Reis Dialog III Control

Press Control
DialogIII
OPERATING MANUAL
preliminary version
Version: DialogIII 05.2004 GB -1

-2 Version: DialogIII 05.2004 GB
TAB LE OF CONTENTS
1 TABLE OF CONTENTS
1 TABLE OF CONTENTS
2 GENERAL DESCRIPTION
2.1 Features of the control 8
2.2 Type test 9
3 QUALIFICATION OF THE PERSONNEL

4 SAFETY INSTRUCTIONS
4.1 Explication of terms and symbols 14
4.1.1 User 14
4.1.2 Insured 14
4.1.3 Warnings 14
4.1.4 Skilled personnel 15
4.2 Instructions concerning safety
regulations 16
4.2.1 Setting (observe national regulations) 16
4.2.2 Maintenance (observe national regulations) 17
4.2.3 Instructions of the manufacturer 17
4.2.3.1 General remarks 17
4.2.3.2 Special safety instructions for the insured 18
4.2.3.3 Special safety instructions for the user 19
4.2.4 Safety equipment 20
4.2.5 Annual safety check 20
4.2.5.1 Inspections 20
4.2.5.2 Safety equipment 21
4.2.5.3 Test instructions of the manufacturer 22
5 HARDWARE AND SOFTWARE

6 INSTALLATION / CONFIGURATION
6.1 Delivery condition 26
6.2 Energy supply 26
6.2.1 Connect power supply 26
6.3 Modifications 26
6.4 Service functions 27
6.4.1 General instructions 27
6.4.2 set encoder to zero 28
6.4.3 Change machine data 31
7 OPERATION
7.1 Operating panel 34
7.2 Operating elements 34
7.3 Control Panel 38
7.4 CHANGE OF OPERATING MODE 38
7.5 SWITCH ON / OFF 39
Version: DialogIII 05.2004 GB 1-3

TAB LE OF CONTE NTS
7.5.1 Switching on 39
7.5.2 Switching off 39
7.6 Move to initial position 40
7.6.1 set encoder to zero 40
7.6.2 Move to home position 40
8 Operating modes
8.1 SYMBOLS - survey and explanation 42
8.2 Operating functions 44
8.2.1 General parameters of the program steps 44
8.2.1.1 TUE - Monitoring time 44
8.2.1.2 TWA - Waiting time 44
8.2.1.3 Parameters indicated in percent (%) 44
8.2.2 Main cylinder 45
8.2.3 Main cylinder on pressure 46
8.2.4 Press pad 47
8.2.5 Lateral slide 48
8.2.6 lateral slide on pressure 49
8.2.7 move removal unit 50
8.2.8 Tilt removal unit 51
8.2.9 Airblast 52
8.2.10 Spraying 53
8.2.11 Dwell time 55
8.2.12 Safety door 56
8.2.13 Pneumatic unit 57
8.2.14 Electric motor 58
8.2.15 Threading unit 59
8.2.16 Sliding table (option) 60
8.2.17 Tilting table (option) 61
8.2.18 output pulse 62
8.2.19 Output with acknowledgement 63
8.2.20 Set output 64
8.2.21 Reset output 65
8.2.22 Input 66
8.2.23 Tool monitoring 67
8.2.24 Release insertion (robot) 68
8.2.25 Release extraction (robot) 69
8.3 Operating mode setting 70
8.3.1 Menu selection manual functions 71
8.3.2 Information 78
8.3.3 Change language 80
8.3.4 Lamp test 81
8.4 Operating mode programming 82
8.4.1 Menu selection programming 82
8.4.2 Program management 83
8.4.2.1 Load program 84
8.4.2.2 Delete program 84
8.4.2.3 Store program 85
8.4.3 Programming 86
1-4 Version: DialogIII 05.2004 GB

TAB LE OF CONTENTS
8.4.3.1 Insert program step 87

8.4.3.2 Edit program step 90
8.4.3.3 Delete program step 92
8.4.4 Tool number 94
8.4.5 Branch Commands 94
8.4.5.1 Example: Loading with / without robot 97
8.5 Operating mode
Single stroke - automatic' 99
8.5.1 Single stroke - manual 100
8.5.2 single stroke robot 101
8.5.3 inching mode (single step) 102
9 APPLICATION SOFTWARE
10 Messages / error messages
10.1 Messages 106
10.2 Fault messages 110
11 APPENDIX
12 GLOSSARY
13 INDEX

TAB LE OF CONTE NTS

GENE RAL DE SCRIP TION
2 GENERAL DESCRIPTION

GE NERAL DES CRIPTION
2.1 FEATURES OF THE CONTROL

Easy programming of all functions, even complex sequences, with
operator guiding via dialog with menu technique in teach-in proce-
dure
Operating menus adapted to the actual accessories of the ma-
chine
Storage of 40 programs possible in the working memory
Arbitrary program runs freely programmable
Automatic preallocation of parameters, e.g. monitoring times, flow
rate, pressure
Programming and scrolling in programs possible without move-
ment
Program change within seconds
Selection of the required program number from program list pos-
sible
Stored programs can be called in dialog
Simple program corrections by modification, insertion and deletion
Comfortable program test by single step mode, returning to home
position in case of tool troubles
Display of the current program step active in any automatic oper-
ation mode
Status indication of the PLC I/O can be called via the operator pan-
el in the operating modes setting and automatic
Automatic diagnosis of errors with description in clear text
Help texts stored in the operator panel
Buffered work memory, i.e. in case of power loss, new loading of
program not necessary.
Freely programmable ram positions
Control of the ram position over the entire stroke through absolute
encoder
Change-over rapid speed - crawling speed - work stroke can be
programmed depending on the path
Exact approach of all positions in both directions with a repeatabil-
ity of +/- 0,5 mm with tolerance monitoring
Accessory functions for trim tools possible in any position of the
ram
Side slide speeds programmable

GENE RAL DE SCRIP TION
Start and duration for airblast programmable

Intervals and duration for spray equipment programmable
Service hours, days and batch counters can be called via the op-
erator panel
Oil level and temperature monitoring
2.2 TYPE TEST

The high-speed presses of the SEP series equipped with control Di-
alog III was designed in accordance with the European regulations
and tested and certified by the employers liability insurance accord-
ing to the machine guideline 98/37/EC.

GE NERAL DES CRIPTION

QUALIFICATION OF THE PERSONNEL
3 QUALIFICATION OF THE PERSONNEL

QUALIFICATION OF THE PERSONNEL
Tab. 3-1: Qualification of the personnel
Operating mode admissible activity Qualification

SINGLE STROKE - - Switch on/off Machine operators:
MANUAL - Loading and unloading Instruction by REIS ROBO-
TICS service personnel or ex-
pert personnel of the operator.
Knowledge of the safety de-
vices and their application
SINGLE STROKE - - Switch on/off see SINGLE STROKE - MANUAL
ROBOT - Start automatic mode
INCHING MODE Step resp. function will be see SINGLE STROKE - MANUAL
executed as long as the + key
is operated
SETTING so-called manual functions, i. Setters and programmers:
e. execution of individual Expert knowledge in trimming
functions
The operating manual must
have been read and under-
stood, in particular the chapter
Safety instructions.

Instruction by REIS ROBO-
TICS service personnel
HAND Generation, storage, and de- see SETTING
letion of movement se-
quences, i. e. editing the
individual program steps

SAF ETY INSTRUCTIONS
4 SAFETY INSTRUCTIONS

SA FETY INSTRUCT IONS
4.1 EXPLICATION OF TERMS AND SYMBOLS

This section explains and defines terms and symbols which are used
for safety-relevant information always with the same meaning.
4.1.1 User
User is the entrepreneur who uses the installation for production pur-
poses, or the person appointed vicariously responsible for the machi-
ne by the company, e. g. head of a department or foreman.
4.1.2 Insured
The insured is the person employed at the machine.
4.1.3 Warnings
Please observe all warnings in the operating manual.
These warnings consist of a warning word and a graphical symbol
which may occur in various combinations. The individual warning
words and graphical symbols are listed in the following.
Tab. 4-1: List of warning words
Warning word Significance
Danger A warning with the warning word 'Danger ' warns of
danger to life and limb. If this warning is not obser-
ved, there is severe mortal danger.
Warning A warning with the warning word 'Warning' warns of
severe risk of injury. If this warning is not observed,
severe injuries or severe material damage up to de-
struction of the machine and/or other components
of the installation are threatening.
Attention A warning with the warning word 'Attention' refers e.
g. to relevant regulation and to the correct se-
quence of works. If this warning is not observed, the
machine and/or other components of the installation
may be damaged.

