USE AND MAINTENANCE INSTRUCTION MANUAL
Electric Metal Bending Machine
This manual was written according to prescriptions of attachment I1.7.4. of :
EEC Directive 89/392 – published on the European Community Official Journal nr. L183 dated June 29, 1989
EEC DIRECTIVE 89/392 «MACHINERY DIRECTIVE» MODIFIED BY DIRECTIVE 91/368 RECEIVED BY PRESIDENTIAL DECREE NR. 459/1996
EEC Directive 91/368 – published on the European Community Official Journal nr. L198 dated July 22, 1991 Presidential Decree 459/1996 – published on the Official Journal Journal nr. 209 dated September 6, 1996
ERCOLINA® by CML International S.p.A. ITALY Tel. +39 0776 40281 Fax +39 0776 404801 www.ercolina.it - www.ercolina.com e-mail:
[email protected]
We wish to thank you for your excellent choice in purchasing an Ercolina® Medi Bender MB42. By following these instructions the Medi Bender will be a simple and useful working tool. Remember: after reading this manual, keep it in a safe place for future reference!
!!WARNING Any use of the machine which does not strictly conform to the instructions of this manual will immediately invalidate the warranty and free the Manufacturer of any responsibility.
Before using the machine read carefully care fully this instruction manual!
!!WARNING: the use and maintenance instructions of this manual apply to each of the following machines, unless otherwise specified: SB48 (single phase) ed SB48T (three phase).
We wish to thank you for your excellent choice in purchasing an Ercolina® Medi Bender MB42. By following these instructions the Medi Bender will be a simple and useful working tool. Remember: after reading this manual, keep it in a safe place for future reference!
!!WARNING Any use of the machine which does not strictly conform to the instructions of this manual will immediately invalidate the warranty and free the Manufacturer of any responsibility.
Before using the machine read carefully care fully this instruction manual!
!!WARNING: the use and maintenance instructions of this manual apply to each of the following machines, unless otherwise specified: SB48 (single phase) ed SB48T (three phase).
CML International S.p.A. WARRANTY ................... ............................ ................... .................... .................... ................... ................... .................... .................... ................... .............. ..... 3 WARRANTY CONDITIONS AND RESTRICTIONS RESTRICTIONS ......................................... ................................................................ ......................... ..3 3
PARTS IDENTIFICATION......... IDENTIFICATION................... .................... .................... .................... .................... .................... .................... .................. ........ 5 GENERAL SAFETY RULES ................... ............................ ................... .................... .................... ................... ................... ................. ....... 6 APPLICATION FIELDS.................. FIELDS............................ ................... ................... .................... .................... ................... ................... ................ ...... 9 TECHNICAL DATA .................... .............................. .................... .................... .................... .................... .................... ................... ................ ....... 10 WORKING CAPACITY ............................................ ................................................................... .............................................. ............................................11 .....................11
ELECTRIC AND ELECTRONIC COMPONENTS....................... COMPONENTS................................. ..................... ............. 12 RISK PREVENTION SOLUTIONS .................... .............................. .................... .................... ................... ................... ............ .. 13 DIRECTIONS FOR RESIDUAL RISK LIMITATIONS ................... ............................. .................. ........ 14 IDENTIFICATION CE MARKING PLATE .................... .............................. .................... .................... ................ ...... 16 ECOLOGICAL INFORMATION............... INFORMATION......................... .................... .................... .................... ................... ................... ............ 17 MACHINE DEMOLITION..................... DEMOLITION ........................................... ............................................. ............................................. .........................................17 ...................17 INDICATION FOR CORRECT WASTE DISPOSAL ............................................. .................................................................17 ....................17
MACHINE TRANSPORTATION ................... ............................. .................... .................... .................... .................... ............... ..... 18 LIFTING FROM BOTTOM WITH PACKING............................ PACKING................................................... .............................................. ......................... ..18 18 PACKING METHODS..................................... METHODS........................................................... ............................................ ............................................ ................................. ...........18 18 TRANSPORTATION ON ROAD USING AUTHORIZED MEAN ............................................19 ............................................19 CHANGE OF WORKING POSITION ............................................ .................................................................. ............................................ ........................ 19
INSTALLING THE MACHINE................ MACHINE.......................... .................... .................... .................... .................... .................... ............ .. 19 USING THE MACHINE .................... .............................. .................... .................... .................... .................... ................... ................... ............ 20 CHOICE OF ACCESSORIES .......................................... ................................................................ ............................................ .......................................21 .................21 INSTALLING THE TOOLING ............................................. ................................................................... ............................................. ................................. ..........21 21 SWITCHING MACHINE ON.................... ON ........................................... .............................................. .............................................. .....................................22 ..............22 MACHINE PREPARATION .............................................. ..................................................................... .............................................. ...................................22 ............22 TIGHTENING THE TUBE ............................................. .................................................................... .............................................. .......................................22 ................22 PROGRAMMING THE MACHINE....................................... MACHINE............................................................. ............................................. ................................ .........23 23
PROGRAMMING MANUAL............. MANUAL....................... .................... .................... .................... .................... .................... ................... ......... 23 INTRODUCTION ........................................... .................................................................. .............................................. .............................................. ................................ .........24 24 KEY BOARD FUNCTIONS .......................................... ................................................................ ............................................ .........................................25 ...................25 LIGHT SIGNALS..................................... SIGNALS............................................................ ............................................... ............................................... ......................................26 ...............26
PROGRAM PROCEDURES ................... ............................. .................... .................... ................... ................... .................... ............... ..... 27 PROCEDURES FOR BEND MAKING.......................................... MAKING................................................................ ............................................ ........................ ..28 28 HOW TO CORRECT THE SPRING-BACK ANGLE ANGLE ............................................ .................................................................30 .....................30 EDITING THE ACTUAL BEND ANGLE ........................................... ................................................................. ........................................31 ..................31 CHANGING THE LANGUAGE .......................................... ................................................................ ............................................ ..................................31 ............31
