HF LT (50-100 Ton) Operator's Manual X40873h (May-2005)

HYDRAULIC PRESS BRAKE
OPERATORS MANUAL
X40873H
BP 40040 95912 Roissy aroport CDG cedex Tel.: +33 (0)1 49 90 30 00, Fax: +33 (0)1 49 90 31 99
Issue 05/2005
Index
Issue
Updated by
Details of revision
02/2002
12/2002
M. Ahmed
09/2003
Ph. Jacquet
09/2004
Ph. Jacquet
Updated :
- Presentation of page 3 chapter 1.
- Label safety chapter 2.
- Add note Switch off operation ch. 3 & 6.
- Pages 19 to 23 ch.5 expert clamp.
- Add paragraph 5.6. chapter 5.
05/2005
Ph. Jacquet
Update to cater for common electric cabinet.

Suppression of the SA2 key selector
switch. Auxiliary function F5 replace it
now.
- SA1 key selector switch is now replaced
by a selector switch without key.
Ch. 3 pages 6 to 9. Ch. 4 pages 9 to 11. Ch. 6
pages 3 to 7, 9 and 10.
Updated, add the Akas option, control
pannels.and USA machines cycles.
Updated,
- Ch.2 , safety label position.
Modifications of Fig.2.4 & 2.5.
- Ch.5 add paragraph for joined mounting
of standard distance pieces. Modification
paragraph 5.5.3 & 5.5.4..
- Ch.7 add oil caracteristics.
Read the manual carefully to obtain a thorough knowledge of this machine.

Strictly follow the installation, operating and maintenance instructions given in this manual to avoid the risk of
operator injury and damage to the press brake.
Keep this document to hand, and refer to it whenever necessary.
Amada, Tremblay, December 2002.
Any representation, translation, adaptation or reproduction, even partial, by any method or in any country
without prior permission is illegal and would make the offender subject to legal action.
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CONTENTS
HF LOW TONNAGE OPERATORS MANUAL X40873H
LIST OF ADDENDA
Modification coming from
Reason
CONTENTS
HF LOW TONNAGE OPERATORS MANUAL X40873G
Destination
Application
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HYDRAULIC PRESS BRAKE

OPERATORS MANUAL
IMPORTANT NOTE
ACCEPTANCE
We loaded your press brake onto the carrier's vehicle. The carrier acknowledged receiving it
in perfect condition.
However, in the case of a problem during shipping (which can happen), or if you notice signs
of damage (impact marks, etc.) on your machine, we would like to remind you that you
should formulate your reservations as follows:
A On the delivery voucher submitted to you for acceptance by the carrier.
B By notifying the carrier and us (for information) by registered letter within 48 hours at the
latest.
FOR ALL PROBLEMS DURING MACHINE INSTALLATION

Telephone ? ................................................. +33 (0)1 49 90 30 00
Fax ? ............................................................. +33 (0)1 49 90 31 99
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CONTENTS
CONTENTS
1. GENERAL DESCRIPTION ............................................................................................... 1
1.1. DESCRIPTION ............................................................................................................... 3
1.2. PRINCIPLE..................................................................................................................... 5
2. ACCEPTANCE, INSTALLATION AND SAFETY MEASURES.................................. 1

2.1. GENERAL INFORMATION ......................................................................................... 3
2.1.1. MARKING............................................................................................................... 3
2.2. PREPARING THE SITE ................................................................................................ 7
2.2.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED .......... 8
2.2.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED..................... 9
2.3. MACHINE RECEPTION ............................................................................................. 10
2.4. RECEPTION & HANDLING....................................................................................... 11
2.4.1. LIFTING ................................................................................................................ 11
2.4.2. BASIC PRINCIPLES............................................................................................. 13
2.4.3. EQUIPMENT......................................................................................................... 19
2.4.4. SPECIAL PARTS FOR TRANSPORT ................................................................. 20
2.5. ELECTRICAL CONNECTIONS ................................................................................. 21
2.5.1. GENERAL CHARACTERISTICS OF THE MAINS SUPPLY ........................... 21
2.5.2. EARTH................................................................................................................... 21
2.5.3. MAINS-RELATED AND ENVIRONMENT-RELATED INTERFERENCE ..... 22
2.5.4. POWER SUPPLY CABLE CHARACTERISTICS .............................................. 25
2.6. WORKSTATION LIGHTING ..................................................................................... 26
CONTENTS
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2.7. SAFETY PRECAUTIONS ........................................................................................... 27

2.7.1. GENERAL POINTS .............................................................................................. 27
2.7.2. REGULAR INSPECTION AND SAFETY POLICY ........................................... 32
2.7.3. ARRANGEMENT OF WORKSTATIONS .......................................................... 33
2.7.4. CONTROL DEVICES ........................................................................................... 35
2.7.5. RULES FOR SAFE OPERATION ........................................................................ 37
2.8. MACHINE OPERATING AND STORAGE CONDITIONS ...................................... 44
2.9. MACHINE CHARACTERISTICS............................................................................... 45
2.9.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED ........ 45
2.9.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED................... 46
2.10. INFORMATION ON NOISE ..................................................................................... 47
2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS ...................................... 48
3. COMMISSIONING ............................................................................................................. 1
3.1. CLEANING .................................................................................................................... 2
3.2. INSTALLATION OF CONTROL DEVICES ................................................................ 2
3.3. CHECKING THE MAINS POWER SUPPLY............................................................... 4
3.4. MACHINE LEVELLING ............................................................................................... 4
3.5. PUTTING THE MACHINE INTO OPERATION ......................................................... 5
3.6. OVERALL CHECK........................................................................................................ 6
4. TECHNICAL DESCRIPTION........................................................................................... 1
4.1. MECHANICAL STRUCTURE...................................................................................... 3
4.2. MECHANICAL CONNECTIONS ................................................................................. 4
4.3. ELECTRONIC STROKE CONTROL AND PARALLELISM BALANCING
SYSTEM
4.3.1. ELIMINATING SOURCES OF ERROR ................................................................ 7

4.3.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY 7
4.3.3. PRECISE CENTRING OF THE BEAMS ............................................................... 8
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CONTENTS
4.4. LOCATION OF CONTROL AND SIGNALLING DEVICES...................................... 9

4.5. PRESS BRAKE OPERATING LIMITS IN OFF-CENTRE WORK........................... 10
4.6. PRESSURE GAUGE .................................................................................................... 10
5. FORMING TECHNIQUE & TOOLING .......................................................................... 1

5.1. GENERAL POINTS ....................................................................................................... 3
5.2. AIR BENDING ............................................................................................................... 7
5.3. COINING ........................................................................................................................ 8
5.4. LIST OF STANDARD TOOLS...................................................................................... 9
5.5. TOOL INSTALLATION .............................................................................................. 11
5.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM .......................................... 11
5.5.2. AMACLIP PUNCH CLAMPING SYSTEM (OPTION)................................... 15
5.5.3. EXPERT CLAMPING SYSTEM MANUAL VERSION (OPTION).......... 20
5.5.4. EXPERT PNEUMATIC CLAMPING SYSTEM AUTOMATIC VERSION
(OPTION)............................................................................................................... 24
5.5.5. PROCEDURE TO BE OBSERVED FOR TOOL INSTALLATION ................... 28
5.5.6. CHANGING TOOLS (WITH AMNC NUMERICAL CONTROL) ..................... 33
5.6. SPECIAL ACCESSORIES AND OPTIONS ............................................................... 39
5.7. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES............................ 39
5.8. PUNCHING .................................................................................................................. 44
6. OPERATION........................................................................................................................ 1
6.1. START-UP...................................................................................................................... 2
6.2. DESCRIPTION OF CYCLES (OUT OF US MARKET) ............................................. 3
6.2.1. LAYOUT OF CONTROLS PANELS ..................................................................... 4
6.2.2. DESCRIPTION OF CONTROL AND SIGNALLING DEVICES ....................... 11
6.2.3. BASIC VERSION MACHINE (WITHOUT LIGHT GUARD) ........................... 13
6.2.4. MACHINE EQUIPPED WITH SICK LIGHT GUARD OPTION ....................... 16
6.2.5. MACHINE EQUIPPED WITH LASER BEAM OPTION ................................... 16
6.3. MOBILE EMERGENCY STOP ................................................................................... 19
6.4. START-UP.................................................................................................................... 19
CONTENTS
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6.5. DESCRIPTION OF CYCLES ...................................................................................... 20

6.5.1. LAYOUT OF CONTROLS PANELS ................................................................... 21
6.5.2. BASIC VERSION MACHINE (WITHOUT LIGHT GUARD) ........................... 23
6.5.3. MACHINE VERSION WITH LIGHT GUARD ................................................... 24
6.5.4. MACHINE VERSION WITH TWO HAND CONTROL OPTION ONLY ......... 25
6.6. PLC MESSAGES LIST ................................................................................................ 28
6.6.1. MACHINE FAULT MESSAGES ......................................................................... 28
6.6.2. MACHINE STATUS MESSAGES ....................................................................... 47
6.6.3. OPERATOR MESSAGES..................................................................................... 51
7. MAINTENANCE ................................................................................................................. 1
7.1. INTRODUCTION........................................................................................................... 2
7.2. MACHINE PERIODIC MAINTENANCE .................................................................... 5
7.2.1. MAINTENANCE OF THE HYDRAULIC INSTALLATION ............................... 8
7.2.2. OIL CHANGES ..................................................................................................... 11
7.2.3. FILLING PROCEDURE........................................................................................ 11
7.3. RECOMMENDATIONS .............................................................................................. 12
7.3.1. SPECIFIC DAILY TEST PROCEDURE .............................................................. 13
7.4. TROUBLESHOOTING ................................................................................................ 26
7.4.1. TROUBLESHOOTING TABLE ........................................................................... 26
7.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL
POINTS............................................................................................................................ 27
APPENDIX A PROGRAMMING MANUAL

APPENDIX B MACHINE SCHEMATICS AND LISTING (see in the electric cabinet
of the machine)
APPENDIX C BACKGAUGE
APPENDIX D SPECIAL MACHINES
APPENDIX E OPTIONS
APPENDIX F SUPPLIERS DOCUMENTATION
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CONTENTS
APPENDICES
IMPORTANT NOTE
Quality Control department completes this technical manual by adding

certain number of appendices relating to the options & accessories
supplied with the machine i.e. the supplied manual complies fully with
your machine.
The list of these additional documents is part of the Quality Control
file, which is delivered with the machine. At the time of delivery, this
file is placed inside the document tray attached to the inner side of the
electric cabinet door.
CONTENTS
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CONTENTS
1. GENERAL DESCRIPTION
GENERAL DESCRIPTION
Chapter 1
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Figure 1.1
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Chapter 1
GENERAL DESCRIPTION
1.1. DESCRIPTION
The purpose of this document is to facilitate the installation of your High Fidelity hydraulic
press brake (Fig. 1.1) and its connection to the electrical and pneumatic supply systems.
This product line includes the following models:
- HF 50-12
- HFx 50-20
- HFx 80-25
- HFx 100-3
(50 tons / 1.2 meter)

(50 tons / 2 meters)
(80 tons / 2.5 meters)
(100 tons / 3 meters)
X is added to specify the level of equipment provided on your machine (T, E or P).
----------T
E
P
NUMERICAL CONTROL
CD2000
OP2000
AMNC
All models are delivered:
In a basic version without light curtain,

Equipped with a A, B or C-type back gauge
In option: - light curtain, which is used as front protection and as an operation
cycle control device
or
- laser safety system used as front protection only.
Note : In this manual, tons is very often used instead of international measurement unit
kN. We remind you that 9.81 kN is equivalent to one ton.
GENERAL DESCRIPTION
Chapter 1
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Figure 1.2
F1 and F1 = Bending force
A and A = Counter acting points
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Chapter 1
GENERAL DESCRIPTION
1.2. PRINCIPLE
The machine is a manual load/unload hydraulic press brake.
HF hydraulic press brakes are down stroking machines equipped with an numerical controller
for the control and adjustment of all bending parameters.
These press brakes are equipped with a central reaction lower beam to ensure bending quality.
An electrohydraulic servosystem controls the travel and ensures that the Upper Beam (UB)
remains perfectly parallel to the Lower Beam (LB).
These machines can be equipped with various options (back gauge, front gauge, etc.), all
Amada tools, and other traditional tools, as well as a range of accessories. (Contact our
Regional Sales Representative to discuss your specific requirements.)
For items heavier than 25 kg, a handling device must be provided for
the operator. This device is not included in the Amada supply (see
5.5).
REVIEW OF THE CONVENTIONAL DESIGN OF PRESS BRAKES

Traditional press brakes with an operating upper beam exhibit an elastic deformation
during bending in opposite directions on each beam due to the reactions of the part
under the thrust of the jacks located at the ends.
These deformations are detectable by slightly less penetration of the punch in the die in
the center than at the ends (Fig. 1.2).
GENERAL DESCRIPTION
Chapter 1
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AMADA SYSTEM: Slotted beam (for 35- to 100-ton press brakes).

The lower beam is a slotted plate. The arrangement, size, and shape of the slots are designed
to allow the lower beam to deform in the same direction and with the same deformation as the
upper beam under the action of the bending force. The lower beam is welded to the flanges
(Fig. 1.3).
ADVANTAGES
Because the small but inevitable elastic deformation of the two beams occurs in the same
direction and has the same value, the punch has constant penetration in the die over the entire
bending length, thus ensuring a perfect angle.
The small deformation of the beams does not affect the linearity of the bend because the stress
induced in the worksheet remains well within the elastic region.
Fig. 1.3
F1 and F1 = Bending force
A and A = Counter acting points
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Chapter 1
GENERAL DESCRIPTION
2. ACCEPTANCE, INSTALLATION
AND SAFETY MEASURES
ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

Chapter 2
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Chapter 2

2.1. GENERAL INFORMATION

2.1.1. MARKING
The marking on your press-brake corresponds to the following specifications :

a)
b)
c)
d)
e)
f)
Name and address of the manufacturer.

Type of machine.
Serial number.
Date machine is manufactured.
Weight of the press-brake without any tooling or sub-equipment.
If needed, weight of the main parts and sub-equipment to be removed with lifting devices.
A specific marking will then be afixed on these items.
g) Maximum tonnage.
h) Data concerning the electric, hydraulic and pneumatic supplies. A specific marking will
then be attached to the optional equipments.
i) Overall response time and minimum separation distance. They are highly dependent upon
the type of protection device installed (safety guard for instance). Additional marking is
also possible whenever several types of protection devices have been selected.

Chapter 2
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j) Warning on residual risks.

On HFT
On HFE
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Chapter 2

On HFP
k) Overall stroke of the beam.

l) Noise level (acoustic pressure).
Plate for a machine

equipped with a light
guard (option).

Chapter 2
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Plate for a machine with laser beam protection LazerSafe model.
Plate for a machine with laser beam protection Akas model.
m) Warning related to high speed operation (only concerns high speed machines).
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Chapter 2

2.2. PREPARING THE SITE

The press brake must be installed on a stable, rigid floor.
A concrete slab 120 to 150 mm thick with a flat surface (maximum tolerance 2 mm per metre)
must be laid in the work area. Please contact our technical department for the installation
requirements.
HF press brakes are manufactured as welded box structures with a low centre of gravity.
Anchoring them to the floor is therefore optional.
The press brake must be accessible from all four sides:
-
At the rear, allow clearance of approximately 1 metre to allow various maintenance

operations and backgauge adjustment to be performed, the same goes to the electrical
cabinet side.
Allow a clearance slightly greater than the maximum bending length of the machine on at
least one of the two sides. The purpose of this is to allow worksheets that are at least as
long as the press brake to be unloaded from the side.
Width
Height
Length
Figure 2.1

Chapter 2
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2.2.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED

DESCRIPTION
UNITS
MODELS
Standard speed
HF 50-12
HF 50-20
HF 80-25
HF 100-3
High speed
HF 50-12 S
HF 50-20 S
HF 80-25 S
HF 100-3 S
(HFT)
mm
1 850
2 950
3 410
3 990
(HFE)
mm
2 165
3 161
3 621
4 201
(HFP)
mm
n/a
3 458
3 918
4 498
(HFT)
mm
1 610
1 820
1 800
1 940
(HFE)
mm
2 165
2 450
2 450
2 450
(HFP)
mm
n/a
2 450
2 450
2 450
mm
2 300
2 450
2 550
2 700
kg
3 350
4 600
5 600
6 600
Distance between uprights
mm
1 035
1 665
2 125
2 705
Thickness of the uprights
mm
35
35
35
35
Centre distance between upright axis
mm
1 070
1 700
2 160
2 740
Machine
(1)
length
With CD 2000
With OP 2000
Machine
(2)
width
With AMNC
(5)
With CD 2000
With OP 2000
With AMNC
(4)
(3)
(4)
(5)
Machine height
GENERAL net weight
(6)
(1)
The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed.
(2)
(3)
The dimensions are with the arm and the NC maximum extended in front, and all doors closed.
With light guard, add 140mm to this dimension. With a laser beam protection, add 100mm to this
dimension. For transport, reduce by 140mm.
(4)
(5)
(6)
For transport, reduce length by 256mm and width by 380mm.

Add to the machine weight, depending on the options, corresponding weight from the following table :
HF BT
Material Description
AMACLIP sectionalised distance pieces
Sick light guard system
LazerSafe system
Akas system
Fixed front table/support
Single manual finger stop assembly
Programmable front table
Work follower Single arm
Work follower Twin arms
Work follower Single arm + Parking
Work follower Twin arms + Parking
Sick light guard system for Parking
WILA hydraulic clamping
Units 1,20 m 2 m 2,50 m

kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
5
250
90
40
14
12
n/a
n/a
n/a
n/a
n/a
280
n/a
8
250
90
40
14
12
200
440
640
620
820
280
120
10
250
90
40
14
12
220
460
660
640
840
280
140
3m
13
250
90
40
14
12
240
480
680
660
860
280
160
n/a : not available

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Chapter 2

2.2.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED

DESCRIPTION
UNITS
Vitesse standard
HF 50-12 L
Vitesse rapide
HF 50-20 L
HF 80-25 L
HF 100-3 L
HF 50-12 LS HF 50-20 LS HF 80-25 LS HF 100-3 LS

mm
n/a
2 955
3 415
3 995
(HFE)
mm
n/a
3 166
3 626
4 206
(HFP)
mm
n/a
3 463
3 923
4 503
(HFT)
mm
n/a
1 952
1 952
2 052
(HFE)
mm
n/a
2 450
2 450
2 450
(HFP)
mm
n/a
2 450
2 450
2 450
mm
n/a
2 770
2 770
2 860
kg
n/a
5 000
5 750
7 000
mm
n/a
1 660
2 120
2 700
Thickness of the uprights
mm
n/a
40
40
40
Centre distance between upright axis
mm
n/a
1 700
2 160
2 740
Machine
(1)
length
(HFT)
Machine
(2)
width
With CD 2000
MODELS
With OP 2000
With AMNC
(5)
With CD 2000
With OP 2000
With AMNC
(4)
(3)
(4)
(5)
Machine height
GENERAL net weight
(6)
(1)
(2)
(3)
The dimensions are with the arm and the NC maximum extended in front, and all doors closed.
With light guard, add 140mm to this dimension. With a laser beam protection, add 100mm to this
dimension. For transport, reduce by 140mm.
(4)
(5)
(6)

Add to the machine weight, depending on the options, corresponding weight from the following table :
HF BT
Material Description
Units 1,20 m 2 m 2,50 m
AMACLIP sectionalised distance pieces

Sick light guard system
LazerSafe system
Akas system
Fixed front table/support
Single manual finger stop assembly
Programmable front table
Work follower Single arm
Work follower Twin arms
Work follower Single arm + Parking
Work follower Twin arms + Parking
Sick light guard system for Parking
WILA hydraulic clamping
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
5
250
90
40
14
n/a
n/a
n/a
n/a
n/a
n/a
280
n/a
8
250
90
40
14
n/a
200
440
640
620
820
280
120
10
250
90
40
14
12
220
460
660
640
840
280
140
3m
13
250
90
40
14
12
240
480
680
660
860
280
160
n/a : not available

Chapter 2
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2.3. MACHINE RECEPTION

Recommendations before handling and installation.
Prohibited procedures:
Never press against, or attach handling equipment (slings, hooks, straps, etc.) to the following
components:
-
Lower beam,
Upper beam,
Electrical cabinet,
NC pendent arm,*
Mechanical guards,
C frame (Goose necks),
Machine covers,
Backgauge.
Refer to Section 2.3 to identify the recommended floor support areas.
IMPORTANT NOTE
CERTAIN AREAS OF THE MACHINE ARE NOT DESIGNED TO
WITHSTAND THE WEIGHT OF A PERSON WITHOUT
DEFORMATION. THESE AREAS ARE IDENTIFIED BY THE
LABEL SHOWN BELOW.
Figure 2.2
* With NC type : OPERATEUR 2000 and AMNC.
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Chapter 2

2.4. RECEPTION & HANDLING

2.4.1. LIFTING
Before the vehicle arrives, provide a crane with sufficient capacity to unload the press brake
from the vehicle. Ensure that the access doors are sufficiently tall and wide to receive the
machine, or its case (in case of sea worthy packing).
To handle the press brake, use the two sling holes located towards the front on the upper part
of the side frames (see fig. 2.3).
CAUTION: Lifting forces should only be applied to the sling points
provided for this purpose. Never apply force to the underside of the
beams, electrical cabinets, covers, etc.
For all machine handling operations, observe the following recommendations:
Attach the lifting beam directly, with a load per strand, not exceeding the
maximum allowable load.
Lift and set down the machine gently, avoiding any side impact on the
machine, or any impact on lowering it to the floor.
To direct the machine during handling, press on the frame or its packaging
only; never press on the beams, electrical cabinets, covers or guides.
CAUTION: When a press brake has been crated for sea transport,
handling it and removing it from the crate are tricky procedures. We
strongly advise you to seek professional assistance. For information
on this point, do not hesitate to contact Amada.
The instructions in this section are given for information only, and do
not engage the responsibility of Amada.

