FP-1000/1400 Fin Line: Global Experience

Global Experience
...Local Solutions
FP-1000/1400 Fin Line Original Instructions

General Instructions
FP1000
FP1400
#403631 (07/2021)
+ 269 651 9393 | 405 W South Street, Sturgis, MI 49091 USA | www.burroak.com
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Global Experience
...Local Solutions Table of Contents
Safety .............................................................................................. 1
Explanation of Precaution Notices ......................................................... 1
Prior to Unloading the Machine............................................................... 2
Training ...................................................................................................... 2
General Precautions ................................................................................. 2
Risk Reduction Measures ........................................................................ 3
Intrinsically Safe Design ................................................. 3
Safeguarding .................................................................... 3
Indicators .......................................................................... 3
Recommended Personal Protective Equipment (PPE) ....................... 10
Eye Protection ................................................................ 10
Hearing Protection ......................................................... 10
Hand Protection ............................................................. 10
Other Personal Protective Equipment ......................... 10
Lock Out / Tag Out .................................................................................. 10
Safety Features ....................................................................................... 10
Guarding ......................................................................... 10
Daily Test Procedure for Light Curtains/Scanner ........11
Electrical ..........................................................................11
Hydraulic and Pneumatic ...............................................11
Hydraulic and Pneumatic - High Pressure ...................11
Overview of Machinery ............................................................... 13

Intended Use / Purpose .......................................................................... 13
Machine Capabilities ..................................................... 13
Materials ......................................................................... 13
Machine Sequence ................................................................................. 14
Electrical and Pneumatic Systems ....................................................... 16
Tooling Overview .................................................................................... 16
Installation & Setup ..................................................................... 17

Transport & Handling ............................................................................. 17
Lifting and Moving Machine Components ........................................... 17
Recommended Foundation ................................................................... 20
Preparation ..................................................................... 20
Vibration Mounts ............................................................ 20
Operating Environment .......................................................................... 20
Ambient Temperatures .................................................. 20
Recommended Lubrication ................................................................... 20
Filling/Re-filling Oils/Fluids........................................... 20
Setup of Machine .................................................................................... 21
Connecting to Power Supply ................................................................. 23
Tooling Changes/Installation ................................................................. 23
Fin Die Removal Preparation ........................................ 23
Fin Die Removal ............................................................. 24
Fin Die Installation ......................................................... 25
FP1000/1400 Bolster ...................................................... 28
Machine Operation ...................................................................... 29

Training .................................................................................................... 29
Die Safety Blocks ........................................................... 29
Startup Procedure .................................................................................. 30
Loading Material ..................................................................................... 33
Operation Procedures/Cycles ............................................................... 35
Adjustments & Settings ......................................................................... 42
Shut Down Procedures .......................................................................... 49
Control Reference ....................................................................... 51

Machine Operations ............................................................................... 51
Main Screen............................................................................................. 52
Part Definition Screen ................................................... 55
Warnings ......................................................................... 56
Inch Screen ............................................................................................. 57
Continuous Run Screen ......................................................................... 58
Fin Chart Screen ..................................................................................... 59
Timing Chart Screen............................................................................... 62
Troubleshooting Timing Items .............................................................. 62
Draw Chart............................................................................................... 64
Production Data Screen ......................................................................... 65
Die Setup Screen .................................................................................... 66
Draw Settings ................................................................. 66
Setup Screen ........................................................................................... 68
Inputs Screen(s)...................................................................................... 68
Outputs Screen(s)................................................................................... 69
Timing Log Screen ................................................................................. 70
PLC Status............................................................................................... 70
Servo Status Screen ...................................................... 71
VFD Drive Faults / Resets ...................................................................... 72
Profibus Diagnostic Screen ................................................................... 72
Line Setup & Error Overrides Screen ................................................... 74
Machine Options (Recipe Based) Screen .................... 75
Die Data & Options Screen .................................................................... 76
Die Function Screen ...................................................... 77
Die Adjust Screen .......................................................... 78
Lube Data & Options Screen ................................................................. 79
Fin Line Data & Options Screen ............................................................ 80
Stacker Data Screen - Rotary........................................ 82
Stacker Data Screen - Elevator Cart Stacker............... 83
Password Configuration Screen ........................................................... 85
Authorization Configuration Screen ..................................................... 85
Calibrate Screen ..................................................................................... 86
Language Selection Screen ................................................................... 87
Exit Application ....................................................................................... 87
Message Log Screen .............................................................................. 87
Resetting the PLC Retained Data Memory ........................................... 88
Maintenance Password .......................................................................... 88
General Maintenance .................................................................. 89

Ordering Spare Parts.............................................................................. 89
Lubrication .............................................................................................. 89
Press Lubrication System ............................................. 90
Locating Blockage in the Lubrication System ............ 90
Grease the Feed Pull Pin ............................................... 90
Accumulator Charging ........................................................................... 91
Preventative Maintenance...................................................................... 93
Every Shift Change ........................................................ 93
Daily ................................................................................ 93
Weekly............................................................................. 93
Monthly ........................................................................... 94
Quarterly ......................................................................... 95
Preventative Maintenance Table................................... 95
Scrap Conveyor Chain Drive Tension and Care .................................. 97
Toledo PWi Tonnage Monitor Configuration Notes for 1000 and 1400
Fin Presses.............................................................................................. 98
Troubleshooting ........................................................................ 101

General Machine / Station Troubleshooting....................................... 101
Uncoiler......................................................................... 101
Fin Press ....................................................................... 103
Suction Unit .................................................................. 104
Stacker .......................................................................... 105
Conveyor ...................................................................... 106
Clutch ............................................................................ 107
Produced Fins .............................................................. 107
Appendices ................................................................................ 109

Appendix A (Uncoiler Spindles) .......................................................... 109
Appendix B (Machine Status Message Descriptions) ....................... 117
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Global Experience
...Local Solutions Safety
Explanation of Precaution Notices
There are five levels of notices in this manual. These precautions range from providing convenience to
avoiding disaster. Each level has a signal word that corresponds with its importance.
NOTICE IMPORTANT
These are helpful hints intended to assist the This information is more significant than that of
operator in avoiding common obstacles. They also a NOTICE. It informs the operator of possible
provide convenient procedures for performing situations that could damage the machine or its
certain tasks. various components.
CAUTION
Beginning with this level, the precautions address the safety of the operator. This notice signals a potential
hazard which may cause minor or moderate injury to the operator, such as a bruise, laceration or broken
bone. This notice will specify the nature of the hazard and give instructions on how to avoid or eliminate it.
WARNING
This notice is meant to warn against the potential hazard which may cause serious injury to the operator.
These injuries might result in the loss of a finger, hand or limb, or could possibly result in death. This notice
will specify the nature of the hazard and give instructions on how to avoid or eliminate it.
DANGER
This notice draws attention to an existing hazard or danger that will result in a serious injury or death. This
notice will specify the nature of the hazard and give instructions on how to avoid or eliminate it.
Prior to Unloading the Machine
WARNING
Hazards can and will arise that may cause severe injury or death. Do not work on the machinery without
training. Read the entire safety section prior to performing any tasks.
Training
WARNING
This information contains step-by-step instructions. It is extremely important that the applicable instructions
are read and understood prior to executing each procedure. Pay close attention to, and follow, all
precautions. Ignoring these notices could potentially lead to severe injury or death.
General Precautions
DANGER
SHOCK HAZARD. Do not touch the main electrical connection. Follow proper lock out procedures before
working around the main power lines or fuses.
DANGER
SHOCK HAZARD. Do not reach hands into the electrical enclosure when powered. Lock out the power at
the disconnect when changing any electrical components.
DANGER
PRESSURE HAZARD. STORED ENERGY. Do not damage lines and loosen connections. Lock out the power
at the disconnect and relieve the stored energy when changing or maintaining any pneumatic component.
WARNING
CRUSHING HAZARD. Do not work on the machine when powered. Shut down the machine before making
adjustments or performing maintenance.
WARNING
CRUSHING OR PINCHING HAZARD. Do not operate the machine with any guards opened or removed.
Keep guards on and safety interlocks functional at all times.
WARNING
CRUSHING OR PINCHING HAZARD. Do not crawl on or under the machine or reach through guarding.
Lock out the machine before attempting access of any kind.
CAUTION
ENTANGLEMENT HAZARD. Do not place any part of the body near moving parts while the machine is in
operation. Maintain a safe distance from the machine at all times.
2 Safety | 04/2019
Risk Reduction Measures
Intrinsically Safe Design
The following safety measures were incorporated into the design of this machine in order to reduce, or
eliminate, various risks:
RISK DESIGN MEASURE

Unintended startup due to operator error; high The controller requires both cycle start and master
pressure. start buttons be pressed before the machine will
cycle.
Unintended motion due to air pressure accumulation An air exhaust valve provides complete exhaustion
of air from the pneumatic circuit prior to machine
maintenance.
Machine damage from potential malfunctions Emergency stop push button is positioned on
operator station and control panel.
Safeguarding
The following measures safeguard the operator against possible injuries with existing risks:
RISK SAFEGUARD MEASURE

Pinching or crushing hazard from moving parts during Guards have been attached to surrounding moving
setup parts.
Indicators
In some cases, where completely eliminating a hazard through safeguarding is impractical, indicators
(warning signs, signals, etc.) are used. These indicators warn against injuries due to the following
residual risks:
RISK INDICATORS
Entanglement hazards at certain areas Warning signs have been placed in critical areas.
Electrical shock due to drilling into frame members Warning signs have been placed on each frame
containing wires member containing wires.
Crushing hazard present from above. Keep hands and other body parts out of the
machine.
Crushing hazard present from below. Keep hands and other body parts out of the
machine.
Safety | 04/2019 3
Crushing hazard present from sides. Keep hands and other body parts out of the
machine.
Crushing hazard present. Keep feet clear of machine.
Crushing hazard from above. The environment may be conducive to injury due to
crushing from above. Stay out of this area.
Magnetic field.
Crushing hazard from the side. The environment may be conducive to injury due to
crushing from the side. Stay out of this area.
Crush/Pinch Point hazard present. Keep hands and other body parts out of the
machine.
Moving chain may cut and crush. Keep hands free and clear of this area.
4 Safety | 04/2019
Burn Hazard. Do not touch. Allow to cool before servicing.
HOT. Surface and/or internal temperatures may be hot enough to burn or injure
you. Keep hands and other body parts out of the machine.
Objects may protrude from this machine at a rapid rate. You may be injured if
standing in front of this machine during operation.
Table may be slippery with water or oil.
Tipping Hazard; high center of gravity.
Equipment starts automatically.
This machine contains sharp equipment that may puncture your skin. Keep hands
and other body parts out of this area.
Safety | 04/2019 5
Moving Material. Hand entanglement possible. Keep hands and other body parts
clear of this area.
Entanglement hazard. Keep hands and other body parts clear of this area.
Laser present. Avoid exposure to laser beam.
Hydraulic or pneumatic explosion possible.
System Under Pressure. Lock out and release pressure before performing any
maintenance, service, or repair.
Fire or gas explosion possible. Be aware of the smell of gas.
Fire hazard / flammable.
Arc Flash Hazard. High energy electrical discharge can occur between two
electrically conductive materials. Follow requirements in NFPA 70E for safe work
practices and appropriate Personal Protection Equipment. Failure to comply may
result in death or injury.
6 Safety | 04/2019
Hazardous Voltage. Contact will cause electric shock or burn.
Static charge present.
Only authorized personnel may service this equipment.
No maintenance while machine is in use.
Do NOT weld.
Do not open until saw stops rotating.
Do NOT operate with guard removed.
Do not operate with the guards removed.
Safety | 04/2019 7
Do not operate with personnel inside the guarded area.
Do not service with the flywheel in motion.
Moving parts will cut. Do not open while saw is rotating.
NOT a step.
No Pacemakers. Magnetic fields may interfere with certain pacemakers.
Stay Clear of machinery that moves automatically.
Lock out power before inspection or service. Always follow your employer’s lock
out procedure.
Apply locking device here.
8 Safety | 04/2019
Follow proper lock out / tag out procedure.
Verify that Emergency Stop and guard switches are functioning properly at the
start of each shift.
Read and understand the instructions.
Verify the Emergency Stop button is functioning properly.
Verify the light curtain is functioning properly.
Verify the interlocking guards are functioning properly.
The equipment is operated by non-hazardous electric energy.
Hearing protection required.
Safety | 04/2019 9
Recommended Personal Protective Equipment (PPE)
Eye Protection
Wear safety glasses, with side shields, while operating on or around this machine. Standard eye
protection is recommended.
Hearing Protection
The sound levels of these machines vary widely with size and tools used. Use ear protection and sound
enclosures to adequately protect operators and other personnel within reasonable proximity to the
machine.
Hand Protection
Hand protection is not necessary to guard against serious injury. Use discretion when determining
whether the use of gloves is necessary.
Other Personal Protective Equipment
The environment in which the machine is used should be the primary factor when determining
what personal protective equipment is necessary for those working around the machine. Though
this machine does not pose any specific danger related to the following, other personal protective
equipment to consider might include steel-toe shoes, hard hats, etc., depending on the environment.
Lock Out / Tag Out

Burr Oak Tool, Inc. reminds all machine operators that each facility has different lock out / tag out procedures.
WARNING
ARCING HAZARD. Always turn the machine off before disconnecting the energy sources. There is a
possibility of arcing and explosion if the machine is disconnected while under load.
Below is an example of such procedure.
. ANNOUNCE SHUTDOWN. Be sure that all workers in the area, especially those working on the
machine, are aware of the shutdown.
. TURN OFF EQUIPMENT. Allow the machine to finish the normal cycle, then turn off the equipment
by pressing the master stop push button.
. DISCONNECT ENERGY SOURCES. Turn off the power at the disconnect and the breaker. Turn off,
or disconnect, the air supply.
. TEST FOR ISOLATION. After the equipment is turned off and isolated from the power source, test
the master start push button to see if the power is off. Also check the pneumatic and hydraulic
pressure gauges.
. RELEASE STORED ENERGY. After all energy has been cut from the equipment, release the stored
energy and bring the equipment to “zero mechanical state” and “zero stored pressure”. It may be
necessary to override valves to release pressure.
. LOCK OUT ENERGY SOURCES. Lock out the energy sources to ensure that energy won’t be
restored while working on the equipment. Place a lock on the disconnect at the electrical enclosure.
Place a lock on the air dump valve, or provide other means to lock, and prevent reenergizing the air
system. Ideally the locks will have a single key that will be in the operator’s possession.
Safety Features
Guarding
Special provisions have been made to guard all points where there are dangerous moving parts. Fixed
guards exist around all accessible moving parts where there is no foreseeable reason for regular
operator intervention.
10 Safety | 04/2019
CE-approved safety switches have been provided on all moveable guards. Opening the guards, under
any condition, while the machine is operating will cause the machine to go into Emergency Stop Mode.
If the machine is already stopped, then it cannot be started until all guard doors are closed and all light
curtains are clear.
WARNING
Never remove or disable interlocking guard switches! Serious injury may result.
Daily Test Procedure for Light Curtains/Scanner

A qualified person must follow this procedure at the beginning of each shift, and after any maintenance.
. Verify that the machine is thoroughly guarded with a combination of properly installed light curtains/
scanner and mechanical guards.
. Verify that the light curtain/scanner distance is at least as great as the calculated minimum safe
distance from the point of hazard.
. Inspect the light curtain/scanner, machine, cables, and wiring for damage. If damage is found, lock
out the machine and report to a supervisor.
. Test the entire sensing field with the provided test wand or other properly-sized test object. Observe
the indicator lights for appropriate response.
. With the machine running, verify that all dangerous motion stops immediately by interrupting the
sensing field with the test wand.
WARNING
If the safety devices or the machine fails any of these tests, DO NOT RUN THE MACHINE. Serious injury
could result. Immediately tag or lock out the machine, then notify your supervisor.
Electrical
The primary and control voltages are shown on a tag on the machine electrical enclosure. These
voltages should be checked and verified.
All electrical standards and procedures requested by the customer or specified by CE requirements
have been followed in the construction of this machine. CE-approved limit switches are provided on
each moveable guard door.
If an E-stop is necessary to meet CE requirements, a mushroom head emergency stop push button
has been provided in strategic positions.
Hydraulic and Pneumatic

All pressure settings for pneumatic and hydraulic components must be properly set. Tags have been
placed near all pressure regulators with the recommended pressure settings for each component.
Both the pneumatic and hydraulic systems have automatic pressure relief valves. When the machine is
in Control Stop or Emergency Stop Mode, the pressure in these lines is released.
Hydraulic and Pneumatic - High Pressure

All pressure settings for pneumatic and hydraulic components must be properly set. Tags have been
placed near all pressure regulators, or are indicated on control screen with the recommended pressure
settings for each component.
Both the pneumatic and hydraulic systems have automatic pressure relief valves. When the machine
is in Control Stop or Emergency Stop Mode, the pressure in the line is released after the main valve
pack.
Safety | 04/2019 11
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Global Experience
...Local Solutions Overview of Machinery
Intended Use / Purpose
The purpose of this Fin Line is to produce precision metal fins to be used in heat transfer for heating and air
conditioning applications.
Machine Capabilities
Three basic processes are involved in the Fin Line operation: uncoiling the material to feed into the line,
stamping and cutting the material into the required pattern using a progressive die, and stacking the completed
material in preparation for the next operation.
Materials
The machine is capable of running a variety of materials used in the production of heat exchanger fins. The
specific limits for material strength, thickness etc. will be determined on a case-by-case basis at Burr Oak Tool.
Machine Sequence
The following are descriptions of the machine sequence.
Fin Stock Uncoiler - 4” Diameter Spindle

The fin stock uncoiler is located at the back of the fin press. It supplies a loop of fin stock to the press. Sensors
in the uncoiler detect the status of the stock. It will stop the press when the fin stock loop is too tight, or the fin
stock supply is exhausted.
Lubrication Tank Stabilizer

The frame design of the swing-away lubricator system requires additional parts for stabilization. The press
produces vibration when in operation, causing the swing-away frame to bounce during production. A level
clamp mechanism prevents the lube tank frame from bouncing on the back of the press. This clamp is only
utilized on the swing-away system. It is usually mounted on the Die Take Out frame opposite the pivot side,
toward the end of the frame. If a Die Take Out table is not present, the lever clamp is mounted directly on the
lube tank frame, with an extended shaft, so that it can support the tank from the floor.
Disengage this clamp before rotating the frame out of position.
Servo Feed Axes

Feed Axis
The Feed Axis is a physical torque motor axis that turns cammed motion into oscillatory linear motion of
a stock feed bar. It uses a rotary-to-linear linkage, similar to that of a train wheel, but in reverse.
Virtual Axis
The feed axis follows the virtual axis with a cammed relationship. Currently, when operating the press,
one (1) of six (6) cams may be selected on-the-fly.
The transition between cams occurs at a common forward feed point of the stock feed bar. This
transition point is also the zero-home position of the feed axis and the virtual axis. The PLC sends the
request to transition to a different cam over Profibus. The signal arrives in the D425 controller, about
90 degrees before the desired transition point. This gives the code time to setup and prepare for the
transition.
External Encoder
The External Encoder is attached to the press, and acts as the master. The virtual axis is geared to the
external encoder 1:1. The gearing relationship is released to allow manual jogging of the feed bar by
jogging the still cammed virtual axis.
Fin Stock Lacer

The Fin Stock Lacer is designed to lace the fin stock into the die automatically. This makes lacing safer, more
convenient, and usually less time consuming, than lacing fin stock through the die by hand.
The lacer feeds stock through the die at the set progression established by the length of the gauge stop. Once
the fin stock has been laced in the die, the feed station begins pulling the stock through the die. The stock lacer
is then de-energized, until needed.
The stock guide keeps the stock straight and consistent with every stroke of the feed station.
WARNING
CUTTING HAZARD. Use caution when handling fin stock. Edges are sharp and will cut if handled improperly. The
use of tight fitting gloves is recommended. Avoid loose gloves because they can create an entanglement hazard.
14 403631
Fin Stock Lubrication
E-Lube
The E-Lube is designed to control the amount of lubricant
delivered to both sides of the fin stock. Specialized felt
application pads remain in constant contact with the fin stock,
using pneumatic cylinders.
The E-Lube is capable of applying lubricant coatings as low

as 25 mg/ft2 (269 mg/m2) to both sides of the fin stock for
protection of the internal Die surfaces, vital forming, and
expensive cutting edges.
In addition to this protection, the E-Lube reduces lubricant waste. In most cases, only one input will be
used to monitor the strokes of the press and control the lubricant output. Burr Oak Tool Inc. provides
several widths (example: 36” and 45” wide) of lubricators that cover the wide range of Fin Press sizes.
Dip Tank
The Dip Tank is an oil bath system that utilizes two (2) rollers to control the film thickness when the Die
leaves the dip tank.
Fin Die
The die creates the desired fin shape progressively, building
each fin feature over several forming stations. As the fin
stock progresses through the die, it is sheared, lengthwise, to
form individual fin rows.
The press provides the necessary force to form the stock into
fins.
The feed linkage allows the action of the press to pull the fin
stock through the die.
Hand Crank Die Take Out (DTO) Table

This unit is comprised of a rectangular tubing swing-away framework that supports the stock lacer and/or
guide, stock lubricator, a die take out cart (including track installation into press bolster), a die support frame,
and a hand crank operated method for moving the die cart in and out of the press.
Upper Suction Unit

The upper suction unit has three basic sections. The UPPER portion of the suction unit consists of the motor,
fan housing, fan, and exhaust cone. The MIDDLE section is the suction tower, with air-cylinder-controlled
doors. The LOWER section consists of the suction box, and the suction sheet.
403631 15
Stacker
As the formed fin strips progress out of the die, they are cut into individual fins. Then, they are dropped on the
stacker rods, where they neatly align into stacks of a defined number of fins. When the required number of fins
have been produced, the press stops automatically. The stacker forwards the fins to the lacing machine or to
an unload position. When the stacker mechanism returns to its stacking position, the press resumes regular
operation.
WARNING
PIERCING HAZARD. Use extreme caution when working on the Suction Unit and around the Stacker Unit.
Stacker rods are sharp and can cause severe injury. Always stay clear of the Stacker Unit when in operation,
and use caution when making any adjustments to any part of the line where one could fall onto the Stacker
Rods.
Electrical and Pneumatic Systems

NOTICE
Ensure that both electrical and air connections to the crown are flexible to allow for crown vertical movement.
Electrical Requirements
All electrical equipment is set for dual voltage operation, but is shipped with the voltage consistent with your
plant. Refer to the wiring diagram, located in the electrical control panel and/or the Parts Manual.
Pneumatic Requirements
The minimum air requirements are 200 SCFM at 80 PSI.
Tooling Overview
Please refer to the Fin Die manual for Tooling information.
16 403631
Global Experience
...Local Solutions Installation & Setup
WARNING
CRUSHING HAZARD. Never place any part of the body under the Press or associated equipment during
setup.
WARNING
CRUSHING HAZARD. Be sure that the apparatus for lifting the Press is capable of safely lifting a minimum of
30,000 lbs.
WARNING
CRUSHING HAZARD. Always stay well away from the machinery when lifting or lowering it into position.
Announce to all in close proximity when you intend to initiate any equipment movement.
WARNING
CRUSHING HAZARD. As tension is applied, keep hands away from any cables used for lifting.
WARNING
Machine is heavy and has the possibility of becoming unbalanced, if it is not picked up properly. Only
qualified, trained personnel should be involved in the lifting, installation, and/or removal of the machinery or
any of its components.
CAUTION
The use of gloves is highly recommended for equipment setup.
Transport & Handling

Each Oak press is carefully prepared for shipment to protect it during transit. In addition, this enables the user
to set up the press with minimum reassembly. When the press arrives it should be thoroughly cleaned. Foreign
matter may have accumulated on the protective coating that has been applied to the hardened gib ways of the
slide. Be sure to remove all contaminates from these areas.
Lifting and Moving Machine Components

