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Pensa Labs D.I.Wire Pro Manual Download Page 7

AC Wall Adaptor 

24 Volts 5A

Used for 

all hardware 

fasterners

D.I.Wire comes assembled with your specific 

Bend Head, Bend Ring  and Feed Wheels. 
Keep tools and hardware somewhere safe!

BEND HEAD + BEND RING + FEED WHEELS

D.I.WIRE PRO

1/8 HEX KEY

3/32 HEX KEY

5/32 HEX KEY

RAMP

GUIDES

Guides are custom for

each material diameter.

45.01

CALIBRATION PLATE

Used for creating Material Profiles

and part inspection 

USB allows D.I.Wire to

communicate with the computer 

SMALL

TORQUE WRENCH

SOCKET 

WRENCH

LARGE TORQUE WRENCH

CUTTERS

For the Feed Wheels

For the Bend Head

D.I.Wire Pro and Its Components 

01 |  INTRODUCTION

THE MACHINE

TOOLS AND ACCESSORIES*

*Your set of tools may differ, depending on what you purchased.

7

Summary of Contents for D.I.Wire Pro

Page 1: ...Version 19 4 16 1 ...

Page 2: ...TableOfContents INTRODUCTION HARDWARE SETUP AND SAFETY BENDING SETTING UP WIREWARE PATH MODE SCRIPT MODE MATERIAL PROFILE MAINTAINANCE AND TROUBLESHOOTING 2 ...

Page 3: ...Introduction SECTION 1 3 ...

Page 4: ...THE D I WIRE PRO D I WIRE PRO AND ITS COMPONENTS GETTING TO KNOW THE D I WIRE PRO Introduction 01 INTRODUCTION 4 ...

Page 5: ...s our newest desktop CNC wire bender offering the power speed precision and modularity that professionals need Bend any wire material between 0 027 0 7mm and 0 188 4 8mm bend strap and add a straightener and other accessories to optimize production 5 ...

Page 6: ...qualified personnel only This manual contains valuable info about the operation care and service of your machine We recommend you keep it handy Note The instructions in this manual are not meant to cover every possible condition and situation that may occur Common sense and caution must be practiced when setting up operating and maintaining any equipment TheD I WirePro 01 INTRODUCTION 6 ...

Page 7: ...KEY 5 32 HEX KEY RAMP GUIDES Guides are custom for each material diameter 45 0 1 CALIBRATION PLATE Used for creating Material Profiles and part inspection USB allows D I Wire to communicate with the computer SMALL TORQUE WRENCH SOCKET WRENCH LARGE TORQUE WRENCH CUTTERS For the Feed Wheels For the Bend Head D I WireProandItsComponents 01 INTRODUCTION THE MACHINE TOOLS AND ACCESSORIES Your set of to...

Page 8: ...eed Wheels and Guides BEND HEAD Typically has two mandrels to form wire ACCESSORY MOUNTS 10 32 tapped holes for holding accessories such as a wedge CUT OFF SLOT Hole for inserting cutters Take a few minutes to get oriented to the D I Wire Pro TOP VIEW WIRE GUIDES Hold material in place as it is bent Interchangeable to accommodate specific material diameters DETAIL Gettingtoknowthe D I WirePro 01 I...

Page 9: ...HardwareSetupAnd Safety SECTION 02 9 ...

Page 10: ...GETTING SET UP D I WIRE ORIENTATION SAFETY AND PROTECTION DO S AND DON TS OF THE MACHINE HardwareSetupAnd Safety 02 SETUP AND SAFETY 10 ...

Page 11: ...ce the machine on a sturdy table or work bench by itself The D I Wire is a heavy machine Make sure you place it on a hard flat and sturdy surface that can support the D I Wire s weight and remain flat Particle boards thin sheet metal or wire racks are not strong enough Make sure the work area is well illuminated and kept clean free of excessive dust debris and liquids GettingSetUp 02 SETUP AND SAF...

Page 12: ...ng areas Back of the system for material loading front of the system for part bending and a dedicated area for the computer running WireWare D I Wire Orientation 02 SETUP AND SAFETY MATERIAL LOADING AREA BEND AREA Keep clear for parts to move freely during bending Caution Area 12 ...

