ISB RBPC User manual

RBPC
RESOLVER BASED PRESS CONTROL
User Manual
Software Version 4.65.00
Manual Version 4.65.01
Jan- 2012

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1 RBPC PRESS CONTROL FEATURES OVERVIEW.................. 9
1.1 ADAPTABILITY TO DIFFERENT PRESS TYPES...............................................9
1.2 BRAKE WEAR MONITOR FEATURES...............................................................9
1.3 LED CIRCULAR ARRAY DISPLAY FEATURES.................................................9
1.4 PLS FEATURES..................................................................................................9
1.5 DIE PROTECTION FEATURES...........................................................................9
1.6 JOB STORAGE FEATURES.............................................................................10
1.7 RESOLVER FEATURES ...................................................................................10
1.8 PASSWORD PROTECTION FEATURES..........................................................10
1.9 COUNTERS FEATURES...................................................................................10
1.10 FAULTS AND WORKING CONDITIONS RECORDING FEATURES ..............10
1.11 SPEED VALVE CONTROL FEATURES..........................................................10
1.12 NETWORK FEATURES...................................................................................11
2 RBPC USER INTERFACE....................................................... 12
2.1 RBPC FRONT PANEL.......................................................................................13
2.2 MAIN MODE SELECTOR SWITCH ...................................................................14
2.2.1 RUN MODE.....................................................................................................................14
2.2.2 OFF MODE......................................................................................................................14
2.2.3 PROGRAM MODE..........................................................................................................14
2.3 LCA - LED CIRCULAR ARRAY DISPLAY........................................................15
2.4 PROGRAMMING OVERVIEW ...........................................................................16
2.4.1 DISPLAYING INFORMATION.........................................................................................16
2.4.2 SELECTING CHOICES...................................................................................................16
2.4.3 ENTERING NUMERIC VALUES.....................................................................................16
2.4.4 ENTERING ALPHANUMERIC CHARACTERS..............................................................16
2.4.5 MENU KEYS ...................................................................................................................17
2.4.6 MENU HOT KEYS...........................................................................................................17
2.4.7 RESET KEY ....................................................................................................................17
2.5 RBPC PRESS CONTROL .................................................................................18
2.5.1 SYSTEM STARTING ......................................................................................................18
2.5.1.1 CHECKSUM SCREEN..................................................................................................................................18
2.5.1.2 SYSTEM READY SCREEN...........................................................................................................................18
2.5.1.3 PRESS CONTROL SCREEN........................................................................................................................18
2.5.2 PRESS CONTROL SCREEN..........................................................................................19
2.5.3 PRESS CONTROL SCREEN: COMPLEMENTARY INFORMATION............................20
2.5.4 RETURNING TO PRESS CONTROL SCREEN FROM MENUS ...................................21
2.6 MENU HOT KEYS .............................................................................................22
2.6.1 MODE HOT KEY.............................................................................................................22
2.6.2 PLS HOT KEY.................................................................................................................22
2.6.3 DIE PROTECT HOT KEY ...............................................................................................22
2.6.4 COUNTERS HOT KEY ...................................................................................................22
2.6.5 PRESS CONTROL HOT KEY.........................................................................................23
2.6.6 BRAKE WEAR HOT KEY................................................................................................23
2.7 DISPLAY TIME OUT..........................................................................................23
2.8 EXTERNAL INPUTS..........................................................................................23
2.8.1 PALM STATIONS............................................................................................................23
2.8.2 FOOT SWITCHES ..........................................................................................................23
2.8.3 KWIKTRIP BUTTON ....................................................................................................... 23
2.8.4 PRESET BUTTON..........................................................................................................23
2.8.5 TOP STOP BUTTON ......................................................................................................24

