Amada HFE M2 User manual

HYDRAULIC PRESS-BRAKE
OPERATOR’S MANUAL
X41176 B
AMADA Europe S.A.
BP 41040 – 95912 ROISSY AÉROPORT CDG CEDEX
Tél : [phone] – Fax : [phone]
Original

2/12 CONTENTS
Issue 05/2010 OPERATOR’S MANUAL HFE M2 – X41176B
Index Issue Updated by Details of revision
A 05/2010 D.Gasior First issue
B 10/2010 D. Gasior Updated Ch6:
- Initialisation of AKAS III
- Bending criteria
- Directory management
In order to achieve a thorough understanding of the machine, it is recommended that this manual should be read
through carefully.
Adhere scrupulously to the detail of the installation operations, operation and maintenance instructions as
described in this manual; so as to avoid all risks of accidents.
Retain this documentation to hand so that it can be used as a reference whenever required.
Amada, Tremblay, December 2002.
Any representation, translation, adaptation or reproduction, even partial, by any method or in any country
without prior permission is illegal and would make the offender subject to legal action.

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LIST OF ADDENDA
Modification coming
from Reason Description Application

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HYDRAULIC PRESS BRAKE
OPERATOR’S MANUAL
IMPORTANT
ACCEPTANCE
We loaded your press brake onto the carrier's vehicle. The carrier acknowledged receiving it
in perfect condition.
However, in the case of a problem during shipping (which may happen), or if you notice signs
of damage (impact marks, etc.) on your machine, we would like to remind you that you
should formulate your reservations as follows:
A– the delivery voucher submitted to you for acceptance by the carrier.
B– By notifying the carrier and us (for information) by registered letter within 48 hours at the
latest.
C– It is strictly prohibited to use this machine if protective covers have been removed or
modified. Only personnel - authorized and qualified by AMADA – is entitled to do so when
maintenance operations turn out to be necessary.
FOR ALL PROBLEMS DURING MACHINE INSTALLATION
Telephone ........................................................... 01 49 90 30 00
Fax ....................................................................... 01 49 90 31 99

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CONTENTS
1. GENERAL DESCRIPTION ............................................................................................... 1
1.1. DESCRIPTION................................................................................................................ 3
1.2. PRINCIPLE ..................................................................................................................... 5
1.3. MACHINE SPECIFICATIONS...................................................................................... 8
1.3.1. STANDARD STROKE............................................................................................. 8
1.3.2. LONG STROKE ....................................................................................................... 9
1.4. BACK GAUGE ............................................................................................................. 10
1.4.1. BASIC PRINCIPLES.............................................................................................. 10
1.4.2. SPECIFICATIONS ................................................................................................. 11
2. SAFETY MEASURES......................................................................................................... 1
2.1. EC DECLARATION OF CONFORMITY ..................................................................... 2
2.2. MARKING ...................................................................................................................... 4
2.3. SAFETY PRECAUTIONS............................................................................................ 10
2.3.1. GENERAL POINTS ............................................................................................... 10
2.3.2. REGULAR INSPECTION AND SAFETY POLICY............................................. 13
2.4. ARRANGEMENT OF WORKSTATIONS................................................................. 14
2.5. CONTROL DEVICES................................................................................................... 15
2.6. PERSONAL PROTECTIVE EQUIPMENTS (PPE)..................................................... 16
2.7. RULES FOR SAFE OPERATION................................................................................ 19
2.8. WORKSTATION LIGHTING...................................................................................... 26
2.9. MACHINE OPERATING AND STORAGE CONDITIONS....................................... 27
2.10. INFORMATION ON NOISE...................................................................................... 28
2.11. NORMAL USE, RESERVATIONS, AND EXCLUSIONS....................................... 29

