Forney Retropak® CA-0397 Installation Guide

A Step-By-Step Procedure to Guide Your Forney VFD Retropak Installation

Disassemble Existing Machine Hydraulics

The first step in preparing your existing machine for upgrade is disconnecting and removing the existing hydraulics and display from your machine.  Follow these steps for the disassembly:

• Make sure you unplug the machine to remove power before doing any work.
• If your machine has a digital display, unplug and remove the digital display's power cord and supply. Remove the screws holding the digital bracket to the machine and remove the digital display and bracket.
• Make sure your piston is fully retracted. Once retracted, disconnect the hose from your pump. All existing hydraulic oil can be drained from the machine. 
  
  
• Remove the bolts from the pump reservoir and remove it from the machine.
  
  
• Remove the bolts holding the pump bracket and remove the bracket from the machine.
  
  

Connecting Retropak to Existing Frame

Once all the original components have been removed from the existing frame, you can connect the Retropak. Follow these steps to connect the existing frame to your new Retropak:

Uncrating

To properly uncrate your new Forney Testing Machine, follow these steps:

• Remove metal straps around the crate/box with suitable cutters (shears) if banded.
• Remove the top of box/crate.
• Remove wooden braces on the top and sides of the machine if braced.
• If crated, remove the sides of the crate; if boxed, remove the entire box.
• If accessories are included, unband/unbrace and remove accessories.
• Locate the packing list and check parts and units against the packing list to make sure the shipment is complete. 
• Cut all remaining bands, and remove all wooden braces on the pallet.
• The machine can now be removed from the pallet.

Positioning

• Position the VFD Retropak next to your existing frame so that you can make the required connections.
  
  
  
  

ForneyLink® Touchscreen Installation

• For security, the ForneyLink touchscreen device is shipped separately and will need to be mounted to the test machine.
•  Unbox the ForneyLink touchscreen device. It is recommended to save the box for the touchscreen as it is custom-designed for shipping the ForneyLink if it needs servicing.
  
  
• Remove the screws, washers, and lock washers from the back of the ForneyLink and set aside.
• Line up the touchscreen with the mounting bracket. There are two sets of four screw holes on the mounting bracket. The touchscreen utilizes the inner set of holes.
• Put one screw in to hold the touchscreen. Finger tighten this screw. Once one screw is holding the touchscreen, align and finger-tighten the remaining three screws.
  
  
• Once all screws are in place, tighten all screws. Care should be exercised to not over-tighten.
• Connect the power plug, round load signal cable, and VFD Cable DB9 connector to their respective ports on the ForneyLink. Tighten the screws on the DB9 with a screwdriver so they are snug, but do not over-tighten these screws.
  
  

• If your machine has additional USB connections for factory-installed options such as MOE, it is important to note that only the blue, USB 3.0 connector should be plugged into the blue USB 3.0 port on the ForneyLink. You can connect other connectors to any available USB ports on the ForneyLink, except for the blue, USB 3.0 port.

• If the frame is equipped with an over-travel limit protection device, we recommend using this device with the new system. A twist lock connector is included to easily accommodate this connection. The female connector comes pre-wired to the VFD control panel. The male connector is shipped loose and requires wiring to the limit switch. Most mechanical switches do not require polarity. Make sure also to check the over-travel protection is turned on in the Forney machine software.
   
  

Install any other electronic devices ordered if applicable (i.e. LDTs, position sensors, etc.)

Hydraulic Connections & Setup

Most machines involve one hydraulic connection to the main ram. Using wrenches, 
remove the existing hydraulic hose and install the new hose to the main ram. Then, 
tighten the hydraulic swivel fitting near the pump to the hydraulic hose. If the machine 
is an optional dual frame type, one additional hydraulic connection must be connected from the other frame to the AB valve mounted on the aluminum post.



Power Connection

• Connect power to the machine by plugging in the standard wall plug. Check the stamped metal ID nameplate for voltage requirements.

Bleeding Air from the System

Upon initial startup, air can accumulate within the hydraulic system. The trapped air can cause the system to advance slowly or surge and make the motor become noisy. To remove the trapped air, try the following steps.

1. With oil in the unit and the machine ready to operate under zero load, advance the piston about 2” of travel and then retract to the starting position. This should be done several times to work the air out of the system. If this does not remove all trapped air, you can perform step #2.
2.  With oil in the unit and the machine ready to operate under zero load, loosen a couple of turns, but do not remove any hose fitting that is situated higher than the rest of the hose fittings in the system. Run the pump until a steady flow of oil, free of air bubbles is observed. Re-tighten the fitting.