PEDDINGHAUS CORP.

CONTROL SOFTWARE
MANUAL
YD-2312234
FOR
AFCPS 643-N, 643-O, 623-O ANGLEMASTERS
REVISION DATE: May 30, 2006
VERSION 1, REVISION 4
TABLE OF CONTENTS
SECTION
NUMBER
Basic Machine Operation Information.......................................................................1.1
Siemens 840Di / OP10C Operators Panel ........................................................1.1.1
Machine Control Panel Illustration...................................................................1.1.2
Siemens 840Di General Information ................................................................1.1.3
Operating Modes...............................................................................................1.1.4
Jog Mode...........................................................................................................1.1.5
Jog Mode – (Incremental Axis Move) .........................................................1.1.5.1
Jog Mode – Ref Point (Manual Axis Reference) .........................................1.1.5.2
MDI Mode ........................................................................................................1.1.6
Automatic Mode ...............................................................................................1.1.7
Part Program Selection.................................................................................1.1.7.1
Load HD→NC..............................................................................................1.1.7.2
Unload NC→HD ..........................................................................................1.1.7.3
Start Cycle ....................................................................................................1.1.7.4
Stop Cycle ....................................................................................................1.1.7.5
Single Block Execution ................................................................................1.1.7.6
View Currently Selected Part .......................................................................1.1.7.7
Edit Currently Selected Part .........................................................................1.1.7.8
Part Program Management ....................................................................................1.2
Copy Part Program............................................................................................1.2.1
Rename Part Program .......................................................................................1.2.2
Delete Part Program(s)......................................................................................1.2.3
Machine Operations ..............................................................................................1.3
Manual Pushbuttons..........................................................................................1.3.1
E-Stop Buttons .............................................................................................1.3.1.1
Pump Pushbutton..........................................................................................1.3.1.2
Clear Reset Pushbutton ................................................................................1.3.1.3
Tool Names ..................................................................................................1.3.1.4
NL Punch and FL Punch Jog Pushbuttons ...................................................1.3.1.5
Feed Override Turn Dial ..............................................................................1.3.1.6
NL Gage and FL Gage Pushbuttons.............................................................1.3.1.7
Axis Display Screen – main 643N Screen........................................................1.3.2
SignoScript Option .......................................................................................1.3.2.1
Machine Offsets ...........................................................................................1.3.2.2
Far & Near Leg Calibration / Parameters / IO Screen ......................................1.3.3
Far & Near Leg Calibration..........................................................................1.3.3.1
Inposition Window .......................................................................................1.3.3.2
High Speed Window ....................................................................................1.3.3.3
X Axis Parameters / Calibration Screen ...........................................................1.3.4
ScaleFactor Encoder1 / Encoder2 ................................................................1.3.4.1
X Home Position ..........................................................................................1.3.4.2
Rev Home Position.......................................................................................1.3.4.3
Options Screen ..................................................................................................1.3.5
Loader Enable...............................................................................................1.3.5.1

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 Unloader Enable ...........................................................................................1.3.5.2
MarkerDevice Enable...................................................................................1.3.5.3
PMA Enable .................................................................................................1.3.5.4
Weld Station Enable.....................................................................................1.3.5.5
Pump Time Out ............................................................................................1.3.5.6
Clamps Screen .......................................................................................................1.3.6
Machine / Control Configuration Data..................................................................1.4
General UD Screen ...........................................................................................1.4.1
Default Dimension G Code ..........................................................................1.4.1.1
Axis MD Screen................................................................................................1.4.2
Home Position for the W (Signoscript) Axis – RefP_Set_POS[0] ..............1.4.2.1
Automatic Operation.........................................................................................1.4.2
Recover from a program fault...........................................................................1.4.3
Access Levels ........................................................................................................1.5
Access Level Retention.....................................................................................1.5.1
Determining Current Access Level...................................................................1.5.2
Raising the Access Level ..................................................................................1.5.3
Lowering the Access Level...............................................................................1.5.4
Changing Passwords .........................................................................................1.5.5
Additional Installed Programs...............................................................................1.6
Peddimat Programming System........................................................................1.6.1
Updating Peddimat............................................................................................1.6.2
Updating VB Screens........................................................................................1.6.3
Step 7 PLC Program .........................................................................................1.6.4
Complete M Code Listing .....................................................................................1.7
Additional Information..........................................................................................1.8
X Axis Referencing...........................................................................................1.8.1
W (Signoscript) Axis Referencing....................................................................1.8.2
Double Punching...............................................................................................1.8.3
Block Search (mid program restart)..................................................................1.8.4
Copying Peddimat part files from a floppy to the 840DI .................................1.8.5
Creating and Deleting directories within Peddimat ..........................................1.8.6

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1.1 Basic Machine Operation Information
1.1.1 Siemens 840Di / OP10C Operator’s Panel
1
 Q5.7 Q5.6 Q5.5 Q2.6 Q4.0 Q3.7

REF NL
JOG REPOS
POINT
Pump Fault X W
I7.6 I4.3 I5.7 Gage

Q5.4 Q5.3 Q5.2 Q2.5 Q3.6 Q3.1

TEACH Auto FL
VAR 1 Loader Unloader
IN Mode I7.3 I7.2 Gage SPINDLE MASTER FEEDRATE
E-STOP
OVERRIDE % OVERRIDE %
Q5.1 Q5.0 Q4.7 Q2.4 Q3.2 Q3.3
50 - 120 0 - 120
MarkMaster
MDA Select
NL FL
10 100 Off Mode Shear
I7.0 Position Punch Punch

Q4.6 Q4.5 Q4.4 * Q2.3 * Q3.4 Q3.5

PMA PMA WCS
Test Manual MarkMaster
1.1.2 Machine Control Panel Illustration

AUTO 1000 10000 Jog Jog

Mode Shear Lift ToolChange Minus Plus MCS

Q4.3 Q4.2 Q4.1 Q2.7 Q3.0

SINGLE CYCLE CYCLE Unloader Loader MarkMaster - RAPID + SPINDLE SPINDLE FEED FEED KEY
RESET Cylindar
BLOCK STOP START Drop Arm Index I4.6 I4.5 I4.7 STOP START STOP START
I3.7

* See Reference further in Manual on PMA Buttons

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1.1.3 Siemens 840Di General Information

The Siemens 840Di CNC control is a VERY robust system. A detailed explanation of its
many facets far exceeds the scope of this manual. This manual will try to provide a brief and
simple explanation of a few basic concepts needed for general operations. A complete listing
of features w/ descriptions can be found in the supplied Siemens documentation.

