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CLN Fusion Manual

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Summary of Contents for CLN Fusion

  • Page 1 CLN Fusion and Fusion Plus Manual...
  • Page 2 CLN Fusion and Fusion Plus Manual 2336 Cypress Lane, Belle Glade, FL 33430 Toll- Free: (877) 256- 1043 Local: (561) 996-5900 www.clnofsfl.com CLN Fusion Manual Ver. 2...
  • Page 3 Important Make sure you read and fully understand this manual before operating your automated machine. Failure to do so will put yourself and others in harm and will void the warranty of this equipment. CLN Fusion Manual Ver. 2...
  • Page 4 • .25” for attachment with spot welder • Machines are not intended for: • Or no flange for attachment with MIG • Bending, Notching, Flanging, or Shearing steel or welder similar materials without custom tooling. CLN Fusion Manual Ver. 2...
  • Page 5 If you use a “Leading Tab” which is the default tab, you will never encounter this rule. If you select “No Tab” then you could encounter this rule. • Bump bending radiuses do not apply to this rule. CLN Fusion Manual Ver. 2...
  • Page 6 Introduction Disclaimer Everyone at CLN of South Florida, Inc. would like to thank you for purchasing the CLN Brand Bending Machine. We understand that you had a choice and CLN of South Florida, Inc. makes every effort to provide you picked ours. Before you get started, there are a their valued customers with current and accurate few things that we need to go over.
  • Page 7 Table of Contents Safety Machine Overview and Assembly Machine Maintenance Machine Operation Machine Software Trouble Shooting CLN Fusion Manual Ver. 2...
  • Page 8 Safety Your Responsibilities: • As an operator of the CLN machine, you are responsible to follow all safety procedures. Any person who operates or does any maintenance on this machine must be aware of all safety procedures. Safety Precautions: •...
  • Page 9 • Your machine should be located in a clean environment. • Keep your machine and work area free of dirt and debris. • Lighting • Your machine should be operated in a well lighted area. CLN Fusion Manual Ver. 2...
  • Page 10 Danger Hazardous Voltage sticker: will remain on with the emergency stop pressed. Means that the area around the sticker can cause an electrical shock to anyone that puts any of there body parts in the area. CLN Fusion Manual Ver. 2...
  • Page 11 Machine Overview and Assembly Components Overview Electronic Components Overview Fusion Footprint Fusion Plus Footprint Assembly Electrical Connection Compressed Air Connection Internet Connection CLN Fusion Manual Ver. 2...
  • Page 12 Components Overview: Rear Rear Front Front Left Side Right side *Machine displayed with the covers removed. CLN Fusion Manual Ver. 2...
  • Page 13 • The Decoiler aids in feeding the material through the machine. It is very important that the Decoiler is at the same height as the CLN Fusion so that the material enters the machine at the same height that it leaves the decoiler.
  • Page 14 If there is a discrepancy the encoder tells the motor to make a correction. The encoder is located just after the rollers and before the homing cell. CLN Fusion Manual Ver. 2...
  • Page 15 Degree notcher and the second is a 100-degree notcher. The 30-degree notcher is used for negative bends and radius bends, as well as a 6-inch repeating relief notch for the flanger. The 100-degree notch is used for positive brake bends. CLN Fusion Manual Ver. 2...
  • Page 16 • The Bending Tool Assembly has clamping brake bend dies which allow for a sharper brake bend. When making a radius bend these dies will rotate out of the way allowing the machine to roll form smooth radiuses. CLN Fusion Manual Ver. 2...
  • Page 17 Components Overview Continued: Broach Station used in Fusion Plus only • This is where the machine scores the material by using a spinning cut wheel. The wheel spins and moves down then up. It also rotates to whatever angle that the bend angle is for the letter.
  • Page 18 Electronic Components Overview: This is a Fusion Plus back panel. The only difference between the Fusion and the Fusion Plus is that the Fusion has only 2 servo drives. Electrical Panel • Main I/O Breakout Board • Contactor • Relays •...
