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Hurco Autobend 6 Installation Manual

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704-0101-761
Autobend 6
Installation Manual
Revision E
November, 1999
Installation Manual
Autobend 6
This manual pertains to the Autobend Control System:
(Record Serial Number here)
Hurco Companies, Inc. reserves the right to incorporate any modifications
or improvements in machines and machine specifications which it
considers necessary, and does not assume any obligation to make any said
changes in machines or equipment previously sold.
Hurco products and services are subject to Hurco's then current prices,
terms, and conditions, which are subject to change without notice.

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Summary of Contents for Hurco Autobend 6

  • Page 1 Hurco products and services are subject to Hurco’s then current prices, terms, and conditions, which are subject to change without notice.
  • Page 2 The information in this document is subject to change without notice and does not represent a commitment on the part of Hurco Companies, Inc. (Hurco). No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, for any purpose without the express written permission of Hurco.
  • Page 3 Revision E Hurco...
  • Page 4 Also review the manuals furnished by your press brake manufacturer for additional safety information and procedures that must be observed. Please read all information for safe, efficient use of the Hurco Autobend 6 Control System. Autobend 6...
  • Page 5 Revision E Hurco...
  • Page 6 Using this Manual The Installation Manual is intended to be used by customers and Hurco service representatives for installing the Autobend 6 control system. This manual employs several conventions to explain the system concepts and point out key concepts. These conventions are described in this section.
  • Page 7 Troubleshooting The toolbox icon indicates steps that can be taken to solve potential problems. These sections contain information for Hurco Technical Service representatives and customers. Warning A “Warning” message indicates that the operator may be injured and the machine tool severely damaged if the described procedure is not followed.

  • Page 8: Table Of Contents

    Part Bending...................1-14 Subsystem Failure ..................1-15 Electrical Systems ..............1-15 Electrical Safety Guidelines ............1-16 Procedures for Handling Printed Circuit Boards......1-17 Fire Prevention and Fighting..............1-18 Additional Safety Information..............1-18 Service Department ....................1-19 Console Keypad Functions.................1-20 Calibration......................1-22 Start-up Procedure....................1-22 Shut-down Procedure ..................1-23 Autobend 6 November, 1999...
  • Page 9 Komatsu Press Brakes ............2-22 LP11 Gauge Mounting Hole Dimensions ........2-24 Dual Gauge Mounting Hole Dimensions ........2-25 S8 Gauges on Hydraulic/Mechanical or Upacting Press Brakes ..............2-25 S8 Gauges on Komatsu Press Brakes......2-26 LP21 and LP22 Gauges—Hydraulic/Mechanical or Upacting Press Brakes............2-28 Revision E Hurco...
  • Page 10 LP11, LP21, and LP22 Gauges ..........2-44 Gauge Bars .....................2-45 Y-Shaped Rigid Gauge Bar............2-45 Tilting Gauge Bar...............2-47 LP11, LP21, and LP22 Gauge Bar ..........2-49 Carriage Arrestor Bars..................2-50 Selecting the Gauging Surface ................2-53 Flip Fingers ....................2-54 Gauge Blocks ..................2-54 Referencing the Gauging Surface...............2-55 Autobend 6 November, 1999...
  • Page 11 AB6 Limit Switch ................2-100 Installing the Assembly ................2-101 Connections between System Components............2-103 AB6 Control Console Cable..............2-105 Gauge Cable ..................2-107 Installing Cable to S6 Gauge............2-108 Installing Cable to S7 Gauge............2-109 Installing Cable to S8 Gauges ..........2-110 Installing Cable to LP Gauges..........2-111 Revision E Hurco...
  • Page 12 Connecting the Plug to the AB6 Power Cabinet ........2-113 Changing Incoming Power Connections ..........2-114 Optional Ram Control ..................2-116 AB6 Installation Checklist ................2-117 Chapter 3 - Maintenance Maintenance Schedule..................3-1 Control......................3-1 X-Axis ......................3-1 Y-Axis Downacting Hydraulic..............3-2 Y-Axis Positive Stop................3-2 Y-Axis Upacting ..................3-2 Index Autobend 6 November, 1999 xiii...
  • Page 13 Installation Manual Revision E Hurco...
  • Page 14 Figure 2-29. Rear View of Vertical S8 Model Gauge ...............2-37 Figure 2-30. Coupling Hubs.......................2-39 Figure 2-33. S6, S7, and S8 Vertical Support Assembly............2-42 Figure 2-34. LP11, LP21, and LP22 Gauge Bar and Vertical Supports ........2-44 Figure 2-35. Position of Gauge Bar and Vertical Supports ............2-45 Autobend 6 November, 1999...
  • Page 15 Figure 2-77. Inside View of IEC Power Entry Plug and Cover..........2-112 Figure 2-78. IEC Power Entry Module ..................2-114 Figure 2-79. Side View of Fuse Clip Showing Voltage Selector ...........2-114 Figure 2-80. Top View of Fuse Clip Showing Voltage Selector Window ......2-115 Revision E Hurco...

  • Page 16: Chapter 1 - Introduction

    The control console, power cabinet, gauge, gauge bar, and supports are components of the AB6. They are attached to the press brake during the component mounting phase of installation. When the system is installed, make arrangements to have the optional second axis installed by a Hurco factory-trained installer. Autobend 6...

  • Page 17: Electrical Connections

    An important step in installing the AB6 is verifying that it is operational. The steps for verifying proper installation of the components and electrical connections are in a checklist at the end of the “Installation” chapter. Follow this checklist while installing the system. Revision E Hurco...

  • Page 18: Safety Precautions

    Hurco does not accept any liability for operator error. It is important to follow all of Hurco and the press brake manufacturer’s safety precautions to avoid personal injury, damage to the machine, and unproductive downtime.

  • Page 19: Control Console Stop Button

    Ram Enable relay (K1) to the press brake logic. The press brake’s Stop or E-Stop does not force either control to stop unless an interlock is wired from the press brake logic to the AB6 relay coil spare relay (K3). Revision E Hurco...