One general concept that all 840Di users need to understand is the concept of system
memory. The 840Di is a PC based system complete with a PC type hard disk. There is plenty
of extra hard disk space (HD memory) that can be used for part program storage. In addition,
the 840Di has an extra system card not found on a normal PC that provides additional
electronic RAM memory for part program storage and execution. This additional memory is
referred to as NC memory. Generally, a part program must be loaded in NC memory before it
can be selected as the active program and executed by the machine.

The Siemens HMI (Human Machine Interface) software treats HD memory and NC memory
as one large “virtual” storage container. The HMI provides the tools to copy, rename and
delete program files as well as move them from HD to NC and NC to HD. The only way to
distinguish whether a part program is located in NC memory vs. HD memory is the “Loaded”
column in all part program listings. If an “X” appears in the “Loaded” column the part
program is located in NC memory, otherwise the part program is located in HD memory.

This “dual memory” concept can cause problems for “normal” software applications (such as
Peddinghaus’ Peddimat programming system) that “see” only the HD memory and cannot
“see” the NC memory. Example: If a part program is located in NC memory and Peddimat
creates a new part program with the same name in HD memory, there is now a conflict. The
HMI will represent this by displaying an “!X!” in the “Loaded” column in all part program
listings. If this situation occurs the 840Di will not allow either of these part programs to be
selected and executed. To correct the conflict the normal HMI tools must be used to delete
the file, which will in fact delete only the part program located in NC memory, leaving the
part program in HD memory.

Another important concept to know about is “Operating Areas”. An “Operating Area” is a

functional area of the HMI software and has nothing to do with the traditional “Operating
Mode” described below. However, when the “Machine” operating area is active the current
operating mode will affect what information is displayed to the operator and what softkeys
are available. Other operating areas include Services (where part programs are managed),
Diagnosis (troubleshooting), Start-Up (configuration data) and 643N. Some of these
operating areas will be discussed later in this manual. To switch from one operating area to
another press the “Menu Select” button then choose the desired operating area softkey.

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1.1.4 Operating Modes

The Siemens 840Di CNC has 4 different main operating modes that can be selected via
appropriately labeled buttons on the machine control panel. This manual will discuss 3
modes. The 4th mode “Teach In” is beyond the scope of this manual:

“JOG”
Manual movement of the machine
Manual machine axis reference of W Axis (SignoScript option)

“MDI”
Manual creation and execution of programs

“AUTOMATIC”
Execution of programs in a continuous cycle

1.1.5 Jog Mode

Enter Jog mode by pressing the “Jog” button on the machine control panel. Jog mode has two
optional sub-modes: “Repos” & “Ref Point” - that are available via buttons located to the
right of the “Jog” button. “Repos” is used to make manual incremental axis moves and “Ref
Point” is used to perform manual axis referencing.

To jog an axis manually while in Jog mode, make sure neither sub-mode (Repos or Ref
Point) is active by looking at the indicator lamps above the sub-mode buttons. If a sub-mode
is active, press the “Jog” button a second time. Next, select the desired axis by pressing the
“X” making sure either entry or exit pinch drive is active, “W” for SignoScript option, “NL
Gage” or “FL Gage” button on the machine control panel. The axis can now be jogged by
pressing and holding the “+” & “-“ buttons on the machine control panel. To jog at a faster
pace additionally press the “Rapid” button.

1.1.5.1 Jog Mode – (Incremental Axis Move)

Enter Jog mode by pressing the “Jog” button on the machine control panel. Next, select the
desired axis by pressing the “X” making sure either entry or exit pinch drive is active, or “W”
for SignoScript option. Select the desired incremental distance by pressing one of the pre-set
distance buttons labeled 1,10,100,1000,10000 (all distances are in thousandths of
millimeters, so 1000 equals one millimeter). Last, press the “+” or “-“ button. The axis will
move the desired distance in the desired direction. To move a variable distance press the
“VAR” button. Next (with the “Machine” operating area active) set the desired distance by
pressing the “INC” softkey, entering a value (in thousandths of millimeters), pressing the
“Input” key followed by the “+” or “-“ button. Note: The NL Gage or FL Gage will not be
able to move incrementally this way.

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1.1.5.2 Jog Mode – Ref Point (Manual Axis Reference)

Notes:
1) Only axis able to use this feature will be the “W” axis (SigonScript option)
and if it has been referenced once manually or from a part program it cannot be
referenced again manually.
2) On the 643N Anglemaster the X axis cannot be referenced, instead a
sophisticated machine cycle is used while executing part programs.
3) The NL Gage and FL Gage will not need referencing since they are both
absolute encoders.

Enter Jog mode by pressing the “Jog” button on the machine control panel. Enter the “Ref
Point” sub-mode by pressing the “Ref Point” button on the machine control panel. When the
“Machine” operating area is active a small circle will appear to the left of the axis name on
screen. If the circle is empty the axis has not been referenced. If the circle has two opposite
quadrants colored black then the axis has already been referenced. . Next, select the desired
axis by pressing the “W” for SignoScript option on the machine control panel. Next press the
“-“ button on the machine control panel. The axis will now reference.