  • Page 19 8 Bottom Bend Bar Station 2 from left to right 1 Shear Arm Drop 2 Shear Lock 3 Shear Cut 4 Bump Bend Shim 5 Drain Hole Punch 6 Broach Material Clamp (Fusion Plus Only) CLN Fusion Manual Ver. 2...
  • Page 20 If you receive a servo fault message from the Fusion program the drive will most likely display an error code. For example, AL.011 is an encoder issue. See Delta Servo Fault codes go to page 288 for a complete list.
  • Page 21 Fusion Footprint: Machine Footprint: • Make sure you have at least 48” of clear workspace around the perimeter of the entire machine to ensure a safe working area for the machine operator. CLN Fusion Manual Ver. 2...
  • Page 22 Fusion Plus Footprint: Machine Footprint: • Make sure you have at least 48” of clear workspace around the perimeter of the entire machine to ensure a safe working area for the machine operator. CLN Fusion Manual Ver. 2...
  • Page 23 Remove the Decoiler side of the wall of the crate. • Remove the Decoiler and cardboard box. • Unbolt the Fusion Machine from the base of the crate. • Now carefully lift the machine off of the base of the crate with a forklift.
  • Page 24 Assembly Continued: Machine Set Up: • Remove the Side Doors of the Fusion Machine by lifting up and tilt the bottom of the door out toward you. • Install the computer on the shelf and plug in all of the computer cables to the back of the computer.
  • Page 25 Machine Set Up: • Install the Decoiler on the rear of the machine. “Caution” the Decoiler is heavy. This is a 3-person job. 2 people hold it in place and 1 person puts in the bolts. CLN Fusion Manual Ver. 2...
  • Page 26 Assembly Continued: • Machine Set Up: • Make sure that you use the shim piece between the straightener and the Decoiler frame. • Install the Straightener on the Decoiler frame. CLN Fusion Manual Ver. 2 CLN Fusion Manual Ver. 1...
  • Page 27 Don’t misplace the small parts. Don’t throw anything away until your sure that you know that you have everything. • Install the tools in the tool holder located behind the drive box. CLN Fusion Manual Ver. 2 27 27 27...
  • Page 28 Test the power at the plug before you plug in the machine! L1 to ground should be 120VAC. L2 to ground should be 120VAC. L1 to L2 should be 208 to 240VAC. • L1=120 L2=208 L3=120 High leg L1=120 L2=120 L3=120 No High leg CLN Fusion Manual Ver. 2...
  • Page 29 • Connect your air supply to the side of the regulator marked in. The picture shows fittings that CLN uses. You can use any suitable hose connection. • When the air line is connected to the machine, the gauge on the air regulator should read 80 psi.
  • Page 30 • Our customer support team can log onto your machine through a software call Team Viewer if you need assistance. For this software to work properly you must be connected to the Internet. CLN Fusion Manual Ver. 2...
  • Page 31 Machine Maintenance Grease Locations Locations Water Separator General Inspection CLN Fusion Manual Ver. 2...
  • Page 32 A standard grease work its way out to where it's intended to be affective. gun will fit the grease fitting located in the rear of the Then you will have to wipe up the excess. grease needle. CLN Fusion Manual Ver. 2...
  • Page 33 Grease Locations Continued: Notcher Assembly: Grease Needle: Brush: Apply all-purpose grease to these locations. Grease Gun: CLN Fusion Manual Ver. 2...
  • Page 34 Grease Locations Continued: Flanging Assembly: Grease Needle: Brush: Apply all-purpose grease to these locations. Grease Gun: CLN Fusion Manual Ver. 2...
  • Page 35 Grease Locations Continued: Bend Head Assembly: Grease Needle: Brush: Apply all-purpose grease to these locations. Grease Gun: CLN Fusion Manual Ver. 2...
  • Page 36 Grease Locations Continued: Shear Assembly: Grease Needle: Brush: Apply all-purpose grease to these locations. Grease Gun: CLN Fusion Manual Ver. 2...