The press may be delivered in an upright position on a lowboy trailer in the Continental North Americas only.
The press may be removed from the trailer with a forklift or an overhead crane. The lifting apparatus must be
capable of lifting at least 30,000 lbs.
See the Oak Press Solutions, Inc. Service Manual for more information about moving and installing the
Press.
Swing-Away Lubrication Support
To move the Swing-Away to its proper location for Setup, follow the procedure(s) below.
Hoist the Swing-Away
1. One separating bar and two straps are needed to move the swing-away correctly.
2. Cradle one strap at the lacer section of the swing-away.
3. Cradle another strap at the roller section of the swing-away.
4. Hook one strap to each side of the separating bar. Lift, and move, the Swing-Away with caution.
Move the Swing-Away with a ForkLift

1. Approach the machine straight on from the lacer or roller side, and slide the forks under the Swing-
Away.
2. Disconnect the pull-pin located on the press post.
3. Remove the four bracket bolts that connect he swing-away to the press.
4. Carefully lift, and move, the Swing-Away.
Conveyor (if applicable)

To move the Conveyor to its proper location for Setup, follow the procedure(s) below.
Hoist the Conveyor

Two straps are needed to move the conveyor correctly.
1. Cradle the conveyor at the top, where the vertical bar connects to the conveyor curve.
2. Lasso the bottom of the conveyor body.
3. Lift the conveyor, and move it with caution.
Move the Conveyor with a ForkLift

One board, one c-clamp, and one strap are needed to move the conveyor correctly.
1. Slide one fork under the cross member.
2. Place a board between the fork and the conveyor body. Clamp them together with a c-clamp.
3. Wrap one end of a strap around the remaining fork.
4. Loop the other end of the strap around the bottom of the conveyor body.
5. Lift, and move the conveyor with caution.
Uncoiler
Refer to the floor plan layout for the minimum required distance between the uncoilder and the press.
Hoist the Uncoiler
1. Center the pinch roll with the center of the press.
2. Four straps are needed to move the uncoiler correctly.
3. Lasso one strap around the bottom of each of the four legs.
4. Slide the strap up until it will not move any further.
5. Lift the uncoiler, and move it with caution.
18 403631
Move the Uncoiler with a Fork Lift
1. Slide the forklift forks into the two (2) tubes underneath the Uncoiler.
2. Be sure the forks stick out at least two inches on the other side of the uncoiler.
3. Lift, and move the uncoiler with caution.
Suction Unit
To move the Suction Unit to its proper location, follow the procedure(s) below.
Hoist the Suction Unit

1. Loop one strap through each end of the hooks on top of the mounting plate.
2. Lift, and move the Suction Unit with caution.
3. The Suction Unit may be set in its location, or moved to a skid larger than the suction unit, so the
unit can easily be moved again, if needed.
Move the Suction Unit with a Fork Lift

1. A skid, larger in size than the suction unit, is needed to move the suction unit correctly.
2. Use a fork lift to raise the skid, with the unit on top.
3. Remove the nose guard.
4. Swing open the suction unit support arms, and move the unit with caution.
5. Both forks may also be placed underneath the mounting plate to move the unit.
6. Move the Suction Unit with caution.
Material
To properly move the material, follow the procedures below.
Hoist the Material

A board and strap are needed to move the material correctly.
1. With the material on its side, cradle one strap around the material.
2. Place a board a few inches above the material, inside the loop, to prevent the strap from tangling.
3. Lift, and move, the material with caution.
Lift the Material with a Fork Lift
A board and strap are needed to move the material correctly.
1. Place a fork in the hole that runs through the center of the material.
2. Lift, and move, the material with caution.
403631 19
Recommended Foundation
A foundation gives support and mass to the press. Keep the press as level as possible on the foundation, so
the weight is evenly distributed to each of the press legs. This will effect the alignment of the entire machine.
See the Oak Press Solutions, Inc. Service Manual for more information.
Preparation
Thoroughly clean the top of the bed, and use it as a reference point. Place a precision level, running right to
left, on the front edge of the bed. Shim the right or left side of the press to balance the level. Take a reading on
the back of the bed.
Vibration Mounts
Reference the installation and leveling instructions in the Micro/Level Isolators Technical Bulletin in the
Literature Section for installation instructions. Adjust the mounts so each Press leg receives an equal share
of the load. With proper settings, the vertical movements will be in a single plane and avoid twisting action. A
twisting motion is unacceptable with no-clearance conditions of the press slide. See the Oak Press Solutions,
Inc. Service Manual for more information.
Operating Environment
This machine is intended to be used in an Indoor industrial facility.
Ambient Temperatures
The Ambient Temperature range should be between 40 and 120 degrees Faranheit.
Recommended Lubrication
The Fin Stock Lubrication system must be filled with proper lubricant, after it is mounted and connected. The
die being used in the press dictates the type of lubricant to be used. Refer to the draw charts of the Fin Die
Machine Manual for Fin Die lubricants.
See the chart in the General Maintenance section of these instructions, under “Lubrication” for machine
lubricants for specific locations on the Fin Press.
Filling / Re-Filling Oils / Fluids

Dip Tank
Utilize the automatic refill system (if purchased) when filling the lubrication tank. This allows the system
to properly control the amount of lubricant added to the tank.
If manually filling the lubrication tank, fill the tank until the lubricant is just below the bottom wiper roll.
This allows for displacement of the lubricant when the lid with the roller is lowered into the lubricant.
The wiper rolls are not as effective if the lubricant makes contact with the bottom roll. This allows too
much oil to pass through the die. However, the low-level shut off switch will not allow the press to turn
on if there is not enough lubricant in the system. Lubricant must be added to the system in order to
restart the press.
E-Lube
Refer to E-Lube manual for more information on installation and refilling of the E-Lube system.
20 403631
Setup of Machine
Follow the procedures below to properly set the machine up for installation and operation.
Die Take Out (DTO)

1. Place the Die Take Out table behind the press.
2. Move the DTO table so the front member is against the back of the bolster.
3. Position the DTO table so the four holes on the front member and the back of the press are in line,
ensuring the top rails sit in the bolster.
4. Insert a roll pin into the two inner most holes.
5. Screw a bolt into the two outer holes.
6. Raise the two front leveling feet of the DTO table off the floor.
7. Adjust the back two feet so the table is level. Lower the front feet to the floor.
8. Connect the Hydraulic, Pneumatic, and Electrical systems.
Suction & Stacker Units

A Stacker is designed to work in conjunction with the Suction Unit to stack completed fins. Follow the directions
below to properly set up the Suction and Stacker Units.
Locating the Suction Unit
1. Set the Suction Unit on the support arms, and slide it toward the die until the back of the suction
box is approximately 1/8” from the cutoff screws.
2. Tighten the clamp to hold the unit in place.
3. Level, and position, the Suction Unit correctly before moving the Stacker Unit into position.
4. Place the Stacker Unit underneath the Suction Unit.
WARNING
PIERCING HAZARD. Use extreme caution when working around the Stacker Unit. Stacker rods are sharp,
and may cause severe injury. Always stay clear of the Stacker Unit when in operation. Use caution when
making any adjustments to any part of the line where someone could fall onto the rods.
As the fins progress out of the die, the suction unit secures them until cutoff. The fins are released onto the
Stacker Unit rods. The left and right sides are unloading positions, with a constant center stacking position.
Locating the Stacker
To locate the Stacker, follow the directions below.
1. Place the floor plate in front of the press.
2. Secure the Floor Plate to the press using the tie bars with the corresponding die in the press.
3. Attach the floor plate to the press feet with two locating pins.
4. Pin the Stacker Unit to the locating blocks at the opposite end of the floor plate with 1” diameter
locating pins or cones. The stacker will sit on the pins, or cones.
403631 21
5. Level the Stacker Unit with the adjustable feet, mounted to the bottom of the framework. Level the
Stacker in both directions across the Stacker Rod Holders.
• The distance between the tips of the stacker rods,
and the fins being held on the suction sheet,
should be a minimum of 1/8” and a maximum of
1/4” clearance.
6. If using a Rotary Stacker with a Pullback, adjust the
threaded rod connected to the cylinder on the side
of the frame to move the Stacker into position for the
Die.
7. Fully tighten all bolts on the suction unit, if not
already done.
8. Check to ensure all other bolts are tightened
securely.
Swing-Away System
Follow the instructions below to Install the Swing-Away system.
1. Lift the Swing-Away system into place.
2. Mount the support bracket assembly for the Swing-
Away to one side of the press posts by using L
brackets to hold the pivot shaft.
3. Attach the L brackets to the post by using four dowel
pins and two 5/8”-aa studs with nuts.
4. Tighten the nuts.
5. Swing the Lube Tank closed to engage the lock pin
on the opposite side.
6. Install the pierce and enhance lube tanks to the
Die Take Out Table, if applicable. A filtration system should already be mounted to the table if it is
included.
Pneumatic and Electrical connections

Connect all pneumatic, oil, and electrical connections from the lubrication system(s) to the press.
WARNING
ELECTRIC SHOCK HAZARD. Only a qualified electrician should disconnect power from the machinery or
work on electrical components. Do not attempt to open the control panel door with the machine powered.
Move the Electrical Box

Turn the machine off before disconnecting the power. An arc flash and/or explosion may occur if the
power is disconnected with the machine on.
Follow the instructions below to move the Elelctrical Box with a Hoist or Fork Lift.
22 403631
Hoist the Electrical Box
Two double chains and a bolt are needed in order to move the electrical box correctly.
1. Disconnect all power from the plant electrical supply to the electric box.
2. Wrap two double chains through the two holes on top of the electrical box.
3. Bolt the chain together.
4. Lift the electrical box, and move it with caution.
Move the Electrical Box with a Fork Lift

1. Disconnect all power from the plant electrical supply to the electric box.
2. Two people will need to lay the back of the electrical box on a skid.
3. Lift the skid with the fork lift.
4. Move the electrical box with caution.
Connecting to Power Supply

All electrical equipment is set for dual voltage operation, but is shipped with the voltage consistent with your
plant. Refer to the wiring diagram located in the electrical control panel.
Ensure that both electrical and air connections, which are connected to the crown, are flexible to allow for
vertical crown movement.
• Each hose connector pair has a corresponding number and/or color.
• Connect the hoses to the corresponding number and/or color on the connector.
• Connect electrical lines per the electrical print.
Tooling Changes / Installation

Follow the directions below to prepare, and perform, Tooling Changes.
Fin Die Removal Preparation

Follow these steps prior to the “Fin Die Removal” instructions on the next page.
1. Verify that the Press Guard Switch is in setup mode.
2. Remove the feed connector pin, feed connector links, and all lines and hoses connected to the die.
3. Place the feed connector pin in the key lock pull-pin switch.
4. Place the Cutoff, Blowoff, Lacer, and Stacker switches in the off position.
5. Turn the air retard regulator off.
6. Enter the Setup Screen, Line Setup & Error Overrides.
7. Select No Die and No Stock options. This will keep the Blowoff from blowing and the fin stock uncoiler
from feeding fin stock.
403631 23
Fin Die Removal
Be sure the steps in the “Fin Die Removal Preparation” steps are followed on the previous page, prior to
following these instructions.
WARNING
CRUSHING HAZARD. Never place any part of the body under the Press or associated equipment during
setup.
WARNING
CRUSHING HAZARD. When moving the die in and out of the press, keep fingers and hands clear of stops
and other areas where they can be pinched.
WARNING
CRUSHING HAZARD. Always stay well away from the machinery when lifting or lowering it into position.
Announce to all in close proximity when you intend to initiate any equipment movement.
WARNING
CRUSHING HAZARD. Never reach around the guarding. Stay clear of the machine while it is in motion.
1. Press Master Start, Pump Start, and Motor Start.

CAUTION
Allow the press flywheel to stop turning before doing any work or adjustments on the Press or Die.
2. Ensure the Crown Selector Switch is in the down position. The low hydraulic pressure indicator light
should shut off.
3. Inch the press until the slide position indicator on the rotary limit switch points to the 7 o’clock position.
4. Press Motor Stop.
5. Loosen all ram mounting screws one full turn.
6. Jog the Slide up, using the Crown Selector Switch, far enough to insert the die straps.
• If a die strap prevents access to the lower die shoe mounting bolt, remove the bolt before
installing the die strap.
7. Insert the lower strap bolts, and tighten them with your fingers only. If internal straps are used, screw
them into the lower die shoe.
8. Jog the crown down, using the Crown Switch, until the bottom of the upper die shoe makes contact with
the die strap.
CAUTION
Do not allow the die shoe to apply pressure on the die strap.
9. Remove die locating pins from the lower die shoe.
10. Remove all lower die shoe screws.
11. Insert the upper die strap bolts.

NOTICE
The press motor must be off and the flywheel stopped, or the press slide must be raised
hydraulically to its highest point anytime the die straps are on the die and the die is in the press.
24 403631
12. Tighten all bolts at this time.
13. Verify that all lower die shoe mounting bolts have been removed.
14. Raise the crown to the top, using the crown switch.
15. Press Motor Start.
16. Inch the slide to the top of stroke (12 o’clock).
17. Pull the pin on the Lube System and Swing Lube system to the side.
18. Ratchet the Hand Crank by hand in the installation direction, or toward the Press, to move the die cart
into position under the Die.
19. Lift the Die with a crane system by using the 3/4” lift holes provided in the Punch Holder.
20. Remove the mounting bolts to release the Die Punch Holder from the crane system.
21. Press Motor Stop.
22. Follow the “Die Installation” instructions below to install a Fin Die.
Fin Die Installation

Follow the instructions in this section after completing all Setup Instructions, and/or removing a previous Die.
1. Locate the die onto the cart using the locating pins that normally locate the die to the bolster.
2. Remove the locating pins after the die has been located on the takeout cart.
3. Lower the RAM to within 3/8” of the top of the Upper Die Shoe, using the Crown Selector Switch.
4. Install all Upper Die Shoe Screws. Tighten them with your fingers only.
5. Raise the die off the takeout cart, using the Crown Selector Switch, so it can be removed.
6. Inspect the following locations, and clean them, if necessary, with a cloth on a stick:
7. Top surface of the bolster
8. Bottom surface of the die shoe
9. Slowly lower the die to within 1/4” above the bolster by alternating the Crown Selector Switch between
the down and hold positions.
NOTICE
Failure to maintain a gap between the slide and the top of the die while the die straps
are on could result in damage to the die.
10. Install the die locator pins using the Die Bar.
11. Lower the die onto the bolster, using the Crown Selector Switch. Maintain a 1/8” gap between the slide
and the upper die shoe. Finger tighten all upper die shoe screws.
12. Remove all die strap screws from the upper die shoe with the Crown Switch in the hold position. The
same applies if internal die straps are used.
403631 25
13. Install screws holding the lower die shoe to the bolster. Some may not be accessible at this time.
14. Raise the crown and upper die shoe, with the Crown Selector Switch, just enough to completely
remove the die straps from the lower die shoe. The same applies if internal die straps are used.
15. Install the rest of the lower die shoe screws, and tighten them.
16. Verify that all lower die shoe screws are tight and that the die straps have been removed.
17. Place the crown switch in the up position.
18. Press the Motors On and Start pushbutton, and inch the slide to the top of stroke (12 o’clock on the
slide indicator).
19. Press the Motors Stop pushbutton.
20. Turn all punch holder ball cages to check that they can freely move up and down at this position.
21. Inspect the Die interior for any foreign objects.
22. Verify all lines and hoses are in their proper locations.
23. Place the crown switch in the down position. The low hydraulic pressure light will shut off when the
crown is completely down. Leave the crown switch in the down position.
24. Press the Motors On and Start pushbutton, and inch the slide to the bottom of the stroke (6 o’clock).
The bottom of the upper die shoe must contact the die stop posts. The bottom of the slide should
contact the upper die shoe.
25. Press the Motors Stop pushbutton.
26. Tighten all upper die shoe screws to the slide.
27. Press the Motors On and Start pushbutton.
28. Inch the slide to the top of stroke (12 o’clock on the slide indicator).
29. Press Motors Stop, and wait for the flywheel to stop.
30. Place the crown switch in the UP position to raise the crown.
31. Connect all lines and hoses between the press and die.
32. Use a carpenter’s square to verify that the Stock Lacer Guides are square with the back of the first Die
Station.
33. Follow the “Throw Guage” and “Fin Line Guards” instructions on the next page, as needed.
26 403631
Throw Gauge
Follow these instructions to install the proper throw gauge for the Die.
1. Inch the press to position the eccentric adjusting bolt at Throw Gauge Eccentric Adjusting Bolt
approximately 9 o’clock.
2. Turn the eccentric adjusting bolt counter-clockwise to
remove the existing throw gauge.
3. Replace the throw gauge that corresponds with the die used.
4. Turn the eccentric adjusting bolt clockwise to tighten the
throw gauge. Eccentric Plate
Fin Line Guards

Shipping personnel at Burr Oak Tool, Inc. removes all guarding during shipping preparation. The
following guards must be installed prior to operation. All required fastening bolts are included.
• 2 Rear Press Guards • 2 Feed Arm Guards

• 2 Side Die Guards • 1 Suction Unit Guard
• 2 Front Guards • 1 Front Servo Door Guard
NOTICE
Use the thread lock on all screws during installation to reduce loosening during operation.
403631 27
FP1000/1400 Bolster
NOTICE
Bolster weighs approximately 4,500 lbs. (2,041 kg.)
Installation
1. Ensure the eccentric shaft is at the top of stroke (T.D.C. / 0°), and the crown is fully up.
2. Position the Drive Arms on the feed shaft fully outward.
3. Remove the oil line along the left side of the press bed to prevent damage during bolster
installation.
4. Clean and stone the press bed.
• On FP1000 press, ensure two (2) alignment bushings are secured in press bed.
5. Apply a thin coating of oil to the press bed prior to installing the bolster.
6. Secure the bolster lifting bracket to the bolster.
7. Lift the bolster using an industrial forklift truck.
8. Clean and stone the bottom surface.
• On FP1000 press, ensure two (2) alignment bushings are secured in bottom sur-
face of bolster.
9. Position the bolster above the press bed, and carefully lower onto press bed.
• On FP-1000 fin press, ensure locating pins in press bed engage locating bushing
in bottom surface of bolster.
• On FP-1400 fin press, install one (1) mounting screw centered on the bolster, be-
fore backing the forklift away.
10. Remove the bolster lifting bracket.
• On FP-1400 fin press, visually align the locating pin holes in the bolster and press
bed. Lubricate the two (2) supplied locating pull dowels with grease, and install
them with the threaded hole through the bolster and into the press bed.
11. Install all remaining mounting screws and tighten, working from center outward.
12. Secure the oil line along the left side of the press bed.
Removal:
1. Ensure the eccentric shaft is on top of the stroke (T.D.C. / 0°), and the crown is fully up.
2. Ensure drive arms on the feed shaft are positioned fully outward.
3. Remove the oil line along the left side of the press bed to prevent damage during bolster
removal.
4. Remove all mounting screws that are securing the Die Take-Out Table to the rear of the
bolster.
• On FP-1400 fin press, remove the two (2) locating pull dowels, using an M8 jack-
ing screw or slide hammer.
5. Loosen, and remove, all bolster mounting screws.
6. Install, and secure, the bolster lifting bracket.
7. Using an industrial forklift, lift the bolster high enough to clear the slug chute.
8. Back the Bolster straight out of the Fin Press area.
9. Place the bolster on wooden supports, to prevent damaging bottom surface.
28 403631
Global Experience
...Local Solutions Machine Operation
Training
This technical manual is intended as a guide for the skilled technician assigned to work on this machinery. Only
those who have been properly trained should be allowed to set up and adjust this machinery and its systems.
It is the sole responsibility of the user to ensure that any person or group of persons assigned to work on this
machinery has sufficient training. The operator, and any technicians who regularly work on this machinery,
should read the entire technical manual.
Die Safety Blocks

One (1) Die Safety Block hangs on each side of the Fin Press. Both Safety Blocks must be plugged into the
Fin Press before the machine will operate (Image 1). A message will display on the operator station if the user
attempts to operate the machine without plugging the Safety Blocks in.
To use the Die Safety Blocks, follow these instructions:
1. Move the Mode Selector Switch to the Inch position.
2. Inch the Press to TDC (Top Dead Center) proximity (355°-5°) with the slide fully raised or retracted.
3. Unplug each Die Safety Block from the sides of the Fin Press.
4. Place the Safety Blocks inside the open Press (Image ).
5. Use other safety precautions, as needed (see the Safety section at the beginning of these general
instructions) while working on the Fin Press.
Remove the Die Safety Blocks from inside the Fin Press before attempting normal operation. Hang them back
on the sides, and plug the Safety Blocks into the corresponding holders (Image 1).
Safety Block
Plug
Image 1 Image 2
Startup Procedure
Before operating the press, be sure the instructions in each of the listed sections have been followed:
1. Power Up the Press (in this section) 4. Verify the correct fin is programmed in
the touchscreen. See Fin Chart Screen in
2. Installation of the Die (refer to the “Installation the “Control Reference” section for more
& Setup” section) information.
3. Lacing the Material (in this section)
Fin Die & Fin Press Preparation

1. Stone and clean all mounting surfaces.
WARNING
• Die mounting surface on slide
• Top surface of bolster CRUSHING HAZARD. Never place hands under
the die when it is in the press.
• Top surface of die punch holder
• Bottom surface of the die shoe
2. Check for, and remove, anything that may interfere with the press post while positioning the die under
the slide.
3. Install feed connector links.
4. Press Motors On and Start.
30 403631
5. Lower the slide, and inch the press to the forward feed position.
6. Insert the feed connection pin into the feed linkage.

• The feed bar should remain within .010” of the feed stop blocks with the pin in place. Adjusting
the feed linkage rod can alter this dimension.
7. Inch the press until the feed bar is in its back feed position.
8. Measure the distance between the front of the feed bar and the feed stop block.
• This dimension should be between 1/16” and 3/32,” plus one full feed progression.
• Refer to the Fin print for feed dimension.
Power Up the Press

1. Press Master Start on the control station.
2. Press the Motors On and Start button.
3. Turn the guards selector switch to run.
4. Turn the lacer selector switch to on.
5. The lacer will grab the stock and hold it in place.
Before loading material in the Press, perform a Dry Run - run the Fin Press without any stock.
After the dry run is complete:
• Check the Fin Press for levelness, alignment, and bolt snugness.
• Be sure to adjust anything that became unleveled, loosened, or unaligned during the dry run.
Break-In Period
All moving parts of the Oak Press are mounted on anti-friction bearings, and do not require a break-in period.
Each press has been run at the factory a minimum of twenty hours at speeds in excess of normal operation.
All bearings are checked for alignment and temperature, so the press will immediately run at the desired
production speeds.
After the first day in operation, bearing temperature should be checked closely, as clearances may have
changed during transit to your facility.
NOTICE
The press flywheel is marked for proper rotation. It is very important for the flywheel to rotate in the correct
direction.
403631 31
Unexpected Power Outage/Loss
If an unexpected power outage occurs during normal operation, all entered values that have previously been
saved in data entry screens should remain stored in the program upon power-up of the machine. The required
number of Fins, as well as the number already produced, should still be stored in the machine program.
Before resuming operation, check the Die Progression and the Crank Angle.
• If the Die Progression needs to be adjusted, follow the Feed Adjustment Settings (FP1/2/3) or
Setting the Servo to Forward Feed instructions (FP1000/1400).
• If the Crank Angle on the screen does not match the physical dial on the front of the Fin
Press, follow the Crank Angle instructions below.
When both of the items above have been verified and/or adjusted, resume operation.
Crank Angle Adjustment

1. Login with a password that allows changes to the Crank Angle value on the Inch screen.
2. Inch the Press until the dial on the front of the Fin Press is at the top of the Stroke (0°).
3. Enter ‘0’ for the Crank Angle on the screen.
4. The Crank Angle is now set accurately.
32 403631
Loading Material
WARNING
Use caution when handling fin stock. Edges are sharp and will cut if handled improperly. The use of tight fitting
gloves is recommended. Avoid loose gloves because they can create an entanglement hazard.
WARNING
CUTTING OR PINCHING HAZARD. Personnel must be clear of the Uncoiler before performing the following.
Lacing the Material

Follow the instructions below to correctly lace the material for a Fin Press. The material should feed from the
bottom side of the roll.
Steel Roller Rubber Roller
1. Turn the press off. Hinged Roller

Guard
2. Remove the pin from feed linkage.
3. Disengage the slit station to aid in lacing the fin

stock through the Fin Die.
4. Remove the feed cover tray.