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3. TECHNICAL DESCRIPTION OF THE MACHINE...................................................... 1
3.1. MECHANICAL CONNECTIONS.................................................................................. 5
3.2. ELECTRONIC STROKE CONTROL AND PARALLELISM BALANCING
SYSTEM................................................................................................................................. 7
3.2.1. ELIMINATING SOURCES OF ERROR ................................................................. 9
3.2.2. PROPORTIONAL VALVE TECHNIQUE FOR CONTINUOUS RELIABILITY. 9
3.2.3. PRECISE CENTRING OF THE BEAMS .............................................................. 10
3.3. LOCATION OF CONTROL AND SIGNALLING DEVICES.................................... 11
3.4. PRESS BRAKE OPERATING LIMITS IN OFF-CENTRE WORK............................ 11
3.5. A-TYPE BACK GAUGE .............................................................................................. 12
3.5.1. DESCRIPTION OF X1 AND X2 AXES................................................................ 13
3.5.2. DESCRIPTION OF R AXES.................................................................................. 15
3.5.3. DESCRIPTION OF Z1 AND Z2 AXES................................................................. 17
3.6. B-TYPE BACK GAUGE .............................................................................................. 18
3.6.1. DESCRIPTION OF X1 AND X2 AXES................................................................ 19
3.6.2. DESCRIPTION OF R AXES.................................................................................. 21
3.6.3. INTERFACE BETWEEN R AXIS MODULE AND Z AXIS CROSS-MEMBER23
3.6.4. DESCRIPTION OF Z1 AND Z2 AXES................................................................. 23
3.7. DESCRIPTION OF C-TYPE BACK GAUGE ............................................................. 24
3.7.1. DESCRIPTION OF X-AXES ................................................................................. 25
3.7.2. DESCRIPTION OF R-AXIS................................................................................... 27
3.7.3. DESCRIPTION OF Z1 AND Z2 AXES (FINGERS)............................................. 29
3.8. GENERAL DESCRIPTION OF HA-TYPE BACK GAUGE....................................... 30
3.8.1. DESCRIPTION OF THE X1 AND X2 AXES ....................................................... 31
3.8.2. DESCRIPTION OF THE R AXES......................................................................... 33
3.8.3. DESCRIPTION OF Z1 AND Z2 AXES (FINGERS)............................................. 35
3.9. DESCRIPTION OF THE FINGER SUPPORTS .......................................................... 36
3.10. DESCRIPTION OF THE LIGHT GUARD ................................................................ 39
3.10.1. MECHANICAL UNIT.......................................................................................... 40
3.10.2. LIGHT GUARD.................................................................................................... 41

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4. TRANSPORT, INSTALLATION AND DISMANTLING............................................... 1
4.1. TRANSPORTATION...................................................................................................... 2
4.2. PREPARING THE SITE................................................................................................. 7
4.2.1. STANDARD STROKE............................................................................................. 9
4.2.2. LONG STROKE ..................................................................................................... 10
4.3. MACHINE RECEPTION.............................................................................................. 10
4.4. RECEPTION & HANDLING ....................................................................................... 12
4.4.1. LIFTING.................................................................................................................. 12
4.4.2. BASIC PRINCIPLES.............................................................................................. 14
4.4.3. EQUIPMENT.......................................................................................................... 17
4.4.4. SPECIAL PARTS FOR TRANSPORT .................................................................. 19
4.5. INSTALLATION .......................................................................................................... 20
4.6. ELECTRICAL CONNECTIONS.................................................................................. 28
4.6.1. GENERAL CHARACTERISTICS OF THE MAINS SUPPLY ............................ 28
4.6.2. EARTH.................................................................................................................... 28
4.6.3. MAINS-RELATED AND ENVIRONMENT-RELATED INTERFERENCE....... 29
4.6.4. POWER SUPPLY CABLE..................................................................................... 31
4.7. DECOMMISSIONING.................................................................................................. 32
4.8. DISMANTLING............................................................................................................ 33
5. FIRST COMMISSIONING ................................................................................................ 1
5.1. CLEANING..................................................................................................................... 2
5.2. INSTALLATION OF CONTROL DEVICES................................................................. 2
5.3. CHECKING THE MAINS POWER SUPPLY ............................................................... 4
5.4. MACHINE LEVELLING................................................................................................ 4
5.5. MACHINE COMMISSIONING ..................................................................................... 5
5.6. OVERALL CHECK ........................................................................................................ 6