  • Page 20: Power Cabinet And Console Location

    An alternative method of attaching the control console is to attach it with the optional pendant arm. (Refer to the Installation manual for details.) Figure 1-3. Front View of Upacting Press Brake with AB6 Control Console Attached Autobend 6 November, 1999...

  • Page 21: Gauges

    The gauge bar length and horizontal adjustment vary among these gauges. The S8 gauge can be mounted horizontally or vertically, while the S6 and S7 can only be mounted horizontally. The LP gauges are longer and narrower than the S gauges. Figure 1-4. Autobend Gauges Revision E Hurco...

  • Page 22: Axes' Orientation

    The Y-axis controls the stopping point of the press brake’s ram for the desired bend to occur. For hydraulic downacting press brakes, the Y-axis can also control the ram’s opening height and speed change point. Figure 1-5. Typical Axes’ Configuration Autobend 6 November, 1999...

  • Page 23: Owner's Responsibilities

    Then be certain that the operators in the shop are properly trained by Hurco and are using the AB6 as it was intended to be used. If the Hurco trained operator leaves the shop, the owner is responsible for providing training for the new operator assigned to run the AB6.

  • Page 24: Hardware And Software

    AB6 with those modifications, such operation is extremely hazardous, a foreseeable misuse, and voids the Hurco warranty. If the owner or an operator finds that such modifications have been made, that person must immediately switch off the AB6 and prevent its use until it has been repaired.

  • Page 25: Maintenance

    Figure 1-6. Warning Decal The yellow and black caution tape (Hurco Part No. 703-0003-009) is applied across the top rear of the gauge carriage(s) and the gauge bar(s) alerting operators to a hazardous area.

  • Page 26: Operators' Responsibilities

    Training All operators must be trained in order to operate an AB6. The operators who are going to run the press brake must be trained by Hurco or an authorized representative. Before attempting to run the control, study this manual and become familiar with the functions and safety features.

  • Page 27: System Operation

    When testing the AB6, check the ram adjustment before stroking the press brake. Set the down limit switch as required per the press brake’s manufacturer. Tooling must not bottom out before the ram reaches the low end of its stroke. 1-12 Revision E Hurco...

  • Page 28: Part Dimensions And Fixturing

    AB6 and personal injury to the operator may result from such actions. It is also dangerous to bend a part that requires operation outside the limits of the AB6. A larger press brake should be used for such a part. Autobend 6 November, 1999 1-13...

  • Page 29: Part Bending

    Always work within reach of the Stop keys and observe the operation of the gauge. Running a program out of reach of the Stop key and not observing the gauge is considered unattended operation and is viewed as a foreseeable misuse of the AB6. 1-14 Revision E Hurco...

  • Page 30: Subsystem Failure

    In addition, brown-out conditions and surges may occur in the shop, and the AB6 electrical components may fail and require replacement. Autobend 6 November, 1999 1-15...

  • Page 31: Electrical Safety Guidelines

    Attach all system cables properly to the press brake’s frame. Loop cables with excessive length. Use the extra large tie wraps and 3/8" self-tapping screws provided to attach the cables to the frame. 1-16 Revision E Hurco...

  • Page 32: Procedures For Handling Printed Circuit Boards

    Limit the direct handling of the PCB to reduce the chance of damage. Keep the PCB in a protective bag until it is installed. Use static handling procedures before opening the bag and removing the circuit board. Return all replaced PCBs to the static protective bag. Autobend 6 November, 1999 1-17...

  • Page 33: Fire Prevention And Fighting

    Fire extinguishers should be tested for proper operation at least three times a year by a trained and certified inspector. Additional Safety Information For additional safety information Hurco recommends the following sources: National Safety Council 444 N. Michigan Avenue...

  • Page 34: Service Department

    Introduction Service Department The goal of Hurco’s Autobend Service Department is to provide customers with services necessary to help ensure success in their investment. If customers experience problems with the AB6 components such as screen errors, lack of power to the components, or gauge performance that are not solved by suggestions in the “Error Codes”...

  • Page 35: Console Keypad Functions

    P ate n ts: 4 ,4 77 ,7 54 (U S ) 1 ,10 2,43 4 (C an ad a ) 1 ,6 49 ,6 0 6 & 1 ,3 75 ,1 24 (Jap an ) O p era tion K e ys Figure 1-8. AB6 Control Layout 1-20 Revision E Hurco...
  • Page 36 Use the number keys to input numerical values, or to perform special functions when used in conjunction with the Funct key. Important Refer to the Programming and Operations manual for more information about calibration and job programming. Autobend 6 November, 1999 1-21...

  • Page 37: Calibration

    4. Press the Job key. 5. Select a job from memory by inputting a Job number, or program a new job. 6. The axes calibrate and then position to the first bend. 7. The bending operation may begin. 1-22 Revision E Hurco...

  • Page 38: Shut-Down Procedure

    To shut-down the AB6, follow these steps: Press Stop. This disables the servos and turns off the Run key’s LED. Block the press brake’s ram and turn off the power to the press brake by following the manufacturer’s instructions. Autobend 6 November, 1999 1-23...
  • Page 39 Installation Manual 1-24 Revision E Hurco...

  • Page 40: Chapter 2 - Installation

    Chapter 2 Installation This chapter contains directions for installing the Autobend 6 (AB6) control system. Familiarity with this information before beginning the process provides better results. Warning Do not connect electrical cables until completing the procedures in the “Electrical Connections” section.

  • Page 41: Parts List

    AB6 power cabinet. Caution To avoid personal injury be certain to follow safe shop practices. Be familiar with technical work and press brake operation. Revision E Hurco...

  • Page 42: Drill Bits And Tap Sizes

    13/64 bit 6.80 bit M6 × 1.0 P tap 10-24 tap #24 bit 5.0 bit 1/4 - 20 × ½ 7/32 bit self-tapping screw (AB6 small Power Cabinet) 5/16-18 tap Size F bit (AB6 large Power Cabinet) Autobend 6 November, 1999...

