PC800/PUNCHWIZARD TURRET CONTROL MANUAL

801 Secretary Drive, Suite A Arlington, TX 76015

Phone: 817-861-6955 Fax: 817-796-2983 Website: www.pccontrols.net E-mail: Sales @pccontrols.net

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TABLE OF CONTENTS

PC Controls Licensing Agreement. 3 Safety & Product Warnings 4 PC800 Front Panel.. 5 Main Menu Screen.. 6 Edit Tool Library Screen. 7 Turret Layout Screen9 Define Part Screen..11 Create Part Screen.......13 Define Hole Pattern Screen.15 Define Bolt Hole Pattern Screen.16 Define Arc Pattern Screen ..17 Define Line Pattern Screen..... 19 Define Window Pattern Screen21 Run Mode Screen.... 23 Load File Screen...25 Save A Punchwizard File Screen......26 Machine Status Screen. ....27 Manual Controls Screen...32 Terminal Screen...33 Appendix A Programming examples....34 Appendix B Tooling Descriptions..........48 Appendix C M-Codes....50 Appendix D Part Grouping, Zoom, & Mirror Commands....54 Appendix E Networking.....58 Appendix F File Structure.........59 Appendix G Punchwiz.ini & Criblist.tlf.....60 Appendix H Special tool files........67 Appendix I File Conversion......69 Appendix J Security Key/Dongle...74 Appendix K MCC Parameter Maintenance........75 Appendix L Plasma Operations.....81 Appendix M PC800 Restore CD...........86

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PC Controls License Agreement

This is a legal agreement between you the purchaser (either as an entity or individual) and PC Controls. PunchWizard and AcroWizard S are copyrighted products owned solely by RGAM Creations and PC Controls respectively and are protected by United States copyright laws and international treaty provisions. Any other distribution is illegal and subject to appropriate legal action.

GRANT OF LICENSE: This License Agreement allows you to use the programs mentioned above on one punching machine and on one external, i.e. programming/engineering/training machine. The program is considered "in use" on a computer if it is loaded into temporary memory (i.e. RAM) or installed onto permanent memory (i.e. on a hard disk, CD-ROM or other storage device). UPGRADES: This license also applies to any upgrades that may be sent to you by PC Controls. The license is automatically transferred to the new program with the understanding that all prior versions be removed from use and the disk(s), manual(s) and security key(s) be returned to PC Controls. OTHER RESTRICTIONS: You may not rent or lease this software. You may not give this program to another user (either an individual or an entity) unless it is part of a permanent transfer of ownership of the punch machine, provided that the new owner agrees to this license agreement. You may not alter, reverse engineer, decompile or disassemble this software for any reason. The original disk(s) are your only authorized archival copy, no other copies are permitted without the expressed written consent of PC Controls. NO LIABILITY FOR CONSEQUENTIAL DAMAGES: To the maximum extent permitted by applicable law, PC Controls in no event shall be liable for any damages whatsoever (including without limitation, damage to any individual or hardware, damages for loss of business profits, business interruption, loss of business information or any other pecuniary loss) arising out of normal use, deliberate misuse or the inability to use this product. Because some states/jurisdictions do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.

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SAFETY & PRODUCT WARNINGS

Operation of the PC800 control by untrained or improperly trained personnel

may result in damage to machinery and injury to personnel. Modifying or changing control parameters incorrectly may cause machine

control to operate improperly and may result in damage to machinery and injury to personnel. Only qualified and trained personnel should make any parameter changes.

Improper electrical grounding or excessive electrical noise can cause machine

controls to operate improperly and may result in damage to machinery and injury to personnel. Do not place the PC800 control in the neighborhood of magnetic equipment such as transformers, motors or devices that generate electromagnetic fields.

Automated machine controls may start automatically when under program control. Use Emergency Stop buttons to stop machine movement if necessary.

PC800 control equipment can cause electrical shock. Only properly trained

personnel should perform maintenance on this equipment. Have qualified personnel carry out all electrical work to prevent injuries or accidents

The PC800 unit is a CNC control and not a safety device. Safeguarding of

machinery with proper point of operation safety systems and proper installation and use of such systems is the responsibility of the end user. The PC800 control is designed to work together with standard, point of operation safety systems and will support such systems when properly engineered and integrated together with such point of safety devices. Never eliminate or bypass any of the safety circuits/devices on this machine.

Replace fan filters at regular intervals to avoid overheating.

Do not expose the PC800 control to excessive humidity to avoid risk of

electrical shock and damage to equipment.

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Notes: Edit protect switch in OFF position will not allow any changes to programs in the control. Edit protect switch in ON position allows changes to programs. Edit protect key may be removed from the control front panel to lock control in OFF or ON mode.

Select Power to the PC800 control, OFF or ON

Turn key to select Edit Protect OFF or ON

Push for single step operation of the punch head

Push to command an emergency stop of the machine

PC800 FRONT PANEL

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MAIN MENU SCREEN

Press to toggle the control between Inch and Metric units of measurement

Punch Wizard software version & date

Click to leave the Punch Wizard Program Click to load an

existing part

Click to edit the Tool Library

Click to create a new part

Machine Model

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EDIT TOOL LIBRARY SCREEN

Click to add a newly created tool to master crib list

Click to update & save changes to an existing tool

Highlight tool & click to permanently remove tool from master crib list

Click when complete with all actions in edit tool library screen

Master crib list of all saved tools

Graphical representation of highlited tool in master crib list

Click to enter Turret Layout Screen

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OPERATION IN EDIT TOOL LIBRARY Screen

To add a new tool:

1. Enter X & Y tool dimensions using 2. Select Tool Shape from drop down menu (circle, rectangle, obround, or miscellaneous) 3. Use the tool name automatically generated by the PunchWizard or replace with desired tool

name 4. Check Forming Tool block if you are adding a forming tool

5. Click button to add the newly created tool to the master crib list To edit an existing tool: 1. Highlight existing tool from master crib list 2. Enter changes to the selected tool using keyboard input

3. Click button to save changes made to the selected tool

To remove an existing tool:

1. Highlight the tool you wish to remove

2. Click the button to permanently remove this tool from the master crib list and return to the main menu screen

NOTES:

Use auto generated tool names whenever possible and when naming tools, name all tools

with consistent names and spacing. Use miscellaneous tool type for odd shapes as in diamonds, keyholes or complex items

like an insignia or company logo. Tools classified as miscellaneous are visually represented as a rectilinear shape in Punch Wizard displays unless a Punch Wizard tool file exists (*.pwt).

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TURRET LAYOUT SCREEN

Click to remove selected tool from turret station

Click to add highlighted tool to turret

Click when done resolving tools

Station, angle, and die clearance of tool in selected turret station

List of tools required to punch current part that are not currently in the turret

Graphical representation of current turret layout and tooling

Check box to automatically, physically position the turret after adding or removing a tool

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OPERATION IN TURRET LAYOUT Screen The turret layout screen comes up automatically when a part is selected to punch and all of the tools necessary to punch the part are not currently in the turret. This screen allows the operator to add all necessary tools to the turret so that the part can be punched. The turret layout screen also allows the operator to add and remove tools from the turret for tool change operations. Adding to and removing tools from the turret:

1. To add a tool to the turret, highlight the tool in the left hand tool list and click or highlight the tool and drag the tool and drop it into the desired station

2. To remove a tool from the turret, touch the tool in the turret and then click

NOTES:

A blue colored station represents a tool station of the same size as the currently highlighted

tool in the left hand tool list A black colored station represents a tool station of a different size than the currently

highlighted tool in the left hand tool list

Represents a turret station that currently contains a tool

Represents a turret station that currently contains a tool required for the current part

Represents an turret station that currently is empty

Represents a tool used in the current program that the M&G code was programmed specifically to use the this particular tool

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DEFINE PART SCREEN

Click to leave Define Part screen and return to Main Menu screen

Click to create a new part using information from an existing saved part file

Click to enter the Create Part Screen when all above information for the new part has been input

X,Y table position for loading a new blank

Auto-optimize check box

Click to enter turret layout screen

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OPERATION IN DEFINE PART Screen

To define a new part:

1. Enter X & Y blank dimensions & material thickness, 2. Select Blank Material from drop down menu 3. Enter location of work grippers or click fetch grippers to locate position automatically 4. Input X & Y Load Position if desired, i.e. the load position you want the X & Y gauge to

be in for inserting new blanks 5. Enter Feed Rate setting % 6. Enter a File Name for the newly created part. 7. Check auto-optimize tab to perform tool optimization on parts

8. Click the button when all of the above values for the new parts have been entered and Punch Wizard will move into the CREATE PART Screen

To define a new part from a previously programmed part:

1. Click on the button 2. Select the existing part you wish to use as the basis for creation of your new part from the

LOAD FILE screen selection

3. Click to select this part and the Punch Wizard will move back to the DEFINE PART Screen

4. Make any desired changes in the DEFINE PART screen and click the

Button to move into the CREATE PART Screen

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CREATE PART SCREEN

Part name of current part on screen

X & Y blank dimensions of part on screen

X & Y position of cursor on screen

Current Program sequence

Click to create a single hole pattern

Click to create a bolt hole pattern

Click to create Arc

Click to create a Line

Click to create a Window pattern

Click to return to main menu screen

Click to move to previous step in program

Click to Load an existing part

Click to delete a program step

Click move to next step in program

Red indicates X=0, Y=0 Datum

Click to insert a program step

Click to insert an M-Code (available on gripper units)

Click to enter Run Mode

Part counting field

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OPERATION IN CREATE PART SCREEN

To define new part:

1. Click on HOLE, BOLT, ARC, LINE, or WINDOW to create the next program step

2. Input required parameters to create all desired program steps for the current part

3. Click on button to move into RUN MODE

NOTES:

The program sequence number N is zero when a part is initiated since no actions have been created. Clicking on N moves the program to the last punching block. This function is useful for editing particular blocks in the program Hits made by the current editable action are indicated by N and are displayed in red. Moving all punch actions on the blank is easy with PUNCH WIZARD: After all actions are placed, click to highlight the X or Y position field in the upper right corner of the CREATE screen. Type 'P' (for PART MOVE) and either a '+' or '-' and the value to offset. *Example: On a 16 gauge (.063") plate with a 1" 90 degree flange in the X direction, click in the X field and type 'P+1.032' to offset all the punching actions away from the X reference point by 1.032". (1" for the flange and .032" for the bend allowance stretching) When the part program is saved the offset is also saved.

