Bench Top Tube Bender User`s Manual, (MS-13-145, R5)
Contents
1. Metric Tubing continued Dimensions are in millimeters 18 mm OD 56 mm Bend Radius 56 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bench Top Bender User s Manual Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 8 8 16 14 14 28 22 1 2 11 12 23 17 18 35 30 14 16 30 20 22 42 45 20 24 44 27 30 57 60 25 33 58 32 39 71 75 28 44 72 35 50 85 90 29 57 86 36 63 99 74 81 98 20 mm OD 67 mm Bend Radius 67 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 3 4 7 1 2 3 22 1 2 7 8 15 5 6 12 30 11 13 24 9 11 20 45 18 23 41 17 21 38 60 24 34 57 23 32 55 75 28 46 74 28 44 72 90 29 62 91 29 60 89 27 81 27 79 16 17 12 10 83 80 25 26 Bench Top Bender User s Manual2. 32 Bench Top Bender User s Manual Fractional Tubing with Metric Dimensions continued Tube OD is in inches Bend radius bend shoe and bend dimensions are in millimeters 1 1 4 in OD 112 mm Bend Radius 112 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Steel Bend Shoe Angle Bend Bend Bend Degrees Allowance Deduction Length 15 20 22 42 22 1 2 27 29 56 30 33 37 70 45 45 53 98 60 54 72 75 61 93 90 63 56 35 15 Bench Top Bender User s Manual 33 Minimum Length of Last Leg During bending both rollers must remain on the tube until the desired bend angle is achieved If the length of tube is too short the bend may not reach its desired angle or the end of the tube may be damaged Specifying a final leg length equal to or greater than the minimum length of last leg length in the following tables will ensure a sufficient amount of tube exists to allow the final bend to be made correctly Minimum Length of Last Leg Tables Fractional Tubing Dimensions are in inches Aluminum Bend Shoe Tube OD 1 4 3 8 1 2 5 8 3 4 7 8 1 Bend Radius 1 42 1 42 1 42 1 81 2 20 2 64 3 23 15 2 9 16 2 1 2 2 11 16 3 1 2 4 1 4 311 16 411 16 22 1 2 211 16 2 5 8 2 13 16 3 5 8 4 7 16 3 7 8 4 7 8 30 2 3 4 2 3 4 2 7 8 3 3 4 4 9 16 41 16 5 1 8 45 215 16 215 16 31 16 4 4 7 8 47 16 5 9 16 60 3 3 16 3 3 16 3 5 16 45 16 5 1 4 47 8 6 1 8
3. 3 4 in OD 2 20 in Bend Radius 56 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 3 8 3 8 3 4 1 2 9 16 11 16 22 1 2 1 2 9 16 1 5 8 11 16 15 16 30 5 8 11 16 15 16 3 4 13 16 1 5 8 45 7 8 1 17 8 1 13 16 2 3 16 60 11 16 13 8 2 7 16 11 4 1 1 2 2 3 4 75 13 16 1 13 16 2 15 16 13 8 1 15 16 3 5 16 90 11 4 2 5 16 3 1 2 17 16 2 7 16 3 7 8 11 8 3 41 16 11 4 3 3 16 47 16 11 16 3 15 16 4 5 8 13 16 4 1 8 5 1 4 5 7 16 5 3 16 1 8 5 11 16 5 9 16 2 5 8 8 3 8 5 3 4 2 1 2 8 5 8 6 1 8 10 9 16 16 7 8 6 5 16 10 1 2 17 3 16 6 11 16 49 16 2 5 16 6 7 8 4 3 4 2 7 16 7 1 4 20 Bench Top Bender User s Manual Fractional Tubing continued Dimensions are in inches 7 8 in OD 2 64 in Bend Radius 67 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 1 4 1 4 1 2 0 0 0 22 1 2 3 8 7 16 13 16 1 8 3 16 5 16 30 9 16 5 8 13 16 5 16 3 8 11 16 45 7 8 1 17 8 9 16 3 4 15 16 60 1 1 8 17 16 2 9 16 13 16 13 16 2 75 1 5 16 1 15 16 3 3 16 1 111 16 2 11 16 90 13 8 2 9 16 3 7 8 11 16 2 5 16 3 3 8 11 4 3 5 16 49 16 1 3 1 16 41 16 13 16 47 16 5 1 4 5 8 4 1 8 411 16 5 16 6 1 4 5
4. Carbon steel stainless steel 30 mm All Heavy walled stainless steel All All Cold drawn 1 8 hard stainless steel SAF 2507 All All Alloy 625 All All All All 38 Bench Top Bender User s Manual Accessories Manual Model MS BTB A TC MS BTB A SA Torque Clutch Support Arm Allows 1 2 in electric or pneumatic drill motor to be used in Must be used with torque clutch to support drill motor place of hand crank on manual bender Electric Model All Models MS BTB A FS MS BTB A TP Foot Switch Collapsible Tripod Operates the electric bender in place of the toggle switch Description Ordering Number Tripod MS BTB A TP Manual bender using torque clutch support arm and collapsible tripod with customer electric drill motor Torque clutch MS BTB A TC Support arm MS BTB A SA Foot pedal MS BTB A FS A CAUTION Torque clutch and support arm must be used together for safe operation Achieving Quality Bends Bench Top Bender User s Manual 39 E Always use the correct size bend shoes and rollers for the tube you are bending E Make sure the correct radius bend shoe is used for the wall thickness of the tube that you are bending Tube with less than the recommended wall thickness can be bent properly using a bend shoe with a larger radius E The pressure between the bend shoe and the rollers must be correct You must apply sufficient pressure to avoid wr