Page 13: ...57Kg 125 lb UNPACKING THE DIWIRE 2 PLUG IN 3 POWER CORD USB CORD WHAT S NEEDED ADDITIONAL ELEMENTS Computer D I Wire Pro USB Cord Power Cord The D I Wire weights 57 Kg 125 lb Be safe Seek assistance to pick it up from its case and to carry it to its assigned work area 57Kg 125 lb Only use the only provided power supply Using other power supplies may damage your machine 13 ...

Page 14: ... Button MOVING PARTS NEVER touch the Bend Pins or Feed Wheels during bending Allow the D I Wire to finish bending before reaching into the top plate STOP Your safety and the safety of others is very important to us so we have provided the following safety section and other safety related messages along the manual Always read and follow all safety messages NEVER TOUCH MOVING PARTS AVOID WATER The D...

Page 15: ...ection is mandatory DO NOT TAMPER WITH OVERHEATING EXPOSED HARDWARE DO NOT REMOVE PANELS TheD I WirePROneedssufficientairflowfor properventilation SeetheSettingUpsection forinstructionsonhowtoselectyourworkarea Some hardware components are removable but should not be removed unless instructed by Pensa Labs or the machine can be rendered unusable Refer to the service and maintenance section for det...

Page 16: ...2x R25 55 2x R7 95 170 70 Bending SECTION 03 16 ...

Page 17: ...LOADING MATERIAL CLAMPING AND ALIGNMENT Bending 03 BENDING 17 ...

Page 18: ...eed Wheels with the Preset Torque Wrench LOAD MATERIAL 1 2 3 Loosen the Feed Wheels with the Preset Torque Wrench Load the wire through the Wire Guides 1 into the Feed Wheels 2 and toward the Bend Head 3 HOME BUTTON HOMING SEQUENCE The machine must be homed when turning on the machine or restarting or if it has lost position Before bending the D I Wire needs to go through the homing sequence to en...

Page 19: ... get a feel for variation in how different materials should be clamped Record clamp force in each Material Profile WHAT S NEEDED If your application needs higher clamping force email us at support pensalabs com TORQUE WRENCH 1 4 HEX BIT CLAMP ADJUSTMENT 2 PREPARATIONS Torque wrench uses a stepped 5 32 to 1 4 hex bit 1 You received a pre set torque wrench that has been selected for your specific ap...

Page 20: ...SettingUpWireWare SECTION 04 20 ...

Page 21: ...DOWNLOAD WIREWARE PATH MODE SCRIPT MODE MATERIAL PROFILE MODE SettingUpWireWare 04 SOFTWARE 21 ...

Page 22: ...ownload or installation of WireWare please contact us WINDOWS MAC EMAIL PHONE Choose either Windows or Mac version of WireWare to install on the computer support pensalabs com 1 844 434 9473 CONTACT US 2 INSTALL WIREWARE Download WireWare Download WireWare software to run the D I Wire Pro WireWare prepares your files for bending on the D I Wire 04 SOFTWARE 1 22 ...

Page 23: ...PathMode SECTION 04 23 ...

Page 24: ...pare them for bending It has been designed to provide basic manipulation and adjustments to bend points and line segments and to manage multiple paths on the work area 04 SOFTWARE OVERVIEW GETTING STARTED PATH WORKSPACE INFO TOOLBAR MATERIAL PROFILE SELECTION ACTION LIST CONTROL JOG BAR ARROW KEY CONTROLS OTHER FEATURES 24 ...

Page 25: ...PATH INFO WORKSPACE TOOLBAR GRID TOOLS SELECTED MATERIAL PROFILE INFO CONTROL JOG ACTION LIST ScreenOverview 04 PATH MODE 25 ...

Page 26: ...to view and manipulate the new set of segments and bend points The path is a series of bend angles and line segments These bend angles and line segments can be manipulated using the tools on the following pages IMPORT A FILE CREATE A SHAPE WORKSPACE Go to File Open to open a saved SVG file from your computer Add Bend B and Feed F points to the Action List to start creating a new part GettingStarte...

