Manual Ibst2011041501

TBLU9.
52-7/4500M2Q
HAIRPIN BENDER
USER’S GUIDE
Zhongshan OMS Industrial Co.,Ltd.

Http:// www.china-oms.com Tel: +86-760-88885860 Fax: +86-760-88885870
Contents
1. Purpose and characteristic ................................................................................... 1
2. Main technical parameters .................................................................................... 2
3. Machine structure .................................................................................................. 2
4. Installation and maintenance ................................................................................ 3
5. Operating panel and indicator .............................................................................. 3
5.1 Panel and buttons........................................................................................... 3
5.2. Three color indicator ...................................................................................... 3
6. Operating instruction ............................................................................................. 4
6.1 Power supply .................................................................................................. 4
6.2 Starting status ................................................................................................. 4
6.3 Manual mode .................................................................................................. 5
6.4 Parameter setup ............................................................................................. 8
6.5 Auto mode..................................................................................................... 15
6.6 Auto running.................................................................................................. 17
6.7 Stop machine................................................................................................ 17
7. Alarm display ........................................................................................................ 18
7.1 Cutter backward detection alarm .................................................................. 18
7.2. Cutter rest move forward alarm ................................................................... 18
7.3. Cutter rest move backward alarm ................................................................ 19
7.4 Feed overtime............................................................................................... 19
7.5 Cutter head photoelectric detection .............................................................. 20
7. 6 Bend photoelectric detection........................................................................ 20
7.7 All pipes have processed .............................................................................. 21
7.8 Machine isn’t starting status.......................................................................... 21
7.9 Machine can’t auto run ................................................................................. 21
7.10 Oil pressure system .................................................................................... 21
7.11 Oil temperature is over high ........................................................................ 22
7.12 Cutter motor................................................................................................ 22
7.13 Oil motor ..................................................................................................... 23
7.14 Battery voltage............................................................................................ 23
7.15 Photoelectricity safety detection alarm ....................................................... 23
7.16. Bend motor, pipe return motor, frame moving motor alarm........................ 24
7.17 Common malfunctions and solution…………………………………………...25
Appendix:
1. Layout drawing
2. Electric control drawing
3. Electrical components listing
4. Pneumatic and hydraulic elementary drawing
5. Wearing parts drawing
6. Alarm codes and solution
Hairpin Bender
1. PURPOSE AND CHARACTERISTIC
This machine is designed for bending pipes into “U” shape. It is a professional and precision
machine, using imported electronic components and precision technique. It satisfies client’s need
to close pipe end flat.
The machine adopts program Logic Control (PLC) for centralized control and operating type of
human-computer. Also adopt AC servo system to control bend-mechanism, returned pipe
mechanism and frame moving mechanism. It is featured by high automation, quick speed,
operating convenience, running uniformity, high precision, reliable capability, adjusting
expediently assembly and beautiful appearance. Main characteristic are as follows:
1. High degree of automation and low labor intensity. One person can operate
multi-machines at the same time.
2. Neatly wire layout in cabinet of electricity control, wire size is marked in favor of
maintenance.
3. Simply and convenient operation. There are two operating modes, auto mode and
manual mode. It is easy for operator to learn and understand. After alarm or failure happens,
panel menu will display the reason for alarm and solution, in favor of settling a question and
enhancing efficiency.
4. Strong working stability, low noise, low failure rate and high machining precision. It can
adapt itself to working continuously and stably for 24 hours each day. Also it is adapted to
mass production.
5. Hydraulic system works reliably without oil leaks and oil impregnate.
6. High producing efficiency. Max time of machining cycle is less than 15 s.
7. Power consumption is relatively low.
8. Cutting motor adopts transducer to control soft startup and extend service life of strap, in
favor of achieving better cutting effect.
9. To apply AC servo motor benefits smooth startup, quick speed and high machining
precision.
10. The machine is equipped with complete safety apparatus, measures and warning sign.
Adopt light curtain to keep person safe.
11. Oil injection of core rod adopts CNC adjustment at single fixed quantities.
1 Zhongshan OMS industrial Co. Ltd

Hairpin Bender
2. MAIN TECHNICAL PARAMETERS
SN Item specification
1 Process materil Coper (roilling)
2 Pipe diameter× wall thickness Ф9.52×0.28/0.30/0.35/0.40 mm
3 Pipe number of once process 7 pcs
4 Pitch Ф9.52×25/32/35 mm
5 Process length Min300 mm Max 4500mm
6 Length precision ±0.8 mm/m
7 Flatness rate ≤10%
8 Efficiency If L<1000mm，t<15 s
9 Air pressure 0.4-0.6Mpa
10 Hydaulic pressure 5-10 Mpa
11 Power supply, 3PH 380V/50Hz
12 Total power 12.7 KW
3. MACHINE STRUCTURE
Drawing 1: Layout drawing

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4. INSTALLATION AND MAINTENANCE
1. Put the machine on flat and hard ground. When installing machine, please refer to layout
drawing.
2. Check whether each lubricating part has lubricant.
3. Please check whether each oil tank has oil and fill the oil with oil tank periodically.
4. Please check whether cooling system fan of oil pump works normally.
5. Main supply power of equipment must use reliable earth wire.
6. After completing work, should clear all the sundries away and clean the machine. Before
starting, should check whether each fastener is fastened and machine is laid steadily.
When machine is working, if abnormity happens, should stop machine immediately for fear
of being damaged.
7. Please Check that there is water in filter of pneumatic parts periodically and drain in time.
Check whether there is oil in oil mist tank. If lacking, please exchange oil mist tank in time.
8. Please check whether the fans in electricity box work normally.
9. Strictly prohibit piling up sundries in the electricity box, and keep the electricity box clean
and dry. Prevent screw, cable piece, other conductive body and flammable object from
entering electricity box and operating box.
10. If the machine is not used for a long time, should turn the main power off.
11. Must turn the power off and make sure safety before repairing the machine
12. Strictly forbid using sharp tool to operate on operating panel for avoiding panel damage.
13. Strictly forbid modifying motor controller parameter in distributing electricity box.
5. OPERATING PANEL AND INDICATOR

5.1 Panel and buttons
Panel drawing
The panel is consisted of the human-machine interface operation and some buttons. When the
corresponding button motion works, button’s indicator light will be turned on.
Human-machine interface: displaying the parameters, processing counts, manual/auto
operation, alarm messages and so on during operations.
Auto start/ stop: the start-up and stop of auto processing cycle.
Power on / off: turning on/off of the controlling power source.
Manual and auto: switchover between the manual and auto.
Emergency stop: urgent stop of machine running.
5.2. Three color indicator

Three colors indicator is equipped with and installed in front of machine in favor of that operator
monitors machine’s running at a distance.
5.2.1 Green: In auto mode, the machine auto runs normally, green indicator turns on.
5.2.2 Yellow: in manual mode, yellow indicator turns on.

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5.2.3 Red: When equipment fails, operation mistakes or abnormality occurs, red indicator turns
on and alarms.
6. OPERATING INSTRUCTION
Hairpin bender adopts advanced MITSUBISHI system to control. The whole control system is
centralized control by PLC. Operate the machine by operating human-computer interface, buttons
and switches. Also we can directly set parameters, such as bend angle, output counting etc.
Advantages like operating convenience, safety and data accuracy etc are incarnated adequately.
There are two types of operation modes (manual mode and auto mode). In manual mode, press
button to fulfill processing and production; in auto mode, press button to auto start, the machine
can complete the whole course of production with auto cycle. Detailed operation is below:
Notice: Read this manual and relate documents before operating.
6.1 Power supply

Before running the machine, must supply power and reliable exterior earthing circuitry.
Specification: three-phase AC 380V/50Hz，
6.1.1 Turn power on

Firstly turn on main power supply switch to electrify the equipment; Pull the protection switch of
breaker in distributing electricity box up to the position of “ON”. And then turn on master switch of
power. At the moment, the button of “POWER OFF” on operation panel lights. And then pressing
the button of “POWER ON”, the machine is completely electrified at this time. Besides the button
of “POWER ON” lights and the button of “POWER OFF” goes out.
6.1.2 Turn power off

We can do the following operations to cut off the power of operating system:
Close exterior mains power.
Pull the protection switch of breaker in distributing box down to the position of “OFF”
Rotate master switch of power to close equipment’s power.
Press the button of “POWER OFF”
Notice: It is not an effective method to cut off the power for a long time by pressing the
button of “POWER OFF”. This method is only used to temporarily cut off the power. When
don’t use the equipment or before maintaining the equipment, must directly close exterior
mains power so as to completely cut power off.
When turning power on, screen will display information as follows. After five seconds, system will
enter into operation menu.
Drawing 2: machine name menu
6.2 Starting status

There are monitor menus of “STARTING STATUS” in auto or manual mode. Press 【STARTING
STATUS】to enter follow menu. (Drawing 3)The menu displays information about every detector
switch, motor and position etc. Before auto start, the equipment can’t be started until it is at the
status of starting. (The indictor of starting status turns on). When detector switch reaches the
designated position, indicator corresponding to the switch will light. When motor alarm happens,
indicator corresponding to the switch will light.

Hairpin Bender
Drawing 3: starting status menu

“Starting status” is a necessary initial status before machine auto start.
【PHOTOELECTRIC DETECTION OF CUTTER HEAD】/【PHOTOELECTRIC DETECTION OF
BEND】:When photoelectric detection of cutter head is at the position of cutter head, its indicator
turns on; when photoelectric detection of bend is at the position of bend, its indicator turns on.
【DETECTION OF CUTTER REST BACKWARD】:When detection of cutter rest backward
reaches designated position, its indicator turns on.
【DETECTION OF CUTTER REST FORWARD】: When this detection switch doesn’t switch on,
its indicator turns off.
【BEND STARTING】:When detection of bend zero reaches designated position, its indicator
turns on, and bend device and cutter head locate at one central line. At the same time, bend
starting position is showing “0” degree.
【RETURN PIPE STARTING】:When pipe return device locate at the position of return length, its
indicator turns on and system display setting length of pipe returning.
【CORE PULLING STARTING】:When detection of core pulling starting reaches designated
position, its indicator turns on.
【COLLECTING STARTING】:When detection of collecting starting reaches designated position,
its indicator turns on.
【No 1-6 # FEED REACHES DESIGNATED POSITION】:When one detection of No 1-6 feed
reaches designated position switch on, its indicator turns on.
If machine is not in the start status before auto starting, operators must enter into manual mode
to reset it. If machine can’t start, check whether the switch is loosed. Install and fix switches again
if necessary. If switch is broken, replace it. After the motor alarming, relieve the malfunctions
according to alarm content and code.
6.3 Manual mode