1.1.6 MDI Mode

Enter MDI mode by pressing the “MDI” button on the machine control panel (“MDA” button
on early versions). If the “Machine” operating area is active a small editable window titled
“MDI” will appear in the lower left quadrant of the display. Programs of any type can be
manually entered and executed here. Program execution is identical to Automatic mode with
normal use of the Cycle Start, Cycle Stop and Single Block buttons.

An advanced level of understanding of Siemens NC language and machine functionality is

required to write fully functional part programs in MDI mode. This is not recommended.
However, only a basic understanding of machine functionality is required to perform some
basic operations. Below is a list of helpful M codes commonly used in MDI mode on the
machine.

Note: Every MDI program should end with an M30

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1.1.7 Automatic Mode

Enter Automatic mode by pressing the “Auto” button on the machine control panel. If the
“Machine” operating area is active a small non-editable window titled “Current Block” will
appear in the lower left quadrant of the display. The currently “selected” part program name
will be displayed in the upper right corner of the screen. If no part program is currently
selected the default “empty” program MPF0 will be shown.

1.1.7.1 Part Program Selection

In Automatic mode (with the “Machine” operating area active) press the “Program
Overview” softkey. You may need to press one of the storage location softkeys (ie. Work
Pieces or Part Programs) to locate the desired part program. Use the ⇑ & ⇓ arrow buttons to
highlight the desired part program. Press the “Select” softkey. If the part program is already
loaded into NC memory it will be selected as the currently active program. If the part
program is loaded into HD memory it will automatically be moved into NC memory first and
them be selected as the currently active program.

1.1.7.2 Load HD → NC

In Automatic mode (with the “Machine” operating area active) press the “Program
Overview” softkey. You may need to press one of the storage location softkeys (ie. Work
Pieces or Part Programs) to locate the desired part program. Use the ⇑ & ⇓ arrow buttons to
highlight the desired part program. Press the “Load HD→ NC” softkey. This will move the
desired part program from HD memory to NC memory however it will NOT become the
currently active program.

1.1.7.3 Unload NC → HD

In Automatic mode (with the “Machine” operating area active) press the “Program
Overview” softkey. You may need to press one of the storage location softkeys (ie. Work
Pieces or Part Programs) to locate the desired part program. Use the ⇑ & ⇓ arrow buttons to
highlight the desired part program. Press the “Unload NC→ HD” softkey. This will move the
desired part program from NC memory to HD memory. If the part program was the currently
active program it WILL be unloaded and a default “empty” part program MPF0 will be set as
currently active.

6
1.1.7.4 Start Cycle

In Automatic mode (regardless of what operating area is active) pressing the Cycle Start
button (located on the machine control panel) will cause the machine to start execution from
the current block.

1.1.7.5 Stop Cycle

In Automatic mode (regardless of what operating area is active) pressing the Cycle Stop
button (located on the machine control panel) will cause the machine to stop execution at the
current block. As long as the shear or punch has not reached its bottom of stroke, hitting
cycle start button will re-issue the command at that block. Otherwise it continues on with the
next block.

1.1.7.6 Single Block Execution

In Automatic mode (regardless of what operating area is active) pressing the Single Block
button (located on the machine control panel) will cause the machine to stop execution at the
end of each block. Cycle Start will start the execution of the next block. Pressing the Single
Block button a second time will return the control to full automatic execution.

1.1.7.7 View Currently Selected Part Program

In Automatic mode (with the “Machine” operating area active) press the “Program Blocks”
softkey. The “Current Block” window will change into a non-editable scrollable window
displaying the entire part program. The window is somewhat narrow and some blocks may
be “wrapped” onto a second or third line.

1.1.7.8 Edit Currently Selected Part Program

In Automatic mode (with the “Machine” operating area active) press the “Correct Program”
softkey. A full screen block editor will now display the entire part program. Changes can be
made if desired. Caution: Only experienced NC programmers with specific knowledge
about this machine should manually edit a part program.

7
1.2 Part Program Management
The “Services” operating area is used to manage part programs. From here part programs can
be copied from diskette, copied from NC or HD memory, renamed or deleted. Although none
of these should be attempted on the currently selected, executing part program they can be
applied to other part programs while the machine is running. In addition, the “Services”
operating area can be used to load part programs into the NC memory from HD memory and
unload part programs into HD memory from NC memory. Note: The “Services” operating
area you cannot be used to “Select” the active part program.

Like most operating areas there are different sub-levels, screens and menus in the “Services”
operating area. If one of these sub-levels is active and a different operating area is activated,
when the “Services” operating area is re-entered it will remember which sub-level is active
and return there. If needed press the Recall button (^) to move up one level at a time or the
ETC button (>) to see additional menus.

1.2.1 Copy Part Program

Enter the “Services” operating area. Enter the “Manage Data” sub-level by pressing the
“Manage Data” softkey. A “Source” file list will be displayed. If needed the
“Programs/Data”, “Disk/Card” & “Clipboard” softkeys can be used to change which source
is displayed. Use the ↑, ↓, “Input” and “Select” buttons to navigate the source and select the
files to be copied. Press the “Copy…” softkey. The display will split horizontally with the
“source” at top and the “target” at bottom. If needed, the “Programs/Data”, “Disk/Card” &
“Clipboard” softkeys (upper right) can be used to change which target is displayed. Use the
↑, ↓, and “Input” buttons to navigate the target and highlight the target location. Press the
“Insert” softkey. The file(s) will now be copied. If problems arise a notification will be
displayed along with appropriate action softkeys.

1.2.2 Rename Part Program

Enter the “Services” operating area. Enter the “Manage Data” sub-level by pressing the
“Manage Data” softkey. A “Source” file list will be displayed. If needed the
“Programs/Data”, “Disk/Card” & “Clipboard” softkeys can be used to change which source
is displayed. Use the ↑, ↓, “Input” and “Select” buttons to navigate the source and select the
file to be renamed. Press the “Properties” softkey. A file properties page is displayed with the
“Name” field highlighted by default. Type the new name using the Alpha-numeric keys.
Press “OK” to complete.

