User Manual - Trick
Contents
1. RUSCH MACHINE amp DESIGN FRACTIONAL ANGULAR MACH BEND CHECKED TWO PLACEDECIMAL ENG APPR PROPRIETARY AND CONFIDENTIAL APPR 1 5 SQ UA RE DIE SETASSY THE INFORMATION CONTAINED IN THIS ETAR QA DRAWING IS THE SOLE PROPERTY OF Material not specified gt comments RUSCH MACHINE amp DESIGN INC ANY REPRODUCTION IN PARTORASA WHOLE FINISH WITHOUTTHE WRITIEN PERMISSION OF NEXT ASF MEDION SZE DWG NO REV RUSCH MACHINE amp DESIGN INC IS A DH 1500S R500 0 PROHIBITED APPLICATION DO NOT SCALE DRAWING SCALE 1 8 WEIGHT 58 54 SHEET1 OF 1 11 INDEX TABLE ATTACHMENT OPTIONAL EQUIPMENT a b c Introduction I The IDX 10 Indexing table was designed to allow you too accurately and repeatedly position distances between bends by using the adjustable stops Also the IDX 10 can be used to hold the material being bent perfectly level while bending or altering the angles between bends Connection to your machine I Remove the shaft mounting bracket 2 angle iron leaving the slide shaft 16 in place ii Slide the front of the main track tube 1 onto the slide shaft 16 iii Reattach the shaft mounting bracket 2 and tighten bolts Iv With the front of the main track tube attached lift up the rear and support It with a sturdy saw horse or equal v Attach the rear leg adjuster 13 using the supplied 3 8 X 1 bolts vi Align the keyways with the slide bolt and slip the caster m2. Operation I After the connection to your machine is complete and the height and center line positions are verified the IDX 10 can be used ii Your first part should now be clearly marked These marks will be used to position the tubing perfectly with the 0 mark on the die and to set your IDX stops Only your first part needs to be marked after that the IDX stops will be used iii Insert a piece of material through the hook arm of the die being used and Insert through the chuck note If multiple parts are being produced the material should be marked so the chuck position can be repeated position the material so the start of bend mark lines up with the 0 mark on the die now set your first stop on the index table and produce the first bend NOTE The complete table will swing be sure not to interfere with the motion iv After the bend is complete the die must return to home Once the die is home the material can be advanced and rotated if required to the next 0 mark The next stop can now be set Repeat as required your IDX table comes standard with 4 stops CAUTION Make sure the hook arm of the die does not catch the tubing when returning v The previous steps are just examples how to set stops and produce various bends it is up to the user to define exactly how his her IDA will be set up RMD will be glad to offer any suggestions for your application 18 HEIGHT ADJUSTMENT CW TO RAISE URNS CCW
3. u uuu uqa eeen tema miu Si m 9 j Reverse Machine Operatlion ean aa aa aa sananen 9 k Bending More than 180 22222 4422222 1 2 110200000000000000000000000000 10 I Die Selection and Installation 000000010000000000 10 Mal nal inserto en en ne Sapa nee 12 n Material Removal Advancement nennen enne 14 9 MATERIAL LAYOUT asussa PIE LO e bett np heit IIR MP e 14 10 BENDING SUGGESTIONS uses 14 11 INDEX TABLE ATTACHMENT OPTIONAL EQUIPMENT 00 17 a INU OAUCTI Oss UT 17 b Connection to your machine s a 17 c Height Adjustment and Leveling 17 d Material layout MER Meise Mean 18 e Opera ON asks C PL 18 12 WARRANTY aaan 20 oon DESI uyu a 20 b EXEIUSIONS oss ne E utasa 20 c u RAT RT Rie s usnu 20 Extended Parts Warranty cisco otro A DA Pa Eestin 20 Appendik A Pipe bending and Tube bending Diagram s
4. 21 Appendix B Glossary of Commonly Used Termns 22 Appendix C Pipe OD and Wall Thickness Chall 23 1 IMPORTANT INFORMATION AND CONTACTS Machine Information Model 250 220VAC 1 Phase Neutral 20 Amp 60Hz 800 Ibs 363 kg Maximum Sound level lt 70 db Distributed By Manufactured By Baileigh Industrial Inc Rusch Machine amp Design Inc PO Box 531 PO Box 375 Manitowoc WI 54220 1911 Columbus St United States Two Rivers WI 54241 Phone 920 684 4990 United States Fax 920 684 3944 P 920 793 2936 www bill com F 920 793 9746 www rmdbender com 2 INTRODUCTION i ii You have made a practical choice in purchasing an RMD INC Model 250 Fully Programmable Bending Machine It has been carefully built of high quality materials and designed to give many years of efficient service The simplicity of design and minimum effort required to operate the machine contributes towards meeting schedules and producing greater profits The Model 250 is an electric powered Rotary Draw bending machine To bend material a bending die and counter die are required The material is hooked by the bending dies hook arm and is powerfully rotated in the clockwise direction As the bending die rotates the counter die remains stationary forcing the material to conform to the radius and