Tab. 4-2: List of graphical symbols

Shearing off Inflammable
Ear protection Hot surface
Electrical cur-
rent
Entanglement Squeezing
Eye protection General danger
4.1.4 Skilled personnel
Fig. 4-1: Symbol for skilled personnel

This symbol identifies works which must only be executed by skilled
personnel

4.2 INSTRUCTIONS CONCERNING SAFETY

REGULATIONS
We are not liable for damage and failures in operation resulting from
disregard of the operating manual.
4.2.1 Setting (observe national regulations)

(1) The entrepreneur must make sure that the press will only be star-
ted-up after
1. the setter charged by him
a) has set the tools,
b) adjusted the operating mode,
c) set the safety equipment acc. to 3, section 1,
d) taken the safety measures acc. to 3, section 3, if necessary
e) safeguarded the change-over equipment against unauthorized
operation
and
2. an inspector charged by him in writing has ascertained that the
tools are set and that the measures acc. to no. 1, letters d) through e)
have been taken and are effective.
(4) The written confirmation of the taken measures acc. to section 3
has to be made by the setter for each setting procedure in a control
book related to the corresponding press, indicating
Tool designation
Taken safety measure
Date and time
(5) During setting the setter has to operate the switch-off device acc.
to 9 with drive being switched on, and when moving the tools toge-
ther he has to use safety equipment acc. to 3, section 1 or safety
measures acc. to section 3.
Notes:
Change-over equipment = operating mode selector switch
Switch-off devices = switch lock, i. e. hydraulic motor remains swit-
ched on, press movement is not possible.
Equipment against sagging of ram (ram lock), if existing, see
chapter Description of assemblies in the operating manual of the
machine.

see Chapter 4.2.5, Annual safety check

(6) For works at the mounted tool at presses with a table depth of
more than 800 mm and a stroke height of more than 500 mm the set-
ter must bring the equipment acc. to 12 (ram lock) into safety positi-
on or insert a support which can hold the occurring forces with drive
being switched off.
4.2.2 Maintenance (observe national regulations)

1. The entrepreneur has to see to it that in case of irregularities in
operation of the press it will be checked if there is any defect. Ope-
ration of the press must be stopped until the detected defect has
been eliminated.
2. Insured who are employed at the machine have to inform the su-
perior immediately of any irregularities in press operation.
3. For works at the mounted tool at presses with a table depth of
more than 800 mm and a stroke height of more than 500 mm, in-
sured must bring the device acc. to 12 into safety position or in-
sert a support acc. to 20, section 3.
4. Insured must switch off the drive and actuate the switch-off device
acc. to 9 during maintenance, inspection and repair.
4.2.3 Instructions of the manufacturer

4.2.3.1 General remarks
1. Insured who are occupied with works related to assembly, opera-
ting, servicing and repair of the machine in the company of the
user, must have read and understood the operating manual, par-
ticularly the present chapter 'General safety instructions'. The user
is recommended to have this confirmed in each case by written
evidence.
2. The machine may be operated by trained and authorized insured
only. Competences for works related to and with the machine must
be clearly fixed and kept so that no unclear competences occur
with regard to safety.
3. In case of inappropriate use or use not complying with the applica-
tion of the machine, or operation by unskilled personnel, the follo-
wing dangers impend:
Danger to life and limb of the insured
Danger for the machine and other property assets of the user
as well as negative effects on the function and operational cha-
racteristics of the machine

As a consequence of inappropriate use there may occur faults in

functioning or the original quality of the machine may be reduced.
4. Arbitrary convertment and modifications at the machine - especi-
ally at its safety equipment - by the user, by the insured or by third
parties are prohibited.
5. The user must issue a written operating and working instruction.
For operation of the machine within the EC, this has to be done in
the native language of the insured. Extracts from this operating
manual can be taken for formulation.
6. When purchasing lubricants, the corresponding safety data sheets
have to be requested from the lubricant manufacturer.
These safety data sheets contain the complete information about
handling, use and waste disposal of the lubricants.
4.2.3.2 Special safety instructions for the insured

1. Prior to repair or maintenance works in the production cells, switch
off all drives and controls.
2. Prior to works at the machine, switch off the main switch and se-
cure it against unauthorized switch-on!
3. The insured also must take care that only authorized persons work
at the machine.
4. Any method of working which impairs the safety at the machine
must be omitted, particularly the safe functioning of components
of the
Mechanics
Hydraulics / Pneumatics
Electrics
5. The insured must inform the user immediately of changes at the
machine which impair safety.
6. Never dismount or disable safety equipment.
If safety devices are disabled while the machine is in a production
cycle, the insured or third person is no longer sufficiently protected
against operation dangers. The insured or third person is threate-
ned by severe, in the extreme case lethal, risk of injury.
7. Prior to dismounting safety equipment for repair or maintenance
works the machine must be switched off. The safety equipment
must be remounted immediately after completion of the repair or
maintenance works.

8. Works at the electric unit must only be executed by skilled person-

nel as a matter of principle. For all works at the electric unit obser-
ve the national safety regulations!
9. If hydraulic medium escapes under pressure there is risk of injury.
10.For operation of machines equipped with HFC hydraulic units (hy-
draulic oil) there is risk of fire breaking out if there are flames close
to the machine.
11.Prior to works at hydraulic and pneumatic components (especially
cylinders, pressure accumulators) it has to be ensured that those
are no longer under pressure. Components under pressure must
be switched pressureless.
4.2.3.3 Special safety instructions for the user

1. Condition for running the installation in automatic mode is an in-
stalled, closed, and controlled safety equipment, also around indi-
vidual machines and equipments of this production unit, if
necessary. The user must make sure that no person stays within
this perimeter guarding during production.
2. The user must run the machine only in faultless condition.
3. If a complete screening of the machine with regard to the safety
regulations is not part of the delivery of Messrs. Reis, the user
must ensure that the working range of the machine is screened by
appropriate measures. Doing so, the safety regulations in the
users country must be observed.
4. As far as required, the user must oblige the insured to wear pro-
tecting equipment.
5. The user must guarantee cleanness and clearness of the work-
shop place in the machine area by means of corresponding in-
structions and checks.

4.2.4 Safety equipment

Every insured working at the machine must be informed about arran-
gement and functioning of the safety devices for being able to release
them quickly and safely in case of danger.
Before the machine will be put into motion, all safety devices must be
checked for orderly functioning.
No person must stay within the safety equipment during operation of
the press - MORTAL DANGER!
As additional protection against stepping behind the safety equip-
ment, the press has to be operated with a scrap container placed un-
derneath, if necessary.
4.2.5 Annual safety check

4.2.5.1 Inspections
(observe national regulations)
The entrepreneur must make sure that presses and their safety
equipment acc. to 3, section 1 and safety measures acc. to 3, sec-
tion 3 will be checked by an expert1) charged by him with regard to
their safe condition, depending on their strain, but at least once a
year, and the result of these inspections will be entered by the expert
into the control book or into the machine card file.
Instruction for execution:
This requirement is met if
the presses are checked for their faultless condition and correct
functioning, and in particular
the safety equipment is checked for orderly condition and efficien-
cy.
See also section 7.2 of the Sicherheitsregeln fr berhrungslos wir-

kende Schutzeinrichtungen an kraftbetriebenen Pressen der Metall-
bearbeitung (ZH 1/281) (safety regulations for non-contact safety
equipment at power driven metal working presses) and section 6.2 of
the Sicherheitsregeln fr Zweihandschaltungen an kraftbetriebenen
Pressen der Metallbearbeitung (ZH 1/456) (safety regulations for
two-hand controls at power driven metal working presses).
1)
Experts are persons who, due to their skills and experience, have
sufficient knowledge in the range of the press to be checked and who
are well acquainted with the national work safety directions, the acci-

dent prevention regulations, guidelines and the generally accepted

rules of technique (e. g. standards, VDE regulations) so that they are
able to comment on the safe operation of the hydraulic press.
4.2.5.2 Safety equipment