8
1.2.3 Delete Part Program(s)

Enter the “Services” operating area. Enter the “Manage Data” sub-level by pressing the
“Manage Data” softkey. A “Source” file list will be displayed. If needed the
“Programs/Data”, “Disk/Card” & “Clipboard” softkeys can be used to change which source
is displayed. Use the ↑, ↓, “Input” and “Select” buttons to navigate the source and select the
files to be deleted. Press the “Delete…” softkey. A list of files to be deleted is displayed
along with appropriate confirmation softkeys. Select “Yes” to confirm file deletion
individually or “Yes All” to confirm all the file deletions at once.

1.3 Machine Operations

1.3.1 Manual Pushbuttons

1.3.1.1 E-Stop Buttons

There is one E-Stop button located on the machine and one E-Stop button located on the
machine control panel. Pressing any one of these buttons will immediately switch power off
to the machine in the event of an emergency.

To restore machine functions after an E-Stop event, all “tripped” E-Stop switches need to be
“cleared” either by pulling firmly on the button or by giving a slight twist (depending on
switch type). The E-Stop Light Button (located near the Power On and Power Off buttons) is
pressed to reset the E-stop condition. The “Reset” button located on the MCP must be
pressed in order to clear the E-stop message. Note: If an E-Stop event occurs while
processing a part program in Automatic mode it is NOT possible to recover gracefully and
start processing from where it stopped.

1.3.1.2 Pump Pushbutton

Press once to turn the hydraulic pump on, then again to turn off. The lamp above the button
will indicate pump status.

1.3.1.3 Fault Pushbutton

The fault PB is used to clear most “normal” status and error messages including safety
curtain and E-Stop events. Some events require the pressing of additional buttons (such as
the normal Reset button on the MCP) to clear messages.

9
1.3.1.4 Tool Names

Shear

Near Leg Far Leg

W Axis
(Signoscript)

X Axis

Far Leg Tool 1

Near Leg Tool 2

Far Leg Tool 2

Near Leg Tool 1

1.3.1.5 NL Punch and FL Punch Jog Pushbuttons

These buttons are used to manually extend the punch for maintenance purposes only. Once
selected, the ‘+’ button will extend the punch while the ‘-‘ button will retract the punch.
Used mainly to line up the punch with the die in the initial setup of the machine and anytime
a punch needs to be changed.

1.3.1.6 Feed Override Turn Dial

This dial is used override the feedrate of the X and W (SignoScript option) axis. Operational
speed for both axes will have the dial set at a 100%.

10
1.3.1.7 NL Gage and FL Gage Pushbuttons

Selection of either of these buttons to jog the gages of the punches by using the ‘+’ or ‘-‘
keys. The ‘+’ keys will increase the gage of the punch selected and vice versa for the ‘-‘ key.
Selecting the Rapid button down while selecting either the ‘+’ or ‘-‘ key will move the punch
gage at its high speed.

1.3.2 Axis Display Screen – main 643N Screen

This is the main starting screen to some custom screens accessible by the “643N” softkey.
To access these screens press the “Menu Select” button followed by the “643N” softkey. All
Axes for the 643N can be viewed on this screen. FL and NL not seen on normal Siemens
display screens and were added to display the gage dimension of the punches. Normally only
the X axis, FL, and NL will appear on the screen.

1.3.2.1 SignoScript Option

If a SignoScript option has been purchased, then the Signo Axis will appear underneath NL
as well as in Siemens normal display screens as axis ‘W’.

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1.3.2.2 Machine Offsets

Exit Measuring
Wheel Near Leg W Entry Measuring
Shear Far Leg (Signoscript) Datum
58.86” 41.77” Wheel
66.33” 41.77” 7.00” 0.00” -3.00”

7.88” 7.88” 7.88” 7.88”

Note: Tool 1 and Tool 2

for each leg are offset 1.5
inches from each side of
the center of the leg.

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1.3.3 Far & Near Leg Calibration / Parameters / IO Screen

In the above two screens, all inputs and outputs involving Far Leg and Near Leg are shown
here for easy diagnosis. Along with the IO, a few parameters for each Leg are shown here
for easy adjustment. Note: Access to specific data in these screens (as well as all the other
configuration data) is controlled by password protected access levels. The standard “User”
access level does NOT have access to configuration data. See the “Access Levels” section

13
of this manual for more information about access levels. Setting these parameters will
require a NCK Reset (“po”).

1.3.3.1 Far Leg & Near Leg Calibration

Upper limit and lower limit are the high and low travel of the cylinder for the gage location.
A calibration procedure is performed at checkout and should not have to be performed again
unless instructed to. If fine tuning of the zero and span adjustments on the temposonic units
are needed then the following procedure should be followed. These two adjustments are
used to set 10 and 0 volts for the upper and lower limit of the travel of the punches. Make
sure the wires connected to the analog input module 3 are White to 1, Red to 5, Black to
2 and 4, and Violet to 3 and 5.