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OPERATION IN DEFINE HOLE PATTERN SCREEN

To define a new hole pattern:

1. Select tool from tool select drop down bar 2. Input X & Y location on part blank for hole location 3. Input tool angle for selected tool 4. Select pause if you desire machine sequence to pause after the hole is punched

5. Click on when all required information has been input

NOTES: Define Hole Pattern is center of tool oriented Drop chute, pause, punch, and delay should not be used on parts that are auto-optimized or

that contain repositions.

DEFINE HOLE PATTERN SCREEN

Select tool drop down bar

X & Y location on blank for hole pattern

Cancel and return to Create Part Screen

Click when finished input of required information

Check to halt automatic operation & require pushing start to continue program execution

Uncheck creates move/no punch operation

Check to automatically open small part drop chute

Input number of seconds of delay to put the table in a temporary pause condition

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OPERATION IN DEFINE BOLT HOLE PATTERN SCREEN

To define a new bolt hole pattern:

1. Select tool for punching a bolt hole pattern from select tool drop down bar 2. Input X & Y location on blank for center of bolt hole pattern 3. Input radius of bolt hole pattern 4. Input initial or starting angle for bolt hole pattern (0-360) 5. Check boxes for pause or CW operation if desired

6. Click on when all required information has been input

NOTES: Define Bolt Hole Pattern is center of tool oriented Bolt Hole Pattern requires two or more holes Bolt Hole Pattern is a full 360 degree circular pattern. Use bolt hole pattern to place

2 to 999 holes around an X, Y origin.

DEFINE BOLT HOLE PATTERN SCREEN

Radius of bolt hole pattern

Number of holes in bolt hole pattern

X & Y origin of Bolt Hole Pattern

Select tool drop down bar

Check box for punching in clockwise direction

Check to halt automatic operation & require pushing start to continue program execution Cancel and

return to Create Part screen

Click when finished input of required information

Initial or starting degree for bolthole pattern (0-360)

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OPERATION IN DEFINE ARC PATTERN SCREEN

To DEFINE a new arc pattern:

1. Select tool for punching arc pattern from select tool drop down bar 2. Input X & Y location on blank for origin of arc pattern 3. Input radius of arc pattern 4. Check boxes for pause or CW operation if desired 5. Check box for desired tool comping 6. Input starting and ending angles for arc pattern (0-360) 7. Input starting angle of arc 8. Input tool angle value (0-360)

DEFINE ARC PATTERN SCREEN

Radius of arc pattern

Check box for punching in clockwise direction

X & Y origin of ARC Pattern

Select tool drop down bar

Check box for pause before continuing to

Check box for tool comping in arc pattern operation

Cancel and return to Create Part screen

Click when finished input of required information

Check box for nibbling option of arc pattern

Start & End angles for arc pattern Number of holes in arc

pattern

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9. Click on when all required information has been input

NOTES:

Define Arc Pattern is center of tool oriented The Arc Pattern is a partial circular pattern, Arc can be from 2 to 999 punches. Arc Radius is defined as the center of the pattern to the center of the non-comped punch Tool comping will compensate the arcs punches. Selecting outside will increase the

Arcs radius the amount of the selected tool radius. Select inside to shrink the arcs radius the same amount.

Scallop displays the height of the material left between two circular hits.

scallop

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DEFINE LINE PATTERN SCREEN

Starting & Ending X & Y positions for line pattern

Input for number of holes in line pattern

Check to comp tool to inside of line

Select tool drop down bar

Tool angle for selected tool (0-360)

Click to Create Punch Wizard Line

Click to cancel and return to Create Part screen

Distance & Angle Input values for Line At Angle

Click to Create Line At Angle

Axis alignment selection bar

Click to auto-calculate # of hits to punch a slot pattern

Check to enable nibbling

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OPERATION IN DEFINE LINE PATTERN SCREEN

To define a new line using PW line pattern::

1. Select tool for line pattern from select tool drop down bar 2. Input starting & ending X & Y locations for line 3. Input number of holes to punch line pattern 4. Select pause, End-to-End, nibbling options if desired 5. Input tool angle for selected tool

6. Click on to create the new line

To define a new Line using LINE AT ANGLE pattern::

1. Select tool for line pattern from select tool drop down bar 2. Input starting X & Y locations for line 3. Input number of holes to punch line pattern 4. Select Pause, End-to-End, Nibbling options if desired 5. Input tool angle for selected tool

6. Click on to create the new line

NOTES: The line command is used to place equally spaced holes in a straight line (horizontally,

vertically or at any diagonal). The minimum number of hits is 2; the maximum number is 999.

When Slot is checked, the program will calculate the number of holes to connect the first and last hits in the line.

When Pause is selected, the program will halt all movements after the action finishes. When End-to-End is selected, the program compensates the leading and trailing edges

of the tool to align with the beginning and ending of the line rather than with the center of the tool

When Nibbling is selected, the program will create optimally spaced hits at optimal speed by keeping the clutch/brake assembly from fully cycling. Clutching will always occur when Nibbling is not selected. Select Nibbling for most standard, flat-faced tools.

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DEFINE WINDOW PATTERN SCREEN

Radius tool selection bar

Check box for nibbling of arcs

X & Y origin of Window Pattern

Window or Disk Selection check boxes

Arc Radius input

Radius tool drop down bar

Cancel and return to Create Part Screen

Click when finished input of required information

Check box for pause before continuing to next punch & tabs

X & Y Window cutout size

Window Angle input

Min & Max inputs for punch hits & No of scallops

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OPERATION IN DEFINE WINDOW PATTERN SCREEN

To DEFINE a new WINDOW pattern::

1. Select Window or Disk option check box 2. Input X & Y location on blank for center of Window pattern 3. Input X & Y dimensions of Window cut out 4. Select Tabs and pause check boxes if desired 5. Select Radius tool for Window pattern cut out 6. Select Nibble & Arcs check box if desired 7. Input Arc radius and Window angle (0-360) 8. Input min number of hits and scallops if desired 9. Select a line tool for punching out the Window pattern

10. Click on when all required information has been input

NOTES:

Define Window Pattern uses tool compensation. WINDOW comps the tooling to allow

for Punch-out and Disk-out. WINDOW either cuts a hole (window) or drops a slug to the selected dimensions (Disk). Select the Window or Disk button at the top of the screen to select either option.

Hits are the number of punches in each of the four window radiused corners; scallop is the height of the material left between 2 circular hits. See below. A value entered in either hits or scallop will cause the program to calculate the other value.

In the radius tool selection, Punch Wizard will not allow a number of hits less than a one-half tool overlap, nor a number of hits greater than a tool overlap less the thickness of the blank. The one-half overlap limit is for speed and to ensure that the hits are connected, the later limit is to prevent excessive tool wear. Because of this, selecting a tool with a tool radius less than the blank thickness will cause a warning message from Punch Wizard that the tooling is too small.

Entering an Arc Radius less than .001 will cause the function to completely ignore any Arc tool as it is assumed you want a square cornered window or disk

Entering an Arc Radius greater than one half of either the X Width or the Y Width will cause a warning dialog box. You will have to change one of your entered values. A bad radius value is the usual culprit.

scallop

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RUN MODE SCREEN

Part name of current part on screen

X & Y blank dimensions of part on screen

X & Y position of cursor on screen

Click to move to previous program stepfrom an existing saved part

Click to move to next program step

Click to enter STATUS screen

Click to return to CREATE PART screen

Click to move to MANUAL screen

Click to run current part program

Click to select Auto, Single Block, or Simulate

Click to pause punching action

Batch Counter

Click to turn Punch Off/On

Gripper detect zones

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OPERATION IN RUN MODE SCREEN

1. Select either Single, Auto, or Simulate mode to run the parts. Single mode steps through the program one block at a time. To do so, use the Cycle Start button or the START button on the screen.; Auto runs all blocks of the part automatically and sequentially Simulate runs the part in a dry-run simulation mode allowing you to verify correctness of the program prior to actually running the program.

