Numeric Control for Bending

Presses

Interface Signals and

Protocols Description (DS)
OEM Documentation

Valid for:

Product: S530 SW 198

from version 6.2

Edition: June 2011

Code: 91813.DS.0.GB

Esa/Gv s.r.l.
15 via Zamboni, CP 43 I 41011 Campogalliano Modena
tel. +39/059/851414 - fax +39/059/851313
E-MAIL [email protected] http://www.esagv.it
Restrictions Duplication, transmission and use of this document or its contents shall be considered
prohitibed unless prior authorization has been received from Esa/Gv. All rights are
reserved.
Even when authorized, modification of this document (either by computer or on paper)
voids the guarantees specified below.

Guarantees The product may offer performances that are not described in these manuals. Esa/Gv
shall neither be obliged to maintain these functions in new versions of the product nor
to guarantee the relative assistance.

Checks have been carried out in order to ensure that the contents of these manuals
correspond to the documented product. Despite this fact, there may be discrepancies.
Esa/Gv therefore offers no guarantees as to the full compliance and completeness of the
texts.
The information in this document is periodically revised and new editions are issued
when necessary.

This manual has been compiled in partial compliance with ANSI/IEEE std 1063-1987
“IEEE Standard for software User Documentation”.

Editions This document is liable to be modified without prior notice. These modifications may
involve further editions or revisions of the document.
Further editions imply complete substitution of the document.
Revision involves replacement/addition/elimination of pages of the document.
Each page is identified by the code of the document at the bottom.

Notes
MS-DOS® Trademark registered by Microsoft Corporation.

ii 91813.DS.0.GB Esa/Gv
 The chronological list of editions of this document is given in the following table:

Evolution of the document

Edition Document Code Release Type of edition
24/06/2011 91813.DS.0.GB 1 New Document

Modifications
Release Chapters - Pages Description

Esa/Gv 91813.DS.0.GB iii

iv 91813.DS.0.GB Esa/Gv
DS Interface Signals and Protocols Description

Interface Signals and Protocols Description

Notes for the reader........................................................................................................i

Explanation of the symbols ..................................................................................................................ii
Printing conventions............................................................................................................................iii
Glossary..............................................................................................................................................iv

1 Descriptive Connection Table Synchronized Presses .........................................1.1

1.1 View panel.................................................................................................................................. 1.2
1.1.1 Front view ..................................................................................................................... 1.2
1.2 S530 holder assembly layout ..................................................................................................... 1.3
1.2.1 Rear view...................................................................................................................... 1.3
1.3 Fixing.......................................................................................................................................... 1.6
1.3.1 Overall dimensions ....................................................................................................... 1.6
1.3.2 Fixing ............................................................................................................................ 1.7
1.3.3 Location ........................................................................................................................ 1.7
1.4 Environmental conditions ........................................................................................................... 1.8
1.4.1 Climatic conditions for operation .................................................................................. 1.8
1.5 Instrument supply....................................................................................................................... 1.9
1.5.1 Power supply ................................................................................................................ 1.9
1.6 Axes board connection layout .................................................................................................. 1.12
1.6.1 Signalling devices ....................................................................................................... 1.18
1.7 Location of signals on the board with 16 activated up inputs................................................... 1.22
1.8 Location of signals on board with 16 pnp transistor outputs: ................................................... 1.23
1.9 Location of Signals on board with 16 Pnp transistor outputs: .................................................. 1.25
1.10 Location of signals on board with 16 high activated inputs .................................................... 1.27
1.11 Output for proportional valves (Proportional driver) ............................................................... 1.29
1.11.1 PROPORTIONAL DRIVER connector ..................................................................... 1.29
1.11.2 Signalling devices ..................................................................................................... 1.30
1.11.3 Reconfigurability ....................................................................................................... 1.30
1.11.4 Output for proportional valve Y1. .............................................................................. 1.31
1.11.5 Indicating devices ..................................................................................................... 1.32
1.11.6 12 Output for proportional valve Y2 .......................................................................... 1.33
1.11.7 Indicating devices ..................................................................................................... 1.34

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Interface Signals and Protocols Description DS

2 Description of the inputs and outputs ...................................................................2.1

2.1 Inputs (Config I/O 1)................................................................................................................... 2.1
2.2 Outputs (Config I/O 1)................................................................................................................ 2.7
2.3 Input (Config I/O 2) .................................................................................................................. 2.11
2.4 Outputs (Config I/O 2).............................................................................................................. 2.14

END OF SUMMARY

ii 91813.DS.0.GB Esa/Gv
DS Notes for the reader

Notes for the reader

General information The information in this document is only applicable to the software versions indicated
on the frontispiece.

Not all the functions carried out by the product may be described in this documentation. In such cases, Esa/Gv shall
neither be obliged to guarantee these functions nor to maintain them in future versions.

Purpose The purpose of this document is to help the installer/test technician when the machine
parameters are defined.

Users This document contains information for:

• the specialized technician with a good working knowledge of the numeric control,
the machine and the processing technology.

Use of the document The document is divided into chapters that describe a group of interface signals or a
certain communication protocol.

Notification of Please contact Esa/Gv if you should encounter any difficulties when studying this
difficulties document.

Esa/Gv 91813.DS.0.GB i
Notes for the readerr DS

Explanation of the symbols

Graphic symbols may appear alongside the text. These are used to emphasize information of particular importance.

Attention
This symbol appears when failure to take the necessary precautions could cause slight
damage to persons and property.

Danger
This symbol appears when failure to take the appropriate precautions or when incorrect
manoeuvres could cause serious damage to persons and/or property.

Important
This symbol appears in the documentation to indicate information of particular
importance. It is essential to read these sections in order to fully understand the manual.

Option
This symbol appears to indicate sections of the document that describe functions or
parts only available as options. Use of optional performances must be agreed with the
machine manufacturer.

Manufacturer
This symbol appears to indicate sections of the document reserved to the machine
manufacturer.

Password
This symbol appears to indicate sections of the document that describe functions whose
access is safeguarded by software access passwords.

NC
This symbol appears to indicate sections of the document that describe functions only
available on the NC and not on the PC.

PC
This symbol appears to indicate sections of the document that describe functions only
available on the PC and not on the NC.

ii 91813.DS.0.GB Esa/Gv
DS Notes for the reader

Printing conventions

To make the information in this manual easier to identify, use has been made of particular printing conventions.
These conventions are illustrated below.

Keyboard and video The following conventions are used.

• The names of the screen-printed keys are printed in boldface type enclosed within
square brackets. If the name of the key is followed by “button”, reference is being
made to a key on the push button panel.

− [ENTER]. Identifies the key.

− [+] indicates the + key of the keyboard while the button indicates the +
key of the push button panel.
• The names of the function keys are printed in boldface italics and are enclosed
within square brackets.
− [Menu Plc]. Identifies the function key bearing the words Menu Plc.
• References to fields and/or messages on the video are written in boldface italics.
• The specific text to be digitized by the user is underlined.
− If the manual indicates “digitize ok ”, this means that the word “ok” must be
digitized.
• DIRECTION or DIRECTIONAL keys is the collective name given to the UP,
DOWN, LEFT and RIGHT arrows.
• Pressure on a series of keys in sequence is written by separating the identifiers of the
keys to press with the “>“ character.

− > . Describes pressure, in sequence, on the [Manual] and

[START] keys.

Text The following conventions are used.

• Italics are used to emphasize specialistic terms.
• Boldface type is used to emphasize words of particular importance.

Esa/Gv 91813.DS.0.GB iii

Notes for the readerr DS

Glossary

CNC Initials that abbreviate Computerized Numerical Control and that indicate the instrument
that controls the machine, i.e. the electronic device through which the machining cycles
are programmed, the axes moved, etc....
Corresponds to one of the instruments whose operation is described in this manual.

Previous.

Next.

Save.

Cancel.

Arrows to move in the data entry fields.

List of programs

Fixturing

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DS Notes for the reader

Corrections

Save / Load from disk

Entries

Manual

Semiautomatic

Automatic

Stop

Start

Manual movement keys.