Chapter 2
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LIFTING BEAM
Only use these holes for
anchoring lifting slings
Only use these holes for

anchoring lifting slings
Center of
gravity
Figure 2.3
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Chapter 2

2.4.2. BASIC PRINCIPLES

Lifting forces must only be applied to the anchoring points provided for this purpose and a
lifting beam or sling should be used for machine handling.
Distance
between
uprights
mm
50-12
807.5
1 400
500
35
3 350
65
50-20
870
1 400
770
35
4 600
65
80-25
926
1 400
950
35
5 600
65
100-3
1 026
1 400
1 150
35
6 600
65
50-20 L
908
1 600
770
40
5 000
65
80-25 L
960
1 600
950
40
5 750
65
100-3 L
1 068
1 600
1 150
40
7 000
65
Center of gravity
Press-brake
Machine
weight
kg
anchoring
holes
mm
NOTE
For options, see 2.2.1. & 2.2.2.

Chapter 2
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The holes at the top front and back of the side frames are used to anchor the machine during
transport, but only the front holes are used to handle the machine.
LOAD DISTRIBUTION
ACCORDING TO SLING ANGLES.
Example A : 45 angle
50% of load weight
on each sling.
Example B : 90 angle
75% of load weight
on each sling.
WE RECOMMEND NOT TO
EXCEED AN ANGLE OF 90.
The table below specifies the distance between uprights as well as the minimum length of the
slings to be used for the handling operation.
Distance in mm
between uprights
Minimum length of the

slings in mm
50-12
1 035
2 000
50-20
1 665
2 400
80-25
2 125
3 100
100-3
2 705
4 000
50-20 L
1 660
2 400
80-25 L
2 120
3 100
100-3 L
2 700
4 000
Press-brake
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Chapter 2


Chapter 2
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Prohibited areas
Areas authorised for shipping/transport
Mandatory ground footing areas for
installation or for moving on skates.
Figure 2.4
CAUTION: The choice of footing or anchoring points other than

those specified in Fig. 2.3 and Fig. 2.4, is prohibited. Incidents
resulting from a failure to comply with these instructions may lead to
the suspension of your guarantee.
The following table gives the load distribution on the footing
Machine Type
50-12
50-20
80-25
100-3
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LOAD PER FOOT (kg)

Front: 420 x 300
Rear: 150 x 150
920
1 400
1 850
2 270
Chapter 2
630
900
950
1 030

ANCHORING THE MACHINE TO THE GROUND :
Figure 2.5
NOTE
All dimensions are given in mm.
Machine type
A (mm)
B (mm)
E (mm)
50-12
1 200
1 236,5
894
50-12 S
1 200
1 236,5
894
50-20
1 840
1 305
1 535
80-25
2 320
1 305
2 015
100-3
2 900
1 405
2 595

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Figure 2.6
Figure 2.7
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Chapter 2

2.4.3. EQUIPMENT
Handling operations must be performed as follows:
- Using lifting gear such as a gantry or crane. Use the sling points. These holes can directly
receive the shackles to which the hoist rings are attached.
- If appropriate lifting equipment is not available, the press brake can be moved on skates
(Figs. 2.5 and 2.6).
CAUTION: Strictly observe the authorised support areas as shown in

Fig. 2.4.

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2.4.4. SPECIAL PARTS FOR TRANSPORT

For transport purposes, the upper beam is mechanically held at top dead centre using two
props (Item 1), the backgauge cross member is immobilised using two brackets (Item 2), each
C-frame side door is blocked using a bracket (Item 3) and a red coloured spacer is mounted in
between the motor and its mounting plate (Item 4). These accessories are removed by the
Amada technician during commissioning, before starting up the machine. They should be kept
in a safe place for future use (if the machine is moved to another location in the future).
m
Only on 80 and 100 Tons machines
CAUTION
IN NO CASE AN UPPER BEAM LOWERING COMMAND BE
GIVEN WHEN THE IMMOBILISING DEVICES ARE IN
POSITION.
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Chapter 2

2.5. ELECTRICAL CONNECTIONS

Correct operation of an electrical system depends on the quality of its power supply ; it must
be stable and free of interference.
The installation must be designed and built in accordance with the regulatory requirements in
force.
2.5.1. GENERAL CHARACTERISTICS OF THE MAINS SUPPLY
- Power supply:
Three-phase (according to mains).

10% in steady-state,
20% in transient (20 ms).
- Pulse mode: 50% of rated value, maximum duration 5 ms

- Harmonics: Maximum 5%
- Frequency: 50 or 60 Hz (according to mains).
- Electrical power supply line: Special supply line should be drawn for the EXCLUSIVE use
of the system from the main LOW VOLTAGE panel. The entire system is powered by a
single three-phase + earth cable.
2.5.2. EARTH
This equipment lacks double insulation hence requires an earthing connection. This is also
important for machine operation and to drain electrical noise to the ground.
The earthing conductor must have a sufficient cross-section. It must be connected to the
terminal board of the power supply panel. Like the electrical installation, this earthing
connection must be periodically checked by an approved organisation.
The resistance of the earthing connection measured must comply with the applicable laws and
standards.
The green/yellow earthing conductor is exclusively reserved for the system. It is directly
connected to the earthing terminal.

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2.5.3. MAINS-RELATED AND ENVIRONMENT-RELATED INTERFERENCE

CAUTION: Never solder or weld a component to the machine using
any process whatsoever. This could damage the mechanical, electrical,
and electronic devices.
Certain electronic components may be subjected to abnormal or excessive voltages or currents
liable to cause their destruction.
The installation of adapter components without a galvanic connection to the mains (voltage
stabiliser, inverter, converter unit, transformer, isolating transformer, etc.) may need to be
considered. If necessary, the quality of the electrical power supply should be checked by an
approved organisation, and an analysis of the results should determine the type of equipment
required.
The following types of interference can be considered as a disturbance to any electronic
system:
Electrostatic Discharge
Electrostatic discharge is particularly critical where the ambient relative humidity is low. It is
not unusual for a person or group of people on the move to generate discharges amounting to
several thousand volts when touching a door handle or metal frame. It may be necessary to
install antistatic equipment. The machine has passed tests to European Standard EN 61000.4.2
concerning immunity to electrostatic discharge.
Mains Transients
Transients are spurious pulses propagating along mains conductors which may affect system
operation. They may be from an internal source, e.g. welding unit, or any other machine
generating mains interference, or they may be from an external source, e.g. stormy weather,
neighbouring factory, etc. The machine has passed tests to European Standard EN 61000.4.4
concerning immunity to fast transients.
Stormy Weather
The charges that accumulate during a storm cause transients in electrical lines or connecting
cables. Do not use excessively long overhead lines.
Magnetic Fields
A variable magnetic field causes induction in circuit loopsa major source of interference
voltage. Cathode ray tubes are sensitive to magnetic fields, and display this sensitivity by a
change in image chromatics or geometry. This is why they are equipped with protective
shielding.
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Chapter 2

Medium- or High-Frequency Electromagnetic Radiation

This type of interference can cause many problems in systems (operational amplifiers,
computer memory, etc.). In general, the extent of the disturbance depends on the duration and
intensity of the radiation. It may be caused by nearby radar systems or radio transmitters
(military, police, FM radio station, etc.), or even by poorly filtered cathode ray tubes.
For optimum operation of your machine, install the press brake in an environment that is free
of the disturbances mentioned above (reference values : field 0.2 to 0.5 V/m, frequency band
10 kHz to 1 GHz).
Although the machine has passed tests to European Standards EN 50140 and 50141, we
recommend that you install the press brake in an environment that is free of the abovementioned types of interference.

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Example of wire attachments for

the customer supply cable to QS1
Earth terminal
Figure 2.8
NOTE
Component layout, not binding.
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Chapter 2

2.5.4. POWER SUPPLY CABLE CHARACTERISTICS

The characteristics of the power supply cable must comply with the safety regulations in
force. Cable cross-sections (mm) are given for a line less than 20 m long. They are different
for the three models in the product range, and for a 400-V power supply. For any other
specifications, refer to standard.
Example : EN 60204-1 (IEC 204-1).
Manufacturer-recommended cross-section
Country
Voltage / Frequency
Europe
400 V / 50 Hz
7,5 kW
4 mm
10,5 kW
4 mm
18 kW
6 mm
See Figure 2.8 as well electric diagram on how to pass the incomming power supply cable
through the electric cabinet.
The power supply cable should never be passed through the C frame in front of the
electrical cabinet.
The machine is equipped with its own current protection devices, but the supply line must be
equipped with a cutoff device to protect it from short circuits and overcurrents (not included
in Amada supplies).
The cable and its mechanical protection devices, if any (cable troughs, raceways, sheaths,
etc.) must have a protection rating according to the mechanical risks and corrosive agents to
which they are liable to be exposed (not included in Amada supplies). The routing of cables
and their protective equipment must not create any hazard (falling) to personnel.
Connect the three power supply wires directly to the corresponding terminals of the circuit
breaker, with the earth wire (green/yellow) directly on the earth terminal intended for this
purpose.
The circuit breaker is designed to accommodate up to three padlocks. We recommend that
you install a padlock immediately, to prevent the system being switched on until the
Amada Department Services technician arrives to put your machine into operation.
CAUTION: All work on electrical installations must be performed by

qualified personnel trained for the purpose in order to prevent any
accidents or damage to equipment.

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2.6. WORKSTATION LIGHTING
CAUTION: Ensure that the workstation has sufficient lighting for the
parts to be worked on.
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Chapter 2

2.7. SAFETY PRECAUTIONS

2.7.1. GENERAL POINTS
During machine installation, operation, and maintenance, apply all necessary safety measures,
and the following in particular :
Do not adjust or service the machine until you have read the manual.
All electrical work must be performed by a qualified electrician, to avoid all equipment
damage or physical injury.
Never place your hands between tools for any reason.
Do not modify the control circuits or any component of the machine.
Never use the machine with any of its safety devices removed or disabled.
Do not enter inside the safety device covered area nor in the hazardous zone.
Daily inspect the machine before starting work to ensure that :
- All protective devices are in place.
- There is no obstruction in between the tools.
- There is a free access to command devices.
- The floor around the machine is free of grease, oil, and water.
Never wear a tie, scarf, or loose clothing when adjusting or operating a press brake.
Make it a rule that a single qualified, trained operator performs machine adjustments. When
working on large parts, the operator may be helped by an assistant operator whose sole task
is to help handle the blank. The assistant must have an equivalent control panel (electric
footswitch) to authorise the operator to start the cycle. We supply on request, special
equipment, to allow working on 2 stations or plus, with or without light guard.
Before machine inspection or maintenance, switch off the main electrical isolating switch
unless power is required for the procedure concerned. In such cases, only personnel with the
appropriate training are authorised to carry out the procedure.
Wear protective gloves whenever possible.

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On rare occasions when the user bends parts whose overall size exceeds the length of the
machine's beam, protective measures must be implemented to prevent injury to other
persons. If this type of job is performed frequently, additional protective measures must be
permanently installed, in association with the machine's control circuit where appropriate.
CAUTION : Use of the machine by unqualified, untrained personnel

engages the employer's liability (Labour Law L 233-5-1) as well as
the operator's liability (Labour Law L 230-3). Applies to France only.
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Chapter 2

Important note relating to

Personal Protective Equipments (PPE)
The so-called Personal Protective Equipments (PPE) are not included in Amada supplies.
You will find below as informative examples the type of Personal Protective Equipments that
one will require on our machines:
gloves,
helmets,
ear guards,
goggles,
goggles to protect against laser radiations,
safety shoes,
etc.
It is the responsibility of the user of the PPE to ensure that the equipment he /she is using
fully complies with the European Directive 89/686/CE. This verification should be carried out
with in the guide-lines of the European Directive 89/656/CE. The said directive is transposed
in the French Labour Law Code de Travail and applies to the employer (Act 93-41 dated
11/01/1993 and article R233-1 and R233-83-3) i.e. all French employers are obliged to:
ensure that the appropriate PPE are selected relating the risks involved,
supply the appropriate PPE to the employee concerned,
ensure that the employee is using them efficiently,
ensure their compliance with the regulation,
inform people who are responsible for the implementation (work shop manager,
foremen, etc.),
ensure the PPE are in perfect working condition and periodic maintenance is carried
out,
inform users which potential risks are protected by the use of PPE,
train and lead users in the regular use of PPE.
In any case, the PPE which are in compliance (self certified or certified by a notified body)
should have:
A CE marking (visible and affixed firmly) and showing:
the name or the trade mark of the manufacturer,

identified either by commercial name or the reference of the PPE,
the size, if implies,
the expiry date, if implies,
and should be accompanied by the information leaflet and user manual along with the CE
declaration stating that it complies fully with the European Directive 89/686/CE.

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CAUTION: The machine may not be used in an explosive environment.
The operation and maintenance of this machine are strictly reserved for qualified
professional personnel.
For this purpose, Amada Department Services provides training for operators, fitters,
programmers, and maintenance technicians on its own premises or on the customer site.
Fire Prevention & Emission of Harmful Substances
HF press brakes present a low risk of fire or emission of harmful substances. Even through,
we recommend that you keep fire extinguishers for electrical equipment and oil near the
machine.
Ensure that the strength and length of the tools used are compatible with the pressure setting
(see Para. 2.9, Machine characteristics and Para. 5.5 tool installation).
Press brakes are supplied with the following safety equipment :
-
A set of two footswitches (closing/opening),

Cycle selector key switch,
Self controlled side and rear guards,
Self-controlled electrohydraulic circuit.
Options:
1) Light guard to protect the front area.
2) Another control unit for assistant operator, including 2 footswitches
(opening/closing).
3) A laser beam, to protect the front area.
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Chapter 2

The press brakes listed in Appendix IV of Machine Directive 98/37/CE have fulfilled the
requirements of the
Type Testing procedure, as certified by NORISKO, a notified body
registered with the European Community by the French Ministry of Labour.
Each machine delivered in European Union is therefore accompanied by a
declaration of
conformity like the following example :

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2.7.2. REGULAR INSPECTION AND SAFETY POLICY
NOTE
The below-explained items are valid for France only.
Any other country should refer to its current and domestic regulation.
Article R233.11 of the labour law and the Act dated 5 March 1993, modified by the
Act dated 4 June 1993, require preventive maintenance to be performed on a quarterly
basis. The purpose of this regular servicing is to detect any fault liable to cause an
accident in advance, so that such faults can be rectified.
The results of this service call are recorded in a safety register opened by the Site Manager
and made available to the Health and Safety Executive and the CHSCT (if any) at all times.
This measure applies to any manual-feed press working on cold rolled metals. The servicing
must be performed under the responsibility of the Site Manager by qualified persons trained
in risk prevention. A list of such personnel is made available to the Health and Safety
Executive.
For all utilisation of press-brake, the user is obliged of :

-
Use the protection devices in order to secure the front faces on press-brakes.
Arrange the working stations through the installation of devices suited to the parts to be
bent : part-holder , adjustable table.
Think out of a convenient working organization due to secure the passing-through of
batches of new parts.
As for safety instructions, provide the proper training to operators and particularly to nonexperienced benders or temporary workers.
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Chapter 2

2.7.3. ARRANGEMENT OF WORKSTATIONS

There are five separate working zones, which are as follows:
j
k
l
m
n
Electrical cabinet
Backgauge adjustment
Start-up and Programming*
Production
Assistant Operator in the event when production is carried out by two operators
(Caution : the assistant operator should be provided with similar equipment as for
the main operator. See 2.7.1).
k
j
* When equipped with OPERATEUR 2000 controller or AMNC controller
k
j
l
m
* When equipped with CD2000 controller

NOTE
Visuals, not binding.

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Figure 2.9
Figure 2.10
Figure 2.11
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Chapter 2

2.7.4. CONTROL DEVICES

The press brake is supplied with a control device composed of one opening footswitch j and
one closing footswitch k (Fig. 2.10).
When the press brake is controlled by two operators, a second unit (option), identical to the
first, is required. A selector key switch (option) is used to switch it on.
Depending on the type of NC fitted to your machine, the teaching will be carried out as
follows:
-
With the help of an electronic hand wheel remote controller having magnetised base plate,
supplied as standard accessory and can be moved around (figure 2.9). For further details,
see appendix "A2" programming manual (machine equipped with OPERATEUR 2000
NC).
Directly using the push buttons on the NC key- pad (figure 2.11). For further details, see
appendix A3, programming manual (machine equipped with CD2000 NC).
With the help of an electronic hand wheel remote controller having magnetised base plate,
supplied as standard accessory and can be moved around (figure 2.9). For further details,
see appendix "A4" programming manual (machine equipped with AMNC NC).
CAUTION : Working from the rear side of the machine is strictly

forbidden.

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Figure 2.12
Figure 2.13
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Chapter 2

2.7.5. RULES FOR SAFE OPERATION

Release the part to be bent as soon as it is gripped between the tools (Fig. 2.12).
Install or remove the tools ( 5.5 Fig. 2.13) in strict compliance with the procedure
described in the Operator Manual and/or the recommendations specific to your tooling.
To avoid damage to your tooling or any accident, Amada urge you to

follow strictly the procedure below :
Every time you change a program, select adjustment mode and

mute stop.
Carryout a dry cycle (without material).
Check visually that all parameters correspond to the tooling
mounted on the machine, the mute point is 6 mm above sheet
pinch point and the end of bend is correct.
Then and only then choose the normal operating mode for the
program in question.
CAUTION: Handling devices for heavy parts are not included in the
Amada supplies.
They must be installed for risk-free use in accordance with ergonomic
principles.

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Figure 2.14
Figure 2.15
Figure 2.16
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Chapter 2

Never attempt to support the end of the worksheet by holding it on either

side of the tools. Only install the tool length required for the current job
on the machine (Fig. 2.14).
Never place your hand between the worksheet and the backgauge during
operation (Fig. 2.15).
Never place your part against/over the backgauge finger before backgauge
is positioned on programmed position.
No part of your body must enter the hazardous area during bending
operations (Fig. 2.16).

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Figure 2.17
Figure 2.18
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Chapter 2

Beware of sudden movements of the worksheet during bending (Fig.