2. Click to begin execution of the selected program.

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OPERATION IN LOAD FILE SCREEN

Loading a Part File: 1. Highlight the file directory from which you want to load a part 2. Highlight the part file you want to load into the Punchwizard

3. Click to load the part

Permanently Removing a Part File: 1. Highlight the file directory from which you want to remove a part file 2. Highlight the part file you want to remove from the load file list

3. Click to permanently remove the part file

NOTES: Multiple part folders can be created for part loading and storage in the [paths] section of the

Punchwizard.ini file. Part storage and loading folders can be located in any drive, local or network.

Click to Remove part from saved file list

Click to return to main menu screen

Click to display information about highlighted parts

File directories for selecting existing part programs

LOAD FILE SCREEN

Click to load a part into Punchwizard

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OPERATION IN SAVE PUNCH WIZARD SCREEN

1. Enter the name of the part file you wish to save the current part as. Parts will be stored and retrieved in alph-numeric sequence. Additional part information and notes may be entered and saved in the file name area.

2. Select the path to which you want the part file saved into 3. Select the type of file you wish to save the part as, default is a .pwz file

Click to save the current part file

Notes:

SAVE PUNCH WIZARD FILE SCREEN

Enter name of part to be saved

Click Cancel to return to main menu screen

Click to save part to selected path

Path of file to be saved

Type of file to be saved

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NOTES:

The Status screen displays all the machine's electrical functions. These include the X and Y limit and home switches, the turret home switch, the ram position switches, lube and pressure switches , etc.

The Status screen is available from the Run and Manual screens, click on the Status button to check machine status at any time.

MACHINE STATUS SCREEN

Click to reset machine flags

Click to go to terminal screen

Click to close out of status screen

Click to enter MCC variable screen

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The Status Flags indicate the status of various machine conditions. Green indicates the status of a particular function, Gray indicates the opposite condition, ex. When the Punch On TDC flag is green it shows that feedback from the machine indicates to the control that the Punch is physically on top dead center.

Alarm Flags indicate a machine alarm for a particular function. If the machine halts punching operation because of a fault, the program will immediately display the Alarm screen with the error displayed in red, otherwise the color of the alarm circle is gray indicating a normal condition.

All alarms latch and stay on until they are reset. This means that the error condition may have occurred only for an instant.

Clicking the reset button will cause the program to retest the alarm conditions, if the alarm clears, the system returns to an operating state. If the alarm does not clear the root cause of the problem has not been remedied.

Deselecting any of the update check boxes will enable a faster test of the machine functions to locate error conditions.

Status Flag Definitions: Press Motor On Green indicates that the Press Motor has been commanded by the control to turn on Press On TDC Green means that the proximity sensor on the crankshaft indicates to the PC800 control that the Punch Head is physically at Top Dead Center position Index Pins In Green means that sensor feedback (proximity switches) from the machine indicates to the PC800 control that the index pins are physically IN System Calibrated Green means that sensor feedback from the machine indicates that the machine has successfully completed the calibration routine System Fault Green indicates that a general system fault has occurred on the machine Cycle Stop Green indicates that a cycle stop condition has been commanded to the machine Auto Index Pins In Green means that that sensor feedback from the machine indicates that the auto index pins are physically IN Auto Index Pins Out - Green means that that sensor feedback from the machine indicates that the auto index pins are physically OUT Auto Index Brake Green means that feedback from the machine indicates that the auto index brake is engaged

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Side Gauge Green means that sensor feedback (proximity or limit switch) from the machine indicates that the side gauge is in the UP position In Cycle Green means that the machine is currently executing an automatic cycle Run Mode Green indicates that the machine is currently in RUN MODE Manual Mode - Green indicates that the machine is currently in MANUAL MODE Undefined This status flag is currently undefined and can be configured as an additional status indicator Alarm Flag Definitions: X Axis Overtravel The X axis has moved beyond its designated travel limits Y Axis Overtravel - The Y axis has moved beyond its designated travel limits Stripper Miss Machine sensor feedback indicates that the punch has not correctly stripped the material and the tool may be stuck causing the machine to halt operation System Fault Sensor feedback has caused the control to go into a cycle stop condition T Axis Origin Error Sensor feedback indicates that the T-axis has failed to origin correctly Index Pin Fault - The index pins that lock the turret in place before the Ram is fired were commanded to engage or disengage and sensor feedback (proximity switches) indicates the pins are not in their commanded position Striker Fault Sensor feedback (proximity or mechanical limit switches) indicates that the striker did not reach its commanded position Emergency Stop The control has commanded the machine to enter an emergency stop condition Repo Cylinder Fault - Sensor feedback (air or hydraulic pressure sensors) indicate a problem with one of the reposition cylinders. Either the cylinders were commanded to lower or raise and sensor feedback indicates they did not reach their commanded position

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Gripper Fault Sensor feedback (air or hydraulic pressure sensors) indicates that the clamps are open while trying to start a program TDC Fault Control feedback (proximity sensor on crankshaft) indicates that the crankshaft is not at the top dead center position when it should be. Any time the striker or turret is commanded to move the ram must be at TDC position or a TDC fault is declared. Either the crankshaft is not physically at TDC or the sensor feedback is incorrectly indicating the crankshaft is not at TDC. X Following Error The actual position of the X-axis determined from encoder feedback differs (greater than the allowed threshold) from the position commanded by the control Y Following Error - The actual position of the Y-axis determined from encoder feedback differs (greater than the allowed threshold) from the position commanded by the control T Following Error - The actual position of the T-axis determined from encoder feedback differs (greater than the allowed threshold) from the position commanded by the control C Following Error - The actual position of the C-axis determined from encoder feedback differs (greater than the allowed threshold) from the position commanded by the control Servo Fault One of the servo drives (X, Y, T, or C) has indicated a servo fault condition to the control Low Air Pressure- Sensor feedback (air pressure sensor) to the control indicates a low air pressure condition exists in the main air line Gripper Failure During motion sensor feedback (air or hydraulic pressure sensors) indicates the material clamps are open Tool Door Fault The control has commanded motion but feedback to the control (switch) indicates that a tool door is open Auto Index Fault Sensor feedback (proximity or limit switches) to the control indicates a problem with the auto-index mechanism. Any failure of the auto-index system to properly engage or disengage will cause an auto-index fault Lube Fault- Sensor feedback to the control indicates that the lube system is not functioning properly X OverTravel Precheck Before executing a program the control has determined that the machine is being commanded to move outside the X-axis travel limits

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Y OverTravel Precheck - Before executing a program the control has determined that the machine is being commanded to move outside the X-axis travel limits Repo Cylinder Safety Control feedback indicate that in the current program the material grippers may collide with the reposition cylinders Undefined - This alarm flag is currently undefined and can be configured as an additional status indicator

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NOTES:

Calibration causes the X,Y,T, and C axes to come to home position. Click and holding on

the +X, -X, +Y, -Y button will drive the axis selected in the direction selected at a slow speed until the button is released.

Enter X & Y calibration values

Click to enter MACHINE STATUS screen

Click to manually jog X axis in minus direction

Click when complete to move to previous screen

Click to manually jog Yaxis in minus direction

MANUAL CONTROLS SCREEN

Click to manually jog X axis in plus direction

Click to calibrate machine

Click to manually jog Y axis in plus direction

Click to enter Plasma option controls screen

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NOTES:

TERMINAL SCREEN

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APPENDIX A Programming examples

Punch Wizard Line Example:

PW LINE punches from a Starting X and Starting Y location to an Ending X and Ending Y location equally spacing the holes along a line, horizontally, vertically or at any diagonal.

ToolList: Where the tool is selected. Starting X and Starting Y describe the beginning of the line. Ending X and Ending Y describe the end of the line. Number of Holes: the amount of equally spaced hits. Slot: when clicked, will calculate the Number of Holes to connect the first and last hits in the line. Pause: If selected, will halt all movements after action finishes. End-to-End: If selected compensates the leading and trailing edges of the tool to align with the beginning and ending of the line rather than with the center of the tool. Nibbling: When making closely spaced hits optimal speed can be reached if the clutch/brake assembly doesnt have to cycle. Clutching will always occur when Nibble is not selected. Select Nibble for most standard flat-faced tools. If using a forming tool (a louver, raised counter-sink or other type of extrusion tooling) or a very large perimeter tool, stripping of the punch/die set may not occur on time. This could cause damage to the part, tooling or the machine. When using forming type tools dont select Nibble.

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Tool Comping will calculate left, right or no tool comping. Click to select which comping is needed. PW LINE examples:

A part calls for five .250" holes equally spaced on a 1" wide by 24" long flange. The five holes should start and end 1" in from the ends of the flange and be centered midway down the length of the flange. Knowing the beginning, end and width dimensions of the flange, use PW LINE. Start by clicking line from the Create Screen. Select a .250" RND tool for the punch. From the drawing above enter start X at 1", start Y at .5" then ending X at 23" and ending Y at .5". Enter 5 in the hits field. Click PW LINE (Don't click 'SLOT' - leave 'End-to-End' unchecked - 'None' comping is checked) Side to Side comping: To trim off the flange on the previous drawing it would be easier if we used Tool Comping. Use the sketch below now.