(observe national regulations)
(1) Presses must be made in such way that injuries through the press
die are prevented. Injuries are prevented by:
1. Press dies which exclude access to the danger area through their
design or through additionally attached coverings.
2. Stationary coverings of the dangerous areas. For this purpose,
such parts of the covering which can be removed without hand tools
or which can be opened, must be connected with the press control in
such way that on the one hand, closing movement cannot be introdu-
ced with any part of the covering being removed or opened, and on
the other hand, the ram will be stopped in due time in case of removal
or opening during the closing movement.
3. Mobile coverings acc. to 6,
4. Non-contact safety equipment acc. to 7,
5. Two-hand controls acc. to 5,
6. Devices rejecting persons from the danger areas depending on the
ram movement (rejecting safety devices).
(2) Safety equipment must be designed and arranged in such way
that they cant be easily bypassed or disabled.
(3) If safety equipment acc. to section 1 cannot be used for reasons
of production engineering, it must be ensured that injuries are preven-
ted by other safety measures. The employers liability insurance as-
sociation must be notified of the substitute measures at least two
weeks before the works are started, indicating the reasons and des-
cribing the substitute measures. If the employers liability insurance
association wont reject the planned substitute measures within two
weeks, the entrepreneur may suppose that the planned substitute
measures are sufficient until another decision will be made by the em-
ployers liability insurance association.
(4) If several persons are working at one press simultaneously, for
each person there must be available safety equipment acc. to section
1 or safety measures acc. to section 3 must be met in order to avoid
mutual endangering.

(5) Press where setting is performed without the safety equipment

mentioned in section 1 or without the safety measures in section 3
being taken, must be equipped in such way that during adjustment of
operating mode SETTING
the ram closing speed automatically will be limited to equal or
smaller 10 mm/s and
a control device with automatic reset becomes effective.
4.2.5.3 Test instructions of the manufacturer

Press frame
Safety equipment
Hydraulic unit
Control cabinet and operating panel
Other tests (see also in the operating manual of the machine in
chapter Maintenance)

HARDWA RE AND S OFT WA RE
5 HARDWARE AND SOFTWARE

HARDWARE AND SOFTWARE
The PLC control Dialog III is based on the Siemens series S7-300. It
consists of a central processing unit CPU 315-2DP and as a standard
feature is extended with Profibus components for local peripheral
equipment. An operator panel OP170B ensures operator guiding,
programming and visualization.
Control and the operating elements are accommodated in a control
cabinet in standard version being arranged at the right front machine
side.
Tab. 5-1: Standard components of the control
Designation Type Manufac-
turer
central assembly unit CPU 315 - 6ES7 315-2AG10-0AB0 Siemens
2DP
Operator Panel OP 170B 6ES7 542-OBB15-2AX0 Siemens
Micro-Card for S7-300 512 KB 6ES7 953-8LJ00-0AA0 Siemens
Profi-bus coupler DP (12 MB) BK 31220 (BK 3150) Beckhoff
Bus end terminal KL9010 Beckhoff
Bus feed terminal KL9110 Beckhoff
Bus digital input terminal 4 KL1104 Beckhoff
Bus digital output terminal 4 KL2134 Beckhoff
Bus digital output terminal 2 KL2022 Beckhoff
Tab. 5-2: Extension of control

Designation Type Manufac-
turer
DP/DP coupler 6ES7 158-0AD00-0XA0 Siemens
Bus analog output terminal 2 KL4032 Beckhoff

IN STAL LATION / C ONF IGURA TION
6 INSTALLATION / CONFIGURATION

INSTALLATION / CONFIGURATION
6.1 DELIVERY CONDITION

The control of the machine is already completely configured on
delivery.
6.2 ENERGY SUPPLY
6.2.1 Connect power supply
DANGER!
High voltage!
Danger to life
Disconnect energy supply
Observe the circuit diagram!
Fig. 6-1: Connecting terminals in the control cabinet
6.3 MODIFICATIONS
If changes shall be made at the volume of the controllable accessory
in the scope of modification works, the modifications of the configura-
tion can only be performed by the Service of REIS ROBOTICS. The
corresponding programming levels are password-protected.

6.4 SERVICE FUNCTIONS
6.4.1 General instructions

This menu serves for adaptation of the machine data and requires a
password in order to avoid modifications by mistake. The passwords
may only be disclosed to the setter or to authorized personnel.
Fig. 6-2: Setting mode - selection menu
Tab. 6-1: Survey - menu selection setting mode

Key Symbol Menu
F7 Administration of the inputs and outputs
F9 Manual functions
F10 Information
F11 Machine data -> Service REIS ROBOTICS
F12 Language change-over
F13 Lamp test
F14 Operator Panel -> Service REIS ROBOTICS

6.4.2 set encoder to zero

Password for Level 7 required: see file concerning technical docu-
mentation, register Machine data.
Password: 700
The machine is equipped with absolute value encoders. After ex-
change of the encoder the reference value is to be determined prior
to start-up of the machine.
Condition:
Key-operated switch in the following position:
Main cylinder is in the upper dead center (T.D.C.)

Tilting table is in load position
Fig. 6-3: Setting mode - selection menu
Machine settings
Enter password for Level 7
Machine settings

Fig. 6-4: Machine settings
WARNING!
Damage of the machine!

Wrong positions of the main cylinder and the tilting table cause faulty
initial positions.
Make sure that the positions mentioned in the prerequisites are
maintained (see Chapter 6.4.2, set encoder to zero).
set encoder to zero
Fig. 6-5: set encoder to zero

Select encoder
Keep key pressed so long until the preset values are dis-
played:
Main cylinder: 10
Tilting table: 1
Finish entry
Finish entry

6.4.3 Change machine data

Password for Level 8 required: see file concerning technical docu-
mentation, register Machine data.
Condition:

Display MANUAL FUNCTIONS:see chap. 8.3.1 / fig. 8-29
WARNING!
Damage of the machines and tools!

Modifications may be executed by authorized personnel only. Consult
the manufacturer in case of any uncertainties.
Cautiously adapt the given values to the requirements.
Machine settings
Enter password for Level 8
Machine settings
Fig. 6-6: Machine settings
Machine data

Fig. 6-7: Machine data - Parameter
scroll
or
Select action
Enter values via the numeral keyboard
Finish entry

OPERATION
7 OPERATION
Version: 7-33
OP ERA TION
7.1 OPERATING PANEL
Fig. 7-1: operating panel

1 Operating panel
2 Graphic display
3 EMERGENCY-OFF
4 Function keys
5 Numeral keyboard
6 Operating and indication elements -
Standard
7 Selector switch for operating modes
8 Key - Close safety door / Cycle Start
7-34 Version:
OPERATION
7.2 OPERATING ELEMENTS

EMERGENCY- Immediately switches off the power parts.
OFF Key has to be unlocked into arrow direction.
selector swit- Positions of the key operated switch:

chOPERATING (from the left h.s.)
MODE
PROGRAMMING
SETTING
SINDLE STROKE / AUTOMATIC
PRO- Establishment, modification, and deletion of programs
GRAMMING
SETTING Editing parameters of the program steps
SINGLE STRO- Production

KE AUTOMA-
TIC
MOTOR ON Switches on the power parts.
Lamp lights when the machine is ready for operation.
MOTOR OFF Switches off the power parts.
SAFETY Closes the safety door in any operating state.

DOORCLOSE Safety door must be closed, before Cycle -Start can be
executed.
Omitted for machines with light curtain (BWS)
SAFETY DOO- Opens the safety door in any operating state.
ROPEN The machine stops in automatic work cycle if the safety
door is opened. PLC outputs are switched off.
Omitted for machines with light curtain (BWS)
Version: 7-35
OP ERA TION
CYCLE START Machines with safety door:

Close safety door or start work cycle.
Machines with light barriers (Non-contact safety de-
vice):
Acknowledge command unit or start work cycle.
AUTO-START Condition:
Operating mode SINGLE STROKE AUTOMATIC
Start of the automatic work cycle.
Lamp lights in automatic work cycle.
AUTO-STOP Stops the automatic work cycle.
Lamp lights after stopping.
MOVE TO Establish initial position (home position).

HOME POSITI-
ON
RETURN Condition: Operating mode HAND or SETTING
Moving back the selected function.
AHEAD Condition: Operating mode HAND or SETTING
Moving ahead the selected function.
Lock SWITCH- The motor remains switched on.