5. Roller bracket lever Hand crank Calibration Calibration is the process of positioning the bend degree wheel to accurately display the angle being generated by the bender Calibration accounts for tube variables and mechanical play in the bender which is typically observed as springback Different materials different lots of the same material and different wall thicknesses of the same material may exhibit different bend characteristics Once the bender has been calibrated recalibration is recommended whenever m OD or wall thickness of tube being bent is changed m The roller knob has been turned after Calibration completed m The bend degree wheel does not accurately display the bend angle 1 Place the hand crank on the desired speed selector for the tube being bent m Low bend speed selector 1 is suggested for large diameter or heavy wall tube m Medium bend speed selector 2 is suggested for intermediate size and medium wall tube m High bend speed selector 3 is suggested for small diameter and thin wall tube 2 Slowly rotate the hand crank until the tube begins to deflect or bend looking to the right of the rollers m On low 1 and high 3 bend speeds rotate the hand crank clockwise m On medium 2 bend speed rotate the hand crank counter clockwise Bench Top Bender User s Manual 9 3 Keep the hand crank still and rotate the bend degree The bend angle indicated on the bend degree wheel will
6. Once the bender has been calibrated recalibration is recommended whenever m OD or wall thickness of tube being bent is changed m The roller knob has been turned after Calibration has been completed 1 Set the right most bend angle thumb wheel to the value noted in step 12 of Setup Hold the toggle switch in the bend direction until the motor stops do not jog the switch 2 Carefully insert the tube into the bend shoe past the clamp arm CAUTION The end of the tube must extend past the right edge of the clamp arm to prevent potential damage to the tube during bending Bend shoe Clamp arm 3 Turn the roller bracket lever clockwise until the roller bracket assembly stop makes contact with the bracket post stop Roller bracket assembly stop Bracket post stop 4 Hold the tube in the bend shoe and turn the roller knob clockwise until the G and D rollers both make contact with the tube Note The rollers may need to be guided onto smaller diameter tubing Note The clearance between the D roller and the clamp arm will now be approximately 1 4 in Note Do not turn the roller knob after this point or bend consistency will be affected 5 Set the bend angle thumb wheels to the desired bend angle 6 Hold the toggle switch in the bend direction until the motor stops do not jog the switch CAUTION PINCH POINT 7 Unload the bender see Unloading the Bender and measure the bend angle of t
7. 125 8 15 15 16 8 5 8 8 3 4 8 5 8 811 16 87 16 8 3 8 127 16 105 16 12 3 8 13 11 16 16 15 16 21 13 16 14 1 8 14 1 4 14 1 8 143 16 1315 16 137 8 2015 16 173 8 20 15 16 23 7 8 29 3 8 38 7 8 411 16 4 3 4 4 7 8 4 3 4 4 5 8 4 9 16 6 3 16 5 1 4 6 3 16 6 3 4 8 1 16 9 9 16 n oO 2 D oO ia S D i lt ge o m 34 Bench Top Bender User s Manual Minimum Length of Last Leg Tables Metric Tubing Dimensions are in millimeters Aluminum Bend Shoe Tube OD Bend Radius 15 22 1 2 30 45 60 75 90 Bend Angle Degrees Steel Bend Shoe Tube OD Bend Radius 15 22 1 2 30 45 60 75 90 n O z D O Q C D lt ge 0 a Bench Top Bender User s Manual 35 Minimum Length of Last Leg Tables Fractional Tubing with Metric Dimensions Tube OD is in inches Bend radius and length are in millimeters Aluminum Bend Shoe Tube OD Bend Radius 15 22 1 2 30 45 60 75 90 Bend Angle Degrees Steel Bend Shoe 1 4 3 8 1 2 Medium Medium Medium Tube OD Pressure Pressure Pressure Bend Radius 36 36 36 15 89 89 85 22 1 2 91 91 87 30 94 94 90 45 99 99 95
