CALIBRATING THE F6 SPACER BENDER
Once the F6 has been setup, powered up and the die library has been established for at least one bend die for a given spacer, it is time to calibrate the machine. Although your F6 has been fully tested before it left the factory. You will have to calibrate it your self or with the help of one of our technicians. It is very important that for at least your maintenance people to fully under stand how to calibrate the F6 properly. This is a very simple procedure if done in the proper sequence. And the data that the F6 generates from this procedure can be recorded so that reloading the set up information can do future tuning.
Any time that a die is added to the die library or you reconfigure the timing and get a better running machine you should up date your set-up information. After calibrating your machine go to the file options menu to see more on how to record setup information.
Calibrating the machine for dimensional accuracy must be done in the following order:
1) Input the correct MOTOR VALUES.
2) Input the correct TIME VALUES.
3) Air pressures.
4) Select the desired spacer width.
5) Centering Multipliers.
6) Acquire and input calibration offsets.
7) Motor 2 test.
8) Calibrate the Drive wheels.
9) Calibrate the Radius Factor.
STEP 1: MOTOR VALUES
A) From the MASTER MENU select SET-UP, and then select MOTOR VALUES. Input the following
values depending on which type of bend arm your F6 spacer bender has:
| Electric bend arm motor values: |
Pneumatic bend arm motor values: |
| Motor 1 Ramp |
40 |
Motor 1 Ramp |
40 |
| Motor 1 Speed |
80 |
Motor 1 Speed |
80 |
| Motor 2 Ramp |
100 |
Motor 2 Ramp |
100 |
| Motor 2 Speed |
200 |
Motor 2 Speed |
200 |
| Bend Arm Ramp |
180 |
|
|
| Bend Arm Speed |
360 |
|
|
| Auto Ramp % |
25 |
|
|
| These values may have to be adjusted after calibration depending on the type of spacer material in order to achieve proper bends.
(Pneumatic bend arms do not have BEND ARM RAMP, BEND ARM SPEED or AUTO RAMP capabilities.) |
STEP 2: TIME VALUES
A) From the MASTER MENU select SET-UP, and then select TIME VALUES. Input the following values:
SAW UP DURATION .75
DELAY SAW ADVANCE .3
DRIVE CLAMP 1 TIME .2
DRIVE CLAMP 2 TIME .2
MAIN CLAMP TIME .2
SPLIT DIE TIME .0
WIPE CLAMP TIME .2
DELAY DRILL ADVANCE .1
(These values may have to be adjusted after calibration depending on the type of spacer material in order to achieve proper bends.)
STEP 3: AIR PRESSURES
MAKE CERTAIN THAT THERE IS NO WATER IN THE AIR TANK AND REGULATOR FILTER! THIS SHOULD BE CHECKED ON A REGULAR SCHEDULE! MAKE CERTAIN THAT THE AIR LINE FROM THE SOURCE TO THE F6 SPACER BENDER IS ?" DIAMETER.
SOURCE PRESSURE: 120 PSI (This pressure will not change.)
DRIVE CLAMP PRESSURE: 30 PSI
MAIN CLAMP PRESSURE: 5 PSI
WIPE CLAMP PRESSURE: 30 PSI
These pressures may have to be adjusted depending on the type of spacer material in order achieve proper bends and prevent slippage,denting, or scarring of the spacer material. Adjustments as low as 15 PSI may be needed for delicate aluminum or thin wall spacer. Higher pressures for heavier spacers, Lower pressures at the regulators also slows the air cylinders movement, additional time may have to be added to the time delays.
STEP 4: SELECT THE DESIRED DIE MARKER OR LABEL
From the MASTER MENU select PROGRAM, then select part number 1 by pressing 1 and then press E. Then select SPACER....#/#, then select the desired Die Marker or Label. Exit back to the MASTER MENU by pressing EXIT on the bottom of the part screen. The MASTER MENU should display the Die Marker you have selected. (ie... SPACER: ? IN) Remember this marker or label represents the proper data the machine requires for accurate frames. It must be matched to an individual die and spacer pair.