END OF PREFACE

Esa/Gv 91813.DS.0.GB v
Notes for the readerr DS

vi 91813.DS.0.GB Esa/Gv
DS Descriptive Connection Table Synchronized Presses

1 Descriptive Connection Table Synchronized

Presses

Type of Control unit S530

NC holder HW code S530.521
Date of document revision 30/06/2010
Axes configuration Y1-Y2-X1-R1

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Descriptive Connection Table Synchronized Presses DS

1.1 View panel

1.1.1 Front view

Figure 1.1 - Front view

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DS Descriptive Connection Table Synchronized Presses

1.2 S530 holder assembly layout

1.2.1 Rear view

Figure 1.2 - Rear view

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Descriptive Connection Table Synchronized Presses DS

1) Screws for fixing the numeric control

2) Serial interface COM1 (optional in the first version)
3) VGA interface
4) Y1 Axes, output current driver
5) Y2 axes, output current driver
6) Proportional driver valves output
7) LEDs to signal power supply and NC status
8) Dip switches for customizing
9) USB interfaces
10) Analog outputs of the axes
11) Encoder 1
12) Encoder 2
13) Encoder 3
14) Encoder 4
15) Digital inputs IW0 0 to 15
16) Digital inputs IW3 0 to 15
17) Digital outputs QW1 0 to 15
18) Power socket
19) Grounding screw
20) Digital outputs QW2 0 to 15
21) 0-10V 12-bit analog outputs
22) 12-bit analog inputs
23) Analog inputs range selection jumpers
24) Product identification label
25) Keyboard interface (optional in the first version)
26) System Monitor Display
27) CAN interface
28) Serial Interface COM 2
29) Ethernet interface

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Right side view

Figure 1.3 - Right side view

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Descriptive Connection Table Synchronized Presses DS

1.3 Fixing

1.3.1 Overall dimensions

Instrument

Specification Value
Height 319.0 mm
Width (maximum dimension) 269.0 mm
Depth (maximum dimension) 126.6 mm
Weight 2.3 kg

Figure 1.4 - Dimensions of Instrument

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1.3.2 Fixing

Instrument The instrument is pre-engineered for installation on a panel. Proceed in the following
way to install:
• drill the panel with the template shown in the figure;
• fix the instrument to the panel by tightening the seven screws supplied.

Figure 1.5 - Template of fixing instrument

1.3.3 Location
The position in which the instrument is mounted in the electric cabinet must be chosen
so as to ensure that it is at least 50 cm away from the power components and cables
(remote control switches, actuators, inverters...).
If it is impossible to comply with the indicated distance, split the equipment from the
components and from the power cables with metal screens.
In the majority of cases, the vicinity of the instrument to power components will lead to
interference and even breakage of the actual instrument itself.

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Descriptive Connection Table Synchronized Presses DS

1.4 Environmental conditions

The product has been designed to operate in the environmental conditions described in
this chapter.
To ensure correct operation:
• comply with the indicated environmental conditions during operation, transport and
storage;
• make sure that the product is correctly installed.

Information and Contact Esa/Gv’s “Assistance Service” if information and/or assistance are required
assistance

1.4.1 Climatic conditions for operation

It is advisable to leave a gap of about 10 cm or so all around the instrument, to facilitate

the air flow.

Install a heat exchanger or conditioner if it is impossible to comply with the specified

limit values.

Specifications Limit value

Operating temperature:
Minimum 5°C
Maximum 50°C
Average during the 24 h period 45°C
Relative humidity
Minimum 50%
Maximum 95%
Condensation Not permitted
Maximum altitude tolerated 2000 m

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1.5 Instrument supply

1.5.1 Power supply

Electrical The power supply for the instrument must comply with the following values:
specifications

Specifications Limit value

Typical power supply voltage rating 24V DC
Maximum power supply voltage rating 28.8V DC
Minimum power supply voltage rating 20.4V DC
Maximum current 2.A
Maximum power used 50VA
DC/GROUND input insulation voltage The instrument
must be powered
with an insulated
and stabilized DC
power supplier.
Protection against overvoltages YES, with varistor
Hold up Time >10 mSec

The instrument will switch off if the powering voltage drops below the nominal values.
If the powering voltage is not sufficiently stable, it is advisable to power the instrument
by means of a no-break unit. Consider the power draw of the instrument and its technical
specifications when choosing the no-break unit. It is certainly advisable to use no-break
units with zero activation time and not stabilizers (even electronic ones) which supply a
certainly stable output voltage but which, in the event of even brief voltage drops, are
unable to guarantee continuity for the output.

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Descriptive Connection Table Synchronized Presses DS

Type of connector

Figure 1.6 - Power socket

Pin Name Type

1 DC -TERMINAL VI
2 FIELD GND VI
3 DC + TERMINAL VI

Name of signal:
DC TERMINAL Power supply voltage rating
FIELD GND Ground reference

Type of signal:
VI Input voltage rating

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Connection examples

Figure 1.7 - Power 24V DC, correct

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1.6 Axes connection layout

There are 5 Axes connectors on this CNC. 4 are the multiple type with 9 female pins to
interface with the encoders and 1 is the multiple type with 15 female pins to interface
towards the drives (analog outputs).

Axes connections

Connector Name Axis type

ENC 1 Y1 Axis
ENC 2 Y2 Axis
ENC 3 X1 Axis
ENC 4 R1 Axis

Encoder connector

Pin Signal
1
2 + Power supply (5V)
3 - Power supply
4 /A (Not essential)
5 A
6 /B (Not essential)
7 /0 (Not essential)
8 0
9 B

To comply with CE marking specifications, the braid of the screened cable must be
connected to the metal part of the connector (e.g. squashed when the two halves are
joined). Consult the Guide to Installation in Compliance with EMC and LVD Directives
(HW) for further details.

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Analog Out connector

Pin Signal
1 Y1 Axis + Reference
2
3 Y2 Axis + Reference
4
5
6 X1 Axis + Reference
7
8 R1 Axis + Reference
9 Y1 Axis - Reference
10
11 Y2 Axis - Reference
12
13 X1 Axis - Reference
14
15 R1 Axis - Reference

Analog input The first of these inputs is normally used to interface the potentiometer of a bending
connections table. The other three input are normally not used. Refer to the machine parameter
manual for the settings relating to the bending table.

Name of Connector Type of Axis

Analog In A1 axis

Electrical
specifications
Static specifications Value
Number of inputs 4 (in the first version 2)
Input impedance in the signal field 1 M Ohm
Input voltage range 0 ÷ +5 VDC
0 ÷ +10 VDC
Digital resolution 12 bits
Potentiometer supply
• Power supply voltage rating + 5V DC.
• Maximum current 40 mA
• Protection against short-circuits YES (not permanent)

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Descriptive Connection Table Synchronized Presses DS

Type of connector Male 6-pin terminal strip (in the first version was 4-pin)

Analog In
Figure 1.8 – Analog input terminal strip

Pin Name Type

1 INPUT 1 (used for bending table) I
2 INPUT 2 (normally not used) I
3 INPUT 3 (normally not used) I
4 INPUT 4 (normally not used) I
5 VAL VO
6 GND VO

Name of signal:
GND Power source ground
INPUT Signal input
VAL + 5V power supply

Type of signal:
I Input signal
VO Output voltage

To comply with the standards governing CE marking, the braid of the screened cable
must be connected to the metal body of the connector (e.g. crimped when the two shells
are joined). Consult the Installation Guide according to Directives EMC and LVD (HW)
for greater details.

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Connection example

Clamp the braiding in the terminal,

screw it down in the insert beside
the connector.

Figure 1.9 - Potentiometer connection

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Descriptive Connection Table Synchronized Presses DS

Analog 2xVout The first of these output can be used to drive an external proportional driver pressure
connector valve (in alternative to the first output PROPORTIONAL DRIVER) or to manage the
torque of an electric pressbrake. The second of these output can be used to drive an
external proportional driver crowning valve (in alternative to the second output
PROPORTIONAL DRIVER).

Name of Connector Type of Axis

2xVout Proportional valve or Torqued electric pressbrake

Electrical
specifications
Static specifications Value
Number of outputs 2
Output voltage range 0 - 10 VDC
Maximum output current 5 mA
Output ripple 20 mV
Digital resolution 12 bits
Value of the least significant bit 2.44 mV

Type of connector Male 4-pin terminal strip

Figure 1.10 – Analog output terminal strip

Pin Name Type

1 OUTPUT 1 (used for proportional valve or torqued Y axis) O
2 GND REF
3 OUTPUT 2 (used for proportional valve ) O
4 GND REF

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Name of signal:
OUTPUT 1 - 2 Signal output
GND Ground

Type of signal:
O Output signal
REF Signal reference

The connection must be made with a screened cable. The screen must only be connected
from the CNC side.

If the cable must be sectioned with a removable connector, never install the analog
output cable with the power cables in the same connector. This is because there is no
braid in the section where the contacts pass. It is thus unable to exercise its screening
function and could allow spurious signals to enter.

If the cable is sectioned with a removable connector, connect the screen on both sides of
the connector so that it remains unbroken.

Connection examples

Clamp the braiding in the terminal,

screw it down in the insert beside
the connector.