5. away from the material 6 Important Do not lube the bending die surfaces This will increase the possibility for slippage 7 Caution make sure all the die cap clamp handles 3 are inside the die diameter They could catch the counter die mounting assembly and break off 8 If the material slips during the bending operation install the hook arm clamp 5 Do not use it unless you have to 9 Activate the bender and bend to the desired angle 10 To remove the material open the counter die and return bender to the home position Using a soft mallet gently tap the cap clamps open and the material will spring out of the die 1 Remove the material and re snug the cap clamps 11 Install the next piece of material to be bent and repeat steps 1 9 d LARGE DIAMETER SQUARE When bending large diameter thinner wall square tubing the counter die position seems to work better between 2 and 1 farther away from the die This seems do reduce side wall distortion and inner wrinkling Although this suggestion is to help on large diameter the same steps can be used for any square if trying to achieve better results If the square material slips in the hook arm use the supplied clamp and bolts to hold in place 16 TY 1 2 3 5 7 CDM 006 25THCKSQC DEMOUNT 1 8 165 30500 625 X 3 0 STUD NEN NN 5 6 NEN O UI DIMENSIONS ARE IN INCHES DATE DIMENSONS
6. Die sets are excluded from warranty 3 Machine maintenance adjustments setups or downtime costs are excluded from warranty Rusch Machine amp Design Inc will in no event be liable for incidental or conseguential damages c Conditions 1 All warranty work must be approved by RMD Inc 2 All defective items must be returned to RMD Inc for inspection 3 Customer pays freight travel and all other associated costs other than parts and labor d Extended Parts Warranty All electrical components and gearboxes carry a one year replacement warranty from manufacturer Replacement labor not included Customer pays freight costs Any questions pertaining to this limited warranty should be addressed to Rusch Machine amp Design Inc P O Box 375 Two Rivers WI 54241 20 Legend L Arc length outside R Rise inside D Tube outside diameter t Tube wall thickness a First bend arc angle H Height of offset b Second bend arc angle L Length of offset A First tangent R1 First radius B Straight between bends R2 Second radius C Second tangent t Tube Wall Thickness D Tube outside diameter 21 Appendix B Glossary of Commonly Used Terms Arc Length The length of material along the centerline of the tubing Centerline Radius CLR Distance in inches from the center of curvature to the centerline axis of the tube bending or pipe bending bends Abbreviated as CLR See Tube Bending and Pi
7. Red for metric and Gray for square or rectangle tubing See pipe sizing chart Wall thickness is too thin 24 Key 1 Key 2 Key 3 Key 4 A Key 6 Key 5 Key 8 XLE 1 RMD startup screen Key 7 P E I 4 gt _ 1 Key 11 Key 10 Key 9 29 A y XLE 2 Program Selection Screen XLE 3 Edit Program screen MADE IN U S A AHUAL XLE 4 Manual Bend XLE 5 Edit Screen 26 MADE IN U S A XLE 6 Edit Screen XLE 7 Part Count Memory 27 Actual Machine Position MADE IN U 5 A Counterdie Position Bend Angle Springback Material Rotation T ne 2 gt E 22 8 iJ S if Bend Sequence in Program of Bends Completed XLE 8 Run Program Screen 28 XLE 9 Run Program Screen XLE 10 Run Program Screen XLE 11 Run Program Screen XLE 12 Run Program Screen 29 MADE IN U S A 550 U MADE IN U S A Contact Info Wersion 1 01 fiurch Machine Derinn Inc PI pss pl 1311 Columbur Street TY Tus Rivers HI Horne Position 320 Tiz 29356 xU XLE 13 Contact Information XLE 14 Machine Homing Screen aas MADE IN usa USE PEDALS SET HOME HOLD 1 TO SAVE XLE 15 Homing Instruction Screen 30 MADE IN U S A r Tupe Password amp Press Enter FIG Choose One System Motor Settings 3 Contact