2.17).
Observe the allowable tool loads (Fig. 2.18 and Para. 5.5).
For example:
- 1.2 T/cm for standard punches, except:
- 1.5 T/cm for heavy punches,
- 0.5 T/cm for punches with extra thin blades.
(1 T = 10 kN)
The specific value for each tool type is marked on the side of the tool and is
also shown in the special Tool catalogue.

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Figure 2.19
Figure 2.20
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Chapter 2

The dutch bending or hemming tool should be firmly secured to the lower
beam (Fig. 2.19).
This type of tooling shouldnt be used on High Speed press brakes i.e.
where working speed can reach 20 mm/s.
Never hold the sheet by its folded edge; hold it from the sides
(Fig. 2.20).

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2.8. MACHINE OPERATING AND STORAGE CONDITIONS

To ensure long life for the electronic and hydraulic components, conditions should be
maintained within the following limits:
Min.
Ambient machine storage temp. ............................. -10C
Ambient operating temp. ..........................................+5C
Oil temp. ...................................................................+5C
Relative humidity ......................................................20%
Max.
................................... +50C
................................... +35C
................................... +80C
.................................... 75%
For temperatures below 5C, the NC unit must remain powered to keep the components and
circuit at a normal temperature.
No equipment that produces swarf, dust, paint flakes, etc. must be installed in the immediate
vicinity of the machine. If this is not possible, apply all possible measures to protect the press
brake from all factors liable to hinder its smooth operation.
CAUTION: Amada engineer will put your machine into operation.

Please provide a supply of test sheets for this purpose. Select the
material and sheet thicknesses you use most often.
CAUTION : Any prior use of the machine will lead to suspension of

the guarantee. Validity of the guarantee will not be restored until the
installation has been inspected and, where necessary, the machine has
been repaired at your expense.
CAUTION : Use of the machine by unqualified, untrained personnel
engages the employer's liability (Labour Law L 233-5-1) as well as
the operator's liability (Labour Law L 230-3). These labour laws
applies to France only.
NOTE: To gain maximum benefit from our technician's visit,

remember to remove the equipment from its crates and degrease it
before the technician's arrival.
If the oil temperature is below 5C, there is a risk of the machine

operating incorrectly.
To prevent this, press the STOP button, and then press the opening
footswitch for 5 to 10 minutes (see . 3.7).
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Chapter 2

2.9. MACHINE CHARACTERISTICS

2.9.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED
DESCRIPTION
Standard speed
High speed
Nominal force
1
Minimum force
Table length
Table width
Work surface height
Open height without tools
Cylinder stroke
Throat depth
Max. pressure
Number of cycles
Oil capacity 2
With CD2000 (HFT)
Machine
With OP2000 (HFE)
length 3
With AMNC (HFP)
With CD2000 (HFT)
Machine
With OP2000 (HFE)
4
width
With AMNC (HFP)
Machine height
GENERAL net weight 5
Number of adj. dist. Pieces 6
Height of distance pieces
lg 835 mm
Number of
tools
lg 415 mm
Motor power (Europe) 7
Pump capacity (Europe) 2
Motor power (USA) 7
Pump capacity (USA)
Max. approach speed
Max. work speed 2 et 8
Max. return speed 2
UNITS
kN
kN
mm
mm
mm
mm
mm
mm
mm
bar
litres
mm
mm
mm
mm
mm
mm
mm
kg
MODELS
HF50-12
HF50-12 S
500
40
HF50-20
HF50-20 S
500
40
HF80-25
HF80-25 S
800
70
HF100-3
HF100-3 S
1 000
75
1 270
60
960
370
150
100
1 035
270
4
55
1 850
2 165
n/a
1 610
2 165
n/a
2 300
3 350
2 090
60
960
470
200
420
1 665
270
4
55 / 110
2 950
3 161
3 458
1 820
2 450
2 450
2 450
4 600
2 570
60
960
470
200
420
2 125
275
4
90 / 185
3 410
3 621
3 918
1 800
2 450
2 450
2 450
5 600
3 110
90
960
470
200
420
2 705
280
4
110 / 225
3 990
4 201
4 498
1.940
2 450
2 450
2 700
6 600
6/8
10/13
13/17
15/21
kW
120
1
3
4
120
2
5
4 / 7,5
120
3
6
7,5 / 15
120
4
7
7,5 / 15
cm3/T
kW
8,2
-
8,2 / 16,4
4/9
13,3 / 26,6
7,5 / 12,5
15,8 / 31,6
7,5 / 17
cm3/T
6,4 / 12,8
10, 2/ 20,4
13,3 / 26,6
mm/s
mm/s
mm/s
100
10
100
100 / 200
10 / 20
100 / 200
100 / 200
10 / 20
100 / 200
100 / 200
10 / 20
100 / 200
mm
AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to
alter their characteristics at any time.
Value affecting the smallest allowable length of tools (Para. 5.5).

Standard speed / High speed.
3
4
The dimensions are with the arm and the NC maximum extended in front, and all doors closed. For HFT models, add 140mm to this
dimension for the light guard option, and add 100mm for a laser beam protection option.
5
Weights are approximate and correspond to basic machines, for optional equipment, see 2.2.1.
6
Standard distance pieces / Abutting distance pieces.
7
Machine power = Motor power + 3 kW.
8
20mm/s work speed is incompatible with the Akas system
2

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2.9.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED

DESCRIPTION
UNITS
Standard speed
High speed
MODELS
HF50-20L
HF80-25L
HF100-3L
HF50-20LS
HF80-25L
HF100-3LS
kN
500
800
1 000
kN
40
70
75
Table length
mm
2 090
2 570
3 110
Table width
mm
60
60
90
Work surface height
mm
960
960
960
Open height without tools
mm
620
620
620
Cylinder stroke
mm
350
350
350
Throat depth
mm
420
420
420
mm
1 660
2 120
2 700
Max. pressure
bar
270
275
280
litres
55 / 110
90 / 185
110 / 225
Nominal force
Minimum force
Number of cycles
Oil capacity
Machine
length 3
Machine
width 4
With CD2000
(HFT)
mm
2 955
3 415
3 995
With OP2000
(HFE)
mm
3 166
3 626
4 206
With AMNC
(HFP)
mm
3 463
3 923
4 503
With CD2000
(HFT)
mm
1 952
1 952
2 052
With OP2000
(HFE)
mm
2 450
2 450
2 450
With AMNC
(HFP)
mm
2 450
2 450
2 450
mm
2 770
2 770
2 860
kg
5 000
5 750
7 000
10/13
13/17
15/21
120
120
120
Machine height
GENERAL net weight
Number of adj. dist. Pieces
Height of distance pieces

Number of
tools
mm
lg 835 mm
lg 415 mm
Motor power (Europe)
Pump capacity (Europe) 2

Motor power (USA)
Max. work speed 2 et 8

Max. return speed
4 / 7,5
7,5 / 15
7,5 / 15
Cm3/T
8,2 / 16,4
13,3 / 26,6
15,8 / 31,6
kW
7,5 / 12,5
7,5 / 17
Cm /T
10, 2/ 20,4
13,3 / 26,6
mm/s
100 / 200
100 / 200
100 / 200
mm/s
10 / 20
10 / 20
10 / 20
mm/s
100 / 200
100 / 200
100 / 200
Pump capacity (USA)

Max. approach speed
5
kW
AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to
alter their characteristics at any time.
1
Value affecting the smallest allowable length of tools (Para. 5.5).

Standard speed / High speed.
3
4
The dimensions are with the arm and the NC maximum extended in front, and all doors closed. For HFT models, add 140mm to this
dimension for the light guard option, and add 100mm for a laser beam protection option.
5
Weights are approximate and correspond to basic machines, for optional equipment, see 2.2.1.
6
Standard distance pieces / Abutting distance pieces.
7
Machine power = Motor power + 3 kW.
8
20mm/s work speed is incompatible with the Akas system.
2
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2.10. INFORMATION ON NOISE
The measurements methods and the operating conditions used comply with EN 31202
standards.
1 EQUIVALENT ACOUSTIC PRESSURE LEVEL AT WORKSTATION

LAeq:
The equivalent continuous acoustic pressure level at the workstation,

LAeq, is less than 75 dB(A).
2 PEAK ACOUSTIC PRESSURE LEVEL AT WORKSTATION

Lpc:
The peak acoustic pressure level at the workstation, Lpc, is less than
130 dB
Measurements were carried out at 1 m from the front side, at the centre of the machine and at
a height of 1.6 m.

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2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS
Normal Use
Bending and forming of sheet metals of various types of material and thicknesses by inserting
the blank to be folded in between punch/die, whose shape and size depend on the properties of
the material.
Bending can be performed by one of the following methods:
- Air bending or three-point bending,
- Bottoming
- Coining
In all cases, it is essential to observe the tool unit load limits.
Reservations and Exclusions

Punching is not permitted on this type of machine.
Bending/forming of any material other than sheet metals, such as plastics (PVC, Makrolon,
polycarbonate, etc.) in particular, should not be undertaken without consulting the supplier
and checking the mechanical properties (ductility, strength, formability, etc.) of the product
concerned.
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Chapter 2

3. COMMISSIONING
COMMISSIONING
Chapter 3
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3.1. CLEANING
To gain maximum benefit from our technician's visit, we strongly recommend that you
remove the equipment from its crates and degrease it before the technician arrives.
Use paraffin to remove the grease or storing polish, and oil the machined surfaces to prevent
oxidation.
CAUTION: Never use abrasive products or solvents liable to damage
surfaces with protective coatings.
3.2. INSTALLATION OF CONTROL DEVICES

The footswitch is supplied wired and connected. It is in a box secured to the backgauge.
CAUTION: Do not remove this box. Our technician will do so.
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Chapter 3
COMMISSIONING
IMPORTANT NOTE
AFTER LEVELLING, TIGHTEN THE TWO NUTS OF THE ADJUSTMENT
SYSTEM ON BOTH THE UPRIGHTS.
Levelling
screw
Figure 3.1
COMMISSIONING
Chapter 3
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3.3. CHECKING THE MAINS POWER SUPPLY

As supplied, the machine is intended to run on a three-phase 400 V 50/60 Hz power supply.
Any other voltage requires a transformer (not supplied).
3.4. MACHINE LEVELLING
To set your machine up with the correct geometry, apply the following procedure
strictly.
Because your press is designed not to be anchored to the floor, the concrete slab must be flat to
within 2 mm per metre.
Horizontal levelling does not require great accuracy; 1 mm per metre is sufficient.
The levelling of each upright is performed using each of the two screws at the rear of the machine
(Fig. 3.1). The perpendicularity reference is taken with a precision level (accurate to 0.05 mm/m)
placed on a straightened rule which is in turn resting on two dowel pins in each of the uprights.
Tolerances: 0.05 mm/m per upright, and 0.05 mm/m with respect to each other.
IMPORTANT NOTE
THE MACHINE MUST NOT REST ON SUPPORTS OTHER
THAN THOSE DEFINED IN FIG. 2.4 (CHAPTER 2) OF THIS
MANUAL.
For specific installation conditions, contact Amada Technical
Department.
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Chapter 3
COMMISSIONING
3.5. PUTTING THE MACHINE INTO OPERATION

START-UP
. SEE CHAPTER 6.1.
DIRECTION OF ROTATION
Check the direction of rotation of the hydraulic unit. To do this:
- Start the pump by turning the
key selector to the right.
- Compare the direction of rotation of the motor blades to the red arrow on the motor
casing.
- If the direction does not match, stop the pump rotation by turning the
key
selector to Position 0.
- After switching off the main circuit breaker of the machine swap 2 phases at the
supply terminals.
NOTE
Switch off operation.
First step : turn the motor start up key switch to the 0 fix position.
Second step : turn the handle of the main circuit breaker to position 0.
COMMISSIONING
Chapter 3
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3.6. OVERALL CHECK

Check the mountings of all covers and casings.
Check that no foreign body is present on the ball screws of the backgauge axes or the guide
rails.
Check that the cables are secure in the stuffing boxes (electrical power supply cable), and
check the cable grip at the bottom of the electrical cabinet (footswitch). In the electrical
cabinet, check that the earthing wires are properly connected to the terminal blocks.
Check that the limit switches are operating correctly.
Check that no cover is liable to be caught during movement.
Check that all the indicator lights, machine stops and key switches are operating correctly.
Check that the light guard (if any) is operating correctly. Refer to the specific Appendix
concerning the light guard.
WARM-UP
In the event of a low ambient temperature, it may be necessary to warm up the hydraulic
circuit. To do the warm up, apply power to the machine, start up the hydraulic unit, and lets
climb up the temperature for 5 to 10 minutes.
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Chapter 3
COMMISSIONING
4. TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
Chapter 4
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Figure 4.1
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Chapter 4
4.1. MECHANICAL STRUCTURE

Comprising: (Fig. 4.1)
1) A welded frame, including:
-
Two uprights (Items 1 and 1)

Two groundplates (Items 2 and 2)
One connecting beam (Item 3)
One lower beam (Item 6)
2) Removable mechanical components:

- One moving upper beam (Item 5)
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4.2. MECHANICAL CONNECTIONS

1) The upper beam is supported by the uprights via the two hydraulic cylinders. Four sets of
track-eccentric roller assemblies ensures the perfect guiding of the upper beam, and at the
same time provide the means for axial adjustment.
A linearity device with a push-pull system located at the rear of the upper beam ensures
that this beam is perfectly linear, resulting in straight bends.
2) There are two hydraulic cylinders. Their purpose is to transmit the required bending force
to the upper beam, and to provide lateral guidance. The NC unit synchronises them via
very high precision linear scales to obtain parallelism and positioning accuracy to within
1/100th mm.
The piston rods press on the upper beam via spherical supports.
This linkage ensures that the piston is perfectly aligned in the cylinder by maintaining the
reaction due to the thrust effects in the axis of the uprights.
3) The lower beam is welded to the machine uprights at each end.
4) A uniquely designed external C frame that remains rigid under all bending conditions
insures that accurate ram positioning is maintained even with the side frame deflection.
The reference of the moving beam is taken completely independently of the side frame to
avoid introducing any error resulting from side frame deflection.
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Chapter 4
4.3. ELECTRONIC STROKE CONTROL AND PARALLELISM BALANCING

SYSTEM
The clever design of the catches which are located exactly in the bending axis of the fixed and
mobile beams allows the reference positions of the mobile beam to be read accurately,
independently of the slightest deformation of the frame. The great rigidity of the strong
external C frames and the securing of the linear glass scales provide a reading to 1/100th of
a millimetre, irrespective of the loads applied to the frame and the beams.
Extremely Accurate Incremental Measurement
The linear scale is made of glass and has a grid (40- steps). It represents the travel of the
upper beam with positioning of 0.01 mm between the punch and the die.
Measurement
scale (Y1-Y2)
Line grid
Reference
mark
Photoelectrics
cells
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To B
B
From Y2
Y1
Reference
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Chapter 4
4.3.1. ELIMINATING SOURCES OF ERROR

Under normal conditions of press brake use, several parameters have a direct effect on the
accuracy of the bending angle.
Oil viscosity (temperature).
Operating pressure (working force).
Position of the parts (if off-centre, this leads to unequal forces on the uprights).
Because it is virtually impossible to have full control over all these factors, risk of error
introduction, which is liable to affect the bending quality. A new technique allows Amada to
eliminate these risks completely.
4.3.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY
This extremely sophisticated electronic regulating technique guarantees perfect balancing of
the parallelism by making it independent of factors liable to alter it.
Two incremental linear sensors Y1 and Y2 are mounted at each end of the upper beam.
The sensors are directly connected to the electronics of the NC controller A of the Machine.
This controls the oil flow to each cylinder via proportional valves B and B.
When the upper beam is lowered, the sensors continuously record the changing positions very
accurately. These signals are immediately sent to the NC controller, which checks the
respective values.
The slightest difference between the data supplied by the sensors automatically triggers oil
level compensation and pressure balancing.
On HFP, adding some pressure sensors will improve the accuracy of the results.
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4.3.3. PRECISE CENTRING OF THE BEAMS

The upper beam is guided by a set of four pairs of generously sized roller guide assemblies (1)
running on hardened ground steel surfaces, securely fastened to the machine uprights.
The maximum spread between the upper and lower roller guide assemblies (E max) ensures
precise alignment and centring of the beams, with perfect rigidity. Reference cylinder D
provides lateral positioning.
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Chapter 4
4.4. LOCATION OF CONTROL AND SIGNALLING DEVICES
EITHER ON NUMERICAL CONTROL OR ON CONTROL PANEL

- SEE CHAPTER 6 OPERATION
Chapter 4
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4.5. PRESS BRAKE OPERATING LIMITS IN OFF-CENTRE WORK

The further a point is from the centre of the machine, the smaller the available resultant force
at that point. This information is taken into account by the NC controller, which calculates the
force required according to the user-programmed part position.
4.6. PRESSURE GAUGE
A pressure gauge is placed on the outer side of the left upright. By comparing the displayed
pressure (in bars) to the maximum pressure given in the machine characteristic table 2.9 in
Chapter 2, you can see if the machine is reaching its operating limits.
Pressure gauge
The NC unit permits to limit the force according to the tool (refer to limit
values in tool catalogues).
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Chapter 4
5. FORMING TECHNIQUE & TOOLING
FORMING TECHNIQUE & TOOLING

Chapter 5
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Figure 5.1
Figure 5.2
Figure 5.3
Figure 5.4
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Chapter 5
5.1. GENERAL POINTS

Bending consists of forming parts from flat sheets. Deformation is linear and simultaneous
over the entire length of the part on a finite machine and tool, and continuous when rollers are
used (infinite length).
Fig. 5.1: Punch and die. Press brake.
Fig. 5.2: Gripper plate and punch. Press. Tangent bending. Hole cut off edge.
Fig. 5.3: Fixed gripper plate, rotating beam. Folding press.
Fig. 5.4: Rotating grippers plates.

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Figure 5.5
Figure 5.6
Figure 5.7
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Chapter 5
Fig. 5.5: Fixed guide and rotating gripper plate. Manufacture of shrouds.
Fig. 5.6: Three rollers. Roll bending machine.
Fig. 5.7: Flat roller. Infinite bending length. Angular variation limited to each pair of rollers.
This list of forming methods is not exhaustive. This chapter only deals with punch-and-die
bending (Fig. 5.1).
There are two basic bending techniques:
-
AIR BENDING
Commonly performed because it requires relatively low bending forces.

-
COINING
Requires forces equal to three to five times those of air bending. Allows the inside radius to
be coined, which practically eliminates the elasticity of the material.

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t = thickness
Distanc
e of penetration
Sheet contact
Die = 8 to 10 t.
Figure 5.8
Figure 5.9
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Chapter 5
5.2. AIR BENDING

During air bending, the sheet metal retains certain amount of elasticity in the plastic region.
An acute angle, higher than the desired angle, is generally performed to compensate for the
opening due to spring back effect. The NC unit is designed to take into account all these
parameters required for air bending. Our standard air bending tools too are designed
accordingly. The bending chart located in the press brakes electrical cabinet indicates the
required force and internal radius which can be obtained in relation with the other
characteristics (thickness, die opening, etc.).
During air bending, the sheet is in contact with the tools at three points (A, B1, B2) as shown
in Figure 5.8. To obtain quality bend using air bending, it is necessary that the die opening is
8 to 10 times the sheet thickness. (For angles 135, it is preferable to use a die opening 10
to 12 times the sheet thickness). In this way, sheet deformation is interrupted before it reaches
the bottom of the die.
NOTE
If there is a specific requirement for bending, e.g. edge dimension, inside radius, etc., use the
technique for air bending at the bottom of the die (partial coining) or coining.
AIR BENDING AT BOTTOM OF DIE OR PARTIAL COINING (Fig. 5.9)

In this case, the sheet penetrates to the bottom of the die and is supported by the sides, with no
increase in the bending force. This type of bending is seldom used because of the inaccuracy
of the results obtained. Coining should be chosen over partial coining whenever possible.