  • Page 43: Affixing Safety Decals

    Installation Manual Affixing Safety Decals At the beginning of the installation process it is important to affix Hurco’s safety-related decals to the press brake in the locations shown below. Figure 2-1. Warning and Danger Decals on Press Brake and Power Cabinet...

  • Page 44: Power Cabinet

    Drill the four (4) mounting holes, using the drill bit and tap sizes indicated in the drawing on the following page. Clean the surface of the press brake and bolt the power cabinet in position. Autobend 6 November, 1999...
  • Page 45 Important The power cabinet can be mounted to either side of the press brake provided the cable length requirements are met. Figure 2-2. AB6 Power Cabinets Mounted to Clear Area on Sides of Press Brakes Revision E Hurco...

  • Page 46: Control Console

    There are two methods of mounting the AB6 control console to a press brake: directly, or with the optional pendant arm. The sections that follow describe these methods. This is the AB6 control console: Figure 2-3. AB6 Control Console Autobend 6 November, 1999...

  • Page 47: Mounting Ab6 Control Console Directly To Press Brake

    Figure 2-4. AB6 Control Console Mounted Directly to an Upacting Press Brake Caution Do not mount the control console on a moving part of the press brake or where it could cause interference. The placement of the control console depends on the type of press brake. Revision E Hurco...

  • Page 48: Mounting Control Console With Optional Pendant Arm

    Attach the control console’s pendant arm bracket with the four (4) M8 x 1.25 P x 16 LG SHCS to rear of the control console. Figure 2-5. AB6 Control Console Mounted to Press Brake with Pendant Arm Autobend 6 November, 1999...
  • Page 49 The figure below shows the pendant arm’s mounting plate dimensions: Figure 2-6. Optional AB6 Pendant Arm Bracket and Dimensions Important If using the optional pendant arm, install it onto the press brake then mount the console to the arm. 2-10 Revision E Hurco...

  • Page 50: Gauge Installation

    The figure below illustrates the S6, S7, S8, LP11, LP21, and LP22 gauges. This section also contains installation procedures for the LP22-54 and vertical S8 gauges. Figure 2-7. Types of Autobend Gauges Autobend 6 November, 1999 2-11...

  • Page 51: Gauge Installation Overview

    6. Mount the gauge bar as described in the “Gauge Bar and Mounting Devices” section of this manual. 7. Consult the “Maintenance” chapter for maintenance procedures. Where can we go from here? Begin with the “Centerline of Press Brake” section of this chapter. 2-12 Revision E Hurco...

  • Page 52: Centerline Of Press Brake

    Where can we go from here? Depending on the press brake’s configuration, refer to either the “Dovetail Slots,” “Die Retainer Plates,” or “Gauge Mounting” section in this chapter before mounting the gauge to the press brake. Autobend 6 November, 1999 2-13...

  • Page 53: Dovetail Slots

    3. If the mounting surface is irregular or not machined, use shims between the press and the gauge’s mounting plate. 4. Place the die retainer plates over the bolts and support pins. 2-14 Revision E Hurco...

  • Page 54: Die Retainer Plates With S6 Or S8 Gauges

    Die Retainer Plates with S7 Gauges This figure represents an S7 gauge: Figure 2-11. Top View of S7 Mounting on Upacting Press Brake Where can we go from here? Proceed to the “Gauge Mounting” section of this chapter. Autobend 6 November, 1999 2-15...

  • Page 55: Gauge Mounting

    The number of mounting holes varies among the types of gauges: Gauge Mounting Holes 4 (2 for each gauge) LP11 LP21 4 (2 for each gauge) LP22 4 (2 for each gauge) LP22/54 4 (2 for each gauge) 2-16 Revision E Hurco...

  • Page 56: Gauge Height

    (See the figure below.) 2. Use a plumb and level to ensure the mounting holes are parallel to the top of the press brake’s bed. Figure 2-12. Configuration to Determine Gauge Mounting Height Autobend 6 November, 1999 2-17...

  • Page 57: S6 Gauge Mounting Hole Dimensions

    This section contains measurements for correct placement of mounting holes for the S6 gauge and different types of press brakes. Hydraulic/Mechanical or Upacting Press Brakes For hydraulic/mechanical or upacting press brakes, refer to these figures: Figure 2-13. S6 Gauge Mounting Pattern 2-18 Revision E Hurco...

  • Page 58: Komatsu Press Brakes

    Autobend gauges are attached to Komatsu press brakes with mounting plates. For Komatsu press brakes, refer to these figures: Figure 2-14. Komatsu S6 Mounting Plate Drill and tap to the size and depth recommended in the figure below. Figure 2-15. Komatsu S6 Mounting Configuration Autobend 6 November, 1999 2-19...
  • Page 59 Tighten the bolts securely. Note Adjust the leveling screws as required to prevent cocking and to level the gauge assembly. Where can we go from here? Proceed to the “Attaching Gauge to Press Brake” section in this chapter. 2-20 Revision E Hurco...

  • Page 60: S7 Gauge Mounting Hole Dimensions

    Figure 2-16. S7 Mounting Pattern Important Remove the left and right covers from the S7 gauge. Do not re-install the covers until completing the cable connections as outlined in the “Electrical Connections” section of this chapter. Autobend 6 November, 1999 2-21...

  • Page 61: Komatsu Press Brakes

    Autobend gauges are attached to Komatsu press brakes with mounting plates. For Komatsu press brakes, refer to these figures: Figure 2-17. Komatsu S7 Gauge Mounting Plate Drill and tap to the size and depth recommended in the figure below. Figure 2-18. Komatsu S7 Mounting Configuration 2-22 Revision E Hurco...
  • Page 62 Tighten the bolts securely. Note Adjust the leveling screws as required to prevent cocking and to level the gauge assembly. Where can we go from here? Proceed to the “Attaching Gauge to Press Brake” section in this chapter. Autobend 6 November, 1999 2-23...