Page 27: ... path The estimated total wire length needed for the part Bend points and line segments will snap to the ghosted imported path as they are moved around on the workspace Shows the minimum distance between bend points on a path Enter a small segment length value to get a smoother curve with many bend points 8 25 209mm of extra wire is needed in addition to the path length so that the feed wheels are...

Page 28: ...g Move around the viewable area of the workspace by clicking and dragging ADD A PAUSE POINT Select a Bend Point where the machine will pause before the bending at that location CTRL U CTRL SHIFT U Undo previous action on the Workspace Redo previous action on the Workspace Zoom tools help you to navigate around your workspace Select Tool allows you to click on line segments and bend points and move...

Page 29: ...s and Bend Head In order to modify or create new material profiles go to Material Profile Mode Always make sure to select the proper material profile of the wire you are bending Using other profiles will make Wireware calculate the wrong compensation angles Selecting the Material Profile that matches the wire in use ensures accurate bending of the Path A Material Profile is needed to bend from Pat...

Page 30: ... and manipulate the new set of segments and bend points The Plus icon adds Feed and Bend Points to the list Clicking the Plus will add a bend and feed after the last segment of a shape If a file is imported into the Path Mode workspace WireWare breaks the shape up into Feed and Bend actions Action List values can be changed on the list and the Path will update on the workspace Add Bend B and Feed ...

Page 31: ...he machine must be homed when turning on the machine or restarting or if it has lost its location Starts bending the active path Controls the feed of the wire measured in the units in use inches or mm Immediately stops moving the machine axes Jog controls the machine with simple movements set in the numerical fields for each moving part of the machine HOME BEND STOP JOG Control JogBar The Control ...

Page 32: ...ise 1 SHIFT CMD CTRL SHIFT CMD CTRL Moves the Bend Pin incrementally 0 5 per move Moves the material incrementally 0 20 0 5 mm per move Moves the Bend Ring up and down incrementally 0 047 1 mm per move CTRL CMD SHIFT 2 CTRL CMD LEFT RIGHT ARROW UP DOWN ARROW INCREMENTAL MOVES CMD CTRL SHIFT CMD CTRL CMD CTRL LESS THAN 2 CTRL CMD GREATER THAN GREATER THAN LESS THAN 3 RAISE LOWER BEND RING Z AXIS 2 ...

Page 33: ...ve to the path size Hides Shows the ghosted silhouette of the imported SVG Selects the next Path in order of creation if Workspace has multiple Paths Deletes selected Bend Point Use these tools to modify the imported Path Paths must be modified to accomodate Bend Head geometry and minimum segment lengths e g a 160 bend angle into two 80 Bend Points This allows easier manipulation of larger angles ...

Page 34: ...ScriptMode SECTION 05 34 ...

Page 35: ...se shapes using written WireWare script commands or G Code commands to control the D I Wire These allow for a higher level of control over the output OVERVIEW GETTING STARTED MATERIAL PROFILE SELECTION CONTROL JOG BAR ARROW KEY CONTROLS 35 ...

Page 36: ...FILE INFO SELECTED MATERIAL PROFILE INFO SCRIPT MODE GLOSSARY CONTROL JOG BAR G CODE GLOSSARY SCRIPT WINDOW ScreenOverview 05 SCRIPT MODE 36 ...

Page 37: ...dow to type in commands or copy and paste text SCRIPT WINDOW Paths can be saved as G Code from Path Mode and opened in Script Mode Refer to the Reference section at the end of this manual for a complete glossary of terms and other available commands SCRIPT MODE GLOSSARY IMPORT A FILE Use the file menu to open a saved file from your computer This is a glossary of WireWare Script and G Code commands...

Page 38: ...Material Profile you will also be able to view its associated information The Drop down menu lets you select among saved Material Profiles in your Library Bend Velocity is measured in degress minute Feed Velocity is measured in mm minute in min For more information see the References section MaterialProfile Selection 05 SRIPT MODE When using the WireWare script select a Material Profile to compens...

Page 39: ...e units in use inches or mm Controls the height of the Bend Pin in relation to the top shape 0 to 12 mm Immediately stops moving the machine axes Jog controls the machine with simple movements set in the numerical fields for each moving part of the machine HOME BEND STOP JOG Control JogBar The Control Bar and Jog Bar at the bottom of the workspace can be found in every mode These controls are Home...

