11 (Output) CAM 12 (Output) CAM 13 (Output) CAM 14 (Output) CAM 15 (Output) CAM 16 (Output) CAM 17 (Output) CAM 18 (Output) CAM 19 (Output) CAM 20 (Output) CAM 21 (Output) CAM 22 (Output) CAM 23 (Output) CAM 24 (Output) Die protection sensor 1 Die protection sensor 2 RUN button, left Start RUN button, left Restart auxiliary RUN button, right Start RUN button, right Restart auxiliary External start signal External start auxiliary signal Operation selector OFF Operation selector INCH Operation selector SINGLE Operation selector CONT. Operation selector CONT. SINGLE Operation selector MICRO-INCH Control selector BUTTON Control selector EXTERNAL AUTOHAND MASTER OFF AUTOHAND MASTER ON PSDI Protect PSDI Break Button with green lamp Button with orange lamp RESET button TOP STOP button



PLC Address



Wire No



DM28-15 DM28-0 DM28-1 DM32-11 DM32-10 DM30-0 DM30-1 DM30-2 DM30-3 DM30-4 DM30-5 DM30-6 DM30-7 DM30-8 DM30-9 DM30-10 DM30-11 DM30-12 DM30-13 DM30-14 DM30-15 DM31-0 DM31-1 DM31-2 DM31-3 DM31-4 DM31-5 DM31-6 DM31-7 DM29-4 DM29-5 DM25-8 DM25-9 DM25-10 DM25-11 DM25-12 DM25-13 DM25-14 DM25-15 DM25-0 DM25-1 DM25-2 DM25-3 DM25-4 DM25-5 DM25-6 DM25-7 DM26-8 DM26-9 DM26-10 DM26-11 DM26-12 DM26-13



1001 1002 1003 1004 1101 1102 1103 1104 1106 1107 1201 1202 1203 1204 1205



Name



PLC Address



Stop position Top dead center Stop position Preset stop position Front guard ineffective Select Rear guard ineffective Select Emergency stop (Spare 1) Guard close (Spare 2) Spare 3 (Presence sensing device effective, normal)



Slide adjustment UP Prior action (Indicator lamp) Slide adjustment DOWN Additional RUN button, left Start Additional RUN button, left Restart auxiliary



DM26-14 DM26-15 DM26-0 DM26-1 DM32-7 DM32-8 DM32-9 DM32-4 DM32-6 DM32-5 DM26-2 DM26-3 DM26-4 DM26-5 DM26-6



Front guard Close 2 Rear guard Close 2 Additional guard 1 Close 2, or Front aux. presence sens. device pass 2 1206 Additional guard 2 Close 2, or DM26-7 Rear aux. presence sens. device pass 2 1207 Additional RUN button, right Start DM27-8 1208 Additional RUN button, right Restart auxiliary DM27-9 1209 FEEDER MASTER Start DM27-10 1210 FEEDER MASTER Restart auxiliary DM27-11 1211 PRESS MASTER Select DM27-12 1212 FEEDER MASTER Select DM27-13 1213 Front guard Close 1 DM27-14 1214 Rear guard Close 1 DM27-15 1215 Additional guard 1 Close 1, or DM27-0 Front aux. presence sens. device pass 1 1216 Additional guard 2 Close 1, or DM27-1 Rear aux. presence sens. device pass 1 1301 UP ineffective OK DM27-2 1303 Station selection Standard DM27-3 1304 Robot Home position DM27-4 1305 Slide adjustment Thermal relay DM27-6 1306 Front presence sensing device ON DM27-7 1307 Front presence sensing device OFF DM28-8 1308 Front presence sensing device Beam is not intercepted DM28-9 1309 Front presence sensing device Beam is intercepted. DM28-10 1310 Rear presence sensing device ON DM28-11 1311 Rear presence sensing device OFF DM28-12 1312 Inner presence sensing device Beam is not intercepted DM28-13 1313 Inner presence sensing device Beam is intercepted. DM28-14 1314 Slide adjustment Upper end DM28-2 1315 Slide adjustment Lower end DM28-3 X000 Motion detector proximity sw (Top dead center) DM29-6 X001 Motion detector proximity sw (Preset stop position) DM29-7 X002 External Emergency stop signal DM27-5 X007 Operation ready DM32-3 X008 CPU1 normal pulse DM32-0 X012 C&B immediate stop DM32-1 X013 C&B stop at Preset stop position DM32-2 X014 Home position stop cam DM31-13 X015 SINGLE cam DM31-12