ZERO & SPAN

ZERO
Remove screws to
access zero and span
potentiometers

SPAN

Connector end
of sensor
Figure 1

Null End of Stroke

Position Position

Active Stroke Dead

Null Length Zone

Outputs:
10 to 0 V

Figure 2

1. With power on, connect the sensor’s output leads to a voltmeter/ammeter.

14
2. Remove the screws that protect the zero and span potentiometer ports (see Fig. 1 above).
3. Move the corresponding punch which needs adjusting to its highest position (to the null
position) (see Fig. 2 above).
4. You can measure the voltage directly from the Analog Module on the rack.
a. Far Leg measure across 200+ (term#2) and 0V (term#20).
b. Near Leg measure across 202+ (term#4) and 0V (term#20).
4. Use a small, flat-head screwdriver to adjust the zero potentiometer until the output reads:
• + 10.02 V (± 0.010 V)
5. Next move the punch to the lowest position it can go (to the end of stroke position).
6. Use a small, flat-head screwdriver to adjust the span potentiometer until the output reads:
• - 0.020 V (± 0.005 V)
7. Since the null setting can affect the end of stroke setting, return to the highest position
to verify that the output still reads within the acceptable range. If not, repeat the
procedure until the null and end of stroke settings provide a full output range (0 to 10 volts).
8. IMPORTANT: Replace the screws which protect the zero and span potentiometers.
9. Have a set of punches and dies set in the machine to measure against.
10. Check the lower limit by using a straight edge on the datum rollers to check the passline
to the center of the die. Enter this value into the Lower Limit value either in inches or mm
corresponding to what shows on the screen. Keep in mind that the heel should be 0, and so if
the center of the die is below the heel then your value will be a negative number.
11. Next raise the punch to its highest position. Check the upper limit by using a straight
edge on the datum rollers and measure from the passline to the center of the die. Enter this
value into the Upper Limit value either in inches or mm corresponding to what shows on the
screen.
12. Repeat 1-12 for the next leg if needed.
13. After having run some parts and the gage is still a little off keep the following in mind:
a. To raise the gage, subtract the distance needed from both the Upper and Lower
limit.
b. To lower the gage, add the distance needed from both the Upper and Lower limit.

1.3.3.2 Inposition Window

This setting is the value which determines if the gage distance for the leg is in position or not.
If the measurement of the Actual Position minus the Distance to Go (Lag) is greater then this
value, the gage distance for the leg has not reached its position.

1.3.3.3 High Speed Window

This setting is the value in which the Far or Near leg will switch to its slow speed for its final
positioning. If the measurement of the Actual Position minus the Distance to Go (Lag) is
greater then this value, the Far or Near leg will travel at its full speed until it reaches below
value.

15
1.3.4 X Axis Parameters / Calibration Screen

1.3.4.1 Scale Factor Encoder1 / Encoder2

Since the 643N Anglemaster switches automatically from entry encoder to exit encoder over
the course of running an automatic part program it is NOT possible to perform an X axis
calibration while running a part program. Instead follow the procedure outlined below. You
will need a long (40’ or 12m minimum) straight angle without holes.

1. Position the Far and Near leg so that the angle will clear them in a X axis move. Position
the angle on the entry side of the machine with the leading edge just past the entry pinch
drive.
2. In MDI mode, execute the “Entry Calibration” program where ??? equals the longest safe
X axis move (in inches) before the trailing end of the material would pass the entry
measuring disk. This move will be known as the “commanded distance”.
3. At the first program stop (M00), scribe your first mark on the angle to be used in
measuring the Actual distance the X axis travels.
4. Execute the program by hitting cycle start once the first mark is done.
5. At the second program stop (M00), scribe a second mark on the angle using the same
method as you performed the first mark. Execute the program by hitting cycle start to
return to where the angle started from.
6. Execute the remaining program by hitting cycle start to finish unclamping the material
and ending the program.
7. Using a certified measuring tape that is used to inspect finished parts measure (in inches)
the distance from the first mark to the second mark. This will be known as the “Actual

16
 Distance”. After measuring, be sure to label the marks with soap stone so they do not
become confused with subsequent marks made by subsequent calibrations.

8. On the bottom half of the screen, select the encoder you are working with. Encoder 1
corresponding to pinch drive 1 and encoder 2 corresponding to pinch drive 2. Enter the
commanded and actual measured values either in inches or mm corresponding to what
the screen is asking for. Hit the Calculate button to have the new scale factor calculated
for you. Keep in mind the following formula is being used in calculating this new scale
factor in case you desire to do it manually:

New Scale Factor = (Old Scale Factor x Actual Distance)

Commanded Distance

Repeat the process using the exit clamp and the following program to calculate a new exit
encoder scale factor. Keeping in mind the second pinch drive is the only pinch drive to be
clamped. Note: Access to specific data in these screens (as well as all the other
configuration data) is controlled by password protected access levels. The standard “User”
access level does NOT have access to configuration data. See the “Access Levels” section
of this manual for more information about access levels. Setting these parameters will
require a NCK Reset (“po”). We have added a ExitCal.mpf and EntryCal.mpf part
program for easy use within MDA mode instead of having to type the following all of the
time. The two programs are set for 10 foot moves.

Entry Calibration Exit Calibration

G700 G700
G90 G90
M51 M56
M00 M00
G0 G91 X ??? G0 G91 X ???
M00 M00
G0 G91 X -??? G0 G91 X -???
M00 M00
M61 M66
G90 G90
M30 M30

1.3.4.2 X Home Position

The X zero point is the point from which all punch, shear, and clamp offsets are measured. It
is the point where the leading edge of the material will be when the X-Axis position reads
“0.0”. The position of the X zero point is determined by the placement of the X-Axis
Reference Switch and the value of the Home Position. In practice it is easier to change the
offset then it is to move the actual switch.

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To calibrate the X zero point, create a program for a short clip angle. Make sure the
theoretical position of the distance between the X zero point and the Shear position is correct.
Make sure you have calibrated both X axis encoders before proceeding with this calibration.
Run the program without a crop cut to create a single clip angle. If the clip is short, subtract
the error from the Home Position. If the clip is long, add the error to the Home Position. Run
the program again and repeat the process with the new clip angle. Note: This will require
you to hit the Reset button (“re”) on the MCP once the change has been entered.

1.3.4.3 Rev Home Position

The value of the Rev Home Position is used for referencing the trail end of the material used
by the Middle Remnant feature in Peddimat. Adjustment of this value will be recognized if
Peddimat uses Middle Remnant and your last part comes out short or longer then what it
needs to be. If your last part is long by a certain amount then you’ll need to add that amount
to the Rev Home Position in order to correct the last part. If your last part is short by a
certain amount then you’ll need to subtract that amount to the Rev Home Position in order to
correct the last part. Note: This will require you to hit the Reset button (“re”) on the
MCP once the change has been entered.