  • Page 63: Lp11 Gauge Mounting Hole Dimensions

    LP11 Gauge Mounting Hole Dimensions For hydraulic/mechanical or upacting press brakes, refer to this figure: Figure 2-19. LP11 Mounting Pattern Where can we go from here? Proceed to the “Attaching Gauge to Press Brake” section of this manual. 2-24 Revision E Hurco...

  • Page 64: Dual Gauge Mounting Hole Dimensions

    This section contains measurements for correct placement of mounting holes for dual gauges and different types of press brakes. S8 Gauges on Hydraulic/Mechanical or Upacting Press Brakes For hydraulic/mechanical or upacting press brakes, refer to this figure: Figure 2-20. S8 Mounting Pattern Autobend 6 November, 1999 2-25...

  • Page 65: S8 Gauges On Komatsu Press Brakes

    Autobend gauges are attached to Komatsu press brakes with mounting plates. For Komatsu press brakes, refer to these figures: Figure 2-21. Komatsu S8 Mounting Plate Drill and tap to the size and depth recommended in the figure below. Figure 2-22. Komatsu S8 Mounting Configuration 2-26 Revision E Hurco...
  • Page 66 Tighten the bolts securely. Note Adjust the leveling screws as required to prevent cocking and to level the gauge assembly. Where can we go from here? Proceed to the “Attaching Gauge to Press Brake” section in this chapter. Autobend 6 November, 1999 2-27...

  • Page 67: Lp21 And Lp22 Gauges-Hydraulic/Mechanical Or Upacting Press Brakes

    Installation Manual LP21 and LP22 Gauges—Hydraulic/Mechanical or Upacting Press Brakes For hydraulic/mechanical or upacting press brakes, refer to this figure: Figure 2-23. LP21 and LP22 Mounting Pattern 2-28 Revision E Hurco...

  • Page 68: Dimension Tables For Dual Gauges

    2743.2 785.0 2895.6 785.0 3048.0 900.0 3200.4 900.0 3352.8 1100.0 3505.2 1100.0 3657.6 1100.0 3810.0 1100.0 3962.4 1300.0 4114.8 1300.0 4267.2 1300.0 Table 1. S8 Gauges on Hydraulic/Mechanical and Upacting Press Brakes  X Dimension Autobend 6 November, 1999 2-29...

  • Page 69: S8 Gauges On Komatsu Press Brakes

    900.0 3200.4 35.43 900.0 3352.8 43.31 1100.0 3505.2 43.31 1100.0 3657.6 43.31 1100.0 3810.0 43.31 1100.0 3962.4 51.18 1300.0 4114.8 51.18 1300.0 4267.2 51.18 1300.0 Table 2. S8 Gauges on Komatsu Press Brakes  X Dimension 2-30 Revision E Hurco...

  • Page 70: Lp22, Lp22/54 Gauges On Hydraulic/Mechanical And Upacting Press Brakes

    Gauge Size Inches Millimeters 1.5 M 11.81 300.0 2.0 M 19.69 500.0 2.5 M 27.56 700.0 3.0 M 35.43 900.0 4.0 M 43.31 1100.0 Table 4. LP21 Gauge on Hydraulic/Mechanical Press Brakes  X Dimension Autobend 6 November, 1999 2-31...

  • Page 71: Mounting Dimensions For Dual Gauges

    Refer to the X Dimension tables in the previous section and the appropriate figure below to determine the location for dual gauges. S8 Gauges on Hydraulic/Mechanical and Upacting Press Brakes Figure 2-24. S8 Mounting Dimensions—Hydraulic/Mechanical and Upacting Press Brake 2-32 Revision E Hurco...

  • Page 72: S8 Gauges On Komatsu Press Brakes

    Installation S8 Gauges on Komatsu Press Brakes Figure 2-25. S8 Mounting Dimensions—Komatsu Press Brake Autobend 6 November, 1999 2-33...

  • Page 73: Lp21, Lp22, Lp22/54 Gauges-Hydraulic/Mechanical, Upacting Press Brakes

    LP21, LP22, LP22/54 Gauges—Hydraulic/Mechanical, Upacting Press Brakes Figure 2-26. LP21 and LP22 Mounting Dimensions—Hydraulic/Mechanical and Upacting Press Brake Where can we go from here? Proceed to the “Attaching Gauge to Press Brake” section of this manual. 2-34 Revision E Hurco...

  • Page 74: Vertical Mounting For S8 Gauges

    Scribe a horizontal line on both side frames using the top of the press bed as a basic reference point. Using a plumb and level, extend this line the full length of the side frame. Figure 2-27. Top View of Vertical S8 Gauge Autobend 6 November, 1999 2-35...
  • Page 75 Use the 15/64" drill bit and drill one hole in each gauge frame for connecting the tie wraps. Each hole should be located 8" from the rear and 1/2" up from the bottom. b. Insert the self tapping screws, and attach one tie wrap to each frame. 2-36 Revision E Hurco...
  • Page 76 Installation Here is a vertical S8 gauge configuration: Figure 2-29. Rear View of Vertical S8 Model Gauge Autobend 6 November, 1999 2-37...

  • Page 77: Attaching Gauge To Press Brake

    Attaching LP21 Rear Cover Kit Assembly LP21 gauge assemblies consist two sides, a rear connector which attaches the two sides together, and one motor. Refer to Hurco Part Number 001- 2010-008/009/010. First mount the two sides, then assemble the rear connecting shaft, support bearing assemblies, and couplings.
  • Page 78 12. Tighten the bottom hole on the inside coupling hub. 13. Tighten the bearing support housing block’s screws. 14. Test before installing the covers. Operate with the control to ensure the left and right gauges are the same distance from the die. Autobend 6 November, 1999 2-39...
  • Page 79 Center rear connecting cover — use two (2) M6 x 16 BHCS and flat washers. d. Rear Cover strap — use four (4) M6 x 16 BHCS and flat washers (2 with washers in back and 2 with washers and nuts). 2-40 Revision E Hurco...