Guard Switch
5. Wipe the outside of the fin stock coil clean of all
residues.
6. Align the material side-by-side with the die.
7. Open the hinged roller guard.
8. Lace material over the rubber roll and under the steel roll.
9. Close the hinged roller guard.
10. Ensure the guard switch is actuated.
Feed Stock Through the Lubricator

1. Open the lubrication tank.
2. Remove the upper wiper roller.
3. Pull the stock over the stationary roller at the back of the lube tank, through the tank, over the lower
wiper roller, and out the front of the lube tank.
4. Reinstall the upper wiper roller.
5. Adjust the wiper roller clearance to the desired height.
6. Close, and latch, the lubrication tank lid.
403631 33
Lace the First Draw Station
1. Feed the stock through the lacer and guide, so the stock covers the first draw station on the die.
2. Check for 1/64” clearance between the stock and guide rails on both sides.
• If necessary, adjust the guide rails to obtain a 1/64” clearance.
3. Remove a 3” x 35” piece from both sides of the leading edge of the stock to prevent problems with
advancing the fin stock through the lacing process.
4. Follow the Advance the Stock instructions in “Operation Procedures/Cycles” to continue lacing the
stock to the next station.
Loading the Uncoiler

Follow the instructions below when loading, or re-loading, material on the Uncoiler.
CAUTION
Wear/Use proper personal protective equipment when lacing the material.
Spindle Support
Gate
Red Handle
1. Lift the red handle to release the spindle support gate, when applicable.
2. One strap (rated for poundage of coil) is needed to load the coil. CAUTION
The red handle latch can pinch.
3. Lace the strap through the core and attach two (2) ends level to the
hoist. The material needs to be balanced and level.
4. Position (rotate) the spindle jaws to create an opening at 12 o’clock for the strap.
5. Lift the balanced coil onto the spindle.
NOTICE
For extended life of the spindle, do not release all the weight of the coil until one jaw is straight
up and down.
6. Slide the coil onto the spindle jaws, centered to the die. NOTICE
Material should be loaded to pay off from
7. Close the spindle support gate. the bottom. This will provide greater
surface area of stock to the nitrile roll.
34 403631
8. Lower the red handle.
9. Expand the jaws.
10. Tighten the inner core, before releasing the weight from lifting mechanism to spindle.
11. Remove the strap.
12. Rotate (tighten) the jaw engagement handle, while rotating the coil until the coil is supported equally
by all three (3) jaws.
Spindle Jaws
Jaw
Engagement
Handle
Spindle Core
Operation Procedures / Cycles

Follow the instructions below during the Fin Line operation.
CAUTION
If operated in a humid environment, machine A/C Unit(s) cooling controls parts and/or equipment may
produce condensation, which should be contained to prevent surrounding area(s) from becoming slippery.
CAUTION
All accessible parts and/or motors may be hot while the machine is in operation, and directly after it has been
shut down.
Stroke the Press

1. Turn the crown selector switch down to lower the crown.
2. Turn the SS-Cont-Inch selector switch to SS for Setup Stroke.
3. Press the Run/Inch buttons once to stroke the press.
4. Raise the crown by turning the crown selector switch to Up.
403631 35
Advance the Stock
Follow these instructions to advance the stock to the next draw.
1. Lift the stock off the die using a wooden dowel or flat stick. This will prevent the stock from sticking to
the die, which could bend the stock when the lacer is used.
2. Press the feed advance button once. NOTICE

NEVER use a stacker rod or steel object to free the
3. The lacer will pull the stock to the next draw. stock. DAMAGE TO THE DIE COULD RESULT.
Reaching the Feed Fingers

1. Repeat the Stroke the Press and Advance the Stock procedures until the stock reaches the feed
fingers.
2. The feed fingers should be able to grab the stock when the feed bar is in the back position.
3. Repeat the instructions to Stroke the Press.
Manual Feed to Cutoff

When the stock has reached the feed fingers, the lacer will no longer be needed to feed the stock. Follow
these procedures instead.
1. Turn the lacer knob to the off position.

2. Move the feed to the back position, by hand.
3. Hold the stock onto the feed fingers by hand, if the feed fingers do not grab the pierced stock.
4. Advance the feed by hand.
5. Repeat the instructions for Stroke the Press.
6. Repeat Steps 2-5 until the stock has advanced past the cutoff.
Cutoff
1. Install the feed cover tray.
2. Turn the SS-Cont-Inch selector switch to Inch.
3. Inch the slide/RAM, with the feed in the forward position, to the feed forward position.
• The feed forward position is the bottom of the stroke.
4. Install the pin into the feed linkage mechanism.
5. Inch to the top of the stroke.
6. Engage the slit station.
7. Ensure all guards are closed.
8. Turn the SS-Cont-Inch selector switch to SS until the slit fins are past the cutoff.
9. Manually engage the cutoff, and remove the scrap fins.
10. Adjust the counter to the appropriate setting.
11. Begin the automatic production.
36 403631
Lubricate the Stock
During fin line operation, take note of the quality of fins produced. The lubrication system is a vital part of the
production process and protects the fin die from damage.
Lubricant evaporates from fin stock when the press is idle for long periods of time. If the Press has been idle
for 2-3+ hours, follow the instructions below to manually lubricate the stock before machine operation.
1. Turn the Crown Switch to the Up position. The crown will raise.
Crown
Switch
2. When the crown has reached the top, spray fin lube
on the fin stock entering the press, and the fin stock
located inside the die. Close and latch all guards when
finished.
3. Turn the Crown Switch to the Down position.

NOTICE
The crown must be down, or a fault will occur.
4. Turn the key to the Setup Stroke position. The Pre-

Lube Pierce Punches message appears if the press
has been idle for a period of time.
5. Press the Cont. Run button twice. Wait for blowoff. Blowoff will sound like air pressure releasing. The
press lubricates the pierce punches inside the die.
403631 37
Run / Inch the Press
Follow these instructions to Run / Inch the Fin Press.
1. Simultaneously hold, then release, both Run / Inch buttons (Image ), with the key in the Setup Stroke
position (Image ).
Image 1
Image 2
2. Repeat step 1 as many times as the number indicates in the Stroke Count area on the Main Screen
(this is the number of strokes required to produce one fin) (Image -a). The number of strokes the
press has completed towards achieving this number is shown as well (Image -b).
Image 3
Image 4
B A
3. Turn the key to the Inch position (Image ).
4. Ensure the Inch Mode is set to Automatic (Image ).
5. Press the Forward Feed button on the Inch Screen (Image ).
6. Press, and hold, both Run / Inch buttons (Image ).

Image 5
7. The Press will inch forward, until the moving feed bar
reaches the forward feed position.
38 403631
Homing
The feed axis and the external encoder, which is attached to the press are both absolute encoders. Therefore,
homing of these axes should only happen if the eccentric plate is decoupled from the torque motor or if the
external encoder is decoupled from the press.
Homing of the Feed Axis

Follow this procedure to Home the Feed Xxis.
1. Manually move the eccentric, while the motor is disabled, so the feed bar is fully forward.
• The eccentric is aligned using a spring loaded tooling pin that is dropped into a closely sized
slot that helps define forward feed very accurately.
2. Access the Fin Line Data/Stock Feed screen (FL_StockFeed in HMI).
3. Press the Home Feed Axis at Forward Feed button.
Verify Homing of the Feed Axis

Proper homing of the feed axis can be verified by following the instructions below.
1. Switch the system to Manual Jog mode.
2. Jog the Feed Axis to the forward feed location.
3. Inspect the eccentric’s location, or using the tooling pin.
4. The virtual axis should be set to zero. The virtual axis position value will be retained during the
power cycle.
Homing the External Encoder

Follow this procedure to Home the external encoder at the forward feed.
1. Inch the Press to the forward feed location, as specified on the Inch Screen (AutoInch in HMI)
2. Access the Fin Line Data/Stock Feed screen.
3. Press the Home External Encoder at Forward Feed button.

A check will soon be added for encoder consistency, by passing the current value of the external
encoder to the PLC utilizing Profibus. When mapped within 0-360 degrees, the External Encoder will be
equal to Crank angle - Forward Feed.
Homing the Servo Tap Down Motor (if applicable)
1. Click Setup on the Main Screen.
2. Click Logon and use password botg .
3. Click Fin Line Data and Options.
4. Click Suction Unit.
5. Look at the Servo Motor Status.
6. Compare the color to that of the color code.

403631 39
• Press Reset if the motor is Faulted, or Waiting to be Homed.
• Reset may need to be pressed twice to clear a fault.
7. Follow the instructions on the screen to home the servo motor.
8. When the servo motor is homed, the buttons under Test Tap Down will be functional.
9. Press Single Tap Down to see the tap down cycle once.
10. Press Continuous Tap Down Running to cycle the Tap Down once every few seconds.
11. Press Continuous Tap Down Running again to stop cycling the system.
If the Servo Motor Status turns RED during either of the Tap Down tests, there is likely a mechanical bind in the
mechanism, or the belt is improperly tensioned for the Servo Tap Down.
When the light is GREEN on the Servo Motor Status, return to the main screen. The MS174 error will be gone.
Upper Suction Unit Fan Housing

The fan housing framework is mounted on linear rails for quick adjustments to the distance of the suction
unit from the Press, depending on the length of the Die. Adjusting screws are located in the caps of each
support arm, and in the slotted frameworks of the suction tower to set the proper height and level of the
suction unit. With the Suction sheet mounted in the suction box, the distance from the Fin Stock line should be
approximately 1/8” to the bottom of the Suction Sheet.
To adjust for leveling the suction box:
1. Loosen screws in the slots.
2. Adjust the turnbuckle to the appropriate height, being sure to keep it level.
3. Re-tighten the screws.
40 403631
Produce Fins
To begin producing fins, follow the instructions below.
1. Press the Reset Fins Produced button on the Main Screen (Image ).
Image 1
Image 2
2. Turn the key to the Cont. position (Image ).
3. Press Continuous Run twice (Image ).
Image 3 Image 4
4. Simultaneously press both Run / Inch buttons (Image ).
NOTICE
The Cont. Run button is on a time delay. If you don’t press both Run / Inch buttons quickly, it will
time-out. If this happens, press the Cont. Run button again before pressing the Run / Inch buttons.
Coils Complete
If message [MS010] “Fins Produced Equals or Exceeds Fins Per Stack Required” appears, press the Manual
Shuttle button. The stacker will rotate to the next station.
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Complete Order
When an order is complete, do the following to reset production for the next order.
1. Press Reset Coils Produced on the Main Screen.
2. Press Yes when the confirmation dialog appears.
Adjustments & Settings

The instructions in this section provide information and instructions to adjust several parts and settings for the
Fin Line.
Uncoiler Air Pressure Setting

The Uncoiler air pressure should be set as indicated on machine the tags,
as pictured.
Press Lubrication System Wiper Rollers

The stock passes through a set of wiper rollers, which control the amount of lubricant supplied to the Fin Die.
The wiper rollers are stacked on top of each other. The bottom roller is held in place, while the top roller may
be adjusted to create a gap between the two rollers.
The gap between the wiper rollers controls the amount of lubricant on the material as it enters the Fin Die.
A cone-point socket cap adjustment screw, with a nut to lock it into position on the mounting block, controls
the gap. The screws are located on both ends of the wiper rollers, and must be adjusted the same amount
simultaneously to keep them parallel. The material may bind or improperly track if these rollers are not parallel
to one another. The rollers must also be parallel to the lacer/guide.
• Turn the adjusting screws counter-clockwise to decrease the amount of lubricant left on the
material before entering the die.
• Turn the adjusting screws clockwise to increase the amount of lubricant left on the material before
entering the die.
The lubrication tank lid has two pressure pad assemblies that apply pressure to the top roller. With the use of
evaporative lubricants, these pads are effective in applying pressure to the top wiper roller. If the lubrication
tank contains non-evaporative oils, inserts may need to be installed in the lid above the pressure pad with a
1/4”-20 bolt to apply more pressure.
WARNING
OIL MIST. Excessive application of oil to the Fin Stock may create an oil mist in the air. The inhalation of this
oil mist can be dangerous. Please refer to the MSDS for the oil being used to lubricate your Fin Stock.
42 403631
Fin Hole to Stacker Rod Alignment
While the fins are held up by the Suction Unit, check alignment of the fin holes to the stacker rods.
Correct Alignment Incorrect Alignment
Incorrect Alignment Image 1

To correct alignment of the Fin Hole to the Stacker Rod, do the
following.
1. Loosen the Rod Holders on both sides of the Stacker Station,
while the fins are still in the Suction Unit (Image ).
2. Adjust the rods to accommodate the fins.
3. Ensure the rod holders are located in the detents of the

locating rails.
4. Loosen the screws on the side of the locating rail if it is still

not in position (Image ).
5. Move both the rod holder and locating rail until they are
aligned.
6. Open the Inch Screen.
7. Press the Preferred Top Stop button (Image ).
Image 2
Image 3
Image 4
8. Hold both Run / Inch buttons until the press

reaches the preferred top stop (Image ).
9. Open the Main Screen.
10. Press the Last Stroke button (Image ).
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11. Turn the key switch to Setup Stroke (Image ).
Image 5
12. Hold both Run / Inch buttons (Image ) until the Press proceeds one stroke.
13. The Press will cut off the fins.
14. Verify all stations on the stacker system are aligned correctly.
Shut Height Adjustment

The shut height of the press must match the shut height indicated in the die. To adjust this setting, do the
following:
1. Raise the crown (this allows easier sprocket turning)
2. Adjust the hydraulic shut height lever on the side of the press, mounted below the sprocket with the
micrometer scale.
Setting the Servo to Forward Feed

1. Press the Master Stop pushbutton to stop the Fin Press.
2. Open the guard on the servo feed motor.

Throw Gauge Eccentric Dovetail
3. Rotate the motor until the throw gauge is
exposed.
4. Loosen the dovetail screw.
5. Remove the throw gauge.

Dovetail Screw Eccentric Plate
6. Install the new throw gauge.
7. Tighten the dovetail screw until it is firmly locked on the throw gauge.
8. Break loose the Drive Shaft Locking Nuts.

(Tear Drop) Throw Arm Locking Nuts
9. Twist the Turn Buckle Top down to
shorten the throw of the drive shaft.
10. Rotate the motor.
11. Insert the alignment pin into the slot on Turn Buckle Clevis
the eccentric hub.
• If the motor will not fully rotate, continue shortening the drive shaft by twisting the turn buckle
clockwise.When the pin is installed, the feed system is at
forward feed. Alignment Pin
• Twist the turn buckle bottom up until the feed bar is barely
touching the urethane pads on the die.
12. Tighten the two locking nuts on the drive shaft, making sure not
to change the location of the turn buckle.
13. Pull the alignment pin and make sure it is nestled in the retained
position.
44 403631
14. Press the Master Start and Motors Start pushbuttons.
15. Twist the mode key to Inch.
16. Set the feed mode to Manual.
17. Push the -ਆ button at the lower right corner of the screen.
18. Press the Feed/Jog pushbutton until the -ਆ turns solid yellow and the feed bar stops moving.
19. The Forward Feed button should be flashing. If it is not, reposition to the back feed.
20. Press the Master Stop pushbutton and measure the back feed.
21. Press the Master Stop pushbutton.
22. Press the Motor Start pushbutton.
23. With the Forward Feed button flashing, press the Feed/Jog button and hold it until you reach forward
feed.
24. Synchronize the Servo Feed System to the Fin Press. Follow the Syncing the Feed System instructions
below.
25. If the Die is a 2:1 die, set the fin length to 1; if it is a 4:3 die, set the fin length to 3, 6 or 9.
26. Perform a few setup strokes to ensure the press is feeding the correct fin length.
27. Switch to Auto Inch
28. Select Back Feed and inch the press to the back feed of the die.
29. Press the Master Stop pushbutton, and measure the back feed.
30. Make adjustments as necessary by following the procedure again to ensure the system is feeding
properly.
Syncing the Feed System

If the MS086 message “Servo not in Sync. (Go to Inch and set Feed Mode)” appears on the main screen,
follow these instructions.
1. Move the Mode Selector Switch (Setup Stroke, Continuous, Inch) to the Inch position.
2. Ensure the guard doors are closed, the Crank Angle is near the top, and the Crown is down, and the
Crown Pressure indicator is green.
• If the guard doors are not closed, the feed will not move and the Fin Press will not stroke. If
the guards are closed and the Fin Press still does not stroke, check the guard door safety
wiring.
• If the Crank Angle is not near the top, inch the Press until it is near the top of the Stroke. The
machine should be clear of any obstructions and the guards should be closed before stroking
the Press.
• If the crown is not down, move and hold the Crown selector switch in the Down position to
lower the crown. If the crown does not lower, make sure the guard doors are closed. If the
guards are closed, check the safety wiring of the guard doors, crown selector switch, and the
crown down solenoid.
403631 45
• The Crown Pressure Indicator will turn green when the crown is down and contains sufficient
pressure. If the indicator does not turn green, make sure the pressure switch is set correctly
and check the input wiring. In addition, ensure an adequate level of hydraulic fluid is in the
tank. Also check the motor and accumulator pressures to be sure they are set correctly.
3. Select the Forward Feed button in the lower right corner of the Inch Screen. The button will turn from
gray to flashing yellow, indicating the feed is not in the forward position yet.
• If the feed is already in the forward position, the button will turn solid yellow. Skip to step 6.
4. Press, and hold, the Jog button on the pendent to move the feed to the Forward position.
• When the feed is in position, the rear feed position indicator will begin to flash and the forward
feed button on the screen will turn solid yellow.
5. Quickly move the Mode Selector Switch (Setup Stroke, Continuous, Inch) to the Setup Stroke position.
6. Press the blue Feed Mode button.
7. Wait about five (5) seconds for the small yellow “Synchronized” banner to flash.
8. Do a Setup Stroke. The feed will engage and the Ram will stop at the top of the stroke.
9. The small yellow “synchronized” banner should be solid yellow.

• If it is, run another Setup Stroke or run in Continuous mode.
• If it is not, try to resync the motor.
NOTICE
On Fin Presses with a Servo Movement update, if a guard is opened before another Setup Stroke,
Continuous Run, or Inch is performed, the feed motor will need to be resynchronized.
Press Intensifier Manifold Settings

WARNING CAUTION
Possible injury, and/or hydraulic component failure, may occur. Extremely high pressure is possible.
Back the pressure reducer adjustment screw (Port PRV1) out all the way, prior to turning the Fin Press on, to
prevent injury or hydraulic component failure. The intensifier has a 4-1 intensifying ratio. The intensifier mani-
fold contains the following three (3) adjustable valves. Refer to the machine Control Schematics for the
required Intensifier Manifold settings.
• A system relief valve located in port RV1.
• A remote compensator valve located in port RV2.
• A pressure reducer located in port PRV1.
Follow the procedures below to set each adjustable valve.
System Relief Valve (RVI)

1. Turn the adjustment in all the way
2. Back the adjustment out ½ turn
3. Lock down the Jam Nut.

46 403631
Remote Compensator Valve (RV2)
1. Press Master Start.
2. Adjust the system pressure until it reads 800 PSI at the pump.
Crown Pressure (PRV1) on the Manifold

1. Press Master Start.
2. Adjust the manifold to the desired crown pressure

• The compensator on the pump needs to be adjusted to match pressure (PRVI). See
“Compensator Settings” for more information.
• The applicable crown pressure is available with the machine specifications found on the Fin
Line layout.
Compensator Settings
The procedures for adjustment the Compensator settings requires two (2) people. The crown should be
bottomed out against the Jam Nuts. While one person maintains the Lower Crown Switch, the other person
should follow the directions below, depending on the type of Compensator on the Pump.
Screw #1
Pump with an AM Compensator and One Adjustment Screw
1. Adjust the Compensator, located on the pump, to the full crown
pressure.
2. Lock down the jam nut.

When the crown is moving, the pump will switch to the required crown pressure.
After the crown switch is returned to the neutral position, the pump will maintain AM compensator
the higher crown pressure for 1.5 seconds. The pump will then return to the 800
PSI Press setting.
Pump with a BA Compensator and Two Adjustment Screw #1 Screw #2

Screws
1. Adjust compensator screw #1 (located on the pump) to full
crown pressure.
2. Lock down the jam nut.
3. Adjust compensator screw #2, while the crown is moving, to

no more than 1000 PSI (68 BAR) in either the up or down BA compensator
movement of the crown.
When the crown is moving, the pump will switch to the required crown pressure. After the crown switch is
returned to the neutral position, the pump will maintain the higher crown pressure for 1.5 seconds. The pump
will then return to the 800 PSI Press setting.
403631 47
PRV1
PPBD-LBN
R04C3-10N
5
48
6
CXDA-XCN
1
3 4
RV1
RV2 DSL081N
RD102S30
RAH081S30 CCP-024D
717943
403631
Shuttle Stacker Air Pressure Settings
Refer to the image and table below to set the Shuttle Stacker air pressure settings, when necessary. This must
be monitored so the cylinder Rod end and Cap end have the same force when energized.
Shuttle Stacker
Pressure Settings
Cylinder Cap Cylinder Rod
CAP Pressure
30 PSI 33 PSI
35 PSI 39 PSI
40 PSI 44 PSI
45 PSI 50 PSI
50 PSI 56 PSI
55 PSI 61 PSI
60 PSI 66 PSI
65 PSI 72 PSI
70 PSI 77 PSI
75 PSI 83 PSI
80 PSI 89 PSI
ROD Pressure
85 PSI 94 PSI
90 PSI 99 PSI
95 PSI 105 PSI
100 PSI 111 PSI
Shut Down Procedures

Use the following procedures to shut down the machine.
Stop Operation
Press Finish Fin to finish the current fin. The Press will stop operation after cutoff.
403631 49
Shut Down the Machine
Press the Top Stop pushbutton to shut down the Fin Press after the current stroke is finished.
Top Stop
Emergency Stop
Emergency Stop
Press the Emergency Stop pushbutton to immediately stop the press, in case of an emergency.
Emergency Stop buttons are located in convenient areas for the operator to reach.
NOTICE
The Emergency Stop button should ONLY be used to prevent machine damage or human injury from the
machine. It should not be used for standard machine shut down purposes, except for needing all electrical
power to the machine shut down.
NOTICE
If the machine needs to be disabled completely, turn the power off at the plant main electrical disconnect that
supplies the machine with power.
50 403631
Control Reference
This section provides instructions on working with data to produce desired Fins in correct quantities for a given
size and number of production coils. Additionally, this section explains how to setup and configure the operator
touchscreen interface such as passwords, lubrication schedule, and various Fin Die data.
Machine Operations
The default screen displayed when the machine is initially powered up, is the Main screen. The touchscreen
displays various intermediate screens during power up. Wait until the Main screen is displayed before
proceeding. See “Main Screen” in this section for more information.
Changing Screens
The Screen Change Menu Bar appears along the bottom of most screens. It provides a quick and easy way to
switch to a desired screen when the menu is visible. The buttons stay in the same order from screen to screen,
but the button for the current screen disappears.
Automatic Screen Changes

The Inch & Continuous Run screens appear automatically, based on the Pushbutton(s) selected, and can’t be
accessed manually. These are discussed in more detail below.
Acknowledge Message & Confirmation Screens