ON LOCK The outputs of the control are without power supply.
Application for short-term works inside the press
room.
Unlock The outputs of the control are activated.
SWITCH-ON
LOCK
Selector Option: Only for machines with light barrier
switch:Opera- Operating modes: SINGLE CYCLE, DOUBLE CYCLE,
ting mode Safety mode
BWS(non-con-
tact safety de-
vice)
7-36 Version:
OPERATION
Operating mode Removal of the workpiece through the parts removal

SINGLE CYCLE unit.
Insert workpiece on the operator side through the light
curtain.
Work cycle is automatically released when the protection
field is left. (1.cycle).
Operating mode Unload workpiece on the operator side through the light
DOUBLE CY- curtain (1.cycle).
CLE Insert workpiece on the operator side through the light
curtain.
Work cycle is automatically released when the protection
field is left. (2.cycle).
Operating mo- Insert workpiece on the operator side through the light
deSAFETY curtain.
MODE Release work cycle by operation of the luminous key
'CYCLE START'.
FAULT Lights in case of EMERGENCY-OFF or other fault mes-
sages.
Detailed fault: see message on the display
Version: 7-37
OP ERA TION
7.3 CONTROL PANEL

At the upper edge of the screen the following information is perma-
nently displayed:
Current program number of the program which is just situated in
the working memory
Current operating mode
Unlocked or locked position of the ram lock (if existing)
The key HELP gives current support for operation when the LED
lights.
7.4 CHANGE OF OPERATING MODE

Change of operating mode is performed with the selector switch on
the operating panel.
On each change of operating mode the hydraulic motor is
switched off for the safety of operating personnel and tools.
After the selector switch has been brought to the desired position, the
steps shown on the display have to be executed. Those depend on
the selected operating mode and on the operating state of the ma-
chine.
The selector switch is lockable, designed as so-called key-operated
switch'. Only authorized personnel should have access to.
7-38 Version:
OPERATION
7.5 SWITCH ON / OFF
7.5.1 Switching on
After initialization the following display appears:
The further steps depend on the selected operating mode and are in-
dicated by the operator guidance on the display.
1. Bring lateral safety grids into locking position
2. Switch on main switch
3. Acknowledge the message 339 Start-up terminated
The display corresponding to the selected operating mode ap-
pears.
4. Switch on hydraulic motor
5. Close safety door
or
Activate light curtain
Further procedure according to the operator guidance on the dis-
play. This depends on the selected operating mode.
7.5.2 Switching off

The machine should only be switched off after termination of the work
cycle.
DANGER
Sagging of the ram due to its dead weight

In case of leakage the ram may move to the bottom - danger of pinch-
ing / mortal danger!
For machines without ram lock: Place safety jack between ram
and table platen
For machines with ram lock: Make sure that there is a safe latch-
ing position of the bolt. Indication AB locked on the display
(see description of assembly units ram locking device)
1. Execute the safety measures described above

2. Switch off hydraulic motor.
3. Switch off main switch
Version: 7-39
OP ERA TION
7.6 MOVE TO INITIAL POSITION

In case a status should occur in SINGLE STROKE operating mode
which makes completion of the cycle impossible, you can reach the
initial position by approaching the home position resp. referencing the
machine.
7.6.1 set encoder to zero

Since the machine is equipped with absolute value encoders, refer-
encing will not be necessary.
In case, however, it should be required to excahnge the absolute val-
ue encoder, the zero values have to be set ( see Chap. 6.4.2, set en-
coder to zero). This may be executed by authorized and skilled
personnel only.
7.6.2 Move to home position

1. Operate key 'AUTO-STOP' if approach of the home position shall
be executed from the cycle.
2. Select operating mode SINGLE STROKE-STOP
3. Switch on hydraulic motor
4. Close safety door
5. Cycle start
6. If necessary, move accessory to the program-depending initial po-
sition after request on the display.
a. orOperate key and keep it pressed so long until the movement
is finished.
b. Observe message on the display
7. Move to home position:
Operate key 'HOME POSITION'
Message on the display: Home position was reached
7-40 Version:
Operating modes
8 OPERATING MODES

Operating modes
8.1 SYMBOLS - SURVEY AND EXPLANATION

Language Language change-over of the display.
GERMAN - OTHER LANGUAGE
ESC Operation of the function key arranged under this
(Display) symbol: Return to the previous menu.
ESC Delete fault
(numeral
keyboard)
ACK Confirm message
(numeral
keyboard)
Arrow keys Movement of the cursor
(numeral
keyboard)
Arrow key scroll down
forward
Arrow key back scroll up
Manual Execution of individual movements with the keys -/+.

functions
Program Selection list of the available programs
management
Load program Selection key in the menu Programming.
Store program Selection key in the menu Program management.
Delete program Selection key in the menu Program management.

Program is definitely deleted!
Adopt program
data
Programming Establish and modifiy programs
Insert program Selection key in the menu Program management.

step
Delete program
step
Editing Modification of the parameters of a program step

Operating modes
Delete working
memory
Information Information about the software revision, date and time
Lamp test Function test of the lamps and luminous keys installed in
the operating panel. On subsequent operation of the '+'
key all the lamps must light.
Take over The currently approached ram position can be stored by
position this.
Tool number Allocation of a tool number to a press program.
Output no. Freely programmable outputs not used by the system,

for control of external devices.
Input no. Freely programmable inputs not used by the system, for
control of external devices.
Electric motor Selection of an electric motor, e. g. for milling unit,
no. sawing unit of a press tool.
Threading unit Threading unit of a press tool.
no.
Reset stroke When operated, the stroke counter is reset to the value
counter zero.
Pneumatic unit Freely programmable pneumatic units of the press tool.
no.
Side slide no. Freely programmable side slides of the press tool.
Central
lubrication
Airblast
Spraying
Operator Panel Service REIS ROBOTICS
Machine Service REIS ROBOTICS

settings
Machine data Service REIS ROBOTICS

Operating modes
8.2 OPERATING FUNCTIONS

Not available functions (option is not included in the delivery of the
machine) are omitted and not indicated in the display.
8.2.1 General parameters of the program steps

8.2.1.1 TUE - Monitoring time
This parameter serves for time monitoring of a movement. After expi-
ration of the defined time the movement must be terminated (signal
from limit switch). If the time is exceeded, an error message will be
displayed and the work cycle is stopped.
Tab. 8-1: TUE - Values
Unit: Second
Range of values: 0 - 999
Note:
When exceeding the defined monitoring time, a detailed error mes-
sage will be displayed in case of faults. If no time is entered for TUE
(TUE = 0), then an error message <0161 error from Interpreter> will
be given.
The value set in factory is 10 seconds.
8.2.1.2 TWA - Waiting time

This parameter activates a waiting time running simultaneously to the
current program step. .
The next step will only be introduced when the following conditions
are fulfilled in the current step:
End position is reached and
Waiting time of the parameter TWA has expired
Tab. 8-2: TWA - Values
Unit: Second
Range of values: 0 - 999
8.2.1.3 Parameters indicated in percent (%)

This possibility is only available for machines the hydraulic system of
which is equipped with proportionate valves (OPTION).

Operating modes
8.2.2 Main cylinder
Fig. 8-1: Main cylinder on position

F9 Take over values into the current pro-
gram
F10 Take over current position
F14 Return to the previous menu
Tab. 8-3: Parameters - main cylinder

Parameters Unit Description
Current position mm Current position of the main cylinder,
related to the reference point.
Reference posi- mm Defined distance from the reference
tion point (value > 0!).
Work path mm The work path depends on ram
weight and ram speed.
Set value: 200 mm.
Tolerance mm Accuracy to be kept for the pro-
grammed position.
Example:
Tolerance 4 = reference position +/-
4
Pressing pres- % Range: 0 - 100 %.
sure Set value: 100 %.
Work stroke % Range: 0 - 100 %.
Set value: 100 %.

Operating modes
8.2.3 Main cylinder on pressure

ATTENTION! - This function must only be programmed with closed
tool (BDC)! In case of inexpert application the tool may be de-
stroyed!
Fig. 8-2: Main cylinder on pressure
Tab. 8-4: Parameter - Main cylinder on pressure

Parameter Unit Description
Linear The main cylinder is kept on pres-
sure in the programmed position.
Parallel The main cylinder is kept on pres-
sure in the programmed position
during execution of the next com-
mand (e. g. side slides forward).