• Add the “amount off” to the Rev Home Position for a Shorter Last Part.
• Subtract the “amount off” to the Rev Home Position for a Longer Last Part.

1.3.5 Options Screen

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Note: Access to specific data in this screen is controlled by password protected access
levels. The standard “User” access level does NOT have access to configuration data. See
the “Access Levels” section of this manual for more information about access levels.
Setting these parameters will require a NCK Reset.

1.3.5.1 Loader Enable

Activating this parameter will enable the Loader to work in the PLC when installed. By
selecting the Loader button on the MCP, the “+” (towards the entrance conveyor) and “-“
keys (away from the entrance conveyor) will jog the loader in the desired direction. As long
as the loader button is active, the loader cylinder can be raised or lowered by the Loader
Cylinder button on the MCP.

1.3.5.2 Unloader Enable

Activating this parameter will enable the Unloader to work in the PLC when installed.
Having the pump on, unloader button active, jog mode button active, and holding the “+” key
down will result in the unloader moving forward. Having the pump on, unloader button
active, jog mode button active, and holding the “-” key down will result in the unloader arm
dropping The unloader dump time is the amount of time the drop arm will stay down in
milliseconds. This parameter will only be visible if the enable is on for the unloader. There
is now a Unloader Drop Arm button on the MCP for manually keeping the drop arm down
when doing shorter parts for those situations where the unloader can not move them to a bin.

1.3.5.3 Marker Device Enable

Activating this parameter will enable a marking device to work in the PLC when installed.
What type of marking device is also needed to activate the correct logic in the PLC. The
selection for what type will only be visible if the enable is on for the marking device.

1.3.5.4 PMA Enable*

Activating this parameter will enable a PMA (Power Material Advance) to work with the
software when a PMA is installed. For the 643N Anglemaster, selecting the PMA button on
the MCP, the PMA clamp automatically comes down. The “+” (towards the machine) and “-
“ (away from the machine) keys will jog the material in the desired direction only if the pinch
drives are not clamped. For the 643O and 623O Anglemasters, there are actually two buttons
on the MCP, PMA Jog Minus and PMA Jog Plus. These machines do not use the “+” and “-
“ keys. Movement towards the machine will be allowed up to the reference switch only for
all anglemasters.

1.3.5.5 Weld Station Enable

Activating this parameter will enable the Weld Station option to work in the PLC when
installed. More information to come later.

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1.3.5.6 Pump Time Out
If there is no machine action (punching, shearing, entry or exit pinch drives closed, plus or
minus jog keys, other options) for this amount of time the Pump will automatically kick off.
This is only true if the machine has not already started a part program.

1.3.6 Clamps Screen

These clamp buttons will only be enabled while the machine is in Jog Mode. These buttons
will toggle the entry/exit pinch drives on and off as well as toggle the pneumatic clamps on
and off. Markmaster buttons will only be enabled if a MarkMaster exists with the machine.

1.4 Machine/Control Configuration Data

The Siemens 840Di CNC control has thousands of pieces of configuration data used to
control various aspects of the 643N Anglemaster’s operation. Nearly all of this data is pre-set
at Peddinghaus and does not need to be adjusted or changed from one anglemaster to the
next. However, one parameter you might be interested in is accessed from the “Start-Up”
operating area. Enter the “Start-Up” operating area by pressing the “Menu Select” button and
choosing the “Start-Up” softkey. Press the “Machine Data” softkey, followed by the

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“General MD” softkey. Note: Access to this special data (as well as all the other
configuration data) is controlled by password protected access levels. The standard “User”
access level does NOT have access to configuration data. See the “Access Levels” section
of this manual for more information about access levels.

1.4.1 General MD Screen

The General MD screen is used for general machine data.

1.4.1.1 Default Dimension G Code 20150

This data determines whether the various linear axis position displays are displayed in inches
or millimeters. Set this data to “2” for millimeters and “3” for inches. Important Note: This
data does NOT determine the unit of measure for the linear configuration data. ALL
linear configuration data for the Anglemaster is measured and set in millimeters and
cannot be changed to inches. In addition, this data does not determine whether the part
program blocks are interpreted in inches or mm. How part program blocks are interpreted
is based on separate G codes contained within the part program.

1.4.2 Axis MD Screen

The Axis MD screen is used for Axis machine data. Be sure you select the correct axis
before making any changes.

1.4.2.1 Home Position for the W (SignoScript ) Axis - RefP_Set_POS[0]

Code 34100 is the reference point value/target point once the axis has been referenced. Make
sure the correct axis you want to effect is selected before making this change. This
parameter is similar to the Home Position parameter seen on the X Axis screen seen earlier.
Note: This will require you to hit the Reset button (“re”) on the MCP once the change
has been entered.

1.4.3 Automatic Operation

• Using methods described earlier in this manual “Select” a part program for execution.
Part program may need to be copied from another location and/or loaded into NC
memory.

• Position material into machine with powered rolling devices or manually.

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• Press the “Auto” button to enter Automatic mode. This can be done from any Operating
Area. The control does NOT need to be in the “Machine” operating area to run part
programs automatically.

• Press “Cycle Start” located on the machine control panel to start automatic operation of
the machine as programmed.

• Immediately after initiating “Cycle Start” the machine will begin processing.

1.4.4 Recover from a program fault

At times it may become necessary to halt the execution of a part program after holes have
been punched but before the part program has completed. Some program stops such as Cycle
Stop or Safety Stop can be recovered from simply by clearing a message by using the Fault
key on the MCP and pressing the Cycle Start button. However, in the case of an Emergency
Stop or certain program faults (red in color) it will become necessary to press the “Reset”
button to clear the fault. In this case quickly pushing the “Reset” button will clear these
errors and then a Block Search will need to be done in order to prevent from having to start
over from the beginning of the part program. Holding the “Reset” button for more then 2
seconds will cause the control to unclamp and the “current” block will be reset to the
beginning of the part program.