Acknowledge Messages and Confirmation screens are displayed when an operator response is required. After
the operator acknowledges the message, or answers the question, the previous screen is restored.
Notice the unique message number when communicating a problem with the Burr Oak Tool, Inc. service
department. Messages, along with helpful suggestions, are listed in Appendix B.
Main Screen
Press the Main button at the bottom of the screen to access the Main screen, which displays information about
Press operation. The selected mode is displayed to the left of the screen name (currently Setup Stroke).
Using Help
Pressing the Using Help button to display the following text box, describing the role of the Help button. Press
the small x in the upper right corner of the info box to exit the popup message.
NOTICE
If the small size of the x makes it difficult to close the text box, press slightly higher, lower, or to either
side of the x.
Help
Most screens contain a Help button in the top right corner of the screen. Press this button to activate the help
function. Then press any button or display area on the current screen to display a context-sensitive description
for that button or display.
Press Help again to cancel/deactivate the help function.
52 403631
Data for Fin Production
Data related to the number of fins to produce on the stacker is entered in this section of the Main Screen.
The Coil Length is the size value of the coil produced. If each stack becomes its own coil, the coil length is the
same as the stack height. If multiple stacks produce one coil, the Coil Length is the stack height multiplied by
the number of Sections Per Coil.
Fins Per Inch is the number of fins in one (1) inch of coil. In the example above, the display shows 375 Fins
per Coil. This number is generated by multiplying the Coil Length by Fins Per Inch.
Fins Per Coil is automatically calculated by multiplying the Coil Length by Fins Per Inch inputs.
Rows Per Die represents the total number of rows in the die. This number does not typically change unless
the Die is changed, or the Die has adjustable edge trims that can remove one or two rows. This value is also
referred to as the Stock Width (measured in rows).
Rows Per Fin describes the width of the fin, as measured by its number of rows. It is the same as the number
of rows, as set by the slit station.
Sections Per Stack is calculated by dividing the number of Rows Per Die by the number of Rows Per Fin. The
Rows Per Fin value should always be evenly divisible into the Rows Per Die value.
Sections Per Coil represents the number of sections needed to make one coil. For shorter coils, this value is
often one (1). This value may be as high as 4 or 5 for longer coils.
Fins Per Stack is automatically calculated by dividing the Fins Per Coil by the Sections Per Coil input.
Units of Measurement
This system also supports the use of metric units measured in millimeters. The option to use metric
units may be selected from the Draw Chart Screen. When using metric units, Fins Per Coil is calculated
by dividing the Coil Length by Fin Spacing, instead of Fin Density, as is done when using English inch
units.
All other data entry on the Main screen is the same, regardless of which unit system is active.
Fins Per Stack Override

If one of the previous sections, such as Coil Length, is re-entered, Fins Per Stack is recalculated. The Fins
Per Stack Override value is replaced with the new calculated value. A Reset button will appear next to the
input fields. This is a visual reminder that the calculated value has been overridden. Press the Reset button to
recalculate the values using the numbers previously entered in the fields.
403631 53
Fins Produced
Fins Produced represents the number of fins on any given section of the stack. When Fins Produced
equals Fins Per Stack, the system stops fin production because the stack is complete. The Fins Per
Stack input field allows entry if fins are damaged, and must be removed from the stack.
When the fins have been removed, press the Reset Fins Produced button to set the Fins Produced to
zero. The value of 0 can also be entered directly into the Fins Produced field.
Draw Chart Selection

The bottom half of the left side of the image above shows the current Draw Chart information. Select
a created, or imported, draw chart from the drop down above the Draw Chart data. Select the Draw
Chart button at the bottom of the screen to view, or edit, the chart data.
Stroke Control
The figure below shows the Stroke Control portion of the Main screen.
Target Press SPM is the desired press speed entered in the Timing Chart Screen.
The Stroke Count is 1 / 5, meaning the press is on stroke, or inch, 1 of 5. The first count starts at the bottom
of the stroke, after cutoff. The screen will display stroke 1 for 360 degrees, until the bottom center is reached.
Press the First Stroke button, while the cutoff switch is set to Auto, to begin counting strokes with the current
stroke set to 1.
Press the Last Stroke button to have fins cutoff on the next stroke, or inch, of the Press.
Holes/Fin displays the number of holes to be produced per fin. The operator can enter a new value in the input
field. Data displayed on the Fin Chart dictates the number of holes per fin to produce if the Prog. Fin button is
on (colored yellow).
The system will show an error if the Holes/Fin based on the Prog. Fin data does not match the value entered in
the input field. To correct this, turn the Prog. Fin off, or enter the same value in the Holes/Fin input field.
54 403631
Recipe Selection
Below is an example of a recipe selection dropdown. These are located throughout the program. Each are
capable of recalling their existing recipe(s). With proper login credentials, users have the ability to create, save,
and delete recipes.
The Main screen contains up to four (4) recipe dropdowns to select from: part selection, timing chart, fin chart,
and draw chart. It is not necessary to use all of the recipe tools. The drop down selectors shown here are Part
Selection (top one) and Timing Chart selection (bottom one).
Some operators enter the data manually on the Main screen. Others prefer entering the data correctly once,
with the ability to quickly recall the data by part number or coil information.
Part Definition Screen

Press the Define Part button on the Main screen to open the Part Definition screen. This screen allows the
user to create, update, and save part recipes.
To create a new name for a Part, Fin Chart, Timing Chart, or Draw Chart, select the disk icon with three (3)
dots below the drop down menu of the corresponding box. Type a name for the new item, and select Ok.
If any changes are made to the part data, choose the save icon below the corresponding dropdown box to
403631 55
save the updated information, and overwrite the existing part data.
Visit the Fin Chart, Timing Chart, or Draw Chart screens to update data for a name in the corresponding drop
down selection box. These screens will be discussed in detail further in this section. New names and data
records can be created on those screens as well. Proper login credentials are required to edit data records.
To delete any item name, select the name in the drop down, and press the trash icon.
Error Messages
The figure below displays an error message. The operator must press the Master Start button to continue with
operation. Messages shown in red with a corresponding red button and the word “Error” cannot be overridden.
The error must be corrected in order to proceed with Fin Line operation.
Some error conditions will lock the Press, and the error will not clear without cycling the main power. The
message will indicate this in the description.
NOTICE
The main power should ONLY be cycled by an electrician.
Warnings
Warnings appear with black text on a yellow background. The button color matches the message line with the
words “Override Warning” on the button. If appropriate, press the yellow button on the screen or the Top Stop
pushbutton to override these messages.
The Fin Press is ready when all error and warnings have been cleared or resolved. The message line will turn
white and the message “[MS001] Press is Ready to Run” will appear.
This same message line and button appear on the Fin Chart, Timing Chart, and Inch Screens. The operator
may initiate Press motion from any of these screens on which the message line appears.
Machine Status
This line displays the status of
the machine and any faults,
errors or warnings that may be
present.
Run Status
This line displays the results of the last main action that occurred. It will display the reason(s) the Press
stopped running continuously, even after the condition that caused the problem has been resolved.
For additional information on Machine Status and Run Status messages, see Appendix B.
56 403631
Inch Screen
Switch to Inch Mode on the operator station to automatically display the Inch screen. The Inch screen will
disappear when the machine is switched to a different mode.
The Inch screen is designed to inch the press to various crank angle positions. The screen displays differently,
depending on the selected Inch Mode. The figure below shows the Inch Screen while in Manual Mode. The
message line prompting the operator to start the motors means the Fin Press may be run from this screen after
all errors have been resolved.
Press, and hold, the Inch buttons to inch the press. Pressing these buttons, without being in Inch Mode, will
not inch the press.
The operator may sychronize the Servo Feed Motor to the Crank Angle of the machine when there are no
active errors, by doing the following:
1. Push the Master Start pushbutton on the Operator station.
2. Push Motors On and Start on the Operator station.
3. Switch the Inch Screen to the Manual Jog Mode.
4. Bring the Feed Bar to the Forward Feed position before attempting to synchronize the Servo Feed to
the Press. To move the feed bar, do the following:
a. Select a position using the position buttons below the Feed Mode status message (-6, -5, -4, -3,
-2, -1, forward feed).
b. The position buttons will begin to flash yellow/gray to indicate the selected move location.
c. Press, and hold, the Feed Jog button on the pendant.
d. The Servo Feed Motor will slowly move until it reaches the desired position; the button will turn
solid yellow.
When the feed system is at Forward Feed, the operator may synchronize the feed, or inch/setup stroke the
Press, without the feed bar moving. See the “Syncing the Feed System” instructions in the Machine Operation
section of these instructions for more information.
403631 57
When the Press is ready for operation, manually Inch the press by doing the following:
1. Push, and hold one (1) of the black Run buttons, while quickly tapping (fully press and release,
repeatedly) the other black Run button.
2. If the operator holds both buttons without quickly releasing one of them, the clutch will remain engaged
for only a short period of time, before stopping.
3. Release both Run buttons.

a. A new target is automatically selected as either the Preferred Top Stop or the Forward Feed
position, depending on which target is the next closest.
Press the Inch Mode button to toggle between Auto and Manual Inch modes.
Each number on the Crank Angle Dial represents a target to which the operator may inch the Press. Tap one
(1) of the blue buttons on the dial to transfer the associated displayed crank angle value to the Inch to Target
readout.
NOTICE
Due to the possibility of large strokes, use the Auto Inch Mode to move the Press to Crank Angle locations.
Continuous Run Screen

Switch to Continuous Run Mode on the operator station to display the Continuous Run screen. This screen
displays all timing items that may need to be adjusted while the Press is running. The Continuous Run screen
will disappear when the machine is switched to a different mode.
When the press stops, the program will return to the Main screen, providing access to the Reset Fins
Produced and Reset Coils Produced buttons.
Timing items may be adjusted only if an adequate password level has been entered, or if items have previously
been enabled for adjustment in the Timing Chart Screen. To adjust a timing item, follow the directions below.
1. Select the timing item to be adjusted.
58 403631
2. Press the Increase Value or Decrease Value button to increase or decrease the value. The change is
made to the value shown in the “Apply New” field.
NOTICE
Increase Value and Decrease Value will only appear if the selected timing item is allowed to be adjusted.
3. Press the Apply New button to apply the desired value displayed.
Finish Fin Button

Press the Finish Fin button to perform a Top Stop after the current fin is complete. Finish Fin will flash during
production of the final fin when the stack is complete, or the button has been pressed.
When the Press stops, the system will return to the Main screen.
Fin Chart Screen

The Fin Chart Screen enables programming of unique fins. Various die functions may be turned on or off on a
per-stroke basis within this chart.
In the example shown, the Prog. Fin button is highlighted yellow, indicating the programmable data is active.
When this button is not highlighted, the system calculates the cutoff and changer strokes required to produce
the entered Holes/Fin value.
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Programming a Fin
When programming a fin, first set the cutoff stroke. Various combinations of changer extend and retract strokes
may add up to the same number of holes produced.
Program the new stroke by doing the following:
1. Press the desired number under the “Stroke” column.
2. Press the highlighted button under the “Cutoff” column.
3. Delete the previously programmed cutoff, or enter new values.
4. Set the gag stations, as required, after setting the cutoff.
5. Program a needed gag station anywhere in the fin sequence and stamp out several fins.
6. The effect of setting the gag will not appear for the first several fins.
This trial and error process can become complicated if a changer stroke is required to shift in the gag’s position
on the fin.
Non-Programmed Parts
The Fin Chart is in the non-programmable mode when Prog. Fin is turned off (black).
In this mode, the number of stokes and changes are calculated by the system to produce the entered Holes/
Fin value. The column headings under the gag station numbers describe what controls the gag station(s). In
this example, all of the gags are defined as “Sw.” This is typical when the Prog. Fin is off.
The gag stations will turn on/off with the die function selector switch.
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Timing Chart Screen
The Timing Chart screen is used to adjust the timing of events in relationship to the Press Crank Angle. Screen
settings, and other parameters that relate to the press, may also be adjusted here.
The timing items on the left side of the screen, with the exception of Top Stop, have associated values
referring to the Press Crank Angle when the solenoid associated with that action is too energized or de-
energized. These values are not intended to indicate when the actual event takes place. There are electrical
and mechanical delays from the time voltage is first applied to, or removed from, the solenoid until the action
completes.
It is important to watch the Press to see if a timing item is happening too soon or too late. The timing may be
changed to correct the problem.
Target Press (SPM)

The Target Press Strokes Per Minute (SPM) is the set point value for machines with the Auto Speed
Adjustment DC actuator option installed. The system will adjust the motor sheaves over a number of steps to
make the actual Press speed match the Target Press speed.
Uncoiler Speed
The Uncoiler Speed (%) is a percentage of the maximum allowable speed. A larger number will cause stock to
pay out more quickly when the uncoiler clutch is engaged. While in Continuous Operation, if the Press stops
often because of a stock fault, this value may need to be increased.
NOTICE
When the stroke mode is set to Setup Stroke or Inch Mode, the uncoiler speed is set to a fixed failure of 40
hertz, regardless of the press speed.
Vacuum Speed (%)

Vacuum Speed affects the strength of the suction on the plate. Caution should be used when changing
this value. The Stacker Door Open and Close settings may need to be adjusted when adjusting the Vacuum
Speed.
An adequate password level must be entered in order to enable adjustments of timing items through the
Timing Chart Screen. When an item is enabled for adjustment, the operator password level will be sufficient to
adjust the enabled timing items. Timing items will show a green circle in the Adj. column when they have been
enabled.
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Adjusting Press Speed
Press speed is adjusted automatically using a DC motor self-contained actuator system or Variable Frequency
Drive (VFD).
Follow the steps below to adjust the Press speed on machines with the Automatic Press Speed Adjustment
option:
1. Highlight the Target Press Speed timing item
2. Press the Increase Value or Decrease Value buttons to set a new value for the specified item.
3. Press the Apply Value button.

These values may be adjusted whether the machine is in operation or not. The actual adjustment to the sheave
only occurs when the Press is running in Continuous Mode.
Troubleshooting Timing Items

Timing of the fins falling onto the stacker rods often involves mechanical setup, as well as setting timing values.
1. Stroke a fin to the last stroke before cutoff.
2. Inch the press to forward feed.
3. Look at the fin to see if the collars are tracking properly in the suction sheet grooves. If not, shift the
suction sheet or make an adjustment to the left-right position of the cutoff stripper bar, if one is installed.
4. Look at the alignment of the stacker rods beneath the holes of the fins. The rods should be centered on
the holes left-to-right and front-to-back. If not, a qualified die setup person will be required to make the
proper adjustment. See “Fin Hole to Stacker Rod Alignment” in the Machine Operation section.
NOTICE
A qualified die setup person will be required to make the proper adjustments!
5. Inch through the bottom and back to the top of the stroke. Watch for the fins to drop. Look for any hang-
ups as the press inches through the bottom.
6. When the press is near the top, put the press in Single or Continuous Run Mode (whichever is
experiencing difficulty with stacking).
7. Go to the Timing Chart Screen and disable both the Fin Blow-Down and the Fin Tap-Down. With
these functions off, it is easier to see the effects of the stacker door open timing.
8. Run the press, and watch carefully. The leading edge of the fins will start to drop before cutoff occurs if
the Stacker Doors Open timing item is set too early. If the fins drop, and catch on the tips of the stacker
rods before reaching their full forward position, increase the Stacker Doors Open value.
9. Return to the Timing Chart Screen.
10. Enable one, or both, fin release functions so the fins drop parallel to the suction plate.
Fin Tap-Down works best with thin stock single row fins.
1. Start with the Fin Tap-Down option only.
2. Set the ON value(s) close to the actual cutoff, such as 110 for Cont. Run and 130 for Setup Stroke.
The wire tap-down happens quickly, in comparison to the stacker doors. Since this is being set late, the
wire tap-down should have no effect. The fin should be partially on the stacker rods.
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3. Adjust the tap-down timing to lesser degrees, in increments of 10, causing the tap-down to occur
sooner. It is best to disable the wire tap-down until the stacker doors open.
a. The timing is set too early if the edge of the fin that was cutoff is struck by the next incoming fin.
The Wire Tap-Down Both Off timing setting is flexible. The wires only need to move a short distance before
retracting.
The Suction Doors Close time is more sensitive. If the doors close too early, the fin could be drawn back
toward the suction sheet. If the doors close too late, the next fin coming out of the press might not pull up
against the suction sheet, causing it to be blocked against the tip of the first stacker rod.
Changer Extend Timing

The changer could shift prior to reaching its full back feed position, and possibly miss the intended pickup hole
if the extend timing is too early (-160). There will be more movement in the feed bar as it moves farther from
the forward point when the changer switches. The normal motion of the press moves the stock forward station
about 300° and continuing until around 120°. If this additional feed bar movement peaks at around 0°, it will
further accelerate the stock forward. The stock can be flung ahead of its normal position if this happens before
the stock retard pins engage. This will result in the loss of progression.
Changer Retract Timing

If the retract timing is too early, the feed bar will appear to stall or come to a stop on its way toward forward
feed. This might lead to more wear on the bearings. Advancing the timing (larger values) will cause this stalling
out effect to blend better with the normal stopping that occurs at forward feed.
The changer might not be fully retracted by the time the press reaches the full back feed position if the
retracting timing is too late. This will result in fewer holes than expected.
General Changer Timing Comments

When the changer extend and the changer retract both fire too late, the correct number of holes will be
produced in Continuous Mode, but enhancement features will not appear in the proper locations.
Another timing effect is that long or short fins are produced in Setup Stroke, but not in continuous run, or vise
versa. The late changer extend may produce an extra hole, but the late changer retract loses a hole so that the
net effect is the correct number of holes with an apparent shift in the fin configuration.
This same pattern might not hold true for Setup Stroke because the timing for single stoke is different than
that used for continuous run, and it may be set correctly. If this problem is present in Setup Stroke, it can be
detected by carefully counting the number of holes produced with each stroke and checking them against the
expected results.
Top Stop Timing

The top stop value does not have the same input range as the other timing items in the left-hand column. It
represents the number of degrees required to stop the press from the point where the clutch is disengaged
to a point near the top of the stroke. The preferred stopping point is usually around 10:30, or 345 degrees on
the crank angle. The number of degree needed to stop the press is smaller for Setup Stroke. The required
stopping degrees might exceed 400 (maximum allowable: 450) in continuous run, when running the press fast
and with a heavy die.
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Draw Chart
Draw Chart data is used for reference, only. It does not affect operation of the Fin Line. A warning will display
if a match is not found. The draw setting for the corresponding row in the Draw Chart is copied to the Main
Screen. These values will also be used as the Move To values for Fin Lines installed with the Auto Draw Adjust
option.
Draw Chart data is entered manually, based on the Draw Charts included in the Machine Manual that was
shipped with the Fin Die purchased from Burr Oak Tool, Inc. Press the Save As ( ) button on the Draw Chart
screen, and enter a new recipe name. Enter the desired the data (see the Draw Charts included in the Machine
Manual that was shipped with the Fin Die purchased from Burr Oak Tool, Inc.). Press the Save ( ) button
when all desired data is entered.
Collar Height may be manually entered or automatically calculated. When Man. Height Entry is marked, as
shown, any value may be entered in the Height column.
If (1+Shrink)/FPI is marked, the system will use this equation to calculate the collar height based on the
FPI entry in the column to the left. The entry for Shrink Rate is hidden in this example, but will be visible if
this option is selected. Enter 0 in the Shrink Rate field to calculate the coil height, but not the shrink rate
compensation.
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Production Data Screen
The production Data Screen tracks the total accumulation of strokes, fins, and coils since the last time the
counter was reset. These can be used to track coils produced for a given work shift or total strokes since the
last preventative maintenance action.
Press any of the Reset buttons to reset specific items to zero (0). Proper login credentials are required to utilize
any Reset button.
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Die Setup Screen
The Die Setup screen is used to view, and modify, the current state of the Fin Die. The screen(s) include
displays for such things as auto draw adjust, auto slit select, and auto edge trim adjust. Most of the draw
settings are visible, even if the fin line is not equipped with auto draw adjust.
Draw Settings
When a value is entered for Fins/Inch, the system searches the active draw chart to find a row that contains
a matching value for the fins/inch value. The system copies the data in that row to the New column in the Die
Setup screen.
If any of the values in the New column are edited, a button appears allowing the operator to copy these new
values to the active draw chart. The currently-entered password requires proper credentials to allow draw chart
editing. This method can be used to edit existing data, as well as enter new data. The system will create a new
row of data if the fins/inch value entered does not match any in the active draw charts.
Copy “New” to “Current”

The Copy “New” to “Current” button copies the values in the New column to the Current column.
Use this button to update the current draw position with values displayed in the New column. Retrieve
new values from the active draw chart, and manually move the draw stations to the displayed new
settings.
Sequenced Die Adjust

The Sequenced Die Adjust button is only available for fin lines equipped with the Auto Draw Adjust
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option. This button quickly adjusts the draw settings from one set of values to another. This preserves
the integrity of the stock in the die, so the material does not have to be laced through the die. The
draws are moved to an intermediate setting, and then the Press should be switched to Setup Stroke.
One or more draw stations might be adjusted simultaneously, in order to achieve the most rapid
transition from one setting to the next.
This tool works best when moving from one known set of draw values to another. The biggest
advantage to using this tool comes when moving from a low collar to a high collar setup. The
adjustment process may be resumed if it is aborted, but there will be an increased risk of stock
damage.
All at Once Die Adjust

Press the All at Once Die Adjust button to simultaneously move the draw stations from their current
positions to the listed new positions. This is ideal when there is no stock in the die. It can also be useful
if the collar height is only changing by a small amount. The current and new positions must accurately
represent the current actual positions of the draws and the desired “move to” new positions.
Correcting Draw Setting Discrepancies

Values for the current draw setting, and the actual values as read on the dial at the die, may not match.
Generally a small error like this will not affect the performance of the die in producing fins.
Large errors should be corrected by entering the actual value in the Current column. It may be
necessary to home the draw stations by manually cranking them down to the hard stops, and entering
zeroes in the Current column. The physical dials should read zero, when the die is fully moved down. If
not, contact Burr Oak Tool Inc. service department. If the fin line has the auto draw adjust option, unlock
the die in order to make any manual adjustment to the draw stations. Buttons are provided to lock and
unlock the die. The current status of the die is shown in the green box. Once any manual adjustments
have been made, the die should be locked again.
Edge Trim
Fin lines with auto edge trim can be equipped with controls for left, right, or both edge trims. A button is
provided to extend and retract the edge trim. Some dies also have a mid-stop position. The retracted
position provides the widest stock. Mid-stop in “narrower and extended” creates the narrowest of the
three. The operator is required to update the rows per fine value on the Main Screen in order to match
the actual rows per die as affected by the edge trim settings. This value should be updated if the edge
trim is manually changed to a different location.
Adjust Slit Station

Fin lines with auto slit adjust will have controls visible to adjust the slit station from the Die Setup
Screen. The entry for the rows per fin value is identical to the one found on the Main Screen, and
changing the value in one place will change it in the other. Like the edge trim, it is the operator’s
responsibility to change the slit station to get the desired rows per fin (fin width as measured in rows).
With the auto adjust, simply press the blue Adjust Slit Station button. A Please Wait message will
appear while the system makes the change.
Vacuum Motor
The vacuum motor can be turned off while still allowing the vacuum doors to operate. This is useful
when producing short fins.
Straightener Bar and Cutoff Stripping

Some machines have additional automated equipment. Controls for these features appear only if they
are installed. The controls allow the operator to raise and lower the bars that affect fin straightening and
cutoff fin stripping. There are no physical operator switches associated with these bars. The bars will
automatically raise when the lacer switch is turned to the ON position. A pop-up screen will prompt the
operator with a choice to lower them when the lacer is turned off again.
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Setup Screen
Press the Setup button at the bottom of the screen to access the Setup screen. This screen allows access to
several Diagnostics screens, Line Setup & Data Configuration, and Touch Screen Configuration options. The
rest of this section provides a brief overview of all common options found on this screen. The Setup screen
layout, and button availability may differ slightly, depending on the options added to each specific machine.
Inputs Screen(s)
Press the Inputs button from the Setup Screen to access the Inputs screen(s). The Inputs screen(s) indicate
which inputs are currently powered by the green circle next to the input.
There are several pages of inputs. The heading at the top of each screen describes the physical location to find
the remote I/O modules for these inputs. Press the arrow buttons to view the other input pages.
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The wires connected to the inputs are numbered to indicate they are inputs, the rack number, and the address
of the I/O point. For example, the wire connected to the input for the Right Run Inch PB would be numbered
I9.5.
Tap the Outputs button on the bottom of the screen to access the Outputs screen(s).
Outputs Screen(s)
Press the Outputs button on the Setup, or Inputs, screens to acccess the Outputs screen(s).
Active Outputs are indicated by a value of 1 and a red square to the left of the output description. If an
adequate password level has been entered through the logon process, outputs can be turned on/off in this
screen. Some pairs of I/O are interlocked such that both sides of a double acting solenoid valve cannot be
energized at the same time.
NOTICE
Use care when turning any output on or off. The outputs are not interlocked to protect the machine.
There are several pages of outputs. The heading at the top of each screen describes the physical location
where the remote I/O modules for the outputs can be found. Use the arrow buttons at the bottom of the screen
to view the other output pages.
Tap the Inputs button to access the Inputs screen(s).
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Timing Log Screen
Press the Timing Log button on the Setup screen to access the Timing Log screen, which shows time stamps
obtained throughout the program usage. This screen is used by BOTI programmers for troubleshooting the
program, if needed.
This screen shows no data necessary for general machine function. An adequate password level must be
logged in to access this screen.
PLC Status
Press the PLC Status button on the Setup screen to access the Status/Force PLC Data screen which is used
by BOTI service representatives for troubleshooting the program, if needed. It allows certain data points in the
program to be viewed, and modified, for testing.
This screen has no relevancy to general machine function. An adequate password level must be entered to
access this screen.
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Servo Status Screen
Press the Servo Status button on the PLC Status page to access the Servo Status screen. This screen is
used to diagnose machine issues concerning the feed servo. It allows BOTI service representatives to view
Temperature and Torque readings from the Servo Motor.
This screen has no relevancy to general machine operation.

