PC800/PUNCHWIZARD TURRET

CONTROL MANUAL

801 Secretary Drive, Suite A

Arlington, TX 76015
Phone: 817-861-6955 Fax: 817-796-2983
Website: www.pccontrols.net
E-mail: Sales @pccontrols.net

TABLE OF CONTENTS
PC Controls Licensing Agreement. 3
Safety & Product Warnings 4
PC800 Front Panel.. 5
Main Menu Screen.. 6
Edit Tool Library Screen. 7
Turret Layout Screen9
Define Part Screen..11
Create Part Screen.......13
Define Hole Pattern Screen.15
Define Bolt Hole Pattern Screen.16
Define Arc Pattern Screen ..17
Define Line Pattern Screen..... 19
Define Window Pattern Screen21
Run Mode Screen.... 23
Load File Screen...25
Save A Punchwizard File Screen......26
Machine Status Screen. ....27
Manual Controls Screen...32
Terminal Screen...33
Appendix A Programming examples....34
Appendix B Tooling Descriptions..........48
Appendix C M-Codes....50
Appendix D Part Grouping, Zoom, & Mirror Commands....54
Appendix E Networking.....58
Appendix F File Structure.........59
Appendix G Punchwiz.ini & Criblist.tlf.....60
Appendix H Special tool files........67
Appendix I File Conversion......69
Appendix J Security Key/Dongle...74
Appendix K MCC Parameter Maintenance........75
Appendix L Plasma Operations.....81
Appendix M PC800 Restore CD...........86

PC Controls License Agreement

This is a legal agreement between you the purchaser (either as an entity or individual) and PC
Controls. PunchWizard and AcroWizard S are copyrighted products owned solely by RGAM
Creations and PC Controls respectively and are protected by United States copyright laws and
international treaty provisions. Any other distribution is illegal and subject to appropriate legal
action.
GRANT OF LICENSE: This License Agreement allows you to use the programs mentioned
above on one punching machine and on one external, i.e. programming/engineering/training
machine. The program is considered "in use" on a computer if it is loaded into temporary
memory (i.e. RAM) or installed onto permanent memory (i.e. on a hard disk, CD-ROM or other
storage device).
UPGRADES: This license also applies to any upgrades that may be sent to you by PC Controls.
The license is automatically transferred to the new program with the understanding that all prior
versions be removed from use and the disk(s), manual(s) and security key(s) be returned to PC
Controls.
OTHER RESTRICTIONS: You may not rent or lease this software. You may not give this
program to another user (either an individual or an entity) unless it is part of a permanent transfer
of ownership of the punch machine, provided that the new owner agrees to this license
agreement. You may not alter, reverse engineer, decompile or disassemble this software for any
reason. The original disk(s) are your only authorized archival copy, no other copies are permitted
without the expressed written consent of PC Controls.
NO LIABILITY FOR CONSEQUENTIAL DAMAGES: To the maximum extent permitted by
applicable law, PC Controls in no event shall be liable for any damages whatsoever (including
without limitation, damage to any individual or hardware, damages for loss of business profits,
business interruption, loss of business information or any other pecuniary loss) arising out of
normal use, deliberate misuse or the inability to use this product. Because some
states/jurisdictions do not allow the exclusion or limitation of liability for consequential or
incidental damages, the above limitation may not apply to you.

SAFETY & PRODUCT WARNINGS

Operation of the PC800 control by untrained or improperly trained personnel
may result in damage to machinery and injury to personnel.
Modifying or changing control parameters incorrectly may cause machine
control to operate improperly and may result in damage to machinery and
injury to personnel. Only qualified and trained personnel should make any
parameter changes.
Improper electrical grounding or excessive electrical noise can cause machine
controls to operate improperly and may result in damage to machinery and
injury to personnel. Do not place the PC800 control in the neighborhood of
magnetic equipment such as transformers, motors or devices that generate
electromagnetic fields.
Automated machine controls may start automatically when under program
control. Use Emergency Stop buttons to stop machine movement if necessary.
PC800 control equipment can cause electrical shock. Only properly trained
personnel should perform maintenance on this equipment. Have qualified
personnel carry out all electrical work to prevent injuries or accidents
The PC800 unit is a CNC control and not a safety device. Safeguarding of
machinery with proper point of operation safety systems and proper installation
and use of such systems is the responsibility of the end user. The PC800
control is designed to work together with standard, point of operation safety
systems and will support such systems when properly engineered and integrated
together with such point of safety devices. Never eliminate or bypass any of the
safety circuits/devices on this machine.
Replace fan filters at regular intervals to avoid overheating.
Do not expose the PC800 control to excessive humidity to avoid risk of
electrical shock and damage to equipment.

PC800 FRONT PANEL

Select Power to the
PC800 control, OFF
or ON

Turn key to select Edit

Protect OFF or
ON

Push for single step

operation of the punch
head

Push to command an
emergency stop of the
machine

Notes:
Edit protect switch in OFF position will not allow any changes to
programs in the control. Edit protect switch in ON position
allows changes to programs. Edit protect key may be removed from
the control front panel to lock control in OFF or ON mode.

MAIN MENU SCREEN

Press to toggle the control
between Inch and Metric
units of measurement

Machine Model

Punch
Wizard
software
version
& date

Click to leave the Punch

Wizard Program

Click to load an
existing part

Click to edit the

Tool Library

Click to create a new

part

EDIT TOOL LIBRARY

SCREEN
Graphical
representation of
highlited tool in
master crib list

Master crib list of all

saved tools

Click to add a newly

created tool to
master crib list

Click to enter
Turret Layout
Screen

Click to update &

save changes to an
existing tool

Click when complete

with all actions in edit
tool library screen
Highlight tool &
click to permanently
remove tool from
master crib list

OPERATION IN EDIT TOOL LIBRARY Screen

To add a new tool:
1. Enter X & Y tool dimensions using
2. Select Tool Shape from drop down menu (circle, rectangle, obround, or miscellaneous)
3. Use the tool name automatically generated by the PunchWizard or replace with desired tool
name
4. Check Forming Tool block if you are adding a forming tool
5. Click

button to add the newly created tool to the master crib list

To edit an existing tool:

1. Highlight existing tool from master crib list
2. Enter changes to the selected tool using keyboard input
3. Click

button to save changes made to the selected tool

To remove an existing tool:

1. Highlight the tool you wish to remove

2. Click the
button to permanently remove this tool from the master crib list and
return to the main menu screen
NOTES:

Use auto generated tool names whenever possible and when naming tools, name all tools
with consistent names and spacing.
Use miscellaneous tool type for odd shapes as in diamonds, keyholes or complex items
like an insignia or company logo. Tools classified as miscellaneous are visually represented
as a rectilinear shape in Punch Wizard displays unless a Punch Wizard tool file exists
(*.pwt).

TURRET LAYOUT SCREEN

List of tools required
to punch current part
that are not currently
in the turret

Graphical representation
of current turret layout
and tooling

Click to add
highlighted
tool to turret

Click to remove
selected tool from
turret station

Check box to
automatically,
physically position the
turret after adding or
removing a tool

Click when done

resolving tools

Station, angle, and die

clearance of tool in
selected turret station

OPERATION IN TURRET LAYOUT Screen

The turret layout screen comes up automatically when a part is selected to punch and all of the tools
necessary to punch the part are not currently in the turret. This screen allows the operator to add all
necessary tools to the turret so that the part can be punched. The turret layout screen also allows the
operator to add and remove tools from the turret for tool change operations.
Adding to and removing tools from the turret:
1. To add a tool to the turret, highlight the tool in the left hand tool list and click
or highlight the tool and drag the tool and drop it into the desired station
2. To remove a tool from the turret, touch the tool in the turret and then click
NOTES:
Represents a turret station that currently contains a tool

Represents a turret station that currently contains a tool required for the current part
Represents an turret station that currently is empty

Represents a tool used in the current program that the M&G code was programmed
specifically to use the this particular tool

A blue colored station represents a tool station of the same size as the currently highlighted
tool in the left hand tool list
A black colored station represents a tool station of a different size than the currently
highlighted tool in the left hand tool list

10

DEFINE PART SCREEN

X,Y table
position for
loading a new
blank

Autooptimize
check box

Click to leave
Define Part screen
and return to Main
Menu screen

Click to create a new

part using information
from an existing saved
part file

11

Click to enter turret

layout screen
Click to enter the Create
Part Screen when all above
information for the new part
has been input

OPERATION IN DEFINE PART Screen

To define a new part:
1.
2.
3.
4.