Figure 1.11 –Analog outputs

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Descriptive Connection Table Synchronized Presses DS

1.6.1 Signalling devices

Figure 1.12 - S530 Signals leds

• LED 1: Led that signals when the CNC is operating (RUN) (green led)
• LED 2: Led that signals when the CNC is not operating (STOP) (red led)
• LED 3: Led that signals the +5V internal power supply (green led)
• LED 4: Led that signals the +12V internal power supply (green led)
• LED 5: Led that signals the -12V internal power supply (green led)
• LED 6: Led that signals the +Ve internal power supply (green led)
• LED 7: Led that signals the status of the system (SYSTEM MONITOR)

Power Supply LEDs The 4 LEDs (LEDs 3, 4, 5, 6) indicate the status of the voltages generated by the power
supplier board and used by the numeric control for operation. The following conditions
may occur:
• All LEDs are on: the board operates correctly.
• All LEDs are off: the board is not powered correctly. This can be caused by:
− absence of 24V AC/DC powering voltage;
− there has been a breakdown in the numeric control. Contact Esa/Gv’s assistance
service.

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• LED 6 (+Ve) is off, but all the others are on: the board does not operate correctly.
This can be caused by:
− one of the sensors connected to the CNC (encoder, optic lines, etc.) causes a
short-circuit on the encoder powering line. Disconnect the electric power supply
from the CNC, disconnect all the encoder connectors, replace the 1.25A F fuse
at the rear of the equipment and then power the CNC. If LED 6 comes on, this
means that one of the sensors is broken or the wiring is incorrect. Before
reconnecting the wires check the wiring and sensors (encoder). If LED 6 still
fails to come on and the fuse has not burnt out, this means that the board is
broken.
− the power supplier board is broken. Board replacement requires comprehensive
knowledge of the CNC, thus it is advisable to replace it;
− there has been a fault in the numeric control. Contact Esa/Gv’s assistance
service.
• Any configuration differing from those described above, but with at least one led
off: the board does not operate correctly. This can be caused by:
− one of the boards in the numeric control is broken and trips the powering voltage
protection. In this case, fault finding requires comprehensive knowledge of the
CNC, thus it is advisable to replace it;
− the power supplier board is broken. Board replacement requires comprehensive
knowledge of the CNC, thus it is advisable to replace it;
− there has been a fault in the numeric control. Contact Esa/Gv’s assistance
service.

RUN/STOP LEDs LED 1 and LED 2 indicate the operating status of the machine when this is correctly
powered. The following conditions may occur:
• LED 1 (RUN) is on and LED 2 (STOP) is off: the board operates correctly.
• LED 1 (RUN) is on and LED 2 (STOP) is on: This condition is impossible, the
board does not operate correctly. In this case, fault finding requires comprehensive
knowledge of the CNC, thus it is advisable to replace it;
• LED 1 (RUN) is off and LED 2 (STOP) is on: The CNC does not operate. The
board does not operate correctly. In this case, fault finding requires comprehensive
knowledge of the CNC, thus it is advisable to replace it;

System Monitor The list of messages provided by LED 7 is given below, in the sequence normally
display diagnostics displayed when the numeric control is powered. There are other types of message
supplied by the display that are considered “exceptions”. These exceptions are described
in the software manual of the operating system. The powering sequence terminates with
the display at 0. All the statuses the display can assume during machine operation appear
after the 0 message.
• 8 - Power ON.
− Appears after the CNC has been powered, but must disappear to leave space for
the successive sequences when the CNC is operating. 8 remains when the CNC
fails to operate. In this case, contact Esa/Gv’s assistance service.
• 5 - Kvara loader.

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Descriptive Connection Table Synchronized Presses DS

− Appears after 8 and indicates that the operating system of the CNC is present in
the FLASH memory. When it is in 5, the CNC awaits execution of the Kvara.Gz
file. If it remains in 5, this means that certain files are spoilt and that a System
Setup must be carried out.
• 4 - Kvara application.
− If the Kvara.Gz file runs correctly, 4 will appear on the display. It will remain at
4 if some of the files are spoilt and in this case, a System Setup must be carried
out.
3 - Kvara install CNC.
− When the KVARA application starts up (operator interface), the CNC is
provided with the operating enabling signals and the display changes to 3. If it
remains at 3, this means that the PLC has not started either because it has not
been loaded or because the I/O are absent or not correct. It can remain at 3 if the
IOREDIR file for configuring the I/O in the H disk of the CNC is incorrect or if
the I/O are not connected or fail to operate correctly. Check the I/O, the fiber
and, possibly, the IOREDIR file by means of the relative configuration mask.
Once these elements have been checked, proceed with a CNC Reboot to restore
operation, or an autosetup to reload the correct data.
• 0 - OK.
− the CNC is functional. All the peripheral devices are correctly connected.
• 1 - Reserved.
• 2 - Reserved.
• 6 - Kvara biosext.
− When the CNC is powered, the display indicates 6 if only part of the operating
system is present in the FLASH memory of the CNC. In this case, proceed with
an autosetup of the operating system.
• 7 - Power Fail.
− There has been a powering voltage drop for a shorter time than the system
RESET, meaning that the power supplied to the CNC is not stable. In this case,
turn off the CNC, check the power supply and then power the CNC again. Use a
no-break unit to power the CNC if the fault persists.
• 9 - User interface DLL not present.
− There is no GUIAPP.DLL file in the equipment where it should be installed.
Proceed with an autosetup.
• A - Diagnostic menu.
− After STARTCN has been executed, the display indicates A if the KVARA.GZ
file is missing from the H disk of the CNC or if PERMISSION=LOADER is
present in the KVARA.INI file of the PC. Proceed with an autosetup. If A
remains, this means:
− Autosetup in progress
− Recovery in progress
− Loader, KVARA.GZ decompacting problems, or memory checking or
application loading.
• C - Shut Down.

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− Appears when the CNC shutdown procedure is carried out correctly. The CNC
can be switched off without losing machine data.
• D - Reserved.
− Debug.
• E - Reserved.
− Not used.
• F - MFB reset.
− CNC in the reset mode. A CNC reset command has been transmitted. Wait until
the CNC has been reset. This is normally only displayed during an Autosetup or
if a CNC Reboot is requested.
− Loader with problems during the File System disk opening phase.

System Monitor Once the CNC has been powered in operating systems that handle the System Monitor
display powering display, the following messages will appear in sequence (within a few tenths of a
sequence second).

• Power ON.
− Messages 8
5
4
3
0.

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Descriptive Connection Table Synchronized Presses DS

1.7 Location of signals on the board with 16 activated up inputs

Type of connector 17-pin male terminal strip with puller.

Figure 1.13 - Input terminal strip

Board Name Name of connector

IW0 M.INI

Pin Reference Signal Status Wire

1 IW0.0
2 IW0.1
3 IW0.2
4 IW0.3
5 IW0.4 X1 axis forward travel limit switch NC
6 IW0.5 X1 axis backward travel limit switch NC
7 IW0.6 R1 axis forward travel limit switch NC
8 IW0.7 R1 axis backward travel limit switch NC
9 IW0.8 Down enabled
10 IW0.9 Up enabled
11 IW0.10 Photocell activation NC
12 IW0.11 Accompanying devices enabled
13 IW0.12 Slow manual re-ascent
14 IW0.13 Descent with photocells inhibited
15 IW0.14 General Emergency NC
16 IW0.15 Re-ascent to TDC with up enabled
17 GND (0 Volt)

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1.8 Location of signals on board with 16 pnp transistor outputs:

Type of connector 20-pin male terminal strip with fixing screws.

Figure 1.14 - Output terminal strip

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Descriptive Connection Table Synchronized Presses DS

Board Name Connector name

QW1 M.OUT1

Pin Reference Signal Wire

1 QW1.0 X1 drive enabling
2 QW1.1 R1 drive enabling
3 QW1.2
4 QW1.3
5 QW1.4 X1 backward signal (*)
6 QW1.5 R1 backward signal (*)
7 QW1.6
8 QW1.7
9 QW1.8 Function 1
10 QW1.9 Function 2
11 QW1.10 Function 3
12 QW1.11 Function 4
13 QW1.12 CNC in automatic mode
14 QW1.13 CNC in semiautomatic mode
15 QW1.14 CNC in manual mode
16 QW1.15 CNC OK
17 + +24 V external common contact for outputs
18 + +24V external common contact for outputs
19 + +24V external common contact for outputs
20 + +24V external common contact for outputs

(∗): NOTE. The backward signals must only be connected in the case of motors piloted
by inverters

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DS Descriptive Connection Table Synchronized Presses

1.9 Location of Signals on board with 16 Pnp transistor outputs:

Type of connector 20-pin male terminal strip with puller.