PRACTICAL USE OF THE MACHINE ................... ............................. .................... .................... ..................... .............. ... 32 MAINTENANCE .................... ............................. ................... .................... .................... ................... ................... .................... .................... .............. .... 34 ORDINARY MAINTENANCE ........................................... .................................................................. ............................................. ..................................34 ............34 EXTRAORDINARY MAINTENANCE........................................ MAINTENANCE.............................................................. ............................................ ......................... ... 34
TUBE BENDING TROUBLESHOOTING.................. TROUBLESHOOTING............................. ..................... .................... .................... ............ 35 TROUBLESHOOTING.................. TROUBLESHOOTING........ .................... ................... ................... .................... .................... .................... .................... ............... ..... 36 SB48 TROUBLESHOOTING......... TROUBLESHOOTING................... .................... .................... .................... .................... .................... .................... ............. ... 37 SB48T TROUBLESHOOTING TROUBLESHOOTING.......... .................... .................... .................... ................... ................... .................... .................... .......... 39 MACHINE CE CONFORMITY DECLARATION .................... .............................. ..................... ................ ..... 42 NOISE RATING MEASUREMENT MEASUREMENT ............................................ .................................................................. ............................................. .......................... ... 42
MACHINE CONFORMITY DECLARATION................ DECLARATION.......................... .................... ................... ................. ........ 43 Rev. 00
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CML International S.p.A. NOISE RATING MEASUREMENT MEASUREMENT ............................................ .................................................................. ............................................. .......................... ... 43
TEST CARD ................... ............................. .................... ................... ................... .................... .................... ................... ................... .................... ............. ... 44 SETTINGS OF SB48 ELECTRONIC BOARD .......................................... ................................................................ ..................................49 ............49 SPARE PARTS ARTICLE CODES ............................................. .................................................................... .............................................. .......................... ... 51
REPLACEMENT PARTS REQUEST................. REQUEST........................... ................... ................... .................... .................... ............ .. 54 BENDING FILE .................... ............................. ................... .................... .................... .................... ................... ................... .................... ................ ...... 55
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CML International S.p.A. WARRANTY Every machine is carefully controlled and tested before shipment. Machine installation is under customer’s responsibility, if qualified personnel is required for assistance and training, the cost of the operation will be charged. WARRANTY CONDITIONS AND RESTRICTIONS 1. Each ERCOLINA bender has a 24 month warranty effective from delivery date, against any component’s defect. The company reserves the right to request a copy of the sale invoice. 2. Defects must be notified to us within 2 months from the date the defect has been found. 3. Defects are checked on our premises, so every ERCOLINA® bender must be sent, FREIGHT PREPAID, to our address or to authorized service centres. ANY FREIGHT COLLECT DELIVERY WILL BE REJECTED. If checking at customer’s premises is required, a cost for checking on site will be charged. 4. Warranty includes the defective component’s replacement or repair excluding labour cost. 5. Electrical parts are not included in the warranty in case of incompatibility with power supply ( caused by overvoltage and / or atmospheric events ). 6. Operations performed under warranty do not extend warranty terms. 7. Warranty does not respond to damages caused by wear. 8. The warranty does not apply if damages are a result of incorrect handling or of a use that does not conform with specifications described in this manual. 9. The warranty does not apply if the machine has been modified or tampered with. 10. The warranty certificate IS INVALID INVALID if dealer stamp with sales date is not included at the bottom of the document and in the attached coupon. Furthermore, the part to be sent to us must be mailed within 8 days following the invoice date. 11. The buyer can not claim compensation for damages in any way.
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CML International S.p.A. 12. The warranty does not provide a replacement even temporarily of the machine. 13. The whole warranty declines if:
The machine has been repaired or maintained by personnel that has not been authorised by Ercolina®; Not original parts have been used; Damages or errors are due to connections not performed according to the using instructions; Errors due to the machine wear.
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CML International S.p.A.
PARTS IDENTIFICATION
10 11
9 5
12 8
3 6 4
13 7 15 16 1
Emergency switch mushroom
1 button 2 Foot switch socket 3 Handle for transport 4 Front door 5 Machine Body 6 Labels 7 Bottom Casing 8 Counterbending die support
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2
9
Counterbending die
10 11 12 13 14 15 16
Hexagonal shaft
14
Former Counterbending support bracket Counterbending support bracket arm Hand wheel attachment Control panel Two pedal foot switch with reinforced cable
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CML International S.p.A.
GENERAL SAFETY RULES The Ercolina® Super Bender has been designed following high tecnology standards and in accordance to the latest official safety regulations. The machine if improperly used can be a source of risk for the user or other people. To avoid danger it is important to read and apply the following safety rules.
FORBIDDEN Use the machine only for the purpose for which it has been made and observing the general safety rules. The Manufacturer will not be liable for any damage or harm caused by improper use of the machine;
Do not switch on power supply and use the machine without reading carefullythe instruction manual
Do not install and use the machine in environments containing: flammable fluids or gas; explosive materials;
Do not install the machine in a humid or wet environment; Do not expose the machine to the rain ; Do not touch moving parts of the machine; Do not put hands on the tube during bending; Avoid having more than one person working on the same machine; Working area should not be restricted to a too limited space in proportion to the tube lengths to be bent; Rev. 00
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CML International S.p.A.
Do not use the machine beyond the maximum capacities indicated ; Allow only qualified and authorised personnel to effect maintenance work or repair on the machine ;
Do not clean the machine without switching off power supply; For safety reasons and in order not to invalidate the machine guarantee never modify the electric or electronic circuitry of the machine; Never transport the machine by pulling it by the cable; Do not modify the machine structure.
!!Warning: Only use original Ercolina® accessories made for this type of machine. Any modification will invalidate the machine guarantee. The Manufacturer reserves the right not to supply accessories or spare parts in case of alteration of the machine; To avoid finger pinching never put fingers between formers and machine body; Do not leave the machine unattended with power supply switched on .
MANDATORY
! Allow only trained personnel to work on the machine. Check that the power supply is exactly the same required by the Super Bender before connecting the power cord to an outlet; Allow only trained personnel to work on the machine; Rev. 00
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CML International S.p.A. Store the machine in a dry and safe location; Delimit the machine’s working area with barriers and / or chains in order to avoid non authorised persons entering the working area of the machine when both in motion and switched off ; Mark the working area with appropriate signals; Always stand in a safe position during the functioning of the machine; Never stand on the opposite side of the machine operating controls; Before transporting the machine always disconnect main power plug cable; Check wear of formers and counterbending dies; Wear protective gloves while operating the machine; Wear a protective helmet for upward moving or suspended tubes; Wear safety shoes in case of fall of heavy parts; Read carefully the warning labels and plates on the machine.