Page 40: ...0 20 0 5 mm per move Moves the Bend Ring up and down incrementally 0 047 1 mm per move CTRL CMD SHIFT 2 CTRL CMD LEFT RIGHT ARROW UP DOWN ARROW INCREMENTAL MOVES CMD CTRL SHIFT CMD CTRL CMD CTRL LESS THAN 2 CTRL CMD GREATER THAN GREATER THAN LESS THAN 3 RAISE LOWER BEND RING Z AXIS 2 MOVE BEND PIN A AXIS FEED MATERIAL X AXIS 2 CTRL CMD Moves the Bend Ring up Z0 Moves the Bend Ring down Z 9 max Use...

Page 41: ...MaterialProfileMode SECTION 06 41 ...

Page 42: ... wire used in the D I Wire Material Profile data is used to compensate for wire spring back during a bend A Material Profile is needed to bend from Path Mode or Run WireWare Script commands in Script Mode WireWare comes pre loaded with Material Profiles for wire sold on Pensalabs com 42 ...

Page 43: ... the results into a table It is necessary to complete all three Datasets 0 Whatisa MaterialProfile HARDWARE DEFINITION DATASET MEASUREMENTS Whatisa MaterialProfile When creating a Material Profile the D I Wire learns how much to compensate for wire spring back Material Profiles consist of Hardware Definition information and Dataset measurements The Hardware Definition is information about the Bend...

Page 44: ...al Profile Library is a collection of wire materials that have been calibrated for the D I Wire 06 MATERIAL PROFILE MODE MENU BAR CREATE NEW PROFILE EDIT EXISTING PROFILE IMPORT EXPORT EXISTING PROFILE DELETE EXISTING PROFILE 44 ...

Page 45: ... Library Screen CREATE NEW PROFILE Fill in the information about the wire and the D I Wire hardware setup and click BEGIN when ready to move on PROFILE DEFINITION Red fields are required others are optional CreatingaMaterialProfile 2 1 3 ClampTorqueaffectstheMaterialProfile Usethepresettorquewrenchorrecordtorqueusingadigital torquewrench To determine the Bend and Feed Velocities for the material b...

Page 46: ...s and into the Bend Head HOME BUTTON Commands the D I Wire to locate and rest at Home machine position zero The machine must be homed when booted or if it has lost its location Click BEND to bend your first datapoint Use the cutting tool to remove the bent wire from the D I Wire The BEND button will bend the angle of the active data field CreatingaMaterialProfile 06 MATERIAL PROFILE MODE 5 4 6 46 ...

Page 47: ... press the ENTER key to move down to the next datapoint INPUT SAVE EXIT CANCEL Click the Save Exit button to save a completed or in progress Material Profile Click the Cancel button to exit without saving the file The file will not show up in the Materal Profile drop down lists until all three datasets are complete CreatingaMaterialProfile 06 MATERIAL PROFILE MODE 7 9 8 47 ...

Page 48: ...e linked to this information Make any needed changes to the Material Profile Definition and click BEGIN Click the EDIT icon next to the datapoint that needs to be edited In the Material Profile Library select the Material Profile to be edited and click the EDIT button EDIT PROFILE INITIATE EDITING EDIT DEFINITION 2 1 3 EditingaMaterialProfile 06 MATERIAL PROFILE MODE 48 ...

Page 49: ... is entered press the ENTER key to move down Save and Exit the Material Profile at anytime if needed However this file will not appear in a Material Profile drop down list until all 3 Datasets are complete EDIT DATAPOINT SAVE EXIT 5 4 EditingaMaterialProfile 06 MATERIAL PROFILE MODE 49 ...

Page 50: ...SECTION 07 Maintenance Troubleshooting 50 ...

Page 51: ...HOW TO CARE FOR YOUR MACHINE REPLACING BENDING COMPONENTS TROUBLESHOOTING Maintenanceand Troubleshooting 07 MAINTENANCE AND TROUBLESHOOTING 51 ...

Page 52: ...pensalabs contact info for help for troubleshooting Or contact your local distributor were here to help SECTION 07 HowToCareFor YourMachine 52 ...

