PRESS BRAKE HS SERIES HS 5020/8025/1303/1703/2204 OPERATOR'S MANUAL This product comes standard with * Circuit Diagrams + Operator's Manual QOmava Hs-E01.201407CONTENTS Hazard Information on Machine 1. Overall management responsibilities... 1-1. Reporting plan and applying for permission... 1-2. Preventing hazards, 1-3. Appointing chief operator 1-4, Safety and health education 4-5. Inspection and repair before start of day's work. 4-6. Special voluntary inspection 2. Prohibiting modification of machine 2-1, Prohibiting modification of safety device (option) 2.2. Prohibiting removal, opening, and installation position change of protective devices ... 2-3, Prohibiting adjustment of limit switches and other safety-related devices .. 2-4. Prohibiting change of NC software and hardware. 3, Residual risk map peculiar to machine Model: HS series...... 4. Residual risk list peculiar to machine Model: HS series. 4-1. Installation. 4-1-1. Moving and lifting machin 4-1-2. Light curtain system. . 4-4-3. Machine location 10 4-2. Operation (setup and setting)... 1" 4-2-4. Changing 10018 ..-...-n " 4-2-2. Creating processing program eee 1 4-2-3. Applying force with handwheel....... 118 4-2-4, Before starting machine 4-3. Operation (bending)... 4-3-1. Production bending 4-4. Maintenance 4-4-1. Maintenance 4-4-2. Lubrication 5. Location of warning labels. 17 18 18 27 27 28 29 (Continued on next page.)2-8. Supplying electric power. 2-8-1. Connecting power cable...... 2-8-2. Checking electrical connections 2.9, Leveling 2-40. Paralleling ram and bed 2-11. Checking machine origin 2-12, Checking movement of each axis 2-13, Making final CheCkS 00sec Part3 Controls. 1, Pendant control box 3-2 2, Electrical enclosure ... 3-7 3. Foot pedal unit. 3-8 Part 4 Preparation. 1. Setting up stoppers (for standard machine)... 1-1. Installing stoppers....... eae 43 1-2. Positioning stoppers .... 1-3. Removing stoppers. : 2. Setting up optional stoppers and stopper finger 2-1. Changing optional stopper fingers... 46 2-2. Coordinates of optional stopper fingers. 47 2-3. Installing and removing detachable stationary stoppers (option) 4-10 2-3-1. Installing detachable stationary stoppers... 4-11 2-3-2. Removing detachable stationary stoppers ....... 4-13 3. Workpiece overhang and stopper capability 4, Turning on power... 5, Zero-returning all axes 6. Installing and removing tools 6-1. Installing tools... 6-2. Removing tools 6-3. Installing die holders and dies 6-3-1. Installing 2V-dies. a 6-3-2. Installing 1V-dies for forming sashes 6-3-3. Installing 1V-dies.... 6-3-4, Installing sectionalized 1V-dies and aligning their die holder with punches 4-29 7. Setting up optional two-operator foot pedal units 4-32 7-1. Operation by two operators oe 432 7-2. Operation by one operator... (Continued on next page.)Part6 Alarms 1. NC message list..... 2. Safety PLC message list. Part7 Maintenance. 1. Inspection before start of day's work. 2. Maintaining hydraulic system 2-1. Checking hydraulic system... 2-2. Checking hydraulic oil level 2-3. Changing hydraulic oil 3. Lubrication... 3-1. Lubricating guide rollers 3-2. Lubricating backgauge .. 3-2-1. Standard machiné 3-2-2. Machine with optional Y-axis (Y1, Y2) . 4, Dismantling and scrapping... 4-1. Disposal of machine body .. 4-2. Disposal of grease and oil. 4-3. Disposal of electrical parts wt 5. Fee-based consumable parts list... Appendix. 1. Noise and vibration data 2. Emergency stop time and inertial drop distance of ram 3. Center of gravity of machine 4. Safety data sheets 4-1. Shell Alvania EP Grease 1, 2, RO, ROO, & ROOO 4-2. Shell Tellus Oil -A-10 4-3. THK AFB-LF Grease eS) 4-4. THK AFC Grease. AB, viiHIHS-E01 Hazard Information on Machine The Hazard Information on Machine communicates machine and other hazard information to the user and prompts the employer to perform risk assessment for ‘occupational accident prevention. The residual risk map and residual risk list contain information required to communicate to the employer the hazards that must. be made known to the person or organization to whom the employer transfers the machine. The Hazard Information on Machine forms part of the manuals). Do not use the machine after understanding the Hazard Information on Machine alone, Be sure to carefully read and understand the manual(s) as well before using the machine, In addition to the Hazard Information on Machine, the manual(s) also describes