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2.8.6 AUXILIARY TOP STOP ..................................................................................................24
2.8.7 AUXILIARY IMMEDIATE STOP......................................................................................24
2.8.8 ANTI TIE DOWN FEATURES.........................................................................................24
3 PASSWORD PROTECTION .................................................... 25
3.1 PASSWORD PROTECTED OPTIONS...............................................................25
3.1.1 RBPC MENU TREE ........................................................................................................26
3.2 ACCESSING CONFIGURATION MENU............................................................30
3.2.1 SUPERVISOR LEVEL AND SET-UP LEVEL ACCESS TO CONFIGURATION MENU 30
3.2.2 OPERATORS ACCESS TO CONFIGURATION MENU.................................................30
4 RBPC OPERATION ................................................................. 31
4.1 PRESS CONTROL MODE.................................................................................31
4.1.1 PUNCH PRESS ..............................................................................................................31
4.1.2 PRESS BRAKE...............................................................................................................31
4.1.3 PRESS BRAKE W/ TREADLE........................................................................................31
4.1.4 OPERATION AND ACTUATING MODES AVAILABILITY..............................................32
4.1.5 PRESS CONTROL MODE CONFIGURATION. .............................................................33
4.2 PROGRAM AND RUN MODES .........................................................................34
4.2.1 RUN.................................................................................................................................34
4.2.2 OFF .................................................................................................................................34
4.2.3 PROGRAM......................................................................................................................34
4.3 RBPC OPERATION MODES.............................................................................35
4.4 RBPC ACTUATING MODES.............................................................................35
4.5 OPERATION AREAS.........................................................................................36
4.5.1 TOP STOP ......................................................................................................................36
4.5.2 TOP STOP AREA ...........................................................................................................36
4.5.3 AUTO RETURN AREA....................................................................................................37
4.5.4 RESOLVER CHECK.......................................................................................................37
4.5.5 STROKE STOP...............................................................................................................38
4.5.6 RETURN ANGLE ............................................................................................................38
4.5.7 BENDING ZONE.............................................................................................................39
5 PROGRAMMING OPERATION MODES.................................. 40
5.1 MODES DESCRIPTION.....................................................................................40
5.1.1 INCH................................................................................................................................40
5.1.2 SINGLE STROKE ...........................................................................................................41
5.1.2.1 SINGLE STROKE NORMAL OPERATION....................................................................................................41
5.1.2.2 SINGLE STROKE ACTIVATED BY A TREADLE...........................................................................................42
5.1.2.3 SINGLE STROKE AND STROKE STOP ENABLED......................................................................................43
5.1.3 CONTINUOUS ................................................................................................................ 44
5.1.4 MAINTAINED CONTINUOUS.........................................................................................45
5.1.5 AUTO SINGLE STROKE ................................................................................................46
5.1.5.1 AUTO SINGLE STROKE OPERATION.........................................................................................................46
5.1.6 TIMED INCH....................................................................................................................47
5.1.7 CLUTCH DISENGAGEMENT.........................................................................................48
5.1.8 OFF .................................................................................................................................49
5.2 SELECTING OPERATION MODES...................................................................50
6 PROGRAMMING ACTUATING MODES.................................. 51

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6.1 ACTUATING MODES DESCRIPTION...............................................................51
6.1.1 HAND &/OR FOOT .........................................................................................................51
6.1.2 PSDI 1.............................................................................................................................51
6.1.3 PSDI 2.............................................................................................................................51
6.1.4 KWIKTRIP.......................................................................................................................51
6.1.5 PALM BUTTONS TO FOOT SWITCHES .......................................................................52
6.1.6 TREADLE........................................................................................................................53
6.2 SELECTING ACTUATING MODES...................................................................54
6.2.1 SELECTING HAND &/OR FOOT....................................................................................54
6.2.2 SELECTING KWIKTRIP, PSDI 1 AND PSDI 2...............................................................55
6.2.3 SELECTING TRANSFER FROM HAND TO FOOT........................................................56
6.2.4 SELECTING TREADLE ..................................................................................................57
7 BENDING ZONE SETTINGS ................................................... 58
7.1 BENDING ZONE’S SETTINGS SCREEN..........................................................59
7.2 BEND SPEED SETTINGS .................................................................................61
8 RBPC JOB STORAGE FEATURES......................................... 62
8.1 JOBS MANAGEMENT MENU ...........................................................................62
8.1.1 OPEN JOB ......................................................................................................................63
8.1.2 SAVE JOB.......................................................................................................................64
8.1.3 CLEAR JOB.....................................................................................................................65
8.1.4 RENAME JOB.................................................................................................................66
9 RBPC PLS FEATURES ........................................................... 67
9.1 PLS SETTINGS MENU......................................................................................68
9.2 PLS CHANNEL MAIN CONFIGURATION.........................................................68
9.3 SET POINTS PROGRAMMING .........................................................................69
9.3.1 MULTIPLE DWELLS PER CHANNEL FEATURE ..........................................................70
9.3.2 TYPICAL DWELL CONFIGURATIONS..........................................................................71
9.3.2.1 ANGLE ONLY...............................................................................................................................................71
9.3.2.2 ANGLE + TIME .............................................................................................................................................71
9.3.2.3 TIME ONLY...................................................................................................................................................71
9.4 CONFIGURING PLS OPTIONS.........................................................................72
9.4.1 CONFIGURE PLS...........................................................................................................72
9.4.1.1 CONFIGURE PLS SCREEN ......................................................................................................................... 72
9.4.2 PLS SETTINGS MENU...................................................................................................74
9.4.2.1 DWELL CONFIGURATION PLS CHANNEL..................................................................................................74
9.4.2.2 ALL HIGH PLS CHANNEL ............................................................................................................................ 77
9.4.2.3 DISABLED PLS CHANNEL...........................................................................................................................78
9.4.3 CYCLE DIVIDER.............................................................................................................79
9.4.4 RENAME CHANNEL.......................................................................................................80
9.4.4.1 RENAME PLS CHANNEL SCREEN..............................................................................................................80
9.5 OUTPUTS STATUS...........................................................................................82
9.5.1 PLS DIVIDER STATUS & RESET..................................................................................83
10 RBPC DIE PROTECTION FEATURES.................................. 84
10.1 EVENT DETECTION........................................................................................84
10.1.1 DIE PROTECTION EVENTS ........................................................................................84
10.1.1.1 RISING EDGE EVENT (RISE).....................................................................................................................84
10.1.1.2 FALLING EDGE EVENT (FALL)..................................................................................................................84

