TROUBLESHOOTING

This section is intended to help operators and maintenance people produce consistent and accurate frames.

When inaccuracies occur, the problem usually exists in one of three areas. Improper calibration, improper mechanical/pneumatic adjustment, or faulty TIME VALUES.

A miscalibration can cause both consistent and inconsistent inaccuracies between frames. Therefore, when there are problems with precision follow the calibration procedure. Calibrating the machine is a simple procedure but it is not always infallible. To recognize a mis-tuned machine, look for consistency between bent frames out of tolerance. If the same legs on different frames are equal, the problem can be corrected by changing one of the programmed calibration factors located in the SET-UP mode.

To recognize inaccuracies caused by a mechanical or pneumatic problem, look for inconsistencies between the same leg lengths on consecutive frames. Time values are placed in the machine at the factory. The operator to speed production can alter these. If an erroneous value is entered, accuracy and cycle times can be affected.

1) OFFSET IN NEED OF ADJUSTMENT: If the frames are consistently long or short on one leg, make a note of which leg it is and make adjustments in TUNE FRAME SIZE.

2) RADIUS FACTOR IN NEED OF ADJUSTMENT: If the second or third leg is not within tolerance, re-run the radius factor test making sure that the corners are at 90 degrees before measuring. If the test is run and there is no deviation from the target measurement, the problem is probably mechanical.

3) CLAMP DIE SLIPPAGE: If there are inconsistent inaccuracies, check the pneumatic pressures on the front of the machine. The Main Clamp should be 30 to 45 psi for aluminum, and 50 to 75 psi for steel. The main clamp is responsible for holding the material while the bend operation is taking place. If there is any slippage then inaccuracies will occur. Increase pressure if necessary.

IMPORTANT: The Drive Assemblies have an "idler" wheel and a "drive" wheel. The condition of these wheels is very important to the performance of the machine. The idler wheels are made out of a soft urethane material to provide cushioning against the spacer. Be sure to keep these wheels clean and free of debris. The drive wheels become worn after a long period of use. Even though the drive wheel looks good it may have to be replaced when slippage of the spacer material occurs.

4) DRIVE CLAMP PRESSURE IN NEED OF ADJUSTMENT: The drive clamps should be at 15 to 25 PSI for aluminum, 25 to 30 PSI for steel. The Drive Clamps are tied to a common regulator, and are responsible for holding the spacer material against the drive wheels securely. If there is excessive drag on the material, this pressure should be increased. If the pressure is set too high, the width of the spacer will be increased substantially (drive growth). This will cause distortion in the bends. Also if the clamp is advancing too rapidly, denting will occur (see the air pressure settings section). If all of the pressures are set properly, check the drive motor couplings located between the drive motors and the drive wheels behind the machine. Do not over tighten these, they can be broken.

5) WORN DRIVE WHEEL: The steel drive wheels, after a period of time, wear out. This is another cause of inaccuracy. Drive wheels can't be refurbished and must be replaced
when they wear out.

6) TIMING VALUE IN NEED OF ADJUSTMENT: The bending apparatus must actuate in the proper sequence to produce accurate frames. The order is Main Clamp, Split Die, and Wipe Clamp. If the Main Clamp doesn't grip the spacer before the other two devices come in contact with it, inaccuracies can occur. Correct this problem by altering the Main Clamp Delay in the Time Values section of the Set-up Mode.

7) "S" HOOK: Softer materials tend to get an "S" hook in them. An "S" hook is a distortion in the primary sealant shoulder caused by the 160-degree bend die. Some harder materials, such as steel, are unaffected. A 90-degree bend die is available, and is very effective in preventing "S" hook. However, this die cannot bend triangles or trapezoids. If one finds this hook offending then talk to TFB about special wipe shoes for different spacer profile eliminating the hook.

8) MATERIAL BUILD UP ON CHROME PLATES: This can affect both the accuracy and the quality of the bends. These deposits can be cleaned off easily with a razor blade.

9) MATERIAL IS HANGING UP ON THE SAW: Make certain that spacer fragments are not building up on the saw assembly. If this happens, the stepper motors can stall and miss steps, thus causing inaccuracies. There is a removable nylon insert in which the saw blade has cut a groove while advancing. The width of this groove should be equal to the width of the saw blade. If the groove is chipped or worn away, replace it.

10) SPACER IS SKEWING OUT OF PLANE: Be sure the material guide wheels are aligned properly. If the material guide is in line, check the wiper die to verify that it is adjusted to the center of the bend die. The spacer must be fed into the machine straight and cannot bind. Reduce the Drive Clamp Pressure if necessary.

11) BENT FRAME HAS AN "HOUR GLASS" SHAPE: Increase the Auto Ramp % located in the Motor Values section of the Set-up Mode.

12) MUNTIN OR GAS HOLES IMPROPERLY LOCATED. The F5 uses complicated algorithms to calculate the hole locations. If the machine is displaying "AUTOSAW ONLY" in the RUN MODE menu and all of the holes are O.K. except the first, jump down to the next paragraph. If all of the holes are improperly located, the DRILL->MAIN CLAMP offset is probably in need of adjustment. To verify that this offset is correct, first program in a frame that is 22" X 16" (550MM X 400MM)with 2 X 2 lights. Run the frame and verify that the leg lengths are correct. Measure the location of the first hole. If the first hole location is not correct, adjust the DRILL->MAIN CLAMP offset. The machine calculates from hole to hole. If the first hole is not located properly, the other holes will not be either. When a hole location is required less than 9.25 IN (235MM) from the leading edge, the "AUTO SAW ONLY" message will appear in the RUN MODE menu and the operator will no longer be able to start the cycle by placing the spacer against the main clamp. The holes are drilled into the material as it is advanced to the MAIN CLAMP after a small segment is cut from the leading edge of the spacer. If the drill seems to place the holes correctly when the "AUTOSAW ONLY" message is not present, but incorrectly when drilling while advancing, first check to see if the WHEEL TEST for motor #1 is correct. If the wheel is properly calibrated, then go into the OFFSETS menu (under set-up,-> calibrate) and check the M1 ADV. DIST. If this value is the SAW->MAIN CLAMP offset plus the actual width of the saw blade, then adjust the saw blade width offset. If adding to the offset makes the problem worse, then a negative value can be placed in the offset in order to adjust the first hole.

13) HOLES NOT CENTERED IN SPACER If the holes are not centered in a particular spacer width, first check to make sure there is no deflection as the drill is advanced to the
spacer. In the SET-UP menu under CALIBRATE, there is an option for PRINTER/DRILL CENTERING. Before changing the values, turn the machine off and on again to allow it to find its home position before finding the center of the spacer. If this doesn't work, adjust the steps for the appropriate spacer.