Chapter 6 Electrical

A1200 Control Systems Input/output Keypad & Dip Switch Card Dip Switch 1 Dip Switch 2

Dip Switch 3 Dip Switch 4 Typical Switch layout Off On A1 A2 A3 A4 A5 A6 A7 A8 Page 6 - 1

Note 1: DIP Switch

1=A 2=B 3=C 4=D

Note 2:

On DIP Switch A switches A5 through A8 most always be off as show on the preceding page.

Page 6 - 2

Maximum Angle Adjustment Switch 128 degrees 130 132 134 136 138 140 142 144 146 (K25) 148 150 152 154 156 (15) 158 A1 off on off on off on off on off on off on off on off on A2 off off on on off off on on off off on on off off on on A3 off off off off on on on on off off off off on on on on A4 off off off off off off off off on on on on on on on on

page 6 - 3

Default up-value 0 1 2 3 4 5 6 7 8 9 (normal)

B1 B2 B3 B4 off on off on off on off on off on off off on on off off on on off off off off off off on on on on off off off off off off off off off off on on

Up adjustment switch 5 (shortest time) 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 (longest time)

B5 B6 B7 B8 off on off on off on off on off on off on off on off on off off on on off off on on off off on on off off on on off off off off on on on on off off off off on on on on off off off off off off off off on on on on on on on on

page 6 - 4

Clamp pressure adjustment 40 (shortest time) 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160 (longest time) C1 off on off on off on off on off on off on off on off on C2 off off on on off off on on off off on on off off on on C3 off off off off on on on on off off off off on on on on C4 off off off off off off off off on on on on on on on on

page 6 - 5

Hemming pressure adjustment 8 (shortest time) 24 40 56 72 88 104 120 136 152 168 184 200 216 232 248 (longest) A8 off on off on off on off on off on off on off on off on A8 off off on on off off on on off off on on off off on on A8 off off off off on on on on off off off off on on on on A8 off off off off off off off off on on on on on on on on

page 6 - 6

Backgauge maximum speed 2 (Max output freq) 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 (min output freq) D1 off on off on off on off on off on off on off on off on D2 off off on on off off on on off off on on off off on on D3 off off off off on on on on off off off off on on on on D4 off off off off off off off off on on on on on on on on

page 6 - 7

Backgauge ramp time 2 (shorest ramp time) 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 (longest ramp time) D5 off on off on off on off on off on off on off on off on D6 off off on on off off on on off off on on off off on on D7 off off off off on on on on off off off off on on on on D8 off off off off off off off off on on on on on on on on

page 6 - 8

Trouble Shooting from the LED Relay Card 4321 X6 X7 D28 D29 D30 D31 D32 D33 D10 D11 D12 D13 D14 D15 D22 D23 D24 D25 D26 D27 D16 D17 D18 D19 D20 D21 X9 X11 X10 RE1 RE2 RE3 RE4 RE5 RE6 X12 X3 X4 X5 654321 654321 X8 X1 X2

Harness Connection X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 Serial port communication to I.O. Board 9 vac input power control output sugnal to C1 & C2 relays, (Clamping Beam) control output to C3 & C4 relays, (Bending Apton) control output to backgauge soleniod fingers bending apron encoder input signals clamping pressure input signal backgauge home position switch not used 4/ 5 mm position inputs foot pedal input, clamping beam up, down and bend command. Bending beam return command from right foot pedal; bending beam home; 6 mm.

Page 6 - 9

The LEDs the I/O relay card are visual indicators that provide a visual means of trouble shooting the electrical control system. By observing the LEDs the operator can determine if the correct input commands are being received from the foot pedals, the back gauge home switch, encoder, clamping beam position and bending apron position Switchs. In addition, it is possible to determine if the microprocessor is sending out the correct signals to the various control relays used to operate the bending and clamping beams. All the LEDs on the board are not used, some are reserved for future expansion or functions your unit may not have. Below is a list of the functioning LEDs and what they indicate. D10 Microprocessor is sending an output command to RE1 to open the upper clamping beam.

D11 Microprosser is sending an ouput command to RE2 to close the upper beam. D12 Microprosser is sending an output command to RE3 to move the bending beam up. D13 Microprosser is sending an output command to RE4 to send the bending beam back to home position. D14 Microprosser is sending an output command to RE5 to activate the first set of back gauge fingers. D15 Microprosser is sending an output command to RE6 to activate the second set of back gauge fingers. D16 Normally on, goes off when right foot pedal is activated, works in conjunction with D19, command signal for clamping beam to open up. D17 Normally off, comes on when left foot pedal is activated. Command signal for clamping beam to clamp down. D18 Normally off, comes on when the middle petal is depressed. Is command signal for bending beam to move up. D19 Normally off, works in conjunction with D16, comes on when the right foot petal is activated. Command signal for bending apron to return to home position. Page 6 -10

D20 Bending apron home switch. Normally closed contact, LED is off in the home position, comes on when bending apron is not home. D21 6mm safety switch. LED is on when clamping beam is open more then 3/8 inches. Note: D21 should extinguish before D27 (4 mm switch) when clamping. If the sequence is reversed the microprosser will lock up. The reverse also applies when un-clamping. D22 Not used D23 Not used D24 Not used D24 Not used

D26 Not used D27 4mm position switch. On above 0.200 inches and off below. This is the minimum open height after a bending operation has been completed. D28 & D29 One or both may be on when the bending apron is home. The lights will appear to flicker rapidly during the bending operation. This is the bending apron encoder sending information back to the microposser which determines the bending angle. D30 Not used D31 Clamping pressure switch. Normally open contacts. The switch is activated when the beam is un-clamped.. During the clamping process the switch opens up and this starts a timing sequence for developing clamping pressure. D32 Not used D33 Back gauge home position sensor. Off when the back gauge is forward of 9.5 inches, approximately. On when behind 9,5 inches.

Page 6 - 11