Knowing the beginning, end and width dimensions of the flange use PW LINE. Start by clicking line from the Create Screen. We have selected a 2.00" x .25" RECT tool to demonstrate. From the sketch above enter start X at 0", start Y at 1" then ending X at 24" and ending Y at 1". Click on 'SLOT'. Clicking 'SLOT' caused PW LINE to calculate the number of hits with the selected tool to completely cut-out the material between the two end points. Click PW LINE (leave 'End-to-End' unchecked - 'LEFT' comping is checked. As the arrow above the nibble shows; the center of the tool will go from left (X=0) to the right (X=24). Since the tool is required to be on the left-hand side of the dotted line (1") selecting 'LEFT' comp is correct. Had you wanted to go from the right side (X=24") of the blank to the left (X=0") 'RIGHT' comping would have been correct.

24"0,0

24"0,0

36

End to End comping: To trim off multiple straps of material as before but leave them on the sheet would require tabs to hold them in place until all are punched. Use the drawing below for the next example.

Knowing the beginning, end and width dimensions of the flange use PW LINE. Start by clicking line from the Create Screen. We have selected a 2.00" x .25" RECT tool for the punch to demonstrate. From the drawing above enter start X at .01", start Y at 1" then ending X at 23.99" and ending Y at 1". Starting at X=.01" and ending X=23.99" will leave a .01" 'tab' at both ends of the PW LINE action once 'End-to-End' is checked. 'EndtoEnd' comps the tool from the outer end of tool rather than from the center of tool. Clicking on 'SLOT' causes PW LINE to calculate the number of hits with the selected tool to completely cut out the material between the two end points. Click PW LINE, ('End-to-End' is now checked - 'LEFT' comping is checked). As the arrow above the nibble shows; the ends of the tool will go from left (X=.01") to the right (X=23.99") 'EndtoEnd' of the slot and since the tool is required to be on the left hand side of the dotted line (1") selecting 'LEFT' comp is correct. If going from the right side (X=23.99") of the blank to the left (X=.01") 'RIGHT' comping would have been correct.

24"0,0

37

Punch Wizard Line at Angle Example:

PW LINE can process lines at an angle just as easily. Use the drawing below for this next example.

Left, Right and End-to-End with Slotting capabilities can be used together to make a line at any angle. For this example use a rectangular tool placed in the turret at 45 degrees. Select a 2.00" x .25" RECT tool. Knowing the beginning X, Y and end X,Y locations use PW LINE. Start by clicking nibble from the Create Screen. From the sketch above enter start X at 1", start Y at 1" then ending X at 10" and ending Y at 10". PW LINE will comp the starting and ending X,Y's once 'End-to-End' is checked. 'End-to-End' comps the tool from the ends of the tool rather than calculating from the center of tool. Check 'End-to-End'. Click on 'SLOT'. Clicking 'SLOT' causes PW LINE to calculate the number of hits with the selected tool to completely cut out the material between the two end points. Click PW LINE ('End-to-End' is now checked - 'LEFT' comping is checked) The bottom-right corner of the tool will go from lower-left (X=1",Y=1") to the upper-right corner of the tool (X=10", Y=10") from end to end of the slot and since the tool is required to be on the left hand side of the direction of travel selecting 'LEFT' comp is correct.

Line At Angle uses the 'engineering' form to define degrees: 0 degrees at 3 o'clock and 90 degrees at 12 o'clock.

0,0

1,1

10,10

38

The first punch is offset from the Starting X and Starting Y with the total number of following punches. If Punch origin is selected the Starting X and Starting Y is punched but with the same total number of punches. Starting X and Starting Y describe the beginning of the line. Distance: Spacing between punches. Angle: The direction of the line in degrees. Number of Holes: number of equally spaced holes along the line. Pause: If selected will halt all movements after action finishes. End-to-End: If selected compensates the leading and trailing edges of the tool to align with the beginning and ending of the line rather than with the center of the tool. Nibble: When making closely spaced hits optimal speed can be reached if the clutch/brake assembly doesnt have to cycle. Clutching will always occur if Nibble is not selected. Select Nibble for most standard flat-faced tools. If using a forming tool (a louver, raised counter-sink or other type of extrusion tooling) or a very large perimeter tool, stripping of the punch/die set may not occur in time. This could possibly cause damage to the part, tooling or the machine. When using forming type tools dont select Nibble. Tool comping will calculate left, right or no tool comping. Click to select which comping is needed. Line At Angle example:

In the Line At Angle example above we're going to use a .375 inch RND tool spaced every .5 inch for 9 hits at 30 degrees starting at 1" in X and 1" in Y. Click on LINE in the CREATE screen. Select a .375 RND tool. In the start X field, enter 1 and in the start field enter 1. Enter 30 in the ANGLE field, .5 in the DISTANCE field. Enter 9 in the HITS field. Now click Line At Angle. PUNCH WIZARD will begin at the X, Y start point, place a .5 inch interval between the origin and the first punch at 30 degrees. The program will then incrementally move the part by the required .5 inch at 30 degrees and punch the second hole; and so on until all nine punches are completed. * NOTE * Below the angle field is a check box labeled 'Punch Origin' Selecting it will cause Line At Angle to punch the origin at 1", 1" then incrementally move the part. You will still get nine punches with .5" spacing.

0,0

1,1

30

39

Punch Wizard Window Example:

WINDOW either cuts a hole (window) or a 'Drop or Slug' to your dimensions. Click the Window or Disk button at the top of the screen to select either option. Origin X and Origin Y describe the center of the window. X Width and Y Width describe the overall size of the window. Tabs when selected will leave small connecting pieces of material to prevent the cutout from being loose. Pause: If selected will halt all movements after action finishes. Radius Tool allows selection of the radiusing tool (normally a circular tool). Arc Radius the radial distance for the rounded window corners. Window Angle can be changed from zero degrees to any other angle. The window will be rotated on the blank. Window Angle will work best if the line tool is in a C axis. If Window Angle is used with a fixed angle line tool the tool offset and the Window Angle offset should be the same to prevent a stair-step like result. The line tool chosen can be a circular type tool with only slightly better results. Hits are the number of punches in each of the four window radiused corners.

40

Scallop is the height of the material left between two circular hits. A value entered in either Hits or Scallop will cause PUNCH WIZARD to calculate the other value. Entering a scallop value is the most efficient for later touch-up time. You may enter a HITS value between 2 and 999. PUNCH WIZARD will default to the closest 'legal' limit. MIN and MAX buttons. These buttons will calculate the minimum or the maximum number of hits (mainly used as a quick reference guide). Line Tool allows selection of the linear tool (normally a rectangular tool).

Notes: Entering an Arc Radius less than the tool's radius will cause a warning dialog box. You will have to change one of your entered values. A bad Radius value is the usual culprit. A square WINDOW is created by not selecting a radiusing tool or leaving the Arc Radius value at 0.0. A radius only (circular pattern) is available by setting the radius to one half the X width and the Y height dimensions - X width and Y height must be the same. The radius portion of the window will not allow a number of hits greater than a tool overlap less than the thickness of the blank. The one-half overlap limit is for speed and to ensure that the hits are connected, the latter limit is to prevent excessive tool wear caused by side-shear. Because of this, selecting a tool with a tool diameter less than the blank thickness will show an error message that tooling is too small. If you choose inappropriate tooling for the Arc Radius or Nibble/Line sections unusual punching will happen. If the window's Y size is 1" and you select a 2" Y tool you will get a 2" Y punch, not an error message.

scallop

41

PART EXAMPLE #1

You're given a print for a sump pump cover. It requires punching, bending, welding and finish work.

The material is 14 GA. CR. You decide to relief punch the intersections of the corner notches to give the brake operation a cleaner bend. The welding and finish grinding operations will clean it up. Four tools will be required: .083 C (corner relief hits and threaded holes) .25 C (bolt pattern) 1 C (single hole and the 4 circular cutout) 2.25 x 2.25 R (scrap removal and the 4 corner notches)

2.00"

.250 hole 4 t imeson 6 " x 6 " spac ingcentered @ 25.25 x 13.75

4 " circle25 .2513 .75

6 -32 Thd @15 .00x16 .75

6 -32 Thd @15 .00x10 .5

34"

28"

2 .00 "

1 " circle26 .5007 .000

42

Start PUNCH WIZARD and click NEW PART.

The Define Part screen asks for the blank information: Enter X=34, Y=28, Thickness =.074, for material select steel. Enter a PART NAME. If the machine has been calibrated the gripper positions are known. They should be about 9 and 25, or enter desired gripper positions. Use the default X, Y Load Positions since there are no unusual punches or sheet size demands. Click OK. Now in the Create Part screen select Hole.

43

Punch the relief holes and 6-32 thread holes first using a .083 C tool: From the Define Hole Pattern screen click and drag on the ToolList until the .083 C is highlighted. Four corner relief punches: A .083 Circle punch is now selected. Enter X=2.000, Y=2.000 and click DONE. Click HOLE before entering the remaining three X, Y values. X=32.000 Y=2.000 X=32.000 Y=26.000 X=2.000 Y=26.000 The (4) .083 circles for the relief punches have been placed. Two 6-32 threaded holes: Use the Hole action and the same .083 C tool for the next two X and Y values: X=15, Y=16.75 X=15, y=10.5 Now create the four .250 holes around that 4" hole. With PUNCH WIZARD there are three options. You can place 4 individual .250 HOLEs; you can use LINE to place two lines of two holes, or you can use math to calculate the bolt hole distances.