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5.3. COINING
This type of bending is comparable to stamping. The end of the punch penetrates the sheet at
the bottom of the die, rupturing the elasticity of the sheet, which is then bent exactly to the
shape of the punch.
- In practice, for a 90 bend:
- Die width = 5 to 8 times the thickness.
- Die angle = 90.
- Punch angle = 90.
The state of the part is similar to that shown in Figure 5.9 for partial coining, except that the
forces at the end of bending are 3 to 5 times the air bending forces, which causes the coining
of the sheet.
NOTE
The choice of punch radius is very important for coining, because it determines the inside
radius of the bend (stamping of the punch in the sheet).
Coining can only be performed with a punch and die of the same angular value.
Very high bending forces must be applied; these may reach values from 3 to 5 times those
shown on the air bending chart.
CAUTION: Because coining involves very high forces, take great

care to check the strength of your tools. Never exceed the applicable
force limits. These values depend on the type of tool, and should
normally be shown in tool catalogues ( 5.5).
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Chapter 5
5.4. LIST OF STANDARD TOOLS

(Refer to Amadas Press Brake Tooling catalogue)
Qualitative characteristics common to the whole range:
Easy to store.
Easy for one person to handle.
Hardened working surfaces.
Standardised mounting systems.
Special profiles suited to different sheet
thicknesses.
Wide range of profiles suited to all
applications.
Special
custom-designed
profiles
for
sufficiently large production runs.
Groove in the heel preventing the tool from
dropping when tool clamp plates are
unfastened.
Our tools comes in two standard lengths: 835 mm and 415 mm.
Certain tools are sectionalised in pre-determined dimensions. For details regarding these
tools, please refer to Amadas Press Brake Tooling catalogue.
These sectionalised tools allow four-sided bending for items such as boxes, drawers, shelves,
etc.

Chapter 5
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CAUTION: For any issues involving tools or bending materials other

than sheet metals (list of range, profile, linear strength, etc.), please
contact AMADA. A tooling specialist will analyse your specific
problem. A simple telephone call will make your job easier and help
you to work in complete safety.
The Amadas Press Brake Tooling catalogue gives you the complete list of available
punches and dies.
During commissioning, our technician will enter a list of all your tools in your NC unit, and
will show you how to input new tools yourself. You will then have the complete list of your
punches and dies stored in the NC memory.
You must then identify them very carefully when using them to allow the NC unit to calculate
the penetration from exact values. If for any reason, the numbers were illegible on the tool,
you could identify it by measuring the following parameters:
- Height (mm and hundredths)
- Tip radius
- Angle
and then identify it in the NC unit from these three values by scrolling through the list.
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Chapter 5
Only trained and qualified operators are entitled to work on pressbrakes.
5.5. TOOL INSTALLATION

5.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM
Amadas standard fast punch clamping system allows an easy and fast mounting of the
punches. The use and possibilities are described here after:
Lateral mounting of the punch (short punch lengths)
Punch is clamped

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Punch is released
Lateral extraction of the punch
The procedure remains the same for longer punch lengths:
Lateral mounting of the punch (longer punch lengths)
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Chapter 5
Punch is clamped
Punch is released

Chapter 5
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Standard clamping system for joined mounting (option).

The standard clamping system exist in a special model, for joined mounting of distance
pieces. With the joined mounting, the installation of a short tool is possible at any position of
a line of joined clamps.
To join clamps, from an initial position with space between them :
- Untighten by about one turn the two M10 screws of each upper clamp plate, that fix the
clamp unit to the upper beam.. The clamp unit is then maintained in place by heel of the
clamp plate, that goes into the groove of the clamp unit.
- Slide laterally one or more untightend clamp units until contact between them.
- Push the clamp unit upwards, while tightning the two M10 screws of each clamp plate.
To move the clamp units aprat, from a joined position, follow the procedure above in the
opposite order.
NOTE : Do never separate the clamp units by more than 50 mm between them. In case of too
high distance, the clamp unit might be overcharged.
CAUTION : Overcharge of a clamp unit line might destroy and/or

deform the clamp unit, the upper table and/or the bending tool.
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Chapter 5
5.5.2. AMACLIP PUNCH CLAMPING SYSTEM (OPTION)

To increase safety and flexibility, on top of extra-ordinary qualities of the standard fast punch
clamping system, Amada put together a fast clamping system-permitting front loading and
unloading of the punches. This solution reduces considerably the tool change time when it
comes to frequent punch changes, at the same time remaining totally compatible with
standard Amada range of tooling available in Amadas Press Brake Tooling catalogue. All
existing possibilities of the standard fast punch clamping system is conserved, e.g. stacking of
the distance pieces for bending deep boxes, etc.
The use of AMACLIP punch clamping system under different condition is explained here
after:
-
Short length of punches (less than 200 mm)
Front-loading of the punch
It is to be noted that it is still possible to load punch laterally (in this configuration,
AMACLIP doesnt offer any advantage over standard fast punch clamping system).

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Punch is clamped (this operation is identical to the one used for standard fast clamping
system).
Punch is released (this operation is identical to the one used for standard fast clamping
system).
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Chapter 5
Front unloading of the punch by pressing the punch releasing lever to allow punch to come
off from the bottom.

Chapter 5
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Punches having lengths equal or higher than 200 mm
Front-loading of the punch
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Chapter 5
Punch is clamped (this operation is identical to the one used for standard fast clamping
system).
Punch is released (this operation is identical to the one used for standard fast clamping
system).
Lateral extraction of the punch (this operation is identical to the one used for standard fast
clamping system).
NOTA
It is mandatory to extract laterally the punch when a single length of punch is clamped by
two distance pieces (even though eventually it may be possible to extract the punch from
the bottom by pressing simultaneously the two central releasing levers). Because there is a
risk that the punch may slip and drop during this manipulation and may cause injuries to the
operator.
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5.5.3. EXPERT CLAMPING SYSTEM MANUAL VERSION (OPTION)

In order to increase both safety and flexibility in addition to well-founded functions proper to
the standard fast punch clamping system, Amada has implemented a fast clamping distance
piece-based system allowing what fallows :
Tools
Front loading
Lateral loading
Front unloading
Lateral unloading
< ou = 200mm
415mm
835mm
valid
valid
valid
valid
valid
valid
not valid
valid
not valid
valid
not valid
valid
This is a remarkable time-saving solution when it comes to frequent tool loading/unloading

operations, while remaining in full agreement with Amada standard range of tooling available
in Amadas Press Brake Tooling catalogue. The two models of standard tool fixation
compatibles with Expert are :
Standard punch
Inclined punch
The so-called plating function is also ensured by this device, only with Amada standard
range of tools.
All already existing functions associated to the standard fast punch clamping system are
maintained, for instance the slave distance piece usually used on RG-type press brakes due to
be clamped beneath the expert clamping system.
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Chapter 5
Depending upon the below-described operating modes, use the EXPERT punch clamping
system as follows :
Lateral loading of the punch

Every punches can be laterally inserted
The lateral insertion should be carried out as described below.
NOTE
A 835-mm long tool should be totally supported by 3 distance pieces minimum before the
operator can release it .
Important : remember that the tool should be firmly held in your hands throughout the
entire process.
Front loading of the punch

The front insertion should be carried out as follows (415-mm long punch given as an
example).
For safety reasons, the front loading of 835-mm long punches is not valid.
In order to make the front insertion of the punch easier, the operator should tilt it (see above).
First start with operation then . Also valid for short punches.

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Clamping
With the palm of your hand, move the lever upwards.
Releasing
Move the lever downwards
Anti-fall process push-button
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Chapter 5
Lateral removal of the punch :

Check that the distance pieces are unclamped, slightly slide the punch towards the outer
machine. The anti-fall devices can therefore ensure a safe mouvement .
Important : remember that the tool should be firmly held in your hands throughout the entire
process.
Front removal of the punch
Front removal of the punch: (see table 0.01). 200-long punch given as an example.
Distance piece unclamped,
- hold the tool in your hands.
- Use your thumb as a means of pressure onto the anti-fall push button ; the tool should
be extracted.
- Tilt the punch downwards from one side, then extract it out.
Important : remember that the tool should be firmly held in your hands throughout the entire
process.

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5.5.4. EXPERT PNEUMATIC CLAMPING SYSTEM AUTOMATIC VERSION

(OPTION)
The Expert automatic clamping system allows for an instant clamping and unclamping of an
entire line of bending tools.
The insertion and removal principles are similar to the manual version
The clamping/unclamping operation is ensured by a 2-position Clamping & Unclamping
switch located on a magnetic panel likely to be positionned for instance on the lower beam
cover.
The clamping process is operated through pneumatic actuators located on the rear side of the
upper beam. Several clamping modules have also been provided as equipement.
A clamping module is basically composed of both a control bar and one, or more generally,
two actuators.
A magnetic sensor has been integrated on each module in order to allow for the clamping
position of the system. When the distance pieces are positionned in an unclamping
position, any movement of the beam is prohibited by a safety device.
The design of the control bar allows for a lateral sliding of the clamp units, to put them in a
joined position.
Factory mount installation.

Expert Automatic version can be delivered from factory, equipped onto a new pressbrake. In
this case, only a 5-7 bar pneumatic air supply must be provided.. Use a male threaded
pneumatic connector (not supplied), to be fitted to the Filter-Regulator unit on the rear of the
press brake.
After sales mounting.
It is possible to equip an Amada pressbrake already in operation, by the Expert Automatic
version. This only concerns pressbrakes produced since september 2003 ; also pressbrakes
with the Long Stroke option (350 mm) are excluded..
On each pressbrake, even delivered without the Expert Automatic option, machined surfaces
and holes are made. Threads are not made, and can be done with a M8 thread tap delivered
with the Expert Automatic option kit for after sales mounting.
Then install the clamping modules and make pneumatic and electric installations, necessary
for the options function.
It is recommended to contact your local AMADA Services Department to make any after
sales installation.
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Chapter 5
Switching the distance pieces from manual to automatic version.

For press-brakes equipped with the EXPERT manual version, it is now possible to replace it
by the automatic version.
In this case, manual levers should be replaced by controlled ones.
As a matter of consequence, a mechanical modification consisting in changing the position
of two pins used as stoppers - should be applied onto distance pieces. Please remember that
on the manual version, pins are positionned downwards and upwards in the automative one.
On every machine, even when supplied without the controlled clamping system option ,
machinings and piercings have been operated. Tappings are not provided and may be done
through an optional M8 tap (second installation).
Clamping modules should then be installed as well as pneumatic and electrical connections,
necessary for the option to be operative.
Please contact AMADA Services Department for each second installation.
NOTE
In order to enable detecting possible interferences with the EXPERT clamping system
whenever bending, the NC should be familiar with the machine profile suitable for this
option. In that respect, in second installation, a floppy disk is supplied with options for the
updating of the machine profile in the press-brake NC. Please contact AMADA
Services Department.

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EXPERT in standard manual and automatic versions has been designed for joined mounting.
NOTE : Do never separate the clamp units by more than 50 mm between them. In case of too
high distance, the clamp unit might be overcharged.
CAUTION : Overcharge of a clamp unit line might destroy and/or

deform the clamp unit, the upper table and/or the bending tool.
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Chapter 5
2 V DIE
1 V DIE
DIE HOLDER
FRONT FACE
REAR FACE
SPACER
CLAMP PLATES
LOWER BEAM
Figure 5.10
Figure 5.11

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CAUTION: Tool installation and removal procedures must be

performed by trained personnel qualified for the job. Such procedures
must be performed in manual setting/adjustment cycle, which enables
beam movement at low speed, and taking into consideration the
maximum load and minimum tool length restrictions.
5.5.5. PROCEDURE TO BE OBSERVED FOR TOOL INSTALLATION
Tool Installation (Fig. 5.10 and 5.11)
1) Place the lower part of the tooling in position, according to case:
-
Spacer,
Single V die with die holder
Two V die plate with die holder, which is slid onto the table of the lower beam.
2) Immobilise using the front clamp plates as shown in the diagram (Fig. 5.10).
The rear clamp plates must never be loosened because they provide the reference surface
for tool alignment.
Note: In the event that a 2 V dies require an alignment, make sure that the locking screws
(Hm8) on the die holders are loosened (13-mm flat spanner).
3) Select a program on the NC unit.
4) Go into sheet contact point TEACH mode (see Appendix A: Operators Programming
Manual). The use of this mode guarantees machine operation at minimum pressure.
5) Define the stacking value Y consisting of: lower tools + punch length + 3 mm (Fig. 5.11).
6) Issue an upper beam lowering order using the Closing footswitch and a clockwise rotation
of the remote control hand wheel or push buttons (depending on the NC equipping the
machine) together until the S.P.P. (Sheet Pinch Point) value corresponding to Y is
obtained.
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7) Release the Closing footswitch.

8) Press the machine stop push button.
9) Introduce punch tip in the V groove of the die then slide the lengths of the punches on the
dies, and clamp them.
10) Reset the machine stop.
11) Press the green START button on the NC unit.
12) Press the Closing footswitch.
13) Turn the hand wheel on the remote control clockwise until change in the displayed value
of the sheet pinch point ends.
Or*
Use push buttons on the NC which command the closing of the upper beam until change
in the displayed value of the sheet pinch point ends.
14) If using dies that require centring on the punch (e.g. 2V dies), tighten the screws (Hm8)
using the 13-mm flat spanner whilst holding down the Closing footswitch.
15) Press the Opening footswitch to raise the upper beam.
The machine is now operational.
Special Case
1) Sectionalised tools
When sectionalised tools are used, whether dies or punches, there is
always a risk that the tool settling force may exceed the tool strength.
Each tool type has its own strength, which is given in sales catalogues
as well as marked on the side of each tool.
Sectionalised 4 mm gooseneck punch:
- Maximum load withstood by this tool: 11 T/M i.e. 110 kN
- Total length of sectionalised tool: 800 mm
In this case, the maximum force that this tool can withstand is:
- Max. load withstood by tool (kN) x total tool length/1000
110 x 800/1000 = 88 kN. If you exceed this value it will create
DANGER.

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Minimum force values for each type of machine:

HF 50-12 :
HF 50-20 :
HF 80-25 :
HF 100-3 :
50 kN
50 kN
70 kN
90 kN
The following formula is used to calculate the minimum length required to withstand the
minimum force applied by the machine:
Minimum force of machine (kN) x 1000 / Maximum load withstood by tool (kN).
Example:
- Machine: HF 80.25 (80 T, 2.5 m)
- Minimum force applied by this machine: 70 kN
- Minimum tool length: 70 x 1000 /110 = 636.36 rounded up to 640 mm (due to tool
sections)
But for an HF 100.3, a 800 mm sectionalised tool cannot be used to set the tools as the
minimum tool length required is greater than 800 mm.
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The lateral guarding (size & position) on your press brake is designed
to take in to account the maximum authorised tool length. This value
is given in Para. 2.9, Chap. 2 (Bending Length), and reminded at the
bottom of the Table under Number of Tools.
Do not exceed these limits.
Chapter 5
Note
It is technically in-correct to centre a long length of dies using a short length of punch.
a) When bending with one or more short lengths of punches (< 835 mm) in combination with
a long die, abide the following procedure:
Follow steps 1 to 11 of the procedure where punch length is identical to the die length.
Loosen and remove the punch(es).
Press the Opening pedal to raise the upper beam to top dead centre.
IMPORTANT NOTE
As the rest of the procedure requires the setter to place his hands in
between the tools, it is essential to ensure his safety by turning OFF
the hydraulic unit using SA1 (hydraulic unit ON / OFF selector
switch) and removing the key from the selector switch.
Position the sectionalised punch(es) by laying them under the distance piece bearing
surfaces.
b) When bending with a punch longer in length than one or more short die lengths, proceed as
follows:
Apply the procedure described in a), using a full die length to centre the die & holder,
and then remove this die length and replace with the required sectionalised bits.

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TOOL REMOVAL PROCEDURE

-
Bring the tip of the punch to about 3 mm from the bottom of the die (refer to installation
procedure, Steps 1 to 7).
Loosen the punches, and slide them out via one end of the beams.
When all the punches have been removed, press the Opening footswitch to raise the upper
beam.
Remove the dies by loosening the mounting screws from the front clamp plates. The rear
mounting brackets should not be removed because they are used as a reference for tool
alignment, if this can be avoided.
TOOL STORAGE
-
To protect the working edges of your tools, we recommend that you store them in a
specially-designed locker (Part No. F 93010) near your press brake, or lay them on
wooden slats or other soft materials.
Apply a film of oil to protect them against corrosion.
TO INSTALL AND REMOVE TOOLS IN COMPLETE SAFETY, THE

OPERATOR
MUST
APPLY
THE
ABOVE
SAFETY
RECOMMENDATIONS, AND MUST BE EQUIPPED WITH
PROTECTIVE GLOVES AND APPROVED SAFETY SHOES.
Notified Bodies have harmonised (for both men & women) the weight limit at 25 kg.
Beyond this limit, personnel liable to perform such handling operations must receive
appropriate training, and the items to be handled must be equipped with a handling device
(special machining, tapped holes, etc.).
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Chapter 5
5.5.6. CHANGING TOOLS (WITH AMNC NUMERICAL CONTROL)
The tonnage
applied to tools
will be displayed
Unless a proper pressure is applied to the

tools, the tools may break in a dangerous
manner.
Pay full attention to the allowable tonnage of
the tools. (Refer to the pressure table
attached hereto).
It is dangerous if you have your hands
caught between the punch and die.
Do not put your hand or hands between the
punch and die when you lower the upper
beam. (Refer to Safety Rules).
Installing tools (When the tools are not installed)

Install the tools as described below.
1. Calculate the P value from the tool installation length and tool allowable tonnage by the
following equation:
P=LxT
where,
L = tool installation length (m)
T = allowable tonnage marked on tool
(tons/m)
2. Select SETUP mode and press the ON/OFF
button on the teaching handwheel, Y1 and Y2
will be displayed red (see opposite).

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3. With the DOWN foot pedal pressed and held, slowly turn the handwheel clockwise to
lower the upper beam. When the punch is apart from the die, touch the X5 button to turn
on its light and to bring the punch close to the die at a high speed (5). Slowdown when
the punch gets close to the die and before the punch engages the die, release the
footswitch and press the X5 button again to turn off the light and to bring the punch into
the die at a low speed (1) whenever turning the handwheel clockwise.
Stop the handwheel rotation when the
opposite position is reached (3 to 5 mm).
4. Release the CLOSING foot pedal.

5. Press the emergency stop button.
6. Install the dies and the die holders on the upper beam and tighten their clamping bolts.
7. Install the punches as described below.
1) Insert the fall prevention tongue of the punch into the groove of the punch holder as
shown below and slide the punch into position.
2) Tighten the punch holder levers to prevent the punches from falling.
NOTE
The punches and dies should be staggered as shown above to prevent the worksheet
from being scratched.
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Chapter 5
8. Release the emergency stop button and reset the machine. Press the ON/OFF button on
the teaching handwheel.
9. Press the DOWN foot pedal. Use the teaching handwheel to move the beam down into the
tools (if X5 light is on, press it to turn it off). Check on the NC tonnage display that the
pre-set values are not exceeded.
10. Calculate the P value from the tool installation length and tool allowable tonnage by the
following equation:
P=LxT
where,
L = tool installation length (m)
T = allowable tonnage marked on tool (tons/m)
NOTA
In this operating mode, the tonnage limitation operated by the NC is equivalent to the
load deduction on the relief valve. Although it is inferior to the controlled machine
minimum tonnage, it should be taken into consideration (see table per machine type).
This load deduction directly linked to the hydraulic component is about 7 bars on HFP
Low Tonnage and 15 bars on HFP Medium Tonnage.
The table below will specify the maximum tonnage applicable to the tool if the stroke
required through the handwheel is greater than the tool bottom position.
LT
MT
Machine type
50 T
80 T
100 T
130 T
170 T
220 T
Tonnage applied on
tools
1,2 T
1,8 T
2T
7,5 T
10 T
13 T
NOTE
When the result obtained from the above equation is inferior to the minimum machine
tonnage (see machine chart) - it is highly recommended not to use X5 key - press the
DOWN (closing) foot pedal, turn the handwheel with great care so that an excessive
tonnage is not applied to the tools, while checking P tonnage value as displayed on the
screen.
NOTE
Dies and punches are available in various V angles, punch tip radiuses, V bottom
radiuses and other types. The tools may be misaligned when their angle is not the same
or when the punch tip radius is smaller than the V bottom radius. In such a case, place a
thin material or newspaper between the punch and die and engage them.
12. Raise the upper beam.