Page 53: ...ss Using a fine tip syringe is helpful when applying lubricant to these tight areas Apply once a month or every 50hr of accumulated use CleaningAndLubrication 07 MAINTENANCE AND TROUBLESHOOTING Clean any dust or debris from under the feed wheels The preferred method is by using a vacuum cleaner but compressed air can also be used Just make sure to not blow particles into the bearings 53 ...

Page 54: ...00 to 200 clamping cycles open close Unscrew the clamping screw completely until fully removed Inspect the state of the threads and wipe clean with a shop rag or paper towel Also do a quick inspection of the threads in the nut We normally apply a small amount of Moly Graph 2 grease to the first few threads of the screw and reinsert 54 ...

Page 55: ...SECTION 07 ReplacingYourBending Components 55 ...

Page 56: ...ngYourBending Components 07 MAINTENANCE AND TROUBLESHOOTING REPLACING YOUR BEND RING AND BEND HEAD REPLACING YOUR FEED WHEELS REPLACING YOUR WIRE GUIDES CONFIGURE YOUR D I WIRE PRO FOR A DIFFERENT WIRE SIZE 56 ...

Page 57: ... this section and you ll be ready to continue bending in no time The Bend Head Bend Ring and Wire Guides also need to be changed if you are reconfiguring your machine for a different wire size Just follow the same process as for replacing the bending cmoponents but use your desired size configuration instead of a replacement kit Note If your components wore out but you don t have replacement parts...

Page 58: ...SECTION 07 ReplacingThe BendHead 58 ...

Page 59: ...ND HEAD For Bend Ramp 1 8 HEX KEY For Bend Ring 5 32 HEX KEY SOCKET WRENCH MAGNET ALIGNMENT PLATE TORQUE WRENCH For the Bend Head not provided TOOLS REQUIRED ReplacingTheBendHead 07 MAINTENANCE AND TROUBLESHOOTING 59 ...

Page 60: ...07 MAINTENANCE AND TROUBLESHOOTING 1 2 TOOLS TOOLS 1 8 Hex Key 5 32 Hex Key Remove the ramp guides by unscrewing all the 10 flathead screws Prepare Bend Ring for removal by taking out the 4 10 bolts that hold it in place 60 ...

Page 61: ...Ring to access the Bend Head Once the Bend Ring is removed you will have access to the Bend Head Different Bend Heads will look different but all are installed the same way We did not provide the magnet It is possible to remove the Bend Ring without a magnet but the magnet makes the process easier 61 ...

Page 62: ... AND TROUBLESHOOTING 4 5 TOOLS Bend Head Torque Wrench 30mm Socket Wrench The Bend Head is held by an ER20 collet Start by loosening the collet nut but don t remove it completely Once the collet nut is loosened pull the Bend Head out 62 ...

Page 63: ...NANCE AND TROUBLESHOOTING 6 7 TOOLS Replacement Bend Head Insert the Replacement Bend Head and ensure it is sitting all the way down If Bend Head is not able to be all the way down loosen the collet nut a bit more with your hand 63 ...

Page 64: ...d the plate over the Bend Ring area and orient the center with Bend Head Apply downwards pressure to the top of the Bend Head with one hand as you tighten the collet nut with the other Most Bend Heads cue the same Alignment Tool but some may need a different one If your Bend Head needs a special Alignment Tool we will send it when we ship the Bend Head 64 ...

Page 65: ...ck the Bend Ring and mare sure the flats on the tool engage with the flats on the Bend Head Command your D I Wire to go to the 0 position by either Run the Homing cycle by pressing home Run the following script G90 G1 A0 or PINA 0 Type 0 on the jog box for axis A and hit the go to button Verify the Alignment Tool remains fully engaged with the flats on the Bend Head The process makes sure the Bend...

Page 66: ...Fasten the bend ring into place by reinstalling and tightening the 4 10 screws Do not use excessive force when tightening the screws 10 lb in is sufficient If you don t have a way to measure the force go to hand tight plus a quarter turn Make sure the dowel pins align and gently press down until the Ring is fully seated 66 ...

Page 67: ...SECTION 07 ChangingTheFeed Wheels 67 ...