Enter X & Y blank dimensions & material thickness,

Select Blank Material from drop down menu
Enter location of work grippers or click fetch grippers to locate position automatically
Input X & Y Load Position if desired, i.e. the load position you want the X & Y gauge to
be in for inserting new blanks
5. Enter Feed Rate setting %
6. Enter a File Name for the newly created part.
7. Check auto-optimize tab to perform tool optimization on parts
button when all of the above values for the new parts have been
8. Click the
entered and Punch Wizard will move into the CREATE PART Screen

To define a new part from a previously programmed part:

1. Click on the
button
2. Select the existing part you wish to use as the basis for creation of your new part from the
LOAD FILE screen selection

3. Click
PART Screen

to select this part and the Punch Wizard will move back to the DEFINE

4. Make any desired changes in the DEFINE PART screen and click the

Button to move into the CREATE PART Screen

12

CREATE PART
SCREEN
Part name of
current part on
screen

Red indicates X=0,

Y=0 Datum

Current Program
sequence

X & Y position of
cursor on screen

X & Y blank
dimensions of part on
screen

Click to
create a
single hole
pattern

Click to
create a
bolt hole
pattern
Part
counting
field

Click to
create
Arc
Click to create
a Line
Click to insert
an M-Code
(available on
gripper units)

Click to return to
main menu screen

Click to Load
an existing part

Click to move to
previous step in
program

Click to delete
a program step

Click to insert
a program step

13

Click move to
next step in
program

Click to
create a
Window
pattern
Click to enter
Run Mode

OPERATION IN CREATE PART SCREEN

To define new part:
1. Click on HOLE, BOLT, ARC, LINE, or WINDOW to create the next program
step
2. Input required parameters to create all desired program steps for the current part
3. Click on

button to move into RUN MODE

NOTES:
The program sequence number N is zero when a part is initiated since no actions have been
created. Clicking on N moves the program to the last punching block. This function is
useful for editing particular blocks in the program
Hits made by the current editable action are indicated by N and are displayed in red.
Moving all punch actions on the blank is easy with PUNCH WIZARD:
After all actions are placed, click to highlight the X or Y position field in the upper right corner
of the CREATE screen. Type 'P' (for PART MOVE) and either a '+' or '-' and the value to
offset.
*Example: On a 16 gauge (.063") plate with a 1" 90 degree flange in the X direction, click in
the X field and type 'P+1.032' to offset all the punching actions away from the X reference
point by 1.032". (1" for the flange and .032" for the bend allowance stretching)
When the part program is saved the offset is also saved.

14

DEFINE HOLE
PATTERN SCREEN
Select tool
drop down bar

X & Y location
on blank for
hole pattern
Check to halt
automatic
operation &
require pushing
start to continue
program
execution

Check to
automatically
open small part
drop chute

Input number of
seconds of delay to
put the table in a
temporary pause
condition

Cancel and
return to
Create Part
Screen

Uncheck creates
move/no
punch operation

Click when
finished input
of required
information

OPERATION IN DEFINE HOLE PATTERN SCREEN

To define a new hole pattern:
1.
2.
3.
4.

Select tool from tool select drop down bar

Input X & Y location on part blank for hole location
Input tool angle for selected tool
Select pause if you desire machine sequence to pause after the hole is punched

5. Click on

when all required information has been input

NOTES:
Define Hole Pattern is center of tool oriented
Drop chute, pause, punch, and delay should not be used on parts that are auto-optimized or
that contain repositions.

15

DEFINE BOLT HOLE

PATTERN SCREEN
Select tool
drop down bar
Radius of bolt
hole pattern

X & Y origin
of Bolt Hole
Pattern

Number of
holes in bolt
hole pattern

Initial or starting
degree for
bolthole pattern
(0-360)

Check box
for punching
in clockwise
direction
Cancel and
return to
Create Part
screen

Click when
finished input
of required
information

Check to halt
automatic operation &
require pushing start
to continue program
execution

OPERATION IN DEFINE BOLT HOLE PATTERN SCREEN

To define a new bolt hole pattern:
1.
2.
3.
4.
5.

Select tool for punching a bolt hole pattern from select tool drop down bar
Input X & Y location on blank for center of bolt hole pattern
Input radius of bolt hole pattern
Input initial or starting angle for bolt hole pattern (0-360)
Check boxes for pause or CW operation if desired

6. Click on

when all required information has been input

NOTES:
Define Bolt Hole Pattern is center of tool oriented
Bolt Hole Pattern requires two or more holes
Bolt Hole Pattern is a full 360 degree circular pattern. Use bolt hole pattern to place
2 to 999 holes around an X, Y origin.
16

DEFINE ARC
PATTERN SCREEN
Select tool
drop down bar
Radius of arc
pattern

X & Y origin
of ARC Pattern

Check box
for punching
in clockwise
direction

Check box for

nibbling option
of arc pattern

Check box
for pause
before
continuing to

Check box for

tool comping
in arc pattern
operation
Start & End
angles for arc
pattern

Number of
holes in arc
pattern
Cancel and
return to
Create Part
screen

Click when
finished input
of required
information

OPERATION IN DEFINE ARC PATTERN SCREEN

To DEFINE a new arc pattern:
1.
2.
3.
4.
5.
6.
7.
8.

Select tool for punching arc pattern from select tool drop down bar
Input X & Y location on blank for origin of arc pattern
Input radius of arc pattern
Check boxes for pause or CW operation if desired
Check box for desired tool comping
Input starting and ending angles for arc pattern (0-360)
Input starting angle of arc
Input tool angle value (0-360)
17

9. Click on

when all required information has been input

NOTES:

Define Arc Pattern is center of tool oriented

The Arc Pattern is a partial circular pattern, Arc can be from 2 to 999 punches.
Arc Radius is defined as the center of the pattern to the center of the non-comped punch
Tool comping will compensate the arcs punches. Selecting outside will increase the
Arcs radius the amount of the selected tool radius. Select inside to shrink the arcs
radius the same amount.
Scallop displays the height of the material left between two circular hits.
scallop

18

Starting &
Ending X &
Y positions
for line
pattern

DEFINE LINE
PATTERN SCREEN

Distance & Angle

Input values for Line
At Angle

Select tool
drop down bar

Click to
autocalculate
# of hits
to punch
a slot
pattern

Input for
number
of holes
in line
pattern

Check
to
comp
tool to
inside
of line

Check to
enable
nibbling
Tool angle
for selected
tool (0360)

Click to
Create Punch
Wizard Line

Axis alignment
selection bar

19

Click to cancel
and return to
Create Part
screen

Click to
Create
Line At
Angle

OPERATION IN DEFINE LINE PATTERN SCREEN

To define a new line using PW line pattern::
1.
2.
3.
4.
5.

Select tool for line pattern from select tool drop down bar
Input starting & ending X & Y locations for line
Input number of holes to punch line pattern
Select pause, End-to-End, nibbling options if desired
Input tool angle for selected tool

6. Click on

to create the new line

To define a new Line using LINE AT ANGLE pattern::

1.
2.
3.
4.
5.

Select tool for line pattern from select tool drop down bar
Input starting X & Y locations for line
Input number of holes to punch line pattern
Select Pause, End-to-End, Nibbling options if desired
Input tool angle for selected tool

6. Click on

to create the new line

NOTES:
The line command is used to place equally spaced holes in a straight line (horizontally,
vertically or at any diagonal). The minimum number of hits is 2; the maximum number
is 999.
When Slot is checked, the program will calculate the number of holes to connect the
first and last hits in the line.
When Pause is selected, the program will halt all movements after the action finishes.
When End-to-End is selected, the program compensates the leading and trailing edges
of the tool to align with the beginning and ending of the line rather than with the center of
the tool
When Nibbling is selected, the program will create optimally spaced hits at optimal
speed by keeping the clutch/brake assembly from fully cycling. Clutching will always
occur when Nibbling is not selected. Select Nibbling for most standard, flat-faced
tools.

20

DEFINE WINDOW
PATTERN SCREEN
Window or Disk
Selection check boxes

X & Y origin
of Window
Pattern

Radius tool
selection
bar

X&Y
Window cutout
size
Check
box for
nibbling
of arcs

Check box for

pause before
continuing to next
punch & tabs

Arc
Radius
input

Radius tool
drop down bar

Min & Max

inputs for
punch hits &
No of scallops

Window
Angle input

Cancel and
return to
Create Part
Screen

Click when
finished input
of required
information

21

OPERATION IN DEFINE WINDOW PATTERN SCREEN

To DEFINE a new WINDOW pattern::
1.
2.
3.
4.
5.
6.
7.
8.
9.

Select Window or Disk option check box

Input X & Y location on blank for center of Window pattern
Input X & Y dimensions of Window cut out
Select Tabs and pause check boxes if desired
Select Radius tool for Window pattern cut out
Select Nibble & Arcs check box if desired
Input Arc radius and Window angle (0-360)
Input min number of hits and scallops if desired
Select a line tool for punching out the Window pattern

10. Click on

when all required information has been input

NOTES:

Define Window Pattern uses tool compensation. WINDOW comps the tooling to allow
for Punch-out and Disk-out. WINDOW either cuts a hole (window) or drops a slug to
the selected dimensions (Disk). Select the Window or Disk button at the top of the screen to
select either option.
Hits are the number of punches in each of the four window radiused corners; scallop is the
height of the material left between 2 circular hits. See below. A value entered in either hits
or scallop will cause the program to calculate the other value.
In the radius tool selection, Punch Wizard will not allow a number of hits less than a one-half
tool overlap, nor a number of hits greater than a tool overlap less the thickness of the blank.
The one-half overlap limit is for speed and to ensure that the hits are connected, the later
limit is to prevent excessive tool wear. Because of this, selecting a tool with a tool radius
less than the blank thickness will cause a warning message from Punch Wizard that the
tooling is too small.
Entering an Arc Radius less than .001 will cause the function to completely ignore any Arc
tool as it is assumed you want a square cornered window or disk
Entering an Arc Radius greater than one half of either the X Width or the Y Width will
cause a warning dialog box. You will have to change one of your entered values. A bad
radius value is the usual culprit.
scallop

22

RUN MODE
SCREEN
X & Y position
of cursor on
screen

Part name of current

part on screen
X & Y blank
dimensions of part on
screen

Gripper detect
zones

Batch
Counter
Click to
move to
previous
program step
from an
existing
saved part

Click to
move to next
program step
Click to
enter
STATUS
screen

Click to
turn Punch
Off/On
Click to return
to CREATE
PART screen

Click to move
to
MANUAL
screen

Click to pause
punching
action

23

Click to select
Auto, Single
Block, or
Simulate

Click to
run current
part
program

OPERATION IN RUN MODE SCREEN

1. Select either Single, Auto, or Simulate mode to run the parts. Single mode
steps through the program one block at a time. To do so, use the Cycle Start button or
the START button on the screen.; Auto runs all blocks of the part automatically and
sequentially Simulate runs the part in a dry-run simulation mode allowing you to
verify correctness of the program prior to actually running the program.
2. Click

to begin execution of the selected program.