  • Page 37 Grease Locations Continued: Encoder Assembly: Grease Needle: Brush: Apply all-purpose grease to these locations. Every 6 months Grease Gun: CLN Fusion Manual Ver. 2...
  • Page 38 Wipe down the raw steel with a Lightweight oil “WD-40”. • Apply a lightweight lubricant such as “WD-40” to Notcher Dies and Shear Blades daily. CLN Fusion Manual Ver. 2 CLN Fusion Manual Ver. 1 CLN Fusion Manual Ver. 1...
  • Page 39 Water Separator: Draining the Water Separator: • Check the Air Filter Regulator for moisture every four hours and drain by pressing up on the bottom fitting as needed. CLN Fusion Manual Ver. 2...
  • Page 40 A simple air flow adjustment can prevent a big problem. • Look for any potential mechanical issue like the bending die starting to miss align. Again, a small adjustment to an adjustment bolt can prevent a big problem. CLN Fusion Manual Ver. 2...
  • Page 41 Machine Operation Turning the Machine on and off Compressed Loading Material Set up for Plastic Face Letters Set up for Reverse Letters Set for Profiled material Mechanical Adjustments CLN Fusion Manual Ver. 2...
  • Page 42 Power Down sequence: • Shut the computer down through windows operating system. Wait 30 seconds for the computer to completely power down • Turn off the main power switch located on the rear of the machine. CLN Fusion Manual Ver. 2...
  • Page 43 In order for the machine to function properly your air compressor should have a minimum capacity of 5 cfm at 80 psi. • While the machine is running the gauge shouldn’t drop more than 10 PSI. CLN Fusion Manual Ver. 2...
  • Page 44 • If you have the V Groove Rollers in the deepest slot this will produce a 0.5” flange, the intermediate slot will produce a 0.25” flange, and the highest slot will produce a flangeless letter. Go To Next Page CLN Fusion Manual Ver. 2...
  • Page 45 Make sure the material is seated firmly in How to load material in the machine both of the bottom V Groove Rollers. • Now lower the top V Groove Rollers and tighten. CLN Fusion Manual Ver. 2...
  • Page 46 Then replace the deflector. We highly recommend that you click on the link below and watch the video on this step. Support Ramp CLN Fusion Manual Ver. 2...
  • Page 47 Set the Machine mode to Notch Flange and Bend or Notch and Flange. See Material Selection. • Make sure that the 2 guide rollers are lowered. • Push the material just past the, material homing sensor. CLN Fusion Manual Ver. 2...
  • Page 48 Make sure that the 2 guide rollers are Raised up out of the way. • Push the material just past the shear. • Shear the material. This will be the starting point of the letter. Manually Shearing material CLN Fusion Manual Ver. 2...
  • Page 49 Set up for Profiled Material • Only the Fusion Plus can run Profiled Material • Set the V groove rollers in the highest groove. See Flange Thickness Adjustment. • Load the material into the machine See loading material. • Make sure that the Reverse Channel Letter ramp is installed.
  • Page 50 • Remove the top plate. Loosen the set screws around the bearing and the hand wheel. Remove the hand wheel. Use a 3/16” Allen wrench to remove the 12 ¼-20 SHCS. Go To Next Page CLN Fusion Manual Ver. 2...
  • Page 51 1/6”. Replace the set screw then drill the other hole. Do this for both drive rollers. • Tighten the set screws and replace the drive roller assembly plates. CLN Fusion Manual Ver. 2...
  • Page 52 Loosen the four bolts on the rear of the Notcher Base that you wish to adjust. • Adjust the jack bolt to raise or lower the notch depth. • Once your depth is adjusted tighten the four bolts on the rear of the Notcher Base. CLN Fusion Manual Ver. 2...
  • Page 53 .040 material, use it like a feeler gauge to make sure that the bending ram is parallel. • Gently snug up the ½-13 bolt this will hold the bending ram in place. Go To Next Page CLN Fusion Manual Ver. 2...