920-06900e.xls (3 / 4) ORDER OF WIRE NUMBER



2004/2/3



LIST OF MPC_IO MONITOR (IN THE ORDER OF WIRE NUMBER) This list shows the data in reference to "Controller I/O monitor" function of the display (on the MAINTENANCE screen) Wire No



X101 Y000 Y001 -



Name



Bottom dead center CAM PLC immediate stop PLC CONT. stop C&B 1 fuse has blown. C&B 1 Monitor C&B 2 fuse has blown. C&B 2 Monitor Die protect CAM 1 Die protect CAM 2 Top dead center/Preset stop position CAM



Bottom dead center stop CAM



Crank angle Real data Die height Real data Die height Real data Analog input real data MPC version (Model & Specifications) MPC version 2 digits (Reserved)



PLC Address



DM31-10 DM29-0 DM29-1 DM29-8 DM29-9 DM29-10 DM29-11 DM31-8 DM31-9 DM31-11 DM31-14 DM28-4 DM28-5 DM28-6 DM28-7 DM29-2 DM29-3 DM29-12 DM29-13 DM29-14 DM29-15 DM31-15 DM32-12 DM32-13 DM32-14 DM32-15 DM33 DM34 DM35 DM36 DM37 DM38 DM39



920-06900e.xls (4 / 4) ORDER OF WIRE NUMBER



APPENDIX



APPENDIX



INSTRUCTIONS FOR PRESS MACHINE USAGE (NC1, NC2 and NS2 series) APPENDIX-1 COUNTERMEASURES AGAINST BREAKTHROUGH DURING BLANKING



1. BREAKTHROUGH



Rupture section



Penetration factor= (h/t)x100%



ｈ



ｔ



During blanking, the punch penetrates into the work material, and once the punch penetrates to a certain percentage of the thickness of the work material, the material will suddenly rupture. A phenomenon that occurs during blanking where the punch pressure drops at the instant the forming pressure reaches its maximum value is called breakthrough. During blanking, a great deal of noise and vibration is generated by breakthrough; and that is why it is said that blanking is the most severe presswork.



Fig. 1 Section of Blank



Generally, disadvantages of excessive breakthrough are as follow: (1) It shortens the die life, because the punch is driven into the die at a very high speed. (2) It generates great vibration, which affects the components of the press machine (electrical, hydraulic, and pneumatic components). (3) Since the slide is subjected to a great reverse load, the slide connection is affected adversely. (4) By the abrupt change of a load on the slide, an impact load is exerted on the back face of the main gear tooth, shortening gear life. (This applies to gear-driven press machines.) Although certain allowances for breakthrough have been taken into consideration in the design of NC1, NC2 and NS2 Series press machines, the following should be taken into consideration when constructing the dies in order to alleviate the effects of breakthrough and to prolong die life.



2. CONSTRUCTION OF DIES (1) A fixed stripper (Fig. 2) is not desirable, because the effects of breakthrough during blanking is greatest in this type of a stripper, and shortens the die life.



Countermeasure: Use a movable stripper as shown in Fig. 3. In this type, the effects of breakthrough will be reduced, because blanking is performed while the movable stripper is pressing into the work material, and as a result vibration is reduced and tool life is prolonged. The pressing force of the movable stripper should be 5 to 10 percent of the tonnage capacity. Example: For the NC1-1100 Press machine capacity 1100 kN Pressing force (at bottom dead center) 55 to 110 kN



Fixed Stripper



Fig. 2 Fixed Stripper Type Urethane spring Movable Stripper



Fig. 3 Movable Stripper Type



APPENDIX-1



APPENDIX



APPENDIX-2



3. CONSTRUCTION OF DIES (2) Cases where the pressing force of the movable stripper of the die cannot be increased because of the product shape:



Punch



Countermeasure: In addition to the above, install urethane springs in the die set as shown in Fig. 4. The pressing force of the urethane springs should be 5 to 10 percent of the tonnage capacity. Example: For the NC1-1500 Press machine capacity 1500 kN Urethane spring: φ60x50 mm high Hardness: Hs (JIS A) 90 Pressing force per spring at 20% compression: 15 kN Therefore, install 6 to 10 springs at suitable positions in the die set. Then, the total pressing force will be 90 to 150 kN.