24

LOAD FILE
SCREEN
Click to load a
part into
Punchwizard
Click to return
to main menu
screen
Click to
Remove part
from saved file
list
Click to display
information about
highlighted parts

File directories
for selecting
existing part
programs

OPERATION IN LOAD FILE SCREEN

Loading a Part File:
1. Highlight the file directory from which you want to load a part
2. Highlight the part file you want to load into the Punchwizard
3. Click

to load the part

Permanently Removing a Part File:

1. Highlight the file directory from which you want to remove a part file
2. Highlight the part file you want to remove from the load file list
3. Click

to permanently remove the part file

NOTES:
Multiple part folders can be created for part loading and storage in the [paths] section of the
Punchwizard.ini file. Part storage and loading folders can be located in any drive, local or
network.
25

SAVE PUNCH WIZARD

FILE SCREEN
Enter name of
part to be
saved

Path of file to
be saved

Type of file to
be saved

Click Cancel to
return to main
menu screen

Click to save part

to selected path

OPERATION IN SAVE PUNCH WIZARD SCREEN

1. Enter the name of the part file you wish to save the current part as. Parts will be stored and
retrieved in alph-numeric sequence. Additional part information and notes may be entered
and saved in the file name area.
2. Select the path to which you want the part file saved into
3. Select the type of file you wish to save the part as, default is a .pwz file

Click

to save the current part file

Notes:

26

MACHINE STATUS
SCREEN

Click to reset
machine flags

Click to go to
terminal screen

Click to enter
MCC variable
screen

Click to close
out of status
screen

NOTES:

The Status screen displays all the machine's electrical functions. These include the X and Y
limit and home switches, the turret home switch, the ram position switches, lube and pressure
switches , etc.
The Status screen is available from the Run and Manual screens, click on the Status button to
check machine status at any time.
27

The Status Flags indicate the status of various machine conditions. Green indicates the status
of a particular function, Gray indicates the opposite condition, ex. When the Punch On
TDC flag is green it shows that feedback from the machine indicates to the control that the
Punch is physically on top dead center.
Alarm Flags indicate a machine alarm for a particular function. If the machine halts
punching operation because of a fault, the program will immediately display the Alarm
screen with the error displayed in red, otherwise the color of the alarm circle is gray
indicating a normal condition.
All alarms latch and stay on until they are reset. This means that the error condition may
have occurred only for an instant.
Clicking the reset button will cause the program to retest the alarm conditions, if the alarm
clears, the system returns to an operating state. If the alarm does not clear the root cause of
the problem has not been remedied.
Deselecting any of the update check boxes will enable a faster test of the machine functions
to locate error conditions.

Status Flag Definitions:

Press Motor On Green indicates that the Press Motor has been commanded by the
control to turn on

Press On TDC Green means that the proximity sensor on the crankshaft indicates to the
PC800 control that the Punch Head is physically at Top Dead Center position
Index Pins In Green means that sensor feedback (proximity switches) from the machine
indicates to the PC800 control that the index pins are physically IN
System Calibrated Green means that sensor feedback from the machine indicates that
the machine has successfully completed the calibration routine
System Fault Green indicates that a general system fault has occurred on the machine
Cycle Stop Green indicates that a cycle stop condition has been commanded to the
machine

Auto Index Pins In Green means that that sensor feedback from the machine indicates
that the auto index pins are physically IN

Auto Index Pins Out - Green means that that sensor feedback from the machine indicates
that the auto index pins are physically OUT
Auto Index Brake Green means that feedback from the machine indicates that the auto
index brake is engaged

28

Side Gauge Green means that sensor feedback (proximity or limit switch) from the
machine indicates that the side gauge is in the UP position
In Cycle Green means that the machine is currently executing an automatic cycle
Run Mode Green indicates that the machine is currently in RUN MODE
Manual Mode - Green indicates that the machine is currently in MANUAL MODE
Undefined This status flag is currently undefined and can be configured as an additional
status indicator

Alarm Flag Definitions:

X Axis Overtravel The X axis has moved beyond its designated travel limits
Y Axis Overtravel - The Y axis has moved beyond its designated travel limits
Stripper Miss Machine sensor feedback indicates that the punch has not correctly
stripped the material and the tool may be stuck causing the machine to halt operation
System Fault Sensor feedback has caused the control to go into a cycle stop condition
T Axis Origin Error Sensor feedback indicates that the T-axis has failed to origin
correctly

Index Pin Fault - The index pins that lock the turret in place before the Ram is fired
were commanded to engage or disengage and sensor feedback (proximity switches) indicates the
pins are not in their commanded position
Striker Fault Sensor feedback (proximity or mechanical limit switches) indicates that
the striker did not reach its commanded position
Emergency Stop The control has commanded the machine to enter an emergency stop
condition

Repo Cylinder Fault - Sensor feedback (air or hydraulic pressure sensors) indicate a
problem with one of the reposition cylinders. Either the cylinders were commanded to lower or
raise and sensor feedback indicates they did not reach their commanded position

29

Gripper Fault Sensor feedback (air or hydraulic pressure sensors) indicates that the
clamps are open while trying to start a program

TDC Fault Control feedback (proximity sensor on crankshaft) indicates that the
crankshaft is not at the top dead center position when it should be. Any time the striker or turret is
commanded to move the ram must be at TDC position or a TDC fault is declared. Either the
crankshaft is not physically at TDC or the sensor feedback is incorrectly indicating the crankshaft is
not at TDC.
X Following Error The actual position of the X-axis determined from encoder
feedback differs (greater than the allowed threshold) from the position commanded by the control
Y Following Error - The actual position of the Y-axis determined from encoder feedback
differs (greater than the allowed threshold) from the position commanded by the control

T Following Error - The actual position of the T-axis determined from encoder feedback
differs (greater than the allowed threshold) from the position commanded by the control
C Following Error - The actual position of the C-axis determined from encoder feedback
differs (greater than the allowed threshold) from the position commanded by the control

Servo Fault One of the servo drives (X, Y, T, or C) has indicated a servo fault condition
to the control

Low Air Pressure- Sensor feedback (air pressure sensor) to the control indicates a low air
pressure condition exists in the main air line

Gripper Failure During motion sensor feedback (air or hydraulic pressure sensors)
indicates the material clamps are open
Tool Door Fault The control has commanded motion but feedback to the control
(switch) indicates that a tool door is open

Auto Index Fault Sensor feedback (proximity or limit switches) to the control indicates
a problem with the auto-index mechanism. Any failure of the auto-index system to properly engage
or disengage will cause an auto-index fault
Lube Fault- Sensor feedback to the control indicates that the lube system is not
functioning properly

X OverTravel Precheck Before executing a program the control has determined that
the machine is being commanded to move outside the X-axis travel limits

30

Y OverTravel Precheck - Before executing a program the control has determined that
the machine is being commanded to move outside the X-axis travel limits

Repo Cylinder Safety Control feedback indicate that in the current program the
material grippers may collide with the reposition cylinders
Undefined - This alarm flag is currently undefined and can be configured as an additional
status indicator

31

MANUAL
CONTROLS SCREEN
Click to manually
jog Y axis in plus
direction

Enter X & Y
calibration values

Click to enter
MACHINE
STATUS
screen

Click to
manually
jog X axis
in plus
direction

Click to
manually jog X
axis in minus
direction

Click to
calibrate
machine

Click when
complete to
move to previous
screen
Click to manually jog Yaxis
in minus direction

Click to enter
Plasma option
controls screen
NOTES:

Calibration causes the X,Y,T, and C axes to come to home position. Click and holding on
the +X, -X, +Y, -Y button will drive the axis selected in the direction selected at a slow
speed until the button is released.

32

TERMINAL SCREEN

NOTES:

33

APPENDIX A Programming examples

Punch Wizard Line Example:
PW LINE punches from a Starting X and Starting Y location to an Ending X and Ending Y location
equally spacing the holes along a line, horizontally, vertically or at any diagonal.

ToolList: Where the tool is selected.