Press the Reset All MSG button on the bottom left to clear any existing messages.
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VFD Drive Faults / Resets
Press the VFD Drive Faults/Resets button on the Setup screen to access this screen. An adequate password
level must be entered to access this screen.
If the Suction Unit and Uncoiler are equipped with Variable Frequency Drive (VFD) drives, this screen will show
relevant data concerning the drives, including fault codes (if faulted), Fault Reset, Frequency Setpoint, and
Actual Frequency, etc.
This screen is for troubleshooting and informational purposes only. It has no effect on general machine
function. Press the Setup button to return to the Setup screen.
Profibus Diagnostic Screen

Press the Profibus Diagnostics button on the Setup screen to access this screen. The Profibus Diagnostic
screen is used as a troubleshooting tool to help diagnose issues with the profibus nodes and network. If a
node is missing, it will be Red. If a node is present, it will be green. Nodes that are disabled or not used will be
marked as well.
Tap the Reset Refresh button on the Profibus Diagnostics page to reset the errors, and try to communicate to
the unseen (red) nodes again.
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Press any of the nodes displayed on the screen (boxes labeled 1-32 in the image) to display the use and
location of that particular node in the Profibus Node Description box at the bottom of the page.
Touch the Configure Control button to access the control configuration screens (pictured below), which
shows the IO layout at the Left, Right, Crown, Die, and Vacuum electrical enclosures. If an IO point shows
“Err,” a fault exists with that IO point which could consist of: loss of power to the IO rack, loss of power to the
IO card, or the IO card has a physical hardware fault.
The control box location is displayed at the top (Left Enclosure Hardware Configuration). Touch the Left, Right,
Crown, or Die/Vac buttons at the bottom of the page to access the corresponding control enclosure layout.
Touch the Main, Profibus Diagnostics, or Setup buttons to return to the appropriate screen.
Touch the Detailed Diagnostics button on the Profibus Diagnostics screen to see detailed information
regarding the specific node (image below). Press the Select Slave Manually/Cycle Between Faulted Slaves
button to switch from the manual to the auto slave selection options.
Press the Cycle to Next Faulted Slave or the Next Error button to view the next node with an error.
Touch the Return to Overview button to return to the Profibus Diagnostics screen.
Touch the Return to Setup button to return to the Setup screen.
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Line Setup & Error Overrides Screen
Press the Line Setup & Err. Override button on the Setup screen to access the Line Setup & Error Overrides
screen. An adequate level password must be entered to access this screen. This allows continued operation in
the event of a failed sensor, and/or operation of the Press when the Die has been removed during Die change-
outs.
Press the No Die and/or No Stock button(s) to turn off functions relating to the Die and the handling of the
stock.
Press the Motors On and Start pushbutton while in the Line Setup and Overrides Screen to prevent misuse of
the overrides. All overrides will be cleared if the motors are started in any other screen.
The system alerts the operator with various warnings stating that overrides are active. Errors displayed as
yellow warnings can, and must, be overridden in order to run the Press.
NOTICE
Before using any of these overrides, understand the implications of doing so. Do NOT use these overrides
if you are uncertain. Damage to the machine and/or die could result from improperly setting overrides.
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Machine Options (Recipe Based) Screen
Touch the Mach Options button at the bottom of the Line Setup & Error Overrides screen to access the
Machine Options screen (pictured below).
The Export Recipes button is used by BOTI employees to export the recipes to Excel for easy access to the
machine-specific recipies, if needed.
No data for the Machine Options recipes should be changed, without the assistance of BOTI employees.
Changes could cause damage to the Fin Line and/or Fin Die.
Touch the Main, Overrides, Control Config, or Setup button to return to the corresponding page. See
“Profibus Diagnostic Screen” in this section for an overview of the Control Configuration pages.
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Die Data & Options Screen
Touch the Die Data & Opt. button on the Setup screen to enter this screen. An adequate password must be
entered to access this screen. Data for multiple Dies may be configured, and saved here, with unique names.
The Die No. Field allows flexibility in naming the recipe something other than the Die Number, if desired.
Use the recipe window in the upper left to save all data pertinent to the use of a particular die. This is most
useful if there is a need to run multiple Dies in the Fin Line.
If the Fin Line has a progression changer or servo feed option, the upper right corner will be visible. Enter the
number of holes fed during a full feed (Changer Ret. Holes), and the number of holes fed during a partial
feed (Changer Ext. Holes). The forward feed position, in degrees, must also be set. Typically, this is 102 for a
progression changer, and 85 for a servo feed.
A collection of options appear in the center of the screen. Most fin dies do not need these options; however,
they can be enabled and disabled for the particular die being run in the Fin Line.
Press the Die Functions button to setup the behavior of the gag stations and auxiliary blowoffs, based on the
Die function switch positions. This button will only be visible if the machine option is active. Use programmed
fin(s) from the Fin Chart, which shows possible number of gags and auxiliary blowoffs available on the Fin
Line. Each of these gags may be set to work in a particular way.
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Die Function Screen
Touch the Die Functions button on the Die Data & Options screen to access this screen. This screen will
only be accessible if the option is active on the Fin Line. This screen gives operators control to determine how
installed Die gags will react when the Prog. Fin (from the Fin Chart screen) is on or off.
Click red square(s) under the corresponding Gag station number of the “Gags” row at the top to enable the
gag functionality for that particular station. When enabled, the button will turn green. To disable a particular gag
station, press the green button under the corresponding gag station number.
Prog Fin On
Press the button in the “Prog Fin On” row for the desired gag station number to change the definition for
a particular gag station. The readout in the button will rotate between Prog., Sw, and –Sw.
• Prog. means the state of the gag station is directly set by the state of the button on the Fin Chart
Screen.
• Sw means the state of the gag station is directly controlled by the position of the die function
selector switch.
• -Sw means the state of the gag station is opposite the position of the die function selector switch.
When the die function selector switch is off, the gag station will be energized. This is useful when
the wiring, plumbing, or function of the die gag is reversed from the expected or desired behavior.
Prog Fin Off
The “Prog Fin Off” row determines how the gags behave when the system is not using programmable
fin chart data. Press the button in the “Prog Fin Off” under the desired gag number to change a
definition for that gag station. The readout in the button will rotate
between Sw, -Sw, On, and Off.
1
• On means the gag station is energized, regardless of the die
function selector switch position. 2
3
• Off means the gag station is de-energized, regardless of the die
4
function selector switch position.
5
Auxiliary Blowoff 6
Shown in the figure above are rows labeled “Aux. Blowoff 1” and “Aux. 7
Blowoff 2”. Auxiliary blowoff is an option for machines with extra notch 8
stations. The Die Data screen allows blowoff functions to be associated 9
with any valid gag station(s). The auxiliary blowoff will energize every 10
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stroke in which any one of the associated gag stations creates a true condition. Press the red button
in the “Aux. Blowoff 1 or 2” row to enable the Auxiliary Blowoff to energize with the corresponding gag
station. Press the green button in the “Aux. Blowoff 1 or 2” row to disable the Auxiliary Blowoff for that
particular station.
Auto Slit Adjust

The Auto Slit Adjust button is an option to automatically set the number of rows on a die if both the fin
line and die have this option. The setup of the table will be specific to a particular die, and the number
of rows desired. Refer to the Fin Die manual to properly select Extend (Ext.) or Retract (Ret.) on the
cylinder to configure the die for the proper number of slits selected.
Auto Die Adjust

The Auto Die Adjust button is an option to automatically set the draws on the die.
Die Adjust Screen

Press the Auto Die Adjust button on the Die Data and Options screen to access the Die Adjust screen. This
data is only available on Fin Lines with the Auto Die Adjust option installed and Fin Dies with the Automatic
Adjuster compatible with this option.
Max Reflare/Restrike Dial should be set to the maximum dial setting that either adjuster may move to before
hitting their upper-limit hard stops. The system uses these values to recognize the upper limit of travel.
Stroke to Next must be entered so the system knows how many full progression strokes it takes to move
the stock from one draw station to the next. Typically the value is 1 or 2. The value under the last active draw
station is usually larger since it indicates the number of strokes from that station to the reflare or restrike
station. The value listed under the reflare or restrike is typically larger (10-15) and indicates the number of
strokes to move the stock from that station to just beyond the cutoff. These values are used in conjunction with
the Sequenced Die Adjust method.
The Station Number must be entered so the system can relate valves with die stations. These numbers are
not necessarily in order since the valves could alternate between the left and right side of the die.
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Lube Data & Options Screen
Touch the Lube Data & Opt. button the Setup screen to view this screen. An adequate level password must be
entered to access this screen. Data may be entered, and changed, for the various lubrication systems on the
machine in this screen. Lube setup and maintenance functions, such as purging air out of the lube lines and
greasing the Press, are found on this page as well.
Pre-lube automatically occurs when the operator initiates Continuous Mode. Press the green Prior Action/Run
Continuous button if the timer has expired, based on the “Prelube Timeout” value entered in this screen. The
square in the top right shows a value of 10 minutes for Prelube Timeout, which means the machine will only
idle for 10 minutes after the last activity before it will lubricate the stock.
Continuous Mode will lube the stock since the stock is pulled through the stock lube tray/tank. Press the green
Prior Action/Run Continuous button twice, within a few seconds, to force a manual pre-lube before the
elapsed time has expired.
The Injection Pulse values in the Prelube data section tells the system how many pulses of lube to inject into
the different areas of the die. Enter a larger number of injections for more lubricant.
After the pre-lube stock has completed, the system automatically extends the prelube for several strokes to
allow time for the stock to reach the die when running continuously. After the extended prelube, the system
begins running the continuous lube function.
Data in the Continuous Lube section controls how many strokes happen between injections into the various
areas of the die listed. If more lube is desired, reduce the number, which makes the injections more frequent.
Strokes Between Greasing the Press (Thousand) affects how often the press is greased.
Strokes Since Last Grease (Thousand) is a readout that shows how many thousands of strokes have
happened since the press was last greased. When this number reaches the value entered above it, a greasing
cycle will automatically happen and this number will reset.
Pulses During Tie Rod Lube sets the number of injection pulses sent to the tie rods when they are lubricated.
The tie rods are lubricated every time the press is greased. Changing how often the press is greased also
changes how often the tie rods are lubed. Use a value of at least 10 for this setting in case it takes 8 pulses to
refill lines that have partially drained.
Press the desired Purge button(s) with the Master Start ON to apply the purge(s). The pressed button will turn
yellow, and the appropriate injector will cycle off and on. Press the same Purge button again to turn the purge
function off.
Press the Grease Press button to run the press greasing function. The counter will reset.
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Fin Line Data & Options Screen
Touch the Fin Line Data & Opt. button on the Setup screen to enter this page. An adequate level password
must be entered to access this page. Enter data specific to the machine and installed options in the Fin Line
Data & Options Screen. All options selected on the following screen(s) will be saved by the recipe window in
the upper left of the screen. The screens that are accessible will depend on the options on the Fin Line. Press
the Return to Fin Line Data button on each sub-screen to return to the Fin Line Data & Options screen.
Auto Inch Data Screen

The Auto Inch function is used to inch the Press to a specific crank angle position. Depending on the target
angle, the auto inch clutch on time will be either large, medium, or small. As the crank angle approaches the
target, the choice will shrink from large to small. The move time is also sealed by the die/no die weight. If a
Press can run several Fin Dies, of different weights, the die weight should be adjusted to allow the crank to
move normally.
Fin Production Options Screen

Both options displayed on this screen are typically enabled to increase efficiency.
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Machine Behavior Options Screen
Touch the Enabled/Disabled button to toggle between the two (2) options for each section.
Shutdown Master When Idle

This option will turn the master power off if the machine is left idle for the specified amount of time.
Touch the Shut Down Idle Time (Minutes) box to change the number of minutes.
Count Down Timer

Count Down Timer is used to notify the operator of required Fin Die maintenance that must be
performed before continuing with production.
Count Down Time (minutes) determines how long the machine will run until Die maintenance must be
performed.
Die Cleanout Interval (minutes) determines how long the machine should be stopped/idle for Die
cleanout to be performed. This timer will delay the onscreen Acknowledge button from appearing for
the specified amount of time to prevent the operator from immediately acknowledging the message and
continuing production without performing Die maintenance.
Display Fin Chart

This option will hide the Fin Chart if the current Fin Die doesn’t have to be setup as a programmable fin.
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Misc. Hardware Options Screen
This screen is used to activate additional options that
may have been purchased for the Fin Line.
Press Speed Control Screen

If an electric sheave is installed, this screen will allow the
operator to perform sheave maintenance. The sheave
maintenance function will lower the speed of the flywheel
and verify the system is working within the tolerable
range. It will also increase the speed of the fly wheel and
verify the system is working within the tolerable range.
The flywheel can be controlled manually from this screen.
Stacker Data Screen - Rotary (2 or 3 Position)

Choose the Stacker Type used with the Fin Line to change to appropriate options screen. The various options
and controls for the Rotary Stacker are described below.
Stacker Jam Delay allows a fin to be touching both the suction sheet and the stacker for X msec before the
press will fault with a stacker jam.
NOTICE
If the operator releases the manual stacker pushbutton too early, the stacker will immediately stop rotating.
Max. Stack Height is used, along with the collar height, to determine how many fins can fit on the stacker rod,
leaving an inch from the bottom of the suction sheet to the top of the stack. The vacuum system draws the fins
off the top of the stack if they do not have room to set flat on the stack.
Hold to Rotate determines whether or not the operator must hold the Manual Stacker pushbutton to rotate
the stacker. NO means the operator does not have to press, and hold, the pushbutton the entire time the
stacker is rotating. YES means the operator must hold the pushbutton the entire time.
Rotation Time (msec) is the amount of time, in milliseconds, the stacker has for completion of its rotation.
The stacker will stop attempting to complete the rotation after this set amount of time. If the stacker does not
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have the pull back option the value does not affect the speed of rotation. A flow metering unit on the stacker
controls the rotation speed. If the stacker is equipped with the pull back option, the stacker will push forward
after rotation is complete based on an in-position sensor. This means the process might finish much faster than
the maximum allowable time, which can be set as high as 20 seconds.
Stacker Has Elevator is an option to turn on control of an elevator, if an elevator stacker is installed.
Elevator Drop (msec) determines how many milliseconds the elevator stacker will drop each time it calculates
an inch worth of fins placed on the stacker. This value should be increased if the stacker does not drop far
enough each time. The collar height and/or fins per inch value are used to determine when an inch worth of
fins has been produced. Be sure these values are entered correctly on the Main Screen.
Initial Drop (inch) is the amount of fins (in inches) that must be placed on the stacker before it begins
dropping with each inch of fins.
Pull Back is an option to turn on control of pull back, if the stacker has the pull back option.
Edge Guard EStop is an available option if the edge guard bumper EStops are installed on stacker.
Own Remote IO is an available option if the machine has an elevator stacker with a dedicated PLC to control
its operation.
Auto Raise Elevator will only be used if the machine is equipped with a fantail stacker.
Auto Lower Elevator will only be used if the machine is equipped with a fantail stacker.
Stacker Data Screen - Elevator Cart Stacker

The various options and controls for the Elevator Cart Stacker are described below.
Regular Velocity is the speed the motor spins when the elevator has fins on it. The default is 1000 rpm.
Empty Cart Velocity is the speed the motor spins when no fins are being moved by the elevator. This includes
when the elevator is below the damper bar or when the Fins Produced value on the Main screen is zero (0).
The default is 2200 rpm.
Edge Velocity is the speed the motor spins when the elevator thinks it is close to the top or bottom of its full
travel distance, using the travel distance calculation on the right side of the screen. The default is 500 rpm.
Homing Velocity is the speed the motor spins when it is going through the homing sequence. The default is
500 rpm.
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Maximum Velocity is the upper limit for the rest of the velocity settings on this screen.
Minimum Velocity is the lower limit for the rest of the velocity settings on this screen.
Manual Boost Delay is the number of seconds the elevator will move at Regular Velocity before ramping up to
Empty Cart Velocity. This only happens when the conditions for Empty Cart Velocity are met.
Encoder Resolution is the number of pulses the internal encoder sends to the motor controller. The default is
4096.
Start Position Calculation: If the Start Position Calculation option is on, the elevator will find its start position
based on a calculation using the Current Fins Produced. If the option is off, the elevator will find its start
position by going up until it senses fins or reaches the top of the Elevator.
Cart Damper Bar Assembly is available if the user finds he doesn’t need to use the Elevator while filling
a particular cart. If this option is set to NO, the program will assume no damper bar is installed, and it won’t
automatically go to the start position when the cart is locked. In this case, the Press will not require the elevator
to be homed before operation begins.
Fins Per Drop is calculated using Height Per Drop and the Fins Per Inch from the Main screen.
First Drop Fins is calculated using First Drop Height and the Fins Per Inch from the Main screen.
Travel distance is measured by the Measure Travel Height function on the Elevator Controls screen.
Max Stack Height is a copy of the Fins Per Stack value on the Main Screen. When this number is reached,
the Elevator Cart Stacker automatically returns to the bottom and unlocks.
Light Curtain Laser: When this is on, one side of the light curtain will emit a laser for aligning the light curtain.
Stock Feed Screen

Die Jam Delay (msec) is the amount of time the die jam detector can be high before the press stops.
Keylock Pull Pin in to Stroke is only enabled if the pull pin must be installed in the feed system to perform set
up or continuous running of the press.
Servo Feed (if installed) is an option that will home the servo motor. The feed bar should be in the forward feed
position before homing the encoder. See the “Homing” section in Machine Operation for more information.
Uncoiler Data Screen

Uncoiler Slack Stock Delay (msec) determines how long the uncoiler will continue to pay out after the switch
has been seen.
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Password Configuration Screen
Data access restrictions are set to commonly used levels. Because each company has different views for
who should access certain data, the system allows the customer to configure their own passwords, and
authorization levels.
Passwords may be edited, created, and deleted on this screen. Password levels may also be assigned and
altered. Anyone entering a valid password when logging on may enter the Password Configuration Screen.
Only passwords at their level will be displayed.
Authorization Configuration Screen

Anyone with a level-5 password has access to enter this screen to change passwords and levels, as desired.
The machine owner/supervisor has access to levels 1-5. Multiple users may be created within the same
access level. Passwords may contain any number of numeric values only.
If the supervisor password is forgotten, contact Burr Oak Tool, Inc. to recreate the top-level password. Make
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every effort to safeguard passwords. For security reasons, the operator must log back on after leaving the
Password Configuration and Authorization Configuration Screens.
Set password levels required to perform various machine and data entry functions on the Authorization
Configuration screen. Some input fields are hidden when the required password level is not entered. Some
data may be viewed, but not edited.
The Logon Required to Operate Press toggles between Logon Not Required and Logon Required. When set
to “Logon Required,” a password (at any level) must be entered, or the press will not Master Start.
Line Setup and Overrides password level should be set to a high value. Overriding normal warnings, without
understanding the implications and circumstances, could lead to machine damage.
Validating the software license

Above the bottom of the screen are three circles (1, 2, & 3). To verify the software license is installed, circle 3
should be green. Enter the supplied authorization code in the text box to the right and click … to validate the
entered code.
If circle 3 doesn’t change to green after the code is entered, contact Burr Oak Tool, Inc.
Calibrate Screen
Touch the Calibrate Screen button on the Setup screen to align the touch zones on the physical membrane
of the screen. The screen rarely needs to be recalibrated after it has been done correctly. The only reason to
recalibrate is to adjust for slight differences in view angle for operators of different heights.
The screen will look like the image below. Follow the directions on the screen to calibrate the screen.
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Language Selection Screen
Touch the Language Selection button on the Setup screen to switch between different languages. Select the
language desired. Press a button at the bottom of the screen to proceed with operation.
Exit Application
Touch the Exit Application button on the Setup screen to close the program and view the desktop. A
password is required for this function to work. Press the Start button in the Start Center box that appears on
the desktop to restart the program.
Message Log Screen

The most recent operator message(s) are displayed at the top of the Message Log Screen, with progressively
older messages displayed down the page. These messages are stored for reference, so Burr Oak Tool, Inc.
technical support personnel may obtain internal messages and time-based sequencing of events for further
diagnosis. A list of all messages, and required actions, is located in Appendix B manual.
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Resetting the PLC Retained Data Memory
Unknown problems in the software are referred to as “bugs” in the code. Some bugs cause only minor
annoyances, and can be worked around until a software fix can be developed and a program update sent for
installation. Other bugs cause more difficult problems. Some of these bugs can be cleared by cycling the main
power to the machine.
The PLC has a section of memory that retains certain data values, even when the main power is cycled. If
a bug interacts with one of these retained values, cycling the main power may not fix the problem. It may
become necessary to reset the PLC Retained Data memory. Resetting this data will not affect any of the stored
recipes, since that data resides on the memory card in the touchscreen, not on the PLC.
To reset the PLC data, complete the following steps:
1. Switch the Operator Station to Inch Mode to view Inch screen.
2. Record the current crank angle (to be reset afterwards).
3. Open the door on the operator pendant (holding the touchscreen) to access to the PLC CPU module.
4. On the CPU module (furthest to the left), there is a switch that controls the CPU operation mode. It is
normally in the Run mode. Move the switch to the MRES position. Press it down somewhat firmly for
two seconds (the switch is spring-loaded in this lower position).
5. A light on the CPU should flash on, then off, then on again during this period.
6. Release the downward pressure on the switch, after the light comes back on, for about one (1) second.
7. Press down on the switch again to initiate the memory resetting process. The lights will begin to flash.
8. Move the switch to the RUN position after the resetting process has started. Wait until all lights stop
flashing and the status light indicates the CPU is running (about one (1) minute).
9. Cycle the main disconnect power.
10. Leave the power off for about ten (10) seconds before restoring the main power.
11. Login on the Inch screen with a high-level password.
12. Reset the crank angle.