Operating modes
8.2.4 Press pad
Fig. 8-3: Press pad
Tab. 8-5: Parameter - Press pad

forward Direction workpiece
back Into the initial position
Loading time Seconds Time for generation of an ejection
pressure. If the max. adjustable
loading time of x seconds is not suffi-
cient to eject the workpiece out of
the tool, the pressure must increase
at the pressure relief valve --> De-
scription of assemblies in the oper-
ating manual of the press.
TUE Seconds Set value: 2 seconds
TWA seconds Set value: 10 seconds

Operating modes
8.2.5 Lateral slide
Fig. 8-4: Lateral slide
Tab. 8-6: Parameter - Lateral slide

Crawling speed Flow rate 2
Rapid speed Flow rate 1
Speed % Range: 0 - 100 %.
Set value: 100 %.
Pressure % Range: 0 - 100 %.
Set value: 100 %.
The side slides can be moved individually and in combinations.

By operation of the function key arranged under the symbol, the side
slide is added or deleted from the selection.

Operating modes
8.2.6 lateral slide on pressure

ATTENTION! - In case of inexpert application the lateral slide
may be destroyed. Ram movements may only be continued, af-
ter the lateral slide will have moved out of the workpiece / die
again!
This function maintains the adjusted pressure of the lateral slide for a
given period.
Fig. 8-5: Lateral slide

Tab. 8-7: Parameter - Lateral slide
Crawling speed Flow rate 2
Rapid speed Flow rate 1
Set value: 100 %.
The side slides can be moved individually and in combinations.

By operation of the function key arranged under the symbol, the side
slide is added or deleted from the selection.

Operating modes
8.2.7 move removal unit
Fig. 8-6: Move removal unit
Tab. 8-8: Parameter - Move removal unit


Operating modes
8.2.8 Tilt removal unit

This function is only required with the use of a pneumatically or hy-
draulically driven removal unit (special version).
The electrically driven removal unit is tilted by means of mechanical
components.
Fig. 8-7: Tilt removal unit
Tab. 8-9: Parameter - Tilt removal unit

down Tilt off workpiece.
up Back into the initial position.
Tilting time Seconds Tilts the removal unit in the specified
time. For this purpose the removal
unit must be in the rear end position
beforehand. After expiration of the
tilting time the removal unit tilts back
into horizontal position.
Linear No other command can be executed
during the movement.
Parallel During the movement the control
can execute other commands, e. g.
tilting back, close main cylinder.

Operating modes
8.2.9 Airblast
This is a parallel step, i. e. while the times are running, the control can
execute other commands. If airblast shall be executed as individual
step, a dwell time of same duration must be programmed as next
command (see Chapter 8.2.11, Dwell time).
Fig. 8-8: Airblast

Tab. 8-10:Parameter - Airblast
Lead time seconds After expiration of the entered time
sets the output signal for beginning
of the airblast time.
Airblast time seconds Duration of airblast. After expiration
of the airblast time the output is re-
set.

Operating modes
8.2.10 Spraying
This is a parallel step, i. e. while the times are running, the control can
execute other commands. If spraying shall be executed as individual
step, a dwell time of same duration must be programmed as next
command (see Chapter 8.2.11, Dwell time).
Fig. 8-9: Spraying1

Tab. 8-11:Parameter - Spraying
Spray time seconds Duration of spraying. After expiration
of the spray time the output is reset.
Interval cycles Number of work cycles between the
spray procedures.
step mode: parallel Switch system pressureless for grip-
per change!
step mode: linear Next command can only be started
after having finished spraying.
Two further spray circuits can optionally be controlled.

Operating modes
Fig. 8-10:Spraying 2
Fig. 8-11:Spraying 3

Operating modes
8.2.11 Dwell time
Fig. 8-12:Dwell time

Tab. 8-12:Parameters - dwell time
Dwell time seconds The movement sequence is inter-
rupted during this time.

Operating modes
8.2.12 Safety door

This command is inserted for manual loading of the press before the
step PROGRAM END'. Closing of the safety grid is automatically ex-
ecuted after operation of the key Close safety door / Cycle Start' and
cannot be programmed.
In case of automatic work cycle with a robot this command must
not be programmed!
Fig. 8-13:safety door
Tab. 8-13:Parameter - Safety door

Up Open safety door.

Operating modes
8.2.13 Pneumatic unit
Fig. 8-14:Pneumatic unit

Tab. 8-14:Parameter - Pneumatic unit
Ahead Direction workpiece.
back Back into the initial position.
TUE seconds Set value: 10 seconds.

Operating modes
8.2.14 Electric motor
Fig. 8-15:Electric motor
Tab. 8-15:Parameter - Electric motor

ON Switch on. Rotation direction see
electric circuit diagram.
OFF Switch-off.

Operating modes
8.2.15 Threading unit
Fig. 8-16:Threading unit
Tab. 8-16:Parameter - Threading unit

Ahead Direction workpiece.
Rotation direction 1.
back Back into the initial position.
Rotation direction 2.
The rotation direction depends on whether a left-handed or a right-

handed thread shall be cut and must be defined in the threading unit.

Operating modes
8.2.16 Sliding table (option)
Fig. 8-17:Sliding table
Tab. 8-17:Parameter - Sliding table

Ahead Move into the machine
back Move out of the machine
Rapid speed Speed: see TECHICAL DATA of
the existing press type.
Crawling speed Speed: see TECHICAL DATA of
the existing press type.
Set value: 100 %.

Operating modes
8.2.17 Tilting table (option)
Fig. 8-18:Tilting table
Tab. 8-18:Parameter - Tilting table

Up Back to initial position
Down Tilting off for scrap removal
Current position mm Current position of the main cylinder,
related to the reference point.
Reference posi- mm Defined distance from the reference
tion point (value > 0!).
Work path degree The work path depends on the die
weight.
Set value: 20.
Tolerance mm Accuracy to be kept for the pro-
grammed position.
Example:
Tolerance 4 = reference position +/-
4
Set value: 100 %.

Operating modes
8.2.18 output pulse

Only free outputs not already used by the system may be pro-
grammed!
Occupation of the free outputs is defined by the manufacturer in the
machine data of the software and cannot be modified by the user.
Fig. 8-19:Output pulse
Tab. 8-19:Parameter - Output pulse

Advance seconds Sets the selected output after expira-
tion of the entered time.
Pulse duration seconds Period in which the output signal is
set.
The outputs are set with the function keys via Out1 to Out4.
Note:
Pulse duration = 0: Single step
Pulse duration > 0: Parallel step, i.e., further commands are pro-
cessed while the output is set.
Listing of the outputs.

Operating modes
8.2.19 Output with acknowledgement

The signal of the selected output remains active so long until an ac-
knowledgement comes from the programmed input.
Only free outputs not already used by the system may be pro-
grammed!
Fig. 8-20:Output with acknowledgement
Tab. 8-20:Parameters - output with acknowledgement

output Number Select number of the output.
Input Number Select number of the input.

Operating modes
8.2.20 Set output

Setting an output signal.
Only free outputs not already used by the system can be pro-
grammed!
Resetting this signal: see Chapter 8.2.21, Reset output.
Fig. 8-21:Set output

Tab. 8-21:Parameter - Set output
Output Number Select number of the output.

Operating modes
8.2.21 Reset output

The signal activated in the program step Set output is deleted.
Fig. 8-22:Reset output
Tab. 8-22:Parameter - Reset output

Parameter unit Description
Output Number Select number of the output to be re-
set.

Operating modes
8.2.22 Input
Inquiry of an input for no applied signal.
Fig. 8-23:Input = 0
Inquiry of an input for an applied signal.
Fig. 8-24:Input = 1
Tab. 8-23:Parameter - Input

Parameter unit Description
Input Number Select number of the input.

Operating modes
8.2.23 Tool monitoring

This command for control of the correct position of the workpiece in
its fixture should always be programmed for reasons of safety when
the press is operated with a robot.
Condition: Corresponding components for control are integrated in
the tool (e. g. reflex keys, limit switches).
Fig. 8-25:Tool monitoring
Tab. 8-24:Parameter - Tool monitoring

Parameter Value Description
ON 1 Activation of tool monitoring
OFF 0 Deactivation of tool monitoring
Recommendation: Insert this command in the programmed work cy-

cle directly after the work step for insertion of the workpiece into the
press or at the start of the program.