Starting X and Starting Y describe the beginning of the line.
Ending X and Ending Y describe the end of the line.
Number of Holes: the amount of equally spaced hits.
Slot: when clicked, will calculate the Number of Holes to connect the first and last hits in the line.
Pause: If selected, will halt all movements after action finishes.
End-to-End: If selected compensates the leading and trailing edges of the tool to align with the
beginning and ending of the line rather than with the center of the tool.
Nibbling: When making closely spaced hits optimal speed can be reached if the clutch/brake
assembly doesnt have to cycle. Clutching will always occur when Nibble is not selected. Select
Nibble for most standard flat-faced tools.
If using a forming tool (a louver, raised counter-sink or other type of extrusion tooling) or a very
large perimeter tool, stripping of the punch/die set may not occur on time. This could cause damage
to the part, tooling or the machine. When using forming type tools dont select Nibble.

34

Tool Comping will calculate left, right or no tool comping. Click to select which comping is
needed.
PW LINE examples:

0,0

24"

A part calls for five .250" holes equally spaced on a 1" wide by 24" long flange. The five holes
should start and end 1" in from the ends of the flange and be centered midway down the length of
the flange.
Knowing the beginning, end and width dimensions of the flange, use PW LINE. Start by clicking
line from the Create Screen. Select a .250" RND tool for the punch. From the drawing above enter
start X at 1", start Y at .5" then ending X at 23" and ending Y at .5". Enter 5 in the hits field. Click
PW LINE (Don't click 'SLOT' - leave 'End-to-End' unchecked - 'None' comping is checked)
Side to Side comping:
To trim off the flange on the previous drawing it would be easier if we used Tool Comping. Use the
sketch below now.

0,0

24"

Knowing the beginning, end and width dimensions of the flange use
PW LINE. Start by clicking line from the Create Screen. We have selected a 2.00" x .25" RECT tool
to demonstrate.
From the sketch above enter start X at 0", start Y at 1" then ending X at 24" and ending Y at 1".
Click on 'SLOT'. Clicking 'SLOT' caused PW LINE to calculate the number of hits with the selected
tool to completely cut-out the material between the two end points. Click PW LINE (leave 'End-toEnd' unchecked - 'LEFT' comping is checked. As the arrow above the nibble shows; the center of the
tool will go from left (X=0) to the right (X=24). Since the tool is required to be on the left-hand side
of the dotted line (1") selecting 'LEFT' comp is correct.
Had you wanted to go from the right side (X=24") of the blank to the left (X=0") 'RIGHT' comping
would have been correct.

35

End to End comping:

To trim off multiple straps of material as before but leave them on the sheet would require tabs to
hold them in place until all are punched. Use the drawing below for the next example.

0,0

24"

Knowing the beginning, end and width dimensions of the flange use
PW LINE. Start by clicking line from the Create Screen. We have selected a 2.00" x .25" RECT tool
for the punch to demonstrate.
From the drawing above enter start X at .01", start Y at 1" then ending X at 23.99" and ending Y at
1". Starting at X=.01" and ending X=23.99" will leave a .01" 'tab' at both ends of the PW LINE
action once 'End-to-End' is checked. 'EndtoEnd' comps the tool from the outer end of tool rather than
from the center of tool.
Clicking on 'SLOT' causes PW LINE to calculate the number of hits with the selected tool to
completely cut out the material between the two end points. Click PW LINE, ('End-to-End' is now
checked - 'LEFT' comping is checked). As the arrow above the nibble shows; the ends of the tool
will go from left (X=.01") to the right (X=23.99") 'EndtoEnd' of the slot and since the tool is
required to be on the left hand side of the dotted line (1") selecting 'LEFT' comp is correct.
If going from the right side (X=23.99") of the blank to the left (X=.01") 'RIGHT' comping would
have been correct.

36

Punch Wizard Line at Angle Example:

PW LINE can process lines at an angle just as easily. Use the drawing below for this next example.

10,10

1,1
0,0

Left, Right and End-to-End with Slotting capabilities can be used together to make a line at any
angle. For this example use a rectangular tool placed in the turret at 45 degrees. Select a 2.00" x .25"
RECT tool. Knowing the beginning X, Y and end X,Y locations use PW LINE. Start by clicking
nibble from the Create Screen.
From the sketch above enter start X at 1", start Y at 1" then ending X at 10" and ending Y at 10".
PW LINE will comp the starting and ending X,Y's once 'End-to-End' is checked. 'End-to-End'
comps the tool from the ends of the tool rather than calculating from the center of tool. Check 'Endto-End'.
Click on 'SLOT'. Clicking 'SLOT' causes PW LINE to calculate the number of hits with the selected
tool to completely cut out the material between the two end points. Click PW LINE ('End-to-End' is
now checked - 'LEFT' comping is checked) The bottom-right corner of the tool will go from lowerleft (X=1",Y=1") to the upper-right corner of the tool (X=10", Y=10") from end to end of the slot
and since the tool is required to be on the left hand side of the direction of travel selecting 'LEFT'
comp is correct.
Line At Angle uses the 'engineering' form to define degrees: 0 degrees at 3 o'clock and 90 degrees at
12 o'clock.
37

The first punch is offset from the Starting X and Starting Y with the total number of following
punches. If Punch origin is selected the Starting X and Starting Y is punched but with the same total
number of punches.
Starting X and Starting Y describe the beginning of the line. Distance: Spacing between punches.
Angle: The direction of the line in degrees.
Number of Holes: number of equally spaced holes along the line.
Pause: If selected will halt all movements after action finishes.
End-to-End: If selected compensates the leading and trailing edges of the tool to align with the
beginning and ending of the line rather than with the center of the tool.
Nibble: When making closely spaced hits optimal speed can be reached if the clutch/brake assembly
doesnt have to cycle. Clutching will always occur if Nibble is not selected. Select Nibble for most
standard flat-faced tools.
If using a forming tool (a louver, raised counter-sink or other type of extrusion tooling) or a very
large perimeter tool, stripping of the punch/die set may not occur in time. This could possibly cause
damage to the part, tooling or the machine. When using forming type tools dont select Nibble.
Tool comping will calculate left, right or no tool comping. Click to select which comping is
needed.
Line At Angle example:

30

1,1
0,0

In the Line At Angle example above we're going to use a .375 inch RND tool spaced every .5 inch
for 9 hits at 30 degrees starting at 1" in X and 1" in Y. Click on LINE in the CREATE screen. Select
a .375 RND tool. In the start X field, enter 1 and in the start field enter 1. Enter 30 in the ANGLE
field, .5 in the DISTANCE field. Enter 9 in the HITS field. Now click Line At Angle.
PUNCH WIZARD will begin at the X, Y start point, place a .5 inch interval between the origin and
the first punch at 30 degrees. The program will then incrementally move the part by the required .5
inch at 30 degrees and punch the second hole; and so on until all nine punches are completed.
* NOTE * Below the angle field is a check box labeled 'Punch Origin' Selecting it will cause Line At
Angle to punch the origin at 1", 1" then incrementally move the part. You will still get nine punches
with .5" spacing.
38

Punch Wizard Window Example:

WINDOW either cuts a hole (window) or a 'Drop or Slug' to your dimensions. Click the Window or
Disk button at the top of the screen to select either option.
Origin X and Origin Y describe the center of the window.
X Width and Y Width describe the overall size of the window.
Tabs when selected will leave small connecting pieces of material to prevent the cutout from being
loose.
Pause: If selected will halt all movements after action finishes.
Radius Tool allows selection of the radiusing tool (normally a circular tool).
Arc Radius the radial distance for the rounded window corners.
Window Angle can be changed from zero degrees to any other angle. The window will be rotated on
the blank. Window Angle will work best if the line tool is in a C axis.
If Window Angle is used with a fixed angle line tool the tool offset and the Window Angle offset
should be the same to prevent a stair-step like result. The line tool chosen can be a circular type tool
with only slightly better results.
Hits are the number of punches in each of the four window radiused corners.

39

scallop

Scallop is the height of the material left between two circular hits. A value entered in either Hits or
Scallop will cause PUNCH WIZARD to calculate the other value. Entering a scallop value is the
most efficient for later touch-up time. You may enter a HITS value between 2 and 999. PUNCH
WIZARD will default to the closest 'legal' limit.
MIN and MAX buttons. These buttons will calculate the minimum or the maximum number of hits
(mainly used as a quick reference guide). Line Tool allows selection of the linear tool (normally a
rectangular tool).
Notes:
Entering an Arc Radius less than the tool's radius will cause a warning dialog box. You will have
to change one of your entered values. A bad Radius value is the usual culprit. A square WINDOW is
created by not selecting a radiusing tool or leaving the Arc Radius value at 0.0.
A radius only (circular pattern) is available by setting the radius to one half the X width and the
Y height dimensions - X width and Y height must be the same.
The radius portion of the window will not allow a number of hits greater than a tool overlap less
than the thickness of the blank. The one-half overlap limit is for speed and to ensure that the hits are
connected, the latter limit is to prevent excessive tool wear caused by side-shear. Because of this,
selecting a tool with a tool diameter less than the blank thickness will show an error message that
tooling is too small.
If you choose inappropriate tooling for the Arc Radius or Nibble/Line sections unusual punching
will happen. If the window's Y size is 1" and you select a 2" Y tool you will get a 2" Y punch, not an
error message.

40

PART EXAMPLE #1
You're given a print for a sump pump cover. It requires punching, bending, welding and finish work.
2 .0 0 "

2 .0 0 "

.2 5 0 hole 4 t imes
on 6 " x 6 " spac ing
cent ered @ 2 5.2 5 x 1 3.7 5
6 -3 2 Thd @
1 5 .0 0x1 6 .7 5
4 " circle
2 5 .25
1 3 .75

28"

6 -3 2 Thd @
1 5 .0 0x1 0 .5
1 " circle
2 6 .50 0
7 .0 00

34"

The material is 14 GA. CR.