Figure 1.15 - Output terminal strip

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Descriptive Connection Table Synchronized Presses DS

Board Name Connector name

QW2 M.OUT2

Pin Reference Signal Wire

1 QW2.0 Valve 1
2 QW2.1 Valve 2
3 QW2.2 Valve 3
4 QW2.3 Valve 4
5 QW2.4 Valve 5
6 QW2.5 Valve 6
7 QW2.6 Valve 7
8 QW2.7 Valve 8
9 QW2.8 TDC
10 QW2.9 PCV (photocell inhibition)
11 QW2.10 PCL
12 QW2.11 BDC
13 QW2.12 PCL Before recoil
14 QW2.13 Axes in position
15 QW2.14 Y1 drive enabling (not used)
16 QW2.15 Y2 drive enabling (not used)
17 + + 24 V external common contact for outputs
18 + + 24 V external common contact for outputs
19 + + 24 V external common contact for outputs
20 + + 24 V external common contact for outputs

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1.10 Location of signals on board with 16 high activated inputs

Type of connector 17-pin male terminal strip with puller.

Figure 1.16 - Input terminal strip

Board Name Connector name

IW3 M.IN2

Pin Reference Signal Status Wire

1 IW3.0
2 IW3.1
3 IW3.2
4 IW3.3
5 IW3.4
6 IW3.5
7 IW3.6
8 IW3.7
9 IW3
10 IW3
11 IW3
12 IW3
13 IW3
14 IW3
15 IW3
16 IW3
17 GND (oVolt)

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Descriptive Connection Table Synchronized Presses DS

Connection examples

Figure 1.17 - Connection Input

Figure 1.18 - Connection Output

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1.11 Output for proportional valves (Proportional driver)

1.11.1 PROPORTIONAL DRIVER connector

Conventional terms:

The pressure valve signals are indicated with CH1 while the crowning valve signals are
indicated with CH2.

Type of connector Male 6-pin terminal strip

Figure 1.19 – Output terminal strip for pressure and camber proportional valves

Pin Signal Description

1 + 24 Volts DC Power supply for the pressure valve control board
2 0 Volts 0 Volt reference for pressure valve
3 CH1 output power Proportional pressure valve
supply
4 CH1 output Proportional pressure valve
5 CH2 output power Proportional crowning valve
supply
6 CH2 output Proportional crowning valve

The electrical specifications of the two output channels are as follows:

• Operating voltage rating: 24V dc +/-15%
• Minimum output current: 0A
• Typical output current: 500mA
• Maximum output current: 3.4A

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Descriptive Connection Table Synchronized Presses DS

Connection axamples

Figure 1.20 - Pressure and Crowning valve connection

1.11.2 Signalling devices

There are 2 signalling leds on the board:

1) Status of the CH1 output channel (LED on = ON, LED off = OFF or short-circuited
valve.
2) Status of the CH2 output channel (LED on = ON, LED off = OFF or short-circuited
valve.
The status of the LED does not mean ON, but that the valve is connected.
The LED tends to go out during the valve piloting phase (when current passes through).

1.11.3 Reconfigurability
The description of the connections given in the previous chapters is the standard one
supplied by Esa/Gv. The user can modify this standard to suit his requirements which
could also lead to the complete elimination of input or output boards as compared to the
indicated configuration; the instructions on how to modify the connections are given in
the Machine Parameters manual: consult the AXES configuration Parameters chapter for

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DS Descriptive Connection Table Synchronized Presses

the axes signals (limit switches, encoder inputs, analog outputs, motor control outputs)
and the input and output Enabling chapter for all the other signals.

1.11.4 Output for proportional valve Y1

Type of connector Male 6-pin terminal strip

Figure 1.21 – Valve Y1 terminal board

Pin Name Type

1 +24V DC. V1
2 FIELD GND REF
3 Y1-A valve output (Ascent) IO
4 Y1-A valve return (Ascent) II
5 Y1-B valve output (Descent) IO
6 Y1-B valve return (Descent) II

Name of signal:
+ 24 Volt DC +24V dc power supply
FIELD GND Power source reference
Y1-A, Y1-B valve Current output for proportional valve
output
Y1-A, Y1-B Current return
return

Type of signal:
VI Input voltage rating
REF Reference
IO Output current
II Input current

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Descriptive Connection Table Synchronized Presses DS

Connection examples

Figure 1.22 – Proportional valve Y1 connection

1.11.5 Indicating devices

The connector has 2 LEDs used as indicating devices:
1) Status of the Y1-A output channel (LED on = ON: valve energized, LED off =
OFF).
2) Status of the Y1-B output channel (LED on = ON: valve energized, LED off =
OFF).

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1.11.6 Output for proportional valve Y2

Type of connector Male 6-pin terminal strip

Figure 1.23 – Valve Y2 terminal board

Pin Name Type

1 +24V DC. V1
2 FIELD GND REF
3 Y2-A valve output (Ascent) IO
4 Y2-A valve return (Ascent) II
5 Y2-B valve output (Descent) IO
6 Y2-B valve return (Descent) II

Name of signal:
+ 24 Volt DC +24V dc power supply
FIELD GND Power source reference
Y2-A, Y2-B valve Current output for proportional valve
output
Y2-A, Y2-B Current return
return

Type of signal:
VI Input voltage rating
REF Reference
IO Output current
II Input current

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Descriptive Connection Table Synchronized Presses DS

Connection examples

Figure 1.24 – Proportional valve Y2 connection

1.11.7 Indicating devices

The connector has 2 LEDs used as indicating devices:
1) Status of the Y2-A output channel (LED on = ON: valve energized, LED off =
OFF).
2) Status of the Y2-B output channel (LED on = ON: valve energized, LED off =
OFF).

END OF CHAPTER

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DS Description of the inputs and outputs

2 Description of the inputs and outputs

This section describes the general inputs and outputs (not in relation to the axes)
handled by kvara series numeric controls for bending presses.

2.1 Inputs (Config I/O 1)

N Name of input Type Description of operation

1 Descent enabling NO Used to lower the ram. It is activated in the following masks:
(essenzial)
• Manual
• Semiautomatic
• Automatic

If activated in manual mode, it lowers the ram down to the minimum target. The
decompression operation is carried out if it is released.
If activated in the semiautomatic and automatic modes and the axes are in
position, it starts the bending cycle. The bending cycle continues for as long as the
signal remains activated. If it is released, the cycle will halt and wait for a new
enabling signal.
From the moment in which decompression begins, the bending cycle no longer
requires this signal but carries out the decompression operation and re-ascent to
TDC even if the signal is de-energized.
If the Ascent enabling signal is energized along with this signal during a
downward movement, the NC generates a PHOTOCELL ACTIVATION alarm
status and attempts to move the ram to TDC (reasons depending on the
manufacturer's electrical system may prevent this phase from being carried out).
2 Ascent enabling NO Lifts the ram and is activated in the following masks:
(essenzial)
• Manual
• Semiautomatic
• Automatic

If activated in manual mode when the ram is not sized, it triggers off the resetting
procedure which causes the ram to rise until the zero signals of the optic lines are
detected. Just the pulse is required in this phase. If released, the resetting
procedure continues.
If activated in manual mode when the ram is sized, it causes the ram to rise to the
top-most target. The ram will stop during its ascent if the input is deactivated.

If activated in semiautomatic and automatic mode, it causes the ram to rise to its
top-most target while the ram stops if it is deactivated during the ascent.

If the Descent enabling signal is energized along with this signal during the
downward movement, the NC generates a PHOTOCELL ACTIVATION alarm
status and attempts to move the ram to TDC (reasons depending on the
manufacturer's electrical system may prevent this phase from being carried out).

Esa/Gv 91813.DS.0.GB 2.1

Description of the inputs and outputs DS

N Name of input Type Description of operation

3 Photocell NC Stops the ram from lowering if the photocells are obscured in order to safeguard
activat.(essential) the operator.

If this signal is energized along with this signal during the downward movement,
the NC generates a PHOTOCELL ACTIVATION alarm status and attempts to
move the ram to TDC (reasons depending on the manufacturer's electrical system
may prevent this phase from being carried out).