Page 68: ...For Feed Wheel Fasterners 3 16 HEX KEY 1 8 HEX KEY For Ramp SMALL TORQUE WRENCH For the Feed Wheels TOOLS REQUIRED 07 MAINTENANCE AND TROUBLESHOOTING ChangingTheFeedWheels 68 ...

Page 69: ...AND TROUBLESHOOTING 1 2 TOOLS 1 8 Hex Key Loosen the fasteners for the ramp Remove the ramp from the system TOOLS Feed Wheel Torque Wrench Start by clamping the Feed Wheels together by tightening the clamp screw with your Torque Wrench 69 ...

Page 70: ...OTING 3 4 TOOLS TOOLS 3 16 Hex Key Feed Wheel Torque Wrench Feed Wheel Torque Wrench With the feed wheels pushed together loosen and remove the feed wheel fasteners Loosen and fully open the feed wheel carriage to allow the removal of the feed wheels 70 ...

Page 71: ...d Wheels from the D I Wire by pulling them out of their shafts Insert new Feed Wheels into the D I Wire Align the keyway on the wheels to the keys on the shafts Ensure they are fully seated If the Wheels are too tight use the help of a strong magnet to pull them out 5 6 71 ...

Page 72: ...gingTheFeedWheels 07 MAINTENANCE AND TROUBLESHOOTING 7 8 TOOLS TOOLS Feed Wheel Torque Wrench 3 16 Hex Key Tighten the feed carriage With the feed wheels pushed together tighten the feed wheel fasteners 72 ...

Page 73: ...ChangingTheFeedWheels 07 MAINTENANCE AND TROUBLESHOOTING 9 10 TOOLS 1 8 Hex Key Place the ramp back onto the system Tighten the fasteners for the ramp 73 ...

Page 74: ...SECTION 07 ChangingTheGuides 74 ...

Page 75: ...1 8 HEX KEY For Ramp REPLACEMENT GUIDES Guides are custom for each material diameter ChangingTheGuides 07 MAINTENANCE AND TROUBLESHOOTING TOOLS REQUIRED 75 ...

Page 76: ...ChangingTheGuides 07 MAINTENANCE AND TROUBLESHOOTING 1 2 TOOLS 1 8 Hex Key Loosen the fasteners for the ramp Remove the ramp from the system 76 ...

Page 77: ...and remove the guides by pulling them out Insert the new guides into the ramp Make sure they are fully seated This section describes the process for our most common type of wire guides If your guides look different and need some help send us an email to support pensalabs com 77 ...

Page 78: ...ChangingTheGuides 07 MAINTENANCE AND TROUBLESHOOTING 5 6 TOOLS 1 8 Hex Key Place the ramp back onto the system Tighten the fasteners for the ramp 78 ...

Page 79: ...ave found on the field but we cannot cover every imaginable scenario If you can t find your issue in the following tables or the solution proposed is not solving it for you feel free to give us a call or shoot us an email at support pensalabs com and we will be more than happy to help 79 ...

Page 80: ...to your system available Be prepared to work with the machine as many issues will require live troubleshooting Check the basic settings of the computer you use to operate the D I Wire such as the operating system and version e g MacOS X Windows 10 A description of the issue the more detailed the better Troubleshooting 07 MAINTENANCE AND TROUBLESHOOTING Technical support phone number Email Technica...

Page 81: ...SECTION 08 References 81 ...

Page 82: ...or negative backwards Uses the feed speed defined in the Material Profile BENDa Moves the Bend Ring an a amount in degrees The a value can be either positive Clockwise or negative counterclockwise Uses the bend speed defined in the Material Profile REPEATn END A loop that repeats the code between REPEAT and END an n number of times Very useful when bending many copies of the same part or bump bend...

Page 83: ...Undo ConnecttoapluggedinD I Wire OpenafileineitherPathorScriptMode QuitsWireWare SwitchtoMaterialProfileMode SwitchtoScriptMode SwitchtoPathMode SavesshapeinPathModeWorkspace OpensSaveAsdialogforpathinWorkspace UndolastactioninWorkspace RedolastactioninWorkspace SwitchtothenextpathwhentherearemultiplepathsontheWorkspace inorderofcreation SwitchtothepreviouspathwhentherearemultiplepathsontheWorkspa...

Page 84: ...http www pensalabs com support pensalabs com 84 ...

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