6.3.1 Manual mode
Select manual mode and system enter manual menu. (Drawing 4)
Drawing 4: manual mode

【CUTTER OIL INJECTION】/【CUTTER GAS INJECTION】:Press 【CUTTER OIL INJECTION】

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to spray oil on the cutter for the blade protection. Quantities of oil and gas spraying on the cutter
head are controlled through time measurements by “PARAMETER SETUP”.
【EXPLORATOR PRESS】/【EXPLORATOR LOOSEN】:
When press【EXPLORATOR PRESS】,explorator die clamps;
when press 【EXPLORATOR LOOSEN】, explorator die looses.
【CLAMPING DIE PRESS】/【CLAMPING DIE LOOSEN】:
When press button of 【CLAMPING DIE PRESS】, clamp die clamps;
when press 【CLAMPING DIE LOOSEN】, clamp die looses.
【CURRENT ANGLE】:Display current angle. There are the manual and jog mode.
【CURRENT POSITION】: :Display current position.
【JOG BEND FORWARD】: Bending forward by the jog mode.
【JOG BEND BACKWARD】: Bending backward by the jog mode. When press the button,
bending device will bend; when the button loose, bending device stops immediately.
Remark: parameters of the bending system’s velocity and angle are set in menu of parameter
setup.
【 OIL PRESSURE START 】 / 【 OIL PRESSURE STOP 】 :When press 【 OIL PRESSURE
START】,hydraulic motor start; when press 【OIL PRESSURE STOP】,hydraulic motor stop.
【CUTTER MOTOR START】/【CUTTER MOTOR STOP】: When press 【CUTTER MOTOR
START】,cutter motor start; when press 【CUTTER MOTOR STOP】,cutter motor stop.
【JOG RETURN PIPE FORWARD】: Return pipe forward by the jog mode.
【JOG RETURN PIPE BACKWARD】: Return pipe backward by the jog mode.
【FEED SELECT】: Press 【FEED SELECT】to enter into feed select menu.(Drawing 5)
【PARAMETER SETUP】:Press 【PARAMETER SETUP】to enter into the parameter adjustments
of the manual movement.
【CORE ROD OIL INJECTION】: Press 【CORE ROD OIL INJECTION】to enter into core rod oil
injection menu.(Drawing 13)
6.3.2 Feed select

Press 【FEED SELECT】to enter feed select menu.(Drawing 5)
Drawing 5: feed select menu.

【No.1-7 CLAMP】:When press any button of “No.1-7 CLAMP”, related feed cylinder clamps.
There are two kinds of speed, high speed and low speed.
【H.SPEED FORWARD】/【H.SPEED BACKWWARD】:Feed forward/backward in high speed.
【L.SPEED FORWARD】/【L.SPEED BACKWWARD】:Feed forward/backward in low speed.
【FEED:0.1234.67 mm】:Display feed length. Press 【RESET】to clear feed length value.
【HIGH】/【LOW】:When press 【HIGH】,high pressure is chosen; when press 【LOW】,high
pressure is chosen. If you have not chosen between high pressure and low pressure, system will
exchange pressure between high and low automatically.
【RETURN PIPE SHEATH RESET】:When press 【RETURN PIPE SHEATH RESET】,detection
of feeding reach designated position reset.
【STARTING STAUTUS】:When press 【STARTING STAUTUS】, system change into starting
status menu.(drawing 3)

Hairpin Bender
WARNING:
1. Firstly clamping die clamps, and then explorator presses. Meanwhile, Cutter rest
should move backward to the designated position. After doing the above all, the
operation of bend can be executed.
2. Please loosen clamping die and explorator, and make mechanism of returned pipe
return to setting position. Meanwhile, cutter-rest moves backward to the designated
position, and collecting mechanism returns to the designated position, and there is
no pipe in tooling. After doing the above all, the operation of “bend backward” can
be executed.
3. During feed-forward, can’t execute the operations of clamping die’s clamping,
explorator’s pressing and cutter forward
4. During cutter forward, can’t execute the operations of cutter-rest forward and
cutter-rest backward
5. It can’t execute the operation of cutter-forward until cutter-rest moves forward to the
designated position.
6. When cutter is forward or cutter hasn’t all forward /backward the designated
position, can’t execute the operation of cutter-forward/backward.
Warning:
1. Firstly loosen the clamping die and explorator, make bend move forward to the
designated position. Besides, the bend angle is beyond 170 degree. Only doing so
can execute the operation of returned pipe.
2. It can’t execute the operation of collecting pipe until the bend-mechanism is at
over 90 degree.
3. Frame moving: Only when adjusting the length of machining pipe, this menu can
6.3.
3 Other buttons on panel
Other manual operation on the human-machine interface, there are operating buttons on the
operation panel for convenient feeding.
【FEED FORWARD】【FEED
/ BACK】: press【FEED FORWARD】 button, feed clamping cylinder
clamp completely, meanwhile the feeding motor deliver or withdraw tubes. The indicator will light
during the running.
【CUTTER REST FORWARD】/ 【CUTTER REST FORWARD】 to move cutter head frame
forward and backward. Press CUTTER REST BACK】 button, cutter rest moves forward until the
moving forward inspection switch reaches its designated position.
【JIG FORWARD】【 / JOG BACK】: Press 【JOG FORWARD】to clamp clamping and exploratory
die; press 【JOG BACK】to loosen the clamp and exploratory die.
【CUTTER FORWARD】【 / CUTTER BACK】: Press 【CUTTER FORWARD】to cut forward; press
【CUTTER BACK】to return cutter.
【BEND FORWARD】: bend forward manually. After pressing the button, the bending device will
automatically bend forward from the current position to the setup. When current value more than

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or equal to the setting angle, bend mechanism stop.
【BEND BACK】: bend backward manually. After pressing the button, the bending device will
automatically bend backward from the current position to the setup. When current value less than
or equal to the setting angle, bend mechanism stop.
【CORE PULLING FORWARD】/【CORE PULLING BACK】: press the 【CORE PULLING
FORWARD】button to pull out the core bar, the core pulling length can be adjusted by the pulling
time of “PARAMETER SETUP”. Press 【CORE PULLING BACK】and core bar returns to its
starting position (at the inspection switch of core pulling start).
【COLLECT FORWARD】/【COLLECT BACK】: when tube collection frame operates, press the
【COLLECT FORWARD】and the collecting device will ascend. The tube collection device
descents when【COLLECT BACK】 is pressed. The button becomes ineffective when the
collecting frame shut off its functions.
【RETURN PIPE FORWARD】: to return pipe forward manually. After pressing the button, the
return pipe device will automatically return pipe backward from the current length to the setup.
When current value more than or equal to the setting length, return pipe mechanism stop.
【RETURN PIPE BACKWARD】: to return pipe backward manually. After pressing the button, the
return pipe device will automatically return pipe backward from the current length to the setup.
When current value less than or equal to the setting length, return pipe mechanism stop.
Remark: in the manual operation, the system will give hints of alarms in the alarm display
area if there is operating mistakes. Operations may be carried through only after clearing
the alarm based on the revealing hints.
6.4 Parameter setup

Press 【PARAMETER SETUP】on drawing 4,system enter parameter setting menu.(drawing 6)
Drawing 6. Parameter setup menu

6.4.1 Bend and return pipe setup
Press 【BEND AND RETURN PIPE SETUP】 on drawing 6,systemcan enter into menu of bend
and return pipe setting. (drawing 7)
Drawing 7. Bend and return pipe setting menu

【CURRENT ANGLE】: Display bend system current position.

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【ANGLE SETUP】:Setup angle for bend system.
【CURRENT LENGTH】: Display current length of tube return system.
【U PIPE LENGTH】: Setup the length of U tube.
【LENGTH COMPENSATION】: compensate with “+”when the actual tube processing length is
less than the setup number and “-” when the processing length is greater than the setup number.
【RETURN PIPE COMPENSATION】: the compensative number of tube return sheath moving
out of the die during the course when the tube is moving backward. Range: ±10.00mm.
6.4.2 Speed setup

Press 【SPEED SETUP】 on drawing 6,systemcan enter into menu of speed setting.(drawing8,9)
Drawing 8: speed setup menu 1
Drawing 9: speed setup menu 2

System control bend device and return pipe device in three parts.
【FORWARD】/【BACKWAR】: Setup speed of bending or pipe returning forward or backward.
（1%～100%）
【FORWARD SPEED UP】/【BACKWARD SPEED UP】: Set time of bend or pipe return device
move form zero speed to setting speed. （50～5000ms）
【FORWARD SPEED DOWN】/【BACKWARD SPEED DOWN】: Set time of bend or pipe return
device move form setting speed to zero speed. （50～5000ms）
【BEND FORWARD ANGLE OF SPEED-DOWN】: Setup angle value of speed-down when
bending.
【BEND FORWARD SPEED OF SPEED-DOWN】：Setup running speed of bend device when the
bend forward reaches to angle of speed-down.
【BEND BACKWARD ANGLE OF SPEED-DOWN】：Setup angle of speed-down for bending
backward.
【BEND BACKWARD SPEED OF SPEED-DOWN】：Setup running speed of bend device when
the bend backward reaches to the angle of speed-down..

Hairpin Bender
6.4.3 Frame moving setup
Press 【frame moveing】on drawing 6 to enter frame detection length setting menu (drawing 10)
Frame moving is used to adjust specification of machining pipe. First enter into password menu
as below. It can’t enter into the operation of frame moving until input the password which is 5870.
WARNING: Must close all manual and automatic operations before entering into the
operation of frame moving.
Drawing 10.frame moving menu 1

After confirm the warning items in the menu, click【ENTER】and then system will open controller
power supply of frame moving motor. System will enter into drawing 11, click the button of
【BACK】 to return last menu.
Drawing11 .frame moving menu 2

【CURRENT LENGTH】: Display current length of current machining pipe.
【U PIPE L.SETUP】: Display length setting value of current machining pipe
【U PIPE LENGTH COMPENSATION】 :When practice machining length is less than setting value,
you should execute the “+” for compensation. When practice machining length is greater than set
value, should execute the “-“for compensation.
Manual backward: Move frame backward. When click the button can make frame move from
current position backward to the zero position, and then stop.
Manual forward: Move frame forward. To click the button can make frame move from current
position forward to set distance position, and then stop.
Jog backward: move backward by jog.
Jog forward: move forward by jog. To press the button can make frame move, and to loosen the
button can make frame stop immediately.
Auto: To click the button of 【START】can move pipe returning device form current position to
setting position and stop. To click 【STOP】can make frame moving stop.
Frame moving will stop and alarm system detected limit switch during frame moving. At this time,
click the button of 【CANCEL LIMIT】, and it will move in reverse direction with jog mode.
To click the button of 【ZERO SETUP】can make system enter into password menu firstly. After
input the correct password (8888), system will automatically enter into the menu of “FRAME
MOVING ZERO SETUP”.(drawing 12)

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Method for setting zero
After click【ZERO】, frame will move forward slowly toward zero position. When the frame moves
to absolute zero position, click the button of 【STOP】 to stop and then press the button of
【RESET】to reset it. So zero system reset will be confirmed. In zero’s setting, press 【STOP】
can make it stop at any position, but this position is not system zero.
Drawing12 .frame moving zero setup menu
6.4.4 Core pull oil injection

Press 【 OIL INJECTION SETUP 】 on drawing 6 to enter into the following function
setting.(drawing 13)
Drawing13 .core pull oil injection menu

OILINJ.: Set up time of oil injection for core pulling. (1#--7#)
GAS INJ: Set up time of air injection for core pulling. (1#--7#)
Cutter head oil injection: Set up time of oil injection for cutter head.
Cutter head gas injection: Set up time of air injection for cutter head.
Unit: 0.01s, range: 0.01-2.00s
6.4.5 Bend zero, pipe return zero