44

The print calls for 4) .250 with 6" spacing centered at X=25.25 by Y=13.75. Since none of the holes have an X, Y coordinate, use a little simple geometry. Since the square root of 2 = 1.41421, and there is a 6" spacing between two side holes equals 6 x 1.41421 divided by 2 = 4.2426, or the radius of the bolt hole pattern; enter 4.2426 in the RADIUS field. Enter 4 in the HOLES field. Enter 45 as the START ANGLE to radially offset the holes by 45 degrees. Now cut out the 4 hole: The circle can be cut out with either Bolt, Arc or Window actions, Arc is used in this example. Using a 1 circle tool will leave a 2 diameter loose scrap piece inside the hole. Punch out the center first with the 2.25 square. Click Hole. Select the 2.25 R tool and enter X=25.25 and Y=13.75. Click Done.

6"

T h e diagonal is 6 t imes t he sqrt of 2 t herefore t he radius is one half t hat , or 6x1.41421/ 2 = 4.243

45

Click the ARC button. Reselect the 1" circle tool. Enter the X origin as 25.25, Y as 13.75. The radius of the hole is 2. Select Inside for the Tool Comping. Entering a Start Angle of 0 and an End Angle of 359.999 will cause a complete circle to occur. Enter a value in the Number of Holes and examine the Scallop amount (20 hits = .059). Click DONE. A 4" hole is created. Click HOLE again, this time selecting a 1" circle tool and enter: X=26.5, Y=7. Now position the 2"x2" corner notches: Click the Hole Button again: Select a 2.25" x 2.25" square tool from the ToolList, and enter: X=.875, Y=.875 X=33.125, Y=.875 X=33.125, Y=27.125 X=.875, Y=1.875 The over-sized tool makes a cleaner notch with no spikes. Click DONE.

46

Part Example 2

Radiused and square WINDOW actions:

Start PUNCH WIZARD and click NEW PART. The Define Part screen asks for the blank information: Enter X=24, Y=13.5, Thickness =.074, for material select aluminum; Enter a PART NAME. If the machine has been calibrated the gripper positions are known. They should be about 4 and 20, or enter gripper positions that are desired. Use the default X, Y Load Positions since there are no unusual punches or sheet size demands. Click the OK button.

13.5

24

2.375

8.51.75

2.75

6

2.25

.375 Rad

.5 Rad

7.75 x 6

12.25 x 8

20 x 6.5

47

Left-side Window: Click Window, a window punch-out is assumed, enter X Origin of 7.75, Y Origin of 6, X Width of 2.375 and Y Height of 8.5. Select a .25 Circle tool for the circle nibbling tool. Enter .375 for the Arc Radius; 3 hits and .015 scallop are shown. Select the .5 Square tool for the line nibbles. Click Done. Right-side Window: Click Window, change X Origin to 20, Y Origin to 6.5, X Width to 6 and Y Height to 2.25. Enter .5 for the Arc Radius. Select the .5 Square tool for the line nibbles. Click Done. Center-most Window: Click Window, enter X Origin of 12.25, Y Origin of 8, X Width of 1.75, Y Height of 2.75. Enter 0 for the Arc Radius. Select the .5 Square tool for the line nibbles. Click Done.

48

APPENDIX B TOOLING DESCRIPTIONS

Tooling uses the 'engineering' form to define degrees: 0 degrees at 3 o'clock and 90 degrees at 12 o'clock.

Tool descriptions and the part are viewed from above the punch ram looking down at the table. X is the first dimension, Y second. A .25" x 1." 'RECT' (rectangular) tool is one quarter-inch wide in the X dimension and one inch high in the Y dimension. PUNCH WIZARD uses four simple tool shapes:

'C': circular tooling - a .500" round tool. * NOTE * A prick punch, embosser or stenciler would best be described as a 'C' - circular tool.

'R': rectangular tooling All tools with four right angles and straight sides are considered rectangular. * NOTE * A square is a rectangle with four sides of equal length.

'O': obround tooling

.500"

.250"

1.000".500"

.500"

1.000"

.375"

X

YTURRETRAM

49

An obround is defined with the smallest dimension being the flat sides and the longer dimension having radiused cap ends. The sketch above would be a 1" x .375" 'O'

'M': MISCELLANEOUS tooling Any tool that doesnt fit the first three descriptions is considered a miscellaneous tool or 'M'. All 'M' tools are drawn on the screen as a rectangle with the center of the tool being the center of the tool holder. A keyhole, hexagon or the 'D' tool shown above or other like punches should be described as a 'M' tool. Tooling holders have several sizes, designated 'A', 'B', 'C' and so on. When describing a tool to PUNCH WIZARD the type of tool ('C', 'R', 'O' or 'M') AND the holder size ('A', 'B', 'C', etc). AND the actual tool dimension AND the tool angular offset are required. Tool angular offsets are shown below using a 1.000 x .250 R tool.

.750"

.625" D punch

1.000" x .250"at 0 degrees

X

YTURRET

TOOL

1.000" x .250"at 90 degrees

X

YTURRET

TOOL

50

APPENDIX C M-Codes

The M-Code button is for various miscellaneous actions. These machine functions aren't punching actions, and can act separately or with punching actions. After clicking the M-Code button a screen with tabs is displayed. Selecting a tab will display the needed input(s). These M-Code actions are: Feed Rate, Dwell, Drop Door, Pause, Reposition, Home Table, Ram Speed, Air Blow and Macro Settings. These are shown below:

Feed Rate changes table movement speed. Enter a value between 10 and 100%.

Dwell halts table motion for a specified time in whole seconds.

1.000" x .250"at 30 degrees

X

YTURRET

TOOL

51

Drop Door may be commanded to open or close. Resets to closed at end of part.

Pause halts all movement. After performing activity required (scrap removal, ETC.) use Cycle Start or Resume to continue.

52

Reposition allows programmable reposition marks on blanks longer than the X table travel would otherwise permit.

Load Position returns table to the load position. Requires Cycle Start to continue.

Ram Speed changes the ram motor speed during punching. Machines with a multi-speed ram motor may use a lower speed for more efficient nibbling. A lower ram speed can allow the table to move a longer distance without requiring the ram to fire the clutch and brake.

53

Air Blow to help remove scrap or blow off slugs may be commanded on or off. Resets to off at end of part.

Macro Settings: G98 codes from the converter may require adjustments in direction and offset dimensions. Macro Settings allows these corrections.

54

APPENDIX D Part Grouping & Zoom & Mirror

Part Grouping:

Once a punch action or a series of actions are created, (ARC, WINDOW, ETC.), you may want one or more duplicates of that group of actions without reprogramming each action. PUNCH WIZARD has three forms of grouping: Single, Rectangular Matrix and Radial. Single grouping will place one copy of the original at a new location Rectangular grouping will place multiple copies of the original in a row/column arrangement. Radial grouping will allow one or more copies to be rotated around a given X,Y point in specified angular displacement increments. [Group Terminology]: F2: the F2 key on the keyboard used to start the grouping function or edit the current group. Parent: the original punching action(s) you are duplicating. Parent Origin: The origin of the Parent is the intersection described by two imaginary lines. These lines are created from the outermost edge of the punch closest to the X and Y coordinates of the selected group. This X and Y is oriented closest to the machine table origin. See Bounding box example on next page. Child: a copy of the original (the parent)

55

Matrix: copies in an X and/or Y (row/column) with a given incremental displacement value. Displacement: (X and/or Y offset spacing): the measured amount of unpunched spacing between matrix children and the parent. The measurement of unpunched spacing is calculated from the rectangular bounding box surrounding the parent plus the amount of extra space needed. When Rectangular Matrix is chosen the X and Y dimensions displayed are the dimensions of the bounding box. Example 1: After selecting a group, Matrix displays an X dimension of 5" and a Y dimension of 4". You want 1" of material to remain between the groups. Enter 6 (5+1) in the X spacing and 5 (4+1) in the Y spacing. Example 2: Select a single .500" round hole. You want 1.3875" hole centers. In Matrix the bounding box dimensions for X and Y are .5". Add .5 to 1.3875 = 1.8875. Radial: one or more copies with an angular displacement of the child relative to the parent around an X, Y point of rotation. Click and Drag: using the touch screen or mouse, position the cursor over a beginning point; click and while holding down move to the ending point (touch screen and mouse work the same)

Bounding Box: Click and Drag will create a bounding box that grows or shrinks as you move around. Once it contains the action(s) you want, lift your finger from the mouse or screen. The minimum sized rectangle or Bounding Box that contains the Parent will contain the action(s) selected. NOTE * Any alteration to the parent will alter the child(ren) Single: You've created a window action and want to duplicate that same window elsewhere on the blank. Press the F2 key, click and drag over the window action. It may be from any corner to any diagonally opposing corner. After the selection has been made, you will then be given the Group screen. Click on the Single checkbox. A green box will appear on the part blank showing the outer dimensions of the copy. Touch the screen and drag the box to a place near where you want. Now enter exact values in the X and Y Coordinate boxes in the upper right corner of the screen to offset the Child exactly from the Parent. Matrix: Press F2 and select the Parent group as before. When given the Group screen, enter the total number of products for X and Y. Enter the amount of displacement between each row and column.