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10.1.1.3 DWELL LOW (LOW) ...................................................................................................................................85
10.1.1.4 DWELL HIGH (HIGH)..................................................................................................................................85
10.1.1.5 ALL HI (ALL_H)...........................................................................................................................................85
10.1.1.6 ALL LOW (ALL_L).......................................................................................................................................85
10.1.1.7 EYELET PROBE (EYE-P)........................................................................................................................... 85
10.1.1.8 DISABLE CHANNEL...................................................................................................................................85
10.1.1.9 DIE PROTECTION FAULT DETECTION TYPES........................................................................................86
10.1.2 DIE PROTECTION FAULTS.........................................................................................87
10.1.2.1 E- STOP......................................................................................................................................................87
10.1.2.2 T- STOP......................................................................................................................................................87
10.1.2.3 FAULT.........................................................................................................................................................87
10.2 PART IN PLACE DETECTION ........................................................................87
10.2.1 PART IN PLACE CONFIGURATION............................................................................87
10.2.2 PART IN PLACE MESSAGES......................................................................................87
10.2.3 PART IN PLACE EVENT CONSIDERATIONS.............................................................87
10.3 DIE PROTECTION SETTINGS MENU.............................................................88
10.3.1 DIE PROTECTION SETTINGS SCREEN.....................................................................88
10.3.2 RENAME DIE PROTECTION CHANNEL.....................................................................91
10.3.2.1 RENAME DIE PROTECTION CHANNEL SCREEN.....................................................................................91
10.3.3 DIE PROTECTION AND INCH MODES.......................................................................93
10.3.4 DIE PROTECTION STATE SCREEN...........................................................................94
10.3.4.1 TEMPORARILY DISABLING DP CHANNELS............................................................................................. 95
10.3.5 CONFIGURING DIE PROTECTION CHANNELS ........................................................96
10.4 DIE PROTECTION STATE ..............................................................................98
11 OPTIONAL DIE PROTECTION SETTINGS ........................... 99
11.1 CONFIGURING OPTIONAL DIE PROTECTION SETTINGS.........................101
12 RESOLVER SETTINGS....................................................... 102
12.1 RESOLVER CHECK......................................................................................102
12.2 RESOLVER OFFSET.....................................................................................103
12.3 SET WORK DIRECTION................................................................................104
12.4 MOVEMENT DETECTION.............................................................................105
12.5 RESOLVER CHECK DWELL ........................................................................106
12.5.1 CONFIGURING RESOLVER CHECK DWELL...........................................................106
12.6 RESOLVER FILTER......................................................................................107
12.6.1 CONFIGURING RESOLVER FILTER.........................................................................107
13 BRAKING SETTINGS.......................................................... 108
13.1 WARNING TIME ............................................................................................109
13.2 FAULT TIME..................................................................................................110
13.3 JOB BRAKE TIME.........................................................................................111
13.4 BRAKING ZONE............................................................................................112
13.5 TOP STOP BRAKING....................................................................................113
13.6 ACCESSING BRAKE WEAR SCREEN.........................................................115
13.7 BRAKE WEAR SCREEN...............................................................................116
14 AUTO RETURN SETTINGS................................................. 117
14.1 CONFIGURING AUTO RETURN ANGLE......................................................117