the warnings in detail for specific tasks. Also comply with the warnings in the manuals). ‘The Hazard Information on Machine and manual(s) classify the hazardous situations into the following levels: DANGER _ Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING | Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION _ Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (For contents, refer to next page.)1. Overall management responsibilities 1-1. Reporting plan and applying for permission Reporting plan to Labor Standards Office Report the plan to install, relocate, or alter the machine to the Chief of the Labor ‘Standards Office. Have the safety of the machine checked and receive guidance on the safety of the machine. Reporting machin pec ied facility and applying for permission to use machine as specified facility ‘The machine belongs to the class of specified facilities under the Noise Control Act and Vibration Control Act as well as under the environmental protection ordinances of local governments. Reporting duties and regulation values vary from region to region. For details, contact the environmental protection office in your area. Reporting appointment of pollution control manager and pollution control supervisor This regulation applies to sheet metal shops equipped with mechanical presses with ‘a nominal capacity of 980 kN or more or with hydraulic presses with a nominal capacity of 2941 kN or more and located in areas designated by the Noise Control Act and Vibration Control Act. For details, contact your local government office in your area. 7 2. Preventing hazards Press brakes belong to power presses under the Industrial Safety and Health Act. Install protective devices and take safeguarding measures for power presses. The protective devices recommended by AMADA are made available to you. Take safeguarding measures suitable for your bending jobs. Check this Hazard Information on Machine, perform risk assessment, and take necessary safeguarding measures.2, Prohibiting modification of machine 2-1, Prohibiting modification of safety device (option) Do not make modifications such as removing and disabling your safety device, The light curtain system is installed to maintain the safety distance from the hazard limit. Never change its installation position. (When the laser safety device is installed, the laser beam position must be adjusted according to its manual.) 2-2. Prohibiting removal, opening, and installation position change of protective devices Do not remove the covers and guards of the machine. Do not change their installation position. Do not operate the machine with its covers and rear guard door open. Doing so may get you pinched or caught in the moving parts of the machine. If you touch a live part in the machine, you may get an electric shock. While the electrical enclosure is turned on, do not open the door of the electrical enclosure, and do not operate the machine with the door of the electrical enclosure open. 2-3. Prohibiting adjustment of limit switches and other safety-related devices Do not adjust limit switches and other safety-related devices. Doing so may result in a serious accident. 2-4, Prohibiting change of NC software and hardware ‘The machine is controlled by a personal computer-based NC unit. Any software or hardware changes may cause the machine to malfunction and lead to a serious accident. Do not install or uninstall software. Do not add or change hardware.4, Residual risk list peculiar to machine Model: HS series For the locations of residual risks on the machine, refer to “3. Residual risk map Peculiar to machine” described earlier. 4-1. Installation 4-1-1. Moving and lifting machine 1A WARNING > Hazard Machine > Description When you move or lift the machine, take appropriate methods and use appropriate shipping jigs and lifting devices. Failure to do so ‘may cause the machine to tumble or drop. > Measure 4 Ask AMADA or a specialized contractor to move or lift the machine. 