8. The electrical connection must be inspected by a certified electrician and the incoming voltage must be verified to be correct before the machine is turned on Have a certified electrician verify that the power source is correct for the machine s specifications and that the plug is correct and properly grounded to an earth ground The warranty is void if Incorrect power is supplied to the machine iv The machine is supplied with a lockable disconnect switch the machine must be locked out for any maintenance work 6 POWER REQUIREMENTS AC Voltage 20 Amps 220V 208 240 Single Phase AC Voltage 480v 3 phase AC Voltage 575v 3 phase Frequency 60 Hz The power source cable should be protected by fuse or breaker and dedicated to this machine only 7 MAINTAINANCE I The gearbox oil should be checked monthly and changed every three years with 80 W90 gear lube ii Check periodically for leaks If a leak is detected consult RMD Inc iii On very hot days gear oil may drip from the breather this is normal expansion of the oil iv Be sure to keep the slide ways and lead screws lubricated with light hydraulic oil or equivalent v The only grease zerk on the machine feeds the main spindle bearing Grease this zerk every six months with only one pump from a standard grease gun vi Check for any worn or damaged parts and replace immediately 8 OPERATION a Programmer Overview b c i ii The Model 250 utiliz
9. 6 Edit a Use this key to enter the edit program screen XLE 3 This will also be the P R S and 7 for data entry 7 Key 7 Run a Use this key to run a desired program choose program from the program selection screen XLE 2 This button will also be the W X Y and 9 for data entry 8 Key 8 Bend a Use this Key to scroll through the bends Up This will also be used for G H I and 4 for data entry 9 Key 9 Enter a Use this key to activate a field to change add data as well as storing the data after a change is made 10 Key 10 Manual bend a Use this key to enter the manual bend screen XLE 4 11 Key 11 Edit Run Programs a Use this key to enter the program selection screen XLE 2 Here Is where you can select 1 View programs ii Edit programs iii Run programs d Creating a Program 1 From the RMD main screen XLE 1 Press Edit Run Programs 2 The Programmer selection screen will be displayed XLE 2 3 Choose a Bend using the side arrow keys or Press 1 through 5 The Program Selection will be displayed in the upper left corner 4 o change or edit the program press the Edit key 6 5 The edit screen is now displayed XLE 3 here you can enter a Program Name b Bend angle c Spring back d Speed Press the more arrow XLE 6 e Counter die position f Material Rotation Press the more arrow XLE 7 g Part count memory 6 To enter Data a Use the arrow key
10. DIE THICKNESS 00 25 2 50 0 10 0 O 19 9000 d4 00 1hf rvZ HISNY 9 371871 X3ONI UISUOOSIM SASAIY OMI NV1d 30014 S OOEN ou fuBiseq 9 uosny 438NnN ONIMVIA JING 90014 1 aan NOVYL NIVN 81 302018 4015 o Su31SVO EE EN EXT SEP 11 21 1 ii zi INNON 3al1svo H se LAN ONILSNraVv c1 831LSnrav 931 SINN E H m S 00 W LS lor N oz LJVHS XNNVUI Nid 2 ge MINHI 8 ge via YJINIOd rz 4vT109 87 MOVML A ec 133HMQNVH 5 TVINALYN 3 sm E NI ri uva dWv1o om Jie m T J 91 14VHS 30115 L ze 31V9S 1431 OL HON34M N3TIV 7 1 hon E TIAVUL LOMA 12 A339S ININISNFAV Nen 001 LV NMOHS Ld JIA EL sz 331109 A MM nn z INNON LIVHS 41 LINNON 431SVO 12 WARRANTY a Coverage 1 Rusch Machine amp Design Inc warrants to the original purchaser for use that the products sold by RMD Inc will be free from defects in workmanship and material for a period of one year from the date of purchase provided such goods are installed operated maintained and used in accordance with RMD Inc s written instructions b Exclusions 1 Ordinary wear and tear and damage from abuse neglect or alterations are not covered by this warranty THIS WARRANTY IS NULL AND VOID IF INSTRUCTIONS AND OPERATING PROCEDURES ARE NOT FOLLOWED 2
11. info Change Password XLE 1610 Password Screen XLE 1711 Password Protected Menu a EMU MADE IN U S A D MADE IN U S A Machine Machine Rotation Rotates n ERAM Bar Allow Hor OEM Dir 7 XLE 18 Bend Direction Selection XLE 19 Bend Direction Selection 31 WU MADE IN U S A MADE U S A Machine Rotation XLE 20 Bend Direction Selection XLE 21 Reverse Direction Screen 32