If this process does not correct the problem, the bug is likely interacting with a machine hardware or electrical
hardware malfunction and is not related to retained data.
Contact Burr Oak Tool, Inc. for further assistance.
Maintenance Password
The Maintenance password is 6514324.
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Global Experience
...Local Solutions
General Maintenance
Ordering Spare Parts
Spare parts may be ordered by calling Burr Oak Tool Inc. at (269) 651-9393.
Please have the following information readily available when ordering spare parts
• Machine Number
• Detail Number
• Part Description
• Item Number, if possible
Lubrication
Essential to the smooth operation of the Fin Line is a machine lubrication system, Fin Stock lubrication, and a
Die Lubrication system. See the Oak Press Solutions Fin Press Operators Manual for additional maintenance &
lubrication information.
The table below lists recommended oils for parts/locations of the Fin Line. Also see “Recommended
Lubrication” in the Installation & Setup section of these instructions for more information.
PART / LOCATION LUBRICATION
Air Line Lubricators, Die Pin/Tie Rod Lube ISO AW10 Hyrdaulic Oil
Bearings, Clevis Pin, Connecting Links, Grease See the Fin Press Operators Manual for all grease
points on Rotary Frame, Feed Pull Pin, Rotary Table, points on the Fin Press.
Rotary Stacker Fittings, Shuttle Wheels, Spindles,
Uncoiler Clutch
Chain Joints without Lube Fittings S.A.E. 30 Oil (up to 70C (160F) temperatures)
Drive Unit ISO VG 220 Gear Lube
Lube Fittings Lithium Soap E.P. Grease of Medium NLGI #2
Other Recommended Lubricants include the following:

• Metalloid 707P-15 • Mettaloid 4116
• Metalloid 4200 • Metalloid 4111
Press Lubrication System
There are 22 points to be lubricated, including eight lower gibs and four upper gibs. Inspect the press
lubrication system each month for broken or loose lubrication lines. See the Fin Press Operator’s Manual for
lubrication information.
Locating Blockage in the Lubrication System

One of the following reasons will cause blockage in the lubrication system:
• Crushed oil line
• Blocked nozzle
• Valve stuck closed
• Clogged filter
Cleaning a blocked, dirty, or contaminated nozzle will temporarily solve contamination blockage problems.
Eliminate the source of the contamination for satisfactory service. Investigate the filtering system or change
filer elements, as required. Inspect, and clean, the reservoir if necessary. Review the reservoir filling method
to eliminate any chance for foreign material to enter the reservoir during filling. All lubricating systems require
filtered lubricant. Keep lids on all lubricants to reduce outside contaminants.
In the case of a blocked nozzle, removing the oil line from the blocked nozzle and injecting compressed air
from the front and back of the nozzle will often clear any internal blockage to the nozzle. When the blockage
is gone, remove the air and reinstall the oil line. Perform the clogged nozzle retest to verify the nozzle pair is
working properly.
Grease the Feed Pull Pin

Follow the instructions below to grease the Feed Pull Pin on the Servo Feed.
1. Open the guard door covering the pull pin.
2. Grease the zerk on the clevis and throw arm.
3. Close the guard door.
Feed Pull Pin
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Accumulator Charging
This equipment may have an accumulator as part of the Hydraulic System. It is important that the accumulator
has the proper pre-charge on it. The Hydraulic schematic will show the desired pressure. Should you need to
replace the accumulator or verify the one you have, follow these steps:
*Recommendation: A charging kit may be purchased from Burr Oak Tool Inc. (item #310847), and is
recommended for this procedure.
*Pre-charge must be checked before installation on all new accumulators.
WARNING
Accumulator and nitrogen supply tank are under pressure.
WARNING
Accumulators must be pre-charged prior to installation to prevent damage to the accumulator bladder.
Initial Setup Before First Time Charging

The charging kit purchased from Burr Oak Tool, Inc. includes a hose, a special shutoff valve and liquid
pressure gauge. (photo 1)
Photo 1 Photo 2
Liquid Pressure Shutoff Valve

Gauge Assembly
Charge Kit
Hose
Shutoff
Valve
1. Assemble the shutoff valve and liquid pressure gauge, as shown (photo ).
2. Tighten the shutoff valve to the liquid pressure guage, using a wrench, to ensure a better seal.
3. Connect the hose to the shutoff valve and the supply tank, as shown (photos 2 & 3).The supply tank
should have a pressure regulator system attached to it, to prevent overcharging the accumulator.
(photo 3).
4. Set the regulator to the desired pressure per machine drawing(s).
5. Remove the accumulator cap nut for charging. This nut protects the accumulator gas stem from
damage and prevents any leakage if the gas stem should fail.
6. Remove the O-ring around the accumulator gas stem. (Photo )
Regulator Gas Stem

O-Ring Photo 4
Photo 3
Release Cap Nut

Valve
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7. Mount the shutoff valve assembly onto the accumulator gas stem, as shown. (Photos & )
8. Tighten the shutoff valve nut, using a wrench, to ensure a tight seal.
Liquid Pressure Liquid Pressure Relief Valve

Gauge Relief Valve Gauge
Shutoff Valve
Hose Connection Shutoff Valve
Cap Nut O Ring Shutoff

Valve Nut
Accumulator
Accumulator
Photo 5 Photo 6
CHARGING THE ACCUMULATOR

1. Open the release valve on the nitrogen tank, and slowly open the shutoff valve on the accumulator
until the pressure gauge starts to increase, then stop.
2. Do not open the valve all the way, as damage may occur to the bladder inside the accumulator.
3. Close the release valve on the Nitrogen Tank after the accumulator has been pressurized.
4. Verify the pressure is still within the desired range, after letting the accumulator set for several
minutes. If the pressure is too high, open the relief valve to bleed the pressure down to the desired
pressure. If the pressure is too low, repeat steps 1-3.
5. Close the shutoff valve on the accumulator, when desired pressure is maintained.
6. Remove the assembly from the accumulator.
7. Replace the o-ring and the cap nut on the accumulator.
RECHARGING AN EXISTING ACCUMULATOR

The machine must be off, and all hydraulic pressure must be released.
1. Install the shut-off valve assembly to the accumulator.
2. Slowly open the shut-off valve to read the pre-charge pressure of the accumulator. If pre-charge
pressure is low, follow the Charging the Accumulator instructions.
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Preventative Maintenance
Use the following Preventative Maintenance guidelines to maintain steady operation of your Fin Press. For
alternate organization of this checklist, see the Preventative Maintenance Table below.
Every Shift Change

Uncoiler (See Appendix A for Maintenance of the Uncoiler Spindle)
 Check, and fill, the air line lubricator
Lube System at rear of Press

 Check, and fill, both air line lubricators
 Check, and fill, the Die Pin / Tie Rod Lube reservoir
Daily
Stock Lubrication System
 Purge the system to evacuate air from the oil lines, as needed.
 Run a nozzle test to check the system for blocked nozzles. (See “Locating Blockage in the Lubrication
System” under Lubrication in this General Maintenance section).
Weekly
Servo Feed
 Grease the tear drop bearing
 Grease the Feed Pull Pin (See “Grease the Feed Pull Pin” under Lubrication in this General
Maintenance section).
 Grease Feed Linkage Arm Bearings (2)
 Grease Feed Shaft Support Bearings (5)
 Grease Yoke Bearings (3)
 Grease Feed Connector Link Bearings

 Check, and fill, the pierce and enhance lube reservoirs

 Clean the machine of excess oil
 Ensure there are no plumbing leaks
 Wipe inside of the pans and stock width detector. Remove aluminum dust and foreign debris.
Stacker
 Grease four (4) grease points on side of Rotary Frame
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Conveyor
 Check the chain tension (See “Chain Drive Tension and Care” in this General Maintenance section).
Monthly
Uncoiler (See Appendix A for Maintenance of the Uncoiler Spindle)
 Grease the Spindle Jaws (6)
 Grease ends of the Spindles
 Grease the Spindle Bearings (2)
 Grease the Uncoiler Clutch
 Check, and fill, the Drive Unit
Suction Unit
 Grease the Suction Door Bearings (4)
 Grease Flange Bearings (6)
 Grease the Clevis Pin
 Grease the Connecting Links (3)

 Change the Stock Lube filter bag

 Check, and drain, the air filter.
 Check, and adjust, the air pressure, if needed.
 Check the Stock Width Sensor for proper functioning
 Check the Encoder Wheel for damage or excessive wear.
Stacker
 Grease the point at the center of the Rotary Table
 Grease the Rotary Bearing
 Grease four (4) to six (6) grease points on the Shuttle Wheels
 Grease the Latch Plate
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Conveyor
 Check the Gear Reducer oil level
 Check the Bearing Lubrication
 Check all fasteners
 Check, and adjust the Conveyor Belt, if needed.
 Check all Bushings, Pins, Sprockets, and Side Bars for wear.
 Check for broken, or cracked, parts.
 Check the rollers to be sure they are rolling. If rollers are sliding, determine and alleviate the cause.
 Check the Conveyor Chain for run off in one direction.
 Grease all lube fittings
 Lubricate chain joints without lube fittings with an oil viscous enough to enable it to reach internal surfaces
under normal conditions.
Quarterly
 Change, or clean, the Pre-Pump filter screen
Preventative Maintenance Table

HOURS
2080 (Annually)
224 (Monthly)
8 (Each Shift)
40 (Weekly)
PROCEDURE LUBRICATION TYPE
UNCOILER
Check and fill air line lubricator X ISO 10 Hydraulic Oil
Grease spindle jaws (6) X SHC 460, Lithium Base Grease
Grease end of spindles X SHC 460, Lithium Base Grease
Grease spindle bearings (2) X SHC 460, Lithium Base Grease
Grease uncoiler clutch X SHC 460, Lithium Base Grease
Check and fill drive unit X ISO VG 220 Gear Lube
SUCTION UNIT
Grease suction door bearings (4) X SHC 460, Lithium Base Grease
Grease Flange Bearings (6) X
Grease the Clevis Pin X
Grease the Connecting Links (3) X
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HOURS
2080 (Annually)
224 (Monthlly)
8 (Each Shift)
40 (Weekly)
SERVO FEED
Grease tear drop bearing X SHC 460, Lithium Base Grease
Grease the feed pull pin X SHC 460, Lithium Base Grease
Grease feed linkage arm bearings (2) X SHC 460, Lithium Base Grease
Grease feed shaft support bearings (5) X SHC 460, Lithium Base Grease
Grease yoke bearings (3) X SHC 460, Lithium Base Grease
Grease feed connector link bearings X SHC 460, Lithium Base Grease
LUBE SYSTEM at rear of PRESS
Check and fill air line lubricators (2) X See the Operator Manual.
Check and fill the pierce and enhance lube reservoir X See the Operator Manual.
Change stock lube filter bag X See the Operator Manual.
Check and fill die pin/tie rod lube reservoir X See the Operator Manual.
PRESS
See the Oak Press Solutions Fin Press Manual for Maintenance information.
STACKER
Four grease points on side of rotary frame X SHC 460, Lithium Base Grease
Grease point at center of rotary table X SHC 460, Lithium Base Grease
Four to six grease points on shuttle wheels X SHC 460, Lithium Base Grease
Grease the Latch Plate X
CONVEYOR
Check the chain tension X
Check the gear reducer oil level X
Check the bearing lubrication X
Check all fasteners X
Check, and adjust, the Conveyor Belt, if needed. X
Check Bushings, Pins, Sprockets, Side Bars for wear X
Check for broken, or cracked, parts. X
Check the rollers to be sure they are rolling. X
Check the Conveyor Chain for run off in one direction. X
Grease all Lube Fittings X
Lubricate the Chain Joints without Lube Fittings X
STOCK LUBRICATION SYSTEM
Purge the System to evacuate air from the oil lines. X
Run a Nozzle Test X
Clean the machine of excess oil. X
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HOURS
2080 (Annually)
224 (Monthly)
8 (Each Shift)
40 (Weekly)
STOCK LUBRICATION SYSTEM

Check for any plumbing leaks X
Remove aluminum dust and foreign debris from pans X
and stock width detector.
Check, and drain, the air filter X
Check, and adjust, the air pressure X
Check the Stock Width Sensor for proper functioning X
Check the Encoder Wheel to damage, or wear X
Change, or clean, the Pre-Pump Filter Screen This should be done Quarterly.
Scrap Conveyor Chain Drive Tension and Care

The correct amount of slack is essential to the proper operation of a chain drive. Unlike flat or “V” belts,
chains require no initial tension. When the chain is too tight, working parts carry a much heavier load than is
necessary, resulting in additional wear. Too much slack is also harmful, as it can cause vibration or chain whip.
Make routine inspections for proper elongation and broken parts. Elongation is at fault when the chain rides up
on the sprocket, then snaps into place. Replace both the chain and sprockets in the event that elongation or
damaged sprockets occur. Do not put new chain on old sprockets or old chain on new sprockets; replace both.
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Toledo PWi Tonnage Monitor Configuration Notes for 1000 and
1400 Fin Presses
Refer to the PWI user manual configuration mode section for reference
1. Channel Menu Setting- 4 channels
2. Decimal Point Menu- enter 01 decimal points
3. Capacity Menu- set to 160 tons for 1400 press, 112 tons for 1000 press
4. Trigger Menu- set to Threshold. Threshold value is 6% capacity by default.
5. Learn Menu- set to % of Benchmark
6. Delay Value Menu- set to 0 (default)
7. Offset Value Menu- N/A, only used with resolver
8. Mode Menu- set to Peak (default)
9. Estop Menu- not used
10. Setup Count Menu- set to 100 strokes
11. Address Menu- not used
12. Baud Rate Menu- not used
13. Security Code Menu-default is 4170 (last 4 digits of Toledo phone #). Customer preference- leave
disabled at Oak (default)
General Tonnage Calibration Notes

1. Strain sensors should be torqued to 150 in lb with the crown down and locked after the press has been
leveled with load cells.
2. Zero the balance on the strain sensors and then set the gain numbers. After setting the gain numbers,
recheck the balance numbers. These may move slightly if the gain is changed by a large amount. It’s
a good idea to periodically look at the balance numbers while calibrating to make sure they have not
wandered for any reason.
3. Typical gain number starting point for the 1000 and 1400 press will be about 24-25. After calibration it is
typical to see the RR corner with a somewhat higher gain value than the other 3 corners.
4. Be sure and record the gain numbers on the tonnage calibration sheet.
5. NOTE- To avoid nuisance tripping, upon initial die installation, the monitor should be in SETUP mode.
When the die is running well, the monitor should be placed in LEARN mode, where it will sample and
learn the die tonnage. At that point it will automatically revert to RUN mode and will closely monitor the
die tonnage based on the SETPOINT percentages that are entered in the SETPOINT menu.
98 403631
PWi Tonnage Monitor User Tips
To avoid nuisance tripping, upon initial die installation, the monitor should be in SETUP mode. In SETUP
mode, the tonnage monitor will only trigger a fault when tonnage exceeds the capacity of the press. The
tonnage monitor will allow 100 press strokes in setup mode before it automatically reverts to RUN mode. This
value can be edited if the monitor is put into configuration mode (see PWi user manual). If the monitor reverts
to RUN mode before die setup is complete, simply place the monitor back in SETUP mode. This will reset the
100 stroke count. When the die is running well in continuous, the monitor should be placed in LEARN mode,
where it will sample 8 consecutive press strokes and learn the die tonnage. At that point it will automatically
revert to RUN mode and will closely monitor the die tonnage based on the set point percentages that are
entered in the SETPOINT menu.
Set point percentages- On the SETPOINT menu page, a percentage value is entered for each corner of the
press and also a total percentage. This percentage is based on the running tonnage, or benchmark tonnage
of the die that was measured when the monitor was in LEARN mode. If the running tonnage deviates from
the benchmark by more than the percentages entered on the SETPOINT page, a fault will be declared and
the press will stop. In order to avoid nuisance trips it is recommended to make the corner SETPOINT values
slightly higher than the total value. This is due to the fact that when the press ramps up in speed, many times a
slight variance in corner tonnages will be observed, while the total tonnage usually remains fairly consistent.
Due to the fact that the monitors are operating in threshold mode, it is recommended that the low tonnage set
points remain at 0. This will eliminate nuisance stops while inching. If low tonnage needs to be monitored and
values other than 0 are entered in the low tonnage set point menu, then it is recommended that the monitor be
placed into SETUP mode while inching.
Jobs- On the job menu page, a job number will be displayed. When the LEARN mode is used and die tonnage
is sampled, these numbers will become part of that job recipe, along with any SETPOINT values that are
entered. To save these values for a particular die, simply record the job number, assign it to the die and then
change the job number before loading another die. If the job number is not changed, the tonnage monitor will
simply overwrite the learned tonnage values and entered set point values from the new die.
Alarms- When a tonnage alarm is generated, the red LED values on the monitor will flash and the press
will stop. To reset the alarm, press the SELECT button on the monitor to scroll to the alarm page. Push the
SELECT button again to reset the alarm.
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100 403631
Global Experience
...Local Solutions Troubleshooting
General Machine / Station Troubleshooting
The following guide lists problems / conditions, followed by potential corrections. This is only a quick guide. If
a specific solution cannot be found, please contact Burr Oak Tool, Inc. We will try to help resolve the problem
and return your machine to full production.
Uncoiler
PROBLEM CAUSE SOLUTION
The pinch rollers do not operate. The pneumatic supply line is not Check the connection and correct,
connected to the uncoiler. if necessary.
The electrical supply line is not Check the connection and correct
connected to the uncoiler. if necessary.
The motor, clutch, brake, solenoid, Identify the problem and replace or
and/or stock fault sensor is repair defective part(s).
malfunctioning.
The stock fault sensor is out of Readjust the stock fault sensor.
alignment.
The fin stock wrinkles while The fin stock coil is not centered Center the stock coil.
passing through the pinch rollers. on the spindle, relative to the die.
The compression between the Adjust the spring plungers on the
pinch rollers is uneven. pinch roller locking bar.
The fin stock unrolls from the coil The pressure between the pinch Adjust the spring plungers on the
too slowly. rollers is insufficient. pinch rollers.
The motor speed is set too low. Increase the uncoiler drive speed.
The clutch/brake pressure Adjust the pressure regulator to the
regulator is set too low. appropriate setting.
The fin stock unrolls from the coil There is a spindle brake Identify the problem and replace or
too quickly. malfunction. repair the defective brake unit.
There is a stock fault malfunction Identify the problem and replace or
or misalignment. repair the stock fault sensor.
There is excessive play in the The wear strip is damaged. Replace the wear strip (DET
uncoiler jaws. #3110).
The wedge nut is worn. Replace the wedge nut (DET
#3106).
The wear strip screw(s) are broken Replace the strip screw(s) (DET
or loose. #3111).
The lock pin will not lock. The pin is in the wrong location. Check and locate the pin correctly.
The pin is bent or broken. Replace the pin assembly (DET
#3117A).
Only one side of the jaws expands. The wear strip is damaged. Replace the wear strip (DET
#3110).
The wear strip screw is damaged. Replace the strip screw (DET
#3111).
There is a hydraulic fluid leak. Hoses are damaged, or not Tighten, and replace, all hose
properly tightened. connections, as necessary.
The motor seal is bad. Replace, or rebuild, the Hydraulic
Motor (DET #6112).
The Uncoiler Jaws do not extend. The motor is not functioning. Replace, or rebuild, the Hyrdaulic
Motor (DET #6112).
The Hydraulic pressure is low. Check if the power is on, and
adjust the pressure setting.
102 403631
Fin Press
The press will not run in The fins are binding near the cutoff Adjust the stacker tooling position
Continuous Mode area, causing a stacker jam. as required to insure proper fin
stacking.
The press crown is not resting in Lower the crown onto the adjusting
the adjusting nuts. nuts. See the Operation Manual.
The hydraulic circuit breaker has Determine the cause of the
tripped. hydraulic overload and reset the
circuit breaker.
A light on the control panel Reset the hydraulic pump.
indicates LOW HYDRAULIC OIL
PRESSURE.
Insufficient supply of air to the Increase the incoming pneumatic
press. service volume.
One of the lubricant reservoirs is Verify fluid levels in the reservoirs,
not filled to the proper level. and then fill as needed.
The mode switch is in the wrong Verify that the mode switch is in
position. cont.
There is a malfunction in the pressIdentify the problem and repair the
clutch or the press clutch valve. malfunction.
There is a malfunction in the fin Identify the problem and repair the
line control system. malfunction.
The main press bearings are not There are broken grease lines. Replace all broken grease lines on
receiving sufficient grease the press.
A seal in the lubrication system Locate the leak and replace the
manifold is leaking. seal.
There is a malfunction in the line Identify the problem and repair the
control system. malfunction.
The press crown exhibits uneven, The hydraulic system contains air Bleed the hydraulic system.
spongy action when actuated. pockets. Follow the press cylinder and seal
replacement instructions.
The hydraulic circuit breaker trips The shut height is incorrect. Verify the correct shut height for
often, or the hydraulic system the installed die. Reset the shut
loses pressure when the crown is height. See the Operation Manual.
down. Foreign material in the die is Perform a complete inspection of
causing hydraulic system pressure the die. Look for problems in the
overloads. bushings, under the stripper plates,
and check for slug accumulation.
The hydraulic circuit breaker is Identify the problem and repair the
malfunctioning. malfunction.
No pressure in hydraulic Recharge the hydraulic
accumulator. accumulator. See feed system
section for accumulator recharging
instructions.
403631 103
Fin Press (Cont’d)...
Oil exhausts from vent port of Leaking bleed screw(s) in top of Remove plue and replace using
either of the two counterbalance crown piston(s) pipe sealing compound. Replace
air regulators. leaking piston seals.
The top stop pushbutton does Safety Unit malfunction. Check Identify the problem and repair.
not stop the press. clutch valve wiring.
Suction Unit
The fins do not fit properly against Dirt and debris inside of the suction Check for and remove dirt and
the suction sheet. pan is blocking air flow through the debris from the suction fan and
suction sheet. suction sheet.
The suction doors are not sealing Check the suction unit door seals
properly. and replace if necessary.
The suction sheet is not correct for Check the end of the suction
the die. sheet for the die number. Install
the correct suction sheet for the
current die.
The suction motor velocity is Increase the AC power frequency
insufficient. to the motor.
The suction unit doors break on a The air pressure is too high. Recommended pressure is 5 PSI.
consistent basis.
Fins do not drop off suction unit Flow control valve for suction unit Readjust valve for proper airflow.
quickly enough doors set improperly
Cylinder not working properly. Identify problem and replace or
repair cylinder.
Timing improperly set. Adjust the timing of the suction
door. See controls section.
Oil, dirt, or water in solenoid valve. Identify problem and replace or
repair solenoid.
Suction door mechanism not Identify problem and repair
functioning properly. malfunction.
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Stacker
The fins will not drop onto the rods The stacker rods are misaligned. Realign the stacker rods. See the
properly. Operation Manual.
The stacker is out of position. Realign the stacker base. See the
Installation Manual.
The timing is incorrect. Adjust the suction unit door timing.
The stacker will not rotate. The locking pin will not retract. Identify the problem and repair the
malfunction.
The hydraulic pressure is low. Reset the hydraulic pump.
The limit switch is not making Adjust the mechanism so that the
contact. switch makes contact.
The hydraulic, pneumatic, and/ Check all connections and correct
or electrical lines are not properly if necessary.
connected.
The stacker will not extend or The hydraulic pressure is low. Reset the hydraulic pump.
retract.
The limit switch is not making Adjust the mechanism to ensure
contact. that the switch is making contact.
There is a stacker fault. Check for an issue and correct.
Stacker is blocked Check stacker and surrounding
area for blockage.
The stacker drifts away from the The pull back cylinder seals are Replace the seal kit or the entire
press. (Leaves stacking position by bad. cylinder.
pulling back prematurely.)
403631 105
Conveyor
The roller chain is jumping teeth. The roller chain my require Check the sprocket alignment and
adjusting. roller chain adjustment.
The motor is running, but the belt The torque limiter may require Check the torque limiter for proper
is not turning. adjusting; the roller chain may adjustment. Check the roller chain
be disconnected, key(s) may be adjustment. Inspect the conveyor
sheared or the conveyor belt may for parts that may be causing the
be jammed. belt to jam.
The motor full load current The conveyor belt movement may Inspect conveyor for any parts that
exceeds the name plate rating, be obstructed, causing an increase may be coming in contact with the
causing the control overload to trip. in torque. Ambient temperature is belt and causing the amount of
too high. Reducer oil level is low, torque rating of the drive. Remove
causing high heat condition. the source of heat, shield the
motor from the heat, increase
cooling capacity of the motor,
increase the insulation class of the
motor. Check the reducer oil level.
The belt is pulsating or lurching. The conveyor belt may require Inspect the belt for proper tension.
adjusting.
Parts are adhering to the belt. The coolant or oils are too thick. Reduce the consistency of
Pimples worn from the front belt coolants or change type of coolant.
surface. Parts are caught in hinge Replace belt parts as needed.
loops.
Belt axles are breaking. Belt wheels are wearing into the Belt tension is uneven: replace
belt axles causing the ends of the belt parts as required, readjust belt
axles to break. tension.
NOTE: Always replace belt
sprockets before installing a new
or rebuilt belt when this problem
occurs.
Belt aprons are cracking. Parts impact the belt surface. Reduce the impact.
Belt jamming. Obstruction inside the frame, Inspect the conveyor for
missing cotter keys from belt axles, obstruction, this may require
broken axles or belt hitting the removal of belt. Inspect the axles
frame. for missing cotter keys or broken
axles. Inspect the conveyor frame
for internal or external damage.
106 403631
Clutch
Failure to engage. Air is not getting to the clutch due Check the control valve and the air
to a control valve malfunction or pressure setting.
low air pressure.
Defective O-ring seals are causing Replace o-ring seals.
air leaks.
Lack of lubrication on the hub Lubricate the hub spline or check
spline or in the air chamber. the air line lubricator settings.
Rigid pipe or tubing for air line Use flexible pipe or tubing for all air
connections. line connections.
Failure to disengage. Friction lock due to a lack of Lubricate the hub spline or check
lubrication on the hub spline or in the air line lubricator settings.
the air chamber.
Broken compression spring. Install new compression spring.
Unexhausted air due to a control Check or replace the control valve.
valve malfunction.
Excessive drag on the air line. Defective bearings. Replace bearings.
Air line not properly supported. Rest the air line against a support
that is parallel to the centerline of
the clutch.
Produced Fins
The produced fin stack is uneven. The feed system is deforming the Readjust the feed system. See the
fin collars. Operation Manual.
Foreign matter has accumulated Clean and stone the upper and
between die shoes and press lower mounting surfaces of the
surfaces. press and die.
The press ram surface is not Check for ram parallelism and
parallel to the bolster surface. readjust as necessary. See press
section.
Produced fins are not to A malfunction has occurred in the Reference fin die manual
specifications. fin die. troubleshooting section to
determine the problem.
Final fins are dripping with Too much lubricant is being applied Adjust the Fin Stock Lubricator
lubricant. during production. to reduce the amount of applied
lubricant. Make small adjustments
at a time to prevent dry fins.
Final fins have broken collars. If not enough lubricant when Adjust the Fin Stock Lubricator
entering the draw and/or pierce to incrase the amount of applied
stations. lubricant. Make small adjustments
at a time to prevent dripping fins.
Enough lubricant is present when Refer to the Fin Die Manual for
entering the draw and/or pierce troubleshooting the collar issue.
stations.
403631 107
108 403631
Global Experience
...Local Solutions
Appendix A
Uncoiler Spindles
Maintenance of Standard Uncoiler Spindle
Malfunction of the uncoiler spindle may require the spindle be taken apart to replace internal parts crucial to
proper operation. The following instructions illustrate assembly and disassembly of 4” and 8” uncoiler spindles.
NOTICE
Before disassembly, be sure that the pneumatic supply has been disconnected.
Disassembly of 4” Spindle
1. Using a 1/4” Allen wrench, remove the four socket head cap screws holding the spindle end cap in
position. (Image 1)
2. Remove the end cap and set aside.
3. Pull out the wedge nut stop spacer if there is one in the spindle. (Image ) This stop spacer is not used
on size 18 uncoilers. This spacer prevents the right-hand wedge nut from disengaging from the jaws
during operation.
4. Using a 5/32” Allen wrench, remove two socket set screws from holes A & B that are on the top and
bottom of the spindle located near the middle of the spindle jaws. (Image )
5. Using the 5/32” Allen wrench, remove one socket set screw from hole C. (Image ) The other set screw
(D) is used to stop the left-hand wedge nut from rotating when removal of long draw bar is necessary.
6. Turn the hand wheel to disengage the wedge nuts from the jaws and to get the left hand wedge nut to
pass by the set screw hole C.
7. Remove the right-hand wedge nut by turning the nut counter-clockwise until it comes free from the draw
bar. (Image )
8. Rotate the spindle until one jaw is pointed towards the floor. The jaw should be clamped in the fully
extended position. Repeat this until all three jaws are clamped.
9. Rotate the draw bar until the roll pin that connects the long draw bar to the short draw bar with a
coupling, lines up with the set screw hole A. (Image )
10. Drive out the roll pin with a 1/4” diameter rod or punch. The roll pin will come out through the bottom set
screw hole B. (Image )
11. Using a 1/2” square piece of steel, or a 1/2” drive ratchet extension, unscrew the short draw bar from
the long draw bar by rotating it clockwise. The coupling and stop sleeve are attached to the short draw
bar and will all come out together. (Image )
12. Use a 1/4” Allen wrench to remove the four socket cap screws from the end cap on the hand wheel end
of the shaft.
13. Unscrew the long shaft from the left-hand wedge nut that is still in the spindle. (Image )
14. Remove all grease zerks from each jaw before