NOTE



Movable stripper Additional urethane spring Die Fig. 4



• In the above case, the applied load will be increased. However, it will lead to favorable conditions for the dies and the press machine, because the speed of the punch being driven into the die is lowered and vibration is reduced.



4. CONSTRUCTION OF DIES (3) In the case of so-called on-the block structure: Some dies have a so-called on-the-block structure to enable the placement of a fork of a forklift under the structure when taking out blanks or loading/ removing the dies. (See Fig. 5.) In this case, the die plate will yield substantially to cause a breakthrough. As a result, the press machine will create greater vibrations which shorten the service life of the die. When comparing the vibrations at Point A (on the bolster) and Point B (on the die plate), the vibration created at Point B will be three times as much as those at Point A. (According to measurements performed by AIDA.)



APPENDIX-2



Urethane spring Movable stripper



Point B Point A



Die plate Ｌ



Block



Fig. 5 On-the-block structure



APPENDIX



APPENDIX-3 Counter measures: (1) Change the structure of the die from an onthe-block structure to a direct-placement structure. (2) If the die cannot be placed directly on the die plate, minimize dimension L in Fig. 5 as far as possible and use larger blocks or use a thicker die plate. (See Fig. 6.) The deflection of the die is reduced in proportion to the 3rd power of dimension L.



Block



L (minimum)



Fig. 6After the counter measure has been taken Example: In the case where the dimension L=250 mm has been changed to L=200 mm (200/250)3 = 1/1.95 In this case, the deflection of the die will be halved by changing dimension L from 250 to 200. Tighten the lower die clamping bolt to within the range occupied by the block to help reduce deformation of the die plate.



5. OPENINGS IN THE BOLSTER FOR DROPPING BLANKS



Die plate Ｌ１/３



The description given in paragraph 4 also applies to openings in the bolster for dropping blanks. The direct placement of the die on the die plate will be useless if the bolster has a large opening. Minimize the opening in the bolster so that the press machine bed can securely support the working load. In cases where a large opening in the bolster is necessary for the work, a thicker die plate should be used to compensate for the opening. (As a guide, the thickness of the die plate should be approximately one-third of the longitudinal dimension L1 of the opening.)



Ｌ１ (minimized)



Fig. 7 Opening in bolster



6. LIMIT TO THE CAPACITY OF THE PRESS MACHINE FOR BLANKING The capacity generated by a mechanical press machine varies with the position of the slide above bottom dead center. A press machine should be used within the capacity shown in the stroke-tonnage curve. The maximum working load of a press machine varies depending on variations in work material thickness and hardness and also changes in the cutting edge condition of the punches and dies. Blanking is severe work for a press machine. It is necessary, therefore, to carefully choose dies as described in paragraphs 2 to 5. When calculating the blanking capacity limits based on press machine construction when blanking common cold rolled steel sheet (SPC) (penetration rate: 38 to 60%) after implementing the above countermeasures and taking into consideration the slide acceleration (10 G), the calculated value will agree with the limits on blanking capacity given in Section B SPECIFICATIONS, 5.1 TONNAGE CAPACITY (NOMINAL CAPACITY) (pg. 66). When blanking a sheet with a lower penetration rate (i.e., higher risk of breakthrough) such as S45C, silicone steel sheet, or stainless steel sheet, the working load has to be set to a value 10% lower than the above-mentioned value, or a countermeasure against breakthrough has to be taken to reduce vibration acceleration (peak value) to 10 G or less.



NOTE



• For presswork with a concentrated central load, a one-point press machine is more advantageous than a two-point press machine. Furthermore, because the slide of a two-point press machine is heavier, the blanking capacity limit of a 2-point press machine is set lower than that of a one-point press machine.



APPENDIX-3



APPENDIX



APPENDIX-4



LIST OF LUBRICANTS AVAILABLE ON THE MARKET



CAUTION • The user must receive a product safety data sheet provided by the oil manufacturer when purchasing lubricating oil and grease. The product safety data sheet describes emergency measures, measures to be taken in case of fire, and measures to be taken in case of leakage. In addition, the sheet provides information on how to handle or store the product and cautions relating to its disposal. These instructions are prescribed by laws and regulations. The user must take appropriate measures according to the instructions.