  • Page 54 .040 material, use it like a feeler gage to make sure that the bending ram is parallel. • Gently snug up the ½-13 bolt this will hold the bending ram in place. CLN Fusion Manual Ver. 2 CLN Fusion Manual Ver. 1...
  • Page 55 Release air valve Station # 1 by turning the blue button counterclockwise to raise the Shear. Once the Shear is raised, release air valve Station # 2 by turn the blue button counterclockwise to activate the Shear Lock. Release the Emergency Stop and Restart the software. CLN Fusion Manual Ver. 2...
  • Page 56 Realigning the Break Bend Dies is a difficult task and should be done by a technician or someone with mechanical skills. We highly recommend that you click on the link below and watch the video on this step. Link to Break Bend Die video CLN Fusion Manual Ver. 2...
  • Page 57 • If you receive a message from the Fusion program that says, “the Break Bend Dies hit something,” but there not hitting anything, then you will have to adjust the sensor.
  • Page 58 After you make an adjustment cycle air valve station # 5 a few times to see where it’s naturally sitting. • After making adjustments. Turn on air valve station # 5. Turn off air valve station # 7. Then turn off air valve station # 5. CLN Fusion Manual Ver. 2...
  • Page 59 • If you receive a message from the Fusion program that says (the Bend Bar hit the material while trying to do a bend), but it did not hit anything. Then you need to check two things. The Bend Bar speed and the Bend Bar sensors there are three Bend Bar sensors located on the air cylinders.
  • Page 60 It should extend or retract within 2 seconds. Don’t make it move to fast so that it slams into itself. • Tighten the thumb nut, then test again to make sure that the speed is satisfactory. CLN Fusion Manual Ver. 2...
  • Page 61 Mechanical Adjustments Continued: Fusion Plus machines only Broach Wheel Adjustment: • To adjust the depth of the cut wheel, loosen the 6 - 1/4 -20 bolts, 3 on each side of the base plate. With a soft hammer tap the plate in the direction that you want it to go and retighten the bolts.
  • Page 62 • Mix a small amount of JB Weld and apply it to the 3/8” shaft and the hole of the new lobe. • Position the set screw over the flat of the 3/8” shaft and tighten. • Allow the epoxy ample time to fully cure. CLN Fusion Manual Ver. 2...
  • Page 63 If there's play, then use an epoxy like JB Weld. • Position the lower receiver so that the pin slides into it, then tighten the set screw. • Allow the Loctite or epoxy ample time to fully cure. CLN Fusion Manual Ver. 2...
  • Page 64 Or the sensor is right on the cusp of working or not working and will need to be adjusted. • If the sensor doesn't come on, then adjust the sensor down until it comes on. Rotate the bend head a few time to test. CLN Fusion Manual Ver. 2...
  • Page 65 Machine Software Software Overview Using the Software Manual Machine Control Material Settings Software Settings Tool Settings Machine Calibration CLN Fusion Manual Ver. 2...
  • Page 66 • Software The purpose of the CLN software is to give the operator a way to view the artwork that was sent via a DXF and convert it so that the machine can process the information correctly. From the CLN Software you can alter the start point, split the letter up into sections, set an inline or outline and set drain hole locations.
  • Page 67 This routine calculates what the router bit can not cut and compensates for it by subtracting out the difference from the two lines that create a negative angle. The setting is called Router Bit Size and is in Options > Software Settings. Curfing Loss Original Artwork Actual letter back after being cut on the CNC Router CLN Fusion Manual Ver. 2...
  • Page 68 Using The Software: Start the program: • To open the operating software on the machine simply double click on the desktop icon “CLN Fusion”. • A message will display asking you if it is safe to home the bend head.
  • Page 69 Look and wait for it to finish the rotation sequence. • The Bend Head message will always come up when you start the Fusion program. • To save time the machine will not rotate the Bend Head if it has successfully completed the sequence.
  • Page 70 Using The Software Continued: Open a DXF File: • To open your .dxf file and view your artwork on the machine, Open the Fusion program, go to, File > Open and select your file. • The Artwork will be displayed on the screen in a tab called Working.