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15 SAFEGUARD SETTINGS .................................................... 118
15.1 SELECTING SAFEGUARD DEVICE .............................................................118
15.2 SAFEGUARD SETTINGS..............................................................................119
15.2.1 SELECTING ACTUATORS.........................................................................................120
15.2.1.1 USING A LIGHT CURTAIN AS SAFEGUARD........................................................................................... 120
15.2.1.2 USING AN INTERLOCK GUARD AS SAFEGUARD..................................................................................121
15.3 ACCESSING SAFEGUARD SETTINGS OPTION .........................................122
16 TIMERS SETTINGS ............................................................. 123
16.1 PRESET TIMER.............................................................................................123
16.2 AUTO SINGLE STROKE TIMER...................................................................123
16.3 INCH MODE TIME OUT.................................................................................123
16.4 CLUTCH DISENGAGEMENT TIME OUT ......................................................123
16.5 OPERATOR LEFT TIME OUT .......................................................................124
16.6 CONFIGURING TIMERS ...............................................................................125
17 RPM LIMITS......................................................................... 126
17.1 CONFIGURING RPM LIMITS ........................................................................127
17.2 CONFIGURING MOTION DELAY TIME ........................................................128
18 COUNTERS ......................................................................... 129
18.1 TOOL STROKES COUNTER.........................................................................129
18.2 QUALITY COUNTER.....................................................................................129
18.3 BATCH COUNTER........................................................................................129
18.4 USING BATCH AND QUALITY COUNTERS.................................................130
18.5 COUNTERS VALUES....................................................................................131
18.6 INITIALIZING TOOL COUNTER....................................................................132
18.7 PROGRAMMING QUALITY COUNTER ........................................................133
18.7.1 PROGRAMMING INITIAL VALUE ..............................................................................133
18.7.2 PROGRAMMING QUALITY COUNTER ACTION ......................................................135
18.8 PROGRAMMING BATCH COUNTER............................................................136
18.8.1 PROGRAMMING BATCH COUNTER INITIAL VALUE..............................................136
18.8.2 PROGRAMMING BATCH COUNTER ACTION..........................................................138
18.9 PRODUCTION RATE.....................................................................................139
18.9.1 PRODUCTION RATE VALUES ..................................................................................140
18.9.2 PROGRAMMING LOW PRODUCTION RATE...........................................................141
18.9.3 PROGRAMMING NORMAL PRODUCTION RATE....................................................142
19 TOTAL AND PARTIAL HOUR METER................................ 143
19.1 TOTAL HOUR METER ..................................................................................143
19.2 PARTIAL HOUR METER...............................................................................143
19.3 VIEWING HOUR METERS.............................................................................143
19.3.1 VIEWING TOTAL HOUR METER...............................................................................143
19.3.2 VIEWING PARTIAL HOUR METER ...........................................................................143
19.4 INITIALIZING PARTIAL HOUR METER........................................................145

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20 FAULT MESSAGES AND WORKING CONDITIONS
RECORDING FEATURES .......................................................... 146
20.1 RBPC FAULTS MANAGEMENT ...................................................................146
20.2 UNLOCKING THE SYSTEM AFTER A FAULT CONDITION ........................146
20.3 ERRORS MEMORY MENU............................................................................147
20.3.1 ERRORS MEMORY SCREENS .................................................................................147
20.3.1.1 MAIN ERRORS MEMORY SCREEN.........................................................................................................147
20.3.1.2 COMPLEMENTARY INFORMATION SCREEN.........................................................................................148
20.3.2 ACCESSING ERROR REGISTERS ...........................................................................149
20.3.3 FAULT AND WORKING CONDITIONS STATISTICS................................................150
20.4 CLEAR ERRORS MEMORY..........................................................................151
21 USER PASSWORDS ........................................................... 152
21.1 CHANGING USER PASSWORDS.................................................................153
21.1.1 OPERATOR LEVEL USERS PERMISSIONS ............................................................153
22 PLS AND DIE PROTECTION EXPANSIONS....................... 155
23 SYSTEM BACKUP AND RESTORE FEATURES................ 156
23.1 PERFORMING A SYSTEM BACKUP............................................................156
23.2 RESTORING RBPC CONFIGURATION ........................................................159
24 LANGUAGE SELECTION.................................................... 161
24.1 SELECTING LANGUAGE..............................................................................161
24.2 ENGLISH & SPANISH DEFINITIONS LIST...................................................161
25 NETWORK FEATURES....................................................... 166
25.1 NETWORK MODULE PARAMETERS...........................................................166
25.1.1 GENERAL NETWORK PARAMETERS......................................................................166
25.1.2 WIRELESS NETWORK PARAMETERS ....................................................................167
25.1.3 NOTIFICATIONS PARAMETERS...............................................................................168
25.1.4 APPLYING SETTINGS TO NETWORK MODULE .....................................................169
25.2 CONFIGURING NETWORK PARAMETERS FROM RBPC...........................170
25.2.1 APPLYING NETWORK MODULE SETTINGS ...........................................................170
25.2.2 SETTING RBPC UNIT NAME.....................................................................................171
25.2.3 SETTING NETWORK MODULE IP ............................................................................172
25.2.4 SETTING NETWORK IP SUBNET MASK .................................................................173
25.2.5 SETTING GATEWAY .................................................................................................174
25.2.6 SETTING WIRELESS NETWORK NAME .................................................................175
25.2.7 SETTING WIRELESS NETWORK TYPE ..................................................................176
25.2.8 SETTING WIRELESS CHANNEL ..............................................................................177
25.2.9 SETTING WIRELESS AUTH-ENCR-KEY TYPE........................................................178
25.2.10 SETTING WIRELESS ENCRYPTION KEY..............................................................179
25.2.11 SETTING WIRELESS CONNECTION MODE..........................................................180
25.2.12 VIEWING NETWORK INFO......................................................................................181
25.2.13 SETTING NETWORK MODULE DEFAULT VALUES .............................................182