This signal is always controlled even if the machine lowers at low speed (in
manual mode or after arriving at PCV). It is the task of the manufacturer's
electrical system to disable the photocells and keep the signal de-energized in
non-dangerous situations.
4 Guide enabling NO Enables the guide function in the automatic cycle.
Must be connected to a selector to allow the user to decide whether to use the
guides in a bending program or not.
If 2 In-Out feeders are used and the In-Out feeder 2 enabling input is also
programmed, this input will only enable In-Out feeder 1.
5 Slow manual NO Allows a slower speed than that of re-ascent to be used when ascent enabling is
ascent activated in manual mode. The speed used in this phase is the Sizing speed
parameter (the ram will obviously rise fast if the entered value is too high).
It is normally used to turn very heavy bottom dies: the bottom die is coupled to
the ram which slowly lifts it from the base as it rises. After this, the bottom die is
turned and re-positioned by slowly lowering.
It must be connected to a selector to allow the user to decide when to use this
mode.
If activated, slow manual ascent is also used in the automatic and semiautomatic
modes when ascent enabling is activated after an automatic bending cycle has
been interrupted by releasing the descent enabling input.
6 Descent with NO Used to indicate that the photocells have been cutout and that the down speed
photocells phase of the automatic cycle must be carried out at reduced speed.
inhibited (Photoc. Must be connected to a selector which normally indicates that bending is being
inhibition) carried out by using the descent enabling signal from the pedal and not the one
from the bi-manual push button panel..
The down speed used if this signal is activated is the Manual speed parameter.
The valves used are those of the Machining descent configuration.
7 General NC Used to interrupt the operation of the bending press.
emergency If activated in any condition, it stops the axes from moving and sets them to the
(essential) alarm status. Axes operation will be restored as soon as the signal deactivates.
Must be connected to the pump running signal and to all the mushroom shaped
emergency buttons installed on the machine.
It is obligatory to use this input as the axes of the locators only lock when the stop
is pressed or an emergency activates
8 Re-ascent to TDC NO Used to block the ram at BDC during the accomplishment of an automatic
with ascent bending cycle. The cycle is continued by activating the ascent enabling input.
enabling Must be connected to a selector to allow the user to decide when to use this mode;
for example, when the operator needs to decide when to continue the cycle after
the bend has been made (for safety reasons).
It is very useful when the press operates together with a robot in order to allow the
robot to change the point in which it clamps the workpiece after the bend has been
made.

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DS Description of the inputs and outputs

N Name of input Type Description of operation

9 Automatic remote NO Used to inform the NC that the remote device connected (robot or other press in
status tandem) is in the automatic status. The NC can thus make sure that it is in the
same status as the remote device and enable ram movement. This input must be
activated during operation with the robot.
10 Semiautomatic NO Used to inform the NC that the remote device connected (robot or other press in
remote status tandem) is in the semiautomatic status. The NC can thus make sure that it is in the
same status as the remote device and enable ram movement.
11 Automatic NO Used to activate the start enabling input (usedf to position the axes in the
external Start automatic cycle or to start the stop resetting phase) by means of an external signal.
It is particulary useful when the press is part of a robotized machining island and
the user needs to access this latter to press the[STOP] button or if a machine push
button panel must be used. Essential in the structures Kvara 2000.
12 Selected program NO Informs the NC that the selected workpiece is the same as the one selected by the
OK robot (or by any remote machine).
It is used to synchronize the name of the selected program with the robot.
It is normally not used and is mapped on the same input as operation with the
robot.
13 Machining reset NO Used to interrupt the workpiece machining operation in progress and to return the
process to the beginning, and the first bend.
It is particularly useful when the press is part of a robotized machining island and
the user wishes to be sure that the process begins from the beginning before
machining starts, or to continue machining from the beginning after a fault that
occurred when the previous workpiece was machined
14 Operation with NO Informs the NC that control of the movement enabling signals is handled by a
robot robot. When this signal is present, the NC is able to synchronize with the robot in
certain parts of the bending cycle.
It must be connected to a selector to allow the user to signal when the press is
controlled by the robot or when it is controlled by an operator.
15 Machine in NO Used to inform the NC that there is a press connected in tandem. The NC may
tandem selector handle the enabling signals transmitted by the remote press.
Must be connected to a selector to allow the user to indicate when he wishes to
work in tandem or individually.
16 NC remote NO Informs the NC that the remote machine is at TDC.
machine at TDC It is used in processes with presses in tandem to allow the ram to lower.
17 NC remote NO Informs the NC that the remote machine is at SCP.
machine at SCP It is used in processes with presses in tandem to synchronize the movement of the
(photocells two presses and continue with the automatic cycle.
inhibited)
18 NC remote NO Informs the NC that the remote machine is at PCP.
machine at PCP It is used in processes with presses in tandem to synchronize the movement of the
two presses and continue with the automatic cycle.
19 NC remote NO Informs the NC that the remote machine is at BDC.
machine at BDC It is used in processes with presses in tandem to synchronize the movement of the
two presses and continue with the automatic cycle.
20 NC remote NO Informs the NC that the remote machine is at PCP before recoil.
machine at PCP It is used in processes with presses in tandem to synchronize the movement of the
before recoil two presses and continue with the automatic cycle.
21 Axes in position NO Informs the NC that the axes of the remote machine are in position.
Nc remote It is used in processes with presses in tandem to allow the ram to lower.
machine
22 NC remote NO Informs the NC that the remote machine is in the alarm status.
machine in alarm It is used in processes with presses in tandem to stop the press from operating if
status the remote machine is in the alarm status.

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Description of the inputs and outputs DS

N Name of input Type Description of operation

23 External stop NO Activates the stop enabling signal, which is used to stop the axes from moving or
(alarm reset) to cancel any alarms that may have occurred, with an external signal.
It is particularly useful when the press is part of a robotized machining center and
the user would have to enter the center to press the STOP button, or if a machine
button panel is to be used. Essential in kvara2000 structures
24 Crowning in NO Reserved.
progress OPS
25 Sel. Lower clamp NO Enables the cycle that handles opening/closing of the lower tool clamps.
opening Management of this input is linked to other parameters. Refer to the machine
parameter manual.
26 Index in progress NO Reserved.
OID
27 Sensor sizing NO Reserved.
input
28 Sel. Upper clamp NO Enables the cycle that handles opening/closing of the upper tool clamps.
opening Management of this input is linked to other parameters. Refer to the machine
parameter manual.
29 Change step NO Used for two different purposes:
1) conventional presses: it is the enabling signal that advances workpiece
machining by changing the activated bend.
2) synchronized presses: it is an external request to change step. It is used when
the NC is used along with a robot to allow this latter to decide when to
change the activated bend and re-position the locator axes.
30 Recoil micro NO This is only used in conventional presses. It informs the NC when the rap reaches
(conventional) PCP and recoiling must take place (if programmed).
31 TDC micro NO This is used in conventional presses to inform the NC that the ram has reached
TDC and the adjustable TDC function can be interrupted.
It is used in synchronized presses to stop the ram from re-ascending in the manual
Z cycle.
32 Manual Z cycle NO Activates the manual Z movement cycle.
selector If activated, the ram opens through to TDC, X axis and R axis position near the
operator so that the locator can be moved there in the required position along Z
axis.
It is only activated in the semiautomatic mask.
It must be connected to a selector to allow the user to activate the cycle at the
required time.
33 No air NO Its purpose is to display PLC error message N° 21. The default message is “PE
0021 No air”. The status of the machine cycle will not change in any way if this
input is activated. The message can be modified by the machine Manufacturer.
Refer to the machine parameters manual for a description.
34 Alarm code Bit 0 NO Used to display PLC error messages between N° 34 and N° 45. This function is
enabled if 1 has been set for special parameter “Machine 4”. There will be no
change in the machine cycle status when this input is activated. The message can
be modified by the machine Manufacturer. Refer to the machine parameters
manual for a description and for the code of the type of alarm displayed.
35 Alarm code Bit 1 NO Used to display PLC error messages between N° 34 and N° 45. This function is
enabled if 1 has been set for special parameter “Machine 4”. There will be no
change in the machine cycle status when this input is activated. The message can
be modified by the machine Manufacturer. Refer to the machine parameters
manual for a description and for the code of the type of alarm displayed.

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DS Description of the inputs and outputs