Designation



LubricatAIDA Std. Wet-Type ing Oil AIDA Std. AIDA Std. AIDA Std. CompresGrease Clutch & (for the Oil No. 1 Oil No. 3 Oil No. 5 sor Oil (*1) No. 0 Brake Oil Automatic Oil Pump)



Viscosity ISO or ConsisVG 32 tency



ISO VG100



ISO VG 320



NLGI-0



-



ISO VG 46



ISO VG 460



Exxon Mobil



Mobil DTE Mobil DTE Mobilgear Oil Light Oil Heavy 600 XP 320



-



Mobil ATF 220 Mobil Mobil VacMobilfluid Rarus 425 uoline 546 350



SHELL



SHELL TELLUS OIL 32



SHELL TELLUS OIL 100



SHELL OMALA OIL 320



SHELL STAMINA GREASE RL 0



-



SHELL SHELL CORENA DELIMA OIL P46 OIL S460



CALTEX CALTEX REGAL OIL R&O 32



CALTEX REGAL OIL R&O 100



MEROPA LUBRICANT 320



-



CALTEX TEXAMATIC FLUID (DEXRON)



RPM COMPRESSOR OIL 46



-



Castrol Hyspin brand AWS 32



Hyspin Alpha AWS 100 SP 320



MolubAlloy 9030-0



-



-



-



BP Energol HLP-HM brand 32



Energol HLP-HM 100



-



-



-



-



BP



Energol GR-XP 320



(*1): Air compressor (option) oils shown above are for AIDA standard air compressors. If you use any other type of air compressor, see the instruction manual for the compressor used.



APPENDIX-4



INDEX



INDEX



CONT. operation



125



CONT. SINGLE operation



125



CONTROL POWER switch



A



Counter



98



Abnormal condition in the clutch and brake solenoid valve



147



Abnormal condition reset operation



131



Counterbalance capacity adjustment



Accessory tools table



261



Crank angle indicator



Actions to prevent hazards



Air consumption Allowable number of intermittent strokes Anchor bolt



101



DATA WRITE switch



88 113



55, 68



Die block



23



159



Annual inspection



190



Auto drain filter



217



Automation device



183



Die changing



161



Die clamper



161



Die cushion capacity adjustment



155



Die cushion specifications Die data



60 APPENDIX-1



C



47



Die lifter



161



Die number



96



Die protection



184



Dimensions (list)



Capacity limitation



47



Cautions to be taken when using the die cushion



69



Cautions when disassembling the counterbalance



39



60



Downloading



117



DOWN/CLAMP/ADV. button Draining



201



51 113



Die height



B



Changing clutch and brake oil



DATA screen



Databank



Angle-gain function



Breakthrough



86



77



75



Bolster dimension



154



D



19 APPENDIX-4



AIDA standard oil



23, 87



90 121



E Eccentric load die cushion



69 66



Chart



55



Eccentric load press machine



Checking after installation



81



Ejector



Checking the clutch stroke



207



EMERGENCY STOP button



Circuit drawings



265



Energy capacity



68



Clamper



106



Environment



26



Clutch and brake solenoid valve



219



Essential basic rules



24



182 89, 146



Component designation



63



External operation selection



183



Connection of air supply



77



Externally controlled breaker



147



Construction drawings



232



CONT. ONCE operation



125



F Fault information message list



137



ⅰ



INDEX



Flushing



193



Foundation work



73



Function touchbutton



95



G Glossary



44



Lock-out



33, 44



Lubricating oil system drawings



265



Lubrication



193



Lubrication clutch and brake oil



201 198



Grease gun



222



Grease pack



222



Lubrication hydraulic overload protector



Grease pump (Automatic)



221



Lubrication initial oil servicing



Grease pump (Manual)