You decide to relief punch the intersections of the corner notches to give the brake operation a
cleaner bend. The welding and finish grinding operations will clean it up.
Four tools will be required:
.083 C (corner relief hits and threaded holes)
.25 C (bolt pattern)
1 C (single hole and the 4 circular cutout)
2.25 x 2.25 R (scrap removal and the 4 corner notches)

41

Start PUNCH WIZARD and click NEW PART.

The Define Part screen asks for the blank information:

Enter X=34, Y=28, Thickness =.074, for material select steel.
Enter a PART NAME.
If the machine has been calibrated the gripper positions are known. They should be about 9 and
25, or enter desired gripper positions.
Use the default X, Y Load Positions since there are no unusual punches or sheet size demands. Click
OK.
Now in the Create Part screen select Hole.

42

Punch the relief holes and 6-32 thread holes first using a .083 C tool:
From the Define Hole Pattern screen click and drag on the ToolList until the .083 C is highlighted.
Four corner relief punches:
A .083 Circle punch is now selected. Enter X=2.000, Y=2.000 and click DONE.
Click HOLE before entering the remaining three X, Y values.
X=32.000 Y=2.000
X=32.000 Y=26.000
X=2.000 Y=26.000
The (4) .083 circles for the relief punches have been placed.
Two 6-32 threaded holes:
Use the Hole action and the same .083 C tool for the next two X and Y values:
X=15, Y=16.75
X=15, y=10.5
Now create the four .250 holes around that 4" hole. With PUNCH WIZARD there are three options.
You can place 4 individual .250 HOLEs; you can use LINE to place two lines of two holes, or you
can use math to calculate the bolt hole distances.

43

6"

The diagonal is 6 t imes t he sqrt of 2

t herefore t he radius is one half
t hat , or 6x1.41421/ 2 = 4.243

The print calls for 4) .250 with 6" spacing centered at X=25.25 by Y=13.75. Since none of the holes
have an X, Y coordinate, use a little simple geometry. Since the square root of 2 = 1.41421, and
there is a 6" spacing between two side holes equals 6 x 1.41421 divided by 2 = 4.2426, or the radius
of the bolt hole pattern; enter 4.2426 in the RADIUS field. Enter 4 in the HOLES field. Enter 45 as
the START ANGLE to radially offset the holes by 45 degrees.
Now cut out the 4 hole:
The circle can be cut out with either Bolt, Arc or Window actions, Arc is used in this example.
Using a 1 circle tool will leave a 2 diameter loose scrap piece inside the hole. Punch out the center
first with the 2.25 square.
Click Hole. Select the 2.25 R tool and enter X=25.25 and Y=13.75. Click Done.

44

Click the ARC button. Reselect the 1" circle tool. Enter the X origin as 25.25, Y as 13.75. The radius
of the hole is 2. Select Inside for the Tool Comping. Entering a Start Angle of 0 and an End Angle of
359.999 will cause a complete circle to occur. Enter a value in the Number of Holes and examine the
Scallop amount (20 hits = .059). Click DONE. A 4" hole is created.
Click HOLE again, this time selecting a 1" circle tool and enter:
X=26.5, Y=7.
Now position the 2"x2" corner notches:
Click the Hole Button again:
Select a 2.25" x 2.25" square tool from the ToolList, and enter:
X=.875, Y=.875
X=33.125, Y=.875
X=33.125, Y=27.125
X=.875, Y=1.875
The over-sized tool makes a cleaner notch with no spikes.
Click DONE.

45

Part Example 2
Radiused and square WINDOW actions:

12.25 x 8
.375
Rad
13.5

20 x 6.5

2.75
1.75

8.5
7.75 x 6

2.25

.5 Rad

2.375
24

Start PUNCH WIZARD and click NEW PART.

The Define Part screen asks for the blank information:
Enter X=24, Y=13.5, Thickness =.074, for material select aluminum;
Enter a PART NAME.
If the machine has been calibrated the gripper positions are known. They should be about 4 and
20, or enter gripper positions that are desired.
Use the default X, Y Load Positions since there are no unusual punches or sheet size demands.
Click the OK button.

46

Left-side Window:
Click Window, a window punch-out is assumed, enter X Origin of 7.75, Y Origin of 6, X Width of
2.375 and Y Height of 8.5.
Select a .25 Circle tool for the circle nibbling tool. Enter .375 for the Arc Radius; 3 hits and .015
scallop are shown.
Select the .5 Square tool for the line nibbles. Click Done.
Right-side Window:
Click Window, change X Origin to 20, Y Origin to 6.5, X Width to 6 and Y Height to 2.25.
Enter .5 for the Arc Radius.
Select the .5 Square tool for the line nibbles. Click Done.
Center-most Window:
Click Window, enter X Origin of 12.25, Y Origin of 8, X Width of 1.75, Y Height of 2.75.
Enter 0 for the Arc Radius.
Select the .5 Square tool for the line nibbles. Click Done.
47

APPENDIX B TOOLING DESCRIPTIONS

Tooling uses the 'engineering' form to define degrees: 0 degrees at 3 o'clock and 90 degrees at 12
o'clock.
X

TURRET
RAM

Tool descriptions and the part are viewed from above the punch ram looking down at the table. X is
the first dimension, Y second. A .25" x 1." 'RECT' (rectangular) tool is one quarter-inch wide in the
X dimension and one inch high in the Y dimension.
PUNCH WIZARD uses four simple tool shapes:
.500"

'C': circular tooling - a .500" round tool.

* NOTE * A prick punch, embosser or stenciler would best be described as a 'C' - circular tool.
.250"

.500"

1.000"
.500"

'R': rectangular tooling

All tools with four right angles and straight sides are considered rectangular.
* NOTE * A square is a rectangle with four sides of equal length.
.375"
1.000"

'O': obround tooling

48

An obround is defined with the smallest dimension being the flat sides and the longer dimension
having radiused cap ends. The sketch above would be a 1" x .375" 'O'

.750"

.625"

D punch

'M': MISCELLANEOUS tooling

Any tool that doesnt fit the first three descriptions is considered a miscellaneous tool or 'M'. All 'M'
tools are drawn on the screen as a rectangle with the center of the tool being the center of the tool
holder. A keyhole, hexagon or the 'D' tool shown above or other like punches should be described as
a 'M' tool.
Tooling holders have several sizes, designated 'A', 'B', 'C' and so on. When describing a tool to
PUNCH WIZARD the type of tool ('C', 'R', 'O' or 'M') AND the holder size ('A', 'B', 'C', etc). AND
the actual tool dimension AND the tool angular offset are required.
Tool angular offsets are shown below using a 1.000 x .250 R tool.
X
TURRET

Y
TOOL
1.000" x .250"
at 0 degrees
X

TURRET

Y
TOOL

1.000" x .250"
at 90 degrees

49

APPENDIX C M-Codes

The M-Code button is for various miscellaneous actions. These machine functions aren't punching
actions, and can act separately or with punching actions. After clicking the M-Code button a screen
with tabs is displayed. Selecting a tab will display the needed input(s). These M-Code actions are:
Feed Rate, Dwell, Drop Door, Pause, Reposition, Home Table, Ram Speed, Air Blow and Macro
Settings. These are shown below:
X
TURRET

Y
TOOL
1.000" x .250"
at 30 degrees

Feed Rate changes table movement speed. Enter a value between 10 and 100%.

Dwell halts table motion for a specified time in whole seconds.

50

Drop Door may be commanded to open or close. Resets to closed at end of part.

Pause halts all movement. After performing activity required (scrap removal, ETC.) use Cycle Start
or Resume to continue.

51

Reposition allows programmable reposition marks on blanks longer than the X table travel would
otherwise permit.

Load Position returns table to the load position. Requires Cycle Start to continue.

Ram Speed changes the ram motor speed during punching. Machines with a multi-speed ram motor
may use a lower speed for more efficient nibbling. A lower ram speed can allow the table to move a
longer distance without requiring the ram to fire the clutch and brake.

52

Air Blow to help remove scrap or blow off slugs may be commanded on or off. Resets to off at end
of part.

Macro Settings: G98 codes from the converter may require adjustments in direction and offset
dimensions. Macro Settings allows these corrections.

53

APPENDIX D Part Grouping & Zoom & Mirror

Part Grouping:

Once a punch action or a series of actions are created, (ARC, WINDOW, ETC.), you may want one
or more duplicates of that group of actions without reprogramming each action. PUNCH WIZARD
has three forms of grouping: Single, Rectangular Matrix and Radial.
Single grouping will place one copy of the original at a new location
Rectangular grouping will place multiple copies of the original in a row/column arrangement.
Radial grouping will allow one or more copies to be rotated around a given X,Y point in specified
angular displacement increments.
[Group Terminology]:
F2: the F2 key on the keyboard used to start the grouping function or edit the current group.
Parent: the original punching action(s) you are duplicating.
Parent Origin: The origin of the Parent is the intersection described by two imaginary lines. These
lines are created from the outermost edge of the punch closest to the X and Y coordinates of the
selected group. This X and Y is oriented closest to the machine table origin. See Bounding box
example on next page.
Child: a copy of the original (the parent)

54

Matrix: copies in an X and/or Y (row/column) with a given incremental displacement value.