N Name of input Type Description of operation

36 Alarm code Bit 2 NO Used to display PLC error messages between N° 34 and N° 45. This function is
enabled if 1 has been set for special parameter “Machine 4”. There will be no
change in the machine cycle status when this input is activated. The message can
be modified by the machine Manufacturer. Refer to the machine parameters
manual for a description and for the code of the type of alarm displayed.
37 Alarm code Bit 3 NO Used to display PLC error messages between N° 34 and N° 45. This function is
enabled if 1 has been set for special parameter “Machine 4”. There will be no
change in the machine cycle status when this input is activated. The message can
be modified by the machine Manufacturer. Refer to the machine parameters
manual for a description and for the code of the type of alarm displayed.
38 Internol IN5 NC Used to display PLC error message N° 46. The default message is “PE 0046
Pump Thermic Activation”. This function is enabled if 1 has been set for special
parameter “Machine 4”. The status of the machine cycle will not change if this
input is activated. The message can be modified by the machine Manufacturer.
Refer to the machine parameters manual for a description.
39 Internol IN6 NO Used to display PLC error message N° 47. The default message is “PE 0047 X
Axis Drive Fault”. This function is enabled if 1 has been set for special
parameter “Machine 4”. The status of the machine cycle will not change if this
input is activated. The message can be modified by the machine Manufacturer.
Refer to the machine parameters manual for a description.
40 Internol IN7 NO Used to display PLC error message N° 48. The default message is “PE 0048 R
Axis Drive Fault”. This function is enabled if 1 has been set for special
parameter “Machine 4”. The status of the machine cycle will not change if this
input is activated. The message can be modified by the machine Manufacturer.
Refer to the machine parameters manual for a description.
41 Internol IN8 NO Used to display PLC error message N° 49. The default message is “PE 0049 Z1
Axis Drive Fault”. This function is enabled if 1 has been set for special
parameter “Machine 4”. The status of the machine cycle will not change if this
input is activated. The message can be modified by the machine Manufacturer.
Refer to the machine parameters manual for a description.
42 Internol IN9 NO Used to display PLC error message N° 50. The default message is “PE 0050 Z2
Axis Drive Fault”. This function is enabled if 1 has been set for special
parameter “Machine 4”. The status of the machine cycle will not change if this
input is activated. The message can be modified by the machine Manufacturer.
Refer to the machine parameters manual for a description.
43 Internol IN10 NO Used to display PLC error message N° 51. The default message is “PE 0051 Oil
Filter Clogged”. This function is enabled if 1 has been set for special parameter
“Machine 4”. The status of the machine cycle will not change if this input is
activated. The message can be modified by the machine Manufacturer. Refer to
the machine parameters manual for a description.
44 External + button NO Activates the + enabling signal (used to move the axes in the manual mode) with
an external signal. It has the same functions as the + button on the NC’s keyboard.
It is particularly useful when the press is part of a robotized machining center and
the user would have to enter the center to press the + button, or if a machine
button panel is to be used. Essential in kvara2000 structures
45 External - button NO Activates the - enabling signal (used to move the axes in the manual mode) with
an external signal. It has the same functions as the - button on the NC’s keyboard.
It is particularly useful when the press is part of a robotized machining center and
the user would have to enter the center to press the - button, or if a machine button
panel is to be used. Essential in kvara2000 structures

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Description of the inputs and outputs DS

N Name of input Type Description of operation

46 A2 In-Out feeder NO Used to enable In-Out feeder operation in the automatic cycle.
enabling It must be connected to a selector to allow the user to decide whether to use In-
Out feeder A2 in a bending program or not. This input must be disabled if a single
In-Out feeder is used.

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DS Description of the inputs and outputs

2.2 Outputs (Config I/O 1)

N Name of output Description of operation

51 Function 1 Used to activate a generic output to which the manufacturer can connect a device (for
example, pneumatic bending and squashing dies or pneumatic R axes).
The output is activated when pressed at the same time as the stop axes are positioned
in the automatic cycle if 1 has been selected for the first field of the Functions data
item of the bending program. or if 1 has been set for the first field of the Machine
functions window (setup MENU, key 7) of the bending program
This function remains activated even when the [STOP] key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.
52 Function 2 (Push Used to activate a generic output to which the manufacturer can connect a deviceple,
pneum. C.P. to pneumatic bending and squashing dies or pneumatic R axes).
TDC) The output is activated when pressed at the same time as the stop axes are positioned
in the automatic cycle if 1 has been selected for the second field of the Functions data
item of the bending program. or if 1 has been set for the second field of the Machine
functions window (setup MENU, key 7) of the bending program. 1 is automatically set
for the function by the machining program; if a bending/crimping die of the pneumatic
type is used for crimped bends, the output associated by the function opens and closes
the die. The function is also used to delay step change at TDC instead of at PCP. This
function remains activated even when the [STOP] key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.
53 Function 3 (receoil Used to activate a generic output to which the manufacturer can connect a device (for
axes Z) example, pneumatic bending and squashing dies or pneumatic R axes).
The output is activated when pressed at the same time as the stop axes are positioned
in the automatic cycle if 1 has been selected for the third field of the Functions data
item of the bending program. or if 1 has been set for the third field of the Machine
functions window (setup MENU, key 7) of the bending program. Enables the Z axes
recoil operating mode; operates if the generic parameter Z deviation value is different
from zero. This function remains activated even when the [STOP] key is pressed and
when the automatic or semiautomatic modes are quitted, if 1 has been set for special
parameter “Autorit. Fun. Aux.”.
54 Function 4 Used to activate a generic output to which the manufacturer can connect a device (for
(En.cycle In-Out example, pneumatic bending and squashing dies or pneumatic R axes).
feed. Operate) The output is activated when pressed at the same time as the stop axes are positioned
in the automatic cycle if 1 has been selected for the fourth field of the Functions data
item of the bending program. or if 1 has been set for the fourth field of the Machine
functions window (setup MENU, key 7) of the bending program. Enables the release
cycle of the In-Out feeders to operate. This function remains activated even when the
[STOP] key is pressed and when the automatic or semiautomatic modes are quitted, if
1 has been set for special parameter “Autorit. Fun. Aux.”.
55 CNC in automatic The output is activated on access to the automatic mask and is deactivated when the
mode mask is quitted.
56 CNC in The output is activated on access to the automatic mask and is deactivated when the
semiautomatic mask is quitted.
mode
57 CNC in manual The output is activated on access to the manual mask and is deactivated when the mask
mode is quitted.
58 CNC OK The output is activated if the NC comes on without difficulty.

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Description of the inputs and outputs DS

N Name of output Description of operation

59 Valve1 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
60 Valve2 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
61 Valve3 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
62 Valve4 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
63 Valve5 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
64 Valve6 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
65 Valve7 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
66 Valve8 This output is activated when the ram moves with a valve configuration in which this
valve has been enabled (for example, if 1 has been entered for the Machining descent
configuration and a manual descent is made).
67 TDC In synchronized presses, the output is activated when the ram is at TDC, i.e. in the
following cases:
• After a resetting operation
• After a manual re-ascent that has brought the ram near to the maximum target
(within 5 mm)
• After an externally forced re-ascent that has brought the ram near to the maximum
target (within 5 mm)
• After an automatic bending cycle has terminated and has brought the ram near to
the maximum target (within 5 mm).
The output is deactivated when a ram movement moves it from one of the above
mentioned points.

In conventional presses, the output is activated for the adjustable TDC function:
• When waiting for the change step function.
• For calculation of the re-ascent time according to the theoretic re-ascent speed.
• When waiting for the re-ascent time.
• On activation of the signal for 500 msec to inhibit the ascent enabling signal.
• On deactivation of the signal (the signal is deactivated before the 500 msec if the
TDC Micro input is activated).
68 SCP (photocell The output is activated when the ram reaches SCP during descent in the automatic
inhibition) cycle. It is deactivated at the end of the bending cycle if the programmed TDC value is
at a higher position than the SCP.

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DS Description of the inputs and outputs

N Name of output Description of operation

69 PCL This output is activated when the ram reaches PCL during the descent phase in the
automatic cycle and is deactivated when the ram rises again and passes through PCL
after having made the bend.
70 BDC The output is activated when the ram reaches BDC during the descent phase in the
automatic cycle and is deactivated at the end of the decompression phase.
71 PCL before recoil This output is activated when the ram reaches PCL prior to recoil during the descent
phase of the automatic cycle with presses in tandem and is deactivated when the ram
ascends again and passes through PCL after having made the bend.
72 Axes in position This output is activated after the axes have positioned within tolerance during the
automatic cycle and deactivates when the axes are moving in order to position again.
73 NC in alarm status This output is activated if an alarm occurs (axes alarm, emergency, STOP button) and
tandem mode is activated.
74 Signal 1 program These outputs are activated on access to the automatic mask if the press operates
75 selection together with a robot. These signals encode the number of the selected program to
76 allow the program in progress to be synchronized between the NC and robot. The
77 Signal 2 program outputs are deactivated when the robot responds with the Selected program OK
selection signal.
NOTE: This operating mode is no longer available from version 6.5 inclusive.
Signal 3 program
selection

Signal 3 program
selection

78 Program name This output is activated on access to the automatic mask if the press operates together
reading enabling with a robot. It signals that the number of the program in progress in the NC is
available. The output is deactivated when the robot responds with the Selected
program OK signal.
NOTE: This operating mode is no longer available from version 6.5 inclusive.
79 RALL activation Reserved.
80 POS activation Reserved.
81 IND activation Reserved.
82 DCP activation Reserved.
83 FORK activation Reserved.
84 Punch release valve The output is activated during the cycle that handles opening/closing of the upper tool
clamps. Management of this output is linked to other parameters. Refer to the machine
parameter manual.
85 Manual Z release The output is activated at the end of the manual Z cycle in order to release the solenoid
valve valve that keeps the stops blocked, thus enabling manual positioning.
86 Pressure on/off This output is activated when the In-Out feeders are moving, both during the lifting
solenoid valve and lowering phases.
87 A1-A2 descent This output is activated when the In-Out feeders are moving, during the lowering
on/off solenoid phase.
valve
88 Synchro control This output is activated for 500 ms on TDC activation. It is used in special panels to
allow successive lowering of the ram, which would otherwise be interlocked by the
electromechanics. From version 14.1 onwards, the output is activated for 500 mS each
time the ram stops.