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25.3 R BPC S TATUS WEB PAGE FEATURES ..........................................................183
25.3.1 WEB PAGE OVERVIEW.............................................................................................183
25.3.2 ACCESSING WEB PAGE...........................................................................................183
25.3.2.1 MULTIPLE CONNECTIONS and SINGLE CONNECTION ........................................................................184
25.3.3 PASSWORD PAGE ....................................................................................................184
25.3.4 COMMUNICATIONS PAGE........................................................................................184
TRYING TO CONNECT MESSAGE ...........................................................................................................................186
25.3.4.1 CHANGING SETTINGS MESSAGES........................................................................................................186
25.3.4.2 APPLYING RESULT MESSAGES.............................................................................................................187
25.3.4.3 MAXIMUM USERS CONNECTED MESSAGE..........................................................................................187
25.3.4.4 CONNECTION ERROR MESSAGE..........................................................................................................188
25.3.4.5 RbpcStatus UNUSED TIME MESSAGE.................................................................................................... 188
25.3.5 BASIC INFORMATION ...............................................................................................189
25.3.5.1 REFRESH DATA RATE............................................................................................................................189
25.3.6 LINKS..........................................................................................................................189
25.3.7 RBPC EVENTS REGISTER........................................................................................190
25.3.8 MAIN INFORMATION.................................................................................................190
25.3.9 PLS - GENERAL INFORMATION...............................................................................191
25.3.10 PLS - DWELL INFORMATION..................................................................................191
25.3.11 DIE PROTECTION INFORMATION .........................................................................192
25.3.12 BRAKE WEAR INFORMATION................................................................................193
25.3.13 COUNTERS INFORMATION....................................................................................194
APPLYING PRODUCTION RATES PARAMETERS...................................................................................................195
25.3.14 SETTINGS INFORMATION......................................................................................196
25.3.15 STATISTICS AND NETWORK INFORMATION.......................................................197
25.3.16 ERRORS MEMORY INFORMATION .......................................................................198
25.3.17 NOTIFICATIONS INFORMATION ............................................................................199
25.3.17.1 APPLYING NOTIFICATIONS PARAMETERS.........................................................................................200
25.3.18 NETWORK INFORMATION......................................................................................202
25.3.18.1 APPLYING NETWORK PARAMETERS.................................................................................................. 202
25.3.19 MESSAGE BOXES...................................................................................................204
25.4 CONFIGURING NETWORK CONNECTION AND NOTIFICATIONS.............205
25.4.1 P2P ETHERNET CONNECTION................................................................................205
25.4.2 P2P WIRELESS CONNECTION.................................................................................205
25.4.3 LAN ETHERNET CONNECTION................................................................................206
25.4.4 LAN WIRELESS CONNECTION.................................................................................206
25.4.5 RECOMMENDED LAN WIRELESS CONFIGURATION............................................206
25.4.6 CONFIGURING E-MAILS NOTIFICATIONS ..............................................................207
25.5 REQUIREMENTS ..........................................................................................207
26 APPENDIX 1 – ERROR MESSAGES................................... 208
26.1 ERROR MESSAGES DESCRIPTION............................................................208
27 APPENDIX 2 – DEFAULT SETTINGS................................. 220
27.1 DEFAULT SETTINGS MENU OPTION..........................................................220
27.2 DEFAULT SETTINGS....................................................................................221
27.3 NETWORK DEFAULT SETTINGS.................................................................222