224



Lubrication oil servicing method



196



Ground fault breaker resetting procedure



147



Lubrication oil servicing points



196



Lubrication type and amount of oil



194



Ground wire connection



78



Guard



21



GUARD DISABLE•ACTIVE key switch



87



HOLP



157, 198



Hour meter



108



I



80



M Main motor capacity



H



47



Main motor reverse rotation



142



Maintenance counter



108



Maintenance of guards



208



Maintenance precautions



31



MAINTENANCE screen



108



Material end detection



184



Measuring slide gib clearance



204



Megger measurement



209



INCH operation



125



Inspection every three years



191



Inspection of the clutch and brake solenoid valve



187



Message list fault information



137



Inspection of the limit switch



210



Message list interlock information



132



Inspection of the relay



188



MICRO INCH operation



125



Inspection of the ground fault breaker



Misfeed



102



211



Monthly inspection



187



Installation



73



Installation precautions



27



Instruction for use of press machine Interlock information message list



APPENDIX-1 132



K Knockout adjustment Knockout model



156 53



List of commercially available products



MPC



97, 109



O Oil filter Oil pump Operating device description



L



ⅱ



List of lubricating oil available in the APPENmarket DIX-4



223,224, 225 85



Operating the guards



129



Operation



118



Operation button box 247



225



Operation mode Operation of key switch



86 125 92



INDEX



Operation panel



85



Operation precautions



28



OPERATION SELECT switch Operator interface terminal Option list



89, 92 93 3



S Safe usage of the press machine



24



Safety device



19



Safety devices and operating conditions



126



Option set up



110



Safety procedures during adjustment



33



Overload



142



Selection of preset stop position



184



Overload protector



157, 198



Semi-annual inspection



189



Overrun



146



Service life of electric parts



210



SET UP screen



104



Shank



178



SINGLE operation



123, 125



Slide adjustment



151



P Painting on hazardous areas Periodic inspection annual inspection



43 190



Periodic inspection every three years



191



Periodic inspection monthly inspection



187



Periodic inspection of peripheral devices and accessories



192



Periodic inspection semi-annual inspection



189



PLC battery



212



Pneumatic/hydraulic system drawings



265



Sole plate



73



Spare parts list



259



Specification plate



70



Specifications



47



SPM meter



99



Symbols used in this instruction manual



15



T



Point of operation



44



Power source connection



78



Thermal relay



148



Three elements of the presswork performance



66



120



Timing switch



158



22, 32



To die setters



18



Preset counter



98



To employers



16



Press machine capacity



66



To operators



18



Production counter



98



Tonnage curve



178



Torque capacity



67



Troubleshooting



230



Pre-work checking Presence-sensing device



Punch holder



R RECIPES (databank) screen



113



Replacing the V-belt



206



Routine inspection



121



RUN screen



98



55, 67



Two-hand RUN buttons



20, 44



U Unsticking



150



Upload



114



UP/UNCLAMP/RET. button



90



ⅲ



INDEX



V V-belt adjustment



205



Vibration isolators



73, 74



W Warning display



15



Warning plate



34



Warranty



54



Wiring capacity



79



Work completion procedure



ⅳ



130



Working energy



68



Wrench-shaped symbol



95



INSTRUCTION MANUAL for ACCESSORIES



Be sure to read this Instruction Manual and fully understand the contents before using this machine. In addition, keep the manual near the machine, taking care not to misplace it, so that the operator can access it whenever necessary. This Instruction Manual is intended for the sole use of AIDA’s customers. The use of this manual in part or in whole by any third party is prohibited.



520-90993e



INSTRUCTION MANUAL FOR ACCESSORIES AND COMPONENTS LIST



Name



Type & Model (*1)



Manufacturer



DWG No.



Manual No. SEII 07053000-C



1. SAFETY LIGHT CURTAIN



SE II



RIKEN OPTECH



920-03732e



2. MAIN MOTOR



AD,BD,FE (O,-C)



NIDEC (YASKAWA)



920-07090e



3. AG BRAKE MOTOR



SQUIRREL-CAGE



YASKAWA



920-00198e



TOE-C911-3E



(*1) : For detailed description, see the drawing attached to the instruction manual or the name plate on the accessory or component.



520-78912e



Sales offices and Service offices



Please contact the offices below for further information.