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Description of the inputs and outputs DS

N Name of output Description of operation

89 Finished pieces The output is activated when the remaining pieces in the machining program have
terminated. It is useful for interfacing with the robot. It deactivates when [START] is
pressed or when the automatic mask is quitted.
90 Die release valve The output is activated during the cycle that handles opening/closing of the lower tool
clamps. Management of this output is linked to other parameters. Refer to the machine
parameter manual.
91 Inhibit photocells 5 The output is activated during the automatic or semiautomatic cycle, 5 mm before the
mm before PCP PCP. It can be used to inhibit the photocells in a safe zone, so as to prevent the fingers
inserting between the tools accidentally, even though ram movement is slow.
92 Ram block in This output is activated (thus blocking the movement of the ram) when the conditions
reading only mode for moving it are absent, i.e. if it has not been sized or if the [START] key has not
been pressed in the automatic mode.
93 Output 43 Not used.
94 Output 44 Not used.
95 Output 45 Not used.
96 Output 46 Not used.
97 Output 47 Not used.
98 Output 48 Not used.
99 Slow ascent speed The output is only used in the press with ram in the reading only mode, so as to lower
the speed as the ram re-ascends and approaches the TDC (SCP on ascent). It is
activated at a programmable distance from the TDC, in generic parameters 2.
100 Ultra-slow speed The output is only used in the press with ram in the reading only mode, so as to lower
the speed during the bending phase, before reaching the final target, thus achieving
greater accuracy in this type of machine. It is activated at a programmable distance
from the BDC, in generic parameters 2.

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DS Description of the inputs and outputs

2.3 Input (Config I/O 2)

N Name of input Type Description of operation

101 Maximum NC Signals that the machine has set to the maximum unbalance status. The
unbalance “maximum unbalance input” message appears in any situation if this signal is
activated and ram movement is inhibited.
102 SV Y1 direction NC Following an ascent signal, after a time set in the generic2 parameters
Up “proportional direction monitoring delay”, the system checks that proportional
valve Y1 is not in opposition to the control, i.e. that this input is up. Thus, if this
input is deactivated, ram movement will block and the message “Proportional
valve position incorrect during movement” will appear.
The signal must be activated (NC) when the ram is at a standstill. The
monitoring method is unidirectional (i.e. deactivation of the proportional valve
in the down direction is not monitored).
This operating mode is only valid in the Automatic and Semiautomatic modes if
this input has been configured.
103 SV Y2 direction NC Following an ascent signal, after a time set in the generic2 parameters
Up “proportional direction monitoring delay”, the system checks that proportional
valve Y2 is not in opposition to the control, i.e. that this input is up. Thus, if this
input is deactivated, ram movement will block and the message “Proportional
valve position incorrect during movement” will appear.
The signal must be activated (NC) when the ram is at a standstill. The
monitoring method is unidirectional (i.e. deactivation of the proportional valve
in the down direction is not monitored).
This operating mode is only valid in the Automatic and Semiautomatic modes if
this input has been configured.
104 SV Y1 direction NC Following an descent signal, after a time set in the generic2 parameters
Down “proportional direction monitoring delay”, the system checks that proportional
valve Y1 is not in opposition to the control, i.e. that this input is up. Thus, if this
input is deactivated, ram movement will block and the message “Proportional
valve position incorrect during movement” will appear.
The signal must be activated (NC) when the ram is at a standstill. The
monitoring method is unidirectional (i.e. deactivation of the proportional valve
in the upward direction is not monitored).
This operating mode is only valid in the Automatic and Semiautomatic modes if
this input has been configured.
105 SV Y2 direction NC Following an descent signal, after a time set in the generic2 parameters
Down “proportional direction monitoring delay”, the system checks that proportional
valve Y2 is not in opposition to the control, i.e. that this input is up. Thus, if this
input is deactivated, ram movement will block and the message “Proportional
valve position incorrect during movement” will appear.
The signal must be activated (NC) when the ram is at a standstill. The
monitoring method is unidirectional (i.e. deactivation of the proportional valve
in the upward direction is not monitored).
This operating mode is only valid in the Automatic and Semiautomatic modes if
this input has been configured.
106 Slowing selector NO If this signal is activated, the machine can be operated in the MANUAL mask,
otherwise the message “Manual selector requested” will appear and block the
downward movement. It forces the descent in the slow mode in the Automatic
and Semiautomatic masks, during which the message “Manual selector
activated” will appear. This operating mode is only valid if this input has been
configured.

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Description of the inputs and outputs DS

N Name of input Type Description of operation

107 Descent NO The downward movement of the machine will be inhibited and the message
emergency “Start machine” will appear if this signal is activated. Movement of the locators
is not inhibited. This signal can be used as a normally open emergency. This
operating mode is only valid if this input has been configured.
108 Cycle blocked by NO If this signal is enabled in the Automatic mode, the ram will stop at PCP. When
Robot this input is disabled, the ram will finish the bend and return to TDC. If this
input is enabled again before BDC has been reached, the ram will stop at BDC.
If it is deactivated again, the ram will terminate the cycle and return to TDC.
This operating mode is only valid if this input has been configured and
operation is via robot.
109 Upper clamp NO The message UPPER CLAMPS OPEN will appear and the machine will block
pressure switch if the hydraulic clamps or pneumatic clamps are configured and this signal is
activated.
110 Lower clamp NO The message LOWER CLAMPS OPEN will appear and the machine will block
pressure switch if the hydraulic clamps or pneumatic clamps are configured and this signal is
activated.
111 Monitoring of NC If this signal is activated on a level with a slow or fast ascent signal after a
Relay certain delay time set in PARGEN2 “20KA relay monitoring delay”, the
20KA1,2,3,4 message FAST DESCENT NOT ALLOWED CHECK RELAY 20KA1-2-3-4
will appear, blocking the fast descent movement in the Automatic status and
forcing it to slow.
This operating mode is only valid if this input has been configured.
112 SV A1 NO If this signal is activated for a longer time than the one set in the Conf.generici2
transducer ACC. VALVE MONITORING DEL. Data, the A1 PARKING ERROR will
appear when the In-Out feeders have returned to their hold condition or if they
are in the hold position for any reason, and the descent movement will be
inhibited in the automatic status (only if the ram has not yet started).
This operating mode is only valid if this input has been configured.
113 SV A2 NO If this signal is activated for a longer time than the one set in the Conf.generici2
transducer ACC. VALVE MONITORING DEL. Data, the A2 PARKING ERROR will
appear when the In-Out feeders have returned to their hold condition or if they
are in the hold position for any reason, and the descent movement will be
inhibited in the automatic status (only if the ram has not yet started).
This operating mode is only valid if this input has been configured.
114 Reset PCP and NO In the automatic status, the ram stops at PCP if this signal has been configured.
BDC At the first front of this input, the ram moves to BDC. At the second front, it
moves to TDC. No fronts of this signal are acquired between PCP and BDC and
when the axes are moving.
This operating mode is only valid if this input has been configured and
operation is via robot.
115 Pump on NC The “Pump not started” message appears if this signal is activated, and prevents
the ram from lifting and lowering.
This operating mode is only valid if this input has been configured.
116 Side guards no NO The “side guard open” message appears if this signal is activated, forcing fast
closed descent to slow in the Automatic mode.
This operating mode is only valid if this input has been configured.
117 SQ1 safety NO If this signal remains activated during the ram descent phase (pedal depressed),
SV transducer the machine will inhibit the descent movement after a delay time set in
PARGEN2 “safety solenoid valve transducer monitoring delay” and the
message “Check transducer SQ1” will appear. There will now be no checks
made if this input always remains at 0V.
The signal is deactivated when the ram is at a standstill.
This operating mode is only valid if this input has been configured.