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The following sections of this manual are intended as a guide to supervisors. They contain
the information needed to configure RBPC options. (RBPC Operator Manual is also provided,
containing exclusively operator options and configurations).
1 RBPC PRESS CONTROL FEATURES OVERVIEW
RBPC is a Mechanical Power Press Control designed to operate a Mechanical Power Press.
RBPC provides the user with many operational and safety features.
1.1 ADAPTABILITY TO DIFFERENT PRESS TYPES
RBPC can be used to operate Punch Presses, Press Brake machines and, Press Brakes
with mechanical friction clutch activated by a treadle. Basic Control is performed by energizing
and de-energizing the main safety dual valve that controls the air clutch. The clutch transfers
movement from the wheel to the crankshaft. The logic of the control is based on the state of the
inputs and the sequence they are activated.
1.2 BRAKE WEAR MONITOR FEATURES
RBPC monitors the time elapsed from the moment at which the clutch is released to the
moment the press is stopped.
This measurement is used by the RBPC to adjust Braking Starting Point in order to let the
press to be stopped at TOP-STOP. This measurement is also used to determine if the press
must be stopped to avoid unsafe press operation.
1.3 LED CIRCULAR ARRAY DISPLAY FEATURES
The main function of this LED arrangement, which is located in the front panel of the RBPC,
is to provide information to the user about the approximate position of the wheel of the press. It
also provides the user with a clear interface when PLS (Programmable Limit Switches) and Die
Protection angles are setting.
1.4 PLS FEATURES
RBPC Basic Configuration can drive up to four (4) external outputs. If PLS expansion is
enabled, the number of external outputs is increased to twelve (12). These Programmable Limit
Switches allow the user to set on/off set points that will be triggered by previously stored shaft
angles. This versatile feature enhances the machine control. The RBPC also has four (4) Dwells
for each PLS channel. These Dwells allow multiple on/off cycles in each PLS channel. All PLS
are speed compensated to achieve one degree precision in the outputs.
1.5 DIE PROTECTION FEATURES
Die Protection System is intended to monitor input sensors to ensure that proper conditions
are established before the Die makes a hit.
RBPC Die protection system can monitor up to twenty-five (25) inputs if Die Protection
Expansion is enabled. Basic configuration allows the system to monitor up to four (4) inputs for
Die Protection.
Passwords for Supervisor and Set-Up level users a
re set by default. WE
STRONGLY RECOMMEND TO CHANGE THESE PASSWORDS THE FIRST TIME THE
SYSTEM IS INITIATED BEFORE USING ANY OTHER FUNCTIONALITY OF THE SYSTEM.
SEE USER PASSWORDS SECTION FOR INFORMATION ON HOW TO CHANGE
PASSWORDS.

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Die Protection Channels 1 to 4 can be configured for two different purposes:
- Dwell Event detection:
- Part In Place detection.
Die Protection Channels 5 to 25 can be configured for the first purpose, and only if Die
Protection Expansion is enabled.
1.6 JOB STORAGE FEATURES
RBPC allows the user to store parameters for user-named programs (Jobs). RBPC can store
up to 300 (0 to 299) Jobs. Each Job contains operational press parameters like Operation
mode, PLS settings, Die settings, Braking settings and more.
Once a Job is opened, PLS settings, Die settings, Operation Mode, Actuating Mode and
Braking Settings are loaded into the system. This feature saves considerable set-up time.
1.7 RESOLVER FEATURES
RBPC has a Resolver (position sensing device) to monitor the position of the wheel of the
machine. Motion detection, Movement detection and tachometer are implemented by using the
information given by this device. Minimum and Maximum speeds are also checked to avoid
unsafe press operation.
Security Tests are also performed to ensure proper Resolver operation and to improve the
reliability of the system.
1.8 PASSWORD PROTECTION FEATURES
The access to RBPC options, functions and modes is restricted by a User Level password
based system. These levels include one basic operator level (no password required) and two
restricted modes (both of them require passwords). These modes are Set-Up level and
Supervisor Level.
1.9 COUNTERS FEATURES
Several counters are implemented in the RBPC. RBPC stores total and partial press-running
time for maintenance purposes. Total strokes, batch, total faults and quality counters are also
implemented.
1.10 FAULTS AND WORKING CONDITIONS RECORDING
FEATURES
RBPC keeps track of fault conditions up to one thousand (1000) events. The information
stored when a fault condition occurs includes:
• Fault code
• Hour meters indications
• Last stopping time measured before the fault occurs.
Other relevant information like largest stopping time recorded, the amount of brake failure
shutdowns, the amount of times the emergency stop is detected, and the total amount of faults
detected are stored into RBPC memory. This feature is intended to provide the user with the
information needed to troubleshoot the problem.
1.11 SPEED VALVE CONTROL FEATURES
RBPC can also drive dual Speed Valves to control the speed of the press. This feature is
usually used to control Brake/Bend Presses operation.