Operating modes
8.2.24 Release insertion (robot)
Fig. 8-26:Release insertion

At this point in the program run the robot gets the release signal for
insertion of the workpiece into the press.
For this purpose please observe the separate documentation:
Description of interface trim press - robot.
Tab. 8-25:HANDSHAKE - Example for the signal exchange between the
press and the robot.
Press Robot Robot
Out of dan-
Release signal Start signal to
ger zone of
for insertion the press
the press
1 Initial state X
2 Press ready for insertion X X
3 Robot moves into the press
X
with workpiece
4 Workpiece inserted into the
press and robot out of dan- X X X
ger zone
5 Press has recognized start
X X
signal of the robot
6 Robot resets start signal to
X
the press.

Operating modes
8.2.25 Release extraction (robot)
Fig. 8-27:Release extraction

At this point in the program run the robot gets the release signal for
extraction of the workpiece from the press.
For this purpose please observe the separate documentation:
Description of interface trim press - robot.
seeTab. 8-25

Operating modes
8.3 OPERATING MODE SETTING

Modification of the parameters of individual program steps.
Fig. 8-28:Selection menu setting mode

Tab. 8-26:Survey - menu selection setting mode
Key Symbol Menu
F9 Manual functions
(see Chapter 8.3.1, Menu selection manual
functions )
F10 Information -> Software version, date, etc.
(see Chapter 8.3.2, Information)
F11 Machine data -> Service REIS ROBOTICS
F12 Change language of the display

GERMAN - OTHER LANGUAGE
F13 Lamp test
(see Chapter 8.3.4, Lamp test )
F14 Operator Panel -> Service REIS ROBOTICS
Execution of individual program steps.

see Chapter. 3, QUALIFICATION OF THE PERSONNEL (seeTab. 3-
1)

Operating modes
8.3.1 Menu selection manual functions
Fig. 8-29:Manual functions selection menu
Fig. 8-30:Manual function - main cylinder

Operating modes
Fig. 8-31:Manual function - presspad
Fig. 8-32:Manual functions - lateral slides

Operating modes
Fig. 8-33:Manual function - airblast
Fig. 8-34:Manual function - spraying

Operating modes
Fig. 8-35:Manual function - move removal unit
Fig. 8-36:Manual function - tilt removal unit

Operating modes
Fig. 8-37:Manual function - pneumatic unit
Fig. 8-38:Manual function - threading unit

Operating modes
Fig. 8-39:Manual function - sliding table
Fig. 8-40:Manual function - tilting table

Operating modes
Fig. 8-41:Manual function - electric motor
Fig. 8-42:Manual function - free outputs

Operating modes
8.3.2 Information
Fig. 8-43:Information
The following values can be viewed and modified:
Date ( <Nicht definierter Querverweis>)
Time ( <Nicht definierter Querverweis>)
Working hour meter ( <Nicht definierter Querverweis>)
Software revision ( <Nicht definierter Querverweis>)
Information - 2nd menu
Fig. 8-44:Counter

Operating modes
Fig. 8-45:Counter1
Tab. 8-27:Survey - menu selection counters

Key Symbol Menu
F11 DAY - reset day counter
F12 BATCH - reset batch counter

Operating modes
8.3.3 Change language
Fig. 8-46:Language selection

Operating modes
8.3.4 Lamp test
Fig. 8-47:Lamp test
Activation of the lamp test by operating the key

Operating modes
8.4 OPERATING MODE PROGRAMMING

Generation, storage, and deletion of movement sequences.
( see Chapter. 3, QUALIFICATION OF THE PERSONNEL )
8.4.1 Menu selection programming
Fig. 8-48:Programming
Tab. 8-28:Survey - menu selection programming

Key Symbol Menu
F9 Program management
(see Chapter 8.4.2, Program management )
F10 Programming
(see Chapter 8.4.3, Programming )
F11 Tool number
( see Chapter 8.4.4, Tool number )
F12 Delete program memory

Operating modes
8.4.2 Program management
Fig. 8-49:selection program management
Tab. 8-29:Survey - selection program management

Key Symbol Menu
F9 Program management
F14 ESC key (return)
Fig. 8-50:

Operating modes
Tab. 8-30:Survey - menu selection program management

Key Symbol Menu
F9 Load program
F10 Delete program
F11 Store program
F12 Arrow key up (selection)
F13 Arrow key down (selection)
Operate the function key under the symbol.
8.4.2.1 Load program

Load an already stored program into the working memory.
Condition: Menu Program management is displayed
F9
Select program
<Do you want to load the program?>
<ENTER/Yes ESC/No>
8.4.2.2 Delete program

Delete an existing program from the memory.
F10
Select program
<Do you want to delete the program?>
<ENTER/Yes ESC/No>

Operating modes
8.4.2.3 Store program

Store a newly generated program.
F11
Select program
<Do you want to store the program?>
<ENTER/Yes ESC/No>

Operating modes
8.4.3 Programming
Fig. 8-51:Programming
Tab. 8-31:Survey - menu selection programming
Key Symbol Menu
F9 Insert program step
F10 Edit program step
F11 Delete program step
F12 Arrow key up (selection)
F13 Arrow key down (selection)
Operate the function key under the symbol.

Operating modes
8.4.3.1 Insert program step

Generation and completion of movement sequences.
Each program contains the following steps:
PROGRAM START
PROGRAM END
Selector switch operating mode in the following position:
Fig. 8-52:Selection menu for programming
F10
Fig. 8-53:Program survey

Operating modes
Select the function after which a new step shall be

inserted
Insert program step
Fig. 8-54:input of current program step
Select function
<menu of the selected function appears on the monitor>

see Chapter 8.2, Operating functions
Adopt program step
Finish entry
Program management
CAUTION!
An existing and selected program is overwritten during storage!

Before operating the function key check whether it is the correct
program to be overwritten.

Operating modes
Store program data

Operating modes
8.4.3.2 Edit program step

Change default values of the program steps
F10

Operating modes
Edit program step
Fig. 8-57:input of current program step
Select the function to be edited.
Confirm selection
<menu of the selected function appears on the monitor>

see Chapter 8.2, Operating functions
Select action
Take over action
<Selection window of the possible parameters is faded-in>
Select parameters
Enter values via the numeral keyboard
Adopt data

Operating modes
8.4.3.3 Delete program step

Condition:

F10
Select the function to be deleted.
Delete program step

Operating modes
CAUTION!
The selected program is irrevocably deleted!
Abort action.
Before operating the ENTER key check whether it is the correct

program to be deleted.

Operating modes
8.4.4 Tool number
Fig. 8-60:Tool number

ATTENTION! - Danger of collision in case of wrong allocation -
Check the adjusted tool number and the number on the tool be-
fore starting the works!
For input of the tool number use the keyboard of the Siemens operat-
ing panel. The tool number may consist of numbers and letters (max-
imum 12 characters!).
Only during storage of the program the tool number will

be taken over and allocated to this program (see Chapter 8.4.2.3,
Store program ).
Allocate a tool number to the current program, so you can select the
appropriate program number in the menu Program management by
means of the tool number.
(see Chapter 8.4.2, Program management )
Enter the tool number via the keyboard of the Siemens operating
panel.
8.4.5 Branch Commands

Depending on the activated or existing accessory components the
program sequence can be varied by means of branch commands.
Thus, it is possible for instance to operate the press manually or with
robot without establishing a new program. The programmed branch
commands control the work sequence.

Operating modes
Available branch conditions:

Operating mode
input at 1
input at 0
marker at 1
marker at 0
available branch arguments:
manul loading
robot loading
manual unloading
without removal chute
robot extraction (T)
removal from die upper half
robot extraction (B)
removal from die lower half
Programming of branch commands should only be executed by
persons having sufficient programming knowledge.
Fig. 8-61:Branch Commands

Operating modes
Fig. 8-62:Select branch argument
Fig. 8-63:branch argument - input

Operating modes
Fig. 8-64:branch argument - marker
8.4.5.1 Example: Loading with / without robot

The following program steps are branched in the selected operating
mode Single stroke-manual': 6 - 8.
The following program steps are branched in the selected operating
mode Single stroke-robot': 3, 26.
1. PROGRAM START
2. CONDITIONAL BRANCH
Robot loading
a. Operating mode Single stroke - robot'
b. Branch label 1
3. PRESS PAD FORWARD
4. BRANCH LABEL 1
5. CONDITIONAL BRANCH
manul loading
a. Operating mode Single stroke - manual'
b. Branch label 5
6. TOOL MONITORING
7. RELEASE INSERT
Robot
8. TOOL MONITORING OFF
9. BRANCH LABEL 5
10.PNEUMATIC UNIT 1 AHEAD

Operating modes
11.MAIN CYLINDER
12.PRESS PAD FORWARD
13.LATERAL SLIDE 1 FORWARD
14.LATERAL SLIDE 2 FORWARD
15.PNEUMATIC UNIT
16.LATERAL SLIDE 1 2 BACK
17.PNEUMATIC UNIT 1 BACK
18.MAIN CYLINDER
19.PRESS PAD BACK
20.AIRBLAST 1
21.AIRBLAST 2
22.OUTPUT 1
23.SPRAYING 1
24.SPRAYING 2
25.CONDITIONAL BRANCH
Loading with robot
a. Operating mode Single stroke - robot'
b. Branch label 10
26.SAFETY GRID
27.BRANCH LABEL 10
28.PROGRAM END

Operating modes
8.5 OPERATING MODE

SINGLE STROKE - AUTOMATIC'
Production
Fig. 8-65:Operating mode - selection on the display

This operating mode is used for normal production.
Standard operating modes:
1. Single stroke - manual
2. Single stroke - robot
The operating mode Inching mode serves for control.