4-1-2. Light curtain system 2 A WARNING > Hazard < Between tools > Description € If the light curtain system is installed improperly, the ram may not stop fast enough when the light curtain is interrupted and may get your hands crushed between the tools. > Measure Install the light curtain system to keep the safety distance as specified. >» Reference < Operator's manual of light curtain system4-2, Operation (setup and setting) 4-2-1, Changing tools 4 2 WARNING > Hazard < Between tools > Description -€ If while you are changing the tools without turning the MODE. ‘SELECT keyswitch to OFF, you lose your balance and reach between the tools and if another worker inadvertently presses the CLOSING foot pedal at that moment, you may get your hands crushed between the tools. > Measure 4 Before you change the tools, turn the MODE SELECT keyswitch to OFF, and remove and keep the key on yourself. Do not reach between the tools during the tool change. 6 5 A WARNING » Hazard 4 Between tools > Description < If you inadvertently press the CLOSING foot pedal while you are reaching between the tools and changing the punch, you may get your hands crushed between the tools. > Measure 4 Before you change the tools, turn the MODE SELECT keyswitch to OFF, and remove and keep the key on yourself. Do not reach between the tools during the tool change. Before you change the tools, close the ram to the specified position. 18 44 WARNING > Description< > Measure < > Reference < > Hazard Tools If the tools break and fly off when subjected to force exceeding their allowable tonnage, you may get injured by flying pieces. Do not apply any force above the allowable tonnage to the tools. You are recommended to use the Amada genuine A.L.D. tools that do not readily fly off if they break. Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. Operator's Manual, Part 5, “3. Programming” 9A WARNING >Hazard< > Description< » Measure > Reference < Tools If you move the ram without noticing the presence of an object other than the workpiece on the die when you set up the tools, the tools may break and fly off and may get you injured by flying pieces When you set up the tools, do not place any object on the die. Before you move the ram, check that nothing is placed on the die. You are recommended to use the Amada genuine A.L.D. tools that do not readily fy off if they break Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. Operator's Manual, Part 5, “3. Programming” 1313 4 CAUTION > Hazard Tools > Description When you slide a punch into position, you may get your fingers or hands pinched and injured between the new punch and an already installed punch. > Measure < Install the punch while taking care about where to hold it. 14 £\ CAUTION > Hazard < Tools > Description Non-genuine tools are different from the Amada genuine tools in the toughness and allowable tonnage assumed by the processing programs. If used, such non-genuine tools may break or otherwise fail > Measure < You are recommended to use the Amada genuine A.L.D. tools. 15 4& CAUTION > Hazard < Holders, Tools > Description When you change the holders or tools, you may drop them on your feet and get your feet injured. > Measure < Change the holders and tools while securely holding them. 154-2-4, Before starting machine 18 4\ WARNING > Hazard < Machine > Description -€ If you start the machine without noticing the presence of another worker in or around the machine, the worker may get injured. > Measure < Before starting the machine, check that there are no persons in and around the machine. 19 A. WARNING » Hazard 4 Machine > Description If the processing program has a problem and causes the machine to operate unexpectedly, there is a risk that the tools may break and fly off or the machine may hit and injure you. > Measure After you create or change a processing program, dry run the program and check the operation of the machine. Do not stan front of the tools. 1721 4\ WARNING > Hazard > Description < > Measure > Reference < Between tools |f the workpiece you hold moves and you put your fingers or hands between the tools while you are pressing the CLOSING foot pedal, you may get your fingers or hands crushed between the tools. Before starting the day's work, check that the light curtain system and. laser safety device function properly. Set the ram closing speed to low. If possible, set the stroke length of the ram to 6 mm {0.24 in,} or less. “1. Overall management responsibilities” described earlier Operator's Manual, Part 3, "1. Pendant control box” Operator's Manual, Part 5, "3. Programming” 22 £& WARNING p> Hazard > Description < > Measure >» Reference < Between tools If you inadvertently press the CLOSING foot pedal while the main worker, sub-worker, or another worker is reaching between the tools, they may get their hands crushed between