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Installing 2V-dies
Install the 2V-dies as described below.
1. Install the die holders at the top of the upper beam and fix them with the clamps of the
upper beam. Since the dies and die holders differ in length as shown in the table below,
separate the die holders by about 5 mm as shown in the figure below.
L-type length
S-type length
Die holder
830 mm
410 mm
Die
835 mm
415 mm
NOTICE
Set the die holders for the 2V-dies so that their step and the V-groove of the die to be
used face the rear as shown in the figure above. This orientation is termed front.
This is to prevent the die from flying toward the operator when it breaks.
2. Loosen the die clamping bolts, slide the die from the operators side (the front of the
machine) onto the die holder top with the V-groove to be used facing the rear and
approximately center the die.
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Chapter 5
Installing 1V-dies
Install the 1V-dies as described below.
1. Loosen the die clamping bolts, slide the die from the operators side (the front of the
machine) onto the die holder top and approximately center the die.
If the 1V-dies with a V width of 32 mm or more are installed on the upper beam, they may
produce a large clearance between themselves due to the relationship between the open
height and stroke. In such a case, use die blocks to reduce the clearance. Install the die
blocks by paying attention to their orientation.
NOTICE
The rear clamps of the upper beam and die blocks establish the reference surface for
centering the tools. Never loosen them.

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Dismantling the tools

Remove the tools as described below.
When tool origin is not set
1. Select ON/OFF teach button on the remote handwheel control.
2. Press (hold) down CLOSING footpedal, turn the remote handwheel and lower the upper
beam until the distance between the punch tip and the bottom of the V-groove becomes 2
to 3 mm.
3. Release CLOSING footpedal and press an emergency stop button.
4. Loosen the punch holder clamps and slide the punch sideways to remove it.
5. Remove the die.
6. Release the emergency stop button. Reset the machine. Turn the teach button to OFF
position.
7. Press the OPENING footpedal to raise the upper beam.
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Chapter 5
5.6. SPECIAL ACCESSORIES AND OPTIONS

See Appendix E.
5.7. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES

A) Purpose
To allow fine adjustment of the tools to obtain minimum angular variation over the bending
length under given conditions.
B) Purpose of Adjustment
The purpose of the adjustment is to compensate for differences in penetration between the
punch and die. It is represented by the distance piece curve.
The various adjustment curves for a given machine have a similar overall appearance.
The amplitude of the values varies according to:
Type of material & its mechanical properties (tensile strength).
Length and thickness of sheet to be bent (the adjustable distance piece design enable you to
use all the tools in the Amada range).
Note
The distance piece curve on Amada machines is factory-adjusted according to average values,
and checked by the Amada technician during commissioning on the customer site.

Chapter 5
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Figure 5.12
Figure 5.13
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Chapter 5
C) Adjustment
Preparation: On all distance pieces constituting the tool line.
Release the adjustment wedge by loosening the screw (Item 6) (6-mm hex socket wrench).
Slide the wedge, Item 9, to the bottom of the slot towards the right.
Slightly tighten the screw, Item 6, and then firmly tighten the tool spacer using the two
screws, Item 8 (8-mm hex socket wrench) (see Fig. 5.12).
Settling the Distance Pieces
Either use two identical lengths of punch and die, or use two special devices which are to be
manufactured according to Figure 5.13. These devices are moved simultaneously and
symmetrically for the settling of each pair of distance pieces working from outwards in.
-
Set press brake force to 20 tonnes (200 kN).
Settle the two end distance pieces (simultaneously) first and then the next two, and so on.
At the end, if you are left with only one in the centre of the press brake, it should be
settled using a force of 10 tons (100 kN).

Chapter 5
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Figure 5.14
The distance pieces are set to zero at the factory for the entire range (HF 50-12, 50-20, 80-25
and 100-3) when machines are shipped.
Position of standard distance pieces.
HF 50-12
0
HF 50-20
0
HF 80-25
HF 100-3
0
Position of abutting distance pieces.

HF 50-12
0
HF 50-20
0
HF 80-25
0
HF 100-3
0
Figure 5.15
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Chapter 5
Adjusting the dimension E using sliding dial indicator:

Select the lowest distance piece, i.e. the one with the smallest distance E (Fig. 5.14).
Immobilise its wedge using the 6-mm screw (Fig. 5.12).
Place the sliding dial indicator on the lower beam, at the centre of the distance piece, and set
the pointer to zero.
Adjust the remaining distance pieces:

-
Adjust each distance piece in accordance with the values indicated in the distance piece
curve (Fig. 5.15) which are average values for your machine.
Or by customising the adjustments according to the operating conditions and the results to
be obtained.

Chapter 5
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5.8. PUNCHING
Your machine cannot be used for punching, notching, etc.
BENDING CHART
This chart was drawn up for mild steel with a shearing strength of 40 to 45 daN/mm. Using
the chart, you can normally find the following information if the sheet thickness e and inside
bending radius ri are known:
Force (kN) per metre of bent length f
Size of the smallest possible edge b
Opening of the die to be used, V
Recommended die openings are shown in shaded boxes.
This opening, V, is related to the thickness e of the sheet to be bent. The recommended values
are as follows:
For e 10 mm
V= 8e
Pour e 12 mm
V = 10 e
If the recommended opening cannot be used (small edge cannot be created, tool not available,
insufficient force, etc.), use a die with an opening that is close to the recommended value,
shown in the light boxes of the chart. This chart remains valid for bending other materials
(e.g. stainless steel or aluminium); in which case you will be required to apply a correction
factor to the given values in accordance with the ratio of their mechanical strengths.
Example: If the chart, based on 40 daN/ mm mild steel gives a force of 500 kN for a given
bend then, to perform the same bend in an aluminium sheet, having a tensile strength of 20
daN/mm will be 250 kN.
BENDING CHART LEGEND PLATE
orange
V width
grey
Internal Radius
green
Minimum Flange Length

red
Bending Force kN/M

blue
Sheet Thickness
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Chapter 5

Chapter 5
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Chapter 5
6. OPERATION
OPERATION
Chapter 6
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Only trained and qualified operators are entitled to work on pressbrakes.
6.1. START-UP
1. Turn the handle of the main circuit breaker to Position 1.
2. Turn the motor start-up key switch
to the right unstable position. The motor starts
running.
3. Press the luminous reset push button
. (see NOTE)
4. The green indicator light lights up.

5. At a low ambient temperature, the oil becomes less fluid and the amber filter clogging
alarm light may light up.
The alarm light goes off as soon as the oil temperature rises. If the alarm light remains lit,
the filter is clogged.
The NC unit lights up and is ready to be initialised
NOTE
Machine is equipped with LazerSafe light beam, see appendix E1.4 et E1.5.
Machine is equipped with Akas light beam, see appendix E1.6.
NOTE
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Chapter 6
OPERATION
6.2. DESCRIPTION OF CYCLES (OUT OF US MARKET)

NOTE
The machine cycle depends on:
The programming mode selection on the NC unit.
The mute point.
Presence or absence of a light guard or laser safety system.
The Opening footswitch always overrides any other controls.
Above
Sheet pinch point
Below the sheet pinch point, the Opening footswitch must be kept depressed for slow
opening.
Above the sheet pinch point, the Opening footswitch may be released.
In this case, the press brake opens until it reaches the programmed opening dead centre.
A second press of the footswitch takes it from the programmed opening dead centre to the
mechanical opening dead centre.
OPERATION
Chapter 6
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6.2.1.LAYOUT OF CONTROLS PANELS
OPERATEUR 2000 NC with or without Light Guard option
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Chapter 6
OPERATION
OPERATEUR 2000 NC with LAZERSAFE option
OPERATION
Chapter 6
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OPERATEUR 2000 NC with Akas option
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Chapter 6
OPERATION
CD 2000 control panel with or without Light Guard option
OPERATION
Chapter 6
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CD 2000 control panel with LAZERSAFE option
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Chapter 6
OPERATION
CD 2000 control panel with AKAS option
OPERATION
Chapter 6
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AMNC control panel with or without Light Guard option
AMNC control panel with LAZERSAFE option
AMNC control panel with AKAS option
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Chapter 6
OPERATION
6.2.2. DESCRIPTION OF CONTROL AND SIGNALLING DEVICES
EITHER ON NUMERICAL CONTROL OR ON CONTROL PANEL
: Two-position + one unstable position Hydraulic Unit On/Off selector switch

- 0, Hydraulic unit off
- 1, Hydraulic unit on
, Hydraulic unit start-up (unstable position)
: Machine is equipped with Sick Light Guard (see Appendix E1.3):
Seven-position CYCLE selector key switch:

- Manual mode for tool setting or adjustment.
- Selectors OFF position, machine out of operation.
- Footswitch controls full machine cycle (when machine is not equipped with
light guard-the approach speed remains inferior to 10 m/s but with light guard
it moves at high speed)
- Single passing through mode: single breakage of the light beam triggers the
beam approach phase and ensure total operator protection, beam stops at mute,
then operator finishes the cycle using footswitch.
- Double passing through mode: double breakage of the light beam triggers the
beam approach phase and ensure total operator protection, beam stops at mute,
then operator finishes the cycle using footswitch.
- Single passing through mode: single breakage of the light beam triggers the
cycle where light guard is active throughout the cycle, with or without a mute
stop.
- Double passing through mode: double breakage of the light beam triggers the
cycle where light guard is active throughout the cycle, with or without a mute
stop.
: Machine is equipped with laser safety system (see Appendix E1.4 or

E1.5 for LazerSafe and E1.6 for Akas):
Three-position mode selector key switch:
- Manual mode for tool setting or adjustment.
- Selectors OFF position, Machine out of operation.
- Machines normal operating mode with LazerSafe or Akas beam protection.
OPERATION
Chapter 6
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: LazerSafe test / confirm push-button with blue indicator light (see Appendix
E1.4 & E1.5).
: Machines reset push-button with green indicator light.
: Write protection key switch (On Oprateur 2000).

- 0, keyboard disabled
- 1, keyboard enabled
: Machine stop
: Second Operator Option:

With two-position key selector switch:
- Single-operator cycle control
- Two-operator cycle control
: Light guard or Two hand push-button control key switch selector

(Only on HFE / HFT machines exported to countries outside European Union)
: SPARE
NOTE
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Chapter 6
OPERATION
6.2.3. BASIC VERSION MACHINE (WITHOUT LIGHT GUARD)

CYCLE 1 : SO-CALLED ADJUSTMENT CYCLE
WITH MOBILE BEAM STOPPING AT MUTE POINT
Control: Closing footswitch.
Program auxiliary function F5 to 1 to stop the beam at the mute position.
Switch SA4 on position

BREAKDOWN OF CYCLE :
Over entire stroke: working speed 10 mm/s.
Outside the mute position, pressing the Closing footswitch closes the press brake as far as
the mute point.
Stop at mute point.
Release the Closing footswitch.
Press the Closing footswitch again to continue the cycle.
CYCLE 1 : ADJUSTMENT CYCLE
MOBILE BEAM NOT STOPPING AT MUTE POINT
BREAKDOWN OF CYCLE :
No stop at mute point.
OPERATION
Chapter 6
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CYCLE 2 WITH MOBILE BEAM STOPPING AT MUTE POINT

Control unit: Closing footswitch.

BREAKDOWN OF CYCLE:
Above mute position, pressing the Closing footswitch closes the press brake at slow speed
until the mute point is reached (< 10 mm/s).
Stop at mute point.
Press the Closing footswitch to continue the cycle at working speed.
CYCLE 2 MOBILE BEAM NOT STOPPING AT MUTE POINT

BREAKDOWN OF CYCLE:
Above the mute point, lowering at slow speed (< 10 mm/s).
Working stroke continues below the mute point in working speed.
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Chapter 6
OPERATION
THESE CYCLES ARE INOPERATIVE WITHOUT SICK LIGHT

GUARD OPTION
See appendix E1.3 Light Guard.
OPERATION
Chapter 6
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6.2.4. MACHINE EQUIPPED WITH SICK LIGHT GUARD OPTION

THIS CYCLE IS IDENTICAL TO THE ONE DESCRIBED IN
BASIC VERSION OF MACHINE
(See 6.2.3, CYCLE 1).
See appendix E1.3 Light Guard.
6.2.5. MACHINE EQUIPPED WITH LASER BEAM OPTION

THIS CYCLE IS IDENTICAL TO THE ONE DESCRIBED IN
BASIC VERSION OF MACHINE
(See 6.2.3, CYCLE 1).
See appendix E1.4 & E1.5 LazerSafe or E1.6 Akas.
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Chapter 6
OPERATION
Bending with 2 operators

NOTE : Unless a second control equipment similar to that used for the main operator is added
to our machines, they cannot be run by more than one operator.
An optional second operator control station may be supplied for the second operator.
Nevertheless, due to the occasional use of such a configuration, following should be observed
for safe use of this option :
Select 2 operators mode using
The operator or fitter should remove the key and keep it by himself so as to prevent
anyone else changing the keyswitch position while operators are bending parts.
Test correct operation of the option before bending operation using following procedure :
Select the adjustment cycle (Safety speed).

Press opening footswitch at operator 1 control stations, the beam opens.
Press opening footswitch at operator 2 control stand, the beam opens.
Press closing footswitch at operator 1 control stations, no beam movement should occur.
Press closing footswitch at operator 2 control stations, no beam movement should occur.
Press both closing footswitches, the beam should close.
key selector.
NOTE
For the machines equipped with the safety programmable logic controller, the footswitches
should be operated within 4 seconds. Should it take longer, both operators should have to
release the footswitch before a new cycle can be initiated.
Bending with one operator and 2 control stations (multi staging or multiple bending)
Machines equipped with Safety PLC unit allows a single operator to use two independent
control stations.
Select one operator mode using
Program auxiliary function F (see Appendix A) corresponding to the workstation you

intend to use in each bend.
key selector switch.
For instance it is possible to program footswitch 1 in bends 1, 2, 4 and 5 and then footswitch 2
in bends 3, 6 and 7.
If wrong footswitch is pressed, no motion will occur ; an alarm will be generated and
displayed on the CNC screen.
OPERATION
Chapter 6
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Bending at the extremity of the beam

In some cases for bending specific parts, working on one side of the machine may be
necessary (box, cone, etc.). Since bending at the end of the beam is rather rare, operating
safely implies the following actions :
Select the adjustment mode with
key selector switch, in this case, beam
will only move in safety speed ( 10 mm/s for
out of US market machines and 20 mm/s for
US market machines).
Out of US market
machines
US market machines
Press green
reset push button, the light will come on confirming the new mode of
operation.
Open only the required side gate. Opening both of them will generate a machine stop,
because operators visibility is poor for the far end.
NOTE
Only trained and qualified operators should be entitled to work in this way, taking into full
consideration the backgauge movements while bending such parts.
When the machine is equipped with the optional second operator control panel (footswitch
control), it is possible to operate the machine with both side gates open only if machine is
operated by two operators.
In that case, turn the 2nd operator work switch to
two operator position.
Recommendations specified in section Bending with 2 operators are totally applicable
and should be observed in this case.
NOTE
In this specific case, both foot switches should be pressed within a maximum of 2 seconds.
Otherwise, both operators should release the footswitches and re-initiate a new cycle.
NOTE
If the machine is equipped with a laser beam protection, for the bending at the extremityof
the beam, see also the appendix E1.4 and E1.5 LazerSafe and appendix E1.6 Akas.
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Chapter 6
OPERATION
6.3. MOBILE EMERGENCY STOP

This machine is equipped with a supplementary emergency stop.
It has a magnetic rear-plate who allows to fixed it near the operator, at any bending position.
6.4. START-UP
6. Turn the handle of the main circuit breaker to Position 1.
7. Turn the motor start-up key switch
to the right unstable position. The motor
starts running.
8. Press the green luminous reset push button
9. The green indicator light lights up.

10. At a low ambient temperature, the oil becomes less fluid and the amber filter clogging
alarm light may light up.
The alarm light goes off as soon as the oil temperature rises. If the alarm light remains lit,
the filter is clogged.
The NC unit lights up and is ready to be initialised.
NOTE
OPERATION
Chapter 6
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6.5. DESCRIPTION OF CYCLES

NOTE
The machine cycle depends on:
The programming mode selection on the NC unit.
The mute point.
Presence or absence of a light guard (see Appendix E1).
The Opening footswitch always overrides any other controls.
Above
Sheet pinch point
Below the sheet pinch point, the Opening footswitch must be kept depressed for slow
opening.
Above the sheet pinch point, the Opening footswitch may be released.
In this case, the press brake opens until it reaches the programmed opening dead centre.
A second press of the footswitch takes it from the programmed opening dead centre to the
mechanical opening dead centre.
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Chapter 6
OPERATION
6.5.1. LAYOUT OF CONTROLS PANELS

OPERATEUR 2000 NC
for standard machine and machine with option Light Guard protection
OPERATION
Chapter 6
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CD 2000 control panel

for standard machine and machine with option Light Guard option.
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Chapter 6
OPERATION
6.5.2. BASIC VERSION MACHINE (WITHOUT LIGHT GUARD)

Cycle 1 : so called adjustment cycle with mobile beam stopping at mute point
Switch SA4 on position :
Breakdown of cycle :
Outside the mute position, pressing the Closing footswitch closes the press brake as far as
the mute point.
Stop at mute point.
Press the Closing footswitch again to continue the cycle.
Cycle 1 : adjustment cycle
Mobile beam not stopping at mute point
Control: Closing footswitch .
OPERATION
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BASIC VERSION MACHINE (WITHOUT LIGHT GUARD)

No movement.
6.5.3. MACHINE VERSION WITH LIGHT GUARD
Cycle 2 with mobile beam stopping at mute point
Control unit: Closing footswitch.
Above mute position, pressing the Closing footswitch closes the press brake at high speed
until the mute point is reached (200 mm/s) if light curtain is free.
During high speed closing if light guard is covered , the press brake stops
If light guard stays covered , no movement.
If light guard is free , press the Closing footswitch to continue the cycle at high speed.
Stop at mute point.
Press the Closing footswitch to continue the cycle at working speed.
Cycle 2 mobile beam stopping at mute point
Above the mute point, lowering at high speed
During high closing (high speed) if light guard is covered , the press brake stops
If light guard stays covered , no movement
If light guard is free , press the Closing footswitch to continue the cycle at high speed.
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Chapter 6
OPERATION
6.5.4. MACHINE VERSION WITH TWO HAND CONTROL OPTION ONLY

Cycle 3
Control unit: Two hand control above the mute point.
Closing footswitch Working stroke continues below the mute point in working
speed.
Press two hand control
During high speed closing if two hand control is released , the press brake stop
Stop at mute point.
Release two hand control
Press the Closing footswitch.
VERSION MACHINE (WITH TWO HAND CONTROL OPTION ONLY)

Cycle 4 with mobile beam stopping at mute point
Control unit: TWO hand control
Stop at mute point.
Release two hand control
OPERATION
Chapter 6
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MACHINE VERSION WITH TWO HAND CONTROL OPTION ONLY

Cycle4 with mobile beam not stopping at mute point
Control unit: TWO hand control
Cycle 5 laser protection

Not yet available for USA.
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Chapter 6
OPERATION
Cycle 6 : cycle without safety

With mobile beam stopping at mute pointT
Stop at mute point.
Press the Closing footswitch again to continue the cycle at slow speed .
Cycle 6 : without safety protection

With mobile beam not stopping at mute point
OPERATION
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6.6.PLC MESSAGES LIST

6.6.1.MACHINE FAULT MESSAGES
Message
1
Troubleshooting
(red colour)
PLC error.
Start the PLC

(Programmable Logic
Controller)
E0.08 or A0.24 input

error

error

error

error

error

error
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Issue 05/2005
Problem
Solution
The PLC is in hold..
Change CPU board.