  • Page 71 • Machine Mode • Make sure that you have the right material selected for the type of coil that you have loaded. • Material Selection CLN Fusion Manual Ver. 2 71 71...
  • Page 72 Select the “Add Dual Drain” for letters like the “I”. To process the letters. Select the letter or letters that you wish to run and click Run Tool. The machine will begin making letters. CLN Fusion Manual Ver. 2...
  • Page 73 • Click on split letter again to cancel the function. • Click anywhere in the black screen. • Click on one side of the letter and drag or use the arrow keys to move the letter away from itself. CLN Fusion Manual Ver. 2...
  • Page 74 Using The Software Continued: Splitting A Letter Into Sections Continued: • The fusion program can only add tabs for letters that are not split into sections. • Only in the Working folder will you see this. By default, the green Tab will...
  • Page 75 Splitting A Letter Into Sections Continued: • A long line will pop up, use this line to set the angle of the Tab, then click on the screen. • A ¾” tab will be inserted. CLN Fusion Manual Ver. 2...
  • Page 76 • The other side of the F was split in the center. • Right click anywhere in the black screen and select Add Tabs. • Select Step Bend. This will add the step bend on the beginning part of the letter. CLN Fusion Manual Ver. 2...
  • Page 77 • Notice that it put the artwork back in the Working folder. • Inserted green Lead Tabs for the letters that are not split. • Inserted Red markers on the letters that are open. CLN Fusion Manual Ver. 2...
  • Page 78 • Notice that it put the artwork back in the Working folder. • Inserted green Lead Tabs for the letters that are not split. • Inserted Red markers on the letters that are open. CLN Fusion Manual Ver. 2...
  • Page 79 • Notice that it put the artwork back in the Working folder. • Inserted green Lead Tabs for the letters that are not split. • Inserted Red markers on the letters that are open. CLN Fusion Manual Ver. 2...
  • Page 80 If you're in manual shear mode or the shear hits the letter on the way down, it will display a message asking you to press the shear button. CLN Fusion Manual Ver. 2...
  • Page 81 Note: Its normal for the program to close when you click Update. This is necessary for the machine will automatically retract without the need for the to receive the new settings. operator to hold the button. CLN Fusion Manual Ver. 2...
  • Page 82 • Go to tools / Material Settings. These are settings based on the thickness of material that you are running. • The Fusion is capable of handling a multiple sizes of materials from 0.032” to 0.063”. There are 4 categories.
  • Page 83 Material Settings Continued: Material Definitions Settings and Adjustments: • You need to run the test files located in C:\Jobs\Fusion Test Files to adjust the following. • Brake Bend Positive: This adjust the degree of the bend for the positive break bend function.
  • Page 84 *These are settings are being used as an Note: Typically happens on the inside of an upper case “H” The outside of the “H” is example. Actual Material Settings will controlled by the outline from the cad program. vary.* CLN Fusion Manual Ver. 2...
  • Page 85 Note: Its normal for the program to close when you click Update. This is necessary for the machine *These are settings are being used as an to receive the new settings example. Actual Material Settings will vary.* CLN Fusion Manual Ver. 2...
  • Page 86 Making a change to the “To Second Notcher” value will *These are settings are being used as an example. Actual Tool Settings will vary.* NOT affect the “To First Notcher” value. Once they are CLN Fusion Manual Ver. 2 set, they stay grouped together.
  • Page 87 “To Shear” value. Making a change to the *These are settings are being used as an “To Shear” value will NOT affect the “To Break Bend Dies” example. Actual Tool Settings will vary.* value. Once they are set, they stay grouped together. CLN Fusion Manual Ver. 2...
  • Page 88 • To Broach: Only for the Fusion Plus. This is the distance from the shear to the broach cutting wheel. It’s shown as a negative number because it measures backwards from the shear.
  • Page 89 Flange and Bend the Letter. For Standard Channel Letters. • Broach Pos Brk Bends and Bend All Bends: This mode is only for the Fusion Plus. This mode will only broach cut the positive break bend locations and will not broach the negative bend locations.