12. to the same exact number every time to ensure exact counter die positioning and repeatable bends 12 Figure 6 Leadscrew counter v Be sure there are no obstructions along the draw side of the material vi Be sure to leave enough material past the plastic slide to produce the desired bend f ij Figure 8 Correct amount of material left Figure 9 Maximum amount material can be pulled through the counterdie 13 n Material Removal Advancement i After the die stops at the desired angle the material needs to be removed or advanced if using an Index Table See section 11 ii Activate the reverse foot pedal momentarily to relieve pressure CAUTION DO NOT REVERSE OR HOME ALL THE WAY WITH THE COUNTER DIE UP TIGHT iii Open the counter die assembly using the three legged hand wheel allowing the removal or advancement of the material from the die and hook arm iv Once the material is removed activate the Reverse foot pedal and hold until the die reaches its home or O position If you are using an index table open the counter die and then reverse machine holding material in place Be careful when reversing with material still in die not to catch It on the hook arm of the die v Repeal previous steps for next bend in line 9 MATERIAL LAYOUT In order to create accurate parts you will have to layout the material in flat form First you will need to determine how much material is used per degree of bend Use th
13. BAILEIGH P O Box 531 Manitowoc WI 54220 Phone 920 684 4990 Fax 920 6843944 Web Biil com PLEASE FILL OUT AND RETURN IN SELF ADDRESSED ENVELOPE COMPANY NAME ADDRESS TELEPHONE CONTACT NAME MACHINE SERIAL NUMBER A COPY OF THE INSTRUCTION MANUAL AND WARRANTY HAS BEEN RECEIVED BY Signature Date Rusch Machine amp Design Ine OPERATING MANUAL FOR THE MODEL 250 PROGRAMABLE ELECTRIC TUBE PIPE BENDER 1 7 1 IMPORTANT INFORMATION AND CONTACIS 3 2 INTRODUCTION roc 3 3 SAFE TN ee N NNN ERS ANE 4 a Salely GUIDE 4 b SalelyV PIECAUNONS uu u u ee 4 4 UNPACKING u SN ans an ga A es SI asa 4 5 INSTALLING orbe m M MR S M 5 6 POWER REQUIREMENTS u REIHE e TEE 5 T MAINTAINANGE uuu uyu en cscs P ERR IE ERU 5 8 OPERATION uuu in Hb etu ERRORI EUM UM UNE 6 a Programmer Overview meterbak daens 6 b MACHINE StartUp esre e Key Functions XLE N eu laqa a ee a a 7 DIRUNDING cH 7 f Running a DIOGIAIN sis u sun ebene 8 g Manual nenne 8 h Bending and Speed Control 9 i Reselling nome DOSITION u
14. On 319 9 X3 LA La s M evi WON4 HION31 LV M3YN 0 ev 9 7X4T9 0 rd za yZ SF 6 9r Sr 6 rZ ZA ZV FO LV ZA HLOINII LNI 9F Sr 6 FZ Z8 ta y za z8 18 0 189 2 NVA VIC INOAVI 3NI1431N39 2 X3 419 1d4 70 OE X3 ma X3 14 mnm EE M evi HLONFI LV MUWA Oe On 2 2 lt Z X3 z zxu19 ea sa ig cH 0067211 nn a sasi mmm La za MUWA nOu Oe 6 ZI l hZ Sh 6 CT ET SH 6 4Z TA TV S0 70 1V ZA HLIP9N3 I LNO Appendix D Troubleshooting Problem ss Solution 2 Machine does not power up Check circuit breakers Wrong Power Check for Proper voltage Oil will expand when the gearbox gets hot causing oil to purge from the breather this is Oil leaking from Breather normal Go through the homing Home Position is not correct sequence in section Material slips in the hookarm Too much lube on material and Is transferring to the bend die clean the bend die with degreaser The counter die should be lubed only The material may need to be clamped Wrong material for the die set If the bend dies are not bolted down properly the drive pins will get damaged Replace drive pins Spindle drive pins are damaged Poor Bend Results Check proper tooling for material IE Pipe Vs Tube Green for pipe Blue for tube
15. arting the machine make sure that all workpiece and die tooling are properly installed to avoid accidents vi Operators should wear safety glasses and remove rings watches Jewelry and loose fitting clothing for their own protection while operating the machine vii Never touch switches or controls with wet hands viii Cut off the power immediately if there is electricity power breakdown ix Before proceeding with the daily operation the machine should be warmed up for approximately one minute x There must be no obstacles to obstruct the operator while in the working area xi If machine is going to be left unattended the operator should turn power off until the beginning of the next task xii Please do not put any