Press【BEND ZERO】on drawing 6 to enter into menu of bending system setup.(drawing 14)

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Drawing14 .bend zero menu

Press 【RETURN PIPE ZERO】button to enter menu of bending system setting .
Drawing15 .pipe return zero menu

Zero setup methods are list as follow.
Press【ZERO】, bend device will move forward to the zero position slowly, after inspecting the
detection switch it will stop, and then press 【RESET】button for more than 1 second to confirm
the system zero point reset.
Pipes return system:
Press【ZERO】, pipe return device will move forward to the zero position slowly, after inspecting
the detection switch it will stop, and then press 【RESET】button for more than 1 second to
confirm the system zero point reset.
6.4.6 Program parameter setup

Click【PROGRAM PARAMETER SETUP】on drawing 6,systemcan enter into menu of parameter
setup .(drawing 16)
Drawing 16.program setting menu

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Cut time: Setup the time of cutter forward.
Core pulling: Setup the time of core pulling time to control the length.
Core pulling preact: Setup angle d of core pre-pulling during bending.
Explorator time: Set time form exploratory die clamp to exploratory die loosen.
Clamping die time: Set time form clamp die clamp to clamp die loosen.
Die loosen time: Set time from clamping status to completely loosen.
Reverse feed time: To avoid bend photoelectric detection, the time of feed end moving backward
is set. And feed end move backward length is adjusted by this setting time.
Slowing down length setup: Setup length of speed down when feed device is feeding.
Current feed length: Display current feed length.
Return pipe sheath reset: Setup reset time of feed moving to designated position detection.
Oil injection cycle of die: Die oil injection
6.4.7 Function setup

Press 【function setup】on drawing 6 to enter function setting menu.(drawing 17)
Drawing 17.function setting menu

System provides protection function for hydraulic system. After this function is on, if the time of
starting oil pressure is more than the setting time, hydraulic motor will automatically close and
alarm. Range : 5.0～50.0 minute.
Press 【TURNON】or【DISUE】to open or close function.
Oil level alarm: To detect oil mass of core-pulling oil injection and cutter-head oil injection. When
there is not enough oil, system will alarm. After this function is started, when there is not enough
oil, auto mode can’t be worked and system stops alarming. After this function is closed, when
there is not enough oil, system will not alarm and continue to auto run.
Collecting: Press【DISUE】button, collecting device is unavailable. When collecting material
stand is closed, collecting material can not be operated even at the status of manual operation.
Whatever function of collecting material stand is started or closed, detector switch of collecting
material backward (starting) should check to the designated position before auto-start.
6.4.8 Change die

Press “CHANGE DIE” on drawing 6 to enter menu of exchanging different dies.(drawing 18)
Drawing 18.change die menu 1

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After confirm above operation, can enter below menu.
Drawing 19.change die menu 2

Bend zero: press this button to move bend mechanism to zero position, loosen it to stop moving.
Bend 180°:press this button to operate bend mechanism and stop at 180°position.
Bend 90°:press this button to operate bend mechanism and stop at 90°position.
Exchange collecting stand step:
1. Remove current collecting stand;
2. Operate collecting stand movement and move to zero position. (Namely max process length)
3. Bend mechanism move up more than 170°;
4. Setup parameter of process length;
5. Operate returning pipe forward or backward.
6. Operate clamp die and explorator die. Press” Bend 90°”, mechanism move to 90°position.
7. Adjust collecting stand needed length.
8. Install collecting stand and fix by screw.
9. Loosen clamp and explorator die. Press button of “Bend zero” to move bend mechanism to
zero position, loosen it to stop.
10.Stop collecting stand when bend mechanism backward to 2°,then return to manual mode and
use button on panel to make bend mechanism move to zero position.
Notice: When collecting stand is too long to touch cutter plate, please stop machine.
6.4.9. Change exploratory die

Press 【CHANGE EXPLORATOR DIE】on drawing 6 to enter explortor die exchange menu.(code
is 8888).
Drawing 20. Change exploratory die menu

Press 【UP】to move bending die up, press 【DOWN】to move bending die down.

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6.5 Auto mode
Turn manual/auto witch to the auto direction, system will automatically enter into the auto mode.
Drawing 21: auto mode menu

Auto mode carries out one cycle operation, which reduces laboring intensity, and increases
working efficiency. One person can handle multi-machine operation.
01.3 pc/min:Display running speed that is efficiency.
The status indicator: Display the running status of the every part. The indicator will turn on when
there are alarms or malfunctions.
P./S. H.P H.S: Display pressure and speed of feed clamping.
【PLUNGE】: Displays tube processing quantities during for one time. That is the tube plunge
sequence number.
【SINGLE】: Press 【AUTO START】and the machine will run for a cycle and stop.
【CYCLE】: Press 【AUTO START】 and the machine will continuously operate in cycles.
Machine stops running when pressing【AUTO STOP】button. When machine starts, default
selection of system is auto running.
【 OIL PRESSURE START 】【 OIL PRESSURE STOP 】 :When press 【 OIL PRESSURE
START】,hydraulic motor turns on; when press 【OIL PRESSURE STOP】,hydraulic motor turns
off.
Running conditions and alarm displaying section: Display running condition and hints of alarm,
such as alarm for having no tubes(1～6), cutter moving forward and backward(1～6), the motor
and reaching the processing count taking, etc.
【STARTING STATUS】:Enter starting surveillance menu.(drawing 6)
【OUTPUT MONITOR】:Enter counting supervision menu for output setup.(drawing 22)
【SIMULANT RUNNING】:Enter no pipe stimulant running status.(drawing 27)
【FEED CONTROL】: Enter the feeding control menu for the tube quantity setup. (drawing 26)
6.5.1 Output monitor

Press【OUTPUT MONITOR】on drawing 21 to enter menu of output monitor.
Drawing 22.output monitor menu

Output setup: Set pipe quantities to be processed. If current output is greater or equal, the

Hairpin Bender
equipment will stop automatically and alarm. Output range 1 - 99999. When alarming for having
reached setting output come out, If want to restart, please clear current output or increase setting
output.
Current output: Press 【Current output】to enter zero menu, press button of 【CLEAR】to clear
current output.
Total: To accumulate all of machined pipes from ex-factory to now. What’s more, it can’t be
cleared and set.
Total time of auto run: Calculate total time form adjustment to current operation.
Method for setting data is as follows:
Firstly click the display position where the data needs to be set, and then keyboard menu (As
right diagram) will be displayed. Secondly set the value that you need by pressing keyboard
number. Finally, press “ENT” at the bottom right of keyboard. The whole setting succeeds.
Example: To set output
If want to set output as “12345”, Firstly click date region for setting
output, and then keyboard is displayed. Secondly click the number
keys of “1””2””3’’’4’’and “5” in turn, and then “12345”will be displayed
in the data region. Finally, click the key of “ENT”. The whole setting
succeeds. Meanwhile, the keyboard disappears and setting value
“12345” is displayed.
Method for setting other parameters and data is a duplicate.
6.5.2 Feed control

Press the 【FEED CONTROL】on drawing 21 to enter into feeding control menu.
Drawing 23.feed control menu

The maximum tube processing of the machine is seven; in an actual operation, processing
situation of every tube is different. In auto running, you should choose process condition firstly.
For example, tube 1 must be plunged when choosing the #1 tube, the tube lane’s feeding
cylinder will clamp and then the system may feed. The system will close plunging when there is
no tube on the lane; the automatic running will stop when there are no tubes in all. The upper
side of window displays whether there are tubes on #1～#7 tube lanes. Press 【ALL PLUNGE】
button to start launching where there are tubes, press 【OFF】 to close it.
6.5.3 Simulate running

Press the 【SIMULATE RUNING】on drawing 21 to enter into simulate running menu.

Hairpin Bender
Drawing 24.simulate running menu

Feed time setup: Setup time of simulate running.
6.6 Auto running

We can’t press【AUTO START】 to run automatically until turn switch (MANUAL/ AUTO) towards
auto mode and doing well preparation work before auto-running. After pressing the button of
【AUTO STOP】”, the machine will complete a machining cycle, then stop.
Do well the following preparations before auto start.
1. Open equipment mains power and air supply.
2. Confirm there is safety around the equipment.
2. Confirm that the equipment is at starting status.
4. Start hydraulic motor.
5. Enter into the menu of feed control to elect machining pipe’s plunge.
5. To elect running mode (single and cycle). The default of system is cycle mode.
7. To set the data like machining parameter, etc.
After doing well preparation work, click 【AUTO START】 to start running automatically. When
running, indicator of 【AUTO START】 and green indicator light. “Please pay more regard to
safety during auto-running” will be displayed in show region under auto mode.
6.7 Stop machine

We can stop the machine at any time during the machine’s running.
6.7.1When fault alarm or emergency happens, please press the button of 【EMERGENCY
STOP】 to stop all running. After pressing the button of【EMERGENCY STOP】, oil pump will close
and system will generate alarm cues. Meanwhile, the screen will display the following
information:
Drawing 25.emergency stop alarm

The method for eliminating 【EMERGENCY STOP】is to twist the switch of 【EMERGENCY
STOP】towards the right. Doing so automatically eliminates emergency stop.
After pressing【EMERGENCY STOP】, auto-running will all stop. If want to restart the machine,

Hairpin Bender
should press the button of 【AUTO START】to restart at the starting status.
6.7.2. In auto-running, the following condition will make system automatically stop after finishing
one machining-cycle.
1. Press the button of auto stop, and this indicator lights. In auto mode’s running, system
alarm: please wait……In auto running.
2. Press the button of “Single” to carry through the single mode.
3. When output reaches the setting value, the equipment will automatically stop after finishing
the last cycle. Meanwhile, alarm information will be displayed on the panel and the red alarm
indicator will turn on.
Drawing 26.output alarm

4. After starting oil-level alarm function, when system detect that there is no oil, machine will
automatically stop after finishing one machining-cycle. Meantime, oil-level alarm indicator
turns on.
6.7.3. When fault or abnormity occurs during running, the equipment will automatically stop and
alarm.
6.7.4 When turn hydraulic motor off during running, auto running will all stop immediately.
6.7.5 When somebody or object are tested by light curtain, auto running will stop immediately.
6.7.6 When there are no pipes or all feeding control is closed, auto running will stop immediately.
6.7.7 When each motor fails or some motions don’t reach the designated position, auto running
will stop immediately.
6.7.8 When turn the switch (Manual mode /Auto mode) towards manual mode, auto-running will
stop immediately.
Detailed alarm and solution to eliminate alarm can be seen the chapter of << ALARM DISPLAY>.
7. ALARM DISPLAY
The system automatically monitors running status. When fault happens, it will automatically stop
running, generate alarm information and display relieving method. Meanwhile, the red indicator
wills light.
7.1 Cutter backward detection alarm

There are detector switches of cutter backward. If switch doesn’t detect to the designated
position when cutter move backward, the equipment will alarm as below: All cutters have not
moved backward to the designated position. Detecting alarm!
Solutions are as follows:
1. Please check whether there is enough gas to supply cylinder of cutter-head.
2. Please check whether detector switch works normally, indicator lights and position is
correct or not during cutter forward (Air cylinder moves). Please re-adjust them, or else
replace switches.
3. Please check whether there is pipe to be blocked at the course of cutter forward, cutter
backward. Please adjust it.
7.2. Cutter rest move forward alarm

In auto running, when cutter-rest moves forward, if detecting doesn’t reach the designated

Hairpin Bender
position, the following alarms will be displayed.
Drawing 27.cutter rest forward alarm
REMARKS: W hen alarm menu happens, Method to cancel alarm menu

and enter operating mode is as follows:
1. Eliminate fault according to alarm menu’ cue, and then enter operating
mode after eliminating fault.
2. After eliminating fault, click any position in the menu, and then alarm
will disappear.
7.3. Cutter rest move backward alarm
Drawing 28:cutter rest backward alarm

At auto running, when cutter-rest moves backward, if detecting doesn’t reach the designated
position, the following alarms will be displayed.
7.4 Feed overtime

In the automatic running when ongoing feeding is with pneumatic source opening, the following
alarms will display if the feeding detection switch does not fully reach to detect in a long period of
time.