UL

LL

56

Depending on the placement of the parent, the matrix can generate above or below the parent by clicking the FILL+ / FILL- toggle box. It's recommended you place the parent farthest away from the grippers in the Y-axis and closest to the Zero reference point in the X-axis and use the FILL- function. This helps prevent the sheet from becoming 'spongy' as material is removed during the punching actions. Click the Rectangular button to generate the matrix. Radial: Select the Parent group. In the Radial group area, enter the number of copies and the radius of the group. The copies will be equally spaced around the circumference of the pattern and rotated to have the same orientation as the parent. Optionally, clicking the ROTATE/NO ROTATE toggle box can disable the rotation of each copy. Click the Radial button to generate the radial group. (Parent = 1, plus 9 children = a total of 10 group actions)

Zoom & Mirror Commands

Zoom: A zoom function is available from the CREATE screen. Press F3 then Click and Drag over an area of punches to better visualize or measure various punch placements. Press F3 again to return to normal scale. Zoom is scrollable. Pressing an arrow key will scroll the screen part display. Hold down the Control key then an arrow key will speed-up the scrolling process. Scrolling is limited to the original bounding box selection. Zoom is zoomable. Press the right bracket key once ']' to zoom in by two 'power'. The left bracket key '[' zooms out the same amount. Repeated pressing of either bracket keys multiplies the effect until it reaches either one power or thirty-two powers.

57

A mirror function is available from the CREATE screen. Pressing F4 will allow you to Click and Drag over an action(s). After selecting the action(s) you are presented the mirror screen. The selection is represented by a symbol in the center of a 3 by 3 matrix. The symbol is a capital T with a red dot to the lower right corner.

00

TTT

T

58

APPENDIX E Networking The PC800 Control is networkable out of the box. PUNCH WIZARD is told in its INI file where it should look to find parts. Thesepaths can refer to folders on the PC-800, the floppy drive, or a networked server. When working with a networked volume, PUNCH WIZARD minimizes conflicts between other PUNCH WIZARDs sharing a file server. Using a server for part storage makes backing-up your entire part library simpler and allows all of your PC-800s and any off-line PCs running PUNCH WIZARD to work with one pool of parts, meaning everyone will be getting the correct, current revision. Your Tool Library may also be stored on a network server for the same reasons. To set-up the PC800/PUNCH WIZARD system to use a centralized server the following steps are required: 1) Open the file PUNCHWIZ.INI in the C:\PUNCHWIZ\ directory. Search for the line below [PATHS] - example: C:\punchwiz\punchjob\ 2) Change the DOS path to the directory you wish 3) Do the same changes to CRIB_PATH=C:\punchwiz\punchjob 4) Save the new PUNCHWIZ.INI 5) Restart PUNCH WIZARD NOTE* You may not operate one PUNCH WIZARD program from multiple machines; PUNCH WIZARD tests for this! You may only use the number of PUNCH WIZARD programs purchased for each machine tool.

59

APPENDIX F FILE STRUCTURE The following shows the basic folders and files that are installed in the PC800 hard drive hard drive at setup of the PunchWizard program. To assure proper recovery of this information in the event of a system failure, back up both PunchWiz directories on a regular basis.

C:WINNT\SYSTEM32\

This folder contains files used to convert existing program files into Punch Wizard format.

This folder contains log files that are automatically generated whenever an alarm occurs.

This folder contains the status module exe file

This folder contains information relative to user defined special tools (See Appendix G)

This is the executable file that starts the PunchWizard program

This text file contains all of the tool information used in the Master Crib List (See Appendix F)

This folder contains all of the individual saved part files

This text file contains all of the tool information used in the current turret layout (See Appendix F)

This text file contains all the unique configuration & parameters for a particular machine (See Appendix E)

This folder contains updates by date of the parms.8k file

This text file contains the parms.8k file used when your machine was originally set-up

This text file contains a log of all of the changes made over time to machine parameters

The parms.8k file contains the system parameter settings for your machine

60

APPENDIX G Punchwiz.ini file, Criblist.tlf, Hottools.tlf files

PUNCH WIZARD is designed to work with the wide variety of punch presses from many manufacturers. Each punch press has different hardware characteristics and limits. These differences are defined in the PUNCHWIZ.INI file. !!!ANY CORRUPTION OR UNQUALIFIED CHANGES TO THE PUNCHWIZ.INI MAY CAUSE MACHINE DAMAGE OR PERSONAL INJURY - THEREFORE ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT ANY CHANGES TO THE PUNCHWIZ.INI. CALL PC CONTROLS OR PEREGRINE PRODUCTIONS IF IN DOUBT!!! Example Punchwiz.ini file: [PATHS] 1=*\PUNCHJOB [CONVERTER] load1=*\PUNCHJOB TYPES=TAP END_TO_END=NO SHOW_ALL=1 !HIDE_TYPES=INI,GMT,PWZ,EXE STATION=3,2 SHAPE=9,3 DIMENSIONS=13,19 THETA=33,8 MATERIAL=1 GAUGE=.06 [CONVERTER_MATCH] !METALSOFT=* [TIMEOUTS] MinDropChuteDelay=5 Calibrate=60 TurretMove=30 [MACHINE] download=*\debugcode.txt MACHINE_TYPE=0 TONNAGE=30 UNREPOSITION=OFF REPO_CYLINDER_DISTANCE=14.5 RESOLVE_IGNORE_CLEARANCE=YES RESOLVE_IGNORE_STATIONS=NO

61

ZERO_MARK=UL FEEDRATE=100 LOAD_POSITION_FEEDRATE=100 LOAD_X=-3 LOAD_Y=5 NIBBLE_OFFSET=85 MEASURE=INCH MACHINE_NAME=Whitney 636A ZOOM_2X_CLICK=YES X_AXIS=60.251,-3.251 Y_AXIS=36.251,-0.251 TAB_THICKNESS=.02 GRIPPERS=3.155,1.6,0.5,5.5,.3 GRIPPER_COUNT=2 MAX_DEPTH=36.5 HAS_DROP_DOOR=NO RAMSPEEDDELAY=0.5 RAM_SPEEDS=PUNCH OFF,PUNCH ON STATUS_INTERVAL=50 MAX_INTERVAL=0 !HIDE_DESKTOP=TRUE GLOBAL_OFFSET_EDIT=FALSE !WINDOWS_LOADSAVE=TRUE SERIAL_CODE=BC99C23012805B repo_y_inc_out=0.1 repo_y_inc_in=-0.02 tap_offset_x=0 tap_offset_y=0 tap_diameter=0 tool_load_table_x=0 tool_load_table_y=3 [filetypes] 1=.pwz;Standard Punch Wizard [MATERIALS] 1_NAME=Mild Steel 1_THICK=0.118,0.236 1_FACTOR=0.2,0.25,0.3 1_TONNAGE=1 1_ALIAS=CR,COLD ROLLED 2_NAME=Aluminum 2_THICK=0.098,0.197 2_FACTOR=0.15,0.2,0.25

62

2_TONNAGE=.5 2_ALIAS=AL,ALUM 3_NAME=Stainless Steel 3_THICK=0.059,0.109,0.158 3_FACTOR=0.2,0.25,0.3,0.35 3_TONNAGE=1.5 3_ALIAS=SS, STAINLESS [TURRET] RADIUS=0 GRIPPERS_CLEAR=FALSE SAFE_Y=.5 REPO_Y=6 MIN_LOAD_Y=0 GRIPS_CLEAR_TURRET=4.0 SMART_DETECTION=true [ZONES] A=3.250,1.875,1.938 B=3.375,2.250,2.500 C=3.625,2.562,2.625 D=3.750,3.000,3.062 E=4.375,3.750,3.750 F=5.250,4.125,4.375 G=8.500,1.875,2.125 H=8.500,2.250,2.125 I=8.500,4.125,4.125

63

Criblist.tlf File

Criblist.tlf is a text file that contains all of the stored tooling information in the Master Crib found in the Edit Tool Library Screen. Criblist.tlf is updated every time a tool is added, deleted, or changed in PunchWizards Master Crib List. The criblist.tlf file resides in the C:\Punchwiz folder.

