1. Check the X Probe mechanics: Loose nuts, bolts, & bearings on X Probe assembly. Check the encoder gear, gear rack, mount bar, spring, etc.

2. Check the alignment of infeed conveyor and encoder gear and rack. X Probe should run down entire length of infeed smoothly. If there are any spots where the X Probe bounces or binds, the probe tip moves up/down or in/out in respect to the V-rolls, that area needs to be fixed. Pay particular attention to the joints where the 20’ infeed conveyor sections join together.

3. Check the encoder, encoder cable, connector, shield, & wire connections in console.

4. Set the gear rack. Start near the machine and loosen the 1/4"-20 bolts on every piece of gear rack. Remove the very last piece and use it to mesh the first two pieces together. Use a welding clamp to hold the meshed gear racks tightly. Make sure there is clearance between the two pieces of gear rack (See below). Tighten the bolts. Start from the meshed joint and work to the opposite ends of both pieces. Then mesh the second piece of gear rack (already tightened) to the third piece and tighten bolts on third piece of gear rack (from meshed end to opposite end). Continue all the way down the infeed conveyor.

5. Assuming that the machine is already calibrated, program a mark on the web of an angle every 1’. If the marks are not correct, determine exactly where they start to become inaccurate.

Example: Correct until 15’ and then long 1/16" after.

Position the material in the machine (web punch) where the marks start to become inaccurate. The encoder on the X Probe will be in the area of gear rack that is inaccurate. There will be some mechanical reason for the inaccuracy.

NOTE:

When running small flat bar, if the holddown air pressure is too high, then the restriction to the material moving through the machine is also high. This restriction may cause small flimsy flat bar to bow between the xprobe and the first holddown assembly and also between each holddown assembly inside the machine.

The xprobe may move forward a small distance, but the section of material in the machine may not move. The material bowing between the xprobe and the point(s) of restriction (holddowns) causes this. The xprobe will be in the correct LEN position to perform a function (punch hole, shear, etc.), but the section of material (in machine) that is being fabricated will not be in the correct LEN position. This will lead to inaccurate length measurements for hole placements and part lengths.

For the machine to run flat bar correctly, turn the holddown air pressure as low as safely possible, especially when running small flat bar. The acceleration, deceleration, and velocity can be slowed down as well. See the Machine Manual for the location and description of these constants.

In addition, when running flat bar, as the front end of the material enters and goes through the machine, it may hit the V-rollers, strippers, and/or shear blade due to the material being warped or bowed excessively. Operator assistance may be needed to get the front end of the material through the machine to the shear unit. The operator can halt the machine at any time and move the material forward slowly, using the joystick, to get the front end of the material past a V-roll, stripper, or shear blade. He can then restart the machine process. It is best to not move the material forward past the next operation as this will cause the xprobe to move the material backwards to perform that function.