tools or measuring devices on the moving parts of the machine or on the control panel xiii Identify and make sure of the function of the switches or buttons on the control panel and then proceed to operate them 4 UNPACKING i After receiving machine visually inspect for damage Any damage should be reported immediately to RMD Inc before power is applied to machine ii The machine weight is approximately 800 pounds Extreme care should be taken when unloading from skid A forklift is the best way to remove machine from the skid 5 INSTALLING ij Once unloaded and wheels and casters attached the machine can be wheeled to the operator s desired location ii Be sure to rest machine on a flat surface iii
16. ce ii Use a piece of two sided coarse emery cloth in between the hook arm and the material this works very well iii In only this application high pressure grease applied to the DIE GROOVE also helps ne c Bending with square dies I Die parts 1 Main bending die 2 Die cap 3 Quick release handles 4 Hookarm 5 Hookarm clamp 6 Plastic slide 7 Slide mount il Sguare Tooling Setup 1 Install the bending die 1 on to the spindle Be careful not to pinch your fingers as you lower the die on to the spindle The die will only fit on the spindle one way Bolt the die to the spindle using the holes in the die 2 Install the plastic counter die assembly 6 7 with the long end pointing away from the hook arm 3 Snug up the cap clamps 3 Do not over tighten Or they will be overly difficult to loosen after the bend is complete Note tighten clamps without material in the die The clamps are lift and turn so you can position them anywhere This allows the handles to clear the counterdie mount during bending 4 Insert the material in to the hook arm 4 and pull in to the die It may be a tight fit Continue to pull until the material is fully seated in the die s groove 15 5 Lube the counter die and the material that will slide along the counter die Bring the plastic counter die assembly up to the material leaving about 1 8 to 1 4 gap Note on some thinner material it helps to keep the counter die approx 1
17. e multiplier table on Table 1 to determine the arc lengths for the die in use Or use the following formula Alternate arc length formula k x 2 X x degree of bend 360 a Once the arc lengths are determined you can begin layout of the material using Diagram 1 as a reference b Diagram 1 shows a simple part bent on the same plane in the same direction c Diagram 2 shows bending based off of a centerline in two directions d For symmetrical bends centerline bending is easiest e For non symmetrical bends continuous one direction bending is best 10 BENDING SUGGESTIONS a ALUMINUM If bending aluminum lubrication is very important if the results are less than desirable with WD 40 other lubricants can be used such as I Johnson Paste Wax seems to work the best ii High Pressure grease iii Highly rich dish soap 14 iv he bronze counter die must be polished and have no aluminum deposits or it will continue to pick up metal v If using RMD s standard counterdie is not producing desired results roller counter dies are also available vi Some aluminum will crack as it is being bent 6061 T6 is very hard and may need to be annealed or ordered in the 0 condition b HEAVY WALL DOM TUBING If heavy wall materials are bent to a tight radius they can tend to slip in the hook arm causing a poor bend result below are some suggestions i Use a vise clamp on the outside of the hook arm to lock the material in pla
18. es a fully programmable operator interface The unique operator interface allows you to write and save 170 programs with 10 bends per program Operation is extremely simple to learn Simple foot pedal controls allow you to easily produce fast and accurate bends The following instructions will walk you through the basic functions Be sure to follow the dry running instructions to familiarize yourself with all the functions of the control before any actual bending of material is performed Machine start up i ii Turn on the main disconnect switch It takes about 1 minute for the programmer to boot up iii Once powered up the RMD main screen will be displayed XLE 1 Iv The bender comes with the home position preset from the factory The control will remember its position unless the encoder or any of the spindle mechanics are disassembled If the home position is lost it can be reset see section i Key Functions XLE 1 i The programmer keys are labeled for easy navigation 1 Key 1 Main Exit a Returns to main screen and goes back one screen at a time 2 Key 2 System OEM a Directs you to the contact page as well as OEM password protected screens 3 Key 3 Cancel a Cancels an Entry 4 Key 4 Save a Use this Key to save changes This will also be an O Z and 1 for data entry 5 Key 5 Bend Use this key to scroll through bends down will also be A B and 2 for data entry 6 Key