Hairpin Bender
Drawing 29: feed overtime alarm

Remark: when there is an alarm during feeding, press the AUTO-START for more than 2 seconds
and the automatic running will continue, but the feeding length may be somewhat different.
7.5 Cutter head photoelectric detection

In the auto running, if the photoelectric detection of cutter head frame does not reach to its
designated position.
Drawing 30:Cutter head photoelectric detection alarm

Press the NO 1—NO 6 BACKWARD buttons to return the feeding eliminating the photoelectric
detection, then press【AUTO START】and the automatic operation will continue running.
7. 6 Bend photoelectric detection

During the tube returning, if there are tubes do not return completely and the photoelectric
detection on bending does not reach to its designated position in an automatic running, the
following alarms will be displayed: first eliminate the photoelectric detection, then press
【AUTO-START】 button and the automatic running will continue.
Drawing 31:bend photoelectric detection alarm

Hairpin Bender
7.7 All pipes have processed
In auto running, if all the tubes have already been processed, no pipes detection switch will be
getting through and meanwhile feeding control plunging will shut off, and the following alarms will
be displayed:
Drawing 32: all pipes have processed alarm
7.8 Machine isn’t starting status

In manual mode, if press 【AUTO-START】, the following alarm will be displayed.
Drawing 33: machine isn’t at starting status
7.9 Machine can’t auto run

In manual mode, if press 【AUTO-START】, the following alarm will be displayed.
Drawing 34: machine can’t auto run
7.10 Oil pressure system

If there is no motion’s running in hydraulic system, the following alarm will be displayed after

Hairpin Bender
hydraulic protection’s function reaches the set time.
Drawing 35:oil pressure system alarm

7.11 Oil temperature is over high
When hydraulic oil temperature is beyond the set value, the following alarm will be displayed.
Drawing 36: oil pressure is over high alarm
7.12 Cutter motor

When overload and heating of cutting motor happens, please look over display code on controller
panel of electricity box. First, eliminate alarms according to alarm code. Second, press the button
of “RESET” to reset or turn power on again after it has reached over 10 seconds since turn power
off.
Drawing 37:cutter motor alarm

Hairpin Bender
7.13 Oil motor
When overload or heating happens to hydraulic motor, the following alarm will be displayed：
Drawing 38:Oil motor alarm
7.14 Battery voltage

When battery voltage of PLC is low, the following alarm will be displayed.
Drawing 39:battery voltage is low alarm

When PLC voltage is too low, red indicator in PLC（FX2N-128MT）will light and alarm, and must
replace the battery in ten days. When fault happens to the PLC, red indicator will light. The
solution is to turn power on again after over 10 seconds from turning power off or contact
manufacturer.
7.15 Photoelectricity safety detection alarm

There photoelectricity safety detection on the side of equipment. Machine will stop when
photoelectricity safety device is coved. Meantime, menu will display photoelectricity safety alarm.
After clear problem, press button of “1# RESET” and “2# RESET” to reset the photoelectricity
safety device. In manual mode, press menu to return operation menu after resetting. In auto
mode, press button of “AUTO RUN” to run again after resetting.

Hairpin Bender
Drawing 40.photoelectric safety alarm
7.16 Bend motor, pipe return motor, frame moving motor alarm
When alarm happens to motor of returned pipe, or motor of frame moving, the motor will stop.
Meanwhile, the following will be displayed on current operating menu: motor alarm of returned
pipe or frame. The solution is as follows: First, Please look over alarm code of controller panel of
electric switch box. Secondly, eliminate the alarm according to alarm code’s cue. Finally, turn
power on again after over 5 seconds from turning power off. Alarm code, please refer to
accessory.

Hairpin Bender
7.17 Common Malfunctions and Solutions
MALFUNCTIONS REASONS SOLUTIONS

1. Feeding belt is too loose. 1. Adjust the belt’s tension.
2.Low pressure tension is too 2.Lower the low pressure’s tension
Materials stuck high
1.Volatilization oil spraying is too 1. Adjust the oil spraying quantity.

low in measure 2.Clean out the jamming sundries
2.Mandril and core haulm stuck 3.Clean out the jamming sundries
3.Oil spraying solenoid valve 4. Replace it.
Crinkles and stuck 5. (1) If the velocity is not fast
expanding on 4.Mandril damaged enough, adjust the flux by the
bending 5.Core pulling cylinder doesn’t throttle valve (2) Increase the
work normally hydraulic tension in moderation if
6. Problems on the tubes the pressure were not stable.
7.Die wearing and tearing 6.Replace them
7.Replace it
1.Tube return sheath damaged or 1.Lock the nut tightly after replacing
it’s nut loosened or readjusting it
2. The nut joining of tube return 2.Relock it tightly
Tube lengths are
lead screw is loosening. 3.Replace it
different
3.Cutting blade is damaged

Appendix 1: Layout drawing
Rijiang Li Rijiang Li
layout drawing
Rijiang Li
Appendix 2: Electric Control Drawing
KM1
L1 L2 L3 PE T02 T06 T07
415-380VAC/1∅220VAC
SB00 KM1 KM1

KA1
SA
JBK--1KW
T06-3
T07-02
T06-1
+24V
R01 S01 T01 FR1
FU2
QF 0V
SB01 T07-03
T06-2
R02 S02 T02
KM1 HL00 HL01 KM2
FU1 R05
KM1
R06 R07
fan power power power off hydraulic feed motor
on on indicator motor cool fan
indicator
T02 T02 T02 T02
S02 S02 S02 S02
R02 R02 R02 R02
SG --7KW
3∅415-380VAC/3∅220VAC
T03 L1 L2 L3 L1 L2 L3
S03 KM2
STF Y00 CW start
STF Y04 CW start
R03 STR Y01 C-CW start
STR
FR- FR- RH Y02 high speed
RH Y05 high speed
D 740- RL Y06 low speed D 740- RL Y03 low speed
1.5K 3.7K B X17 abnormal alarm
A X20 abnormal alarm
RES
C
C
SD 0VDC
SD 0VDC
L1 L2 L3 L1 L2 L3 L1 L2 L3 U V W U VW
T07 T07 L11 T07 L11 FR1 U5 V5 W5 U6 V6 W6
L11
R07 L221 R07 L221 R07 L221
U4 V4 W4
MR-J2S-40A MR-J2S-200A MR-J2S-350A M slave station M
PLC
U V W U V W U V W
cut motor feed motor
U1 V1 W1 U2 V2 W2 U3 V3 W3
M
M encoder
M encoder
M
encoder
hydraulic motor
frame move motor pipe return motor bend motor
Zhongshan OMS Industrial Co.,Ltd
electric control drawing
T07 L CN1-B COM1 0VDC
R07 N 5 SON Y04
PE 8 ABSM Y05
24VDC S/S 9 ABSR Y06
0VDC 0V sheild cable 15 EMG 0VDC CN1-A
COM 10 SG sheild cable 10 SG 0VDC
X03 4 D01 8 CR Y07
X04 19 ZSP 3 PP Y00
X05 6 TLC 20 SG 0VDC
X06 18 ALM 20 SG 0VDC
13 COM 2 NP Y03
3 VDD 9 COM sheild cable main station
11 OPC COM2
X07
bend motor MR-J2-350A
19 RD COM3
FX3U-64MT/ES-A
CN1-B
5 SON Y11
8 ABSM Y12
9 ABSR Y13
sheild cable 15 EMG 0VDC CN1-A
10 SG sheild cable 10 SG 0VDC
X10 4 D01 8 CR Y20
X11 19 ZSP 3 PP Y01
13 COM 2 NP Y10
sheild cable
3 VDD 9 COM
pipe return motor MR-J2-200A 11 OPC COM4
X14 19 RD COM5
CN1-B
5 SON Y15
8 ABSM Y16
9 ABSR Y17
sheild cable 15 EMG 0VDC CN1-A
10 SG sheild cable 10 SG 0VDC
4 D01 8 CR Y21
X15 19 ZSP 3 PP Y02
X20 13 COM 2 NP Y14
3 VDD 9 COM sheild cable
11 OPC COM6
frame motor MR-J2-40A
X21 19 RD
X00
X01
X02
KA1 hydraulic solenoid valvle
X22 photoelectric detection at bend position Y22
KA2
X23 bend origin detection Y23 core pull forward solenoid valvle
pipe return zero detection KA3 core pull backward solenoid valvle
X24 Y24
KA4
X25 frame move limit detection Y25 clamp die solenoid valvle
KA5
X26 core pull return zero detection Y26 explortor die solenoid valvle
core pull return protected detection KA6
X27 Y27 core pull oil injection solenoid valvle1#
bend protected detection KA7
temperature detection KA8
frame move zero detection KA9
KA10
X33 level detection Y33 core pull oil injection solenoid valvle5#
KA11
X34 photoelectricity protected detection 1# Y34 core pull oil injection solenoid valvle6#
photoelectricity protected detection 2# KA12
KA13
X36 feed forward to its position 1# Y36 core pull air injection solenoid valvle1#
KA14
KA15
KA16
KA17 core pull air injection solenoid valvle5#
X42 feed forward to its position 5# Y42
0VDC 24VDC