1.5 Access Levels

There are three main password protected access levels in the Siemens 840Di control. They
are from low to high: User, Service & Manufacturer. Certain screens and functions are
hidden from lower access levels. In reality, there are four additional access levels all lower
than “User” that are determined by the keyswitch on the machine control panel. Peddinghaus
has chosen not use these access levels. Anyone operating the machine should be at access
level “User” as a minimum. The Siemens access level / password concept and the softkey
labels can be confusing and it is important for anyone with an access level higher than “User”
to understand the concepts and labeling.

1.5.1 Access Level Retention

The Siemens 840Di control does NOT require a password be entered when the control is re-
started. If the control’s access level is “Service” when the control is shut-down or rebooted it
will restart in access level “User”. The person that raises the access level is responsible for
lowering the access level back to “User” when they are finished with their tasks or simply
power down and reboot.

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1.5.2 Determining Current Access Level

Enter the “Start-Up” operating area by pressing the “Menu Select” (Area Switchover) button
and selecting the “Start-Up” softkey. The “Current Access Level” is displayed near the
bottom of the screen.

1.5.3 Raising the Access Level

Enter the “Start-Up” operating area by pressing the “Menu Select” (Area Switchover) button
and selecting the “Start-Up” softkey Press the “Password…” softkey. Press the “Set
Password” softkey. Enter the password for the higher access level using the alpha-numeric
keys. Press the “Input” key.

1.5.4 Lowering the Access Level

Unlike “Raising the Access Level” it is NOT possible to directly lower the access level by
simply entering the appropriate password. Instead the current password is “deleted” and a
new one is set. Enter the “Start-Up” operating area by pressing the “Menu Select” (Area
Switchover) button and selecting the “Start-Up” softkey. Press the “Password…” softkey.
Press the “Delete Password” softkey. Access level is now reduced to the “keyswitch” level
and needs to be raised for machine operation. Follow the instructions for “Raising the Access
Level” to set the password as desired.

1.5.5 Changing Password(s)

The standard passwords are set by Siemens and Peddinghaus does not change them. If the
machine owner decides to change the passwords and subsequently looses the passwords
Peddinghaus will NOT be able to recover them without a paid visit by a service technician.
For this reason Peddinghaus HIGHLY recommends keeping the verbally supplied password
for access level “Service” unchanged and strictly confidential. As a rule, Peddinghaus
maintains the password for “Manufacturer” access level as private.

However if it become necessary to change a password, enter the “Start-Up” operating area by
pressing the “Menu Select” (Area Switchover) button and selecting the “Start-Up” softkey
Press the “Password…” softkey.. Press the “Change Password” softkey. On the newly
displayed screen, select which access level’s password you wish to change (only the current
access level and lower can be selected) and enter the new password using the alpha-numeric
buttons. Confirm the new password and press the “OK” softkey.

Default password for access level “User”: CUSTOMER

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1.6 Additional Installed Programs
In addition to the standard Siemens control software, Peddinghaus also makes available
several other pieces of software that can be used when necessary. Some of these applications
may only be available at access levels higher than “User”.

1.6.1 Peddimat Programming System

The Peddimat Programming System is used for the viewing/editing of parts and the creation
of part programs. It can be accessed by pressing the “Menu Select” button, followed by the
“Peddimat” softkey. Peddimat can be used at any time, even during part program execution.
Peddimat contains its own built in help system and tutorials.

1.6.2 Updating Peddimat

On occasion it may become necessary to update the version of Peddimat running on the
Siemens control. This is accomplished by placing the update diskette in the diskette drive,
pressing the “Menu Select” button, followed by the “ETC” (>) button and finally the
“Peddimat Update” softkey. Follow the on-screen instructions until complete.

1.6.3 Updating VB Screens

On occasion it may become necessary to update the visual basic screens we add on the
Siemens control as well. This is accomplished by placing the necessary update diskette in the
diskette drive, pressing the “Menu Select” button, followed by the “ETC” (>) button and
using the same “Peddimat Update” softkey as you do for a Peddimat update. Follow the on-
screen instructions until complete. The update disk knows what it needs to update so it will
not touch Peddimat in this instance.

1.6.4 Step7 PLC Program

The Siemens Step 7 program is used to view/monitor/edit the PLC program running on the
machine. Step 7 is a very robust application with its own documentation and help system and
even its basic use beyond the scope of this manual. Siemens offers several classes in Step 7
use and Peddinghaus highly recommends them before attempting to use Step 7 in any
capacity. To access Step 7 press the “Menu Select” button, followed by the “ETC” (>) button
and finally the “Step 7” softkey.

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1.7 Complete M Code Listing
Axis Assignments
X - Material Positioning
W- SignoScript
H1 – Far Leg (punch1) Gaging
H2 – Near Leg (punch2) Gaging

Punching Punch Layout

Far Leg (punch1) – Tool 1 ................................................... M21................................M11 (Future)

Far Leg (punch1) – Tool 2 ................................................... M22................................M12 (Future)
Near Leg (punch2) – Tool 1 ................................................ M23................................M13 (Future)
Near Leg (punch2) – Tool 2 ................................................ M24................................M14 (Future)

Shearing

Shear ................................................................................ M25, M27

Note : M27 will only be used for those with an unloader and a part that is to long for a bin
location. Other wise M25 is used for all shear commands.