  • Page 90 • Shear In Delay: This is the time that it takes for the to receive the new settings *These are settings are being used as an tool to go through the material. example. Actual Tool Settings will vary.* CLN Fusion Manual Ver. 2...
  • Page 91 Tool Settings Continued: • Broach Tool: This mode is only for the Fusion Plus. These values are all related to the Fusion Plus. • Minimum Notch Angle: This value prevents the broach from cutting miniscule break bend angles in the letter that are not needed. The value is in degrees.
  • Page 92 Note: Its normal for the program to close when you click Update. This is necessary for the machine to receive the new settings *These are settings are being used as an example. Actual Tool Settings will vary.* CLN Fusion Manual Ver. 2...
  • Page 93 Note: Its normal for the program to close when you click Update. This is necessary for the machine to receive the new settings *These are settings are being used as an example. Actual Tool Settings will vary.* CLN Fusion Manual Ver. 2...
  • Page 94 • To figure out the correct calibration value, you have to use this formula. Commanded distance / Distance the material moved * the current “Feed Encoder Counts per Inch” Value • Example: 48.0 / 48.125 * 1662.0 = 1657.6 CLN Fusion Manual Ver. 2...
  • Page 95 Bump Bend Calibration: • Calibrating the bend head requires you to run 4 different test files that are located in C:\Jobs\Fusion Test Files. You have to run each file and adjust the bend values until the machine makes the correct shape.
  • Page 96 • Repeat these step for a Roll Bend Positive. Use test file (6 - inch diameter test Neg.DXF). We highly recommend that you click on the link below and watch the video on this step. CLN Fusion Manual Ver. 2...
  • Page 97 Trouble Shooting Software Won’t Start Material Stuck in the Machine The Notch is off the Bend Bend Head Crash on Start Up CLN Fusion Manual Ver. 2...
  • Page 98 Software Will not Start: Com Port (0) 75 Error • The Fusion software starts on 2 stages. The first stage closes all existing parts of the program that are running in the background. If it can’t successfully shut them down a message will pop up in a large black screen telling you to shut it down with the task manager.
  • Page 99 • Go to the device manager and make sure that the com port is working correctly. Take note of the com Port number, you will need this number later. 9 Pin Com Port CLN Fusion Manual Ver. 2 99 99...
  • Page 100 • You need to manually edit the data file that contains the Com Port setting for the Fusion program. • Go to the windows folders, C:\Fusion. Double click on CLNSETUP.DAT It should open with note pad. CLN Fusion Manual Ver. 2...
  • Page 101 • If the program still will not start, then try repeating these steps with the other Com Ports that are available in the device manager. • If the program still fails to start, contact tech support at CLN of South Florida Inc. CLN Fusion Manual Ver. 2...
  • Page 102 To make sure that the material is loaded correctly See Loading Material. • Material stuck in the notching station • Dull Notching Dies: CLN Fusion Manual Ver. 2...
  • Page 103 However, this will cause the material to lift back with the die. You will also hear the notcher cycle very quickly like a machine gun. To fix this clean up the artwork. CLN Fusion Manual Ver. 2...
  • Page 104 Dull Notching Dies: The dies could be wore-out and need sharpening. To sharpen the dies, you must remove the Notching assembly and send it to CLN of South Florida.. Removing a Notching Assembly: • Remove the Clevis pin. • Remove the chip slide.
  • Page 105 Encoder wheel. The Encoder wheel may be loose on the encoder shaft. Remove the Encoder Assembly and check the set screws in the Encoder Wheel. See Encoder Wheel Set Screw video. CLN Fusion Manual Ver. 2...
  • Page 106 Bend Head Crash on Start Up: • If you click okay to rotate bend head message and the Bend Bar rotates counterclockwise, then stops. It most likely missed the home sensor. See Bend Head Sensor Adjustment. CLN Fusion Manual Ver. 2...

This manual is also suitable for:

Fusion plus