KA18
X43 feed forward position detection 6# Y43 core pull air injection solenoid valve 6#
feed forward position detection 7# KA19 core pull air injection solenoid valve 7#
X44 Y44
hydraulic motor thermorelay KA20 return sheath reset solenoid valve
X45 Y45
SB02 KA21
X46 auto start Y46 feed forward solenoid valve
SB03 auto stop KA22 feed backward solenoid valve
X47 Y47
SB04 auto pause KA23 bend forward solenoid valve
X50 Y50
emergency stop KA24 bend backward solenoid valve
X51 Y51
manual/auto KA25 red indicator
X52 Y52
SB05 KA26
X53 manual button of feed forward Y53 green indicator
SB06
manual button of feed backward KA27 yellow indicator
X54 Y54
SB07 KA28 jig indicator
X55 manual button of cut rest forward Y55
SB08 KA29 pipe return forward solenoid valve
X56 manual button of cutter rest backward Y56
SB09 pipe return forward KA30 pipe return backward solenoid valve
X57 Y57
SB10 pipe return backward KA31 auto stop button indicator
X60 Y60
SB11 cutter forward KA32
X61 Y61 cutter forward/backward indicator
SB12 cutter backward KA33 collect forward/backward indicator
X62 Y62
SB13
jig forward KA34 cut rest forward indicator
X63 Y63
SB14 jig backward KA35
X64 Y64 cut rest backward indicator
SB15
bend forward KA36 leadscrew support move up detection 1#
X65 Y65
SB16
bend backward KA37 leadscrew support move down detection 1#
X66 Y66
SB17
core pull forward KA38 leadscrew support move up detection 2#
X67 Y67
SB18 core pull backward KA39 leadscrew support move down detection 2#
X70 Y70
SB19 collect forward
X71 Y71
SB20 collect backward
X72 Y72
X73 leadscrew support down detection Y73
X74 leadscrew support protected detection Y74
X75 leadscrew support down to position detection Y75
X76 Y76
X77 Y77
0VDC 24VDC
24VDC
24VDC
0VDC
0VDC
T07
T07
T07
T07
PE
PE
SDA L N S/S 0V 0V X0 ------ X37 L N COM X40 ------ X67 24+ X70 -- X77 Y70 ---- Y77
SDB
RDA
main station RDB FX3U--64MT--ES FX2N--48ER FX2N-8EX FX2N-8EYR
SG
FX3U-
485BD COM1 COM2 COM3 COM4 COM5 COM6 Y0 ------ Y37 COM1 COM2 COM3 COM4 COM5 Y40 --- Y67
0VDC
0VDC
sheild cable
24VDC
0VDC
T07
T07
PE
SG L N S/S 0V 0V X0 ------ X37

SDA
slave station
SDB
RDA FX3U--64MT--ES
RDB
FX3U-
485BD COM1 COM2 COM3 COM4 COM5 COM6 Y0 ------ Y37
0VDC

T07 L slave station COM1 0VDC
R07 N COM2
PE FX3U-64MT COM3
0VDC 0V COM4
24VDC S/S COM5
X00 encoder A COM6
X01 encoder B Y00 feed motor CW start
X02 Y01 feed motor C-CW start
photoelectric detection at bend position
X03 collect forward detection Y02 feed motor high speed
X04 collect backward detection Y03 feed motor low speed
X05 cutter reset forward detection Y04 cut motor start
X06 cutter reset backward detection Y05 cut motor high speed
X07 cutter backward detection 1# Y06 cut motor low speed
no pipe detection 1# KA40
X10 Y07 cutter rest forward solenoid valvle
no pipe detection 2# KA41 cutter rest backward solenoid valvle
X11 Y10
no pipe detection 3# KA42 cutter foward solenoid valvle
X12 Y11
no pipe detection 4# KA43 collect solenoid valvle
X13 Y12
KA44
X14 no pipe detection 5# Y13 low voltage output solenoid valvle
no pipe detection 6# KA45 feed clamping solenoid valvle 1#
X15 Y14
no pipe detection 7# KA46 feed clamping solenoid valvle 2#
X16 Y15
cutter motor frequency converters abnormal alarm KA47
X17 Y16 feed clamping solenoid valvle 3#
feed motor frequency converters abnormal alarm KA48 feed clamping solenoid valvle 4#
X20 Y17
emergency stop KA49 feed clamping solenoid valvle 5#
X21 Y20
KA50
X22 Y21 feed clamping solenoid valvle 6#
KA51 feed clamping solenoid valvle 7#
X23 Y22
KA52
X24 Y23 cutter oil injection solenoid valvle
KA53
X25 Y24 cutter air injection solenoid valvle
X26 Y25
X27 Y26
X30 Y27
X31 Y30
X32 Y31
X33 Y32
X34 Y33
X35 Y34
X36 Y35
X37 Y36
Y37
0VDC 0VDC
24VDC 0V
KA40 YV24
cutter rest forward solenoid valvle
KA41 YV25
cutter rest backward solenoid valvle
KA42 YV26 cutter foward solenoid valvle
KA43 YV27 collect solenoid valvle
KA44 YV28 low voltage output solenoid valvle
KA45 YV29 feed clamping solenoid valvle 1#
KA52 YV36 cutter oil injection solenoid valvle
KA53 YV37 cutter air injection solenoid valvle

24VDC 0V 24VDC 0V
KA2 YV01 core pull forward solenoid valve KA21 HL04 feed forward indicator
HL02 core pull forward indicator KA22 HL05 feed backward indicator
KA3 YV02 core pull backward solenoid valve KA23 HL06 bend forward solenoid valve
HL03 core pull backward indicator KA24 HL07 bend backward solenoid valve
KA4 YV03 clamp die solenoid valve KA25 HL08 red indicator
KA5 YV04 explorator die solenoid valve KA26 HL09 green indicator
KA6 YV05 core pull oil injection solenoid valvle 1# KA27 HL10 yellow indicator
KA7 YV06 core pull oil injection solenoid valvle 2# KA28 HL11 jig forward indicator
KA8 YV07 core pull oil injection solenoid valvle 3# HL12 jig forward indicator
KA9 YV08 core pull oil injection solenoid valvle 4# KA29 HL13 pipe return forward solenoid valve
KA10 YV09 core pull oil injection solenoid valvle 5 # KA30 HL14 pipe return backward solenoid valve
KA11 YV10 core pull oil injection solenoid valvle 6# KA31 HL15 auto start button indicator
KA12 YV11 core pull oil injection solenoid valvle 7# HL16 auto stop button indicator
KA13 YV12 core pull air injection solenoid valvle 1# KA32 HL17 cut rest forward indicator
KA14 YV13 core pull air injection solenoid valvle 2# HL18 cut rest backward indicator
KA15 YV14 core pull air injection solenoid valvle 3# KA33 HL19 collect forward indicator
KA16 YV15 core pull airinjection solenoid valvle 4# HL20 collect backward indicator
KA17 YV16 core pull air injection solenoid valvle 5 # KA34 HL21 cut rest forward indicator
KA18 YV17 core pull air injection solenoid valvle 6# KA35 HL22 cut rest backward indicator
KA19 YV18 core pull air injection solenoid valvle 7#
KA20 YV19 return sheath reset solenoid valve
KA36 YV20 leadscrew support move up detection 1#

KA37 YV21 leadscrew support move down detection 1#
KA38 YV22 leadscrew support move up detection 2#
KA39 YV23 leadscrew support move down detection 2#
24VDC 0V
GOT touch panel
A相
X00
encoder
B相 X01
photoelectricity detection at
bend point
X22
core pulling origin detection

(limit switch)
X26
safety light screen detection

X34

safety light screen
8# purple 24VDC
Receiver 1# Bn
24VDC
2 1 7# Gn/Ye
3 8 7
6# Bu
IM-T-11A
4 6 0VDC
5
5# Bk
S1
4# Wh
S4
3# Or
S3
2# Or&Bk
S2
13 0VDC
14 X24 or X25
8# purple
Emitter
1# Bn
24VDC
2 1 7# Gn/Ye
3 8 7 ** Not connected
6# Bu X34/X35 is PLC connect point of safety light
4 6 0VDC curetain.
5
5# Bk
4# Wh
3# Or
2# Or&Bk

Appendix 3: Electric Components Listing
Hairpin Bender Machine electrical components listing
No. Name Specification QTY Supply Remark
1 master switch 3LD2504-OTK53 63A 1 SIEMENS
2 breaker 5SJ6/3P/50A 1
3 socket AC30 2P/10A 1
4 fuse base 31110-10×38 2 WOHNER
5 fuse tube RT14-20 6A 1 DELIXI
6 fuse tube RT14-20 10A 1 DELIXI
7 transformer SG415-380/220V 7kVA 1 FUJIE
8 transformer JBK3 380-415/220 1KVA 1 FUJIE
9 aerofoilfan CC12038B 220L 3 CHIEFLY
10 window vent(square hole) 120×120 3
11 middle relay RJ2S-C-D24 53 PANANSONIC
12 middle relay base SJ2S-05B 53 IDEC
13 button switch with a light(green) YW1L-MF2E11Q4G 9 IDEC
14 button switch with a light(red) YW1L-MF2E11Q4R 9 IDEC
15 button switch with a light(green) YW1L-MF2E11QM3G 1 IDEC
16 button switch with a light(red) YW1L-MF2E11QM3R 1 IDEC
17 three color light TL-50BL/RGY23C 1
18 emergency stop switch YW1B-V4EO1R 3
19 one unit button box TYX1S/Y 75×75×65 2 TAYEE
20 green button with mushroom shape YW1B-M4E10G 1
21 two unit switch YW1S-2E10 1
22 switching power supply S-350-24V 1 MINGWEI
23 PLC FX3U-64MT/ES 2
24 extensive module FX2N-48ER 1
25 extensive module FX2N-8EX 1 MITSUBISH
26 extensive module FX2N-8EYR 1 MITSUBISH
27 communicate module FX3U-485-BD 2 MITSUBISHI
28 proximity switch PSE17-5DN 15
29 photoelectric switch PZ-G51N 2 JIENSHI
30 rotary encoder ISC5208-001G-1000BZ3-5-24F 1 HEDS
31 aerofoilfan FP108EX-S1-S 220V 1
32 level switch LFS-SS1-A1-250YK 1 SKYWAL
33 temperature switch WZB30-110 1
34 magnetic switch D-Z73L 4 SMC
35 magnetic switch D-A93L 7 SMC
36 AC contactor 3TF3001-OXMO 1
37 AC contactor 3TF3101-OXMO 1
38 thernorelay 3UA5040-1K 1
39 frequency converters FR-D740-1.5K-CHT 1 CHUANGFENG
40 frequency converters FR-D740-3.7K-CHT 1 CHUANGFENG
41 face film 1
42 photoelectric switch EE-SPX403 7
43 touch panel GT1050-QBBD-C 1 MITSUBISHI
44 communicate cable FX-50DU-CAB-3M 1
45 amplifier MR-J2S-350A 1 MITSUBISHI
46 servo motor HC-SFS352 1 MITSUBISHI
51 CN1 plug MY11-20T 9 XINGHUA
52 battery MR-BAT 3 MITSUBISHI
53 safety light curtain LS2TP30-450Q88 2
54 safety relay IM-T-11A-61424 2
55 middle relay RJ2S-C-D24 2
56 middle relay base SJ2S-05B 2
Appendix 4: Pneumatic and hydraulic Elementary Drawing
L-MDB1B63-150 L-MDB1B63-125 CQ2A32-10D CQ2A50-20DC CDQ2B32-15D
VQZ2115-5GB-C6
clappet valve clappet valve
pressure- pressure-
regulating regulating
valve AR25-02 valve AR25-02
SY7220-5LZD-02 SY7120-5LZD-02 SY7120-5LZD-02 SY7120-5LZD-02 SY7120-5LZD-02
air supply graduating clappet gas manual air valve
valve valve holder L-VHS2000-02 pressure-regulating
valve AR400-05
pneumatic elementary drawing
TBLU0606001-7
Ø33x2 explorator oil cylinder Ø63x1 clamping oil cylinder MOBDØ50x40 oil cylinder of pulling core
ZG3/8" ZG3/8" ZG3/8" ZG3/8" ZG3/8" ZG3/8"
A B A B A B
P T P T P T
P T
20
12
ev
hydraulic elementray drawing
TBLU0606001-6
Appendix 5: Wearing Parts Drawing
Appendix 6: Alarm codes and solution
10. TROUBLESHOOTING
10. TROUBLESHOOTING
10.1 Trouble at start-up
Excessive adjustment or change of parameter setting must not be made as it will