AIDA AMERICA CORPORATION (USA) 7660 Center Point 70 Blvd., Dayton, Ohio 45424-6380 U.S.A. Phone: 1-937-237-2382 Facsimile: 1-937-237-1995 AIDA CANADA, INC. (CANADA) 131 Saunders Road, Unit #9 Barrie, Ontario, L4N 9A7, Canada Phone: 1-705-734-9692 Facsimile: 1-705-734-9695 AIDA ENGINEERING DE MEXICO, S. DE R. L. DE C. V (MEXICO) Av. Rogelio Cantu 374-1, Colonia Santa Maria Monterrey, Nuevo Leon, 64650, Mexico Phone: 52-81-1097-0037 Facsimile: 52-81-1097-0038 AIDA S.r.l. French Branch (FRANCE) 4 rue de l'Artois 68390 Sausheim, France Phone: 33-3-8952-7751 Facsimile: 33-3-8952-6978 AIDA S.r.l. UK Branch (U.K.) City Road, Derby DE1 3RP, U.K. Phone: 44-1332-648200 Facsimile: 44-1332-648223 AIDA S.r.l. (ITALY) Corso Europa, 240-23801 CALOLZIOCORTE(LC)-Italia Phone: (39)0341-634111 Facsimile: (39)0341-634154 AIDA S.r.l. (CZECH) Plzeňská 155/113, 150 00 Praha 5, Czech Republic Phone: (420)255-739-320 Facsimile: (420)255-739-315 AIDA-Pressen GmbH (GERMANY) Suedfeld 9b D-59174 Kamen, Germany Phone: (49)2307-9471-0 Facsimile: (49)2307-9471-40 AIDA STAMPING TECHNOLOGY PTE. LTD. (SINGAPORE) Blk 16 Boon Lay Way #01-55, TradeHub 21, Singapore 609965 Phone: (65)6795-2688 Facsimile: (65)6795-2676 or (65)6795-2678 AIDA STAMPING TECHNOLOGY (THAILAND) CO., LTD. 41/23 MOO 6, BANGNA-TRAD KM.16.5, TAMBOL BANGCHALONG, AMPHUR BANGPLEE, SAMUTPRAKARN 10540 Thailand Phone: (66)2337-0197 Facsimile: (66)2337-0198 PT AIDA STAMPING TECHNOLOGY INDONESIA (INDONESIA) Ruko Mall Bekasi Fajar Blok B No.22 Kawasan Industri MM 2100,Cikarang Barat Bekasi-17520, INDONESIA Phone: 62-21-8998-2432 Facsimile: 62-21-8998-2433 AIDA STAMPING TECHNOLOGY (M) SDN. BHD. (MALAYSIA) No.5 Jalan Pengetua U 1/32 Hicom-Glenmarie Industrial Park 40150 Shah Alam, Selangor Malaysia. Phone: 60-3-5569-2872 Facsimile: 60-3-5569-2879 AIDA ENGINEERING CHINA CO., LTD. (CHINA) Hua Jing Road 9, Waigaoqiao Free Trade Zone, Pudong New Area, Shanghai, 200131, CHINA Phone: 86-21-5046-3588 Facsimile: 86-21-5046-3828 AIDA ENGINEERING CHINA CO., LTD. Shenzhen Branch (CHINA) Room 1803A, West Building, 2nd Term of Chuangxin technology square, Tian'an Digital Mall, Futian District, Shenzhen, 518040, CHINA Phone: 86-755-2601-3818 Facsimile: 86-755-2601-3618 AIDA ENGINEERING CHINA CO., LTD. Tianjin Office (CHINA) Room 1809, Xinmao Software Building No.1, Rongyuan Road, Huayuan Industry Park Tianjin, 300384, CHINA Phone: 86-22-8371-9330 Facsimile: 86-22-8371-9331 AIDA ENGINEERING CHINA CO., LTD. Wuhan Office (CHINA) Room 201, Unit 4, Building 60, Ning Kang Yuan, Economic and Technological Development Zone, Wuhan, Hubei, 430056, CHINA Phone: 86-189-7134-5426 Facsimile: 86-27-8479-8402 AIDA HONG KONG LIMITED Hong Kong Office (CHINA) Rm 901-902, 9/F., 29 Austin Road, Tsimshatsui, Kowloon, Hong Kong Phone: 852-2736-0118 Facsimile: 852-2375-6581



(JAPAN) www.aida.co.jp 2-10 Ohyama-cho, Midori Ward, Sagamihara City, Kanagawa Prefecture 252-5181, JAPAN Phone: (81)42-772-5231 Facsimile: (81)42-772-5263 Overseas Service Center: 1752 Negoya, Midori Ward, Sagamihara City, Kanagawa Prefecture 252-5191, JAPAN Phone: (81)42-784-5537 Facsimile: (81)42-784-5563



Head Office:



AIDA MANUFACTURING (MALAYSIA) SDN. BHD. Plo 524, Jalan Keluli, 81700 Pasir Gudang, Johor, MALAYSIA Phone: (60)7-251-6688 Facsimile: (60)7-252-0688 The information mentioned above is subject to change without notice. (100401)



520- 97366(AMM)