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1.12 NETWORK FEATURES
RBPC Network Module is an optional feature which stores RBPCStatus Web Page.
RBPCStatus Web Page is a user-friendly graphical interface, which allows user to monitor its
production from its own PC through a network connection.
Through RBPCStatus Web Page user is able to know RBPC parameters, check its
production rate and change its production rate set points online, at any time.
RBPCStatus Web Page can be accessed by several users at a time, allowing technical and
production personnel to share information between them.
Events that require technical assistance can generate e-mail alerts to keep user always
informed. These e-mails are generated and sent by RBPC Network Module.

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2 RBPC USER INTERFACE
RBPC control interface in the front panel contains:
• Main Mode Selector Switch (three position keyed switch)
• 27 key-keypad
• Four rows LCD display
• LCA (LED Circular Array for angle display)
(See FIG 1 for Details)
In addition to that RBPC supports the following external inputs and outputs:
The table given below shows RBPC external inputs; both actuators and safety devices.
RUN STATIONS (2 Palm buttons per run station) 4
FOOT SWITCH 1 1
FOOT SWITCH 2 1
KWIKTRIP BUTTON 1
PRESET BUTTON 1
TOP STOP BUTTON 1
SAFEGUARD 1
RESOLVER CHECK 1
AUXILIARY EMERGENCY STOP 1
AUXILIARY TOP STOP 1
DIE PROTECTION (*1) (*2)(*3) 4 (25)
EMERGENCY STOP 1
RESET 1
TOTAL EXTERNAL INPUTS 20(41)
(*1) Die Protection channels 1 and 2 can be used to monitor external valve.
(*2) Die Protection channels 1, 2, and 3 can be used as an External Operation mode selector.
(*3) Die Protection Channels 1 to 4 can be used as Palm Stations Inputs in Punch Press Mode
The table given below shows RBPC outputs. Those include: Control over Safety Valve (clutch
engagement), Safeguard mute, Programmable Limit Switches and Fault Relay.
SAFETY DUAL VALVE (SR) 2
MUTE (SR) 1
FAULT(SR) 1
USER PLS (*) 4 (12)
TOTAL EXTERNAL OUTPUTS 8 (16)
(SR) SR stands for Safety Relay
(*) PLS Channel 1 can be used to drive Speed Valve. If PLS expansion is enabled RBPC can
drive up to twelve (12) PLS channels.

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2.1 RBPC FRONT PANEL
Fig 1 RBPC Front Panel.
Main Mode
Selector Switch
LCA
–
Led
Circular Array
4 Rows LCD
27 Keys Keypad

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2.2 MAIN MODE SELECTOR SWITCH
This keyed switch allows the user to select the main mode of operation.
• RUN MODE
• OFF MODE
• PROGRAM MODE
2.2.1 RUN MODE
In this mode the press can be cycled. Only Operator menu options are available.
This symbol means user must t urn Main Mode Selector Switch to RUN
position to set this mode.
2.2.2 OFF MODE
In this mode no operation is allowed.
This symbol means user must t urn Main Mode Selector Switch to OFF
position to set this mode.
2.2.3 PROGRAM MODE
In this mode the press cannot be cycled until a user password is entered. If a password is
entered, configuration and cycling will be available.
Note: Operation and Actuating Modes can be modified even if no password has been entered.
(This feature allows operators to change operation and actuating modes, but denies access to
other RBPC configuration options.)
This symbol means user must turn Main Mode Selector Switch to
PROG position to set this mode.