CAUTION
make operation instable.
POINT
Ë-·²¹ ¬¸» ±°¬·±²¿´ ÓÎ Ý±²º·¹«®¿¬±® (-»®ª± ½±²º·¹«®¿¬·±² -±º¬©¿®»÷ô §±« ½¿²
®»º»® ¬± «²®±¬¿¬»¼ -»®ª± ³±¬±® ®»¿-±²-ô »¬½ò
Ì¸» º±´´±©·²¹ º¿«´¬- ³¿§ ±½½«® ¿¬ -¬¿®¬ó«°ò ×º ¿²§ ±º -«½¸ º¿«´¬- ±½½«®-ô ¬¿µ» ¬¸» ½±®®»-°±²¼·²¹ ¿½¬·±²ò
10.1.1 Position control mode
(1) Troubleshooting
No. Start-up sequence Fault Investigation Possible cause Reference
ï Ð±©»® ±² ÔÛÜ ·- ²±¬ ´·¬ò Ò±¬ ·³°®±ª»¼ ·º ½±²²»½¬±®- ïò Ð±©»® -«°°´§ ª±´¬¿¹» º¿«´¬
ÔÛÜ º´·½µ»®-ò ÝÒïßô ÝÒïÞô ÝÒî ¿²¼ ÝÒí îò Í»®ª± ¿³°´·º·»® ·- º¿«´¬§ò
¿®» ¼·-½±²²»½¬»¼ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±®- Ð±©»® -«°°´§ ±º ÝÒÐï ½¿¾´·²¹
ÝÒïß ¿²¼ ÝÒïÞ ¿®» ·- -¸±®¬»¼ò
¼·-½±²²»½¬»¼ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±® ïò Ð±©»® -«°°´§ ±º »²½±¼»®
ÝÒî ·- ¼·-½±²²»½¬»¼ò ½¿¾´·²¹ ·- -¸±®¬»¼ò
îò Û²½±¼»® ·- º¿«´¬§ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±® Ð±©»® -«°°´§ ±º ÝÒí ½¿¾´·²¹ ·-
ÝÒí ·- ¼·-½±²²»½¬»¼ò -¸±®¬»¼ò
ß´¿®³ ±½½«®-ò Î»º»® ¬± Í»½¬·±² ïðòî ¿²¼ ®»³±ª» ½¿«-»ò Í»½¬·±² ïðòî
î Í©·¬½¸ ±² -»®ª±ó±² ß´¿®³ ±½½«®-ò Î»º»® ¬± Í»½¬·±² ïðòî ¿²¼ ®»³±ª» ½¿«-»ò Í»½¬·±² ïðòî
øÍÑÒ÷ò Í»®ª± ³±¬±® -¸¿º¬ ·- ïò Ý¸»½µ ¬¸» ¼·-°´¿§ ¬± -»» ·º ïò Í»®ª±ó±² øÍÑÒ÷ ·- ²±¬ ·²°«¬ò Í»½¬·±² êòê
²±¬ -»®ª±ó´±½µ»¼ ¬¸» -»®ª± ¿³°´·º·»® ·- øÉ·®·²¹ ³·-¬¿µ»÷
ø·- º®»»÷ò ®»¿¼§ ¬± ±°»®¿¬»ò îò îìÊÜÝ °±©»® ·- ²±¬
îò Ý¸»½µ ¬¸» »¨¬»®²¿´ ×ñÑ -«°°´·»¼ ¬± ÝÑÓò
-·¹²¿´ ·²¼·½¿¬·±² ¬± -»» ·º
¬¸» -»®ª±ó±² øÍÑÒ÷ ·- ÑÒò
í Û²¬»® ·²°«¬ Í»®ª± ³±¬±® ¼±»- Ý¸»½µ ½«³«´¿¬·ª» ½±³³¿²¼ ïò É·®·²¹ ³·-¬¿µ» Í»½¬·±² êòî
½±³³¿²¼ò ²±¬ ®±¬¿¬»ò °«´-»-ò ø¿÷ Ú±® ±°»² ½±´´»½¬±® °«´-»
øÌ»-¬ ±°»®¿¬·±²÷ ¬®¿·² ·²°«¬ô îìÊÜÝ
°±©»® ·- ²±¬ -«°°´·»¼ ¬±
ÑÐÝò
ø¾÷ ÔÍÐ ¿²¼ ÔÍÒ ¿®» ²±¬ ±²ò
îò Ò± °«´-»- ·- ·²°«¬ò
Í»®ª± ³±¬±® ®«² ·² ïò Ó·-¬¿µ» ·² ©·®·²¹ ¬± Ý¸¿°¬»® ë
®»ª»®-» ¼·®»½¬·±²ò ½±²¬®±´´»®ò
îò Ó·-¬¿µ» ·² -»¬¬·²¹ ±º
°¿®¿³»¬»® Ò±ò ëìò
10 - 1
10. TROUBLESHOOTING

ì Ù¿·² ¿¼¶«-¬³»²¬ Î±¬¿¬·±² ®·°°´»- Ó¿µ» ¹¿·² ¿¼¶«-¬³»²¬ ·² ¬¸» Ù¿·² ¿¼¶«-¬³»²¬ º¿«´¬ Ý¸¿°¬»® é
ø-°»»¼ º´«½¬«¿¬·±²-÷ º±´´±©·²¹ °®±½»¼«®»æ
¿®» ´¿®¹» ¿¬ ´±© ïò ×²½®»¿-» ¬¸» ¿«¬± ¬«²·²¹
-°»»¼ò ®»-°±²-» ´»ª»´ò
îò Î»°»¿¬ ¿½½»´»®¿¬·±² ¿²¼
¼»½»´»®¿¬·±² -»ª»®¿´ ¬·³»-
¬± ½±³°´»¬» ¿«¬± ¬«²·²¹ò
Ô¿®¹» ´±¿¼ ·²»®¬·¿ ×º ¬¸» -»®ª± ³±¬±® ³¿§ ¾» Ù¿·² ¿¼¶«-¬³»²¬ º¿«´¬ Ý¸¿°¬»® é
³±³»²¬ ½¿«-»- ¬¸» ®«² ©·¬¸ -¿º»¬§ô ®»°»¿¬
-»®ª± ³±¬±® -¸¿º¬ ¬± ¿½½»´»®¿¬·±² ¿²¼
±-½·´´¿¬» -·¼» ¬± -·¼»ò ¼»½»´»®¿¬·±² -»ª»®¿´ ¬·³»- ¬±
½±³°´»¬» ¿«¬± ¬«²·²¹ò
ë Ý§½´·½ ±°»®¿¬·±² Ð±-·¬·±² -¸·º¬ ±½½«®- Ý±²º·®³ ¬¸» ½«³«´¿¬·ª» Ð«´-» ½±«²¬·²¹ »®®±®ô »¬½ò øî÷ ·² ¬¸·-
½±³³¿²¼ °«´-»-ô ½«³«´¿¬·ª» ¼«» ¬± ²±·-»ò -»½¬·±²
º»»¼¾¿½µ °«´-»- ¿²¼ ¿½¬«¿´
-»®ª± ³±¬±® °±-·¬·±²ò
10 - 2
10. TROUBLESHOOTING
(2) How to find the cause of position shift

Positioning unit Servo amplifier
(a) Output pulse Electronic gear (parameters No. 3, 4) Machine
counter
Servo motor
L
CMX
Q P M
CDV (d) Machine stop
position M
(A) (b) Cumulative command (B)
(C) Servo-on (SON), pulses
stroke end
(LSP/LSN) input C Encoder
(c) Cumulative
feedback pulses
É¸»² ¿ °±-·¬·±² -¸·º¬ ±½½«®-ô ½¸»½µ ø¿÷ ±«¬°«¬ °«´-» ½±«²¬»®ô ø¾÷ ½«³«´¿¬·ª» ½±³³¿²¼ °«´-» ¼·-°´¿§ô ø½÷
½«³«´¿¬·ª» º»»¼¾¿½µ °«´-» ¼·-°´¿§ô ¿²¼ ø¼÷ ³¿½¸·²» -¬±° °±-·¬·±² ·² ¬¸» ¿¾±ª» ¼·¿¹®¿³ò
øß÷ô øÞ÷ ¿²¼ øÝ÷ ·²¼·½¿¬» °±-·¬·±² -¸·º¬ ½¿«-»-ò Ú±® »¨¿³°´»ô øß÷ ·²¼·½¿¬»- ¬¸¿¬ ²±·-» »²¬»®»¼ ¬¸» ©·®·²¹
¾»¬©»»² °±-·¬·±²·²¹ «²·¬ ¿²¼ -»®ª± ¿³°´·º·»®ô ½¿«-·²¹ °«´-»- ¬± ¾» ³·-ó½±«²¬»¼ò
×² ¿ ²±®³¿´ -¬¿¬«- ©·¬¸±«¬ °±-·¬·±² -¸·º¬ô ¬¸»®» ¿®» ¬¸» º±´´±©·²¹ ®»´¿¬·±²-¸·°-æ
ï÷ Ï Ð ø°±-·¬·±²·²¹ «²·¬ù- ±«¬°«¬ ½±«²¬»® -»®ª± ¿³°´·º·»®ù- ½«³«´¿¬·ª» ½±³³¿²¼ °«´-»-÷
ÝÓÈø°¿®¿³»¬»® Ò±òí÷
î÷ Ð
ÝÜÊø°¿®¿³»¬»® Ò±òì÷
Ý ø½«³«´¿¬·ª» ½±³³¿²¼ °«´-»- »´»½¬®±²·½ ¹»¿® ½«³«´¿¬·ª» º»»¼¾¿½µ °«´-»-÷
í÷ Ý Ó ø½«³«´¿¬·ª» º»»¼¾¿½µ °«´-»- ¬®¿ª»´ °»® °«´-» ³¿½¸·²» °±-·¬·±²÷
Ý¸»½µ º±® ¿ °±-·¬·±² -¸·º¬ ·² ¬¸» º±´´±©·²¹ -»¯«»²½»æ