8. 2 13 16 1 5 16 41 16 3 1 16 3 8 in OD 1 42 in Bend Radius 36 mm Bend Shoe Bend Angle Degrees 1 9 16 Carbon Steel and Stainless Steel Tubing 49 16 3 3 16 1 5 8 4 3 4 Medium Pressure Tubing Aluminum Bend Shoe Steel Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 1 16 1 16 1 16 1 16 1 16 1 8 5 16 5 16 5 8 22 1 2 0 1 16 1 8 1 8 3 16 5 16 3 8 7 16 13 16 30 1 8 1 8 5 16 1 4 1 4 1 2 7 16 1 2 15 16 45 1 4 5 16 11 16 3 8 7 16 7 8 5 8 11 16 15 16 60 7 16 9 16 1 1 2 11 16 13 16 3 4 15 16 111 16 75 1 2 13 16 1 3 8 5 8 15 16 19 16 13 16 13 16 2 90 9 16 13 16 1 3 4 5 8 1 5 16 1 15 16 13 16 1 9 16 2 3 8 9 16 1 9 16 2 1 8 5 8 111 16 2 5 16 3 4 2 2 3 4 3 8 2 1 8 2 1 2 3 8 2 5 16 2 11 16 1 2 2 5 8 3 1 8 3 16 3 1 16 2 7 8 3 16 3 1 4 3 1 16 3 16 3 5 8 3 7 16 1 11 16 4 7 8 3 1 4 1 11 16 5 1 16 3 7 16 1 11 16 5 1 2 3 13 16 6 3 4 10 5 16 3 5 8 6 3 4 10 9 16 3 13 16 6 7 8 11 43 16
9. 60 75 90 wn oO D o Q S 2 me 0 a 36 Bench Top Bender User s Manual Maintenance All Models Using the supplied grease gun grease the two points on the upper gearbox of the bender after every 24 hours of operation Grease points The grease must be a high grade multipurpose grease meeting Castrol Molub Alloy 860 220 1 ES or Tribol 4020 220 1 specifications Electric bender motor brush replacements are available for use in the field Any other repairs to the electric or manual tube bender are to be made by a Swagelok authorized service center Swagelok reserves the right not to make repairs in situations where the bender has been altered Electric Models Inspect components for wear or damage periodically Motor Brush Inspection Removal and Replacement The motor brushes should be inspected for wear after every 800 hours of operation or every six months and replaced when their length is 1 4 in 6 4 mm or less A WARNING Remove unit from power source A CAUTION The motor brushes are under spring tension A CAUTION Serious damage may occur to the motor if brushes are not replaced when worn 1 Turn the bender over Remove the four socket head cap screws using a 5 mm hex key Socket head Socket head a w cap screws cap screws iva Motor brushes 3 Using a flat screwdriver or a s
10. 9 16 11 1 16 10 1 2 5 5 16 16 15 16 11 9 16 21 5 16 34 12 11 16 9 1 8 4 11 16 13 13 16 Bench Top Bender User s Manual 21 22 Bench Top Bender User s Manual Metric Tubing Dimensions are in millimeters 6 mm OD 36 mm Bend Radius 36 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 0 i 8 9 17 22 1 2 1 2 4 10 11 22 30 4 5 8 13 14 26 45 7 10 17 16 19 35 60 11 16 26 20 25 44 75 13 23 35 22 32 53 90 31 45 23 40 63 41 54 52 72 56 63 68 81 79 72 93 90 81 99 90 99 10 mm OD 36 mm Bend Radius 36 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 1 0 1 4 5 9 22 1 2 1 2 4 6 7 13 30 4 5 8 8 10 18 45 7 10 17 11 15 26 60 11 16 26 14 21 35 75 13 23 35
11. Bender 8 Verify the bend angle see Measuring the Bend Angle Make adjustments if necessary see Calibration 9 Use the hand crank on the high bend speed selector 3 to return the bend shoe to the starting position Bench Top Bender User s Manual 11 Electric Bender Roller pins Poller 2 bracket Product Information assembly Bend shoe Roller knob Carrying handle a Power cord Foot switch receptacle Toggle switch Bend angle thumb wheels UNLOAD BEND Overload indicator Zero reference mark A AAE D pin a D roller 3 5 Bend shoe Q H oe G pin Ze G roller Bs vA Reference mark Bracket pin Roller bracket z Siamp arm Bracket post Support bracket Aluminum only