!! WARNING: other safety protections can be adopted by the operator or by the person in charge of the machine. Our technical office is at complete disposal for any further advice needed.
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CML International S.p.A.
APPLICATION FIELDS The SB48 electric tube, pipe and profile bending machine can be used in the following sectors: ♦ mechanical, ♦ hydraulics, ♦ metal fabrication, ♦ marine engineering, ♦ electrical, ♦ general installation. The SB48 machine can bend tubes and profiles of various dimensions, wall thickness and type of materials such as: ♦ ♦ ♦ ♦
steel, brass, copper, alluminium.
The SB48 electrical metal bending machine is provided with an induction motor and an electromagnetic brake, therefore is powerful and practically maintenance free; furthermore the microprocessor electronic control which is divided into 30 blocks of 9 bends each, allows easy achievement of accurate and repeatable bends.
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CML International S.p.A.
TECHNICAL DATA
Min outside diameter Ø Max ouside diameter Working Ø capacity Min bend (R) radius Required time for tool change Maximum bend angle Speed
5 mm 48 mm 2 x tube Ø 10 s 180° SB48
2 rpm
SB48T
4 rpm
Weight of machine body with no accessories
110 kg
Weight of greatest former which can be used
20 kg
Dimensions and Width weight Length
410 mm 570 mm
Height
1000 mm
TECHNICAL NOTE: Design and machine specifications are subject to change without prior notice.
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CML International S.p.A.
WORKING CAPACITY Section
Max ø x wall thick. (mm)
Max ø x wall thick. (inches)OD
Min radius (mm)
Boiler tubes*
48 x 3.5
1"1/2gasx0.134"
100
Standard steel tubes*
48 x 3.5
1"7/8x0.134"
100
60 x 3
2"3/8x0.118"
120
Stainless steel
48 x 2.5
1"7/8x0.095"
100
Welded tube for furniture*
54 x 1.5
2"1/8x0.059"
110
50 x 4
2"x0.157"
100
50 x 2.5
2"x0.095"
100
64 x 2
2"1/2x0.065"
130
Mild steel*
32
1"1/4
60
Mild steel*
48 x 8
1/4"x1"7/8
100
Mild steel*
40 x 20 x 3
Mild steel*
40 x 40 x 3
Mild steel*
30 x 30
1"1/4x1"1/4
60
Mild steel*
40 x 40 x 5
1"5/8x1"5/8x0.20 3"
80
Mild steel*
32 x 16 x 5
1"1/4x5/8"x0.203 "
60
Material
Soft brass
Hydraulic tube ST35 Hydraulic 304L stainless steel tube Hard copper & aluminium
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3/4"x1"5/8x0.118 " 1"5/8x1"5/8x0.11 8"
80 80
CML International S.p.A. *Note: capacity refers to materials with a resistance equal to 42 kg/mm
2
ELECTRIC AND ELECTRONIC COMPONENTS The SB48 machine is provided with the following electric and electronic components: •
electronic board microprocessor control core Zilog Z80, with 3 relay outputs, TA controlled power absorbtion of the motor and LCD display of 16 characters divided into 2 lines working with 10.5V AC and an incorporated rectifier;
•
power supply card, provided with a voltage transformer, AC transformer, machine setting bridges and relays for motor running and brake control;
•
electrical single phase motor with brake for former movement;
•
red emergency switch button , for interrupting power supply to the machine in case of danger;
•
the r eset button ( not on SB48T), supplies power to the machine after connecting AC power cord to an outlet with main power switch on position (1), - or – restores power supply after that emergency button has been pressed;
•
Two pedal foot switch (Bend – Return), allows the operator to bend or to place the former into position without using the manual controls;
•
Degree counter , reads out position of counterbending die in relation to the former;
•
X axis read out system, reads former rotation angle .
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CML International S.p.A.
RISK PREVENTION SOLUTIONS The SB48 electric metal bending machine is equipped with safety systems intended to minimize risks, which operators are exposed to during use or maintenance of the machine. In the following table protection devices are listed associated to the main sources of risk they protect from.
Type of risk
Safety devices “Mushroom” emergency switch in front of machine which can be easily reached by the operator. Once pressed the button remains in emergency position until it is manually released.
DANGERS OF MECHANICAL NATURE
DANGERS OF ELECTRICAL NATURE DUE TO DIRECT OR INDIRECT CONTACT
FALL AND/OR PROJECTION OF BENT PIECE
Rev. 00
Pedal starting command purposefully designed to obstruct unintentional activation with protection on three sides (cover) and internal protection. The foot must be deeply introduced in the pedal cover to reach the pedal. In addition, the command works at low voltage. Low tension command devices (24V). Electrical circuit closed on a panel. During bending there is no risk of projection of workpiece. The risk of injury due to fall of workpiece during insertion or extraction is prevented by the command position which obliges the operator to stand in a safe position. Furthermore having a limited working area with confining barriers such as chains or protective shields with safety labels would avoid third persons coming unintentionally into contact with the workpiece.
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CML International S.p.A. DIRECTIONS FOR RESIDUAL RISK LIMITATIONS To reduce uneliminable residual risks, due to the nature of working operations, we have provided: •
Individual protection systems and tags posted on the machine indicaring the correct operating methods.
In the following table mandatory individual protection devices are listed associated to the risk they protect from. TYPE OF RISK
INDIVIDUAL PROTECTION DEVICES
Abrasion, cutting, collision Gloves danger Falling objects danger Helmet, protective shoes Danger of entanglement of Adequate apparel clothes
The following labels with caution indications have been attached to the machine ; they also provide information on the red emergency button, foot switch socket and the machine voltage.
SB48 Rev. 00
SB48T
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CML International S.p.A.
•
Confining barriers: due to the technical and operating characteristics of the machine, installing rigid protection devices like protective shields would hinder its use, since the necessary operations would become impossible to perform;
!!MANDATORY: confine the working space using adequate barriers.