Operating modes
8.5.1 Single stroke - manual

In this operating mode each cycle is started by the operating person-
nel. Removal of the machined workpieces is either performed in the
press cycle by an automatic parts removal unit or afterwards manual-
ly by the operator.
Condition:
Display SINGLE STROKE

Bring lateral safety grids into locking position
Move machine to home position

(see Chapter 7.6.2, Move to home position)
F9 SINGLE STROKE MANUAL
Insert workpiece
Close safety door.
Release work cycle.
Safety grid automatically opens at the end of the work cycle

Operating modes
8.5.2 single stroke robot

In this operating mode, loading of the press is done fully automatically
by means of robot. Unloading may also be performed with the robot
or alternatively with the automatic parts removal unit.
Condition:

Bring lateral safety grids into locking position

F10 SINGLE STROKE ROBOT
Release signal to the robot for loading the press.

Continuous operation acc. to the signal exchange with the robot.

Operating modes
8.5.3 inching mode (single step)

In this operating mode each cycle is started by the operating person-
nel. Removal of the machined workpieces is either performed in the
press cycle by an automatic parts removal unit or afterwards manual-
ly by the operator.
Condition:

Bring safety grid into locking position

F11 INCHING MODE
Operate anew for each program step and keep pressed so

long until the request for releasing is displayed.

APPLICATION SOFT WARE
9 APPLICATION SOFTWARE

APPLICATION SOFT WARE
see
Siemens Manual
Siemens Manual
Siemens programming software STEP7 / STEP 7-mini
Siemens project planning B+B ProTool

Messages / error messages
10 MESSAGES / ERROR MESSAGES

10.1 MESSAGES
Tab. 10-1:Error messages
Message Cause Remedy
Part not correctly inserted. Correct the position of the workpie-
ce.
Pinch safety operated. Open and close front safety grid.
Press not in home position. Move press to home position.
Version: DialogIII 05.2004 GB

Spray medium container empty. Refill spray medium.
Lubricant container min. level. Refill lubricant.
Oil temperature warning. Cooling water tem- Check cooling water temperature
perature is too high and supply.
or the supply is
blocked.
Oil filter monitoring. Filter contamina- Clean the oil filter.
ted.
Filter monitoring pressure filter Filter contamina- Clean the oil filter.
70%. ted.
EMERGENCY-OFF press. EMERGENCY- Unlock 'EMERGENCY-OFF' key by
OFF was operated. turning.
Exterior grid not locked. Safety circuit is not Close and lock the exterior grid.
closed.
Light curtain was interrupted.
Press without pneumatic pressu- Check pneumatic unit and perhaps
re. supply lines.
Press stop valve hydraulic motor
closed.
Safety circuit press not closed.
10-106
Check sagging of main cylinder!! Leakage Stop machine and check hydraulic
unit!
Slowing-down path measure- Repeat slowing-down path measu-
ment not OK. Move installation to rement. In case of another error
home position. message check hydraulics for lea-
kages.
Removal is not at rear. End position not Move to home position. Perhaps

reached. Scraps in remove scraps (danger of pin-
the way? ching!).
Removal is not at bottom. End position not Removal tilting back. Perhaps re-
reached. Scraps in move scraps (danger of pinching!)
the way?
Pneumatic unit x is not at rear End position not Move to home position. Perhaps
the way? ching!)
Accessory (side slide) is not at End position not Move to home position. Perhaps
rear. reached. Scraps in remove scraps (danger of pin-
the way? ching!)
Electric motor x is not off Move to home position. Perhaps
remove scraps (danger of pin-
ching!)
Threading unit x is not at rear End position not Move to home position. Perhaps
the way? ching!)
Tilting table is not at rear. End position not Move to home position. Perhaps
the way? ching!)
10-107
Sliding table is not at rear. End position not Move to home position. Perhaps
the way? ching!)
Accessory is not at rear. End position not Move to home position. Perhaps
the way? ching!)
Side slide x is not at rear End position not Move to home position. Perhaps

the way? ching!)
Ram lock is not locked. Ram position is Move ram in locking position of the
beyond the hole safety bar.
pattern of the safe-
ty bar.
Main cylinder has overrun the po- Stopping distance Extend stopping distance.
sition. too short.
Error monitoring closing safety. Valve doesnt work Check safety valve.
orderly.
Error monitoring close press. Valve doesnt work Check directional valve 'close
orderly. press'.
Error monitoring open press. Valve doesnt work Check directional valve 'open
orderly. press'.
Error ram lock not unlocked. No pneumatic Check pressure supply.
pressure.
Error part present. Workpiece was not Remove the workpiece from the
removed. tool.
10-108
Lubrication error ram. Lubricant container Check lubricant container, lubricant
empty or fault in distributor, and supply line.
the lubricant distri-
butor or supply line
damaged.
Lubrication error sliding table. Lubricant container Check lubricant container, lubricant
empty or fault in distributor, and supply line.

the lubricant distri-
butor or supply line
damaged.
Fault oil temperature. Oil temperature too Check cooling circuit and pressure-
high. less circulation of the hydraulic
unit.
Fault oil level too low. Refill hydraulic oil.
Fault pressure filter. Filter contamina- Clean the filter.
ted.
Fault return filter. Filter contamina- Clean the filter.
ted.
Overcurrent hydraulic motor. Motor overloaded.
Overcurrent central lubrication. Motor overloaded. Check electrical fuse protection of
the motor.
Overcurrent sawing unit x. Motor overloaded.
10-109
10.2 FAULT MESSAGES
10.2.1 Limit switch faults

Limit switch. Message Cause Remedy
E33.4 Error limit switch press pad not at Limit switch E33.4
rear
E1.3 Error limit switch ram lock unlocked Limit switch E1.3

E1.4 Ram lock not locked Limit switch E1.4
Check TDC + limit switch
E1.3 / E1.4 Limit switch fault ram lock Limit switches E1.3 / E1.4 perhaps
switched at the same time.
E1.5 Error limit switch removal unit at Limit switch E1.5
front
E1.6 Error limit switch removal unit at rear Limit switch E1.6
E1.5 / E1.6 Limit switch fault removal unit Limit switches E1.5 / E1.6 perhaps
switched at the same time.
E1.7 Error limit switch removal unit at bot- Limit switch E1.7
tom
E1.5 / E1.6 / Limit switch fault removal unit Limit switches E1.5 / E1.6 / E1.7
E1.7 perhaps switched at the same time.
E3.3 Error limit switch press pad not at Limit switch E 3.3
front
E32.1 Error limit switch side slide 1 not at Limit switch E32.1
rear
front
10-110
rear
front
rear

front
rear
E32.0 / E32.1 Limit switch fault side slide 1 Limit switches E32.0 / E32.1
perhaps switched at the same time.
E33.3 / E33.4 Limit switch fault press pad Limit switches E33.3 / E33.4
E33.0 Error limit switch pneumatic unit 1 Limit switch E33.0
not at front
not at rear
10-111
E33.0 / E33.1 Limit switch fault pneumatic unit 1 Limit switches E33.0 / E33.1
E44.0 Error limit switch threading unit 1 not Limit switch E44.0
at front
at rear

E44.0 / E44.1 Limit switch fault threading unit 1 Limit switches E44.0 / E44.1
at front
at rear
E44.2 / E44.3 Limit switch fault threading unit 2 Limit switches E44.2 / E44.3
front
front
rear
10-112
rear
not at front
not at rear

E45.0 / E45.1 Limit switch fault pneumatic unit 2 Limit switches E45.0 / E45.1
E48.0 Limit switch monitoring sliding table Limit switch E48.0
in press / acceptance position
E48.1 Limit switch monitoring sliding table Limit switch 48.1
in press / position before accep-
tance position
E48.2 Limit switch monitoring sliding table Limit switch 48.2
out of press / position before
E48.3 Error limit switch sliding table out of Limit switch 48.3
press
E48.4 Error limit switch tool in position Limit switch 48.4
E Error limit switch sliding table in ac-
ceptance position
E Error limit switch sliding table locked
E Limit switch monitoring tilting table
in acceptance / removal position
E Limit switch monitoring tilting table
in removal/locking position
10-113
E Limit switch monitoring locking sli-
ding/tilting table
E Error limit switch tilting table in scrap
removal position
E Error limit switch tilting table in ac-
ceptance position

E Error limit switch tilting table locked
E Error limit switch tilting table in lok-
king position
10-114
APPENDIX
11 APPENDIX

APPENDIX
For interlinkage of the trim press with a robot please observe the do-
cumentation INTERFACE DESCRIPTION TRIM PRESS - ROBOT.