Bracket assembly stop recommended when using 1 in or 25 mm bend shoe Bracket post stop Roller bracket lever Roller knob 12 Bench Top Bender User s Manual Electric bender must be operated in a safe environment to avoid risk of fire explosion or electric shock A WARNING Voltage greater than 30 V ac is present A WARNING KEEP DRY Do not expose the equipment to water or wet locations ZX WARNING FIRE OR EXPLOSION Do not use equipment in a combustible or explosive atmosphere Flammable liquids or gases could ignite Grounding and Extension Cord Information A WARNING Electric bender must be grounded against electrical shock It is equipped with a three wire cond
12. using a bender that was calibrated to make a 90 bend the resulting bend may be larger than desired Conversely if a 150 bend is attempted on the same bender the resulting bend may be smaller than desired It is advised to verify each bend angle Unloading the Bender Note Do not turn the roller knob to unload the bender Doing so will affect bend consistency 1 Hold the toggle switch in the unload position until the motor stops While holding the toggle switch gently turn the roller bracket lever counter clockwise until the rollers swing away from the tube Note Do not force the roller bracket lever Roller bracket lever Toggle switch 2 Hold the tube until the motor stops and the tube can be removed from the bender Operation Before operating the bender mark the tube see Bend Layout and follow the Setup and Calbration procedures A CAUTION PINCH POINTS 1 Set the bend angle thumb wheels to the value noted in step 12 of Setup Bend angle thumb wheels Example only 2 Hold the toggle switch in the bend direction until the motor stops do not jog the switch 3 Set the bend angle thumb wheels to the desired bend angle plus or minus the amount noted in step 8 of Calibration Bend angle thumb wheels Example only 4 Carefully insert the tube into the bend shoe past the clamp arm A Caution The end of the tube must extend past the right edge of the tube clamp support are
13. 15 16 7 16 5 7 8 5 3 8 3 1 16 9 11 16 6 5 8 3 3 16 9 1 4 6 1 16 12 9 16 19 7 8 7 5 16 12 11 16 19 7 16 6 3 4 5 7 16 2 9 16 8 5 1 8 2 5 16 7 7 16 1 in OD 3 23 in Bend Radius 82 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 15 16 15 16 1 13 16 1 2 1 2 15 16 22 1 2 11 8 11 8 2 1 4 11 16 11 16 1 3 8 30 15 16 13 8 2 11 16 7 8 15 16 1 13 16 45 111 16 1 13 16 3 1 2 11 4 13 8 2 5 8 60 2 2 3 8 4 3 8 19 16 1 15 16 3 7 16 75 2 1 4 3 5 1 4 1 3 4 2 9 16 45 16 90 25 16 3 3 4 6 1 16 1 13 16 3 5 16 5 1 8 2 1 8 4 13 16 6 15 16 111 16 45 16 6 11 2 6 1 4 7 3 4 11 8 5 11 16 6 13 16 1 16 8 9 16 8 5 8 1 4 7 7 8 7 5 8 3 7 16 12 7 8 9 7 16 3 11 16 12 3 16 8 1 2 15 1 8 25 7 16 10 5 16 15 5 16 24 5 8 9 5 16 7 7 16 3 3 4 11 1 8 6 7 8 3 5 16 10 1 8 Fractional Tubing continued Dimensions are in inches 1 1 4 in OD 4 41 in Bend Radius 112 mm Bend Shoe Standard Tubing Bend Carbon Steel and Stainless Steel Tubing Angle Bend Bend Bend Degrees Allowance Deduction Length 15 13 16 7 8 111 16 22 1 2 11 16 13 16 2 3 16 30 15 16 17 16 2 3 4 45 1 3 4 2 1 8 3 7 8 60 2 1 8 2 13 16 5 75 2 7 16 3 11 16 6 1 16 90 2 1 2 411 16 7 3 16 2 3 16 6 1 16 8 1 4 13 8 8 9 3 8
14. 16 28 44 90 31 45 36 53 41 54 47 61 56 63 62 70 79 72 87 79 81 88 90 96 99 Metric Tubing continued Dimensions are in millimeters 12 mm OD 36 mm Bend Radius 36 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bench Top Bender User s Manual Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 3 5 1 2 3 22 1 2 0 3 4 8 30 2 4 5 7 12 45 5 13 9 12 21 60 9 22 12 18 30 75 11 31 14 25 39 90 41 33 48 50 43 57 59 58 66 68 82 75 77 84 86 93 95 14 mm OD 46 mm Bend Radius 46 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 5 6 11 8 9 17 22 1 2 8 9 17 11 12 23 30 11 12 23 13 15 29 45 16 19 35 18 22 40 60 20 26 47 22 30 52 75 24 35 58 25 38 63 90 25 46 70 25