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6. OPERATION........................................................................................................................ 1
6.1. START-UP ...................................................................................................................... 2
6.2. DESCRIPTION OF CONTROL UNITS......................................................................... 3
6.2.1. NUMERICAL CONTROL PANEL.......................................................................... 3
6.2.2. DESCRIPTION OF CONTROL AND SIGNALLING DEVICES........................... 4
6.3. OPERATION (WITHOUT LIGHT GUARD) ............................................................. 10
6.4. USE OF THE LIGHT GUARD..................................................................................... 12
6.4.1. SWITCHING ON.................................................................................................... 12
6.4.2. ALTERNATE PROTECTION MODE .................................................................. 13
6.4.3. PROTECTION MODE AND « SINGLE PASSING-THROUGH » CYCLE
CONTROL. ....................................................................................................................... 15
6.4.4. PROTECTION MODE AND « DOUBLE PASSING-THROUGH » CYCLE
CONTROL. ....................................................................................................................... 16
6.4.5. PROTECTION MODE AND « SIMPLE PASSING-THROUGH » CYCLE
CONTROL. ....................................................................................................................... 17
6.4.6. PROTECTION MODE AND « DOUBLE PASSING-THROUGH » CYCLE
CONTROL. ....................................................................................................................... 19
6.5. MACHINE EQUIPPED WITH A FRONT PROTECTION BY LASER..................... 21
6.5.1. INITIAL SETTINGS............................................................................................... 21
6.5.2. STOPPING DISTANCE TEST............................................................................... 21
6.5.3. TROUBLESHOOTING - MESSAGES.................................................................. 22
6.6. DISPLAYS .................................................................................................................... 23
6.7. USB KEY....................................................................................................................... 26
6.8. MACHINE INITIALISATION ..................................................................................... 27
6.9. PROGRAMMING......................................................................................................... 29
6.9.1. PRELIMINARY NOTE CONCERNING PROGRAMMING................................ 29
6.9.2. “MANUAL 1” SIMPLIFIED PROGRAMMING “PROGRAMMING MODE”... 30
6.9.3. “MANUAL 2” MODE: "ANGLE PROGRAMMING" OR "X-ALPHA".............. 35
6.9.4. GRAPHIC MODE PROGRAMMING ................................................................... 42
6.9.5. MULTI-PROGRAM MODE................................................................................... 54
6.9.6. SEMI-AUTOMATIC MODE.................................................................................. 56
6.9.7. AUTOMATIC MODE ............................................................................................ 59
6.9.8. TEACHING MODE................................................................................................ 62
6.10. EDIT MENU................................................................................................................ 65
6.10.1. PUNCH EDIT ....................................................................................................... 65
6.10.2. PUNCH HOLDER EDIT ..................................................................................... 67
6.10.3. DIE EDIT .............................................................................................................. 68

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6.10.4. DIE HOLDERS EDIT........................................................................................... 69
6.10.5. DIE BLOCK EDIT................................................................................................ 70
6.10.6. FINGER EDIT....................................................................................................... 71
6.11. DELETE MENU.......................................................................................................... 72
6.11.1. DELETE PROGRAMS......................................................................................... 72
6.11.2. DELETE PUNCHES............................................................................................. 74
6.11.3. DELETE PUNCH HOLDERS.............................................................................. 75
6.11.4. DELETE DIES...................................................................................................... 75
6.11.5. DELETE DIE BLOCK.......................................................................................... 75
6.11.6. DELETE DIE HOLDERS.................................................................................... 75
6.11.7. DELETE FINGER................................................................................................. 75
6.12. RENAME MENU........................................................................................................ 76
6.12.1. RENAME PROGRAMS ....................................................................................... 76
6.12.2. RENAME PUNCHES........................................................................................... 77
6.12.3. RENAME PUNCH HOLDERS ............................................................................ 77
6.12.4. RENAME DIES .................................................................................................... 77
6.12.5. RENAME DIE BLOCKS...................................................................................... 77
6.12.6. RENAME DIE-HOLDERS................................................................................... 77
6.12.7. RENAME FINGERS............................................................................................. 77
6.13. COPY MENU.............................................................................................................. 78
6.13.1. COPY PROGRAMS ............................................................................................. 78
6.13.2. COPY PUNCHES ................................................................................................. 79
6.13.3. COPY PUNCH HOLDER..................................................................................... 79
6.13.4. COPY DIES........................................................................................................... 79
6.13.5. COPY DIE HOLDERS ......................................................................................... 79
6.13.6. COPY DIE BLOCK .............................................................................................. 79
6.13.7. COPY FINGER..................................................................................................... 79
6.14. SAVE MENU .............................................................................................................. 80
6.14.1. SAVE PROGRAMS.............................................................................................. 80
6.14.2. SAVE PUNCHES ................................................................................................. 83
6.14.3. SAVE PUNCH HOLDER..................................................................................... 83
6.14.4. SAVE DIE............................................................................................................. 83
6.14.5. SAVE DIE BLOCK .............................................................................................. 83
6.14.6. SAVE DIE HOLDER............................................................................................ 83
6.14.7. SAVE FINGER ..................................................................................................... 83
6.15. RESTORE MENU....................................................................................................... 84
6.15.1. RESTORE PROGRAMS ...................................................................................... 84
6.15.2. RESTORE PUNCHES.......................................................................................... 87
6.15.3. RESTORE PUNCH HOLDER.............................................................................. 87
6.15.4. RESTORE DIES ................................................................................................... 87
6.15.5. RESTORE DIE BLOCK....................................................................................... 87