  • Page 80: Attaching Adjustable Leg Assembly For Lp22/54 Gauges

    3. Secure the adjustable leg assemblies to the floor in a safe manner. Note Hurco cannot provide hardware for securing the leg assembly to the floor since floor types vary. Where can we go from here? • Consult the “Maintenance”...

  • Page 81: Gauge Bars And Mounting Devices

    A T-slot in the gauge bearing block provides horizontal movement relative to the tooling. Here is a vertical support for S6, S7, or S8 gauges: Figure 2-33. S6, S7, and S8 Vertical Support Assembly 2-42 Revision E Hurco...

  • Page 82: S6, S7, S8, And Vertical S8 Gauges

    T slot in the bearing blocks. 3. Tighten the clamp handle slightly when in position. Where can we go from here? Proceed to either the “Y-Shaped Rigid Gauge Bar” or “Tilting Gauge Bar” section of this chapter. Autobend 6 November, 1999 2-43...

  • Page 83: Lp11, Lp21, And Lp22 Gauges

    Here is a vertical support for LP11, LP21, or LP22 gauges: Figure 2-34. LP11, LP21, and LP22 Gauge Bar and Vertical Supports Where can we go from here? Proceed to the “LP11 and LP22 Gauge Bar” section of this chapter. 2-44 Revision E Hurco...

  • Page 84: Gauge Bars

    5. Install the upper clamp bars and compression springs, tightening slightly. 6. Using a level, check the gauge surface and make any necessary adjustments to position the gauge bar both vertically and horizontally. 7. Tighten the upper and lower clamp bars securely. Autobend 6 November, 1999 2-45...
  • Page 85 Refer to the figure below when installing a Y-Shaped Rigid Gauge Bar: Figure 2-36. Vertical Support and Y-Shaped Rigid Gauge Bar Where can we go from here? Proceed to the “Carriage Arrestor Bar” section of this chapter. 2-46 Revision E Hurco...

  • Page 86: Tilting Gauge Bar

    3. Install the lower clamp bars with a few turns of the screws. 4. Position the tilting knuckle assemblies into the lower clamp bars and tighten slightly. 5. Install the upper clamp bars and compression springs, tightening slightly. Autobend 6 November, 1999 2-47...
  • Page 87 Adjust the leveling screw as necessary to maintain this movement. 7. Tighten all cap screws. Where can we go from here? Proceed to the “Carriage Arrestor Bar” section of this chapter. 2-48 Revision E Hurco...

  • Page 88: Lp11, Lp21, And Lp22 Gauge Bar

    4. Drill one (1) 7/16" hole at each end 1" from the top rear of the gauge bar. See the figure below. 5. Mount the bar. 6. Tighten the cap screws and spring washers. Figure 2-38. LP11, LP21, and LP22 Gauge Bar and Vertical Supports Autobend 6 November, 1999 2-49...

  • Page 89: Carriage Arrestor Bars

    Set them in the correct position each time after a tooling change and/or re-referencing the gauge bar. Refer to the figure below for the S6 or S8 gauge. Figure 2-39. Carriage Arrestor Bar on S6 or one S8 Gauge 2-50 Revision E Hurco...
  • Page 90 Installation Refer to the figure below for the S7 gauge. Figure 2-40. Carriage Arrestor Bar on S7 Gauge Autobend 6 November, 1999 2-51...
  • Page 91 Figure 2-41. Side View of Press Brake and Gauge Bar with Carriage Arrestor Bar 4. Pull the gauge carriage back to expose the carriage arrestor bars. 5. Tighten the screws to lock the carriage arrestor bars. 2-52 Revision E Hurco...

  • Page 92: Selecting The Gauging Surface

    All adjustments should be made from the rear of the press brake. Do not reach across the tooling or in through the bed and ram. Autobend 6 November, 1999 2-53...

  • Page 93: Flip Fingers

    For the most accurate results, always reference the gauge blocks prior to using them after changing the tooling setup. Refer to the “Referencing the Gauging Surface” section that follows. 2-54 Revision E Hurco...

  • Page 94: Referencing The Gauging Surface

    This pad is a safety feature to reduce the possibility of breakage from slight over- pressure. The pads will not prevent the bars from breaking in the event of severe over-pressure from the press brake. Figure 2-43. Zero Reference bars Autobend 6 November, 1999 2-55...
  • Page 95 10. Lock the clamping bolts at the bottom of the vertical supports. 11. Return the ram to its open position. Remove the zero reference bars and store them in a safe place. 12. Press the console’s Stop button. 2-56 Revision E Hurco...
  • Page 96 Installation 13. Return the Y-Axis mode to Active. 14. Press the Ram On key. The figure below illustrates the gauge referencing process: Figure 2-44. Gauge referencing Autobend 6 November, 1999 2-57...

  • Page 97: Electrical Connections

    Board J8 Connector. This removable 7-pin connector is located on the Main board in the AB6 Small or Standard power cabinet (see the figure below). This figure shows the Main board’s components. Figure 2-45. Main Board with J8 Connector 2-58 Revision E Hurco...

  • Page 98: J8 Connector

    Adira upacting press brakes the advance cable is connected without using the advance switch. An external advance relay provides a direct connection to its upper limit switch for hydraulic press brakes. For more specific connection information, read the press brake’s instructions. Autobend 6 November, 1999 2-59...

  • Page 99: Two-Conductor Shielded Cable

    Adira and Guifil). Or... The “Advance Cable” section contains directions for connecting the advance cable on Guifil and Adira upacting press brakes. Or... The “Advance Relay” section contains directions for installing the advance switch on hydraulic press brakes. 2-60 Revision E Hurco...

  • Page 100: Advance Switch

    The switch should close just before the ram reaches the top of its upward motion and open before the ram completes its downward stroke. Figure 2-48. Advance Switch Mounting for Mechanical Press Brakes Autobend 6 November, 1999 2-61...