Turn off and restart ; if the
problem persists, check that
Fail safe program is
the switch on the controller is
stopped.
in RUN mode.
Check the wiring at input
The input Ex.xx is faulty or
Ex.xx or use an ohmmeter and
the output of the forced
the electric schematics, to
opening relays KAY1 or
check the relay wiring and
KAY2 is in short-circuit.
replace the faulty relay.
The input Ex.xx is faulty or Ex.xx or use an ohmmeter and
the output for KM1, KM2 the electric schematics, to
or KM3 circuit breakers is check the circuit breaker
in short-circuit.
wiring and replace the faulty
circuit breaker.
the non-connected light
guard terminal is in short- Ex.xx or use an ohmmeter and
circuit. This output is used the electric schematics to to
by the programmable front identify short circuit and
support table and sheetreplace the faulty component.
follower options.
10 mm/s working speed
the electric schematics to
output (input to NC) is in
identify short circuit and
short-circuit.
replace the faulty component.
The input Ex.xx is faulty or Check the wiring at input
the machine ready light
HL2 (SLB5) or back gauge the electric schematics to
relay KA4 is in shortidentify short circuit and
circuit.
The input Ex.xx is faulty or Ex.xx or use an ohmmeter and
high speed output (input to the electric schematics to
NC) is in short-circuit.
Chapter 6
OPERATION
Message
Troubleshooting
(red colour)

error
10

error
11
E1.00 or E1.08 or A1.16

input error
12
E1.00 or E1.08 or A1.16

input error
13
E1.01 or E1.09 or A1.17

input error
14
E1.01 or E1.09 or A1.17

input error
15
E1.02 or E1.10 or A1.18

input error
Problem
Solution

press-brake opening output
(input to NC) is in shortidentify short circuit and
circuit.
The input Ex.xx is faulty or Check the wiring at input
slow speed output for
press-brake closing in
(input to NC) is in shortreplace the faulty component.
circuit.
On 35 to 100 T machines : Check the wiring at input
the input Ex.xx is faulty or Ex.xx or use an ohmmeter and
YV1.1 solenoid valve (left the electric schematics to
hand side) is disconnected identify short circuit and
or in short-circuit.
On 130 to 220 T machines: Check the wiring at input
YV1 solenoid valve is
disconnected or in shortidentify short circuit and
circuit.
replace the faulty component..
YV1.2 solenoid valve (right the electric schematics to
YV3.1 solenoid valve (left the electric schematics to
disconnected or in shortidentify short circuit and
circuit.
OPERATION
Chapter 6
29/56
Issue 05/2005
Troubleshooting
(red colour)
Message
16
E1.02 or E1.10 or A1.18

input error
17
E1.03 or E1.11 or A1.19

input error
18
E1.03 or E1.11 or A1.19

input error
19
E1.04 or E1.12 or A1.20

input error
20
E1.04 or E1.12 or A1.20

input error
21
E1.05 or E1.13 or A1.21

input error
22
E1.06 or E1.14 or A1.22

input error
30/56
Issue 05/2005
Problem
Solution
On 130 to 220 T machines:

the input Ex.xx is faulty or
YV3.2 solenoid valve (right
hand side) is disconnected
YV5.1 solenoid valve (left
YV5.1 solenoid valve (left
On 35 to220 T machines:
disconnected or in shortcircuit.
HL5 output : GUARD
OFF lamp is disconnected
(blown) or in short-circuit.

Ex.xx or change the guard off
lamp or check any shortcircuit in the wiring.
Chapter 6
OPERATION
Message
23
24
25
26
Troubleshooting
(red colour)
E1.07 or E1.15 or A1.23
input error
Problem
Solution

the output is disconnected
from its load or is in shortidentify short circuit and
circuit.
The LazerSafe detect

excessive environmental
light.
Reserved
Reserved
The input E0.08 does not
receive slow speed output
from LazerSafe controller.
27
Faulty PV out put

from LazerSafe
28
One of the two channels of

Fault in the machine stop
the machine stop stayed in
line.
close state.
29
The operation of KA4A

Faulty KA4A (Closing
relay is defective. The
authorisation for YV2 commuting time of the
solenoid valve).
relay from 0 to 1
exceed 100 ms.
30
Stopping distance too

large.
The stopping distance

measured by LazerSafe unit
is greater than 8.5 mm.
31

error

the pulse output is
abnormally connected to a
voltage source or is in
short-circuit with 0 volt or
short-circuited with another
pulse output.
32

error
Similar to A0.16.
OPERATION
Chapter 6
Check the cable connection at

E0.08 or use ohm meter and
electric schematics and
identify and replace the faulty
component.
Check for correct operation of
the machine stop contact
switches. If the LazerSafe
option is installed, check the
operation of the KAUX1 and
2 relays.
Using an ohmmeter and the
electrical schematics, check
the breakage in the circuit or
the short-circuit, replace the
faulty component if necessary.
Switch off the machine and
restart. If the fault persist,
YV2 solenoid valves should
be checked.
Ex.xx or check that no voltage
is applied to this output (after
this type of fault, normally this
output should not have any
voltage). Using an ohmmeter,
ensure that this output is not
short-circuited with 0 volt nor
with another pulse outputs.
Similar to A0.16.
31/56
Issue 05/2005
Message
33
34
35
36
37
38
Troubleshooting
(red colour)
error
error
error
error
error
error
Problem
Similar to A0.16.
Similar to A0.16.
Similar to A0.16.
Similar to A0.16.
Similar to A0.16.
Similar to A0.16
Similar to A0.16.
Similar to A0.16
Similar to A0.16.
Similar to A0.16
Similar to A0.16.
Similar to A0.16
39
Error on board 0
(DI2OT)
The board is faulty.
40
Error on board 1 (DIOZ)
41
Error on board 2
42
Reserved
43
YV1 static fault
44
YV1 dynamic fault
45
Static fault on YV1.1 or

YV1.2
32/56
Issue 05/2005
Solution

the piston of the pump relieve
solenoid valve (YV1) is not in
idle (0) position.
the piston of the pump relieve
solenoid valve (YV1) is
faulty. When switching to
status 0 or 1, the displacement
time of the piston is > 80 ms
or it has returned to 0 position
while the solenoid valve is in
status 1.
On 35 to 100 T machines: the
piston of either pump solenoid
relieve valves (YV1.1 or
YV1.2) is not in idle position.
Check if 24 VDC is present

on the board connectors. If
yes, change the board.
Check the operation of

YV1.

YV1.

YV1.
Chapter 6
OPERATION
Message
Troubleshooting
(red colour)
46
YV1,1 dynamic fault
47
YV1.2 static fault
48
YV3 dynamic fault
49
YV3 dynamic fault
50
YV1 static fault
Problem
the piston of the pump
relieve solenoid valve (left
hand side) (YV1.1) is
status 0 or 1, the
displacement time of the
piston is > 80 ms or it has
returned to 0 position while
the solenoid valve is in
status 1.
relieve solenoid valve
(right hand side) (YV1.2) is
status 0 or 1, the
status 1.
the piston of slow speed
solenoid valve (YV3) is not
in idle (0) position.
solenoid valve (YV3) is
status 0 or 1, the
status 1.
(YV1) is not in idle (0)
position.
OPERATION
Chapter 6
Solution
Check the operation of YV1.
Check the operation of YV1.2.
33/56
Issue 05/2005
Troubleshooting
(red colour)
Message
51
52
53
54
55
56
57
58
Problem

(YV1) is faulty.
When switching to status 0
YV1 dynamic fault
or 1, the displacement time
of the piston is too long or
it has returned to 0 position
while the solenoid valve is
in status 1.
Faulty CLP1 check valve
the retaining check valve is
(left hand)
not in position.
YV6 static fault
solenoid valve (YV6) is not
in idle (0) position.
the piston of 10mm/s slow
speed solenoid valve (YV6)
is faulty. When switching
to status 0 or 1, the
YV6 dynamic fault
status 1.
Faulty CLP2 check valve
the retaining check valve is
(right hand)
not in position.
Reserved
Relay KA51 & KA52 is
Faulty KA51 & 2
(closing of YV2 valve
status 0 or 1, the response
authorized)
time of the relay is > 100
ms.
Slow Speed NC output

faulty
34/56
Issue 05/2005
Solution
Check the operation of the

valve.

valve.

the disconnection in the circuit
or the short-circuit, replace the
Check the output connections.
This NC output is not
If everything is OK, turn off
correctly enabled, the
the press-brake, then turn it on
transistor on the NC output again and reset the Y1 and Y2
is either in short-circuit or axes. If the problem persists,
stayed open.
replace the I/O board of the
NC.
Chapter 6
OPERATION
Message
59
60
61
62
63
64
65
66
67
68
69
Troubleshooting
(red colour)
NC Safety Relay output
fault
Problem
Solution
See fault 58 (NC slow

output speed fault).
See fault 58 (NC slow speed

output fault).
See fault 58 (NC slow output
NC axis in position
speed fault).
NC ODC output fault
speed fault).
NC ER output fault
speed fault).
If everything is OK, turn the
All NC output transistors
press-brake on and then off
All NC outputs are in
are in short-circuit or
and reset the Y1 and Y2 axes.
short-circuit.
abnormally activated.
If the problem persists, replace
I/O board of the NC.
When turned on, the NC
If everything is OK, turn the
NC not ready
ODC output remains at 0
press-brake off and then on. If
(transistor not commuting). the problem persists, replace
I/O board of the NC.
The normally closed
SA5 push-button fault at contact of the reset push
Check the wiring ; replace the
power on.
button is closed when the
push button if necessary.
NC controller is turned on.
SA4 mode selector key
The mode selector key
switch (000) fault at
switch is faulty, all contacts
key switch if necessary.
power on
are at 0.
The normally closed
contact of the closing
Footswitch 2 fault (n.c to
footswitch 2 is abnormally
0) at power on.
contact if necessary.
open when PLC unit is
turned on.
The normally open contact
Footswitch 2 fault (n.o to of the closing footswitch 2 Check the wiring ; replace the
1) at power on.
is abnormally close when
PLC unit is turned on.
The machine auxiliary
Footswitch selection
function (NC output is
Check the wiring, replace the
faulty (NC output) at
short-circuited to 0 volt
output board of the NC if
power on
when the PLC unit is
necessary.
turned on.
OPERATION
Chapter 6
35/56
Issue 05/2005
Troubleshooting
(red colour)
Message
70
71
72
73
74
75
76
77
Problem
The normally open contact

of the closing footswitch 1
is abnormally closed when
the PLC unit is turned on.
The normally closed
contact of the closing
Footswitch 1 faulty (n.c
footswitch 1 is abnormally
to 0) at power on
open when the PLC unit is
turned on.
One of the opening
Opening footswitch 1 or footswitch is pressed or a
contact is faulty when the
2 faulty at power on.
PLC unit is turned on.
The contact of KM1 circuit
breaker is abnormally
KM1 contact faulty when
closed or the circuit breaker
at power on.
stayed close when the PLC
unit is turned on.
Closing footswitch 1 is
active at power on.
pressed.
active at power on.
pressed.
Awaiting ODC signal
Reserved for running in
after end of bend.
mode for factory.
The contacts of the relay
KPVR1&2 are defective.
KPVR1 or 2 faulty (arm
When switching to status 0
rotation)
or 1, the response time of
the relay is > 100 ms.
Footswitch 1faulty (n.o
to 1) at power on
78
E2.00 or A2.16 output

error
The output is disconnected

from the load or in short
circuit.
79

error
The output is disconnected

from the load or in short
circuit.
36/56
Issue 05/2005
Solution



circuit breaker if necessary.
Release the footswitch and
reset the fault.
Release the footswitch, reset
the fault.

the breakage in the circuit or
the short-circuit, replace the
electric schematics, check any
short-circuit or disconnection
in the circuit, replace the
faulty component if required.
electric schematics, check any
Chapter 6
OPERATION
Message
Troubleshooting
(red colour)
Problem
80

error
The output is
disconnected from the
load or in short circuit.
81

error
The output is
82

error
The output is
83

error
The output is
84

error
The output is
85

error
The output is
86

error
The output is
87

error
The output is
88

error
The output is
OPERATION
Chapter 6
Solution
electric diagram, check any
37/56
Issue 05/2005
Troubleshooting
(red colour)
Message
Problem
89

error
The output is
90

error
The output is
91

error
The output is
92

error
The output is
93

error
The output is
94
95
96
LazerSafe is incompatible LazerSafe is incompatible

with two hand push button with two hand push
control.
button control.
The mute output signal
from LazerSafe controller
Faulty mute output from
is connected to input
LazerSafe
E1.07 of the PLC unit
does not function in each
bending cycle.
LazerSafe has detected
Upper beam is closing
closing beam movement
with out closing command
without closing foot pedal
signal.
being activated.
38/56
Issue 05/2005
Solution
Check the configuration of the
machine.
Check the connection of this

output cable.

relay KA6 (command to
LazerSafe).
Chapter 6
OPERATION
600
Troubleshooting
(red colour)
PLC error F06
Defective PLC unit.
601
I0.xx input error
Many errors at input I0.xx
602
I0.00 to I0.15 input error
Many errors at the inputs

I0.00 to I0.15
603

I0.16 to I0.31
604
I1.xx or O1.xx input error

I1.xx or outputs O1.xx
605
I1.xx input error

I1.x
606
Many errors at the outputs

O1.xx
607
Tx or O2.xx output error

Tx or O2.xx
608
Tx or O2.8 to O2.15
output error

Tx or O2.8 to O2.15
609
O.16 or O2.17 output error

O1.6 or O1.7
610
I3.x input error

I3.x
611
O4.x output error

O4.x
612
I0.0 (//X, Y) input error
Input error I0.0
613
I0.1 (SQ12) input error
Input error I0.1
Message
Problem
OPERATION
Chapter 6
Solution
Remplace PLC unit.
Check the input cables at I0.xx
or use ohm meter and electric
schematics to trace the fault.
or outputs at O1.xx or use
ohm meter and electric
Check the outputs O1.xx or
use ohm meter and electric
Check the outputs Tx or O2.xx
Check the outputs Tx or O2.8
to O2.15 or use ohm meter
and electric schematics to
trace the fault.
Check the outputs O1.6 or
O1.7 or use ohm meter and
electric schematics to trace the
fault.
Check the input cables at I3.x
Check the outputs O4.x or use
Check the input cables at I0.0
Check the input cables at I0.1
39/56
Issue 05/2005
Troubleshooting
(red colour)
Message
Problem
614
I0.2 (ctrl KA51&52) input

I0.2 input error
error
615
I0.3 (Motor / Pump unit

ON) input error
I0.3 input error
616
I0.4 (NC running) input

error
I0.4 input error
617
I0.5 (Clamping On) input

error
I0.5 input error
618
I0.6 (HF BT / MT) input

error
I0.6 input error
619
I0.7 (axes init OK) input

error
I0.7 input error
620
I0.8 (FGSE OUT1) input

error
I0.8 input error
621
I0.9 (FGSE OUT2) input

error
I0.9 input error
622
I0.10 (NC axe in pos.)

input error
I0.10 input error
623
I0.11 (NC PV) input error
I0.11 input error
624
I0.12 (NC ODC) input

error
I0.12 input error
625
I0.13 (NC end of

I0.13 input error
decompression) input error
626
I0.14 (NC RS) input error
40/56
Issue 05/2005
I0.14 input error
Solution
Check the input at I0.2 or use
Check the input wiring at I0.3
schematics.
Check the input wiring at
I0.10 or use ohm meter and
fault.
fault.
fault.
fault.
fault.
Chapter 6
OPERATION
Message
Troubleshooting
(red colour)
Problem
627
I0.15 (ctrl KPV1&2) input

I0.15 input error
error
628
I0.16 (SA4 bit0) input

error
I0.16 input error
629

error
I0.17 input error
630

error
I0.18 input error
631
I0.19 (CN) input error
I0.19 input error
632
I0.20 (select Robot) input

error
I0.20 input error
633
I0.21 (SA6) input error
I0.21 input error
634
I0.22 (ped2 n.c) input error I0.22 input error
635
I0.23 (ped2 n.o) input

error
I0.23 input error
636
I0.24 (SQ11) input error
I0.24 input error
637
I0.25 input error
OPERATION
Chapter 6
Solution
fault.
fault.
fault.
fault.
fault.
fault.
fault.
fault.
fault.
fault.
fault.
41/56
Issue 05/2005
Troubleshooting
(red colour)
Message
Problem
638
I0.26 (NC pedal select)

input error
I0.26 input error
639
I0.27 (AM NF 1) input

error
I0.27 input error
640
I0.28 (AM NF 2) input

error
I0.28 input error
641
I0.29 (pedal 1 n.c) input

error
I0.29 input error
642
I0.30 (pedal 1 n.o) input

error
I0.30 input error
643
I0.31 (opening pedal)

input error
I0.31 input error
644
I1.0 input error
I1.0 input error
645
I1.1 input error
I1.1 input error
646
I1.2 input error
I1.2 input error
647
I1.3 input error
I1.3 input error
648
I1.4 input error
I1.4 input error
649
I1.5 input error
I1.5 input error
650
I1.6 input error
I1.6 input error
42/56
Issue 05/2005
Solution
fault.
fault.
fault.
fault.
fault.
fault.
Chapter 6
OPERATION
Message
Troubleshooting
(red colour)
Problem
651
I1.7 input error
I1.7 input error
652
I1.8 input error
653
I1.9 (set LS) input error
I1.9 input error
654
O1.16+ (YV1.1) output

error
655
O1.16+ (YV1) output error
656

error
657

error
658
659

error
660

error
661

error
662
663
O1.16- (YV1.1) output

error
664
O1.16- (YV1) output error
665

error
Error at output O1.16 +

(YV1.1) : wiring or
impedance problem.
Error at output O1.16 +
(YV1) : : wiring or
impedance problem.
Error at output O1.17+
(YV1.2) : : wiring or
impedance problem.
impedance problem.
(YV3) : : wiring or
impedance problem.
impedance problem.
impedance problem
(YV5.2) : wiring or
impedance problem.
(YV6) : wiring or
impedance problem.
Error at output O1.16(YV1.1) : wiring or
impedance problem.
Error at output O1.16(YV1) : wiring or
impedance problem.
impedance problem.
OPERATION
Chapter 6
Solution
Check the output wiring using
43/56
Issue 05/2005
Troubleshooting
(red colour)
Message
666
667
668
669
670
671
Problem

impedance problem.
Error at output O1.18O1.18- (YV3) output error (YV3) : wiring or
impedance problem.
Error at output O1.18O1.18- (YV3.2) output
(YV3.2) : wiring or
error
impedance problem.
(YV5.1) : wiring or
error
impedance problem.
(YV5.2) : wiring or
error
impedance problem.
Error at output O1.21O1.21- (YV6) output error (YV6) : wiring or
impedance problem.
error
672
O/T 2.0 impulsive output

error
Pulse output error : wiring

or impedance problem.
673

error

674

error

675

error

676
O2.8 (KAY1&2) output

error
677
678
679
680
Single channel output

error : wiring or
impedance problem.
O2.9 (Pump motor unit
error : wiring or
ON) output error
impedance problem.
O2.10 (command KA51)
error : wiring or
output error
impedance problem.
O2.11 (HL2, KA4) output
error : wiring or
error
impedance problem.
O2.12 (FGV to CN) output
error : wiring or
error
impedance problem.
44/56
Issue 05/2005
Solution
Chapter 6
OPERATION
Message
681
682
683
684
685
686
687
Troubleshooting
(red colour)
Problem

error : wiring or
impedance problem.
O2.14 (FPV to CN) output
error : wiring or
error
impedance problem.
O2.15 (n.c) output error
error : wiring or
impedance problem.
Double channel output
O2.16 + (HL5 or HL7)
error: wiring or
output error
impedance problem.
O2.17 + (n.c) output error error: wiring or
impedance problem.
O2.16 - (HL5 or HL7)
error: wiring or
output error
impedance problem.
O2.17 - (nc) output error
error: wiring or
impedance problem.
O2.13 (Opening to NC)
output error
688
I3.0 (test sec LS) input

error
689
I3.1 (test LED) input error I3.1 input error.
690
I3.2 (nc) input error
I3.2 input error.
691
I3.3 input error.
692
I3.4 input error.
693
I3.5 input error.
694
695
I3.0 input error.