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6.15.6. RESTORE DIE HOLDERS .................................................................................. 87
6.15.7. RESTORE FINGER.............................................................................................. 87
6.16. CUSTOM MENU........................................................................................................ 88
6.16.1. CUSTOMISE PUNCH.......................................................................................... 88
6.16.2. CUSTOMISE PUNCH HOLDER......................................................................... 89
6.16.3. CUSTOMISE DIE................................................................................................. 89
6.16.4. CUSTOMISE DIE BLOCK .................................................................................. 89
6.16.5. CUSTOMISE DIE HOLDER................................................................................ 89
6.16.6. CUSTOMISE FINGER......................................................................................... 89
6.17. PROGRAM DIRECTORY MENU............................................................................. 90
6.17.1. CHANGE DIRECTORY....................................................................................... 90
6.17.2. EXPORT DIRECTORY........................................................................................ 91
6.17.3. IMPORT DIRECTORY........................................................................................ 93
6.18. PARAMETER MENU................................................................................................. 95
6.19. UTILITY MENU......................................................................................................... 96
6.20. BENDING WITH 2 OPERATORS............................................................................. 98
6.21. BENDING AT THE EXTREMITY OF THE BEAM................................................. 99
7. FORMING TECHNIQUE & TOOLING.......................................................................... 1
7.1. GENERAL POINTS........................................................................................................ 3
7.2. AIR BENDING................................................................................................................ 7
7.3. COINING......................................................................................................................... 8
7.4. LIST OF STANDARD TOOLS ...................................................................................... 9
7.5. TOOL INSTALLATION............................................................................................... 11
7.5.1. STANDARD FAST PUNCH CLAMPING SYSTEM ........................................... 11
7.5.2. “AMACLIP” PUNCH CLAMPING SYSTEM ...................................................... 15
7.5.3. TOOLING INSTALLATION PROCEDURE (STANDARD)............................... 21
7.6. OPTIONS AND ACCESSORIES ................................................................................. 29
7.7. PUNCHING................................................................................................................... 29
7.8. MAGNETISM ............................................................................................................... 29
7.9. BENDING CHART....................................................................................................... 30