19. gure 2 Hold down bolts on the die FAILURE TO PROPERLY BOLT DOWN DIE WILL RESULT IN DAMAGE TO MACHINE To install the counter die Remove the hitch pin amp insert the counter die in the opening in the counter die mount until the 34 holes line up Now insert the hitch pin through all the holes reinstall clip on the hitch pin with the engraved side of the counter die facing up Figure 3 Installing counter die 11 IMPORTANT Be sure the long end of the counter die points away from the hook arm or to the right of machine m Material Insertion i Atthe start page choose RUN PROGRAM and choose program to run following screen instructions ii Once the die set is properly installed and the desired program is loaded and performs as needed the correct size material can now be inserted Figure 4Lubricating counterdie Figure 5 inserting material to start bending With the die head at home or 0 position insert material past the hook arm aligning the 0 mark on the die with where the bend will start on the material IMPORTANT Liberally apply lubricant along the material and counter die with a WD 40 style lubricant or equivalent Do not lubricate the die Lubricating the die will encourage slipping of material in the die iii Tighten the counter die assembly applying moderate pressure on the material iv With the counter die tight document the number displayed on the leadscrew counter you will want to return
20. ipe Schedules and Wall Thickness amp Std E H E a 0400 0 050 0 050 0 068 098 095 0 100 0 050 0 088 0 090 0 119 0 120 a 3 8 0 675 0 050 0 090 0 126 0 130 All sizes are in inches 23 TABLE 1 ARC LENGTH TABLE EXAMPLE ARC LENGTH CONSTANT X BEND RADIUS EXAMPLE 90DEG BEND WITH 6 CLR EXAMPLE 1 575 FROM TABLE X 6 CLR 9 45 ARC LENGTH FOR BENDS MORE THAN 90 DEG CONSTANTS CAN BE ADDED TOGETHER DEGREES CONSTANT DEGREES CONSTANT DEGREES CONSTANT 1 00175 31 0 5410 61 10645 2 0 049 32 0 5584 62 1 08199 3 0 0524 33 0 5759 63 1 0994 24 0 0698 34 0 5933 11168 64 5 0 0873 35 0 6108 65 1 1333 6 01047 36 0 6282 66 1 1517 7 01222 37 0647 67 14692 8 0 1396 38 0 6631 68 1 1866 __ 9 01571 39 0 6806 69 1 20931 10 0 1745 40 0 6980 70 1 2205 11 01920 41 0 7155 71 12390 12 02094 42 0739 72 1 2564 _ 13 0 2269 43 0 7504 73 1 2739 _ 14 0 2443 44 1 2913 15 02618 45 0 7853 75 1 308 16 0 2792 46 0 8027 76 13262 _ 18 03141 48 0 8376 78 1 3611 19 49 0 8551 79 1 37860 1 3960 0 5061 59 1 0296 89 1 5531 0 5285 60 1 0470 90 1 5700 N Ve VI 1NOAVI SNONILNOO ss x3 ed 17 X3 419 1d4 70 oe X3 YHVN
21. o run this machine in the counter clockwise direction ii Contact Rusch Machine amp Design Inc for applications and Password XLE 16 21 k Bending More than 180 degrees I This machine is capable of bending more than 180 degrees contact Rusch Machine amp Design about your application I Die Selection and Installation Damaged or worn tooling should be replaced before attempting to bend material This will ensure that bends are correct and provide a longer life to machine components Before any bending can take place the proper die set must be chosen to match the material being bent EX 1 1 2 diameter tubing requires a die set marked 1 1 2 tube Note Pipe and Tube are not the same see chart in appendix c for nominal pipe sizes All RMD dies are color coded to avoid confusion between tube and pipe Color Green Red Caution When installing large dies use either a mechanical lift or a fork lift to prevent serious personal injury EL Figure 1 Spindle drive pins and hold down bolts 10 i To install the die slip the die over the centering pin until the three unequally spaced drive pins engage the receiving holes formed in the die Note The die will only fit one way When the drive pins line up the die will drop all the way down to the spindle If bolt holes are provided in the die ensure that the die is bolted to the spindle with the 2 13 bolts and lock washers provided with the die Fi