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DS Description of the inputs and outputs

N Name of input Type Description of operation

118 SQ2 safety NO If this signal remains activated during the ram descent phase (pedal depressed),
SV transducer the machine will inhibit the descent movement after a delay time set in
PARGEN2 “safety solenoid valve transducer monitoring delay” and the
message “Check transducer SQ2” will appear. There will now be no checks
made if this input always remains at 0V.
The signal is deactivated when the ram is at a standstill.
This operating mode is only valid if this input has been configured.
119 Mask selection NO If this signal is activated, the user can select one of the 32 programs from the list
Settings via between 900 and 931 by means of the machining program selection inputs. The
robot input must be disabled to proceed by executing the program selected in the
automatic mask.
As soon as this signal is activated, the NC only switches to the Settings via robot
mode if the machine was already in the setup status or the automatic mode.
This operating mode is only valid if the “Operation with robot” input has been
configured. This input must remain activated for at least 50 ms.
This function is not available in Kvara2003.
120 Mask selection NO This input is used to access the automatic status when a correct program has
Automatic via been selected with the “machining program selection inputs”. The message
robot “Program via robot not correct” will appear if the name of the program is not
between 900 and 931.
The “Setup mask selection via robot” input must also be deactivated. This
operating mode is only valid if the “Operation with robot” input has been
configured. This input must remain activated for at least 50 ms.
This function is not available in Kvara2003.
121 Bit 0 code NO This input is used to select a program via robot between 900 and 931 in the list
program via of NC programs. This operating mode is only valid if the “Operation with
robot robot” input has been configured.
This function is not available in Kvara2003. This function is not available in
Kvara2003.
122 Bit 1 code NO This input is used to select a program via robot between 900 and 931 in the list
program via of NC programs. This operating mode is only valid if the “Operation with
robot robot” input has been configured.
This function is not available in Kvara2003.
123 Bit 2 code NO This input is used to select a program via robot between 900 and 931 in the list
program via of NC programs. This operating mode is only valid if the “Operation with
robot robot” input has been configured.
This function is not available in Kvara2003.
124 Bit 3 code NO This input is used to select a program via robot between 900 and 931 in the list
program via of NC programs. This operating mode is only valid if the “Operation with
robot robot” input has been configured.
This function is not available in Kvara2003.
125 Bit 4 code NO This input is used to select a program via robot between 900 and 931 in the list
program via of NC programs. This operating mode is only valid if the “Operation with
robot robot” input has been configured.
126 Drives OK NC This input monitors the ready status of the drives. The message “Servo drives
not ready” will appear if it deactivates.
This operating mode is only valid if this input has been configured.
127 End of pressing 1 NC This input terminates the bending phase in HAMMERLE presses (it is the micro
of the hydraulic cushion). It does not work in the other configurations.
128 End of pressing 2 NC This input terminates the bending phase in HAMMERLE presses (it is the micro
of the hydraulic cushion). It does not work in the other configurations.

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Description of the inputs and outputs DS

2.4 Outputs (Config I/O 2)

N Name of output Description of operation

151 Upper clamps The output is activated when the upper clamps are open (if UPPER CLAMPS has been
open indicator configured in Conf.generici2), i.e. when the UPPER CLAMPS PRESSURE SWITCH
(ConfigI/O2) is absent.
152 Lower clamps The output is activated when the lower clamps are open (if LOWER CLAMPS has
open indicator been configured in Conf.generici2), i.e. when the LOWER CLAMPS PRESSURE
SWITCH (ConfigI/O2) is absent.
153 Slow descent The output is deactivated when the machine descends in the slow mode and when the
indicator manual position selector is activated.
154 Hydraulic cushion This output only operates in the configuration for HAMMERLE presses. If enabled,
pressure SV modifies management of the crowning output which is used to inflate the hydraulic
cushion. This output remains activated for the time set in the specific parameter
“hydraulic cushion pressure timer” of generic parameters 2. Do not enable this output
if the hydraulic cushion does not have the relative solenoid valve, but needs a constant
pressure. Do not enable this output for any other reason.
155 Crowning The output is activated between the SCP and BDC (end of decompression) in the self-
SV piloting retention mode (Corresponds to the slow valve with OPERATING MODE = 2 of the
Y1 axis and to the RALL output).
156 START button This output corresponds exactly to the status of the START key of the dedicated
output keyboard (200c for the Kvara200 series) or the START key connected to the relative
input for the Kvara2000 series. The output activates if the START key is pressed and
deactivates when the key is released. It can be used to communicate the status of the
buttons via the field bus or to PILZ. It can be used in external safety logics.
157 STOP button This output corresponds exactly to the status of the STOP key of the dedicated
output keyboard (200c for the Kvara200 series) or the STOP key connected to the relative
input for the Kvara2000 series. The output activates if the STOP key is pressed and
deactivates when the key is released. It can be used to communicate the status of the
buttons via the field bus or to PILZ. It can be used in external safety logics.
158 + button output This output corresponds exactly to the status of the + key of the dedicated keyboard
(200c for the Kvara200 series) or the + key connected to the relative input for the
Kvara2000 series. The output activates if the + key is pressed and deactivates when
the key is released. It can be used to communicate the status of the buttons via the field
bus or to PILZ. It can be used in external safety logics.
159 - button output This output corresponds exactly to the status of the - key of the dedicated keyboard
(200c for the Kvara200 series) or the - key connected to the relative input for the
Kvara2000 series. The output activates if the - key is pressed and deactivates when the
key is released. It can be used to communicate the status of the buttons via the field
bus or to PILZ. It can be used in external safety logics.
160 Descent enabling The output is activated in all conditions in which the ram can descend (even in
SETUPS) with the exception of the manual mode unless the “selector in manual
position “ (config.I/O2) has been enabled.
161 Infeeding This output is activated when the metal plate is infeeding between BDC and PCP.
in progress
162 Stopping space Activates a generic output to which the manufacturer can connect a device. Only
procedure operates if 1 has been entered for the Space data item in the Conf. Generici2
management opt. parameters.
163 Upper clamp Activates a generic output to which the manufacturer can connect a device if 1 has
management opt. been entered for the Upper clamps data item in the Conf. Generici2 parameters.
164 Lower clamp Activates a generic output to which the manufacturer can connect a device if 1 has
management opt. been entered for the Lower clamps data item in the Conf. Generici2 parameters.

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DS Description of the inputs and outputs

N Name of output Description of operation

165 Proportional This output is activated when one of the ram’s proportional valves opposes the
direction errors command and the “Proportional valve position incorrect during movement” message
appears (see UP-DOWN Y1 SV DIRECTION and UP-DOWN Y2 SV DIRECTION
inputs in the ConfigI/O2 parameters).
166 Upper clamps2 Activates a generic output to which the manufacturer can connect a device if 1 has
management opt. been entered for the Bloc.Sup.2 data item in the Conf. Generici2 parameters.
167 Fiessler Activates a generic output to which the manufacturer can connect a device if 1 has
management opt. been entered for the Fiessler Management data item in the Conf. Generici2 parameters.
168 Double pedal board Activates a generic output to which the manufacturer can connect a device if 1 has
management opt. been entered
for the Double pedal board item in the Conf. Generici2 parameters.
169 In-Out feeder Activates a generic output to which the manufacturer can connect a device.
management opt. The output remains activated when the A1 OPERATING MODE axes configuration
parameter is 3 (In-Out feeder axis).
170 Function Activates a generic output to which the manufacturer can connect a device.
(slow descent) The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the fifth field of the Machine
functions window (setup MENU, key 7) of the bending program: forces slow ram
descent.
This function remains activated even when the STOP key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.
171 Function 6 (pedal Activates a generic output to which the manufacturer can connect a device.
board selection) The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the sixth field of the
Machine functions data item (setup MENU) of the bending program.
This function remains activated even when the STOP key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.
172 Function 7 (Fiessler Activates a generic output to which the manufacturer can connect a device.
safety system) The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions data item (setup MENU) of the bending program.
This function remains activated even when the STOP key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.
173 Function 8 (Type of Activates a generic output to which the manufacturer can connect a device.
crowning) The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the eighth field of the
Machine functions data item (setup MENU) of the bending program: used to select
the type of dedicated crowning, either the Automatic type (value 0) of the conventional
type (value 1) if 1 has been set for parameter conf.generici2 “Crowning – 100 + 100”.
This function remains activated even when the STOP key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.
174 Function 9 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the fourth field of the
Functions data item of the bending program.
This function remains activated even when the STOP key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.

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Description of the inputs and outputs DS

N Name of output Description of operation

175 Function 10 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions data item (setup MENU) of the bending program.
This function remains activated even when the STOP key is pressed and when the
automatic or semiautomatic modes are quitted, if 1 has been set for special parameter
“Autorit. Fun. Aux.”.
176 Function 11 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
177 Function 12 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
178 Function 13 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
179 Function 14 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
180 Function 15 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
181 Function 16 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
182 Function 17 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
183 Function 18 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
184 Function 19 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
185 Function 20 Activates a generic output to which the manufacturer can connect a device.
The output is activated when [START] is pressed, at the same time as the locator axes
are positioned in the automatic cycle if 1 has been set for the seventh field of the
Machine functions window (setup MENU) of the bending program.
186 Maximum This output activates the moment in which the ram reaches maximum unbalance and
unbalance can be used to shut off the power supplied to the ram’s proportional valve driver
boards so as to reset them if they are in the protection status. It is deactivated by
pressing the [STOP] key.

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DS Description of the inputs and outputs

END OF CHAPTER

Esa/Gv 91813.DS.0.GB 2.17

Description of the inputs and outputs DS

2.18 91813.DS.0.GB Esa/Gv