GLOSSARY
12 GLOSSARY
A
AB see ram lock
B
BWS Non-contact safety device (light curtain)
H
Handshake Signal exchange between the controls of different machines, e. g. trim
press and robot.
Home position The ram is situated in the upper programmed end position. All acces-
sory components are situated in a defined position.
R
Ram lock Mechanical device which prevents sagging of ram due to its dead
weight in case of leakage of the hydraulic unit/of the hydraulic cylin-
der.
Referencing Generation of a defined zero position of the ram - condition for the fur-
ther operation of the machine. Referencing is performed automatical-
ly when the machine is switched on.
S
safety device Non-contact safety device (light curtain)

GL OSS ARY
T
TDC Top Dead Center - upper programmed end position of the ram. This
end position has to be chosen in such way to allow for locking of the
ram lock can!
Teach-In Programming of movement sequences by approaching the position to
be programmed.

INDEX
13 INDEX
A
Advance 8-19-62
Airblast time 8-10-52
B
Batch counter 8-27-79
C
Change operating mode 7.4-38
Connecting terminals 6-1-26
connection cable for Siemens S7 5-1-24
Control cabinet 7.1-34
Crawling speed sliding table 8-17-60
Current position 8-3-45
current position 8-18-61
D
Date -78
Day counter 8-27-79
Delete program 8.4.2.2-84
Delete program step 8.4.3.3-92
Description of interface press - robot 11-116
Dwell time 8-12-55
E
Edit program step 8.4.3.2-90
EMERGENCY-OFF 7.2-34
Energy supply 6.2-26
Error message 7.2-37
Execute program steps individually 8-26-70
Expert -20
Extension of control 5-2-24
H
Handshake 8-25-68
I
Inching mode -12
Insert program step 8.4.3.1-87
Insured 4.1.2-14
Interface description 8-26-68
Interval 8-11-53
L
Lamp test 8-47-81
Lead time 8-10-52
Load program 8.4.2.1-84
Loading time 8-5-47
M
Maintenance - VGB7n5.2 4.2.2-17
Manual - operating mode 7.2-35
Manual operating mode -12
Monitoring time TUE 8.2.1.1-44
Move to home position 7.2-36, 7.6.2-40

INDEX
Move to initial position 7.6-40

O
Open safety door 7.2-35, 8-13-56
Operating elementns control cabinet 7.1-34
Operating mode - selector switch 7.2-35
Operating mode double cycle (non-contact safety device) 7.2-37
Operating mode safety mode (BWS) 7.2-37
Operating mode single cycle (non-contact safety device) 7.2-36
Operating modes - admissible actions 3-1-12
P
Power supply 6.2.1-26
Pulse duration (output) 8-19-62
Q
Qualification of the personnel 3-1-12
R
Ram lock locked -39
Rapid speed sliding table 8-17-60
Reference position 8-3-45, 8-18-61
S
Safety checks 4.2.5-20
Safety equipment 4.2.4-20
Safety equipment - VGB7n5.2 4.2.5.2-21
Safety instructions 4.1-14
Sagging of the ram due to its dead weight DANGER-39
Selector switch operating mode with light curtain 7.2-36
Setting -12, 7.2-35
Setting - VGB7n5.2 4.2.1-16
Signal exchange press - robot 8-25-68
Single stroke 7.2-35
Single stroke manual 3-1-12
Single stroke robot -12
Skilled personnel 4-1-15
Software revision ( -78
Spray time 8-11-53
Start work cycle 7.2-36
Stepping behind - safety equipment 4.2.4-20
Stop work cycle 7.2-36
Stopping distance 8-3-45, 8-18-61
Store program 8.4.2.3-85
Store tool number 8-60-94
Switch off motor 7.2-35
Switch on motor 7.2-35
Switching off 7.5.2-39
Switching on 7.5.1-39
Switch-on lock 7.2-36
T
Tilting off for scrap removal 8-18-61
Tilting time 8-9-51
Time ( -78

INDEX
Tolerance 8-3-45, 8-18-61

Tool monitoring 8.2.23-67
Tool number 8.4.4-94
TUE 8.2.1.1-44
TWA 8.2.1.2-44
U
User 4.1.1-14
W
Waiting time TWA 8.2.1.2-44
Warnings 4.1.3-14
Working hour meter -78

INDEX

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Press Control

Version: DialogIII 05.2004 GB -1

3 QUALIFICATION OF THE PERSONNEL

5 HARDWARE AND SOFTWARE

Version: DialogIII 05.2004 GB 1-3

1-4 Version: DialogIII 05.2004 GB

8.4.3.1 Insert program step 87

Version: DialogIII 05.2004 GB 1-5

1-6 Version: DialogIII 05.2004 GB

Version: DialogIII 05.2004 GB 2-7

2.1 FEATURES OF THE CONTROL

2-8 Version: DialogIII 05.2004 GB

Start and duration for airblast programmable

2.2 TYPE TEST

Version: DialogIII 05.2004 GB 2-9

2-10 Version: DialogIII 05.2004 GB

3 QUALIFICATION OF THE PERSONNEL

Version: DialogIII 05.2004 GB 3-11

Tab. 3-1: Qualification of the personnel

Operating mode admissible activity Qualification

3-12 Version: DialogIII 05.2004 GB

Version: DialogIII 05.2004 GB 4-13

4.1 EXPLICATION OF TERMS AND SYMBOLS

4-14 Version: DialogIII 05.2004 GB

Tab. 4-2: List of graphical symbols

Ear protection Hot surface

Eye protection General danger

4.1.4 Skilled personnel

Fig. 4-1: Symbol for skilled personnel

Version: DialogIII 05.2004 GB 4-15

4.2 INSTRUCTIONS CONCERNING SAFETY

4.2.1 Setting (observe national regulations)

4-16 Version: DialogIII 05.2004 GB

see Chapter 4.2.5, Annual safety check

4.2.2 Maintenance (observe national regulations)

4.2.3 Instructions of the manufacturer

Version: DialogIII 05.2004 GB 4-17

As a consequence of inappropriate use there may occur faults in

4.2.3.2 Special safety instructions for the insured

4-18 Version: DialogIII 05.2004 GB

8. Works at the electric unit must only be executed by skilled person-

4.2.3.3 Special safety instructions for the user

Version: DialogIII 05.2004 GB 4-19

4.2.4 Safety equipment

4.2.5 Annual safety check

See also section 7.2 of the Sicherheitsregeln fr berhrungslos wir-

4-20 Version: DialogIII 05.2004 GB

dent prevention regulations, guidelines and the generally accepted

4.2.5.2 Safety equipment

Version: DialogIII 05.2004 GB 4-21

(5) Press where setting is performed without the safety equipment

4.2.5.3 Test instructions of the manufacturer

4-22 Version: DialogIII 05.2004 GB

5 HARDWARE AND SOFTWARE

Version: DialogIII 05.2004 GB 5-23

Tab. 5-2: Extension of control

5-24 Version: DialogIII 05.2004 GB

Version: DialogIII 05.2004 GB 6-25

6.1 DELIVERY CONDITION

6.2 ENERGY SUPPLY

6.2.1 Connect power supply

Observe the circuit diagram!

Fig. 6-1: Connecting terminals in the control cabinet