the tools. Do not put your hands on the die. ‘When you work with one or more persons, check each other's working condition. ‘The main worker alone must press the foot pedals, Before starting the day's work, check that the light curtain system and laser safety device function properly. Set the ram closing speed to low. Operator's Manual, Part 3, “1. Pendant control box" Operator's Manual, Part 5, “3. Programming” 1925 4\ WARNING » Hazard < Between tools > Description < If you inadvertently press the CLOSING foot pedal while trying to remove the tool jammed into the workpiece, you may get your fingers or hands crushed. > Measure < When you do not bend any workpieces, release the foot pedal. Before starting the day's work, check that the light curtain system and laser safety device function properly. Set the ram closing speed to low. » Reference “1. Overall management responsibilities” described earlier Operator's Manual, Part 3, “1. Pendant control box” Operator’s Manual, Part 5, “3. Programming” 26 AX WARNING > Hazard Tools > Description 4 If you press the CLOSING foot pedal to bend the workpiece without checking that the displayed D-axis target value and D-axis current value are the same, the tools may break, fly off, and injure you. > Measure € You are recommended to use the Amada genuine A.L.D. tools that do not readily fy off if they break. Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. > Reference-¢ Operator's Manual, Part 5, "3. Programming” 27 A WARNING > Hazard 4 Tools > Description If you bend two overlapped workpieces together, the tools may break, fly off, and injure you. > Measure < Check that two workpieces are not to be bent together. You are recommended to use the Amada genuine A.L.D. tools that do not readily fly off if they break. Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. > Reference < Operator's Manual, Part 5, "3. Programming” 2430 44 WARNING > Hazard < Holders > Description < If the punch holders are subjected to a high thrust load, they may break, fly off, and injure you, > Measure Before you apply the force to the workpiece, check that the tools are fixed securely. > Reference 4 Operator's manual of punch holders 31 A. WARNING > Hazard < Workpiece > Description < If the workpiece jumps out of between the tools in the flattening stage of the hemming process, it may hit your body or face, > Measure < Flatten the sharp-angle bend in several steps during the hemming process. ‘As soon as the workpiece starts to slide, stop the flattening stage of the hemming process. Do not apply pressure to near the bend radius of the workpiece with the edge of the sharp-angle bend flattening part of the punch or double-deck hemming die. > Reference 4 Operator's manual of hemming tooling 32 44 WARNING > Hazard 4 Workpiece > Description If you hold the workpiece improperly and if you reach between the workpiece and tool or between the workpiece and ram, you may get your hands crushed. > Measure Hold the workpiece from below or hold the workpiece with great care. Set the ram closing speed to low. » Reference-< Operator's Manual, Part 5, “3. Programming” _ 2336 44 CAUTION > Hazard < Backgauge > Description If you press the START button without turning the MODE SELECT Keyswitch to OFF and with a part of your body within the travel range of the backgauge, you may collide with the backgauge when the backgauge moves. > Measure Before you reach into the travel range of the backgauge, turn the MODE SELECT keyswitch to OFF, and remove and keep the key on yourself. Before you press the START button, check for safety in the surrounding area. 37 AX CAUTION » Hazard < Workpiece > Description< As soon as the ram opens after the end of the bending operation, the workpiece may lift up, then drop, and injure you in the feet. > Measure < Set the ram slow-opening speed (Return Speed value) to low and securely grip the workpiece. > Reference < Operator's Manual, Part 5, “3. Programming” 38 44 CAUTION > Hazard 4 Workpiece > Description < If the workpiece is pushed forth by the stoppers as the backgauge moves forth, you may get your hands injured. > Measure Use the backgauge (BG) timer. Set the approach speed of the backgauge to low. Push the workpiece against the stoppers after completing the positioning of the stoppers. > Reference Operator's Manual, Part 5, “3. Programming” 254-4, Maintenance 4-4-1, Maintenance 412 WARNING =] > Hazard < Machine > Description-€ If another worker operates the machine without noticing that you are Performing maintenance on the machine, you may collide with the machine or fall and may get injured > Measure 4 Before you perform maintenance on the machine, turn off the shop circuit breaker and properly relieve the residual pneumatic or hydraulic pressure. Turn the machine circuit breaker to OFF and lock out its knob with a padlock. Post a sign to inform other workers that the machine is under maintenance. > Reference < Operator's Manual, Part 7, Maintenance OFF ) _ /|serviewe| 42 4X WARNING > Hazard < Electrical enclosure > Description If you touch a live part that is not fully discharged, you may get an electric shock. > Measure < After you tum off the shop circuit breaker, wait 1 min before you open the door of the electrical enclosure. 275. Location of warning labels Follow the instructions on the warning labels. Keep the warning labels well noticeable and never remove them. If any warning label is damaged or lost, immediately request AMADA for a new one and attach it to the same position. 2930 QOmava4-4-2, Lubrication 43 A CAUTION > Hazard < Backgauge > Description If you lubricate the backgauge while the backgauge is moving, you may get your fingers pinched and injured between the stoppers and die. > Measure 4 Before you lubricate the backgauge, turn off the shop circuit breaker and properly relieve the residual pneumatic or hydraulic pressure. | Tur the machine circuit breaker to OFF and lock out its knob with a padlock. Post a sign to inform other workers that the machine is under maintenance. > Reference Operator's Manual, Part 7, “3. Lubrication” 44 A CAUTION » Hazard 4 Foothold > Description 4 If you perform maintenance on the ram hydraulic unit, you may fall. > Measure 4 Asatule, do not step onto the machine to perform this maintenance. Given the risk of falling from height, ask AMADA to do the maintenance work for a fee. When working at height, wear a safety belt and take any other ‘compulsory measures according to the safety laws, regulations, and standards in your country or region to prevent falling from height. For the work at height, prepare a stepladder. Reference Operator's Manual, Part 7, “2. Maintaining hydraulic system” 2839 4X CAUTION > Hazard 4 Workpiece > Description Ata high ram bending speed, the workpiece suddenly whips up when force is applied and may hit you in the body or face. > Measure 4 Reduce the ram bending speed so that you can safely hold the workpiece. Be careful of your posture when you hold the workpiece. Hold the workpiece from the side of the workpiece or apart from the edge of the workpiece, > Reference 4 Operator's Manual, Part 5, “3. Programming” 40 A CAUTION > Hazard < Machine > Description €_ If another worker operates the machine while you are away from the machine during your work, that worker may get injured. > Measure 4 Before you move away from the machine during your work, turn the MODE SELECT keyswitch to OFF, and remove and keep the key on yourself, 2633 4X WARNING > Hazard Workpiece, Tools > Description 4 If the die is not held securely by the die holder, it may jam into the bent workpiece and drop from the bed together with the workpiece. The workpiece or die may hit you in the feet. > Measure Before you bend the workpiece, check that the die is securely fixed. 34 2X WARNING > Hazard 4 Machine > Description When you feel something wrong with the machine and approach the machine, you may collide with or may be crushed by the malfunctioning machine. > Measure 4 As soon as you feel something wrong with the machine, press the EMERGENCY STOP button. Also turn the machine circuit breaker to OFF and report to that effect to the chief operator. 35 44 WARNING > Hazard < Between tools > Description < Ifa reflecting object is placed below the light source of the light curtain system, the beam delivery path is distorted by the resultant reflection. The light curtain system cannot work as intended and you may get your hands or other parts of the body crushed. > Measure Do not place a reflecting object below the light source of the light curtain system. > Reference Operator's manual of light curtain system28 A WARNING » Hazard 4 Tools > Description If you re-bend the workpiece while the punch tip is not aligned with the bend line of the workpiece, the tools may break, fly off, and injure you. > Measure Before you re-bend the workpiece, align the punch tip with the bend line of the workpiece. You are recommended to use the Amada genuine A.L.D. tools that do not readily fly off if they break. Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. > Reference-4 Operator's Manual, Part 5, “3. Programming” O : SS PUNCH TIP BEND LINE OF ——~" WORKPIECE Y Lo x i (} = AM NY my 29 4X WARNING > Hazard 4 Tools > Description If you bend the workpiece with a larger than necessary bend angle ‘compensation value, the tools may break, fly off, and injure you. > Measure 4 You are recommended to use the Amada genuine A.L.D. tools that do not readily fly off if they break. Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. > Reference < Operator's Manual, Part 5, “3. Programming”23 AX WARNING > Hazard < Between tools > Description If you continue to bend the workpiece without noticing that you place your fingers or hands between the tools while the ram is closing, you may get your fingers or hands crushed between the tools. > Measure 4 Before starting the day's work, check that the light curtain system and laser safety device function properly. Set the ram closing speed to low. » Reference 4 “1. Overall management responsibilities” described earlier Operator's Manual, Part 3, “1. Pendant contro! box” Operator's Manual, Part 5, “3. Programming” 24 A) WARNING » Hazard Between tools > Description -€ If you press the CLOSING foot pedal at the same time as when you reflexively reach between the tools to retrieve the workpiece or tool you dropped into the machine, you may get your fingers or hands crushed between the tools. > Measure Do not reach between the tools. Before starting the day's work, check that the light curtain system and laser safety device function properly. Set the ram closing speed to low. If you must enter the machine, turn the MODE SELECT keyswitch to OFF, remove and keep the key on yourself, open the door of the rear guard, and enter the machine from the rear. > Reference < “1. Overall management responsibilities” desoribed earlier Operator's Manual, Part 3, “1. Pendant control box” Operator's Manual, Part 5, “3. Programming” @ x 204-3. Operation (bending) 4-3-1, Production bending 20 4 WARNING PHazard€ > Description > Measure< 18 Workpiece, Between tools When you press the CLOSING foot pedal, you may get your fingers, hands, or arms pinched between the tools. When you bend a small workpiece or a workpiece with a small grip allowance, you may inadvertently pinch your fingers between the tools and get your fingers injured. (1) Do not hold the workpiece. When the workpiece whips up, you may get your fingers or hands pinched between the workpiece and the punch. (2) Do not hold the workpiece from above with the fingers orhands. You may inadvertently put your fingers or hands between the tools or between the workpiece and tool. It possible, set the stroke length = {ih of the ram to 6 mm {0.24 in.} or Z (o2siny less. Hold the workpiece while —_)/ orless taking care not to place your t fingers on the workpiece. (1) Light hold the edge of the workpiece with the thumb, and hold the workpiece from below with the ing fingers, (2) Bend the fingers other than the thumb against the front of the die, and hold the edge of the workpiece with the thumb,4-2-2. Creating processing program 16 AX WARNING - > Hazard 4 Workpiece > Description -€ If the Tool height value is set improperly, the workpiece may whip up in an unexpected position when subjected to the bending force and may hit and injure you, > Measure Set the Too! height value properly. > Reference < Operator's Manual, Part 5, “3. Programming” 4-2-8. Applying force with handwheel 17. WARNING > Hazard 4 Tools > Description < If you inadvertently tum the handwheel excessively when you apply force to the tools, the tools may break, fly off, and injure you. > Measure < When you apply force to the tools, slowly turn the handwheel clockwise while looking at the current Force value. You are recommended to use the Amada genuine A.L.D. tools that do not readily fly off if they break. Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage > Reference < Operator's Manual, Part 5, "3. Programming” 1610 4X WARNING >» Hazard < Between tools > Description If you inadvertently press the CLOSING foot pedal while you are reaching into the machine from front, you may get body or other parts of your body crushed between the tools. > Measure < When you adjust the backgauge or perform any other work in the machine, turn the MODE SELECT keyswitch to OFF, and remove and keep the key on yourself. And open the door of the rear guard to work from the rear of the machine. © xX 41 WARNING » Hazard 4 Tools > Description If a 2V die breaks and flies off when you use the front V-groove of the 2V die, you may get injured by flying pieces of the tool > Measure < When you use a 2V die, use the rear V-groove. You are recommended to use the Amada genuine A.L.D. tools that do not readily fly off if they break. Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. > Reference-€ Operator's Manual, Part 4, Preparation Operator's Manual, Part 5, “3. Programming” 12 A. WARNING » Hazard < Between tools > Description If the laser safety device is installed improperly, the ram may not stop fast enough when the laser safety device is interrupted and may get your hands crushed between the tools. > Measure Install the laser safety device in the correct position as described in its manual. > Reference 4 Operator's manual of laser safety device 146 A WARNING > Hazard < Between tools > Description 4 If the CLOSING foot pedal is pressed inadvertently while the main worker, sub-worker, or another worker is reaching between the tools to align or change the tools, they may get their hands crushed between the tools. > Measure < Do not reach between the tools while working. When you work with one or more persons, check each other's working condition. 7 A WARNING > Hazard Tools > Description If the tools are not fixed securely, the tools and holders may be subjected to excessive force and may break when the bending force is applied to the tools. If the tools break, they may fly off and may get you injured. With being subjected to the force repeatedly, the tools may move little by little and may eventually break. > Measure 4 Before you apply the force to the tools, check that the tools are fixed ‘securely. You are recommended to use the Amada genuine A.L.D. tools that do not readily fly off if they break Set the maximum bending force (Tonnage value) properly. This setting is expected to be effective in preventing tool breakage but leaves the risk of tool breakage. > Reference < Operator's Manual, Part 5, “3. Programming” .D. 124-1-3. Machine location 3A CAUTION . » Hazard < Machine > Description < If the electronic parts of the machine malfunction due to heat, you may get injured, > Measure < Install the machine where it is not exposed to direct sunlight. Do not obstruct the air inlet and outlet openings of the machine. 10Qmava1-3. Appointing chief operator Appoint a qualified chief operator. Duties of chief operator 1. Check the machine and protective devices. 2. Take necessary measures when any abnormality is recognized. 3. Safekeep keys of the keyswitches. 4, Instruct workers in changing and adjusting tools. 1-4. Safety and health education Conduct safety and health education to workers who operate the machine for the first time. Conduct special education for workers who change and adjust the tools. SAFETY & HEALTH EDUCATION| 1-5. Inspection and repair before start of day’s work Inspect the machine before the start of the day's work. Try to find equipment failures and faults as soon as possible. If you find a problem, repair it or take any other necessary measure to prevent an accident. 1-6. Special voluntary inspection Have legal inspection conducted on the machine by qualified personnel once or more per year. Repair problems found by the inspection, and file the inspection results and repair records.1. Overall management responsibilities 4-1. Reporting plan and applying for permission 1-2. Preventing hazards 1-3. Appointing chief operator 1-4. Safety and health education 1-5. Inspection and repair before start of day's work. 1-6. Special voluntary inspection... 2. Prohibiting modification of machine ... 2-4, Prohibiting modification of safety device (option) 2:2. Prohibiting removal, opening, and installation position change of protective devices .......e 2-3, Prohibiting adjustment of limit switches and other safety-related devices cient 5 2-4, Prohibiting change of NC software and hardware....5 3. Residual risk map peculiar to machine Model: HS series... 4, Residual risk list peculiar to machine Model: HS series. 4-1. Installation .. 4-1-1, Moving and lifting machine 4-1-2. Light curtain system: 4-1-3. Machine location...... 