Displacement: (X and/or Y offset spacing): the measured amount of unpunched spacing between
matrix children and the parent. The measurement of unpunched spacing is calculated from the
rectangular bounding box surrounding the parent plus the amount of extra space needed. When
Rectangular Matrix is chosen the X and Y dimensions displayed are the dimensions of the bounding
box.
Example 1: After selecting a group, Matrix displays an X dimension of 5" and a Y dimension of 4".
You want 1" of material to remain between the groups. Enter 6 (5+1) in the X spacing and 5 (4+1) in
the Y spacing.
Example 2: Select a single .500" round hole. You want 1.3875" hole centers. In Matrix the bounding
box dimensions for X and Y are .5". Add .5 to 1.3875 = 1.8875.
Radial: one or more copies with an angular displacement of the child relative to the parent around an
X, Y point of rotation.
Click and Drag: using the touch screen or mouse, position the cursor over a beginning point; click
and while holding down move to the ending point (touch screen and mouse work the same)
U
L

LL

Bounding Box: Click and Drag will create a bounding box that grows or shrinks as you move
around. Once it contains the action(s) you want, lift your finger from the mouse or screen. The
minimum sized rectangle or Bounding Box that contains the Parent will contain the action(s)
selected.
NOTE * Any alteration to the parent will alter the child(ren)
Single: You've created a window action and want to duplicate that same window elsewhere on the
blank. Press the F2 key, click and drag over the window action. It may be from any corner to any
diagonally opposing corner. After the selection has been made, you will then be given the Group
screen. Click on the Single checkbox. A green box will appear on the part blank showing the outer
dimensions of the copy. Touch the screen and drag the box to a place near where you want.
Now enter exact values in the X and Y Coordinate boxes in the upper right corner of the screen to
offset the Child exactly from the Parent.

Matrix: Press F2 and select the Parent group as before. When given the Group screen, enter the total
number of products for X and Y. Enter the amount of displacement between each row and column.
55

Depending on the placement of the parent, the matrix can generate above or below the parent by
clicking the FILL+ / FILL- toggle box. It's recommended you place the parent farthest away from
the grippers in the Y-axis and closest to the Zero reference point in the X-axis and use the FILLfunction. This helps prevent the sheet from becoming 'spongy' as material is removed during the
punching actions. Click the Rectangular button to generate the matrix.
Radial: Select the Parent group. In the Radial group area, enter the number of copies and the radius
of the group. The copies will be equally spaced around the circumference of the pattern and rotated
to have the same orientation as the parent. Optionally, clicking the ROTATE/NO ROTATE toggle
box can disable the rotation of each copy. Click the Radial button to generate the radial group.
(Parent = 1, plus 9 children = a total of 10 group actions)

Zoom & Mirror Commands

Zoom: A zoom function is available from the CREATE screen. Press F3 then Click and Drag over
an area of punches to better visualize or measure various punch placements. Press F3 again to return
to normal scale.
Zoom is scrollable. Pressing an arrow key will scroll the screen part display. Hold down the Control
key then an arrow key will speed-up the scrolling process. Scrolling is limited to the original
bounding box selection.
Zoom is zoomable. Press the right bracket key once ']' to zoom in by two 'power'. The left bracket
key '[' zooms out the same amount. Repeated pressing of either bracket keys multiplies the effect
until it reaches either one power or thirty-two powers.

56

A mirror function is available from the CREATE screen. Pressing F4 will allow you to Click and
Drag over an action(s). After selecting the action(s) you are presented the mirror screen. The
selection is represented by a symbol in the center of a 3 by 3 matrix. The symbol is a capital T with a
red dot to the lower right corner.

T
T

T
0
0

57

APPENDIX E Networking
The PC800 Control is networkable out of the box. PUNCH WIZARD is told in its
INI file where it should look to find parts. Thesepaths can refer to folders on the PC800, the floppy drive, or a networked server. When working with a networked
volume, PUNCH WIZARD minimizes conflicts between other PUNCH WIZARDs
sharing a file server.
Using a server for part storage makes backing-up your entire part library
simpler and allows all of your PC-800s and any off-line PCs running PUNCH
WIZARD to work with one pool of parts, meaning everyone will be getting the
correct, current revision. Your Tool Library may also be stored on a network
server for the same reasons.
To set-up the PC800/PUNCH WIZARD system to use a centralized server the
following steps are required:
1) Open the file PUNCHWIZ.INI in the C:\PUNCHWIZ\ directory. Search for
the line below [PATHS] - example: C:\punchwiz\punchjob\
2) Change the DOS path to the directory you wish
3) Do the same changes to CRIB_PATH=C:\punchwiz\punchjob
4) Save the new PUNCHWIZ.INI
5) Restart PUNCH WIZARD
NOTE* You may not operate one PUNCH WIZARD program from multiple
machines; PUNCH WIZARD tests for this! You may only use the number of
PUNCH WIZARD programs purchased for each machine tool.

58

APPENDIX F FILE STRUCTURE

The following shows the basic folders and files that are installed in the PC800 hard drive hard drive
at setup of the PunchWizard program. To assure proper recovery of this information in the event of
a system failure, back up both PunchWiz directories on a regular basis.

This folder contains files used to convert existing

program files into Punch Wizard format.
This folder contains log files that are automatically
generated whenever an alarm occurs.
This folder contains the status module exe file
This folder contains all of the individual saved part
files
This folder contains information relative to user
defined special tools (See Appendix G)
This is the executable file that starts the PunchWizard
program
This text file contains all of the tool information used
in the Master Crib List (See Appendix F)
This text file contains all of the tool information used
in the current turret layout (See Appendix F)
This text file contains all the unique configuration &
parameters for a particular machine (See Appendix E)

This folder contains updates by date of the parms.8k file

C:WINNT\SYSTEM32\

This text file contains the parms.8k file used when

your machine was originally set-up
This text file contains a log of all of the changes made
over time to machine parameters
The parms.8k file contains the system parameter
settings for your machine

59

APPENDIX G Punchwiz.ini file, Criblist.tlf, Hottools.tlf files

PUNCH WIZARD is designed to work with the wide variety of punch presses from many
manufacturers. Each punch press has different hardware characteristics and limits. These
differences are defined in the PUNCHWIZ.INI file.

!!!ANY CORRUPTION OR UNQUALIFIED CHANGES TO THE

PUNCHWIZ.INI MAY CAUSE MACHINE DAMAGE OR PERSONAL
INJURY - THEREFORE ONLY QUALIFIED PERSONNEL SHOULD
ATTEMPT ANY CHANGES TO THE PUNCHWIZ.INI. CALL PC
CONTROLS OR PEREGRINE PRODUCTIONS IF IN DOUBT!!!
Example Punchwiz.ini file:
[PATHS]
1=*\PUNCHJOB
[CONVERTER]
load1=*\PUNCHJOB
TYPES=TAP
END_TO_END=NO
SHOW_ALL=1
!HIDE_TYPES=INI,GMT,PWZ,EXE
STATION=3,2
SHAPE=9,3
DIMENSIONS=13,19
THETA=33,8
MATERIAL=1
GAUGE=.06
[CONVERTER_MATCH]
!METALSOFT=*
[TIMEOUTS]
MinDropChuteDelay=5
Calibrate=60
TurretMove=30
[MACHINE]
download=*\debugcode.txt
MACHINE_TYPE=0
TONNAGE=30
UNREPOSITION=OFF
REPO_CYLINDER_DISTANCE=14.5
RESOLVE_IGNORE_CLEARANCE=YES
RESOLVE_IGNORE_STATIONS=NO
60

ZERO_MARK=UL
FEEDRATE=100
LOAD_POSITION_FEEDRATE=100
LOAD_X=-3
LOAD_Y=5
NIBBLE_OFFSET=85
MEASURE=INCH
MACHINE_NAME=Whitney 636A
ZOOM_2X_CLICK=YES
X_AXIS=60.251,-3.251
Y_AXIS=36.251,-0.251
TAB_THICKNESS=.02
GRIPPERS=3.155,1.6,0.5,5.5,.3
GRIPPER_COUNT=2
MAX_DEPTH=36.5
HAS_DROP_DOOR=NO
RAMSPEEDDELAY=0.5
RAM_SPEEDS=PUNCH OFF,PUNCH ON
STATUS_INTERVAL=50
MAX_INTERVAL=0
!HIDE_DESKTOP=TRUE
GLOBAL_OFFSET_EDIT=FALSE
!WINDOWS_LOADSAVE=TRUE
SERIAL_CODE=BC99C23012805B
repo_y_inc_out=0.1
repo_y_inc_in=-0.02
tap_offset_x=0
tap_offset_y=0
tap_diameter=0
tool_load_table_x=0
tool_load_table_y=3
[filetypes]
1=.pwz;Standard Punch Wizard
[MATERIALS]
1_NAME=Mild Steel
1_THICK=0.118,0.236
1_FACTOR=0.2,0.25,0.3
1_TONNAGE=1
1_ALIAS=CR,COLD ROLLED
2_NAME=Aluminum
2_THICK=0.098,0.197
2_FACTOR=0.15,0.2,0.25
61