Clamping Close Open

Clamp 1 (Entry Pinch Drive)(w/MarkMaster Clamp1) ...... M51/M41* ......................M61/M42*

MarkMaster Pneumatic(w/MarkMaster Clamp2) .............. M57 ...............................M67
MarkMaster Pinch Drive(w/MarkMaster Clamp3)............. M58................................M68
Clamp 2(w/MarkMaster Clamp4)...................................... M52................................M62
Clamp 3(w/MarkMaster Clamp5)...................................... M53................................M63
Clamp 4(w/MarkMaster Clamp6)...................................... M54................................M64
Clamp 5(w/MarkMaster Clamp7)...................................... M55................................M65
Clamp 6 (Exit Pinch Drive)(w/MarkMaster Clamp8)......... M56/M43* ......................M66/M44*

Disable X Axis...........................................................................................................M45*
Enable X Axis ...........................................................................................................M46*
Switch to Entry Encoder ...........................................................................................M47*
Switch to Exit Encoder..............................................................................................M48*

* Secondary/special M-codes used in OEM user cycles only!!

Marking
Markmaster Station 1 ...............................................................................................M31
Markmaster Station 2 ...............................................................................................M32
Markmaster Station 3 ...............................................................................................M33
Markmaster Station 4 ...............................................................................................M34
Markmaster Station 5 ...............................................................................................M35
Markmaster Station 6 ...............................................................................................M36

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Markmaster Station 7 ...............................................................................................M37
Markmaster Park ......................................................................................................M39, M30
Signoscript ON..........................................................................................................M80
Signoscript OFF........................................................................................................M81

** Causes OM message & Cycle Start disable / MCP Reset to lower die

Punch Gaging

H1={real value} to position far leg gaging.

H2={real value} to position near leg gaging.

Unloader Selection

H3=xy where “x” = Bin Location and “y” = 1 (Level #)

In addition to the above codes the machine uses special codes which are standard to
the machine tool industry or specific to the Siemens 840Di control.

Miscellaneous Program Codes

Program stop .................................................................................................................. M00
End of program .............................................................................................................. M30
Traverse mode.................................................................................................................G00
Linear interpolation.........................................................................................................G01
Program Jump .......................................................................................... GOTOF, GOTOB
Offset Active...................................................................................................................G54
Offset Inactive...............................................................................................................G500
Exact Stop Mode ............................................................................................................G60
Inch Mode .....................................................................................................................G700
Metric Mode..................................................................................................................G710
Absolute Mode................................................................................................................G90
Incremental Mode ...........................................................................................................G91
X Axis Reference ................................................................................... _XREF( X position (mm) )

1.8 Additional Information

Here is some additional information that may be helpful in running the 643N anglemaster.

1.8.1 X Axis Referencing

Switch to MDA mode. Type the text below and then cycle start to begin.

M51 Æcloses entry pinch drive

M00 Æstops program / waiting for cycle start to be hit again
_XREF(0) Æreferences the X axis

26
M30 Æends program

1.8.2 W (Signoscript) Axis Referencing

Switch to Jog mode on the MCP. Select Ref Point and W axis on the MCP as well. Press the
minus key once and the axis should now reference.

1.8.3 Double Punching

Punching with both tools on one leg at one time is possible if the holes are offset by 3 inches
and does not exceed a punch tonnage of over 75 tons. If you are creating your parts with
Peddimat, Tooling Setup Override must be checked ON for this to work. As well as having a
3 inch offset, the second tool must be programmed first.

1.8.4 Block Search (mid program restart)

This is used mainly after major faults or an E-Stop condition. Follow the steps below to use
block search.
1) You first must remember the block the machine is on before you
attempt to do a block search.
2) Clear the fault or error by quickly pressing the MCP “Reset” button on
the panel.
3) Select Block Search. This is accomplished by being in Auto Mode,
pressing the “Machine” button, followed by the “Block Search”
button.
4) Highlight the block to start from. This should be the block you first
remembered in step 1.
5) Next press the Calculate Block End Point button.
6) You will next hit Cycle Start twice to continue on with the program.

1.8.5 Copying Peddimat part Files from a floppy to a 840DI

a) First you need to be in Peddimat on the 840DI control in order to begin this procedure.
This is accomplished by placing the diskette with all of your part files in the diskette drive of
the 840DI control, pressing the “Menu Select” button on the control and finally the
“Peddimat” softkey.

b) Goto the top menu bar of Peddimat and select File by using Alt-F or your mouse. Use
your mouse right button to select Open on the dialog pull down or use the blue down arrow
key and the yellow Input key on the 840DI control.

c) Select the A:\.

27
d) Highlight the parts to copy to the controls hard drive. By using the mouse and holding
down on the CTRL key you can select all of the parts on the floppy disk at once. Or by
tabbing until you can select the first part then holding down on the shift key and using the
blue arrow down key you can select all the parts this way also.

28
e) Next right mouse click on the highlighted parts and select Copy.

f) Peddimat will now ask for a destination for the parts. Peddimat is stored in
F:\Add_ON\Peddimat on all 840DI controls. So if you want to store them there you can or
another directory which you’ll remember when trying to open one of these parts using
Peddimat. Remember the drive should be set to F:\.

g) Hit OK when you are ready to copy these files to the hard drive.

1.8.6 Creating and Deleting directories within Peddimat

a) First you need to be in Peddimat on the 840DI control in order to begin this procedure.
This is accomplished by placing the diskette with all of your part files in the diskette drive of
the 840DI control, pressing the “Menu Select” button on the control and finally the
“Peddimat” softkey.

29
b) Goto the top menu bar of Peddimat and select File by using Alt-F or your mouse. Use
your mouse right button to select Open on the dialog pull down or use the blue down arrow
key and the yellow Input key on the 840DI control.

c) Using your mouse button within the directory section click on the right mouse button.

d) New Directory and Delete will appear.

e) Deleting a directory. The highlighted directory is what will be deleted if delete is pressed
and only if the directory is empty. If there are parts remaining then the parts must be
removed first. Follow the same procedure you used to copy the files to delete the files.
When you right mouse click instead of Copy choose Delete to remove the files from the
directory. Prompt messages do appear upon removal of any part or directory.

f) Creating a directory. Highlight the directory you wish to create a directory under with
your mouse. Once you have selected New Directory with your mouse it will ask for the
name of the directory and place the new directory underneath the highlighted directory you
selected.

30