  • Page 101: Upacting Press Brakes

    The point of actuation must be in the treadle’s upper mid-stroke. Place the switch as close to this point as possible. Figure 2-49. Advance Switch on Upacting Press Brakes Note The “Advance Cable” section contains directions for connecting the advance cable on Guifil and Adira upacting press brakes. 2-62 Revision E Hurco...
  • Page 102 See the appropriate Advance Switch figure shown previously: Advance Switch Mounting for Mechanical Press Brakes Advance Switch on Upacting Press Brakes. 5. Drill two (2) holes with a #24 bit and tap for a #10-24 thread. Autobend 6 November, 1999 2-63...
  • Page 103 12. Re-install the switch cover. Be sure to firmly tighten both screws. 13. Determine the appropriate actuator rod length to maintain full contact throughout the stroke. 14. Bend the rod’s end to form an upward hook. Cut off the excess. 2-64 Revision E Hurco...
  • Page 104 25. Open position #7 (labeled 24 COM) and insert the black wire. 26. Replace the J8 connector. Important The “Main Board” and “J8 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. Autobend 6 November, 1999 2-65...

  • Page 105: Advance Cable

    • If a grounding wrist strap is not available, touch a grounded point within the enclosure each time before touching a PCB or electronic assembly. An example of a grounding point is the metal cabinet’s screws. Follow the procedures for the appropriate section that follows. 2-66 Revision E Hurco...

  • Page 106: Adira Upacting Press Brakes

    1. Locate the speed change switch labeled FV on the side of the press brake. 2. Remove the cover from the speed change switch. Figure 2-51. Speed Change Switch on Left Side of Adira Press Brake Autobend 6 November, 1999 2-67...
  • Page 107 16. Open position #7 (labeled 24 COM) and insert the black wire. 17. Replace the J8 connector. Important The “Main Board” and “J8 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. 2-68 Revision E Hurco...

  • Page 108: Guifil Press Brakes

    To install the advance cable to the Guifil upacting press brake, follow these instructions: Open the Guifil power box and locate the connection points according to the wiring diagram below. Figure 2-52. Guifil Press Brake Wiring Diagram Autobend 6 November, 1999 2-69...
  • Page 109 14. Open position #7 (labeled 24 COM) and insert the black wire. 15. Replace the J8 connector. Important The “Main Board and J8 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. 2-70 Revision E Hurco...

  • Page 110: Advance Relay - Hydraulic Press Brakes

    The coil voltage of the advance relay depends on the press brake’s circuit voltage. Most press brake manufacturers use the universally accepted values 120VAC and 24VDC. Hurco provides for both voltages. Refer to the press brake manufacturer’s manuals to determine the correct voltage.
  • Page 111 Socket diagram is a track mounted, track size 1.39" (35.30 mm) Omron PTF08A-E socket. The Relay diagram is for 120 VAC and 24 VDC K10 series DPDT Potter and Brumfield relays. Figure 2-53. Relay Socket Diagram Figure 2-54. Relay Diagram 2-72 Revision E Hurco...
  • Page 112 16- to 18-gauge stranded wire to add extra length to the shield. Warning Avoid locating this cable next to the high voltage wiring. 13. Route the two-conductor cable from the relay socket through the fitting of the press brake’s power box. Autobend 6 November, 1999 2-73...
  • Page 113 Main board. 21. Using a small screwdriver, open position #1 (labeled ADVANCE) and insert one of the wires. 22. Open position #7 (labeled 24 COM) and insert the remaining wire. 23. Replace the connector into J8. 2-74 Revision E Hurco...
  • Page 114 Figure 2-55. Relay Socket Press Connections Important The “Main Board” and “J8 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. Autobend 6 November, 1999 2-75...

  • Page 115: Large Power Cabinet With Relay Board

    Relay Board TB14 Connector. This removable 12-pin connector is located on the Relay board in the Large AB6 power cabinet (see the figure below). This figure shows the Relay board’s components. Figure 2-56. Relay Board with TB14 Connector - Positions 6 and 7 2-76 Revision E Hurco...

  • Page 116: Tb14 Connector

    Adira upacting press brakes the advance cable is connected without using the advance switch. An external advance relay provides a direct connection to its upper limit switch for hydraulic press brakes. For more specific connection information, read the press brake’s instructions. Autobend 6 November, 1999 2-77...

  • Page 117: Two-Conductor Shielded Cable

    Adira and Guifil). Or... The “Advance Cable” section contains directions for connecting the advance cable on Guifil and Adira upacting press brakes. Or... The “Advance Relay” section contains directions for installing the advance switch on hydraulic press brakes. 2-78 Revision E Hurco...

  • Page 118: Advance Switch

    The switch should close just before the ram reaches the top of its upward motion and open before the ram completes its downward stroke. Figure 2-59. Advance Switch Mounting for Mechanical Press Brakes Autobend 6 November, 1999 2-79...

  • Page 119: Upacting Press Brakes

    The point of actuation must be in the treadle’s upper mid-stroke. Place the switch as close to this point as possible. Figure 2-60. Advance Switch on Upacting Press Brakes Note The “Advance Cable” section contains directions for connecting the advance cable on Guifil and Adira upacting press brakes. 2-80 Revision E Hurco...
  • Page 120 See the appropriate Advance Switch figure shown previously: Advance Switch Mounting for Mechanical Press Brakes Advance Switch on Upacting Press Brakes. Drill two (2) holes with a #24 bit and tap for a #10-24 thread. Autobend 6 November, 1999 2-81...
  • Page 121 12. Re-install the switch cover. Be sure to firmly tighten both screws. 13. Determine the appropriate actuator rod length to maintain full contact throughout the stroke. 14. Bend the rod’s end to form an upward hook. Cut off the excess. 2-82 Revision E Hurco...
  • Page 122 25. Open position #7 (labeled ADV RTN) and insert the black wire. 26. Replace the TB14 connector. Important The “Relay Board” and “TB14 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. Autobend 6 November, 1999 2-83...

  • Page 123: Advance Cable

    • If a grounding wrist strap is not available, touch a grounded point within the enclosure each time before touching a PCB or electronic assembly. An example of a grounding point is the metal cabinet’s screws. 2-84 Revision E Hurco...