Precautions: Confine working space; Indicate danger using necessary signals.
SSA AF FE ET TY YA AR R E EA A
SB48 position
Tube position
!!WARNING: During bending the operator must always stand in the position indicated in the picture.
Working space (Confined area – access denied to unassigned personnel)
L tube + 1m
L tube + 1m
!!WARNING: Only no.1 person must operate within the working area (UNI EN 294). Rev. 00
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CML International S.p.A.
IDENTIFICATION CE MARKING PLATE According to the rules in force ( Directive nr. CE/89/392 and presidential decree nr. 459/1996), the SUPER BENDER SB48 has an identification plate with CE marking, where information on the machine characteristics that may be relevant in terms of safety is included. Refer to this information in case of doubt. The plate is placed on the lower side opposite to the controls where it can be easily seen and it is not removable. If the idnetification plate for any reason is damaged, contact immediately the manufacturer for its replacement.
PLATE DATA YEAR WEIGHT MODEL MOTOR POWER SUPPLY SERIAL N° MOTOR POWER Max RPM hexagonal shaft
200_ 110 Kg SB48 – SB48T 110V – 230V – 400V 1.5 Kw 2
!!WARRANTY: Whoever tampers with or removes the plate, can be prosecuted by law and frees the Manufacturer from any warranty responsability.
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CML International S.p.A.
ECOLOGICAL INFORMATION The disposal of the SB48 packing materials, replaced parts, lubricants, components or of the machine itself, must be performed respecting the environment, avoiding ground, water and air pollution. It is the machine owner’s duty to perform this operation conforming to the rules in force in the country where the machine is used. MACHINE DEMOLITION We recommend deactivating the machine, before proceeding to its demolition: o
disassembling its components;
o
removing the motor
INDICATION FOR CORRECT WASTE DISPOSAL o
o
Rev. 00
Ferrous materials, aluminium, copper: are recyclable materials that must be taken to the proper authorized collecting centre; Plastic and rubber materials: must be taken to a waste disposal site or to the proper recycling centre.
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MACHINE TRANSPORTATION Before proceeding, respect rules for use of lifting equipment and also verify: ♦ ♦ ♦ ♦ ♦ ♦
♦
Machine weight indicated in the “Technical Characteristics” table; Make sure that ropes used are suitable and in excellent conditions; Always check wear conditions of ropes and hooks used; Make sure load is safely fastened and balanced; Warn start of handling phase; Make sure machine and installed equipment to be lifted does not exceed the ifting mean’s maximum capacity; Do not abandon control place leaving suspended load unattaended.
LIFTING FROM BOTTOM WITH PACKING Before proceeding verify:
Machine weight indicated in the “Technical Characeristics” table ; That the lifting mean used is suitable to lift the weight of machine and installed equipment; Indicated zones of pallet where grabs should be inserted; That the grabs are well placed before lifting the machine on order to avoid tipping it over.
PACKING METHODS All machines, because of vibrations caused by transportation and particularly severe climatic conditions are carefully packed using appropriate materials to guarantee a total chemical and mechanical protection.
!!WARNING: during any machine handling adopt every safety measure and keep the necessary safety distance in case of load fall.
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CML International S.p.A.
TRANSPORTATION ON ROAD USING AUTHORIZED MEAN The machine must be loaded with the maximum precautions and in the way illustrated in the figure to guarantee stability.
CHANGE OF WORKING POSITION If you need to change the machine’s working space, before transporting the machine be sure you: o o o
Disconnect main power cable; Disconnect foot switch; Remove all accessories
While transporting: o o
Beware of machine weight indicated in “Technical Characteristics” table; Keep feet away from machine.
INSTALLING THE MACHINE Place the machine in a safe and stable position. Connect the machine to a power supply circuit provided with a main switch to enable interruption of power supply. The above must be performed by specialized personnel and after verifying that: Main switch is in position (0);
Power supply is exactly the same required by the machine as indicated on the label; Conductors connected to power cord have an adequate section for absorbing same or more power as indicated on the label.
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CML International S.p.A.
USING THE MACHINE The important concepts that need to be known for an optimal use of the SB48 machine are as follows: Required bend angle.
•
Bending angle, is the degree value of the bend you wish to achieve;
•
Spring back angle α, is the difference between the required bend angle and the bend angle which would be actually achieved if the Ercolina system would not be adopted to eliminate it. The spring back angle is due to elasticity of the materials, when bent they tend to “spring back” towards their original shape;
β
Bend angle achieved without adpoting Ercolina system to correct spring back angle.
γ
α = β-γ Difference between two bends : one with spring back angle correction, the other with no spring back angle correction.
Note: the scope of this section is to outline the fundamental concepts for bending. The procedure for correcting spring back angle is explained in the SB48 PROGRAMMING MANUAL - “Editing the actual bend an le”.
Bending radius
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R
CML International S.p.A. •
bending radius, it is the radius of the bend measured from the centre of the tube or profile and the centre of the hexagonal shaft.
Follow these steps for proper use of the machine: CHOICE OF ACCESSORIES Choose the correct former and counterbending die to bend your tube or profile. Always make sure that the external diameter and wall thickness of the workpiece, match the sizes marked on the former and counterbending die. !!WARNING: for a correct choice of tooling , we recommend to use our former and counterbending die charts in our catalogue.
Former
Counterbend.die
INSTALLING THE TOOLING
Install former on upper part of hexagonal shaft as indicated .
!!WARNING: Always align the zero mark of former with the zero mark on the hexagonal shaft and body of machine.
Place the counterbending die on its support bracket.
!!WARNING: fix the counterbending die on its support bracket by the wing as indicated in the figure.
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Wing
CML International S.p.A. Screw the counterbending die to the support bracket . !!WARNING: Screwing the counterbending die to its bracket is necessary only if counterbending die has not the quick “slide” engagement system.
SWITCHING MACHINE ON Switch on machine using main power switch turning it on position (1) and pressing set button.
MACHINE PREPARATION Lubricate adequately counterbending die before insertin tube.
Insert tubeo into former.
Approach counterbending die turning bracket.
TIGHTENING THE TUBE
Tighten the tube between the former counterbending die turning hand wheel.
and
!!WARNING: apply adequate tightening pressure , in order to avoid wrinkles on inside of bend and tube ovalization.