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8. SERVICING AND MAINTENANCE................................................................................ 1
8.1. INTRODUCTION ........................................................................................................... 2
8.2. MACHINE PERIODIC MAINTENANCE..................................................................... 5
8.2.1. CHECKS SPECIFIC TO THE HYDRAULIC INSTALLATION ........................... 9
8.2.2. OIL CHANGES....................................................................................................... 11
8.2.3. FILLING PROCEDURE......................................................................................... 11
8.3. RECOMMENDATIONS............................................................................................... 12
8.3.1. SPECIFIC DAILY TEST PROCEDURE:.............................................................. 13
8.4. TROUBLESHOOTING................................................................................................. 24
8.4.1. TROUBLESHOOTING TABLE ............................................................................ 24
8.4.2. REGULATORY PERIODIC (QUARTERLY) INSPECTION: GENERAL
POINTS............................................................................................................................. 25
8.5. INSTALLATION AND ADJUSTMENT OF DISTANCE PIECES ............................ 27
8.6. ADJUSTMENT AND MAINTENANCE OF THE LIGHT GUARD .......................... 31
8.6.1. ADJUSTMENT....................................................................................................... 31
8.6.2. PROGRAMMING................................................................................................... 34
8.6.3. REGULAR MAINTENANCE................................................................................ 34
8.6.4. DAILY INSPECTION ............................................................................................ 35
8.6.5. MAINTENANCE.................................................................................................... 36
8.7. ADJUSTING AKASIII MAINTENANCE .................................................................. 38
8.8. BACK GAUGE MAINTENANCE............................................................................... 41
8.8.1. INTRODUCTION................................................................................................... 41
8.8.2. MEANS NECESSARY FOR MAINTENANCE.................................................... 42
8.8.3. MONTHLY FREQUENCY .................................................................................... 42
8.8.4. QUARTERLY FREQUENCY................................................................................ 43
8.8.5. SEMI-ANNUAL FREQUENCY ............................................................................ 44
8.8.6. EVERY 2 YEARS................................................................................................... 53
9. ERROR MESSAGES LIST................................................................................................. 1
ANNEXE A –
ANNEXE B – MACHINE SCHEMATICS AND LISTING (see in the elctric cabinet of
the machine).
ANNEXE C – SUPPLIERS DOCUMENTATION
ANNEXE D – SPECIAL MACHINES
ANNEXE E – OPTIONS

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APPENDICES
IMPORTANT NOTE
A certain number of appendices – fully complying with your machine
- is supplied with this technical manual.
The list of these additional documents is part of the Quality Control
file, which is delivered with the machine. At the time of delivery, this
file is placed inside the document tray attached to the inner side of the
electric cabinet door.

GENERAL DESCRIPTION Chapter 1 1/20
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1. GENERAL DESCRIPTION

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Figure 1.1

GENERAL DESCRIPTION Chapter 1 3/20
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1.1. DESCRIPTION
The purpose of this document is to facilitate the installation of your High Fidelity hydraulic
press brake (Fig. 1.1) and its connection to the electrical and pneumatic supply systems.
This product line includes the following models:
- HFE M2 50 to 400 tons
Depending upon the models, lengths start 1.2 meters up to 6 meters
Our models are supplied:
In a « basic » footswitch-controlled version,
Equipped with a “A” or “B”-type back gauge (except with 5012)
Equipped with a “C”-type back gauge (only with 5012)
Equipped with a « HA 5 axes », « HA 2 axes » (only with 320 and 400 T) -type
back gauge
in option :
- light curtain, which is used as front protection and as an operation cycle control
device. Or
- laser safety system used as front protection only.
Note : In this manual, “tons” is very often used instead of international measurement
unit “kN”. We remind you that 9.81 kN is equivalent to one ton.

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Figure 1.2
F1 and F’1 = Bending force
A and A’ = Counter acting points

GENERAL DESCRIPTION Chapter 1 5/20
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1.2. PRINCIPLE
The machine is a manual loading/unloading hydraulic press brake.
HF-type hydraulic press brakes are down-stroking machines equipped with a numerical
control ensuring the control and adjustment of all bending parameters.
These press brakes are equipped with a central reaction Lower Beam to ensure bending
quality.
An electrohydraulic servosystem controls the travel and ensures that the Upper Beam (UB)
remains perfectly parallel to the Lower Beam (LB).
These machines can be equipped with various options (back gauge, front gauge, etc.), with all
Amada tools, and other traditional tools, as well as a range of various accessories. (Contact
our Local Sales Representative to discuss your specific requirements.)
For items heavier than 25 kg, a handling device – not included in
Amada supply - must be provided to the operator.
REVIEW OF THE CONVENTIONAL DESIGN OF PRESS BRAKES
Due to the reactions of the part under the thrust of the cylinders located at both ends,
traditional down-stroking press brakes experience an elastic deflection during bending
in opposite directions on each beam.
These deflections can be detected by a difference in terms of punch penetration in the
die, slightly minor in the center than at the ends (Fig. 1.2).