ï÷ É¸»² Ï Ð
Ò±·-» »²¬»®»¼ ¬¸» °«´-» ¬®¿·² -·¹²¿´ ©·®·²¹ ¾»¬©»»² °±-·¬·±²·²¹ «²·¬ ¿²¼ -»®ª± ¿³°´·º·»®ô
½¿«-·²¹ °«´-»- ¬± ¾» ³·--ó½±«²¬»¼ò øÝ¿«-» ß÷
Ó¿µ» ¬¸» º±´´±©·²¹ ½¸»½µ ±® ¬¿µ» ¬¸» º±´´±©·²¹ ³»¿-«®»-æ
Ý¸»½µ ¸±© ¬¸» -¸·»´¼·²¹ ·- ¼±²»ò
Ý¸¿²¹» ¬¸» ±°»² ½±´´»½¬±® -§-¬»³ ¬± ¬¸» ¼·ºº»®»²¬·¿´ ´·²» ¼®·ª»® -§-¬»³ò
Î«² ©·®·²¹ ¿©¿§ º®±³ ¬¸» °±©»® ½·®½«·¬ò
×²-¬¿´´ ¿ ¼¿¬¿ ´·²» º·´¬»®ò øÎ»º»® ¬± øî÷ø¿÷ Í»½¬·±² ïíòîòêò÷
ÝÓÈ
î÷ É¸»² Ð Ý
ÝÜÊ
Ü«®·²¹ ±°»®¿¬·±²ô ¬¸» -»®ª±ó±² øÍÑÒ÷ ±® º±®©¿®¼ñ®»ª»®-» ®±¬¿¬·±² -¬®±µ» »²¼ ©¿- -©·¬½¸»¼ ±ºº ±®
¬¸» ½´»¿® øÝÎ÷ ¿²¼ ¬¸» ®»-»¬ øÎÛÍ÷ -©·¬½¸»¼ ±²ò øÝ¿«-» Ý÷
×º ¿ ³¿´º«²½¬·±² ³¿§ ±½½«® ¼«» ¬± ³«½¸ ²±·-»ô ·²½®»¿-» ¬¸» ·²°«¬ º·´¬»® -»¬¬·²¹ ø°¿®¿³»¬»® Ò±ò ï÷ò
í÷ É¸»² Ý Ó
Ó»½¸¿²·½¿´ -´·° ±½½«®®»¼ ¾»¬©»»² ¬¸» -»®ª± ³±¬±® ¿²¼ ³¿½¸·²»ò øÝ¿«-» Þ÷
10 - 3
10. TROUBLESHOOTING
10.1.2 Speed control mode

ï Ð±©»® ±² ÔÛÜ ·- ²±¬ ´·¬ò Ò±¬ ·³°®±ª»¼ ·º ½±²²»½¬±®- ïò Ð±©»® -«°°´§ ª±´¬¿¹» º¿«´¬
¿®» ¼·-½±²²»½¬»¼ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±®- Ð±©»® -«°°´§ ±º ÝÒï ½¿¾´·²¹ ·-
ÝÒïß ¿²¼ ÝÒïÞ ¿®» -¸±®¬»¼ò
¼·-½±²²»½¬»¼ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±® ïò Ð±©»® -«°°´§ ±º »²½±¼»®
ÝÒî ·- ¼·-½±²²»½¬»¼ò ½¿¾´·²¹ ·- -¸±®¬»¼ò
îò Û²½±¼»® ·- º¿«´¬§ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±® Ð±©»® -«°°´§ ±º ÝÒí ½¿¾´·²¹ ·-
ÝÒí ·- ¼·-½±²²»½¬»¼ò -¸±®¬»¼ò
øÍÑÒ÷ò Í»®ª± ³±¬±® -¸¿º¬ ·- ïò Ý¸»½µ ¬¸» ¼·-°´¿§ ¬± -»» ·º ïò Í»®ª±ó±² øÍÑÒ÷ ·- ²±¬ ·²°«¬ò Í»½¬·±² êòê
²±¬ -»®ª±ó´±½µ»¼ ¬¸» -»®ª± ¿³°´·º·»® ·- øÉ·®·²¹ ³·-¬¿µ»÷
ø·- º®»»÷ò ®»¿¼§ ¬± ±°»®¿¬»ò îò îìÊÜÝ °±©»® ·- ²±¬
îò Ý¸»½µ ¬¸» »¨¬»®²¿´ ×ñÑ -«°°´·»¼ ¬± ÝÑÓò
-·¹²¿´ ·²¼·½¿¬·±² ¬± -»» ·º
¬¸» -»®ª±ó±² øÍÑÒ÷ ·- ÑÒò
í Í©·¬½¸ ±² º±®©¿®¼ Í»®ª± ³±¬±® ¼±»- Ý¿´´ ¬¸» -¬¿¬«- ¼·-°´¿§ ¿²¼ ß²¿´±¹ -°»»¼ ½±³³¿²¼ ·- ðÊò Í»½¬·±² êòî
®±¬¿¬·±² -¬¿®¬ øÍÌï÷ ²±¬ ®±¬¿¬»ò ½¸»½µ ¬¸» ·²°«¬ ª±´¬¿¹» ±º
±® ®»ª»®-» ®±¬¿¬·±² ¬¸» ¿²¿´±¹ -°»»¼ ½±³³¿²¼
-¬¿®¬ øÍÌî÷ò øÊÝ÷ò
Ý¿´´ ¬¸» »¨¬»®²¿´ ×ñÑ -·¹²¿´ ÔÍÐô ÔÍÒô ÍÌï ±® ÍÌî ·- ±ººò Í»½¬·±² êòê
¼·-°´¿§ ¿²¼ ½¸»½µ ¬¸»
ÑÒñÑÚÚ -¬¿¬«- ±º ¬¸» ·²°«¬
-·¹²¿´ò
Ý¸»½µ ¬¸» ·²¬»®²¿´ -°»»¼ Í»¬ ª¿´«» ·- ðò øï÷ô Í»½¬·±²
½±³³¿²¼- ï ¬± é ëòïòî
ø°¿®¿³»¬»®- Ò±ò è ¬± ïð éî
¬± éë÷ò
Ý¸»½µ ¬¸» ·²¬»®²¿´ ¬±®¯«» Ì±®¯«» ´·³·¬ ´»ª»´ ·- ¬±± ´±© ¿-
´·³·¬ ï ø°¿®¿³»¬»® Ò±ò îè÷ò ½±³°¿®»¼ ¬± ¬¸» ´±¿¼ ¬±®¯«»ò
É¸»² ¬¸» ¿²¿´±¹ ¬±®¯«» Ì±®¯«» ´·³·¬ ´»ª»´ ·- ¬±± ´±© ¿-
´·³·¬ øÌÔß÷ ·- «-¿¾´»ô ½¸»½µ ½±³°¿®»¼ ¬± ¬¸» ´±¿¼ ¬±®¯«»ò
¬¸» ·²°«¬ ª±´¬¿¹» ±² ¬¸»
-¬¿¬«- ¼·-°´¿§ò
ì Ù¿·² ¿¼¶«-¬³»²¬ Î±¬¿¬·±² ®·°°´»- Ó¿µ» ¹¿·² ¿¼¶«-¬³»²¬ ·² ¬¸» Ù¿·² ¿¼¶«-¬³»²¬ º¿«´¬ Ý¸¿°¬»® é
ø-°»»¼ º´«½¬«¿¬·±²-÷ º±´´±©·²¹ °®±½»¼«®»æ
¿®» ´¿®¹» ¿¬ ´±© ïò ×²½®»¿-» ¬¸» ¿«¬± ¬«²·²¹
-°»»¼ò ®»-°±²-» ´»ª»´ò
îò Î»°»¿¬ ¿½½»´»®¿¬·±² ¿²¼
¼»½»´»®¿¬·±² -»ª»®¿´
¬·³»- ¬± ½±³°´»¬» ¿«¬±
¬«²·²¹ò
Ô¿®¹» ´±¿¼ ·²»®¬·¿ ×º ¬¸» -»®ª± ³±¬±® ³¿§ ¾» Ù¿·² ¿¼¶«-¬³»²¬ º¿«´¬ Ý¸¿°¬»® é
³±³»²¬ ½¿«-»- ¬¸» ®«² ©·¬¸ -¿º»¬§ô ®»°»¿¬
-»®ª± ³±¬±® -¸¿º¬ ¬± ¿½½»´»®¿¬·±² ¿²¼
±-½·´´¿¬» -·¼» ¬± -·¼»ò ¼»½»´»®¿¬·±² -»ª»®¿´ ¬·³»- ¬±
½±³°´»¬» ¿«¬± ¬«²·²¹ò
10 - 4
10. TROUBLESHOOTING
10.1.3 Torque control mode

ï Ð±©»® ±² ÔÛÜ ·- ²±¬ ´·¬ò Ò±¬ ·³°®±ª»¼ ·º ½±²²»½¬±®- ïò Ð±©»® -«°°´§ ª±´¬¿¹» º¿«´¬
¿®» ¼·-½±²²»½¬»¼ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±®- Ð±©»® -«°°´§ ±º ÝÒï ½¿¾´·²¹ ·-
ÝÒïß ¿²¼ ÝÒïÞ ¿®» -¸±®¬»¼ò
¼·-½±²²»½¬»¼ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±® ïò Ð±©»® -«°°´§ ±º »²½±¼»®
ÝÒî ·- ¼·-½±²²»½¬»¼ò ½¿¾´·²¹ ·- -¸±®¬»¼ò
îò Û²½±¼»® ·- º¿«´¬§ò
×³°®±ª»¼ ©¸»² ½±²²»½¬±® Ð±©»® -«°°´§ ±º ÝÒí ½¿¾´·²¹ ·-
ÝÒí ·- ¼·-½±²²»½¬»¼ò -¸±®¬»¼ò
øÍÑÒ÷ò Í»®ª± ³±¬±® -¸¿º¬ ·- Ý¿´´ ¬¸» »¨¬»®²¿´ ×ñÑ -·¹²¿´ ïò Í»®ª±ó±² øÍÑÒ÷ ·- ²±¬ ·²°«¬ò Í»½¬·±² êòê
º®»»ò ¼·-°´¿§ ¿²¼ ½¸»½µ ¬¸» øÉ·®·²¹ ³·-¬¿µ»÷
ÑÒñÑÚÚ -¬¿¬«- ±º ¬¸» ·²°«¬ îò îìÊÜÝ °±©»® ·- ²±¬
-·¹²¿´ò -«°°´·»¼ ¬± ÝÑÓò
í Í©·¬½¸ ±² º±®©¿®¼ Í»®ª± ³±¬±® ¼±»- Ý¿´´ ¬¸» -¬¿¬«- ¼·-°´¿§ ¿²¼ ß²¿´±¹ ¬±®¯«» ½±³³¿²¼ ·- ðÊò Í»½¬·±² êòî
®±¬¿¬·±² -¬¿®¬ øÎÍï÷ ²±¬ ®±¬¿¬»ò ½¸»½µ ¬¸» ¿²¿´±¹ ¬±®¯«»
±® ®»ª»®-» ®±¬¿¬·±² ½±³³¿²¼ øÌÝ÷ò
-¬¿®¬ øÎÍî÷ò Ý¿´´ ¬¸» »¨¬»®²¿´ ×ñÑ -·¹²¿´ ÎÍï ±® ÎÍî ·- ±ººò Í»½¬·±² êòê
¼·-°´¿§ ¿²¼ ½¸»½µ ¬¸»
ÑÒñÑÚÚ -¬¿¬«- ±º ¬¸» ·²°«¬
-·¹²¿´ò
Ý¸»½µ ¬¸» ·²¬»®²¿´ -°»»¼ Í»¬ ª¿´«» ·- ðò øï÷ô
´·³·¬- ï ¬± é Í»½¬·±² ëòïòî
ø°¿®¿³»¬»®- Ò±ò è ¬± ïð éî
¬± éë÷ò
Ý¸»½µ ¬¸» ¿²¿´±¹ ¬±®¯«» Ì±®¯«» ½±³³¿²¼ ´»ª»´ ·- ¬±±
½±³³¿²¼ ³¿¨·³«³ ±«¬°«¬ ´±© ¿- ½±³°¿®»¼ ¬± ¬¸» ´±¿¼
ø°¿®¿³»¬»® Ò±ò îê÷ ª¿´«»ò ¬±®¯«»ò
Ý¸»½µ ¬¸» ·²¬»®²¿´ ¬±®¯«» Í»¬ ª¿´«» ·- ðò
´·³·¬ ï ø°¿®¿³»¬»® Ò±ò îè÷ò
10 - 5
10. TROUBLESHOOTING
10.2 When alarm or warning has occurred
POINT
Ý±²º·¹«®» «° ¿ ½·®½«·¬ ©¸·½¸ ©·´´ ¼»¬»½¬ ¬¸» ¬®±«¾´» øßÔÓ÷ ¿²¼ ¬«®² ±ºº ¬¸»
-»®ª±ó±² øÍÑÒ÷ ¿¬ ±½½«®®»²½» ±º ¿² ¿´¿®³ò
10.2.1 Alarms and warning list