15. 2 13 16 13 16 3 15 16 2 7 8 1 5 16 4 1 8 3 1 9 16 4 1 2 18 Bench Top Bender User s Manual Fractional Tubing continued Dimensions are in inches 1 2 in OD 1 42 in Bend Radius 36 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Medium Pressure Tubing Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 1 16 1 16 1 8 1 8 1 8 1 4 1 16 1 16 3 16 22 1 2 0 1 16 1 16 3 16 1 4 7 16 3 16 3 16 3 8 30 1 16 1 8 3 16 1 4 5 16 9 16 1 4 5 16 9 16 45 1 4 5 16 9 16 7 16 1 2 15 16 3 8 1 2 7 8 60 3 8 9 16 15 16 9 16 3 4 15 16 9 16 3 4 1 1 4 75 7 16 13 16 1 1 4 5 8 1 1 5 8 5 8 1 1 5 8 90 7 16 13 16 1 5 8 5 8 13 8 2 5 8 1 5 16 2 7 16 1 9 16 2 9 16 1 3 4 2 3 8 5 8 1 3 4 2 5 16 1 4 2 1 8 2 3 8 3 8 2 3 8 2 3 4 3 8 2 5 16 2 11 16 3 8 3 1 16 2 11 16 1 4 3 5 16 3 1 16 1 4 3 5 16 3 1 16 1 13 16 4 7 8 3 1 16 1 3 4 5 3 16 3 7 16 1 11 16 5 1 8 3 7 16 6 15 16 10 5 16 3
16. 49 74 59 82 63 86 79 94 84 97 23 24 Bench Top Bender User s Manual Metric Tubing continued Dimensions are in millimeters 15 mm OD 46 mm Bend Radius 46 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 4 5 9 8 9 17 22 1 2 7 8 15 11 12 23 30 10 11 21 14 15 29 45 15 18 32 19 22 41 60 19 25 44 23 29 53 75 22 34 56 27 38 64 90 23 45 68 28 49 76 58 80 63 88 78 91 83 16 mm OD 46 mm Bend Radius 46 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 5 6 11 6 6 12 22 1 2 8 9 16 8 9 18 30 10 12 22 11 12 23 45 15 19 34 16 19 35 60 19 26 46 20 27 47 75 22 35 57 23 35 59 90 23 46 69 24 46 70 59 80 60 82 79 92 80 94
17. 7 16 6 7 8 10 11 16 3 13 16 6 13 16 10 5 8 3 13 16 2 5 8 13 16 3 3 4 2 13 16 1 2 in OD 2 20 in Bend Radius 56 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Steel Bend Shoe Bend Allowance Bend Deduction Bend Length 13 8 4 1 8 2 13 16 1 5 16 4 1 8 60 15 16 1 5 8 2 15 16 75 17 16 2 1 16 3 1 2 90 11 2 2 9 16 41 16 105 1 5 16 3 1 4 4 5 8 120 7 8 4 1 4 5 3 16 135 1 8 5 13 16 5 3 4 150 2 1 2 8 13 16 6 5 16 165 10 1 2 17 5 16 6 7 8 180 4 7 8 2 9 16 7 7 16 Bench Top Bender User s Manual 19 Fractional Tubing continued Dimensions are in inches 5 8 in OD 1 81 in Bend Radius 46 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 3 16 3 16 3 8 3 8 3 8 3 4 22 1 2 5 16 5 16 5 8 1 2 1 2 1 30 3 8 7 16 7 8 9 16 5 8 13 16 45 9 16 11 16 15 16 3 4 7 8 111 16 60 3 4 1 1 3 4 15 16 13 16 2 1 8 75 7 8 13 8 2 1 4 11 16 1 9 16 2 9 16 90 15 16 1 3 4 2 11 16 11 16 1 15 16 3 13 16 2 5 16 3 1 8 15 16 2 9 16 3 1 2 1 2 3 1 16 3 5 8 9 16 3 5 16 3 15 16 1 4 45 16 41 16 3 16 4 5 8 4 3 8 2 3 16 6 11 16 4 1 2 2 3 16 7 4 13 16 8 11 16 13 11 16 5 8 3 4 14 1 16 5 5 16 3 11 16 1 3 4 5 7 16 3 13 16 1 15 16 5 3 4
18. 75 3 7 16 3 7 16 39 16 411 16 511 16 5 3 8 6 3 4 90 3 13 16 3 3 4 315 16 51 16 6 3 16 6 7 1 2 43 16 43 16 45 16 5 5 8 6 7 8 6 3 4 8 9 16 4 13 16 4 3 4 4 7 8 6 3 8 7 13 16 7 7 8 10 5 3 4 511 16 5 13 16 7 5 8 95 16 911 16 125 16 7 9 16 7 1 2 7 5 8 10 12 1 4 13 1 8 16 5 8 131 16 12 15 16 13 1 16 17 20 3 4 235 16 293 16 3 13 16 3 3 4 315 16 51 16 6 3 16 6 7 1 2 Bend Angle Degrees Steel Bend Shoe 1 4 3 8 1 2 Medium Medium Medium Tube OD 1 4 Pressure 3 8 Pressure 1 2 Pressure 1 2 5 8 3 4 7 8 1 11 4 Bend Radius 1 42 1 42 1 42 1 42 1 42 1 42 2 20 1 81 2 20 2 64 3 23 4 41 15 3 7 16 3 1 2 3 5 8 3 1 2 3 3 8 3 5 16 4 1 4 311 16 45 16 47 16 5 1 4 5 3 4 22 1 2 39 16 3 5 8 3 3 4 3 5 8 3 1 2 3 7 16 47 16 313 16 47 16 45 8 5 7 16 6 1 16 30 3 5 8 311 16 313 16 311 16 39 16 3 9 16 49 16 315 16 49 16 413 16 511 16 65 16 45 3 13 16 3 7 8 4 3 7 8 3 3 4 3 3 4 4 7 8 43 16 415 16 53 16 6 1 8 7 60 4 1 16 4 1 8 4 1 4 4 1 8 4 4 5 1 4 4 1 2 5 1 4 5 5 8 611 16 711 16 75 45 16 4 3 8 4 1 2 4 3 8 4 1 4 4 1 4 5 11 16 47 8 5 11 16 6 1 8 7 5 16 8 9 16 90 411 16 4 3 4 4 7 8 4 3 4 4 5 8 4 9 16 6 3 16 5 1 4 6 3 16 6 3 4 8 1 16 9 9 16 5 1 8 5 3 16 5 1 4 5 3 16 5 5 6 7 8 5 7 8 6 15 16 7 1 2 91 16 10 15 16 5 3 4 5 13 16 5 7 8 5 13 16 5 5 8 5 9 16 7 7 8 6 5 8 7 7 8 89 16 107 16 12 7 8 6 3 4 613 16 613 16 613 16 69 16 6 9 16 97 16 715 16 97 16 105 16