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CML International S.p.A.
PROGRAMMING THE MACHINE For programming of Ercolina Super Bender, follow instructions of “SB48 SUPER BENDER - PROGRAMMING MANUAL”.
SUPER BENDER SB48
Programming Manual
Hardware ver. RC0063 rev. C Software ver. E198 Edition 1.0 Date 26.04.2000
Rev. 00
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CML International S.p.A. INTRODUCTION The microprocessor controlinstalled on the Super Bender SB48 board is equipped with a lithium back up battery able to store date fro over 10 years. The autodiagnostic electronic system allows a reliable and accurate process of all its functions throughout all the use of its features. The soft touch keypad simplifies the use of the machine and helps data insertion during the programming procedures.
Control Board
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CML International S.p.A. KEY BOARD FUNCTIONS All the program functions can be executed with the use of the few simple keys described below: • • •
•
•
•
•
•
•
•
• • •
• •
Rev. 00
Confirms all data. Starts work program block . Ends data storage. Bending alternative key to move the shaft of the machine (alternative to foot pedal). In the data entry mode this key can be used to insert 90° directly in the program in a quicker way. Return alternative key to move the shaft of the machine backwards (alternative to foot pedal). In the data entry mode this key can be used to insert 45° directly in the program in a quicker way. During the data entry mode allows the insertion of new data or changes in old data stored . In the data entry mode this key can be used to insert 135° directly in the program in a quicker way. When doing the spring back angle it allows to change the previous set value. Program key for increasing bend angle value. Enables data entry. Allows work block selection. Program key for decreasing bend angle value. Erases bend angle values stored in program blocks.
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LIGHT SIGNALS On the main electronic card, there are a number of light signals which will appear accordingly to the machine position as follows:
OVERLOAD: • • • •
Excessive power absorbed Connections to the main motor have been interrupted Emergency stop button activated Magneto thermic switch in the off position
WARNING: • • • • •
Low tension High tension Error 86* Error 87* Error 88*
*Note: information concerning ERRORS 87-88 on the SB48 is on page 37 e 38 of this manual; information concerning ERRORS 86-87-88 on the SB48T is on page 39, 40, 41.
SYNCRO: •
Reset return phase
• •
Machine is ready to bend (flashing) bend is accomplished
•
Power supply going in main electronic board
BEND:
POWER:
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CML International S.p.A. PROGRAM PROCEDURES 1. Activate data entry mode: • Switch on power supply (by using main switch) and press set up button ; •
Press the
button ; the display should show as follows: DATA ENTRY MODE +=YES ENTER = NO
Program Start
2. Press the
or
keys to continue or not the data entry mode;
3. If you have chosen to insert new data pressing the plus
, you will have to
choose the block in which you would like to work with using again the button to select a group to work with from P0 to P9.
plus
By pressing minus button for 4 seconds while the program number is displayed, all the previous stored data will be lost and new data can be memorised. 4. Once the group has been selected and it is ready to be programmed, the display will show as below ; you may now insert the bend angle value and store it with the
button.
INSERT BEND 1(1…P) 000
Insert bend angle
5. To insert the bend angle values press
and
buttons to increase or decrease
the value of the bend angle values or it will be possible with the use of the ,
to insert quick bend angle values such as 135°, 90° e 45°.
6. To store the bend angle values press the will appear on the display:
Rev. 00
,
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button and the following message
CML International S.p.A. STORED
Stored bend angle 7. Once the first bend angle has been inserted, the program will automatically ask for the second bend angle which can be inserted in the same way as the first. The same can be done for the third, the fourth and so on until the ninth of the same group by repeating steps 5 and 6. If instead you wish to end the data entry you must press the :
button without inserting any angle value the display will show
END OF DATA ENTRY
End of data storage
8. For programming new groups press To end data storage press
button and repeat steps from 3 to 7.
.
PROCEDURES FOR BEND MAKING After the full data entry will be finished the machine will be in stand by mode with the following message : FORWARD C.BEND DIE Mm - … PR … 1
Stand by mode In this position if the bend angles memorised are more than one, with the use of the button you may scroll through and choose the bend angle you would like to use . Set all tooling on the machine, former and counterbending die of the same size of the material to be bent. Set in position the support bracket and adjust initial pressure on tube against the former. With the use of the keys, memorize the cursor counterbending die postion :
and
you will need to
FORWARD C.BEND DIE Mm - … PRX1
Rev. 00
Page 28
CML International S.p.A.
Setting the electronic counterbending die position The position of the counterbending die (mm 000.0) is controlled by the microprocessor which enables the machine to carry out the following bends repeating exactly the position of the cursor and counterbending die with a tolerance of + 0.2mm. It will be possible to begin the first bend now by pressing the button; the tube will begin to move in the tools until it will be possible that it will visibly begin to bend the angle moved will be our spring-back angle. See example in the bottom indicating what the display will show: BEND 1 0° Mm 000.0 008°
090° 0°
Spring back Press the
button to memorise the spring back angle (see below). BEND 1 8° Mm 000.0 000°
090° 8°
Spring back storage
It will be possible now to bend by continuing to press the button. Once the bend angle will be achieved, the machine will stop automatically and the yellow light will flash. Press the
button to bring the machine back to the 0 origin point. BEND 1 8° Mm 000.0 8°
090° 090°
Completed memorised bend
Should the (0) position of the machine shaft be lost or offset it will be necessary to set the machine in the shaft reset mode to bring the hexagonal shaft (axis C) back in its original position. The shaft reset procedure can be accomplished as follows: Rev. 00
Page 29
CML International S.p.A.