22. on Fig 6 8 Bend Sequence number out of a possible 10 bends for the program 9 Number of completed bends vill the information displayed is correct activate the forward foot pedal control The degree counter will display the current degrees and will stop at the programmed degree of the bend Degrees plus the additional springback value ix At this point activate and hold the foot pedal control until the screen displays Bend is done The machine position will be 0 0 to 0 4 this amount of variance is OK and it does not affect the accuracy of the machine x The programmer will automatically switch to the next bend in the sequence The parameters for that bend will be displayed on the screen xi Repeat steps viii and ix until all bend for the program are completed The sequencing will restart to the first bend in the sequence after the last bend is completed xii If it is required to skip past bend in a sequence or to start on a different bend sequence simply press the Bend Key 5 or Bend Key 8 on the bend keys until the desired bend in the sequence is displayed 9 Manual Mode 1 The manual bend mode allows the user to preset one bend angle for quick bending 2 From the RMD main screen XLE 1 Press Manual Bend key 10 3 The Manual Bend screen will be displayed XLE 4 4 These are the fields that can be changed a Bend angle b Spring back c Bend Speed 5 ente
23. ount 12 onto the leg adjuster 13 Height Adjustment and Leveling I Level your machine on a flat hard surface The index table must be allowed to pivot and rotate with the casters ii With the machine level choose the desired die set iii The thickness of the die determines the height of the index table Using the chart shown below find the correct number of turns required for your die iv Rotate the height adjustment screw 21 clockwise until it stops This is the lowest the table will go EXAMPLE 1 1 2 die v Rotate the adjustment screw 21 counter clockwise the exact number of turns that were chosen from the chart vi Using a 2 ft level placed on the main track tube rotate the large nut 35 until the main track tube is level vii Position the front of the main track tube so the center line of the track tube matches the center radius line of the die viii The Chuck Gearbox assembly is designed to pivot on its mount tension Is adjusted with spring washers beneath the 2 12 13 mounting bolts 17 d e Material layout i Before you can use the IDX table your first piece of material needs to be laid out Using Diagram1 and Table1 you can determine all of the bend start points these points should be transferred to the material using a fine point sharpie marker This diagram is a generic two bend scenario for more complex parts the steps are generally the same Use section 10 for further reference
24. pe Bending Diagram Degree Angle in degrees to which the tube pipe bends are formed i e 45 degrees 90 degrees 180 degrees etc Easy Way EW Bending of a rectangular tube with its short side in the plane of the tube or pipe bend Hard Way HW Bending of a rectangular tube with its long side in the plane of the tube or pipe bend I D Inside diameter of the tube or pipe bends Minimum Tangent The minimum straight on the end of pipe bends required by the bending machine to form the bend Neutral Axis That portion of the pipe or tube that is neither in compression or tension O D Outside diameter in inches of the tube or pipe Out of Plane The deviation of the horizontal plane of a single pipe bend between its tangent points based on the theoretical center line of the pipe bend Ovality The distortion or flattening of pipe or tube from its normal round shape caused by the pipe bending process Springback Amount of degrees material will return after bending pressure is released Tangent The straight portion of material on either side of arc of bending bends See Tube Bending and Pipe Bending Diagrams Tangent Point The point at which the bend starts or ends See Tube Bending and Pipe Bending Diagrams Wall The thickness in inches of tubular pipe bending material Wrinkles Waving or corrugation of pipe bending bends in the inner radius 22 Appendix C Pipe OD and Wall Thickness Chart Pipe P