19. Metric Tubing continued Dimensions are in millimeters 22 mm OD 67 mm Bend Radius 67 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 9 10 19 7 7 14 22 1 2 13 14 27 11 12 23 30 17 19 36 15 16 31 45 24 29 53 22 26 49 60 30 40 69 29 37 66 75 34 52 86 33 50 83 90 35 68 35 66 88 86 25 mm OD 82 mm Bend Radius 82 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 24 25 49 12 13 24 22 1 2 29 30 60 16 18 35 30 34 36 70 21 24 45 45 43 48 91 29 36 65 60 51 61 37 49 86 75 57 77 41 65 90 59 96 43 84 38 23 13 Bench Top Bender User s Manual 27 Metric Tubing continued Dimensions are in millimeters 28 mm OD 112 mm Bend Radius 112 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend S
20. 22 39 62 25 41 66 43 58 51 71 53 75 58 67 67 80 69 84 82 76 92 89 94 93 85 98 95 3 8 in OD 36 mm Bend Radius 36 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Medium Pressure Tubing Aluminum Bend Shoe Steel Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 1 2 1 2 3 7 8 15 22 1 2 1 3 4 4 8 10 10 20 30 3 7 6 6 12 12 13 25 45 7 17 10 12 22 15 18 34 60 11 26 13 18 31 19 24 43 75 13 35 16 25 40 21 31 52 90 45 17 33 50 21 39 61 54 43 59 51 70 63 58 68 67 79 73 82 77 92 88 82 87 97 91 96 Bench Top Bender User s Manual 29 Fractional Tubing with Metric Dimensions continued Tube OD is in inches Bend radius bend shoe and bend dimensions are in millimeters 1 2 in OD 36 mm Bend Radius 36 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Medium Pressure Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Steel Bend Shoe Angle Bend Ben
21. Bench Top Tube Bender User s Manual E Electric and manual units E Bends fractional and metric tubing E CE compliant OWAN 2 Bench Top Bender User s Manual Contents SAVE MSUMUCHOMS oo oo asacnunascsnsaunnoouune 2 Measuring the Bend Angle 16 TechnicaliDatas 2 72 aceusunnar te seers ose 3 Bend Data Tables Tobing Dala eee wearer eee tee ees 3 Fractional mubin aa a ae nee ae 17 EIo EENEI ES AA eae N A 4 Metric TUDING veces sacncestnae cumeeeaiene cestrater 22 Manual Bender Fractional Tubing with Metric Dimensions 28 Product Informationissacnac enn secre 6 Minimum Length of Last Leg SStll pee Aree re ree ee 7 Fractional Tubing ee e e a eee creer etees 33 Galibratio m ne eA a E i A Cee 8 Metric mubina ae eee e ete eee enone tone 34 Unloading the Bender 02 005 9 Fractional Tubing with Metric Dimensions 35 Operam e a ety eee heyy sere ere eee cee 10 Maintenance moea a aa a E E E E E eee 36 Electric Bender Replacement Parts nenne oaee e nn es eee 37 Product Information 0 ce0ceeceueeas 11 IAC CESSONES Herne ceca unite ater sana eee unamorie aie 38 E UT E E A a tr eee ACCRA RIN Urner 42 Troubleshooting Waser e cesenes Meee eee ase 39 Calibration 22s es eee ate omaha ane 14 Warranty 2 0 cece eee eee eee eee eee e ees 40 Unloading the Bender 0 220eeeee 14 Operation cees ean a a E K e EE REE 15 Safety Instructions READ THIS MANUAL BEFORE USING THE B
22. ENCH TOP TUBE BENDER A WARNING Statements that identify conditions or practices that could result in death or serious injury A CAUTION Statements that identify conditions or practices that could result in minor or moderate injury or damage to property CAUTION EYE PROTECTION Eye protection must be worn while operating or working near equipment CAUTION PINCH POINTS Keep hands loose clothing and long hair away from moving parts Injury can occur Bench Top Bender User s Manual 3 Technical Data Bending Range 1 to 180 Do not bend tube in excess of 180 Dimensions tube bender in case Width 21 in 53 cm Depth 11 in 28 cm Height 14 5 in 37 cm Weight tube bender in case excluding tooling Manual unit 75 Ib 34 kg Electric unit 79 Ib 36 kg Power Requirements electric unit MS BTB 1 110 V ac 50 60 Hz maximum current 10 A MS BTB 2 230 V ac 50 60 Hz maximum current 5 A Tubing Data E The Swagelok bench top tube bender bends 1 4 3 8 1 2 5 8 3 4 7 8 1 in and 1 1 4 in and 6 10 12 14 15 16 18 20 22 25 28 and 30 mm outside diameter tubing in a variety of wall thicknesses E Tubing should be free of scratches and suitable for bending and flaring Fractional Tubing Medium Pressure Tubing sieht Pati Heavy Wall Cold Drawn Ordering nformation Annealed 1 8 Hard High quality soft annealed seamless Approx Carbon Steel Stainless Steel Stainless Steel Stainl