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AMADA SYSTEM: Slotted beam (for 50 to 100 -ton press brakes).
The lower beam is a slotted plate. The arrangement, size, and shape of the slots are designed
to allow the lower beam to deflect in the same direction and with the same deflection as the
upper beam under the action of the bending force. The lower beam is welded to the flanges
(Fig. 1.3).
From 130 to 400 tons.
The lower beam (A) is assembled between two lateral cheeks (B and B') welded to the flanges
through two largely dimensioned pins positioned on both ends of the machine’s central axis
(Fig. 1.3) or (Fig. 1.3’). When bending, reaction forces tend to deform the lower beam in the
same direction and parallel to the upper beam. (Fig. 1.4).
ADVANTAGES
Due to the minor but inevitable elastic deflection of both beams in the same direction and
with the same value, the punch has constant penetration in the die over the entire bending
length, thus ensuring a perfect angle.
The minor deflection of the beams does not affect the linearity of the bend because the stress
induced in the beam remains well within the elastic region.
Up to 220 tons
Fig. 1.3
AB
B’

GENERAL DESCRIPTION Chapter 1 7/20
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Valid for 320 and 400 tons
Fig. 1.3’
Fig. 1.4
F1 and F’1 = Bending force
A and A’ = Counter acting points

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1.3. MACHINE SPECIFICATIONS
1.3.1. STANDARD STROKE
AMADA EUROPE S.A. constantly strives to improve its products, and reserves the right to
alter their characteristics at any time.
(1) - Value affecting the smallest allowable length of tools (§ 7.5).
(2) - The dimensions are with the arm and the NC maximum extended on the exterior, and all doors closed..
(3) - The dimensions are with the arm and the NC maximum extended in front, and all doors closed..
(4) - Les Weights are approximate and correspond to basic machines, for optional equipment, see § 4.2.1.
(5) - Standard distance pieces / Abutting distance pieces.
(6) - Machine power = Motor power + 3 kW.
50-12 50-20 80-25 100-30 130-30 170-30 170-40 220-40
kN 500 500 800 1000 1300 1700 1700 2200
kN 40 40 70 75 150 210 210 260
mm 1270 2090 2570 3110 3140 3170 4230 4280
mm 60 60 60 60 90 180 180 180
mm 960 960 960 960 960 960 960 960
mm 370 470 470 470 470 470 470 470
mm 150 200 200 200 200 200 200 200
mm 100 420 420 420 420 420 420 420
mm 1035 1665 2125 2705 2700 2700 3760 3760
bar 270 270 275 280 296 283 283 288
4 4 4 4 5 5 5 5
litres 55 55 90 110 150 235 235 295
mm 2710 3340 3800 4385 4440 4470 5530 5560
mm 2320 2450 2445 2430 2625 2625 2625 2625
mm 2300 2450 2540 2680 2815 2900 2890 3085
kg 3350 4600 5600 6600 8150 11600 13900 17100
6/8 10/13 13/17 15/21 15 / 21 16 / 21 21 / 28 21 / 28
mm 120 120 120 120 120 120 120 120
lg 835 mm 1 2 4 4 4 4 5 5
lg 415 mm 3 5 7 7 7 7 10 10
kW 4 4 7,5 7,5 11 15 15 18,5
cm
³
/t
8,2
8,2
13,3
15,8
20,7 32,6 32,6 41
mm/s 100 100 100 100 100 100 100 100
mm/s 10 10 10 10 1 à 10 1 à 10 1 à 10 1 à 10
mm/s 100 100 100 100
1 à 100
1 à 100
1 à 100
1 à 100
MODELS HF
Working line height
Nominal force
Minimum force (1)
Beam length
Table width
Max. pressure
Number of cycles
Oil capacity
UnitsDescription
Admission
Cylinder stroke
Throat depth
Distance between uprights
Motor power (6)
Max. return speed
Max. approach speed
Pump capacity
Max. working speed
Number of adj. Dist. pieces (5)
Height of distance pieces
Number of
tools
Length (overall) (2)
Width (overall) (3)
Height (overall)
Total weight(4)