2_TONNAGE=.5
2_ALIAS=AL,ALUM
3_NAME=Stainless Steel
3_THICK=0.059,0.109,0.158
3_FACTOR=0.2,0.25,0.3,0.35
3_TONNAGE=1.5
3_ALIAS=SS, STAINLESS
[TURRET]
RADIUS=0
GRIPPERS_CLEAR=FALSE
SAFE_Y=.5
REPO_Y=6
MIN_LOAD_Y=0
GRIPS_CLEAR_TURRET=4.0
SMART_DETECTION=true
[ZONES]
A=3.250,1.875,1.938
B=3.375,2.250,2.500
C=3.625,2.562,2.625
D=3.750,3.000,3.062
E=4.375,3.750,3.750
F=5.250,4.125,4.375
G=8.500,1.875,2.125
H=8.500,2.250,2.125
I=8.500,4.125,4.125

62

Criblist.tlf File
Criblist.tlf is a text file that contains all of the stored tooling information in the
Master Crib found in the Edit Tool Library Screen. Criblist.tlf is updated every
time a tool is added, deleted, or changed in PunchWizards Master Crib List. The
criblist.tlf file resides in the C:\Punchwiz folder.
Y dimension of tool

X dimension of tool

Tool Shape, C(Circle), R

(Rectangle), O(Obround),
M(Miscellaneous)
000.1000 000.1000 CB
000.3130 000.3130 CB
000.3440 000.3440 CB
000.3750 000.3750 CB
000.4060 000.4060 CB
000.4380 000.4380 CB
000.4530 000.4530 CB
000.4680 000.4680 CB
000.5000 000.5000 CB
000.5310 000.5310 RB
000.5630 000.5630 RB
000.6250 000.6250 CB
000.6400 000.6400 CB
000.6560 000.6560 MB
000.6880 000.6880 CB
000.7190 000.7190 CB
000.7500 000.7500 CB
000.7810 000.7810 MB
000.7970 000.7970 CB
000.8120 000.8120 CB
000.8750 000.8750 CB
000.9380 000.9380 CB
001.0000 001.0000 CB
001.0620 001.0620 RB
001.0940 001.0940 RB
001.1000 001.1000 CB
001.1250 001.1250 CB
001.1880 001.1880 CB
001.2500 001.2500 CB
001.5000 001.5000 CC
001.6250 001.6250 CC
001.6560 001.6560 MC
001.7500 001.7500 CC

63

Tool Size, A, B, C, D, E

HotTools.tlf File
HotTools.tlf is a text file that contains all of the stored tooling information for tools
hat are presently installed in the machine turret. The contents of this file are
graphically shown in the Edit Loaded Tolls Screen. The HotTools.tlf file is updated
every time a tool is added or removed from the turret. The tool content found in the
HotTools.tlf file should always match the physical load contained in the machine
turret. The HotTools.tlf file resides in the C:\Punchwiz folder.
[hottools]
VERSION=1
1_X=2.0
1_Y=2.0
1_SHAPE=R
1_name=
1_theta=0
1_forming=False
1_DIE=0.0120

X tool dimension
Y tool dimension
Tool Shape, C(Circle), R (Rectangle),
O(Obround), M(Miscellaneous)

2_X=0.25
2_Y=0.25
2_SHAPE=C
2_name=
2_theta=0
2_forming=False
2_DIE=0.0120
3_X=1
3_Y=1
3_SHAPE=R
3_name=
3_theta=45
3_forming=False
3_DIE=0.0120
4_X=0.75
4_Y=0.75
4_SHAPE=C
4_name=
4_theta=0
4_forming=False
4_DIE=0.0120
5_X=1
5_Y=0.125
5_SHAPE=R
5_name=

64

Tool Name
Tool Angle
Forming tool designator, True
or False, if not a forming tool
Die clearance

5_theta=90
5_forming=False
5_DIE=0.0120
6_X=0.313
6_Y=0.313
6_SHAPE=C
6_name=
6_theta=0
6_forming=False
6_DIE=0.0120
7_X=
7_Y=
7_SHAPE=
7_name=
7_theta=
7_forming=False
7_DIE=0.0120
8_X=0.937
8_Y=0.937
8_SHAPE=C
8_name=
8_theta=0
8_forming=False
8_DIE=0.0120
9_X=1.0
9_Y=1.0
9_SHAPE=C
9_name=
9_theta=0
9_forming=False
9_DIE=0.0120
10_X=0.375
10_Y=0.375
10_SHAPE=C
10_name=
10_theta=0
10_forming=False
10_DIE=0.0120
11_X=1
11_Y=1
11_SHAPE=R
11_name=
11_theta=0
11_forming=False

65

11_DIE=0.0120
12_X=0.156
12_Y=0.156
12_SHAPE=C
12_name=
12_theta=0
12_forming=False
12_DIE=0.0120
13_X=
13_Y=
13_SHAPE=
13_name=
13_theta=
13_forming=False
13_DIE=0.0120
14_X=0.75
14_Y=0.437
14_SHAPE=R
14_name=
14_theta=0
14_forming=False
14_DIE=0.0080
15_X=1
15_Y=0.125
15_SHAPE=R
15_name=
15_theta=45
15_forming=False
15_DIE=0.0120
16_X=0.313
16_Y=0.75
16_SHAPE=R
16_name=
16_theta=90
16_forming=False
16_DIE=0.0120

66

APPENDIX H- Special Tool Files (*.PWT)

Special Tool File Format:

The file is created as a text file and is automatically processed into a binary file by the Punch Wizard
program. The file is placed in the current Punch Wizard folder \PUNCHWIZ\TOOLSHAPES\.
Only Arc and Line commands are allowed.
A(CX,CY,SA,EA,RADIUS)
L(X1,Y1,X2,Y2)
All coordinates are relative to the center of the tool except for A(SA,EA,RADIUS) which are
relative to the Arc center.
All Units are INCH. (1.0 is 1 inch, -.5 is a negative half-inch)
All Angles are in absolute degrees (180.00 is 180 degrees)
If no decimal is present then the value is a whole number.
The geometry of the Special Tool shape can have two different levels of quality: low mode and high
mode. Low mode limits the number of drawing commands to 100. High mode has a limit of 200
commands. Low mode is the default shape displayed; high mode is used when zooming but not
when punching a part.
Arc:
CX, CY:
SA, EA:

Center of arc. (Relative to the center of the tool)

Arc start angle (SA) and end angle (EA) in degrees. (Relative to the arc
center). Angles are always drawn in a counter-clockwise direction. An arc
with a starting angle of 90 degrees and an ending angle of 45 degrees will
draw a 315-degree arc.

Line:
X1, Y1:
X2, Y2:

Line beginning point. (Relative to the center of the tool)

Line ending point. (Relative to the center of the tool)

Example: Dos file name RADIUS- .250.PWT

[info]
Version=1
Name=RADIUS- .250
Width=.95
Height=.95
IsFormer=false
InventoryID=
SerialNumber=
LengthLeft=
Sharpen=500
CreatedBy=
ManufacturerID=
InventoryData=
67

Size=B
LongName=RADIUS- .250
[low]
1=L(.475,-.125,.475,.125)
2=L(.475,.125,.375,.125)
3=A(.375,.375,180,270,.250)
4=L(.125,.375,.125,.475)
5=L(.125,.475,-.125,.475)
6=L(-.125,.475,-.125,.375)
7=A(-.375,.375,270,360,.250)
8=L(-.375,.125,-.475,.125)
9=L(-.475,.125,-.475,-.125)
10=L(-.475,-.125,-.375,-.125)
11=A(-.375,-.375,0,90,.250)
12=L(-.125,-.375,-.125,-.475)
13=L(-.125,-.475,.125,-.475)
14=L(.125,-.475,.125,-.375)
15=A(.375,-.375,90,180,.250)
16=L(.375,-.125,.475,-.125)
[high]
[comments]
Description of information lines:
Name= the name of this tool, limited to 25 characters. Saved in part files and used for matching.
Does not have to match the .PWT name.
Width= the width of the geometry
Height= the height of the geometry
IsFormer= is this a forming tool (true/false)
InventoryID= your companys inventory id for this tool
SerialNumber= the serial number, if any, for this tool
LengthLeft= usable length left on the tool before replacement
Sharpen= this tool should be sharpened after the specified number of punches (Not yet implemented
as of 12-2001)
CreatedBy= the creator of this geometry file
ManufacturerID= the tool manufacturers id for this tool
InventoryData= additional inventory data for your companys use
Size= the size station this tool fits. Will override the size specified in the ToolCrib if they differ.
LongName= a longer, more descriptive name for this tool.

68

APPENDIX I FILE CONVERSION

FILE CONVERSION PROCESS

To convert an existing file to punchwizard format:

1. Click on New Part in the Main Menu Screen

2. Click on

button on the Define Part screen

69

3. Click on

button on the Load File screen

70

4. Select the existing part text file to be converted & click

71

5. Verify tooling information, type in desired part name or use default name, click
button

72

6. Hit

button to complete part conversion and move to the Create Parts Screen.

7. Verify the converted part is correct and make changes in the create part screen as required
8. Click

button when finished to save the newly converted part file button.