23. IAL OR INCIDENTAL DAMAGES Swagelok TM Swagelok Company Castrol TM BP Lubricants USA Inc 2007 Swagelok Company Printed in U S A OM July 2007 R5 MS 13 145
24. a pencil 3 Align a ruler or other straight edge on one of the marks and extend it past the point where it will intersect with the second mark when it is extended 4 Repeat step 3 with the second mark The intersection point of the two marks represents the vertex of the bend 5 Place the origin of the protractor on the intersection of the line Rotate the protractor so the baseline of the protractor is aligned with one of the marks and the second mark intersects the scale on the protractor extend the marks with a pencil if necessary Origin 6 The second mark indicates the bend angle Note The protractor will contain two scales Read the appropriate scale Bend Data Tables The bend data provided reflects results achieved using the Swagelok bench top tube bender Bend deduction the distance from the vertex of the angle back to the point where the tube breaks tangent and the bend actually begins Sometimes referred to as setback take up or take off Bend length the actual amount of tube consumed by the bend as measured along the centerline of the bend Adjustment gain the difference between the actual length of tube used in a bend and the theoretical distance around a sharp corner The information provided in these tables accounts for adjustment gain Bend allowance the bend mark distance for reverse bends The adjustment gain is pushed towards the reference mark or previous bend d
25. a to prevent potential damage to the tube during bending Tube Bend shoe Clamp arm Bench Top Bender User s Manual 15 5 Align the bend mark on the tube with the reference mark on the bend shoe see Bend Layout for marking tube Reference mark Bend mark 6 Rotate the roller bracket lever clockwise until the roller bracket assembly stop and the bracket post stop make contact Roller bracket assembly stop Bracket post stop Note The clearance between the D roller and the clamp arm will now be approximately 1 4 in 7 Check the following before continuing m The bend mark remains aligned with the reference mark on the bend shoe m The tube is positioned in the correct plane m The tube will not contact the bender housing during the bend operation for a multiple bend Undesired tube contact 8 Hold the tube and push the toggle switch in the bend direction until the motor stops do not jog the switch 9 Unload the tube See Unloading the Bender 10 Verify the bend angle see Measuring the Bend Angle 16 Bench Top Bender User s Manual Measuring the Bend Angle This is one of many methods that may be used to measure the bend angle A protractor will be needed for this method 1 Place the bent tube on a piece of paper with the vertex of the bend on the paper Tube Vertex 2 Hold the tube against the paper and mark the paper along one edge of each leg of the bend with
26. and guide deformation rollers kit Bend shoes and guide deformation rollers kit with carrying case MS BTT K F MS BTT K M MS BTT K F CASE MS BTT K M CASE Individual Tools Ordering Information 1 Select a basic ordering number Bend Shoe Ordering Information Fractional and Metric Sizes Material Basic Ordering Number Example MS BTT B XX Aluminum MS BTT B XX 2 Replace XX with a size designator Steel MS BTT B SXX Example MS BTT B 8 The following sizes require an additional designator be added to the basic ordering number Fractional and Metric Sizes Description Basic Ordering Number G roller MS BTT R XXG D roller MS BTT R XXD