•
The machine shaft should be without any kind of tools;
•
Keeping the button or pressed by turning on the machine simultaneously, you will enter the shaft reset mode. When the mode is entered the display should show the following message:
•
SHAFT RESET MODE
Shaft (axis C) reset mode
In this mode press the or pedals, to move the hexagonal shaft base aligned with the 0 mark, placed on the aluminium body of the machine itself. •
To store the new origin or 0 point, you need to press the display will show as follows:
button and the
SHAFT RESET STORED
New position of the shaft stored ( Axis C )
HOW TO CORRECT THE SPRING-BACK ANGLE If while working you notice that the required bend angle achieved is not conforming to the desired angle you may adjust the spring-back angle to correct the angle in the machine program. To correct the bend angle, while working you need to : • •
•
stop the machine from working by releasing all keys; press the value;
the value of the spring-back angle can be changed with the use of the buttons and
•
button , then a flashing cursor will appear on the spring-back angle
;
The new set value will be stored only after having the following message will then be displayed :
button pressed, the
BEND 1 12° 090° STORED
Spring-back angle change storage Rev. 00
Page 30
CML International S.p.A.
In the example shown in the above picture the new spring-back value (12°) has been stored on the first 90° bend. After the new angle has been stored you may proceed continuing the bend until completed.
•
EDITING THE ACTUAL BEND ANGLE As the spring-back angle you may also modify the bend angle without changing a whole program. To edit a single bend angle you must: • • •
•
interrupt bending ; press the
button until the flashing cursor is on the bend angle value;
at this point with the use of the and buttons you may add or subtract degrees to your original stored angle; Once the bend angle has been changed you will need to store it by pressing the button.
CHANGING THE LANGUAGE In order to change the machine language on the display please act as follows: •
•
Place the machine in the off position and then press the simultaneously while turning on the machine; On the display the following message should be shown:
,
,
Language selection
By pressing the •
button you may scroll through all the available languages;
Make your selection then store with the use of the
Rev. 00
Page 31
button.
CML International S.p.A. PRACTICAL USE OF THE MACHINE Main points to keep in mind for bending correctly with the Ercolina® system: ♦
Before bending make sure that the outside diameter of the tube is of the same size as the one printed on the former and the counterbending die. !!Note: if you measure the former groove with a calibre, do not be surprised to find it a few mm smaller ( if the wall thickness of the tube is smaller than 2,5mm ) or a decimal part of a mm smaller ( if the wall thickness of the tube is greater than 2,5mm ) than the actual marked diameter size. It is perfectly normal and it is part of the Ercolina® bending technology.
♦
♦
Remember that the minimum bend radius depends on the material to be bent, the tube external diameter and the wall thickness of the tube. Improvement of bend quality achieved by fine adjustment of special screw
Correct pressure between former and counterbending die. You must apply just enough pressure to avoid wrinkles on the inside bend of the tube. !!Note: If even with a higher pressure there are still wrinkles in the inside bend use a former with a larger radius.
♦
In case of excessive constriction of the tube on its inside radius use the special screw on support bracket: as soon as tube starts visibly bending tighten screw so that the screw touches the back of the counterbending support bracket. After this continue the bending process as normal. Fine adjustment of this screw will further improve the bend quality.
Rev. 00
Results achieved after bending with no special screw or by using it in a too backward position
Special screw Results achieved after bending with no special screw or by using it in a too forward position.
Page 32
CML International S.p.A. !!Remember to adjust the position of this screw for different tube sizes / materials. ♦
Former and counterbending die must never touch otherwise the tube may break or have wrinkles on the inside bend and the machine can be damaged.
♦
Do not keep tubes in dusty/dirty places, in these conditions the counterbending dies will wear out faster due to increased friction between the dirty tube and counterbending die
Rev. 00
Page 33
CML International S.p.A. MAINTENANCE ORDINARY MAINTENANCE Lubrication. In order to always guarantee optimal functioning of the SB48 machine , grease upper gear box with a grease gun every 40 hours of work.
How to replace the hexagonal shaft (former holder ). Act as follows: a. unscrew all the bolts which hold the shaft ; b. extract the hexagonal shaft ; c. insert new hexagonal shaft so that the zero marked on the machine body match ( only one fitting position is possible ); d. screw the bolts firmly back into place following a cross section order.
EXTRAORDINARY MAINTENANCE Any repair or replacement of internal and exernal parts of the machine must be made only by personnel trained/authorised by the Manufacturer. The Manufacturer reserves the right not to supply accessories or spare parts if the machine has been modified.
Rev. 00
Page 34
CML International S.p.A.
TUBE BENDING TROUBLESHOOTING PROBLEM Wrinkles on surface of bend
internal
Wrinkles on internal surface of bend Wrinkles on internal surface of bend Excessive tube deformation (ovalisation) Excessive tube deformation at beginning and end of bend Excessive tube deformation on internal radius at beginning and end of bend
CAUSE
SOLUTION
Apply more pressure on tube ( the Bending pressure is too maximum pressure is achieved when low former and counterbending die are almost touching ). Counterbending die and Act so that these two parts do not touch former are touching Former radius is too Use former with larger radius. small Bending pressure is too Diminish bending pressure or use high former with a larger radius. Bending pressure is too Diminish bending pressure or use high former with a larger radius. Bending pressure is too Use special screw on support bracket . high
Tube wall thickness Machine fails to bend and/or chemical Try to bend by using the special since machine goes into composition of tube is Ercolina® roll instead of overload beyond machine bending counterbending die. capacity
For any other technical problem on bending, contact your nearest Ercolina® dealer.
Rev. 00
Page 35
CML International S.p.A. TROUBLESHOOTING PROBLEM Does not switch on e n i h c a M
Does not switch on
CAUSE
SOLUTION
Electrical connections in plug Electrical connection
Check plug Check power cable making sure it is not damaged
Check plug and phases on QS1 Display is completely Missing phase off Check fuses and if blown replace Display is completely Burnt fuse off bracket Store bracket position Pushing pedal machine does Support datum position not not start stored
“Error 87”
Low voltage power Switch off machine immediately and connect it to suitable power supply supply. High voltage power Switch off machine immediately and connect it to suitable power supply supply Faulty T.A. Check phases
“Error 87”
C axis beyond 210°
Reset heaxagonal shaft ( C axis )
“Error 88”
C axis beyond 210°
Reset heaxagonal shaft ( C axis ).
“Error 88” “Error 88”
Faulty axis C encoder Check connections on electronic card ( 4 pin connector marked with a C ) with a screwdriver making sure connections are not faulty. Faulty axis C Check integrity of encoder star wheel next to motor shaft, making encoder. sure it is not dirty ( clean with air jet ). Also make sure that star is not loose. Make sure that star wheel is at the centre of the degree reader.