O4.0 (Aut. Sheet follower)
error : wiring or
output error
impedance problem.
O4.1 (nc) output error
error : wiring or
impedance problem.
OPERATION
Chapter 6
Solution
Check the input wiring using
45/56
Issue 05/2005
Troubleshooting
(red colour)
Message
696
697
698
699
Problem

error : wiring or
impedance problem.
O4.8 (KA6 laser) output
error : wiring or
error
impedance problem.
O4.9 (LS ON) output error error : wiring or
impedance problem.
O4.10 (Mute LS) output
error : wiring or
error
impedance problem.
O4.2 (nc) output error
46/56
Issue 05/2005
Solution
schematicsto trace the fault.
Chapter 6
OPERATION
6.6.2.MACHINE STATUS MESSAGES

Message
125
126
127
128
129
130
131
132
Troubleshooting
(white colour)
Problem
The hydraulic unit is

stopped. Close the rear gate
to start it.
The reset push-button is
pressed while the operating
Select operating mode
mode selector key switch is
in stop position.
Over-travel of the back
gauge cross-member (X1 or
X2) due to parallelism loss
and gone on its safety limit
Parallelism lost on X or
switch ; over-travel of the
Y axes.
press brake beam (Y1 and
Y2) due to parallelism loss
and gone on either (Y1 or
Y2) limit switch.
When the above fault has
Reset machine
been corrected, this
(parallelism had been lost
message specifies that the
on X or Y axes).
fault has been rectified.
One of the machine stop
Machine stop pressed.
button is engaged.
Once the machine stop
Reset machine (machine button is released, it
stop had been pressed).
indicate that the fault has
been rectified.
The left side gate door is
Left hand side gate door
open, only adjustment
open.
mode can be executed.
When the above fault has
Reset the machine (Side
been corrected, this
gate doors had been
message specifies that all
opened).
gate doors are now closed.
Close the rear door and
start the motor
OPERATION
Chapter 6
Solution
Close the rear gate and start
the motor (switch located on
the NC panel).
Select an operating mode, then
press reset push-button.
X axes : manually position the

cross-member parallel and
restart.
Y axes : press the opening
footswitch ; the problem
should be solved.
Press reset push-button and

restart.
Release the concerned
machine stop button.
restart.
If the selected operating mode
is not adjustment mode, close
the door then reset.
restart.
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Troubleshooting
(white colour)
Message
Problem
133
The right side gate door is

Right hand side gate door
open, only the adjustment
open.
mode can be executed.
134
Both side gate doors are

open.
135
136
137
138
139
140
141
142
143
144
Both side gate doors are

open.
Every time tool holder is

Tools holder unclamped. unclamped, it will initiate a
machine stop.
Reset the machine (tool
holders had been
Clamp the tool holders.
unclamped).
Reset the machine (Two Each change in mode will
operators mode enabled). initiate a machine stop.
Reset the machine
A new operating mode is
(Single operator mode
activated.
enabled).
Reset the machine (robot
mode enabled during
activated.
beam movement).
Reset the machine (robot
mode disabled during
activated.
beam movement).
If the switch is in 1
operator position, it may be
Reset the machine (1
dangerous when both
operator, 2 footswitches footswitches are enabled. It
mode enabled)
is possible that operator
forgot to switch over to 2
operators mode.
When the robot mode is
Operating mode non
enabled (if robot option
compatible with the
available), the light guard
robot.
modes are disabled.
Reset the machine; pedal Pedal operating mode
operating mode enable.
enable
Reset the machine (>30 In light guard operated
seconds since the last
mode, the press-brake was
light guard operated
inoperative for more than
cycle).
30 seconds.
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Solution
If the selected operating mode
is not adjustment mode, close
the door then reset.
Opening both doors at the
same time is prohibited. Close
one of the door then reset to
operate in adjustment mode.
Clamp tool holders.
Press reset push-button.

Press reset push-button
Select 2 operators mode and

reset.
Change the operating mode

and reset.
Chapter 6
OPERATION
Message
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
Troubleshooting
(white colour)
Problem
Solution
In one of the light guard

Reset the machine (light operated modes, during the
guard broken during high high speed closing phase,
the light guard has been
speed approach).
broken.
When the machine is ready
Reset the machine.
(no fault), but not yet been Press reset push-button.
reset.
Press the opening footswitch if
Either footswitch or the
Enable the opening
Y axis is out of parallelism or
reset push button is pressed
footswitch (forced
move X axis manually if it is
opening) or move X axis while X or Y axis is out of
X axis, then press reset push
parallelism.
manually.
button.
New working mode is
Reset with the push-button.
Reset (adjustment mode)
enabled.
Reset (light guard
New working mode is
protection)
enabled.
New working mode is
Reset (robot control)
enabled.
Reset (single passingNew working mode is
through mode +
enabled.
footswitch)
through mode +
enabled.
footswitch)
through mode)
enabled.
Reset (double passingNew working mode is
through mode)
enabled.
Reset (robot adjustment New working mode is
mode)
enabled.
Reset (adjustment mode New working mode is
enabled)
enabled.
Reset (production mode New working mode is
enabled)
enabled.
When the two-hand push
button control mode is
Operating mode non
enabled (if option
compatible with the two- installed), the modes
Change the mode and reset.
hand push button control corresponding to 2 passingthrough control with the
light curtain are prohibited.
Reset the machine (twoWhenever mode is changed
hand push button control
machine stop occurs.
disabled)
OPERATION
Chapter 6
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Message
160
161
162
163
164
165
166
167
168
169
170
171
Troubleshooting
Problem
Solution
(white colour)
Reset the machine (twoWhenever mode is changed
machine stop occurs.
enabled)
Wait for the temperature to
drop without stopping the
Oil temperature gone too
Oil temperature too high
motor-pump and cooling unit
high.
motors.
Reset (Two-hand push
New working mode is
button control +
enabled.
footswitch)
Reset (Two-hand push
New working mode is
button control)
enabled.
LazerSafe under
initialisation or machine
Wait for ~ 4 seconds.
stop push button active.
Reset (stopping test by
LazerSafe test is finished. Press reset push-button
LazerSafe done)
When laser beam
Working mode non
protection is installed, only
compatible with Laser
setting and production
beam protection.
modes are available at
SA4 key selector.
When machines are in
Working mode non
tandem configuration, only
compatible with Tandem
setting and production
machine configuration.
modes are available.
When machines are in
Side gate open.
tandem configuration, side Close side gates and reset.
gates must remain close.
Whenever separator is
installed on a tandem
Reset machine (SOLO
Press reset push-button to start
machine, it will initiate a
mode enabled)
machine in SOLO mode.
machine stop and call for a
reset.
Whenever separator is
Reset machine
removed on a tandem
Press reset push-button to start
(TANDEM mode
machine, it will initiate a
machine in TANDEM mode.
enabled)
machine stop and call for a
reset.
When LazerSafe option is
Initialisation of axes is
installed, initialisation of
Choose setting mode to
only allowed in setting
axes can only be done in
initialise the machine axes.
mode.
setting mode.
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Chapter 6
OPERATION
6.6.3.OPERATOR MESSAGES
Message
249
250
251
252
253
254
Troubleshooting
(yellow colour)
Problem
In alternate production
mode , once the pressbrake has been turned on or
during the first cycle in this
Break light curtain, then
mode, break the light curtain
reset the machine ; to
to ensure correct operation
authorize high speed
of the light guard. If this
approach is.
operation is not performed,
the press-brake will operate
in working speed.
Once the press-brake is
turned on, you must reset
the machine. This can only
be done by pressing foot
Select Mode 1 to 4 to reset
pedal 1 (or both foot pedals
the machine.
if 2 operators mode has been
selected). Complete cycle
with light curtain cannot be
used.
If the closing of the pressbrake in this mode is
Control device is light
authorized by the light
guard. Footswitches
guard, pressing either
disabled
footswitch produces this
message.
This message indicates that
only footswitch 1 can close
Footswitch 1 selected.
the press-brake. It is
displayed when footswitch 2
is pressed.
This message indicates that
only footswitch 2 can close
Footswitch 2 selected.
the press-brake. It is
displayed when footswitch 1
is pressed.
This message is displayed
Delay between pressing the when de-synchronisation
two footswitches exceeded. time between the two
footswitches is > 4 seconds.
OPERATION
Chapter 6
Solution
Break the light guard.
Do not select single

passing-through complete
cycle or double
passing-through complete
cycle .
Close the press-brake by

breaking the light guard.
Release footswitch 2 and

press footswitch 1.
Release footswitch 1 and

press footswitch 2.
Release both footswitches

then press them within 4
seconds at the most.
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Troubleshooting
(yellow colour)
Message
255
256
257
258
259
260
Problem
In the alternate
production mode , once
the light guard has been
Reset for high speed
broken, it should be reset ;
approach.
if not, the press-brake will
only operate in working
speed.
Once the press-brake has
been turned on, machine
reset can only be carried
out using both
Two operators mode
footswitches if the two
enabled.
operators mode has been
enabled. This message
avoid searches for nonexisting faults.
This message appears in 2
operators mode to specify
that footswitch 1 has been
Footswitch 2 is in stand-by
activated and machine is
position.
waiting for 2nd footswitch
command to close the
press-brake.
that footswitch 2 has been
Footswitch 1 is in stand-by
activated and machine is
position.
waiting for 1st footswitch
command to close the
press-brake.
This message specifies that
only two-hand push button
Two-hand push button
control 1 can close the
control 1 is selected.
press-brake ; it is
displayed if two-hand push
button control 2 is enabled.
This message specifies that
only two-hand push button
control 2 can close the
control 2 is selected.
press-brake ; it is
displayed if two-hand push
button control 1 is enabled.
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Solution
Press the reset push-button

located on the NC panel.
Close the press-brake by

pressing both footswitches,
the message disappears once
the press-brake has been
reset.
Press footswitch 2.
Press footswitch 1.
Release two-hand push

button control 2 and enable
two-hand push button control
1.
Release two-hand push

button control 1 and enable
two-hand push button control
2.
Chapter 6
OPERATION
Message
261
262
263
264
265
266
267
268
Troubleshooting
(yellow colour)
Problem
This message is displayed

Delay between pressing the when de-synchronisation
two, two hand push button time between the two, two
hand push button controls is
controls exceeded.
> 4 seconds.
that two hand push button
control 1 has been activated
Two-hand control 2 is in
and machine is waiting for
stand-by position.
2nd two hand push button
control command to close
the press-brake.
that two hand push button
control 2 has been activated
Two-hand control 1 is in
and machine is waiting for
stand-by position.
1st two hand push button
control command to close
the press-brake.
Once the press-brake has
been turned on, press NC
Press NC Start button to
Start button then press the
RESET.
opening footswitch to reset
the axes.
Oil filter clogged-up
SQ8 filter soiled.
This message is displayed if
two-hand push button
Light guard in control.
control is activated when
selected mode only
control inoperative.
authorize closing of the
press-brake through the light
guard.
two-hand push button
Footswitch control. Twocontrol is activated when
selected mode only
inoperative.
press-brake through the
footswitch.
footswitch is activated when
Two-hand control.
selected mode only
Footswitch inoperative.
press-brake through twohand push button control.
OPERATION
Chapter 6
Solution
Release both two hand push
button controls then press
them within 4 seconds at
the most.
Press two-hand control 2.
Press two-hand control 1.
Release the footswitch and

press NC Start button.
Replace the filter cartridge.
Break the light curtain to

close the press-brake.
Press the footswitch.
Press the two-hand control.
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Message
269
270
271
272
273
Troubleshooting
(yellow colour)
See message 265.
Running in mode active.
Motor pump unit auto
shut-down off.
Watch out oil
temperature too high.
Press INIT button on
LazerSafe.
Problem
Press 5 seconds on START

button.
Press brake is used very
intensively.
Solution
Slow down working rate.
274
Waiting axis in position

signal.
Post NC axes output remain

active (at 1) after end of bend
when beam reaches ODC and
if the closing foot pedal is
activated.
275
LazerSafe : Working
mode changed. Press
Test button.
The working mode has been

changed.
Confirm using Lazersafe

Test / confirmation button.
276
LazerSafe : Obstruction
during set-up.
The LazerSafe laser beam is

obstructed before confirming
the mute point
Remove the part or open

the pressing beam.
277
278
279
280
281
282
283
284
285
286
LazerSafe : Confirm
mute point.
LazerSafe : Start up time
over or encoder error.
LazerSafe : Work sheet
not detected.
Confirm using Lazersafe

Test / confirmation button
Check encoder operation.
After mute point, work sheet

is not detected.
The temperature in the electric

Electric cabinet
cabinet exceed the
temperature too high.
temperature monitored by
thermal sensor TH3.
LazerSafe : Front beam is The front laser beam of the
obstructed.
LazerSafe is obstructed.
LazerSafe : Rear beam is The rear laser beam of the
obstructed..
LazerSafe : Central beam The central laser beam of the
is obstructed..
LazerSafe : Central and The central and rear laser
rear beams are
beams of the LazerSafe are
obstructed.
obstructed.
LazerSafe : Front and
The front and central laser
central beams are
beams of the LazerSafe are
obstructed.
obstructed.
LazerSafe : Front, rear
The front, rear and central
and central beams are
laser beams of the LazerSafe
obstructed.
are obstructed.
54/56
Issue 05/2005
See error message 58 (NC

output error for slow speed
PV ).
Check if the magnetic laser

beam blanking plate is
correctly installed at the die
end or redo teaching of the
mute point.
Check if the cooling unit is
operating correctly.
Liberate the zone
monitored by LazerSafe.
Liberate the zone
Liberate the zone
Liberate the zone
Liberate the zone
Liberate the zone
Chapter 6
OPERATION
Message
287
288
289
290
291
292
293
Troubleshooting
Problem
(yellow colour)
The front laser and rear
LazerSafe : The front and
rear beams of the LazerSafe beams of the LazerSafe are
obstructed
are obstructed
Each time LazerSafe is
LazerSafe secondary test in switched on, it checks the
stopping distance of the
progress, please wait.
upper beam.
The laser beam has detected
Work sheet detected,
release the pedal and press presence of the work sheet.
This position should be
TEST button for
confirmed.
confirmation.
Work sheet detected,
The laser beam has detected
release foot pedal.
presence of the work sheet.
Tool height has been
Teach new mute position
changed, press TEST
due to change in tool height
button to teach.
in the NC program.
When LazerSafe is switched
Place work sheet to be bent
on, it is mandatory to teach
and press closing foot pedal
the mute position using
until sheet is detected.
correct work sheet.
When LazerSafe is switched
Press TEST button.
on, you must press
TEST button to proceed.
OPERATION
Chapter 6
Solution
Liberate the zone
Release the closing foot
pedal and wait for the
LazerSafe test to end.
Press TEST button.
Release closing foot pedal.

Press TEST button.
Press closing foot pedal

until work sheet is detected.
Press TEST button.
55/56
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56/56
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Chapter 6
OPERATION
7. MAINTENANCE
MAINTENANCE
Chapter 7
1/34
Issue 05/2005
CAUTION: Any maintenance operation on components which are liable

to cause upper beam movement (hydraulic circuit, cylinder, etc.) must be
performed with the beam in lower position, or using the beam
immobilising parts intended for transport purposes (Para. 2.4.4).
7.1. INTRODUCTION
This chapter describes the operations required to maintain the qualities and characteristics of
your machine. A press brake is exposed to the harsh conditions of a production shop: welding
fumes, grinding dust, sheet oil, rust particles, etc.
On the other-hand, a modern machine tool like this one is equipped with high-tech precision
components: ball screws and guides, notched belt and pulley, proportional hydraulic valves,
linear scales, floppy disk drive, etc, which require periodic maintenance. The frequency of
periodic maintenance is based on 8 hours of operation per day under normal working conditions.
It must be increased accordingly in the event of two or three shifts production (16 to 24 hours per
day), and it does not eliminate the need for punctual maintenance according to conditions such as
frequent use of oiled or galvanised sheets in large production runs.
2/34
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Chapter 7
MAINTENANCE
IMPORTANT
If necessary, use this type of ladder whenever accessing the top of the
machine (not an AMADA supply).
MAINTENANCE
Chapter 7
3/34
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4/34
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Chapter 7
MAINTENANCE
7.2. MACHINE PERIODIC MAINTENANCE

- COMPOSITION List of components subject to periodic maintenance
Item
1
2
3
4
5
6
7
8
9
10
NC UNIT
ELECTRICAL CABINET
EXTERNAL C FRAME
UPPER / LOWER TOOLS
LOWER BEAM
PROTECTIVE SIDE GATES
BACKGAUGE (see corresponding appendix)
ROLLER GUIDE PLATE
HYDRAULIC UNIT (MOTOR PUMP)
OIL TANK
MAINTENANCE
Chapter 7
5/34
Issue 05/2005
FREQUENCY
Monthly
Fortnightly
2000 hours
2000 hours
2000 hours
PERIODIC MAINTENANCE OF THE MACHINE

ITEM
APPLIES TO
PRODUCT
1
Beam + dist. piece Fine oil
5
Roller guide
TARP S grease
2
Filtering element
H02343 or H02528* / **
3
Breather
H15147**
4
Oil
Shell DS46 or equivalent ***
* High speed machine

** Always check the part list for correct reference
*** ISO VG 46
DIN 51524/2 1st part HL 2nd part HLP
AFNOR NF-E 60-200 category HM
ISO 11158
6/34
Issue 05/2005
Chapter 7
MAINTENANCE
FREQUENCY
PERIODIC MAINTENANCE OF THE MACHINE

ITEM
COMPONENT
PRODUCT/REF.
Monthly
Keyboard/screen
Gentle cleaning agent + soft cloths
Monthly
Floppy disk drive
3 " cleaning diskette

+ alcohol
Quarterly
Linear scale guides
Lithium grease
MAINTENANCE
Chapter 7
7/34
Issue 05/2005
7.2.1. MAINTENANCE OF THE HYDRAULIC INSTALLATION

The hydraulic installation of your press brake has proportional hydraulic directional control
valves and the reliability of these components depends above all on the cleanliness of the oil.
Remember these fundamental facts:
Every hydraulic circuit is contaminated even before the system is assembled.
Abrasion wear causes additional contamination during system operation.
This also occurs when the circuit is topped up with new hydraulic fluid which is supposed to
be clean.
Basic rules:
Because of this, you are advised not to top up or perform oil changes too often.
Well-filtered oil degrades very slowly.
Always filter the oil before topping up or carry out oil change.
Unfiltered oil increases the contamination level.
IMPORTANT NOTE
Failure to apply the above maintenance instructions can lead to a total or partial loss of
guarantee cover on the units concerned.
CAUTION: The pump should never run without oil.
CAUTION: To continue operating in complete safety, use only original

replacement parts.
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Chapter 7
MAINTENANCE
MAINTENANCE
Chapter 7
9/34
Issue 05/2005
Hydraulic circuit drain

handle
l
10/34
Issue 05/2005
Chapter 7
MAINTENANCE
7.2.2. OIL CHANGES

First oil change: After 1000 hours.
Subsequent oil changes: Every 2000 hours or after one year, whichever comes first.
Turn off and lock the machine's electrical power supply.
Ensure that the upper beam is in its top position.
Remove the drain plug (Item 1) and replace it with a hose.
Swing the drain handle to open the valve and completely drain the reservoir.
7.2.3. FILLING PROCEDURE