É¸»² ¿ º¿«´¬ ±½½«®- ¼«®·²¹ ±°»®¿¬·±²ô ¬¸» ½±®®»-°±²¼·²¹ ¿´¿®³ ±® ©¿®²·²¹ ·- ¼·-°´¿§»¼ò ×º ¿²§ ¿´¿®³ ±®
©¿®²·²¹ ¸¿- ±½½«®®»¼ô ®»º»® ¬± Í»½¬·±² ïðòîòî ±® ïðòîòí ¿²¼ ¬¿µ» ¬¸» ¿°°®±°®·¿¬» ¿½¬·±²ò É¸»² ¿² ¿´¿®³
±½½«®-ô ßÔÓ ¬«®²- ±ººò
Í»¬ þ ïþ ·² °¿®¿³»¬»® Ò±ò ìç ¬± ±«¬°«¬ ¬¸» ¿´¿®³ ½±¼» ·² ÑÒñÑÚÚ -¬¿¬«- ¿½®±-- ¬¸» ½±®®»-°±²¼·²¹
°·² ¿²¼ ÍÙò É¿®²·²¹- øßÔòçî ¬± ßÔòÛß÷ ¸¿ª» ²± ¿´¿®³ ½±¼»-ò ß²§ ¿´¿®³ ½±¼» ·- ±«¬°«¬ ¿¬ ±½½«®®»²½» ±º
¬¸» ½±®®»-°±²¼·²¹ ¿´¿®³ò ×² ¬¸» ²±®³¿´ -¬¿¬«-ô ¬¸» -·¹²¿´- ¿ª¿·´¿¾´» ¾»º±®» ¿´¿®³ ½±¼» -»¬¬·²¹ øÝÒïÞóïçæ
ÆÍÐô ÝÒïßóïèæ ×ÒÐ ±® Íßô ÝÒïßóïçæ ÎÜ÷ ¿®» ±«¬°«¬ò
ßº¬»® ·¬- ½¿«-» ¸¿- ¾»»² ®»³±ª»¼ô ¬¸» ¿´¿®³ ½¿² ¾» ¼»¿½¬·ª¿¬»¼ ·² ¿²§ ±º ¬¸» ³»¬¸±¼- ³¿®µ»¼ ·² ¬¸»
¿´¿®³ ¼»¿½¬·ª¿¬·±² ½±´«³²ò
(Note 2) Alarm code Alarm deactivation
Press
"SET" on Alarm
Display CN1B-19 CN1A-18 CN1A-19 Name Power
current reset
pin pin pin OFF ON
alarm (RES)
screen.
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10 - 6
10. TROUBLESHOOTING
10.2.2 Remedies for alarms
When any alarm has occurred, eliminate its cause, ensure safety, then reset the
alarm, and restart operation. Otherwise, injury may occur.
CAUTION
If an absolute position erase (AL.25) occurred, always make home position setting
again. Otherwise, misoperation may occur.
POINT
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10 - 7
10. TROUBLESHOOTING

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10 - 8
10. TROUBLESHOOTING

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10 - 9
10. TROUBLESHOOTING

ßÔòíí Ñª»®ª±´¬¿¹» Ý±²ª»®¬»® ¾«- ïò Ô»¿¼ ±º ¾«·´¬ó·² ®»¹»²»®¿¬·ª» ¾®¿µ» ïò Ý¸¿²¹» ´»¿¼ò
ª±´¬¿¹» »¨½»»¼»¼ ®»-·-¬±® ±® ®»¹»²»®¿¬·ª» ¾®¿µ» îò Ý±²²»½¬ ½±®®»½¬´§ò
ìððÊÜÝò ±°¬·±² ·- ±°»² ±® ¼·-½±²²»½¬»¼ò
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íò ß·® ½±±´·²¹ º¿² ±º -»®ª± ¿³°´·º·»® ïò Û¨½¸¿²¹» ¬¸» ½±±´·²¹ º¿² ±® ¬¸» -»®ª±
-¬±°-ò ¿³°´·º·»®ò
îò Î»¼«½» ¿³¾·»²¬ ¬»³°»®¿¬«®»ò
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10 - 10
10. TROUBLESHOOTING

ßÔòëð Ñª»®´±¿¼ ï Ô±¿¼ »¨½»»¼»¼ ïò Í»®ª± ¿³°´·º·»® ·- «-»¼ ·² »¨½»-- ïò Î»¼«½» ´±¿¼ò
±ª»®´±¿¼ °®±¬»½¬·±² ±º ·¬- ½±²¬·²«±«- ±«¬°«¬ ½«®®»²¬ò îò Î»ª·»© ±°»®¿¬·±² °¿¬¬»®²ò
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-»®ª± ¿³°´·º·»®ò ±«¬°«¬ò
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íò Í»¬ ¿«¬± ¬«²·²¹ ¬± ÑÚÚ ¿²¼ ³¿µ» ¹¿·²
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ìò É®±²¹ ½±²²»½¬·±² ±º -»®ª± ³±¬±®ò Ý±²²»½¬ ½±®®»½¬´§ò
Í»®ª± ¿³°´·º·»®ù- ±«¬°«¬ ¬»®³·²¿´-
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ï- ±® ³±®» íò Í»®ª± -§-¬»³ ·- ·²-¬¿¾´» ¿²¼ ïò Î»°»¿¬ ¿½½»´»®¿¬·±²ñ¼»½»´»®¿¬·±² ¬±
Ü«®·²¹ ®±¬¿¬·±²æ ¸«²¬·²¹ò »¨»½«¬» ¿«¬± ¬«²·²¹ò
îòë- ±® ³±®» îò Ý¸¿²¹» ¿«¬± ¬«²·²¹ ®»-°±²-» -»¬¬·²¹ò
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ìò Û²½±¼»® º¿«´¬§ò Ý¸¿²¹» ¬¸» -»®ª± ³±¬±®ò
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10 - 11
10. TROUBLESHOOTING

ßÔòëî Û®®±® »¨½»--·ª» Ì¸» ¼®±±° °«´-» ïò ß½½»´»®¿¬·±²ñ¼»½»´»®¿¬·±² ¬·³» ×²½®»¿-» ¬¸» ¿½½»´»®¿¬·±²ñ¼»½»´»®¿¬·±²
ª¿´«» ±º ¬¸» ½±²-¬¿²¬ ·- ¬±± -³¿´´ò ¬·³» ½±²-¬¿²¬ò
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»¨½»»¼»¼ îòë Ò±òîè÷ ·- ¬±± -³¿´´ò
®±¬¿¬·±²-ò íò Ó±¬±® ½¿²²±¬ ¾» -¬¿®¬»¼ ¼«» ¬± ïò Î»ª·»© ¬¸» °±©»® -«°°´§ ½¿°¿½·¬§ò
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Ò±òê÷ ª¿´«» ·- -³¿´´ò °®±°»® ±°»®¿¬·±²ò
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Í»®ª± ¿³°´·º·»®ù- ±«¬°«¬ ¬»®³·²¿´-
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10 - 12
10. TROUBLESHOOTING
10.2.3 Remedies for warnings
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ßÔòçî Ñ°»² ¾¿¬¬»®§ ß¾-±´«¬» °±-·¬·±² ïò Þ¿¬¬»®§ ½¿¾´» ·- ±°»²ò Î»°¿·® ½¿¾´» ±® ½¸¿²¹»¼ò
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Manual Ibst2011041501

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Manual Ibst2011041501

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TBLU9.

Zhongshan OMS Industrial Co.,Ltd.

1 Zhongshan OMS industrial Co. Ltd

Drawing 1: Layout drawing

2 Zhongshan OMS industrial Co. Ltd

5. OPERATING PANEL AND INDICATOR

5.2. Three color indicator

3 Zhongshan OMS industrial Co. Ltd

6.1 Power supply

6.1.1 Turn power on

6.1.2 Turn power off

Drawing 2: machine name menu

6.2 Starting status

4 Zhongshan OMS industrial Co. Ltd

Drawing 3: starting status menu

6.3 Manual mode

Drawing 4: manual mode

5 Zhongshan OMS industrial Co. Ltd

6.3.2 Feed select

Drawing 5: feed select menu.

6 Zhongshan OMS industrial Co. Ltd

7 Zhongshan OMS industrial Co. Ltd

6.4 Parameter setup

Drawing 6. Parameter setup menu

Drawing 7. Bend and return pipe setting menu

8 Zhongshan OMS industrial Co. Ltd

6.4.2 Speed setup

Drawing 8: speed setup menu 1

Drawing 9: speed setup menu 2

9 Zhongshan OMS industrial Co. Ltd

Drawing 10.frame moving menu 1

Drawing11 .frame moving menu 2

10 Zhongshan OMS industrial Co. Ltd

Drawing12 .frame moving zero setup menu

6.4.4 Core pull oil injection

Drawing13 .core pull oil injection menu

6.4.5 Bend zero, pipe return zero

11 Zhongshan OMS industrial Co. Ltd

Drawing14 .bend zero menu

Drawing15 .pipe return zero menu

6.4.6 Program parameter setup

Drawing 16.program setting menu

12 Zhongshan OMS industrial Co. Ltd

6.4.7 Function setup

Drawing 17.function setting menu

6.4.8 Change die

Drawing 18.change die menu 1

13 Zhongshan OMS industrial Co. Ltd

Drawing 19.change die menu 2

6.4.9. Change exploratory die

Drawing 20. Change exploratory die menu

14 Zhongshan OMS industrial Co. Ltd

Drawing 21: auto mode menu

6.5.1 Output monitor

Drawing 22.output monitor menu

15 Zhongshan OMS industrial Co. Ltd

6.5.2 Feed control

Drawing 23.feed control menu

6.5.3 Simulate running

16 Zhongshan OMS industrial Co. Ltd

Drawing 24.simulate running menu

6.6 Auto running

6.7 Stop machine