STEP 5: CENTERING MULTIPLIERS ( For drill & Printer options)
Centering multipliers are a number, representing a distance that the drill offset stepper motor advances for centering the drill holes on the width of the spacer.From the MASTER MENU select SET-UP, then select CALIBRATE, then select PRINTER/DRILL CENTERING. Coordinate your F5 centering multipliers to the following list:
| 3/16 |
188 |
| 1/4 |
250 |
| 5/16 |
313 |
| 3/8 |
375 |
| 7/16 |
438 |
| ? |
500 |
| 9/16 |
563 |
| 5/8 |
625 |
| 11/16 |
688 |
| 3/4 |
750 |
| 13/16 |
813 |
| 7/8 |
875 |
| 15/16 |
938 |
| 1 |
1000 |
| Centering multipliers may vary according to customer needs. |
STEP 6: ACQUIRE AND INPUT CALIBRATION OFFSETS
MAKE CERTAIN TO USE AN ACCURATE TAPE MEASURE TO ACQUIRE PRECISE MEASUREMENTS.
A) From the MASTER MENU select MANUAL, then select MAIN CLAMP. With the MAIN CLAMP energized, place the end of the spacer firmly against the MAIN CLAMP then energize DRIVE CLAMPS 1 and 2 by selecting DRIVE CLAMP 1 and DRIVE CLAMP 2.
B) AUTO SAW the spacer by selecting AUTO SAW.
C) If the machine has the drill option, select DRILL STOP, then select AUTO DRILL, a small muntin hole will be drilled. De-energize DRIVE CLAMP 1, DRIVE CLAMP 2, DRILL STOP and MAIN CLAMP, then remove the piece of spacer.
D) Measure the entire length of the spacer with an accurate tape measure and record thisfigure as the
SAW->MAIN CLAMP offset.
E) Measure the distance from the center of the muntin drill hole to the MAIN CLAMP end of the spacer and record this figure as the DRILL->MAIN CLAMP offset.
F) Use a new piece of spacer and insert it into the bender so that the right end of it extends at least 6 inches beyond the bend head. While still in MANUAL MODE, energize the MAIN CLAMP, SPLIT DIE, and WIPE CLAMP, then select BEND ARM and bend the spacer 90 degrees. With the bend arm up at 90 degrees, AUTO SAW the spacer. Return the bend arm by selecting BEND ARM again and then EXIT the MANUAL MODE. This will de-activate all of the clamps and return the screen to the MASTER MENU. Remove the spacer and compare the bend to carpenters' square to make certain that the bend is 90 degrees. Measure the distance from the cut end to the inside leg of the 90-degree corner. Record this figure as the SAW->BENT LEG offset. On the New 6020 CPU control when one changes this offset they will see that the die radius input loads to the touch screen. This is normal; the input has been altered. If the saw to main clamp offset has already accurately been set, the only other variable that can change for this offset is the radius of the bend die. For 90 degree tooling the value stored in Saw to Bent Leg should be equal to the radius of the die, ie .156 or .093. For 160 degree tooling increasing the radius will compensate for the hook nature of 160-degree tooling. If one finds this hook offending then talk to TFB about special wipe shoes for different spacer profile eliminating the hook.
G) Measure the saw blade width and record this dimension as the SAW BLADE WIDTH offset.
H) From the MASTER MENU select SET-UP, then select CALIBRATE, then select STEP 1: OFFSETS. Input the previously recorded Offsets.
I) The M1 ADV. DIST. is acquired by adding the SAW->MAIN CLAMP offset and the SAW BLADE WIDTH. The machine looks at this dimension in order to automatically advance a piece of spacer from the saw to the main clamp after a cut is made.All other offsets should be set to zero EXIT back to the MASTER MENU.