000.1000 000.1000 CB 000.3130 000.3130 CB 000.3440 000.3440 CB 000.3750 000.3750 CB 000.4060 000.4060 CB 000.4380 000.4380 CB 000.4530 000.4530 CB 000.4680 000.4680 CB 000.5000 000.5000 CB 000.5310 000.5310 RB 000.5630 000.5630 RB 000.6250 000.6250 CB 000.6400 000.6400 CB 000.6560 000.6560 MB 000.6880 000.6880 CB 000.7190 000.7190 CB 000.7500 000.7500 CB 000.7810 000.7810 MB 000.7970 000.7970 CB 000.8120 000.8120 CB 000.8750 000.8750 CB 000.9380 000.9380 CB 001.0000 001.0000 CB 001.0620 001.0620 RB 001.0940 001.0940 RB 001.1000 001.1000 CB 001.1250 001.1250 CB 001.1880 001.1880 CB 001.2500 001.2500 CB 001.5000 001.5000 CC 001.6250 001.6250 CC 001.6560 001.6560 MC 001.7500 001.7500 CC

X dimension of tool

Tool Shape, C(Circle), R (Rectangle), O(Obround), M(Miscellaneous)

Y dimension of tool

Tool Size, A, B, C, D, E

64

HotTools.tlf File

HotTools.tlf is a text file that contains all of the stored tooling information for tools hat are presently installed in the machine turret. The contents of this file are graphically shown in the Edit Loaded Tolls Screen. The HotTools.tlf file is updated every time a tool is added or removed from the turret. The tool content found in the HotTools.tlf file should always match the physical load contained in the machine turret. The HotTools.tlf file resides in the C:\Punchwiz folder.

[hottools] VERSION=1

1_X=2.0 1_Y=2.0 1_SHAPE=R 1_name= 1_theta=0 1_forming=False 1_DIE=0.0120 2_X=0.25 2_Y=0.25 2_SHAPE=C 2_name= 2_theta=0 2_forming=False 2_DIE=0.0120 3_X=1 3_Y=1 3_SHAPE=R 3_name= 3_theta=45 3_forming=False 3_DIE=0.0120 4_X=0.75 4_Y=0.75 4_SHAPE=C 4_name= 4_theta=0 4_forming=False 4_DIE=0.0120 5_X=1 5_Y=0.125 5_SHAPE=R 5_name=

X tool dimension

Y tool dimension

Tool Shape, C(Circle), R (Rectangle), O(Obround), M(Miscellaneous)

Tool Name

Tool Angle

Forming tool designator, True or False, if not a forming tool

Die clearance

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5_theta=90 5_forming=False 5_DIE=0.0120 6_X=0.313 6_Y=0.313 6_SHAPE=C 6_name= 6_theta=0 6_forming=False 6_DIE=0.0120 7_X= 7_Y= 7_SHAPE= 7_name= 7_theta= 7_forming=False 7_DIE=0.0120 8_X=0.937 8_Y=0.937 8_SHAPE=C 8_name= 8_theta=0 8_forming=False 8_DIE=0.0120 9_X=1.0 9_Y=1.0 9_SHAPE=C 9_name= 9_theta=0 9_forming=False 9_DIE=0.0120 10_X=0.375 10_Y=0.375 10_SHAPE=C 10_name= 10_theta=0 10_forming=False 10_DIE=0.0120 11_X=1 11_Y=1 11_SHAPE=R 11_name= 11_theta=0 11_forming=False

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11_DIE=0.0120 12_X=0.156 12_Y=0.156 12_SHAPE=C 12_name= 12_theta=0 12_forming=False 12_DIE=0.0120 13_X= 13_Y= 13_SHAPE= 13_name= 13_theta= 13_forming=False 13_DIE=0.0120 14_X=0.75 14_Y=0.437 14_SHAPE=R 14_name= 14_theta=0 14_forming=False 14_DIE=0.0080 15_X=1 15_Y=0.125 15_SHAPE=R 15_name= 15_theta=45 15_forming=False 15_DIE=0.0120 16_X=0.313 16_Y=0.75 16_SHAPE=R 16_name= 16_theta=90 16_forming=False 16_DIE=0.0120

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APPENDIX H- Special Tool Files (*.PWT)

Special Tool File Format: The file is created as a text file and is automatically processed into a binary file by the Punch Wizard program. The file is placed in the current Punch Wizard folder \PUNCHWIZ\TOOLSHAPES\. Only Arc and Line commands are allowed.

A(CX,CY,SA,EA,RADIUS) L(X1,Y1,X2,Y2)

All coordinates are relative to the center of the tool except for A(SA,EA,RADIUS) which are relative to the Arc center. All Units are INCH. (1.0 is 1 inch, -.5 is a negative half-inch) All Angles are in absolute degrees (180.00 is 180 degrees) If no decimal is present then the value is a whole number. The geometry of the Special Tool shape can have two different levels of quality: low mode and high mode. Low mode limits the number of drawing commands to 100. High mode has a limit of 200 commands. Low mode is the default shape displayed; high mode is used when zooming but not when punching a part. Arc: CX, CY: Center of arc. (Relative to the center of the tool)

SA, EA: Arc start angle (SA) and end angle (EA) in degrees. (Relative to the arc center). Angles are always drawn in a counter-clockwise direction. An arc with a starting angle of 90 degrees and an ending angle of 45 degrees will draw a 315-degree arc.

Line: X1, Y1: Line beginning point. (Relative to the center of the tool) X2, Y2: Line ending point. (Relative to the center of the tool) Example: Dos file name RADIUS- .250.PWT [info] Version=1 Name=RADIUS- .250 Width=.95 Height=.95 IsFormer=false InventoryID= SerialNumber= LengthLeft= Sharpen=500 CreatedBy= ManufacturerID= InventoryData=

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Size=B LongName=RADIUS- .250 [low] 1=L(.475,-.125,.475,.125) 2=L(.475,.125,.375,.125) 3=A(.375,.375,180,270,.250) 4=L(.125,.375,.125,.475) 5=L(.125,.475,-.125,.475) 6=L(-.125,.475,-.125,.375) 7=A(-.375,.375,270,360,.250) 8=L(-.375,.125,-.475,.125) 9=L(-.475,.125,-.475,-.125) 10=L(-.475,-.125,-.375,-.125) 11=A(-.375,-.375,0,90,.250) 12=L(-.125,-.375,-.125,-.475) 13=L(-.125,-.475,.125,-.475) 14=L(.125,-.475,.125,-.375) 15=A(.375,-.375,90,180,.250) 16=L(.375,-.125,.475,-.125) [high] [comments] Description of information lines: Name= the name of this tool, limited to 25 characters. Saved in part files and used for matching. Does not have to match the .PWT name. Width= the width of the geometry Height= the height of the geometry IsFormer= is this a forming tool (true/false) InventoryID= your companys inventory id for this tool SerialNumber= the serial number, if any, for this tool LengthLeft= usable length left on the tool before replacement Sharpen= this tool should be sharpened after the specified number of punches (Not yet implemented as of 12-2001) CreatedBy= the creator of this geometry file ManufacturerID= the tool manufacturers id for this tool InventoryData= additional inventory data for your companys use Size= the size station this tool fits. Will override the size specified in the ToolCrib if they differ. LongName= a longer, more descriptive name for this tool.

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APPENDIX I FILE CONVERSION

FILE CONVERSION PROCESS

To convert an existing file to punchwizard format:

1. Click on New Part in the Main Menu Screen

2. Click on button on the Define Part screen

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3. Click on button on the Load File screen

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4. Select the existing part text file to be converted & click

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5. Verify tooling information, type in desired part name or use default name, click button

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6. Hit button to complete part conversion and move to the Create Parts Screen.

7. Verify the converted part is correct and make changes in the create part screen as required

8. Click button when finished to save the newly converted part file button.

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Appendix J Security Key/Dongle

A security key, or dongle is required for Punch Wizard to operate on each punch press or desktop programming computer. Each dongle is constantly checked by the Punch Wizard program during the programming and punching cycle to assure that a legal copy is running. Attach the dongle to the CPU's parallel (printer) port. Any peripheral equipment that uses the parallel port may still be connected to the dongle. Dongles are designed to be transparent to the user or other programs. If for any reason a dongle needs to be replaced; either from damage, inoperative or a special upgrade; contact PC Controls.

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Appendix K Parameter Maintenance Password To access and modify the gauge parameters for your single station punch press do the following:

1. Access the Status screen when working in Run Mode screen 2. In the Status screen, click on the Show MCC Variables button

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3. Enter one of the following passwords in the Security Screen

eveningeven if the current time is evening (after 12:00 PM) and the current day of the month is an even number eveningodd - if the current time is evening (after 12:00 PM) and the current day of the month is an odd number moringeven - if the current time is morning (after 12:00 AM) and the current day of the month is an even number morningodd - if the current time is morning (after 12:00 AM) and the current day of the month is an odd number

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Adjust MCC parameters shown below as required:

Caution: Modifying or changing control parameters incorrectly may cause machine control to operate improperly and may result in damage to machinery and injury to personnel. Only qualified and trained personnel should make any parameter changes.