Close the drain valve and remove the hose.
Reinstall the drain plug.
Remove the air filter (Item 2) to fill in the tank.
Fill the reservoir with Shell Tellus 46 or an equivalent ISO 46-compliant oil *. For reservoir
capacity: see Chapter 2, Characteristics.
During the filling operation, filter the oil through a 6-micron absolute filter cartridge
x = 200.
Check the level. It should be between the minimum and maximum marks on the gauge.
Replace the air filter of the hydraulic tank breather (Item 2), Amada Part No. H02160 (ensure its
the correct reference for your machine using part list).
Remove the bowl feeder (Item 3) from the high pressure filter.
* ISO VG 46
DIN 51524/2 1st part HL 2sd part HLP
AFNOR NF-E 60-200 category HM
ISO 11158
MAINTENANCE
Chapter 7
11/34
Issue 05/2005
Replace the oil filter cartridge, for Amada reference see Ch. 7, page 6 and parts list.
Reinstall the filter bowl feeder.
NOTE
After an oil change, do not replace the filter cartridge until the hydraulic unit has been
running for half an hour. The purpose of this is to avoid contaminating the new cartridge.
Unlock the electrical power supply.
CAUTION: The legislation in force prohibits the disposal of oil into the
environment. Take care to observe the regulations in force in your region.
7.3. RECOMMENDATIONS
For these maintenance operations, we have created kits containing the products you need for
your machine*:
Machine maintenance kit, Part No. M90074 (see description).
Numerical Control unit maintenance kit, Part No. M90075.
IMPORTANT NOTE
Failure to apply the above maintenance instructions can lead to a total or
partial loss of guarantee cover on the units concerned.
CAUTION: All maintenance and preventive maintenance operations

must be performed with the hydraulic unit shut down, with the power key
removed or main circuit breaker locked.
ACCESS
For access at a height (e.g. above 1.8 m), additional equipment must be used (such as an
inspection platform, ladder, or stepladder). This equipment should be used only after appropriate
training (checking fitness for purpose and stability of the equipment).
The manufacturer recommends access via the rear of the machine for the hydraulic components.
* Available as option.
12/34
Issue 05/2005
Chapter 7
MAINTENANCE
7.3.1. SPECIFIC DAILY TEST PROCEDURE

1- Light guard (see option, appendix E1.3)
2- LazerSafe system (see option, appendix E1.4 et E1.5)
3- Akas system (see options, Appendix E1.6)
MAINTENANCE
Chapter 7
13/34
Issue 05/2005
PERIODIC INSPECTION AND CLEANING LIST

FOR THE VARIOUS COMPONENTS
WARNING
THIS PERIODIC MAINTENANCE SCHEDULE IS
RELATED TO MACHINE SAFETY.
14/34
Issue 05/2005
Chapter 7
MAINTENANCE
For HFE, HFT

Upper beam guiding
Tooling
Lower beam
Floppy drive
Main power supply

circuit breaker
MAINTENANCE
Chapter 7
15/34
Issue 05/2005
For HFP
Main power supply

circuit breaker
k
Floppy drive
16/34
Issue 05/2005
Chapter 7
MAINTENANCE
ASSEMBLY
SUBASSEMBLY
ITEM
FREQ.
INSPECTION/METHOD
General items
Weekly
- Clean the carbon deposits

and dust from the following,
using a shop vacuum
cleaner:
- The various parts of the
back gauge (see appendix
C)
- The working parts of the
upper and lower beams
- Tooling (die block,
spacers, punches, dies)
Use of an air gun should be
avoided because it blows off
dust into inaccessible areas.
Safety switches
Weekly
Item 1
Item 2
Item 4
MAINTENANCE
Chapter 7
TIME
Check that the safety

switches are operating
correctly on :
Lateral protection
Rear screen door
Out-of-parallelism sensor
17/34
Issue 05/2005
UPPER BEAM GUIDING
Upper beam guiding
Fig. 7.2
Fig. 7.1
Tooling
Lower beam
Fig. 7.1
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Issue 05/2005
Chapter 7
MAINTENANCE
ASSEMBLY
SUBASSEMBLY
Upper beam
guiding
Filtering
elements
ITEM
FREQ.
INSPECTION/METHOD
TIME
Fig. 7.1 Fortnightly - Check the (mounting)

screws + rollers.
Fig. 7.2
- Dry lubrication
Remove the soiled grease
and replace it by a clean
and new one. Use TARP
S -type grease on the
upper beam guidings.
Fortnightly - Remove and clean using

compressed air:
- Electrical cabinet filters
Light guard
interlock (option)
- See Appendix E1.3
Laser beam
protection
(option)
- See Appendix E1.4 ,E1.5

or E1.6.
MAINTENANCE
Chapter 7
19/34
Issue 05/2005
Fig. 7.3
Upper beam bearing surface

Sectionalised
distance pieces
Lower beam
bearing surface
Fig. 7.4
20/34
Issue 05/2005
Chapter 7
MAINTENANCE
ASSEMBLY
SUBASSEMBLY
ITEM
FREQ.
INSPECTION/METHOD
TIME
Mechanical
NC cabinet
Fig. 7.3
Monthly - Clean using a cloth soaked

in dilute ammonia solution
- Screen
- Keyboard
Tools
Fig. 7.4
Monthly - After cleaning, protect the

unpainted surfaces using
PTFE (Teflon) spray-on or
protective grease:
1) Adjustable sectionalised
distance pieces
2) Bearing surfaces of
distance pieces under
upper beam
MAINTENANCE
Chapter 7
21/34
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Breather
Upper beam
guide rail
Oil tank
Linear scale
guide rail
Filter
22/34
Issue 05/2005
Chapter 7
MAINTENANCE
ASSEMBLY
SUBASSEMBLY
ITEM
FREQ.
INSPECTION/METHOD
TIME
After cleaning use lithium

grease to grease the
following:
Upper beam
3 months
- Guide rail
External C
frame
3 months
- Linear scale guide rail

(remove cylinder covers)
Hydraulic
2000 hours
MAINTENANCE
Chapter 7
Replace oil filters and

breathers
Drain oil tank
23/34
Issue 05/2005
Fig. 7.5
Silent block mountings
Fig. 7.6
24/34
Issue 05/2005
Chapter 7
MAINTENANCE
ASSEMBLY
SUBASSEMBLY
ITEM
FREQ.
INSPECTION/METHOD
Frame
Fig. 7.5
6 months
- Check machine levelling

(see Ch. 3.3)
Motor
Fig. 7.6
6 months
- Check securing of motor

to its plates and silent
blocks
Hydraulic/pneumatic pipework
(see Maintenance
of the Hydraulic
Installation)
6 months
- Check connections
- Detect leaks
Electric cabinet
6 months
- Check fan operation
Machine stop
Quaterly
- Check machine stop

operation (safety devices)
Rear grid
Quaterly
- Visual control + door

opening trial
Side
protections
Quaterly
- Visual control + opening

trial
Opening
footswitch
Quaterly
- Check the operation
Closing
footswitch
Quaterly
- Check the operation
TIME
Mechanical
MAINTENANCE
Chapter 7
25/34
Issue 05/2005
7.4. TROUBLESHOOTING
7.4.1. TROUBLESHOOTING TABLE
The purpose of this table is to help you rectify simple problems such as an operating error or
blown fuse. If the problem persists, please contact the Amada Department Services (telephone
and fax numbers given at the beginning of manual).
PROBLEM
SOLUTION
Keyboard does not operate.
Check position of keyboard interlock key.

Position 0: Keyboard inactive
Position 1: Keyboard active.
The backgauge is not parallel to the tools
If the backgauge is outside the tolerance for

parallelism with the tools, it goes into
interlock mode (pumps green indicator light
goes off).
Push or pull the backgauge to reset the
pump.
For the pump to reset, (X1 X2) must be
within axes off-set limit.
Green indicator light does not light up.
Check the Left, Right, and NC unit machine

stops.
Refer to the Incidents table in the machine electrical drawing.
TO CONTINUE OPERATING IN COMPLETE SAFETY, USE ONLY ORIGINAL

REPLACEMENT PARTS
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7.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL POINTS

(APPLICABLE TO FRANCE ONLY)
Article R233.11 of the labour law and the Act dated 5 March 1993, modified by the Act dated 4
June 1993, require preventive maintenance to be performed on a quarterly basis. The purpose of
this regular servicing is to detect in advance, any fault liable to cause an accident, so that such
faults can be rectified.
These checks are limited to the visible parts and components accessible by removing the covers
and cowlings include the following:
Visual check on the physical condition of the equipment:
- Stability of the machine and its accessories: mounting of components liable to fall or be
thrown off,
- Mounting of protective components,
- Condition of equipment: detection of abnormal oxidation, deformation and cracks,
- Cleanliness: accumulation of debris or dust,
- Condition of filters and outlets,
- Condition of interfaces and electrical, hydraulic, and pneumatic connectors.
Operating tests to check functional components involved in the work:
-
Presence and operation of protective devices in all operating modes,

Abnormal operating characteristics: noise, vibration, temperature, impact,
Operation of manual stopping devices,
Operation of stopping devices associated with a protective function,
Electrical operation under manual force of false parallelism sensor SQ1 and SQ2 contacts
located on the upper beam.
Check the settings and clearances

- Fluid levels,
- Air and oil pressure,
- Limit switch adjustment.
Check the state of indicators:
- Condition of measuring devices: pressure gauges,
- Condition of signalling devices: indicator lights and inscriptions.
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The results of this service call are recorded in a safety register opened by the Site Manager and
made available to the Health and Safety Executive and the CHSCT (if any) at all times.
This measure applies to any manual-feed press working on cold rolled metals.
The servicing must be performed under the responsibility of the Site Manager by qualified
persons trained in risk prevention. A list of such personnel is made available to the Health and
Safety Executive.
These provisions came into force on 15 / 01 / 1993.
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MACHINE MAINTENANCE KIT

Part No.: M90074
Precautions: Easily flammable liquid
- Use and store away from any flame, heat source, or electrical
device in operation. Do not smoke during use.
- Spray in short bursts only.
- Air thoroughly the area after use.
This kit was specially designed to facilitate the routine maintenance of Amada press brakes and
shearing machines. The products it contains are specifically suited to the heavy duty conditions
of an industrial environment.
An aerosol is easy to use, prevents waste, and provides access without disassembly.
The contents are optimised for the latest machines, equipped with micro-mechanisms, charged
rails, and precision tools.
Description:
2 lubricant aerosols:
For the ball screws and guides, micro-mechanisms and notched pulleys.
1 cleaning and anti-seizing aerosol:
To correct any maintenance and cleaning deficiency, for guide, ball screw, and
precision mechanisms.
1 greasing aerosol:
For guides (rails and rollers) of the beams and punch holder, as well as chamfered
screws.
1 protective aerosol:
For the unpainted parts of the machine and press brake tools.
Use:
The products should be applied according to the instructions in the Maintenance chapter of
your machine's operator manual, as often as necessary.
Clean the surfaces to be treated. Use the cleaning/anti-seizing spray for the inaccessible parts.
Spray in short bursts, 30 cm distance away from the part to be treated.
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APPENDIX TO CHAPTER 7
SAFETY DATA SHEET
DRAWN UP ACCORDING TO NF T.01.100
IN COMPLIANCE WITH THE ACT DATED 5 JAN. 1993
1 - IDENTIFICATION
Product concerned: SHELL TELLUS 46 oil
Supplier: Shell Oil Company
Responsible body: M.K.L.U.
Use: Hydraulic oil
Ingredient subject to health and safety regulations: Zinc dithiophosphate
Maximum content: 0.4%
2 - STORAGE AND HANDLING
2.1 - SPECIAL PRECAUTIONS FOR STORAGE AND HANDLING
Keep away from combustible materials; keep away from foodstuffs and drinks.
Prolonged and repeated contact with the skin can cause skin irritations which are
aggravated by minor injuries or rubbing against soiled clothing.
Avoid splashing.
After contact with the skin, wash immediately with copious water and approved
detergents.
Do not use irritant products or solvents.
Do not wipe hands with cloths that were used for cleaning.
Immediately remove any soiled or splashed clothing.
Do not inhale the vapours, fumes, or spray.
Do not eat, drink, or smoke during use.
2.2 - PACKING OR BOTTLING MATERIALS
Use only containers, seals, pipes, etc. that are resistant to hydrocarbons.
Dispose any soiled packaging materials via an approved waste processing organisation.
2.3 - HAZARDOUS REACTIONS WITH: oxidant products

PREVENTIVE MEASURES: Store in a cool, clean, dry location with appropriate
ventilation. Keep away from heat and oxidising agents.
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2.4 - HAZARDOUS DECOMPOSITION PRODUCTS

During combustion, unidentified organic or inorganic compounds can be formed, as well
as sulphured hydrogen and short-chain alkylmercaptans.
2.5 - INDIVIDUAL PREVENTIVE MEASURES
Barrier cream (on medical advice) or gloves,
Goggles in the event of splashing,
Avoid inhaling oil droplets,
Avoid repeated or prolonged contact,
When handling drums, wear safety shoes.
2.6 - SPECIAL PROTECTIVE MEASURES: not applicable
2.7 - MEASURES FOLLOWING A LEAK OR SPILLAGE
Eliminate or destroy the product: localise and remove the spilled oil using physical means
(e.g. absorbent materials), degrease surfaces, dispose the used items in accordance with
Section 6. Do not use dispersing agents whenever there is a risk of polluting the
environment.
3 - INFLAMMATION AND EXPLOSION
3.1 - FLASH POINT: > 190C in accordance with AFNOR NF M 07 019
3.2 - SELF-IGNITION TEMPERATURE
> 250C according to ASTM E 659 standards. This value can be significantly reduced
under particular conditions (slow oxidation in strongly divided media).
3.3 - SPECIFIC FIRE OR EXPLOSION HAZARDS
Explosivity limit in air at ambient temperature = 1 to 10% vapour volume. The vapour
pressure of this product is too low at ambient temperature for the lower explosivity limit to
be reached.
3.4 - EXTINGUISHING EQUIPMENT
RECOMMENDED:
TO BE AVOIDED:
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Foam, carbon dioxide, powder

Water jet and water spray extinguisher
Chapter 7
MAINTENANCE
3.5 - SPECIAL PROTECTIVE MEASURES FOR FIREFIGHTING

Wear breathing apparatus if required due to copious fumes.
3.6 - OTHER RECOMMENDATIONS
Arrange your installation to avoid accidental oil splashes (e.g. seal failure) on hot covers
and cowlings and electrical contacts.
Hydraulic oil leaks in a circuit under pressure result in jets of a fine spray that can reach
very high speeds. Under these conditions, the lower ignition limit of the oil spray is
reached for concentrations in the region of 45 grams per cubic metre.
4 - TOXICOLOGICAL DATA
Maximum allowable concentration of oil spray in air: approximately 5 mg/m3.
Under normal conditions of use, the mineral oils and other components of this product
do not present an acute intoxication hazard.
SPECIFIC TOXICOLOGICAL DATA: In the absence of toxicological data specific to

SHELL TELLUS 46, we are able to provide the following indicative information by
analogy with similar mineral oils:
ACUTE ORAL TOXICITY
DL50: > 5 ml/kg
ACUTE PERCUTANEOUS TOXICITY
DL 50: > 4 ml/kg
IRRITATION: - Skin: Considered to be a mild irritant

- Eyes: Considered to be a mild irritant
SENSITISATION: Unlikely to sensitise the skin.
CHRONIC TOXICITY: SHELL TELLUS products are formulated from severely refined
mineral oils which are considered to be non-cancer causing following toxicological tests
performed on the skin of mice using the same types of oil.
SUMMARY: SHELL TELLUS oils are considered to be of a low level of acute systemic
toxicity. In normal use, they are unlikely to irritate the skin or eyes, or to sensitise
the skin. No long-term toxic effect is likely. Users are nonetheless advised to
avoid repeated and/or prolonged contact with mineral oils such as SHELL
TELLUS, which could lead to irritation or even dermatitis in the event of
conditions of poor personal hygiene.
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USED OILS:
Used oils may contain impurities that are health hazards. They must be
handled with care, and contact with the skin must be avoided whenever
possible. Collection and disposal must be carried out in accordance with the
regulations in force (see Section 6).
5 - FIRST AID
Call a doctor
Whilst waiting for the doctor to arrive, refer to the following guidelines:
INGESTION:
No special treatment is normally required. Do not induce vomiting to

avoid the risk of debris being sucked into the respiratory passages.
INHALATION:
This risk exists only for oils that contain a high proportion of very
light distillates.
If inhalation occurs, the mouth and gastro-intestinal tract may become
irritated. In the event of exposure to a high vapour concentration, move
the patient to a location with fresh air. Keep the patient warm and
relaxed.
ASPIRATION:
The risk of aspiration depends on the viscosity, which determines the

ability of materials to be sucked into the respiratory system. In the event
of suspected aspiration (e.g. during vomiting), transport the patient to
hospital for emergency treatment.
EYES:
Wash eyes with copious water, and consult a specialist.
SPECIFIC CASE: In the event of contamination via the skin by a high-pressure jet, there is
a risk of contaminant introduction into the patients system. The patient
must be taken to hospital even if there is no obvious injury.
6 - ENVIRONMENTAL PROTECTION
Regulations concerning the disposal of oils and lubricants in surface, underground, and sea
water: Acts 73-218 dated 23-02-73 and 77-254 dated 8-03-77, information notes dated 14-01-77
and 4-11-80.
Regulations concerning waste: Law 75-633 dated 15-07-75 and Act 77-974 dated
19-08-77 and Act 79-981 dated 21-11-79, modified by Acts 85-387 dated 29-03-85 and
89-192 dated 24-03-89 applying to the regulations concerning the recovery of used oil: Law 881261 dated 30-12-88.
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HF LT (50-100 Ton) Operator&#39;s Manual X40873h (May-2005)

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HYDRAULIC PRESS BRAKE

Update to cater for common electric cabinet.

Read the manual carefully to obtain a thorough knowledge of this machine.

HYDRAULIC PRESS BRAKE

FOR ALL PROBLEMS DURING MACHINE INSTALLATION

2. ACCEPTANCE, INSTALLATION AND SAFETY MEASURES.................................. 1

2.7. SAFETY PRECAUTIONS ........................................................................................... 27

4.3.1. ELIMINATING SOURCES OF ERROR ................................................................ 7

4.4. LOCATION OF CONTROL AND SIGNALLING DEVICES...................................... 9

5. FORMING TECHNIQUE & TOOLING .......................................................................... 1

6.5. DESCRIPTION OF CYCLES ...................................................................................... 20

APPENDIX A PROGRAMMING MANUAL

Quality Control department completes this technical manual by adding

(50 tons / 1.2 meter)

All models are delivered:

In a basic version without light curtain,

REVIEW OF THE CONVENTIONAL DESIGN OF PRESS BRAKES

AMADA SYSTEM: Slotted beam (for 35- to 100-ton press brakes).

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

2.1. GENERAL INFORMATION

The marking on your press-brake corresponds to the following specifications :

Name and address of the manufacturer.

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

j) Warning on residual risks.

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

k) Overall stroke of the beam.

Plate for a machine

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

Plate for a machine with laser beam protection LazerSafe model.

Plate for a machine with laser beam protection Akas model.

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

2.2. PREPARING THE SITE

At the rear, allow clearance of approximately 1 metre to allow various maintenance

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

2.2.1. STANDARD STROKE WITH STANDARD SPEED AND HIGH SPEED

Distance between uprights

Thickness of the uprights

Centre distance between upright axis

For transport, reduce length by 256mm and width by 380mm.

Units 1,20 m 2 m 2,50 m

n/a : not available

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

2.2.2. LONG STROKE WITH STANDARD SPEED AND HIGH SPEED

HF 50-12 LS HF 50-20 LS HF 80-25 LS HF 100-3 LS

Distance between uprights

Thickness of the uprights

Centre distance between upright axis

For transport, reduce length by 256mm and width by 380mm.

Units 1,20 m 2 m 2,50 m

AMACLIP sectionalised distance pieces

n/a : not available

2.3. MACHINE RECEPTION

Refer to Section 2.3 to identify the recommended floor support areas.

* With NC type : OPERATEUR 2000 and AMNC.

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

2.4. RECEPTION & HANDLING

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

Only use these holes for

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

2.4.2. BASIC PRINCIPLES

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

Minimum length of the

ACCEPTANCE, INSTALLATION AND SAFETY MEASURES

HF LT (50-100 Ton) Operator's Manual X40873h (May-2005)

HF LT (50-100 Ton) Operator's Manual X40873h (May-2005)