25. r or change data use the arrow keys to put the dashed selection box around the field that you are changing Press enter this allows the data to be changed Using the numerical keys enter in the desired data Press enter again to store the data 6 Also displayed on this screen are a Actual machine position b Analog degree indicator c Amperage Draw Machine Load 7 To run the program activate the foot pedals as in the previous steps h Bending and Speed Control I After the desired degree is programmed bending can take place ii Follow previous steps iii Keep hands away from the bending zone iv Press and hold the forward foot pedal until bend is complete v Always start out using slower speeds with heavier material and increase as needed Resetting home position i If the home position is lost it can be reset ii From the RMD main screen XLE 1 press System OEM Key 2 The RMD contact page will be displayed XLE 13 iii Press the arrow right key and the homing screen will be displayed XLE 14 iv Press the 0 key and the home setting screen will be displayed XLE 14 v Follow the directions on the screen to position the spindle back to 0 degrees vi Save the new position by holding the Save Key Don t Change the home position unless you are sure the position was lost damage to the machine and tooling can occur ifthe home position is set incorrectly Reverse Machine Operation i lis possible t
26. s to put the dashed selection box around the field that you are changing XLE3 5 Press enter this allows the data to be changed Using the numerical keys enter in the desired data Press enter again to store the data e Dry Running i Once you are familiar with the machine and programming unit it is important to dry run a few programs without any tooling installed ii Follow the next steps In sections F and G to produce a generic bend and dry run without material iii Repeat this process as many times as needed to fully understand the functions and controls f DO NOT ATTEMT TO OPERATE IF YOU ARE NOT CONFIDENT OR DON T UNDERSTAND THE CONTROLS iv Feel free to consult the factory with any questions Running a program i From the RMD main screen XLE 1 press Edit Run Programs Key 11 ii The Program Selection Screen XLE 2 will be displayed iii Select the program you want to run using the side arrow keys or by pressing the 1 5 keys iv The selected program will be displayed in the upper left box v Once the desired program is selected press the run key Key 7 vi The run program screen XLE 8 will now be displayed vii This screen will give you all of the information needed for this particular bend 1 Actual machine position 2 Program name 3 Programmed bend angle 4 Spring Back 5 Material rotation 6 Speed 7 Counterdie Position This correlates to the leadscrew counter positi
27. shape of the bending die iii The Model 250 Bending Machine you have purchased is built of solid steel ensuring maximum rigidity Tongue and groove design with grade 8 bolts throughout provides very high rigidity and stability IV In the next chapter of this manual there are safety related descriptions for attention Ihese matters for attention contain the essential Information to the operators while operating and maintaining Failure to follow these instructions may result in great damage to the machine or the operator 3 SAFETY a Safety Guide b i Read this manual before operating the machine Carefully read the safety guide for doing safety work ii Keep this manual handy for answers to any questions you may have Store it near the machine to be usable in the future iii Operators and maintenance workers shall not depend on only the safety equipment They shall familiarize and understand the machine before operating and maintaining the machine Safety Precautions i Before being engaged in operating this machine please read and understand the entire instruction manual and follow all the warning signs labeled on the machine Do not disfigure or remove ii During operation please do not expose any of your body parts near to the moving parts of the machine iii Never touch workpiece tooling or spindle unless the spindle stops completely iv Before operation make sure all the guards are in place v Before st
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