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2.3 LCA - LED CIRCULAR ARRAY DISPLAY
This interface in the front panel allows the user to know the angular position of the wheel of
the machine. It also shows the angles in PLS and Die Protection settings.
The LCA uses 36 LED to show the following information:
• Approximate ram position is displayed by a GREEN point.
• Braking angle settings are displayed by ORANGE points.
• PLS angle settings are displayed by RED points.
• Die angle settings are displayed by BLUE points.
The images given below shows some examples:
Typical Top Stop at 0º Braking Angle from 290º to Top
PLS Channel 45º to 90º Die Protection Channel 180º to 360º

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2.4 PROGRAMMING OVERVIEW
2.4.1 DISPLAYING INFORMATION
The 27 key-keypad, LCA and alphanumeric display provide a user friendly programming
interface for the RBPC. RBPC programming is menu driven. The display shows programming
options and it also allows the user to set or change the required parameters.
2.4.2 SELECTING CHOICES
Choices are selected as follows:
• Arrow keys are used to navigate through menus.
• The key is used to select menu options.
• The key is used to exit from current menu.
• The key is used in conjunction with Hot Keys to access RBPC configuration menus.
• Menu keys are used to activate options that appear at the bottom
of the screen.
2.4.3 ENTERING NUMERIC VALUES
The numeric values are entered in two ways:
• Press or arrow keys to increase or decrease values.
• Enter the number directly by using the number keys. Entry is accepted after pressing
key.
2.4.4 ENTERING ALPHANUMERIC CHARACTERS
Arrow keys are used to enter alphanumeric characters.
• Use keys to navigate through character sets: [A... Z], [a.. z], [+,-,*,?] and [0..9].
• Use keys to select characters into words.

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2.4.5 MENU KEYS
Menu keys are located right under the RBPC Display.
• keys are used to select menu options that appear in the bottom
row of each menu screen.
2.4.6 MENU HOT KEYS
Several hot keys are implemented to allow fast access to the main RBPC Setting Menus.
These Hotkeys are:
• DIE PROTECT (Die Protection)
• PLS (Programmable Limit Switches)
• PC (Press Control)
• COUNTERS
• BRAKE WEAR
2.4.7 RESET KEY
• The Key is used to clear any fault status.

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2.5 RBPC PRESS CONTROL
2.5.1 SYSTEM STARTING
2.5.1.1 CHECKSUM SCREEN
This screen appears when RBPC starts. The screen shows the date of release of the software.
Software version and internal checksum of the system ROM memory is also shown on the
screen.
2.5.1.2 SYSTEM READY SCREEN
After two seconds the system ready screen will appear. Turn the Main Mode Selector Switch
either to Run or Program position.
2.5.1.3 PRESS CONTROL SCREEN
Press Control Screen (PC) is the main screen of RBPC. This screen is described with more
detail in section 2.5.2.
ISB RBPC Punch Press
V4.64.00
Checksum CD123FFA
Jun 15 2010 02:43:19
ISB RBPC Punch Press
V4.64.00
RBPC1562340000000003
SELECT RUN OR PROG

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2.5.2 PRESS CONTROL SCREEN
The Press Control screen is the screen shown when the machine is operated. It provides the
following information to the user:
• Current Strokes per minute.
• Angular position of the ram of the press.
• Current Operation Mode.
• Current Actuating Mode.
PC: Press Control screen.
SPM: Current Strokes per minute.
POS: Current angular position of the ram of the press.
Op. Mode: Current Operation Mode.
Ac. Mode: Current Actuating Mode. (If Hand &/or Foot Mode is selected, the screen will show
the actuators selected.
P1 = Palm Station 1 P2 = Palm Station 2
F1 = Foot switch 1 F2 = Foot switch 2
The Message Line at the bottom of the screen is used for:
• Showing messages when an action is required from the user.
• Showing warning and fault messages.
PC SPM 64 POS 0º
Op. Mode Single Strke
Ac. Mode P1 F1
Press RESET to work

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2.5.3 PRESS CONTROL SCREEN: COMPLEMENTARY
INFORMATION
This screen can only be accessed if RBPC is in Press Brake Mode. This screen shows the
current settings for:
• Stroke Stop.
• Bending Zone Speed.
• Status of the Safeguard Settings.
• Current Job.
PC: Press Control screen.
SPM: Current Strokes per minute.
S.Stop: Shows the current status of the Stroke Stop Setting.
Spd: Shows the current speedsetting for the Bending zone.
SG: Current status of the Safeguard.
Job #: Shows the number of the present Job in the system.
The Message Line at the bottom of the screen is used for:
• Showing messages when an action is required from the user.
• Showing warning and fault messages.
PC SPM 64 POS 0º
S.Stop Ena Spd High
SG:Enable Job #25
Press RESET to work
Switch between Press Control screens by pressing key.