Overload light on
Machine overloaded.
Switch off machine. Use within its capacity. Use correct tooling and materials.
Overload light on
Faulty motor.
Check motor connections.
Warning light on
Faulty motor.
Turn emergency button, switch machine off and reswitch on QS1.
Overload light on
Faulty encoder.
“Low tension” “High tension” : s w o h s y a l p s i D
: f I
axis
C Check C axis encoder and its connections.
The machine works but Broken or dirty axis Clean encoder with an air jet from beneath the hexagonal shaft holder. Check integrity of the encoder and of star wheel. shows Error 88 every now C encoder. and then
TROUBLESHOOTING (only for SB48T)
: s w o h s y a l p s i D
Rev. 00
Reverse main switch QS1.
“Incorrect rotation direction Inverted phase reverse switch” “Error 86” Missing phase “Error 88” and when pedals Faulty are pressed the machine rectifier. clicks “Error 87”
Faulty T.A.
TR1
Check plug. or Press on KM’s and check outlets 101-102 (100 V), if there is no power on replace TV1, if there is power press on KM’s and check outlets 200-201 (110 V), if there is no power replace rectifier. Check phases on T.A. n.400,403
Page 36
CML International S.p.A. SB48 TROUBLESHOOTING ERROR 87
If when pressing on the pedal the motor does not start and “ERROR 87” appears on the display
Cause
AXIS “C” HAS HIT THE LIMIT MICROSWITCH
INTERRUPTED T.A.
End of operation at 210° Origin axis C indicator
REMEDY
T.A. JP2 Setting
REMEDY See “ERROR 88”
Rev. 00
Page 37
CML International S.p.A.
ERROR 88
If when pressing on the pedal the motor Premendo il pedale il but motore accenna a appears to want to start, then stops partire ma si ferma immediatamente immediately and “ERROR 88” appears e onsul the display display appare: ERRORE 88.
If, when pressing on theilpedal the Premendo un pedale motore motor does not start and “ERROR non parte e sul display appare: 88” apperas on the display
ERRORE 88.
Cause
Cause
“AXIS C “ AT LIMIT MICROSWITCH
INTERRUPTED T.A.
Special key
End of operating at 210°
Cap Origin “Axis C” indicator
Connector
Electronic board
Motor
REMEDY 1.
2.
Rev. 00
If, the machine is at the end of operations stage at 210°, you have to switch machine off and then back on and return. If, the machine passes the “0” point indicator you must reset the origin “Axis C”
Page 38
Star
Encoder
Lower plate
REMEDY
1.Open the window on the microprocessor and lift the microprocessor. Disconnect the microprocessor from the connector “degree counter” identifiable by a “C” on the cap, and with a special key push on the 4 wires to make sure that there is not a faulty connection. 2.Check the encoder which can be found near the motor and make sure all is in order as shown on the drawing. If the fault remains, replace the encoder.
CML International S.p.A. SB48T TROUBLESHOOTING ERROR 86
If, when pressing on the pedal the motor does not start and “ERROR 86” appears on the display
MISSING PHASE
BURNT FUSE
Plug
REMEDY
Replace fuse
On/Off Switch
Magneto thermical switch
REMEDY See “ERROR 88”
Rev. 00
Page 39
CML International S.p.A.
ERROR 87
If, when pressing on the pedal the motor does not start and “ERROR 87” appears on the display
MISSING PHASE
INTERRUPTED T.A.
“AXIS C” HAS HIT THE LIMIT MICROSWITCH
Plug
End of operation at 210°
Origin axis C indicator
On/Off switch
Magneto thermical switch
REMEDY Check the phases in the T.A. nos. 400 and 403
REMEDY See “ERROR 88”
Rev. 00
Page 40
REMEDY See “ERROR 88”
CML International S.p.A.
ERROR 88
If when pressing on the pedal the motor appears to want to start, but then stops immediately and “ERROR 88 “ appears on the display
If, when pressing on the pedal the motor does not start and “ERROR” 88 appears on the display
CAUSE
Damage to encoder “Axis C”
Emergency button pressed
“Axis C” at limit microswitch End of operating at 210°
Special key
Missing phase Plug
Origin “Axis C” indicator
Emergency stop button is pressed
Cap
On/Off Switch
Connector REMEDY
Electronic board
Motor
Release before pressing again on foot switch
Encoder
REMEDY 1.
If, the machine is at the end of operations stage at 210°, you have to switch machine off and then back on and return.
Magneto thermical switch
2. If, the machine passes the “0” point indicator you must reset the origin “Axis C”
Lower plate
REMEDY
REMEDY
1.Open the window on the microprocessor and lift the microprocessor. Disconnect the microprocessor from the connector “degree counter” identifiable by a “C” on the cap, and with a special key push on the 4 wires to make sure that there is not a faulty connection.
1.Check the electrical plug socket. 2. Open the door which gives you access to the electrical panel, and switch the machine on by using the main switch to be found in the panel. This operation is necessary to check whether all three phases are working. Check no. L1, L2, L3 on the magneto thermical switch are receiving power supply ( as indicated in the above drawing )
2. Check the encoder which can be found near the motor and make sure all is in order as shown on the drawing. If the fault remains, replace the encoder.
Rev. 00
Page 41
CML International S.p.A.
MACHINE CE CONFORMITY DECLARATION (Directive n. 89/392 CE, Attachment II, part A).
Manufacturer: C.M.L. International S.p.A. Address: 03030 Località Annunziata snc Piedimonte S. Germano (FR), Italy declares that:
The ELECTRICAL TUBE, PIPE AND PROFILE BENDING MACHINE SB48, Series N° ________________ is: −
−
In confirmity with the Machine Directive (Directive n. 89/392 CE), as modified with the legislation that transposes it; In conformity with conditions of the following CE directives: − directive 73/23/CEE regarding low voltage electrical material; − directive 89/336/EEG regarding electromagnetic compatibility ; − directive 89/392/CEE regarding member countries approaching on machine legislation ; − directive 85/374/CEE regarding member countries approaching on legislation for responsabilities for damages caused by defective products;
NOISE RATING MEASUREMENT TYPE OF MEASUREMENT dB
NOISE RATING < 78
Measurements performed according to machine directives.