proceeding. Remove the jaws by rotating the spindle
until one is pointed downward. Unclamp this jaw and
push up through the slot. While pushing up, move the
jaw towards the end of the spindle for removal. (Image
)
15. Repeat step #14 for the other two jaws.
110 403631
16. Push the left-hand wedge nut to the jaw openings in the spindle using the long draw bar. This will push
the wedge nut out the spindle end. (Image )
NOTICE
The long draw bar will not be able to push the wedge nut out the end.
17. Inspect all parts for damage. Repair, or replace, parts as needed. The wear strips on the jaws are
subject to severe forces and may be damaged. It is recommended that while the spindle is apart, the
wear strips be replaced.
18. Each jaw has two wear strips that have two special screws. (Image ) These screws are glued into
place with Loctite 680 retaining compound. This helps ensure the wear strip screws do not work loose.
Heat is required to remove these screws. Heat should be applied close to the screw location on the jaw;
heating the wear strip will not be as effective.
403631 111
Assembly of 4” Spindle
1. Verify the set screw is in the tapped hole D - farthest from the spindle jaw, as shown. This set screw
prevents the left-hand wedge nut from rotating when installing the long draw bar. Do not put the set
screw in hole C at this time. (Image A)
2. Place the left-hand wedge nut into the spindle, and push it in until it stops by the set screw hole D. It is
important that this nut be put in the spindle, as shown, with the small slot pointed upward. (Image B)
Reversing the nut will cause damage and not allow the jaws to work.
3. Install one jaw into the spindle slot, with one jaw slot pointed downward, and clamp it into position.
(Image C) Rotate spindle and repeat this for the other two jaws.
4. Install the grease zerks into the spindle jaws.
5. Insert the long draw bar from the bearing end of the spindle and screw into the left-hand wedge nut.
(Image D)
6. Fasten the hand wheel end cap onto the spindle with four socket cap screws.
7. Install the short draw bar onto the long draw using a 1/2” drive extension, or 1/2” square bar. (Image E)
8. Line up the roll pin-hole, using a 3/16” diameter rod or punch in the middle set screw hole A, by rotating
the short draw bar until the rod engages the hole. (Image F)
112 403631
9. Rotate the long draw bar with the pin through the set screw hole and into the coupling hole, using the
hand wheel until the holes line up so that the rod can go through.
10. Drive a 1/4” x 1-3/4” roll pin into the coupling and long draw bar. Drive the roll pin far enough so the
draw bar can freely rotate. Use a 1/4” diameter punch to get the roll pin inside of the spindle. (Image G)
11. Slowly rotate the hand wheel, using a 1/4” diameter rod in the set screw hole C, until the left hand
wedge nut makes contact with this rod. (Image H)
12. Remove the rod.
13. Install the right-hand wedge nut onto the short draw bar and rotate it until it touches the jaws. (Image
I) Look into the end of the spindle to determine if the nut is lined up with the jaws. If it is not lined up,
rotate the nut back until it is lined up.
14. Unclamp all of the jaws. While holding the bottom jaw up, rotate the hand wheel clockwise to engage
both nuts onto the jaws. This may take a couple of attempts to line up the wedge nuts properly.
15. Install the wedge nut stop sleeve if the uncoiler is not a size 18. (Image J) Make sure this stop sleeve is
installed. Without it, the wedge nuts could come free from the jaws during operation.
16. Install the spindle end cap.
403631 113
Disassembly of 4” Uncoiler Spindle - Hydraulic Powered
1. Remove the hydraulic motor assembly (Det. 6112) by removing four (4) socket cap screws.
2. Remove end cap (Det. 3122 or Det. 3123) by removing four (4) socket head cap screws.
3. Remove two (2) 5/16-18” set screws approximately 18-1/2” from the right hand end of the coil shaft.
(Det. 3101)
4. Remove one (1) 5/16-18” set screw approximately 27-1/2” from the right hand end of the coil shaft. (Det.
3101)
5. Retract the coil holding jaws, using a 1/2” extension, (Det. 3108) until the left hand wedge nut (Det.
3107) completely passes by the set screw hole at Step #4.
6. Unscrew, and remove, the right hand wedge nut. (Det. 3106)
7. Hold the coil holding jaws (Det. 3108) out, and clamp them in position.
8. Line up the 1/4” x 1-3/4’ inch roll pin with the set screw holes (Step #3) and drive out.
9. Unscrew the short draw bar, (Det. 3103) and remove. The coupling (Det. 3104) and the stop sleeve
(Det. 3105) will come out when you remove the short draw bar using a 1/2” square extension.
Note: Det. # is not used on size and size uncoilers.
10. Put a 1/4” diameter rod in the set screw hole (Step #4) to hold the left hand wedge nut in position.
11. Remove the four (4) socket cap screws on the motor adapter housing (Det. 6117) of the coil shaft.
12. Unscrew the long draw bar, (Det. 3102) along with the motor adapter housing, (Det. 6117) and remove.
This assembly should be taken apart before reassembly.
13. After removing, and unclamping, the grease fittings, the coil holding jaws may be removed one at a
time from inside the coil shaft.
14. Reverse the procedure for reassembly, but first assemble the left hand nut (Det. 3107) and the long
draw bar. (Det. 3102)
114 403631
Disassembly of 8” Uncoiler Spindle
1. Remove the end cap assembly (Det. 3122) by removing 4 socket head cap screws.
2. Remove one (1) set screw from the coil shaft closest to the jaws. (Do not remove the Dog Point set
screw.)
3. Turn the handwheel to retract the coil holding jaws (Det. 3108) until the wedge nuts (Det. 3107 and Det.
3106) disengage from the holding jaws. The jaws are disengaged when the left hand wedge nut (Det.
3107) passes by the set screw hole.
4. Unscrew and remove the right hand wedge nut. (Det. 3106)
5. Hold the coil holding jaws (Det. 3108) out and clamp in position.
6. Put a 1/4” diameter rod in the set screw hole (Step #2) to hold the left hand wedge nut in position.
7. Remove the four (4) end cap screws on the handwheel end of the coil shaft.
8. Turn the handwheel in order to expose the bearing (Det. 3115) and remove the spring pin holding it onto
the shaft.
9. Remove the spring pin from the handwheel. (Det. 3117)
10. Remove the handwheel (Det. 3117), end cap (Det. 3113), bearing (Det. 3115) and bearing housing (Det.
3114) from the shaft. Remove the draw bar (Det. 3103) from the opposite end by unscrewing it from the
left hand wedge nut. (Det. 3107)
11. Remove, and unclamp, the grease fittings, and remove the coil holding jaws from inside the coil shaft.
12. Remove the left hand wedge nut (Det. 3107) out of the same end as the above step.
13. Reverse the procedure for reassembly.
403631 115
Disassembly of 8” Uncoiler Spindle - Hydraulic Powered
1. Disconnect, and remove, the hydraulic lines to the spindle.
2. Remove the hydraulic motor assembly (Det. 6108, 6109, 6110 and 6112) by removing four (4) 1/4” 20
socket cap screws (outermost bolts) from the cover plate. (Det. 6110)
3. Remove the locking plate (Det. 6000) by loosening two (2) set screws on the side of the cap and sliding
off the attached shaft.
4. Remove four (4) socket cap screws in order to remove the end cap. (Det. 3122)
5. Remove the right hand wedge nut (Det. 3106) by rotating the draw bar (Det. 3103) until the holding jaws
(Det. 3108) come free from the wedge nuts and drop in. The right hand wedge nut (Det. 3106) should
come out the end with more rotation of the draw bar. (Det. 3103)
6. Pull the coil holding jaws (Det. 3108) into an extended position and clamp.
7. Remove the draw bar (Det. 3103), stop sleeve (Det. 3105) and the left hand wedge nut (Det. 3107) by
sliding it out the end where the hydraulic motor was removed from.
8. After removing the grease fittings and unclamping, the coil holding jaws may be removed from inside
the coil shaft.
9. Reverse the procedure for reassembly.
116 403631
Global Experience
...Local Solutions Appendix B
Machine Status Message Descriptions
The machine status messages appear near the bottom of the screen on the four screens from which the
operator can run the press and cause motion on the main ram). These messages generally describe what
the operator needs to do next in order to run the press. Sometimes the messages describe errors that are
preventing the press from being operated with the requirement that the error has to be corrected before
proceeding.
A great deal of effort has gone into ordering the messages in a logical fashion so that more fundamental root
cause errors precede and preempt lesser errors. For example, if the machine is displaying “[MS035] Press
the Master Start Pushbutton: as the current message and the operator presses the console e-stop, then the
message will switch to “[MS030] The Operator’s E-Stop is Active”. This is because the Master Start will not
respond until all e-stops have been deactivated.
Even so, the system still tries to help the operator wherever possible. If under the above condition, the operator
were to try pushing the master start pushbutton even though the console e-stop was active, a pop-up screen
would appear with the following message: “[AP041] Master Start Error: Operator Console E-Stop is Active”.
The description of other pop-up messages can be found in Appendix B-3 below.
A button is associated with the machine status messages listed in the Appendix. The figure below shows a pre-
lube warning message and a yellow override error button near the bottom of the Main Screen. The message
line and the button are both either yellow or red. Yellow messages can be overridden by pressing the right
corner of the operator’s hanging console pendant. The top stop button was provided as an alternative method
in order to reduce wear and tear on the touchscreen through repeated touching. Red error messages cannot
be overridden and must be corrected before the press can be run. Some red error messages can be turned
into yellow warning messages through the use of the Line Setup & Overrides Screen.
The prelube warning can be overridden.
MESSAGE CORRECTIVE ACTION
MS001 Press is ready to Run. This is the only message that is neither yellow nor red. When it is displayed
the press is ready to be run (Continuous Run, Setup Stroke, or one of the
Inch Modes).
MS002 Operator Must be This message appears when the “Logon Required to Operate Press” option
logged on to run machine. has been set in the Authorization Configuration Screen and no valid logon
has yet been entered. Press the logon button in the lower right hand corner
of the touchscreen and enter one of the valid passwords.
MS003 Screen
Synchronization Error. Contact
BOTI. Cycle Main Power.
MS005 Fin Chart Data Error: This message occurs when there is data in the programmable fin chart after
Cutoff Must Appear on the the last programmed cutoff.
Last Line of the Fin Chart
MS006 Fin Chart Data Error: This message occurs when a cutoff has been programmed on the first stroke
First Stroke Must Not be a in the Fin Chart.
Cutoff
MS007 Fin Chart Data Error: This message occurs when cutoffs have been programmed on consecutive
Consecutive Cutoffs are not strokes in the Fin Chart. Multiple cutoffs are allowed, but not back-to-back.
permitted
MS008 Fin Chart Data Errors: This message appears when the number of holes calculated from the active
Programmed Holes Does Not Fin Chart does not match the number of Holes Per Fin entered in the input
Match Holes Required box.
MS009 Wrong Safety Unit Contact Burr Oak Tool. Check serial comm card in PLC. Check serial cable.
Program. CRC Check Does Check safety unit power.
Not Match
MS010 Fin Produced Equals This message appears when the machine has produces all the fins required
or Exceeds Fins Per Stack for a given stack according to the data entered in the Main Screen. Either
Required reset the fins produced to zero or increase the number of required Fins Per
Stack.
MS011 Coils Produced Equals This message appears when the machine has produces all the coils required
or Exceeds Coils Required according to the Coils Required input. This warning is given in order to
prevent accidental over production of a given coil run. Either reset the coils
produced counter or increase the number of coils required.
MS012 Warning: One or More This message appears when one or more of the Line Setup Overrides has
Line Setup Overrides is Active been activated in the Line Setup and Overrides Screen. These overrides are
generally set only when first setting up a machine line, changing out auxiliary
equipment, or when a temporary condition exists such as a faulty sensor and
the fault it causes is known to be erroneous.
M013 Warning; No Stock This message appears when the “NoStock” mode has been set in the Line
Mode is Active Setup and Overrides Screen. Setting this mode turns off a number of items
such as the uncoiler. It also activates a number of overrides.
MS014 No Die Mode and No This message appears when the “No Die” mode has been set in the Line
Stock Mode are Active Setup and Overrides Screen. Setting this mode also sets the No Stock mode
as well. It also activates a number of overrides in addition to those set by the
No Stock Mode.
MS015 Press Speed This message appears when the system detects no analog feedback is
Adj. Feedback Inverted/ coming from the potentiometer attached to the press motor speed adjusting
Disconnected. Fix the Cycle actuator. This problem will generally require an electrician in order to
Main Power. troubleshoot this issue further. The main power will need to be cycled in
order to clear this error.
118 403631
MS016 Press Speed Adj. This message appears when the system detects the motor leads to the
Motor Leads Swapped. Fix press motor speed adjusting actuator are swapped. In other words, the
then Cycle Main Power. motor is going the opposite direction from what is expected. This problem
will generally require an electrician in order to troubleshoot the issue further.
It usually only occurs when the machine is initially assembled or after
replacing some other component.
MS017 Encoder Wiring or This message occurs when the system detects the encoder has a wiring
Homing Problem. Contact an problem. For example, one of the two channels A or B has a broken wire.
Electrician! Cycle Main Power.
MS018 Encoder is counting This message appears when the system detects the encoder is counting
backwards. Contact an backwards. This is generally solved by swapping A with -A or B with -B. the
Electrician! Cycle Main Power. problem will still exist if you swap both pairs.
MS019 Top Dead Center This message appears when the system detects that the Top Dead Center
Prox Not Counting Properly. Proximity switch is not counting properly. This is usually due to the sensor
Contact an Electrician! being adjusted too far or too close to the metal pickup bar that rotates with
the crank shaft. Another problem is the presence of electrical noise on the
input causing extra counts.
MS020 TDC Prox. Indicates This message will occur when the entered crank angle does not sufficiently
that the Crank Angle Should match the actual crank angle of the press. When the press sees the Top
Be Larger For Proper Homing. Dead Center Proximity switch it checks the current internal encoder value. If
the internal value is too small, 340 for example, then this message appears.
The TDC Proximity switch is first detected at around 355 degrees.
MS021 TDC Prox. Indicates This message will occur when the entered crank angle does not sufficiently
that Crank Angle Should Be match the actual crank angle of the press. When the press sees the Top
Smaller For Proper Homing. Dead Center Proximity switch it checks the current internal encoder value. If
the internal value is too large, 20 for example, then this message appears.
The TDC Proximity switch is on from about 355 to 5 degrees.
MS022 FM350-1 Saw 2nd This message occurs when the power to the high-speed encoder counter
Power Cycle. Contact an module goes through a power cycle and therefore re initiates itself. Under
Electrician! Cycle Main Power. this condition, the actual position of the crank is unknown. Check for proper
power levels going to this module. Check for loose wires to this module. This
module is in the operator’s pendant.
MS023 FM350-1 OT_ERR This message occurs when the high-speed encoder counter module has an
Contact an Electrician! Cycle internal error after trying to update the encoder crank angle value. This has
Main Power. been caused in the past by software issues and should not occur now. If this
error cannot be cleared by cycling the power or if it happens frequently, then
contact Burr Oak Tool Inc.
MS024 FM350-1 DATA_ERR This message occurs when the high-speed encoder counter module has an
Contact an Electrician! Cycle internal error after trying to update the encoder crank angle value. This has
Main Power. been caused in the past by software issues and should not occur now. If this
error cannot be cleared by cycling the power or if it happens frequently, then
Contact Burr Oak Tool Inc.
MS025 FM350-1 PAEA Bit Not This message occurs when the high-speed encoder counter module has an
Set. Contact an Electrician! internal error after trying to update the encoder crank angle value. This has
Cycle Main Power. been caused in the past by software issues and should not occur now. If this
error cannot be cleared by cycling the power or if it happens frequency, then
MS026 FM350-1 Homing This message occurs when the high-speed encoder counter module has an
Timeout. Contact an internal error after trying to update the encoder crank angle value. This has
Electrician! Cycle Main Power. been caused in the past by software issues and should not occur now. If
this error cannot be cleared by cycling the power or if it happens frequently,
403631 119
MS027 Machine Home Req’d This message should never appear since the system remembers the
in Setup Screen (Only INCH encoder value even between power cycles so that homing is not required
Mode Allowed Until Homed) except after a software download.
MS028 I/P Access Error. This error occurs when the system tries to access an I/O point that does
Contact an Electrician! Cycle not exist on the profibus network. One of the most common ways for this to
Main Power. happen is when an option is set through the touchscreen as being installed
when in fact it is not. To fix this problem, turn off the incorrect option and
cycle the main power.
MS029 I/O Rack Error. This error occurs most commonly when the remote I/O racks are improperly
Contact an Electrician! Cycle addressed. The racks are addressed using a small screw driver. Rack 1 is
Main Power. addressed at 0 and 2 is addressed as 1, etc.
MS030 The operator’s E-Stop This message appears when the operator’s e-stop pushbutton is latched
is Active. in the depressed condition which means that the e-stop is active. Twist the
e-stop button in order to release it so that it can pop out.
MS031 The Fin Line’s Right This message appears when the e-stop pushbutton on the right side of the
Side E-Stop is Active. fin line is latched in the depressed condition which means that the e-stop is
active. Twist the e-stop button in order to release it so that it can pop out.
MS032 The Fine Line’s Left This message appears when the e-stop pushbutton near the uncoiler is
Side E-Stop is Active. latched in the depressed condition which means that the e-stop is active.
Twist the e-stop button in order to release it so that it can pop out.
MS033 The Fin Line’s Left This message appears when the e-stop pushbutton near the uncoiler is
Side E-Stop is Active. latched in the depressed condition, which means that the e-stop is active.
Twist the e-stop button in order to release it.
MS034 Uncoiler Guard is This message appears when the uncoiler guard is open.
Open.
MS035 Press the Master Start This message appears prompting the operator that the master start
Pushbutton pushbutton should be pressed in order to proceed toward getting the press
in a ready to run condition.
MS036 Drive Control in
Overload Condition. Contact
an Electrician!
MS037 Mitsubishi Main Drive
Communication Error. Cycle
Main Power.
MS038 Mitsubishi Drive Not Press reset on Mitsubishi drive in main control cabinet.
Ready or Brake Resistor is
Overheated.
MS039 Right Rear or Main
Enclosure E-Stop is Active
(I97.2 is low)
MS040 Uncoiler Guard is
Open
MS041 MCR Contacts are
Possibly Fused. Contact an
Electrician!
MS042 Press the Master Start
Push Button
MS043 Press Lacing Stick is
Active
120 403631
MS044 Servo Feed Sign of Verify D425 is powered up and in a run condition. Reset E-Stops and cycle
Life Signal Missing power.
MS045 Die Lifters Switch is in To run the Press, move it to Off position.
Up position
MS050 The pump is in an
Overload Condition
MS051 The Press motor is in
an Overload Condition
MS052 The Vacuum Motor is
in an Overload Condition
MS053 The 2nd Vacuum
Motor is in an Overload
Condition
MS054 The Uncoiler motor is
MS055 The Conveyor Motor is
MS056 The Uncoiler Drive is
Faulted. To Clear, Reset the
Master Start
MS057 The Hydraulic Clutch
Condition
MS058 The Hydraulic Clutch
Oil Cooling Fan Motor is in an
Overload Condition
MS059 Press Motor Drive is
Faulted. To Clear, Reset the
Master Start
MS062 Replace Die Safety
Blocks into Plugs before
Running
MS063 Press the Motor Start This message appears prompting the operator that the Motor Start
Pushbuton pushbutton should be pressed in order to proceed toward getting the press
in a ready to run condition.
MS064 Press Motor Drive Not
Running. Cycle Master Start.
MS065 SPM Feedback
Voltage Too High. Set in Fin
Line Data Screen.
MS066 SPM Feedback
Voltage Too Low. Set in Fin
Line Data Screen
MS070 Left Front Die Guard
is Open
MS071 Front Progression
Changer Guard is Open
MS072 Left Rear Die Guard is
Open
403631 121
MS073 Main Progression
MS074 Lower Progression
MS075 Right Front Die Guard
is Open
MS076 Right Side Die Guard
is Open
MS077 Right Rear Die Guard
is Open
MS078 A Rear or Front Die
Guard is Open in Setup And
Inch
MS079 Right Main Feed
Guard is Open
MS080 Right Front Feed
Guard is Open
MS081 Right Lower Feed
Guard is Open
MS082 Left Main Feed Guard
is Open
MS083 Left Front Feed Guard
is Open
MS084 Left Lower Feed
Guard is Open
MS085 Servo Feed Not
on Progression (INCH to
Override)
MS086 Servo Feed Not Follow the “Syncing the Feed System” instructions in the Machine Operation,
Synchronized (Go to INCH Adjustments & Settings section.
and set Feed Mode)
MS087 Must be in CONT Prior
to Switching Press Control to
LINE
MS088 Switch Press Control
to PRESS (Safety Unit
Faulted)
MS089 Stripper Bar Should
be Lowered when running
Continuous
MS090 Straightener Bar
Should be Lowered when
running Continuous
MS091 Press Cannot Run
with Switch in OFF position
MS092 Press Can only INCH This message appears when the press is in Setup, but the stroke mode is
in SETUP not in Inch. In addition to being in Inch Mode, the system restricts the type of
inching to Auto Inch. Manual Inching is not allowed in Setup since the guard
could be open and Manual Inching can produce press movement of up to
1/2 stroke at a time.
122 403631
MS093 Changed is
EXTENDED
MS094 Changer is
RETRACTED
MS095 Servo Feed in E-Stop
Condition. Input dio_x122_1
is Off.
MS096 Must be in INCH to
Run Press from Remote Lacer
Station
MS097 Cannot Run Press
in Setup from Remote Lacer
Station
MS098 Crank Angle is Less This message appears when the current crank angle is past bottom dead
than Allowable Starting Point center, but is less than the minimum crank angle required to initiate a Setup
(Must Inch Toward Top) Stroke or begin running continuous (280 degrees). Switch to Inch Mode and
inch the press toward the top of the stroke before proceeding.
MS099 Crank Angle is Past This message appears when the current crank angle is before bottom dead
Allowable Starting Point (Inch center, but is past the largest allowable crank angle (30 degrees) to initiate
Back Around To Top) a Setup Stroke or begin running Continuous. Switch to Inch Mode and inch
the press through bottom and then back toward the top of the stroke before
proceeding.
MS100 Crank Angle is Past This message appears when the current crank angle is before bottom dead
Allowable Setup Stroke or center, but is past the point needed to fire some critical timing item. When
continuous Run Starting Point this happens, it is almost always near the cutoff stroke. Switch to Inch Mode
and inch the press through bottom and then back toward the top of the
stroke before proceeding. This allows the critical timing item to happen in
Inch Mode, which is always set for a much later point.
MS101 Blowoff Switch Not in
Auto
MS102 Cutoff Switch Not in
Auto
MS103 Lacer Must be OFF to This message appears when the Lacer is ON and the stroke mode is set to
Run Continuous Continuous Run.
MS104 Lacer Must be OFF in This message appears when the lacer is ON, but the pull-pin is not in its
Order to Run when Pull-Pin is holder. The pull-pin must be in the holder in order to be assured that it is not
Installed (Not in Holder) still installed in the feed arm. If it were in the feed arm, then the lacer with
its clamps holding the stock would fight the feed arm as it tried to feed stock
during press motion.
MS105 Pull-Pin Should be This message appears when the lacer is OFF, but the pull-pin is still in its
Installed in Feed Arm When holder. It is only a warning because there are valid reasons to run without
Running Press feeding stock, but generally the pull-pin should be installed in the feed arm.
MS106 Switch Crown to Hold This message appears after the main power on the machine has been
Position Then Down or Up as cycled and the state of the crown is unknown.
Desired
MS107 Crown Must be Down
to Run Setup Stroke or
Continuous
403631 123
MS108 Safety Unit Faulted, This message appears when the safety unit experiences a fault. The most
Switch to INCH Mode to Reset common way for this to happen is if the operator does not hold the run
the Fault button in long enough during the Setup Stroke. Because of the hard wired
circuitry, the system must be in Inch Mode in order for the software to reset
the safety unit’s fault condition. If the fault was caused by not holding the
inch buttons in long enough, then you will probably have to inch back around
to the top of the stroke.
MS109 Switch Operator This happens when the safety unit detects a fault condition that cannot be
Station control to Pendant reset by the software. These more serious fault conditions can only be reset
(Safety United Faulted) using the switch that is on the safety unit. The safety unit is located in the
operator pendant behind the touchscreen To reset the error, turn the key
(aqua-green) to the stop position then back to the run position.
MS110 Safety Unit Faulted,
Switch to INCH Mode to
Reset the Fault
MS111 Major Safety Unit
Fault, Contact Electrician,
Reset with Internal Key
MS112 Press Control is Set to
LINE. Waiting for Remote Run
Signal
MS113 A Front or Rear Die
Guard is Slightly Open.
MS114 A Side Die Guard is
Slightly Open.
MS115 Remote Top Stop is
Active.
MS116 Low Flow for Cooling
Oil to Auxiliary Brake
MS117 Low Flow for Cooling
Oil to Clutch/Brake
MS118 Clutch/Brake Pressure
is Low
MS119 Cooling Oil for Clutch/
Brake System Exceeds high
Temperature Limit
MS120 Crown Hydraulic This message frequently occurs after a main power cycle. The crown is
Pressure Not Seen With down, but not being powered by the valve since it got turned off during the
Crown Down power cycle and will not turn on without being initiated by the operator. To fix
the problem, simply switch to hold and then back to the down position.
MS121 Air Pressure is Not
Present
MS122 Clutch Valve Pressure
is Not Present
MS123 Sensor Indicates
Blowoff Air Pressure When
OFF (Adjust Sensitivity)
MS124 Feed Overload
Pressure is Above High Limit
124 403631
MS125 Feed Overload
Tripped (Low Pressure). Press
Motors Start PB to Reset.
MS126 Inconsistent Homing: The two encoders connected to the press crank shaft no longer agree on the
Check Crank Angle, Forward crank shaft position. Reset crank angle. If this reoccurs, verify tension on
Feed & Amp; External belts.
Encoder
MS127 Feed Parameters not (Create Die Data Recipe)
Set.
MS130 Stock Fault is Present
(Can be Overridden in INCH
Mode)
MS131 Die Jam is Present
Mode)
MS132 Stacker jam is Present
Mode)
MS133 Load Monitor Trend
Fault (Can be Overridden in
INCH Mode)
MS134 Load Monitor Capacity
Fault (Can be Overridden in
INCH Mode)
MS135 Servo Feed System
Must Be Homed (Die Setup
Screen)
Not In Auto Mode (Die Setup
Screen)
Forward Feed Sensor Not
Seen
MS138 Servo Feed System -
Feed Distance is Set to Zero
MS139 Electro Static Lube
System Fault (See Remote
Display)
MS140 Lube Level in Stock
Lube Tray is Low
MS141 Lube Level in Stock
Lube Tray is High
MS142 Lube Level in Pierce
Lube Tank is Low
MS143 Die Lube Flow
Detected After 3 Min. of
Being Idle (Decrease Sensor
Sensitivity)
MS144 Die Pin Lube Level is
Low
403631 125
MS145 Gear Box Lube Level
is Low
MS146 Hydraulic Filter #1 is
Clogged.
MS147 Hydraulic Filter #2 is
Clogged.
MS148 Lube Level in
Enhance Lube Tank is Low
MS149 Grease Cycle Failed:
A Successful Maintenance
Grease Cycle Clears this
Warning
MS150 Gear Box 2 Lube 150
Level is Low
MS151 Electrical Enclosure
Air Conditioner is in an
Overload Condition
MS152 Stock Loop Blower
Condition
MS156 Iron Flange Lube Flow
Detected after 3min. of Being
Idle (Decrease Sensitivity)
MS160 Adjusting Die. Please
Wait or Abort the Process from
Die Setup Screen
MS161 Sequenced Die Adjust
Active. Only Inch or Single
Stock Allowed
MS162 Current Does Not
Match New. Go to Die Setup
and Make Adjustment
MS163 Die Adjustments are
NOT Locked and Press is in
Continuous Run Mode
MS164 Slit Station is
Unclamped
MS170 Shuttle Air Pressure is
OFF. Press Manual Shuttle to
Move to Position
MS171 Shuttle In-Position
Input Not Seen.
MS172 Press Motor Not Yet
at Operational Speed. Please
Wait...
MS173 Fin Counting Has
been Turned OFF in the
Production Data Screen
126 403631
MS174 Tap Down Fault: Go to
Fin Line Data & Options/
Suction Unit to Clear Fault
& Home
MS194 Auto Inch Target
Reached. Update Inch to
Target Value.
MS195 System Believes a
Popup Screen is Active. This
Message Should Not Appear.
MS196 The Feed Servo is
calculating Cam Position.
Please, wait.
MS197 Must Release Prior
Action / Cont. Run Button
(Green)
MS198 Prelube (If Overridden, This message appears to warn the operator that the time has elapsed
Press Green Cont. Run Button since the pressure was last run in Continuous or since the last prelube and
Twice for Prelube) therefore the stock might be dry. Prelube happens automatically before
running Continuous, but not for Setup Stroke or Inching. Also, if you wish
to force an extra prelube before the normal timeout, simply press the green
cont. run button twice with a few seconds of each press and the system will
prelube the die.
MS199 Prelube (If Overridden,
Press Green Cont. Run Button
Twice for Prelube)
MS236 Feed Encoder Saw If lacing, spray lubricant on dry
Motion Without Press Running material entering the die.
Signal
MS237 Lube Filter is Clogged Clogged filter vacuum switch has Clean/replace oil filter. Fix collapsed,
- Change or Clean Filter seen a high vacuum between the pinched, or broken lines.
Element tank and pump.
MS239 Nozzle Test Error A nozzle pair in use has failed the Clean failed nozzle pair and establish
nozzle test. a new nozzle test with valve working
properly.
MS240 Master Nozzle Data The PLC logic does not have any Run master nozzle test to establish
Missing retentive memory saved. the baseline to compare nozzle tests
to in the future.
MS241 Nozzle Test in Nozzle test is in progress. Wait for nozzle test to finish. It should
progress (Diagnostic) take 10-15 minutes.
MS242 Stock Width Array The stock width array is not seeing Verify stock width array is configured
Malfunction the width or material correctly. properly. Contact BOTI to verify
system options.
MS300 Safety System
Initialization. Please Wait.
MS301 Guard Safety Relay
Faulted. Cycle Master Start or
contact Electrician.
403631 127
Run Status Message Descriptions
CODE MESSAGE
RS000 Busy-Please Wait
RS001 Stock fault was detected
RS002 Die was jammed
RS003 Stacker was jammed
RS004 Low die lube flow was detected
RS005 Top stop button was pushed
RS006 Stack was completed
RS007 Finish fin button was pushed
RS008 Low stock lube level was detected
RS009 High stock lube level was detected.
RS010 Low hydraulic pressure was detected
RS011 Low air pressure was detected
RS012 Sensor indicates primary blowoff valve failure
RS013 Sensor indicates auxiliary blowoff valve failure
RS014 End of stock was reached
RS015 Stacker ready input was lost
RS016 Reclaim tank may be overfilling
RS017 Motor Stop Pushbutton Pressed
RS018 Master Stop Pushbutton Pressed
RS019 Open guard was detected
RS020 E-Stop was activated
RS021 Steady state speed not reached
RS022 Press speed exceeded maximum machine limit
RS023 Press speed exceeded timing chart adjustable limit
RS024 Press speed was below machine limit
RS025 Press speed below timing chart adjustable limit
RS026 Pierce Blowoff Sensor Not Detecting Pressure (Cont. Run)
RS027 IO Access Error
RS028 IO Rack Error
RS029 No Press Motion Seen - Reason Unknown
RS030 Run Buttons not held in long enough
RS031 Stopped Continuous Run for unknown reason
RS032 Main Power Restored. Power up Complete. Verify Crank Angle!
RS033 Pierce Lube Tank Level Low
RS034 Press was Setup Stroked
RS035 Press was Inched
RS036 Enhance Lube Tank Level Low
RS040 Saw TDC Proxy Too Late
RS041 Saw TDC Proxy Too Early
RS042 Did Not Reach Steady Stat Speed
RS043 Servo Feed Not Retracted in Time
RS044 Servo Feed not Forward in Time
128 403631
RS045 Remote Top Stop Button was Activated
RS046 Servo Feed Controller Faulted
RS047 Servo Feed Controller Error. Cycle Master Start.
RS050 Hydraulic Clutch motor Overload
RS051 Hydraulic Cooling Fan Motor Overload
RS052 Low Cooling Oil Flow to Aux. Brake
RS053 Low Cooling Oil Flow to Clutch/Brake
RS054 Low Hydraulic Clutch/Brake Pressure
RS055 High Temperature on Clutch/Brake Cooling Oil
RS056 Coils Produced Equaled or Exceeded Coil Required
RS060 Operator Pressed Remote Top Stop/Finish Fin Button
RS061 Load Monitor Trend Fault Detected
RS062 Load Monitor Capacity Fault Detected
RS063 Remote Line Requested a Top Stop/Finish Fin Button
RS064 Upper Die Pin Pressure Not Reached
RS065 Top Stop Failed. Contact Electrical Maintenance!
RS066 Finish Fin Failed. Contact Electrical Maintenance!
RS067 Timing Engine Failed. Contact Burr Oak Tool Inc!
RS068 Feed Overload Condition Detected by High Pressure Sensor.
RS069 Machine was switched out of Continuous Run Mode
RS070 Low Iron Flange Lube Flow Detected
RS071 Electrostatic Lube System Faulted
RS072 Tap Down Servo Motor Faulted
RS073 Left Front Die Guard Opened
RS074 Front Progression Changer Die Guard Opened
RS075 Left Rear Die Guard Opened
RS076 Left Side Die Guard Opened
RS077 Lower Progression Changer Die Guard Opened
RS078 Right Front Die Guard Opened
RS079 Right Side Die Guard Opened
RS080 Right Rear Die Guard Opened
RS081 Operator E-Stop Pressed
RS082 Right Side E-Stop Pressed
RS083 Left Side E-Stop Pressed
RS084 Uncoiler E-Stop Pressed
RS085 Remote E-Stop Pressed
RS086 Misc. E-Stop Pressed
RS087 Stacker E-Stop Pressed
RS088 Run Inch Button Stuck
RS220 Nozzle Pair 1 or 13 Malfunctioned
RS221-244 Nozzle Pair # Malfunctioned
403631 129
Acknowledge Message Screen Descriptions
CODE MESSAGE
AP001 Vacuum System has been Removed
AP002 Vacuum System has been Restored
AP003 Grease Failure. Grease switch input did not transition correctly
AP004 Access Denied. Logon at higher level required
AP005 Aborted: Press Speed In Unknown State
AP006 Uncoiler System has been Removed
AP007 Uncoiler System has been Restored
AP008 Low Grease Reservoir
AP009 Master Start must be energized to Raise or Lower Crown
AP010 Cannot Raise or Lower Crown with Main Changer Guard Open
AP011 Cannot Raise or Lower Crown with Front Changer Guard Open
AP012 Cannot Raise or Lower Crown with Lower Changer guard Open
AP013 Cannot Raise or Lower Crown with Right Main Die Guard Open
AP014 Crown Switch is Up. However, pull-pins, are not installed
AP015 Must have Die Blocks in Holders to Lower Crown
AP016 Crown pressure Override is Active. Do NOT Run Press Until the Crown
is Completely Down to AVOID DIE DAMAGE
AP019 Master Start Must be Active in Order to Lace
AP020 Fin Line Main Crank Must Be Homed in Order to Lace
AP021 Main Crank Must Be in Top Half of Stroke in Order to Lace
AP022 Lacer Switch Must be in ON Position in Order to Lace
AP023 Lacer Cycle Aborted: Master Control Power Lost
AP024 Lacer Cycle Aborted: Lace Switch was Turned to the OFF Position
AP025 Changer Switch Inactive Because a Changer Guard is Open
AP026 Changer Switch Inactive Because a Changer Guard is Open
AP030 Master Start Must be ON for this Lube Operation
AP031 Already Busy with another Lube Operation
AP032 Motors Must be ON to Perform sheave Maintenance
AP037 Master Start Error: A Miscellaneous E-Stop is Active (I97.2)
AP038 Master Start Error: Remote Lacer or Remote Run E-Stop is Active
AP039 Master Start Error: MCR Contact Fused Shut?
AP040 Master Start Error: Logon Required
AP041 Master Start Error: Operator Console E-Stop is Active
AP042 Master Start Error: Left Side E-Stop is Active
AP043 Master Start Error: Right Side E-Stop is Active
AP044 Master Start Error: Uncoiler Side E-Stop is Active
AP045 Master Start Error: Pump Motor is in an Overload Condition
AP046 Master Stopped: Idle/Power Save Mode Activated
AP048 Master Start Error: Master Control Relay Failed to Pull In
AP049 Master Start Error: Pump Motor Contactor Failed to Pull In
AP050 Stacker Error: Master Control Must be ON
AP051 Stacker Error: Stacker Jam
130 403631
AP052 Stacker Error: Operator Released Manual Stacker Button
AP053 Stacker Error: Operator pressed Stacker Stop Button
AP054 Stacker Error: Timeout waiting for pull Back
AP055 Stacker Error: Timeout During Final Rotation
AP056 Stacker Error: Timeout During Final Rotation
AP057 Stacker Error: Table Extend Input Did Not Go Low As Expected
AP058 Stacker Error: Timeout Operator Did Not Release Manual Shuttle PB
AP059 Stacker Error: Motors Must Be ON to Move Stacker
AP060 Motors Start Error: Master Start Must be Active First
AP061 Motors Start Error: Motors Already ON
AP062 Motors Start Error: Die Safety Purge Not in Their Holders
AP063 Motors Start Error: Conveyor Motors is in an Overload Condition
AP064 Motors Start Error: Press Motor is in an Overload Condition
AP065 Motors Start Error: Vacuum Motor in an Overload Condition
AP066 Motors Start Error: Uncoiler Motor is in an Overload Condition
AP067 Motors Start Error: Uncoiler drive is in a Fault Condition
AP068 Motors Start Error: Vacuum Drive is in a Fault Condition
AP069 Motors Start Error: Hydraulic Clutch Oil Level Low
AP070 Motors Start Error: Press Motor Contractor Failed to Pull In
AP071 Motors Start Error: Hydraulic Clutch Motor in Overload Condition
AP072 Motors Start Error: Main Press Motor Drive is Faulted
AP073 Main VFD Drive Not Ready. Please Wait 6 Seconds After Master Start.
AP074 Motors Start Error: Vacuum Drive 2 is in a Fault Condition
AP075 Motors Start Error: Vacuum Motor 2 is in an Overload Condition
AP081 Slit Adjust Error: Rows Per Slit value is not valid
AP082 Slit Adjust Error: Press must be inched toward top
AP083 Slit Adjust Error: Master power Must be ON to Adjust Slit
AP084 Slit Adjust Error: Air Pressure Must be Present to Adjust Slit
AP085 Cannot Raise or Lower Crown with Left Front Die Guard Open.
AP086 Cannot Raise or Lower Crown with Left Rear Die Guard Open.
AP087 Cannot Raise or Lower Crown with Right Front Die Guard Open.
AP088 Cannot Raise or Lower Crown with Right Rear Die Guard Open.
AP089 Cannot Raise or Lower Crown with Right Main Feed Guard Open.
AP090 Cannot Raise or Lower Crown with Right Front Feed Guard Open.
AP091 Cannot Raise or Lower Crown with Right Lower Feed Guard Open.
AP092 Cannot Raise or Lower Crown with Left Main Feed Guard Open.
AP093 Cannot Raise or Lower Crown with Left Front Feed Guard Open.
AP094 Cannot Raise or Lower Crown with Left Lower Feed Guard Open.
AP100 Motors Must Be On To Adjust The Die.
AP101 Crank Must Be Off Bottom To Adjust
AP102 Motors Shutdown. Die Adjust Operation Aborted.
AP103 Lost Master Start. Die Adjust Operation Aborted.
AP104 Changer Must be Retracted for Sequenced Die Adjust
AP105 Change AUTO Not Allowed for Seq. Adjust (RET Suggested)
403631 131
AP106 Master Start Error: Starker E-Stop is Active.
AP107 Stacker Error:Timeout During Transfer
AP108 Master Start Error: Right Rear E-Stop is Active
AP109 Auto Die Adjust Data not Set in Die Data & Options Screen
AP110 Slit Rows Need To Be Set
AP111 Slit Clamp must be on for Slit engagement
AP120 Motors Must Be On To Synchronize Feed
AP121 Lacer Must Be Off To Synchronize Feed
AP122 Cannot Synchronize Feed with No Stock Mode Set
AP123 Run Inch Button Stuck
AP150 Stacker Error: Timeout Lowering Elevator
AP151 Stacker Error: Elevator Not at Bottom or cart not ready
AP152 Stacker Error: Edge guard Engaged Remove Obstruction and Start
Again
AP153 Motor Must be on to Adjust Edge Trim
AP160 Unknown Screen Number Requested
AP302 - Diagnostic Nozzle test
PSI too high
AP303 - Master Nozzle test PSI
too high
132 403631
Confirmation Screen Message Descriptions
MESSAGE RESPONSE
CP003 Warning: No stroke Yes: Go ahead and feed advance without stroking between feeds.
Since Previous Advance
No: Don’t feed advance. I need to stroke the press before feeding again.
CP004 Stripper Bar Should Be Yes: Lower the Stripper Bar.
Lowered to Run Continuous
No: Leave the Stripper Bar Up