  • Page 124: Adira Upacting Press Brakes

    1. Locate the speed change switch labeled FV on the side of the press brake. 2. Remove the cover from the speed change switch. Figure 2-62. Speed Change Switch on Left Side of Adira Press Brake Autobend 6 November, 1999 2-85...
  • Page 125 18. Adjust the speed change switch so the advance occurs during mid-stroke. Important The “Relay Board” and “TB14 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. 2-86 Revision E Hurco...

  • Page 126: Guifil Press Brakes

    To install the advance cable to the Guifil upacting press brake, follow these instructions: 1. Open the Guifil power box and locate the connection points according to the wiring diagram below. Figure 2-63. Guifil Press Brake Wiring Diagram Autobend 6 November, 1999 2-87...
  • Page 127 13. Open position #7 (labeled ADV RTN) and insert the black wire. 14. Replace the TB14 connector. Important The “Relay Board and TB14 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. 2-88 Revision E Hurco...

  • Page 128: Advance Relay - Hydraulic Press Brakes

    The coil voltage of the advance relay depends on the press brake’s circuit voltage. Most press brake manufacturers use the universally accepted values 120VAC and 24VDC. Hurco provides for both voltages. Refer to the press brake manufacturer’s manuals to determine the correct voltage.
  • Page 129 10. Select a relay with a coil voltage that matches the press brake’s control voltage. 11. Install the selected relay in the K4 socket on the Relay board located inside the Large AB6 power cabinet (see the Relay Board figure at the end of this section). 2-90 Revision E Hurco...
  • Page 130 The “TB14 Connector” section at the beginning of this section contains instructions about opening the connection positions on the TB14 connector. 21. Open position #5 (labeled K4 Coil B) and insert the remaining wire. 22. Replace the connector into TB14. Autobend 6 November, 1999 2-91...
  • Page 131 Figure 2-64. Relay Board with TB14 Connector - K4 Coil A (4) and K4 Coil B (5) Important The “Relay Board” and “TB14 Connector” sections earlier in this chapter contain information about locating the connector and opening the position on it. 2-92 Revision E Hurco...

  • Page 132: Optional Retract Sensor

    Please read all instructions pertaining to the installation of the retract sensor prior to attempting installation. Make sure that the retract sensor and magnet will not interfere with the press brake during operation. Autobend 6 November, 1999 2-93...
  • Page 133 Caution To avoid damaging the retract sensor, do not allow the magnet and sensor to touch during a press cycle. Figure 2-65. Top View of Retract Sensor and Magnet Alignment and Spacing 2-94 Revision E Hurco...

  • Page 134: Retract Sensor Assembly

    2. For press brakes with the ram or bed flush with the side wall, use the two “L” brackets together to form an “S” bracket. For press brakes with the ram or bed extending beyond the side wall, use one “L” bracket. Figure 2-67. Magnet Assembly Autobend 6 November, 1999 2-95...

  • Page 135: Installing Magnet Assembly

    (see the Alignment and Spacing figure). 4. Cut the brackets to fit the particular ram to which they are mounted. 5. Clean the mounting surface and secure the retract sensor. 2-96 Revision E Hurco...
  • Page 136 15. Strip back 4" (100 mm) of outer insulation and cut off the shield. 16. Strip back 1/4" (6 mm) of insulation from the individual wires. 17. Cut off shield wire. Autobend 6 November, 1999 2-97...

  • Page 137: Small Or Standard Power Cabinets

    3. Open the connection at pin 2 and insert the red wire. 4. Open the connection at pin 7 and insert the black wire. Figure 2-68. Main board with J8Connector 2-98 Revision E Hurco...

  • Page 138: Large Power Cabinet

    3. Open the connection at pin 9 and insert the red wire. 4. Open the connection at pin 8 and insert the black wire. Figure 2-69. Relay Board with TB14 Connector - Positions 8 and 9 Autobend 6 November, 1999 2-99...

  • Page 139: Advance/Pinch Retract Assembly

    Following are directions for assembling and mounting the advance/pinch retract to a press brake. AB6 Limit Switch Here is an AB6 limit switch for the advance/pinch retract assembly with its J8 and Shield connections. Figure 2-70. AB6 Limit Switch 2-100 Revision E Hurco...

  • Page 140: Installing The Assembly

    The remaining four (4) M6 x 12 mm cap head screws are provided for attaching the adjustable actuator’s brackets to the press brake’s ram and for securing each end of the threaded rod to those brackets. Autobend 6 November, 1999 2-101...
  • Page 141 Installation Manual The figure below shows the switch and bracket mounted properly to the side of an upacting press brake. Figure 2-71. Advance/Pinch Retract Switch Assembly 2-102 Revision E Hurco...

  • Page 142: Connections Between System Components

    • If a grounding wrist strap is not available, touch a grounded point within the enclosure each time before touching a PCB or electronic assembly. An example of a grounding point is the metal cabinet’s screws. Autobend 6 November, 1999 2-103...
  • Page 143 Installation Manual Electrical connections from the AB6 power cabinet to the control console and gauge(s) are described in the following sections. These connections are illustrated below: Here are the AB6 component connections: Figure 2-72. AB6 Cable Connections 2-104 Revision E Hurco...

  • Page 144: Ab6 Control Console Cable

    (See the figure on the following page.) Note the correct alignment of the connector key. Route and secure the cable in a position where it will not be damaged. Replace the cover. Autobend 6 November, 1999 2-105...
  • Page 145 The connector (J3) is keyed and can be connected correctly only one way. Insert the J3 connector with the single red wire on the right-hand side and the key way at the top. Figure 2-73. Inside Front of AB6 Control console Showing Cable Connection 2-106 Revision E Hurco...

  • Page 146: Gauge Cable

    Do not interchange motor and tach wiring. • Do not reverse motor and tach positive and negative terminals as sudden gauge movement may result. Contact Hurco’s Autobend Service Department with questions regarding the wiring of these components. Autobend 6 November, 1999 2-107...