Made in __________ Date _____________ Signatory’s name Signature ___________________________
Rev. 00
Page 42
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CML International S.p.A. TEST CARD MACHINE / COMPONENT TEST CARD NUMBER: N°………. MACHINE / COMPONENT: TEST INSPECTOR : TEST DESCRIPTION:
DATE OF TEST / /200__
START CHECK DESCRIPTION
MODEL: MATERIAL: TYPE OF WORK:
ANOMALY/IES FOUND
DIAGNOSIS
REMEDIES
SUGGESTIONS
TEST RESULTS CONCLUSION NOTES
Rev. 00
Page 44
END
CML International S.p.A. SB48 ELECTRICAL DRAWINGS
Rev. 00
Page 45
CML International S.p.A. SB48T ELECTRICAL DRAWINGS
Rev. 00
Page 46
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CML International S.p.A. SETTINGS OF SB48 ELECTRONIC BOARD
FUSES F1: 1A 250V ( Trasformer protection TV1) F2: 1A 250V (Motor brake protection) F3: 25A 250V (Power supply protection) F4: 1A 250V (Start circuit) ELECTRONIC BOARD CONFIGURATION
Before connecting the machine to power supply, set voltages on the JP1 bridge and the TA values on the JP2 bridge in the following manner: Machine SB48 110V SB48 110V SB48 110V SB48 110V SB48 220V SB48 220V SB48 220V SB48 220V
Voltage 104V 110V 127V 145V 208V 220V 240V 260V
JP1 104 110 127 145 200 220 250 250
JP2 16 16 16 16 7.5 7.5 7.5 7.5
8K6
4K2 2K2
Furthermore set, frequency value on JP2 bridge, in the following manner: 50Hz ⇒ OFF; 60Hz ⇒ ON
Rev. 00
Page 49
CML International S.p.A.
“ER COLINA” S SUPER BENDER SB48 – Exploded v view f f or p parts iidentif ication
1 36
6
79 78 9
32
77
Complete bracket
76
72
75 36
24
74
42
120
121
60 90
111
119
37 (40mm) 38 (50mm)
89 88
33 60
12
36 xxx
35
92
59
112
81 117
49
110
80
61
63
65 66 10
52
70 69
16
91
94
xxx
5
116
15
3
17
73 71
25 28
14 13
103
108
100 (425mm)
23
101 (550mm) 96 (Z90)
83
97 (Z44)
113 4
85
68
98 (Z32)
104 29 34 26
105
27 11
Rev. 00
xxx
34
106
109
82
41
2
12
114
37 39
18
107
22
55
57
58
38
21
56
115
45
xxx
48
51
20
46
19
12
54
95
50
Complete instr. board
53
47 44
40
87 48
43
62
67
68
93
118
64
31
30
Page 50
102
99 (Z36) 84
CML International S.p.A. SPARE PARTS ARTICLE CODES
CHART OF SPARE PARTS ARTICLE CODES POSIT. COMP. ART. 1 810P 2 AD001 AD001/11 3 AP162 4 CPM101 5 MP202A/1 6 P010 7 P050A 8 P050B P050/D 9 P050D/1 10 P050G 11 P050H 12 P103 13 P107/2 14 P108 15 P112 16 P184 17 P190S 18 P191J/1 19 P229 20 P244 21 P352 22 P352A 23 P365 24 P378 25 P502 26 P503 27 P504 28 P507 29 P508 30 P511 31 P514 32 P514A 33 P521 34 P525 35 P526 36 P527 37 P531A 38 P532A 39 P534 40 P535 41 P535N 42 P536 Rev. 00
DESCRIPTION GREASE SPRAY ERCOLINA “BIG” ADHESIVE LABEL SB48 SUPER BENDER ADHESIVE LABEL SCREW MOTOR KW1,5 - 230V - Hz50 ELECTRONIC CARD PLASTIC GREASE GUN 150ml HEXAGONAL SHAFT 40MM HEXAGONAL SHAFT 50MM ADHESIVE LABEL “GREASE EVERY 40 HOURS” COMPLETE SUPPORT BRACKET 4 SPOKE HAND WHEEL FOOT SWITCH CONICAL HEAD PHILIPS SCREW FUSE FUSE HOLDER FOOT SWITCH SOCKET SPRING WASHER SCREW 3 PIN PLUG KEY KEY MICROSWITCH MICROSWITCH SCREW SCREW GRAB HANDLE RUBBER WHEEL SCREW WASHER NUT LOCK KEY FOR CABINET DOOR “T WRENCH “ GREASE NIPPLE NUT SPRING WASHER BLOCKING RING SCREW CAM SHAFT MICROSWITCH PROTECTION COVER PHILIPS SCREW SCREW SCREW
Page 51
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CML International S.p.A. 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 116 117 118 119 120 121
Rev. 00
P705B P705/4 P705/6 P706A P707A P710 P722B P722C P723C P723D P724A1 P724C P725/2 P725A P725/B P725C P725D/2 P725L P725T P725T1 P728NS P730A P731 P732 P735 P735/1 P737 P737/2 P738 P738A P741 P742 TP029
PINION SPACER FOR READER DISC SUPPORT AXIS C READER AXIS BUSHING PINION OIL SEAL PULLEY PULLEY PULLEY PULLEY BELT TOOTHED BELT SUPERBENDER SB48 CABINET CABLE GLAND BRASS BUSH POWER CABLE SINGLE PHASE 2 PLUG PLATE PANEL SERIAL NUMBER PLATE RIVETS COMPLETE SUPER SB48 ELECTRONIC CARD SCREW HEXAGONAL SHAFT COVER SCREW BUTTON BLOC. P9B10VN RELAY SWITCH UNIT RELAY SWITCH UNIT BLACK PLASTIC CAP BLACK PLASTIC CAP FLEX PLATE FIXING PLATE (PLASTIC) STAR CAP
Page 53
CML International S.p.A.
REPLACEMENT PARTS REQUEST In order to achieve a perfect identification of a particular required component please specify:
MODEL: Serial N°: Sub-group: Component position N°: Code N° Description Quantity
Note.: If electrical components are requested please specify voltage in use.
Rev. 00
Page 54