Press to save newly input parameters

Read in current parameter values from the Motion Control Card (MCC)

Read in original factory MCC values

Cancel out of Gauge Parameters Screen

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In the lower-left corner of the Manual screen is a button labeled Tweak MCC. MCC stands for 'motion control card'. This button is password protected. Access to Tweak MCC should only be granted to authorized representatives of PC Controls. The Tweak MCC screens contain variables used by the motion control card to define the machine axes and servo tuning. These include table travel limits, ball screw encoder counts, motor speed min-max limits, ETC. Incorrect changes to any of these variables could cause serious machine damage and will guarantee operational failure. *Note* descriptions of the variable is followed by three numbers in parentheses. The first number is the numerical format and is represented as a number like -123.1234; if the first character is a negative sign '-' a negative value is allowed if necessary. Positive values are otherwise assumed, a plus sign '+' isnt required. The 123 means three digits are required before the decimal point and the 1234 means four digits are required after the decimal. Pay special attention to each variable format to prevent errors! The second two numbers are the minimum and maximum allowable values. A min of 0 and a max of 128 will not accept -5.0 or 1000. Tweak MCC screens are displayed in a row/column format with an axis designation across the top of the screen and a variable definition on the left from top to bottom. Unneeded axis variables will not appear on screen. Screen one: X, Y, T, and C columns ENCODER SCALE FUNCTION (12345.1234 1 max) encoder counts that equals one revolution or one inch MINIMUM LIMIT (-1234.1234 -max max) distance an axis may travel in the negative direction in inches MAXIMUM LIMIT (1234.1234 1 max) distance an axis may travel in the positive direction in inches CALIBRATION LOCATION (1234.1234 -max max) home location in encoder counts CALIBRATION SPEED (123.1234 1 max) axis speed in inches per second JOG SPEED (12.1234 1 100) axis speed in inches per second RAPID SPEED (123.1234 1 100) axis speed in inches per second P-GAIN (12.12345678 0 max) axis motor tuning - proportional gain I-GAIN (12.12345678 0 max) axis motor tuning - iterative gain D-GAIN (12.12345678 0 max) axis motor tuning - derivative gain FF-GAIN (12.12345678 0 max) axis motor tuning - feed forward gain TABLE CALIBRATE SPEED (12.1234 >0 max) X,Y calibration speed in inches per minute

TABLE RAPID SPEED (123.1234 >0 max) X,Y maximum allowable speed in inches per minute MAXIMUM FOLLOWING ERROR (123.1234 >0 max) number of lead/lag encoder counts a drive will allow before faulting JOG ACC RAMP (1234.1234 >0 max) number of encoder counts per sec per sec during acceleration JOG DEC RAMP (1234.1234 >0 max) number of encoder counts per sec per sec during deceleration IPB (123.1234 >0 max) in position band in inches ACC RAMP (1234.1234 >0 max) number of encoder counts per sec per sec during acceleration DEC RAMP (1234.1234 >0 max) number of encoder counts per sec per sec during deceleration STP RAMP (1234.1234 >0 max) stop ramp - should be equal to DEC RAMP CLUTCH DUMP TIMER (123 >0 max) dwell time before clutch can fire - in milli-secs PUNCH ANTICIPATION (123.1234 >0 max) distance the table can be in movement before tool strikes part - in inches PUNCH CLEAR DELAY (123456 >0 max) time punch must retract from part before table can move - in milli-secs FOV TURRET (1.1 >0 max) feed-rate-override in percentage: 1.0 = 100%, .5 = 50% FOV C AXIS (1.1 >0 max) feed-rate-override in percentage: 1.0 = 100%, .5 = 50% GRIPPER LOCATE Y-POS (123.1234 >0 max) Y axis position during find grippers & calibration - in inches REPOSITION FOV (123.1234 >0 max) feed-rate-override during repositioning - in inches per minute Y SLOWDOWN DISTANCE (12.1234 >0 max) distance from turret grippers must slow down passing under turret Y SLOWDOWN FOV (1.1 >0 max) feed-rate-override in percentage: 1.0 = 100%, .5 = 50% LUBE ON TIME (1234567 >0 max) lube system on time in seconds LUBE OFF TIME (1234567 >0 max) lube system off time in seconds STRIP MISS TIMER (1.12 >0 max) max time allowed for strip miss sensor to detect tool in seconds

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Appendix L Plasma Operations Line Contouring Operation:

Select Plasma tool

Click to make last end point become new start point

Select line angle

Select line length

Program feed rate setting

Starting X & Y line position

Check to pause after cut

Click to return to cancel and return to last screen

Check to cut at constant velocity, un-check to decelerate at end of cut

Click to complete the line after all inputs

Select Kerf comp setting

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OPERATION IN Line Contouring

To define a line contour: 1. Select the Plasma contouring tool top of tool list 2. Click on the + button to begin new X, Y value with last line ending

X, Y value OR 3. Enter the Starting X and Starting Y values 4. Enter length of cut line 5. Enter line Angle (+ or 360 degrees) 6. Select Pause to pause after cut 7. Check Constant Velocity if you dont want to decelerate at the end

of the cut; Un-check Constant Velocity if you want to decelerate at the end of the cut

8. Enter Feed rate in Inches-per-Minute 9. Select Kerf Compensation (left, none, or right) 10. Click Line At Angle to complete the line

NOTES: Check Pause to allow scrap removal Kerf is the width of a cut; if the cutting head removes .100 inches of material, the Kerf is .100. Kerf comp is the kerf, i.e. .050.

.100 cut ..100 Kerf

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Arc Contouring:

Select Plasma tool

Click to make last end point become new start point

Select Kerf comp setting

Click when finished input of required information

Check to cut at constant velocity, un-check to decelerate at end of cut

Starting angel of arc

Program feed rate setting

Click to cancel and return to last screen

Select degrees of travel of arc

Starting X & Y origin of arc

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OPERATION IN Arc Contouring

To define an arc contour:

1. Select the plasma contouring tool top of tool list 2. Enter the center of the Arc in Origin X and Origin Y 3. Enter Arc radius 4. Select Pause to pause after cut 5. Check Constant Velocity if you dont want to decelerate at the end of the cut; Un-

check Constant Velocity if you want to decelerate at the end of the cut 6. Enter Start Angle ( 0 degrees is at 3 oclock) 7. Enter Degrees of arc travel (+ or 359.999 degrees) 8. Enter Feed rate in Inches-per-Minute 9. Select Kerf Compensation (left, none, or right) 10. Click Done to complete the arc action

NOTES: Kerf is the width of a cut; if the cutting head removes .100 inches of material, the Kerf is .010. Kerf comp is the kerf, i.e. .050.

.100 cut .100 Kerf

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PLASMA ARC AND LINE PROGRAMMING EXAMPLE

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Appendix M PC800 Recovery CD In the event that your PC800 system fails due to hardware or software problems on the hard disk drive, the system can be restored to the original condition (when your PC800 control was initially installed) by using the PC800 Recovery CD. The recovery CD will reload the Windows operating system and all programs that were present at the initial installation of your PC800 control. If you have installed other software since this time, you will need to reinstall this software. Provided that you have back-up copies of your critical PC800 files (See Appendix F), your PC800 control can be easily restored to its condition as of your last file back up by performing the following steps:

1. Place the PC800 Recovery CD in the CD drive 2. Re-boot the PC800 control, the system will boot from the recovery CD 3. You will see the following screens; respond to each screen as follows:

PC800 Disk Rebuild Utility Press any key to continue --- Press Any Key Partition sizes correct? --- Yes Proceed with Disk Load? --- Yes

4. When the recovery operation is complete, you will see the message: Clone completed

successfully. 5. Take Recovery CD out of Drive & store in a safe location --- Click on Reset Computer 6. Copy your PC800 back-up critical files into their correct location (see Appendix F) 7. Restart the PunchWizard program

Title PageTable of ContentsPC Controls License Agreement Safety & Product WarningsPC800 Front PanelMain Menu ScreenEdit Tool Library ScreenOperation In "Edit Tool Library" Screen

Turret Layout ScreenOperation In "Turret Layout" Screen

Define Part ScreenOperation In "Define Part" Screen

Create Part ScreenOperation In "Create Part" Screen

Define Hole Pattern ScreenOperation In "Define Hole Pattern" Screen

Define Bolt Hole Pattern ScreenOperation In "Define Bolt Hole Pattern" Screen

Define Arc Pattern ScreenOperation In "Define Arc Pattern" Screen

Define Line Pattern ScreenOperation In "Define Line Pattern" Screen

Define Window Pattern ScreenOperation In "Define Window Pattern" Screen

Run Mode ScreenOperation In "Run Mode" Screen

Load File ScreenOperation In "Load File" Screen

Save A Punchwizard File ScreenOperation In "Save A Punchwizard File" Screen

Machine Status ScreenMachine Status Screen - NotesStatus Flag DefinitionsAlarm Flag Definitions

Manual Controls ScreenTerminal ScreenAppendixesAppendix A Programming examplesPunch Wizard Line ExamplePunch Wizard Line at Angle ExamplePunch Wizard Window ExamplePart Example #1Part Example #2

Appendix B Tooling DescriptionsAppendix C M-CodesAppendix D Part Grouping, Zoom, & Mirror CommandsPart GroupingZoom & Mirror Commands

Appendix E NetworkingAppendix F File StructureAppendix G Punchwiz.ini & Criblist.tlfPunchwiz.ini fileCriblist.tlf FileHotTools.tlf File

Appendix H Special tool filesAppendix I File ConversionFile Conversion Process

Appendix J Security Key/Dongle Appendix K Parameter MaintenanceAdjust MCC Parameters

Appendix L Plasma OperationsLine Contouring OperationOperation In Line Contouring Arc Contouring OperationOperation In Arc ContouringPlasma Arc And Line Programming Example

Appendix M PC800 Recovery CD