CP005 Straightener Bar Yes: Lower the Straightener Bar.
Should Be Lowered to Run
Continuous
No: Leave the Straightener Bar Up.
CP006 Accept Input Values as Yes: Update Current Crank Position with Entered Value.
New Crank Angle Position?
No: Reset Entered Value to Match Current Crank Angle.

CP007: Begin Sequence Die
Adjustment?
CP008: Begin All-At-Once Die
Adjust?
CP009: Reset Coils Produced?
CP010: Reset Data To Default
Values?
CP011: Automatically Set the
Edge Trim?
CP012: Automatically Set the
Slit Spacing (Rows Per Fin)?
CP013: Automatically Set
the Die Using the Sequential
Adjust?
CP014: Do Draw Settings
Match Selected Model
Number?
CP020: Abort the Nozzle Test?
CP022: Save test data as
Master?
CP999: Software error Contact BOTI!
403631 133

FP-1000/1400 Fin Line: Global Experience

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Global Experience

FP-1000/1400 Fin Line Original Instructions

Overview of Machinery ............................................................... 13

Installation & Setup ..................................................................... 17

Machine Operation ...................................................................... 29

Control Reference ....................................................................... 51

General Maintenance .................................................................. 89

Troubleshooting ........................................................................ 101

Appendices ................................................................................ 109

RISK DESIGN MEASURE

RISK SAFEGUARD MEASURE

Crushing hazard present. Keep feet clear of machine.

Table may be slippery with water or oil.

Tipping Hazard; high center of gravity.

Equipment starts automatically.

Laser present. Avoid exposure to laser beam.

Hydraulic or pneumatic explosion possible.

Fire or gas explosion possible. Be aware of the smell of gas.

Fire hazard / ﬂammable.

Static charge present.

Only authorized personnel may service this equipment.

No maintenance while machine is in use.

Do not open until saw stops rotating.

Do NOT operate with guard removed.

Do not operate with the guards removed.

Do not service with the ﬂywheel in motion.

Moving parts will cut. Do not open while saw is rotating.

No Pacemakers. Magnetic ﬁelds may interfere with certain pacemakers.

Stay Clear of machinery that moves automatically.

Apply locking device here.

Read and understand the instructions.

Verify the Emergency Stop button is functioning properly.

Verify the light curtain is functioning properly.

Verify the interlocking guards are functioning properly.

The equipment is operated by non-hazardous electric energy.

Hearing protection required.

Lock Out / Tag Out

Daily Test Procedure for Light Curtains/Scanner

Hydraulic and Pneumatic

Hydraulic and Pneumatic - High Pressure

Fin Stock Uncoiler - 4” Diameter Spindle

Lubrication Tank Stabilizer

Disengage this clamp before rotating the frame out of position.

Servo Feed Axes

Fin Stock Lacer

The E-Lube is capable of applying lubricant coatings as low

Hand Crank Die Take Out (DTO) Table

Upper Suction Unit

Electrical and Pneumatic Systems

Transport & Handling

Lifting and Moving Machine Components

Move the Swing-Away with a ForkLift

Conveyor (if applicable)

Hoist the Conveyor

Move the Conveyor with a ForkLift

Hoist the Suction Unit

Move the Suction Unit with a Fork Lift

Hoist the Material

Filling / Re-Filling Oils / Fluids