73

Appendix J Security Key/Dongle

A security key, or dongle is required for Punch Wizard to operate on each punch press or desktop
programming computer. Each dongle is constantly checked by the Punch Wizard program during the
programming and punching cycle to assure that a legal copy is running.
Attach the dongle to the CPU's parallel (printer) port. Any peripheral equipment that uses the
parallel port may still be connected to the dongle. Dongles are designed to be transparent to the user
or other programs.
If for any reason a dongle needs to be replaced; either from damage, inoperative or a special
upgrade; contact PC Controls.

74

Appendix K Parameter Maintenance Password

To access and modify the gauge parameters for your single station punch press do the following:
1. Access the Status screen when working in Run Mode screen
2. In the Status screen, click on the Show MCC Variables button

75

3. Enter one of the following passwords in the Security Screen

eveningeven if the current time is evening (after 12:00 PM) and the current day of the month is
an even number
eveningodd - if the current time is evening (after 12:00 PM) and the current day of the month is
an odd number
moringeven - if the current time is morning (after 12:00 AM) and the current day of the month is
an even number
morningodd - if the current time is morning (after 12:00 AM) and the current day of the month is
an odd number

76

Adjust MCC parameters shown below as required:

Caution: Modifying or changing control parameters incorrectly may cause machine

control to operate improperly and may result in damage to machinery and injury to
personnel. Only qualified and trained personnel should make any parameter
changes.

Press to save
newly input
parameters

Read in current
parameter values
from the Motion
Control Card (MCC)

Read in
original factory
MCC values

77

Cancel out of
Gauge Parameters
Screen

78

In the lower-left corner of the Manual screen is a button labeled Tweak MCC. MCC stands for
'motion control card'. This button is password protected. Access to Tweak MCC should only be
granted to authorized representatives of PC Controls.
The Tweak MCC screens contain variables used by the motion control card to define the
machine axes and servo tuning. These include table travel limits, ball screw encoder counts,
motor speed min-max limits, ETC. Incorrect changes to any of these variables could cause
serious machine damage and will guarantee operational failure.
*Note* descriptions of the variable is followed by three numbers in parentheses. The first
number is the numerical format and is represented as a number like -123.1234; if the first
character is a negative sign '-' a negative value is allowed if necessary. Positive values are
otherwise assumed, a plus sign '+' isnt required. The 123 means three digits are required before
the decimal point and the 1234 means four digits are required after the decimal. Pay special
attention to each variable format to prevent errors!
The second two numbers are the minimum and maximum allowable values. A min of 0 and a
max of 128 will not accept -5.0 or 1000.
Tweak MCC screens are displayed in a row/column format with an axis designation across the
top of the screen and a variable definition on the left from top to bottom. Unneeded axis
variables will not appear on screen.
Screen one: X, Y, T, and C columns
ENCODER SCALE FUNCTION
(12345.1234
encoder counts that equals one revolution or one inch
MINIMUM LIMIT
(-1234.1234
distance an axis may travel in the negative direction in inches
MAXIMUM LIMIT
(1234.1234
distance an axis may travel in the positive direction in inches
CALIBRATION LOCATION
(1234.1234
home location in encoder counts
CALIBRATION SPEED
(123.1234
axis speed in inches per second
JOG SPEED
(12.1234
axis speed in inches per second
RAPID SPEED
(123.1234
axis speed in inches per second
P-GAIN
(12.12345678
axis motor tuning - proportional gain
I-GAIN
(12.12345678
axis motor tuning - iterative gain
D-GAIN
(12.12345678
axis motor tuning - derivative gain
FF-GAIN
(12.12345678
axis motor tuning - feed forward gain
TABLE CALIBRATE SPEED
(12.1234
X,Y calibration speed in inches per minute

79

max)

-max

max)

max)

-max

max)

max)

100)

100)

max)

max)

max)

max)

>0

max)

TABLE RAPID SPEED

(123.1234
>0
X,Y maximum allowable speed in inches per minute
MAXIMUM FOLLOWING ERROR
(123.1234
>0
number of lead/lag encoder counts a drive will allow before faulting
JOG ACC RAMP
(1234.1234
>0
number of encoder counts per sec per sec during acceleration
JOG DEC RAMP
(1234.1234
>0
number of encoder counts per sec per sec during deceleration
IPB
(123.1234
>0
in position band in inches
ACC RAMP
(1234.1234
>0
number of encoder counts per sec per sec during acceleration
DEC RAMP
(1234.1234
>0
number of encoder counts per sec per sec during deceleration
STP RAMP
(1234.1234
>0
stop ramp - should be equal to DEC RAMP
CLUTCH DUMP TIMER
(123
>0
dwell time before clutch can fire - in milli-secs
PUNCH ANTICIPATION
(123.1234
>0
distance the table can be in movement before tool strikes part - in inches
PUNCH CLEAR DELAY
(123456
>0
time punch must retract from part before table can move - in milli-secs
FOV TURRET
(1.1
>0
feed-rate-override in percentage: 1.0 = 100%, .5 = 50%
FOV C AXIS
(1.1
>0
feed-rate-override in percentage: 1.0 = 100%, .5 = 50%
GRIPPER LOCATE Y-POS
(123.1234
>0
Y axis position during find grippers & calibration - in inches
REPOSITION FOV
(123.1234
>0
feed-rate-override during repositioning - in inches per minute
Y SLOWDOWN DISTANCE
(12.1234
>0
distance from turret grippers must slow down passing under turret
Y SLOWDOWN FOV
(1.1
>0
feed-rate-override in percentage: 1.0 = 100%, .5 = 50%
LUBE ON TIME
(1234567
>0
lube system on time in seconds
LUBE OFF TIME
(1234567
>0
lube system off time in seconds
STRIP MISS TIMER
(1.12
>0
max time allowed for strip miss sensor to detect tool in seconds

max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)
max)

Appendix L Plasma Operations

Line Contouring Operation:
Select
Plasma tool
Click to
make last
end point
become new
start point

Select line
length

Starting X
& Y line
position

Select
line angle

Check to
pause after
cut

Click to
complete
the line
after all
inputs

Check to cut at constant

velocity, un-check to
decelerate at end of cut

Program feed
rate setting

Select Kerf
comp setting

81

Click to return to
cancel and return to
last screen

OPERATION IN Line Contouring

To define a line contour:

1.
2.

Select the Plasma contouring tool top of tool list

Click on the + button to begin new X, Y value with last line ending
X, Y value
OR

3.
4.
5.
6.
7.

Enter the Starting X and Starting Y values

Enter length of cut line
Enter line Angle (+ or 360 degrees)
Select Pause to pause after cut
Check Constant Velocity if you dont want to decelerate at the end
of the cut; Un-check Constant Velocity if you want to decelerate at
the end of the cut
Enter Feed rate in Inches-per-Minute
Select Kerf Compensation (left, none, or right)
Click Line At Angle to complete the line

8.

9.
10.

NOTES:
Check Pause to allow scrap removal
Kerf is the width of a cut; if the cutting head removes .100 inches of material, the Kerf is .100.
Kerf comp is the kerf, i.e. .050.

..100 Kerf

.100 cut

82

Starting X
& Y origin
of arc

Arc Contouring:

Select
Plasma tool

Select Kerf
comp setting

Click to
make last
end point
become new
start point

Select degrees of
travel of arc

Check to cut
at constant
velocity, uncheck to
decelerate at
end of cut

Click when finished

input of required
information

Starting
angel of arc

Click to cancel
and return to last
screen

Program feed
rate setting

83

OPERATION IN Arc Contouring

To define an arc contour:

1.
2.
3.
4.
5.

Select the plasma contouring tool top of tool list

Enter the center of the Arc in Origin X and Origin Y
Enter Arc radius
Select Pause to pause after cut
Check Constant Velocity if you dont want to decelerate at the end of the cut; Uncheck Constant Velocity if you want to decelerate at the end of the cut
6. Enter Start Angle ( 0 degrees is at 3 oclock)
7. Enter Degrees of arc travel (+ or 359.999 degrees)
8. Enter Feed rate in Inches-per-Minute
9. Select Kerf Compensation (left, none, or right)
10. Click Done to complete the arc action

NOTES:
Kerf is the width of a cut; if the cutting head removes .100 inches of material, the Kerf is .010.
Kerf comp is the kerf, i.e. .050.
.100 Kerf

.100 cut

84

PLASMA ARC AND LINE PROGRAMMING EXAMPLE

85

Appendix M PC800 Recovery CD

In the event that your PC800 system fails due to hardware or software problems on the hard disk
drive, the system can be restored to the original condition (when your PC800 control was initially
installed) by using the PC800 Recovery CD. The recovery CD will reload the Windows operating
system and all programs that were present at the initial installation of your PC800 control. If you
have installed other software since this time, you will need to reinstall this software.
Provided that you have back-up copies of your critical PC800 files (See Appendix F), your PC800
control can be easily restored to its condition as of your last file back up by performing the
following steps:
1. Place the PC800 Recovery CD in the CD drive
2. Re-boot the PC800 control, the system will boot from the recovery CD
3. You will see the following screens; respond to each screen as follows:
PC800 Disk Rebuild Utility Press any key to continue --- Press Any Key
Partition sizes correct? --- Yes
Proceed with Disk Load? --- Yes
4. When the recovery operation is complete, you will see the message: Clone completed
successfully.
5. Take Recovery CD out of Drive & store in a safe location --- Click on Reset Computer
6. Copy your PC800 back-up critical files into their correct location (see Appendix F)
7. Restart the PunchWizard program

86