4-2. Operation (setup and setting). 4-2-1. Changing tools.. 4-2-2. Creating processing program 4-2-3. Applying force with handwheel 4-2-4, Before starting machine. 4-3. Operation (bending) 4-3-1. Production bending. 4-4, Maintenance... 4-4-1. Maintenance .. 4-4-2. Lubrication 5. Location of warning labels. AabRaRR wowOmapaPart5 Operation... 5-1 1. Main display and program mode.. . 53 2. Common operations for all program modes............. 5-5 3. Programming, 3-4. Direct mod 3-2. Angle mode. 3-3. Shape mode. 3-4. Multi mode... . 3-5. L-shift function (option)........ 3-5-1. Operation in L-shift functio 3-5-2. Procedure 4, Operation of bend process. 4-1. Direct mode 4-4-1, Teaching of pinching point 4-4-2. Teaching of D values... 4-4-3. Teaching of backgauge. 4-2. Semi-auto mod 4-3. Auto mode 4-4, Bending at end of bed 5. Maintenance display 5-1, Parameters 5-1-1. Saving machine parameters. 5-1-2. Restoring machine parameters 5-1-3. Soft parameters .. 5-1-4. Changing user password 5-2. Utilities 5-2-1. Bending chart... 5-2-2, System parameters... 5-2-3. Changing language ... 5-3. Data import and export. 5-3-1. Directory Management 5-3-2. Exporting programs 5-3-3. Importing programs 5-4. Data management. 5-4-1. Edit menu. 5-4-2. Delete menu 5-4-3. Rename menu. 5-4-4. Copy menu 5-4-5, Save on USB Key menu... 5-4-6. Restore from USB Key menu 5-4-7. Custom 6. Turing off power viPart 1 ion .. 1. Main features 2. Names of main parts... 3. Components in electrical enclosure 4. Specifications 4-1, Machine... 4-2.NC coe 4-3. Standard NC functions 5. Composition of axes 5-1. Coordinate system of operating axes. 5-2. Coordinate system of each axis 5-3. Target and current value display of axes by machine specification 6. Dimensions of machine... 6-1. Standard machine ... 6-1-1. Dimensions in millimete’ 6-1-2. Dimensions in inches. 6-2. Machine with eight or ten axes... 6-2-1. Dimensions in millimeters. 6-2-2. Dimensions in inches. 7. Standard accessories. 7-1. Machine 7-2. NC Part 2 Installation 1. Installation considerations. 4-1. Environmental conditions 4-2. Shop power source 1-3. Things to be supplied by customer. 2. Installation ... 2-1. Location 2-2. Carrying 2-2-4, Using crane. 22-2. Using rollers 2-3. Foundation ... 2-4. Cleaning 2-5. Supplying hydraulic oil, 2-6. Removing shipping brackets .... 2-6-1. Ram... 2-6-2. Backgauge. stoppers, and stopper fingers 2-6-3. Pendant control box. 2-7. Pulling out rear guard (for machine with eight of ten ax€S) ...coecneennne 219PREFACE @ Before installing, operating, or maintaining this product, carefully read the manual(s) and thoroughly understand the contents. @ Strictly observe the Hazard Information on Machine and the warnings described in the manual(s). @ If you are not sure of how to operate this product, do not operate it by guesswork, but be sure to reread the manual(s) and operate it correctly as described in the manual(s). @ Always keep the manual(s) near this product so that you can reread the manual(s). @ When you transfer this product to another owner, be sure to hand it together with the manual(s) to the new owner. This manual classifies the hazardous situations into the following levels: ADANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious i Awarnine Indicates a potentially hazardous si avoided, could result in death or serious injury. AACAUTION Indicates a potent avoided, may result hazardous situation which, if not minor or moderate injury. NOTICE Indicates a potentially hazardous situation which, if not avoided, may result in damage to this product. NOTE Indicates not a warning but an item of information which should be known to work. Operator's Manual: HS Series Press Brake © 2014 by AMADA CO., LTD. No part ofthis publication may be photocopied or otherwise reproduced without the prior jul 2014 \wrtten permission of AMADA CO., LTD. ii Printed in Japan3. Residual risk map peculiar to machine Model: HS series For details of residual risks, refer to “4. Residual risk list peculiar to machine” described le 16, 20, 31, 92, 33, 37, 38 44 39 impact 1 42 * Electric shock15,30 + Impact aE + Flying broken pieces + Flying broken pieces. Impact 2, 4,5, 6, 10, 12, 20,21, 22, 23, 24, 25, 36 * Crushing 36, 43 + Impact, + Crushing EMERGENCY STOP buttons 4,3, 18, 19, 34, 40, 41 + Impact, + Crushing [Explanation of map (example) 42 Residual risk No, Hazard + Electric shock «Result of hazard