  • Page 147: Installing Cable To S6 Gauge

    6. After connecting the cable, pull out any slack in the cable through the cord grip. 7. Route and secure the cable in a position where it will not be damaged. Figure 2-74. Inside View of an S6 Gauge 2-108 Revision E Hurco...

  • Page 148: Installing Cable To S7 Gauge

    7. After securing the cable to the gauge, route and secure the cable in a position where it will not be damaged. 8. Install the two top covers to the frame and secure with self- tapping screws. Figure 2-75. Inside View of an S7 Gauge Autobend 6 November, 1999 2-109...

  • Page 149: Installing Cable To S8 Gauges

    Pull out any slack in the cable using the cord grip. d. Route and secure the cable in a position where it will not be damaged. Figure 2-76. Inside View of an S8 Gauge 2-110 Revision E Hurco...

  • Page 150: Installing Cable To Lp Gauges

    Attach this wire with the self-tapping screws to the harness plate. c. Pull out any slack in the cable using the cord grip. d. Route and secure the cable in a position where it will not be damaged. Autobend 6 November, 1999 2-111...

  • Page 151: External Power Source

    IEC power entry plug. Use a size 18-gauge AWG wire for the incoming power line consisting of a hot, neutral and ground wire. Warning After determining the correct input electrical voltage, turn off the external power source. Failure to do so may result in serious injury. 2-112 Revision E Hurco...

  • Page 152: Connecting The Incoming Power Line To The Plug

    1. Connect the plug into the power receptacle located on the right-hand side of the power cabinet. 2. Lock the plug in place with the clamp spring. 3. Route and secure the incoming power line where it will not be damaged. Autobend 6 November, 1999 2-113...

  • Page 153: Changing Incoming Power Connections

    2. Remove the fuse clip by depressing the tab located next to it. Inside the clip are two fuses and the Voltage Selector (see the figure below). FUSE CLIP VOLTAGE SELECTOR FUSES Figure 2-79. Side View of Fuse Clip Showing Voltage Selector 2-114 Revision E Hurco...
  • Page 154 Figure 2-80. Top View of Fuse Clip Showing Voltage Selector Window 4. Replace the two fuses with appropriate ratings to match the power source: 120 VAC uses 8 Amps (Hurco #409-1001- 235), and 240 VAC uses 4 Amps (Hurco #409-1001-234).

  • Page 155: Optional Ram Control

    A factory-trained Service Engineer will install the second axis and provide hands-on training. This service provides operators with the working knowledge and understanding needed to run the Hurco AB6 System confidently. Contact Hurco after installing the items listed below and storing the unused parts: 1. Power cabinet 2. Pendant arm 3.

  • Page 156: Ab6 Installation Checklist

    J8. (Install advance relay on hydraulic press brakes.) 14. Install the optional retract switch (if using that option). 15. Connect the retract wire to the AB6 power cabinet at the main board connector J8. Autobend 6 November, 1999 2-117...
  • Page 157 Verify that the gauge(s) moves back. 23. Program and run a job. Refer to the “Programming and Operations” manual for details. 24. Contact Hurco to schedule an installation date with a factory-trained installer for the Y- axis. 2-118 Revision E...

  • Page 158: Chapter 3 - Maintenance

    If the shop environment is dirty, clean them daily. Every six months inspect belts, couplings, and pulleys for wear or looseness. Tighten as necessary. Every six months inspect the gauge harness for possible cuts in the cable insulation or wires. Replace if damaged. Autobend 6 November, 1999...

  • Page 159: Y-Axis Downacting Hydraulic

    Every six months inspect belts, couplings, and pulleys for wear or looseness. Tighten as necessary. Every six months inspect the Y-axis harness for possible cuts in the cable insulation or wires. Replace if damaged. Revision E Hurco...
  • Page 160 Back key, 1-21 mounting for dual gauges, 2-32 Bend key, 1-21 mounting hole, 2-18, 2-21, 2-24, Bend, 2-25 most recently operated display, 1-22 X for dual gauges, 2-29 number available, 1-22 Dovetail slots, 2-14 Drill bits, 2-3 Autobend 6 November, 1999...
  • Page 161 Stop key, 1-4 Ground wire, 2-108 to 2-111 Emergency Stop button, 1-14 Guifil upacting press brake Emergency stop circuits, 1-12 speed change switch, 2-69, 2-87 Enter key, 1-21 wiring diagram, 2-69, 2-87 External power source, 2-112 Fire hazards, 1-18 Revision E Hurco...
  • Page 162 2-3 (hydraulic/mechanical or tilting gauge bar, 2-47 upacting press brakes), 2-28 tools required, 2-1, 2-3 vertical supports, 2-44 vertical S8 gauges, 2-35 LP22/54 gauge vertical supports, 2-42 adjustable leg assembly, 2-41 Y-shaped rigid gauge bar, 2-45 Autobend 6 November, 1999...
  • Page 163 Power connection, 1-15 Retract sensor, 2-93 to 2-95 Power-up, 1-22 ram control, 2-93 Press brake, 1-5 Rotating shaft, 2-61, 2-79 pwr cabinet mounting position, 2-6 Run key, 1-14 downacting hydraulic optional ram control, 2-116 Press brake (continued) Revision E Hurco...
  • Page 164 Start-up, 1-22 ground wire, 2-108 to 2-111 Steel wear plates, 2-47 grounding point, 1-17, 2-63, 2-66, Stop key, 1-14 2-81, 2-84, 2-96, 2-103 Support pins, 2-14 hardware/software, 1-9 limit switches, 1-13 operator training, 1-11 Safety (continued) Autobend 6 November, 1999...
  • Page 165 Voltage selector, 2-114 Warning sign, 1-10 warning decal, 2-5 X-axis, 1-7 maintenance schedule, 3-1 Y-axis, 1-7 maintenance schedule, 3-2 Y-axis positive stop maintenance schedule, 3-2 Y-axis upacting maintenance schedule, 3-2 Y-shaped rigid gauge bar, 2-45 Zero reference bars, 2-55 Revision E Hurco...

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