STEP 7: MOTOR 2 TEST
A) From the MASTER MENU select SET-UP, and then select MOTOR 2 TEST. Follow the instructions displayed.
STEP 8: DRIVE WHEEL CALIBRATION
A) From the MASTER MENU select SET-UP, then select CALIBRATE, then select [] STEP 2: DRIVE WHEEL. The screen will display "**CALIBRATE WHEEL 2 FOR ## SPACER**. Follow the instructions displayed. It is easier to make the measurement from the MAIN CLAMP to the end of the spacer if you remove the bend die. When DRIVE WHEEL 2 is calibrated, reselect STEP 2: DRIVE WHEEL, then select "CALIBRATE OTHER MOTOR". The screen will display "CALIBRATE WHEEL 1". Follow the instructions displayed.Please note that the wheel calibration is a very important aspect of machine calibration. This test insures that linear movement
is accurate.
STEP 9: RADIUS FACTOR
Reinsert the bend die.While still in the CALIBRATE menu, select STEP 3: RADIUS FACTOR, follow the screen instructions displayed.
After this calibration, EXIT back to the MASTER MENU.
The F5 SPACER BENDER is now completely calibrated.
TEST FRAME:
Program and Bend a RECT.(3 BENDS) frame with approx. dimensions of 12" x 24" with no sight line to keep things simple. If the machine has a drill, program it for 2X2 lights with centered holes. Check TUNE FRAME SIZE to ensure that the leg offsets are set to zero. Bend and measure the frame. If the dimensions are not accurate, consult the troubleshooting guide at the end of this manual. You should now be able to bend any size of frame without further adjustments to the software. If a certain leg is in need of adjustment, it is possible to do this by accessing the TUNE FRAMESIZE menu from either the MASTER MENU or RUN MODE menu. To change a leg dimension, place a positive or negative value in the leg's offset. It should be noted that changing a leg dimension drastically could adversely affect the tolerance of the drill. Because of changing spacer materials properties, you will need to periodically calibrate the DRIVE WHEELS and RADIUS FACTOR for each new spacer width.
REMAINING CALIBRATION OFFSETS
Four of the offsets have already been defined in the calibration section. This section defines
the remaining offsets.
J BENDS 1ST LEG offset:
You may dictate how long the first leg is on a J bend configuration with this offset. A very typical value is 4". (Range is 0-10")
4 BENDS 1ST LEG offset:
You may dictate how long the first leg is on a 4 bend configuration with this offset. A very typical value is 4". (Range is 0-10")
KEEPER CENTERS offset:
This is the center to center dimension for double prong muntin bar keepers. If your keepers have ?" centers, then make certain this offset is ?". If your keepers only have one prong, then make certain this offset is set to 0.(Range is 0-1")
MAIN CLAMP: 30-45 PSI for aluminum....50-75 PSI for steel
DRIVE CLAMPS: 15-25 PSI for aluminum....25-30 PSI for steel
WIPE CLAMP: 15-20 PSI for aluminum....20-30 PSI for steel
Note: If the drive clamp pressure is changed, then the DRIVE WHEELS and RADIUS FACTOR will have to be recalebrated.The MAIN CLAMP pressure should be set to a point where the spacer does not slip when the bending operation takes place. However, setting the pressure too high will cause the MAIN CLAMP to crush the spacer material. The DRIVE CLAMP Pressure should be set to a point where it doesn't dent the spacer, but high enough to attain accuracy.
The WIPE CLAMP Pressure should be lowered if an 'S' hook is present or raised if the inner portion of the bend is distorted.There is a flow control valve assigned to each of the cylinders except for the SPLIT DIE and the DRILL STOP cylinders. These valves regulate the speed at which the cylinders advance and/or retract. As the mechanical parts of the machine 'loosen' up over time, it may be necessary to increase or decrease the corresponding cylinder's speed. This will be evident if there is denting or crushing regardless of the pressure setting. The flow controls are located on the input and or exhaust aperture of the cylinders.