Bend shoe and guide MS BTT K XX aluminum deformation roller set MS BTT K SXX steel Size Designator 6 mm R36 10 mm R36 14 mm R46 15 mm R46 1 2 in OD 56 mm bend radius steel only 1 1 4 in steel only R112 Example MS BTT B 10M R36 R56 Fractional Size Size Size in Designator Designator 1 4 6M 3 8 10M Steel bend shoes are required for bending the following 1 2 12M 5 8 14M 3 4 15M 7 8 16M 1 18M 11 4 20M 22M 25M 28M 30M Wall Tube Material Tube OD Thickness Carbon steel stainless steel 1in gt 0 095 in Carbon steel stainless steel 1 1 4 in All Carbon steel stainless steel 25 mm gt 2 4mm Carbon steel stainless steel 28 mm All
27. between the D roller and the clamp arm of the bend shoe D roller Bench Top Bender User s Manual 13 If all three conditions are met make note of the value appearing on the three right bend angle thumb wheels and proceed to Calibration If all three conditions are not met a Turn the roller knob counter clockwise until the tube can be removed Remove tube b Advance the right most bend angle thumb wheel one digit Bend angle thumb wheel c Hold the toggle switch in the bend direction until the motor stops d Repeat steps 9 through 11 until all three conditions are met 12 Make note of the value on the right most bend angle thumb wheel _ Bend angle thumb wheel Example only 13 Turn the roller knob counter clockwise until the tube can be removed Remove tube 14 Advance the two right most bend angle thumb wheels until they display 010 or higher 15 Hold the toggle switch in the bend direction until the motor stops Wait two seconds then hold the toggle switch in the unload direction until the motor stops 16 Proceed to Calibration 14 Bench Top Bender User s Manual Calibration Calibration is the process of accurately accounting for tube variables and mechanical play in the bender which is typically observed as springback Different materials different lots of the same material and different wall thicknesses of the same material may exhibit different bend characteristics
28. d Bend Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length Allowance Deduction Length 15 4 3 3 6 2 2 4 22 1 2 1 5 6 10 4 5 9 30 5 7 8 15 6 7 14 45 14 11 13 24 10 13 23 60 23 14 19 33 13 18 32 75 32 16 26 42 16 25 41 90 42 35 51 34 50 51 45 60 44 59 60 60 69 59 69 69 85 78 84 78 78 87 87 87 96 96 96 1 2 in OD 56 mm Bend Radius 56 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Steel Bend Shoe Angle Bend Bend Bend Degrees Allowance Deduction Length 15 16 16 32 22 1 2 19 20 39 30 22 24 46 45 28 32 60 60 33 41 74 75 37 52 89 90 38 65 83 30 Bench Top Bender User s Manual Fractional Tubing with Metric Dimensions continued Tube OD is in inches Bend radius bend shoe and bend dimensions are in millimeters 5 8 in OD 46 mm Bend Radius 46 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 6 6 10 9 10 20 22 1 2 8 8 16 12 13 25 30 10 12 22 15 16 31 45 15 18 33 19 23 43 60 19 26 45 23 31 54 75 22 34 57 26 39 66 90 23 45 68 27 50 77 59 80 65 89 79 92 85 3 4 in OD 56 mm Bend Radius 56 mm Bend Shoe Carbon St
29. eel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 9 10 19 13 14 27 22 1 2 12 14 26 17 18 34 30 16 17 33 20 21 41 45 22 26 47 26 30 56 60 27 35 61 31 39 70 75 30 45 75 35 49 84 90 31 58 89 36 62 98 76 80 Bench Top Bender User s Manual 31 Fractional Tubing with Metric Dimensions continued Tube OD is in inches Bend radius bend shoe and bend dimensions are in millimeters 7 8 in OD 67 mm Bend Radius 67 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 6 6 12 0 0 0 22 1 2 10 11 21 4 5 8 30 14 16 30 8 9 17 45 22 25 47 15 19 34 60 28 36 64 21 30 51 75 33 49 82 26 43 68 90 34 65 99 27 58 86 85 25 77 15 12 82 1 in OD 82 mm Bend Radius 82 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Aluminum Bend Shoe Steel Bend Shoe Angle Bend Bend Bend Bend Bend Bend Degrees Allowance Deduction Length Allowance Deduction Length 15 23 23 47 12 12 24 22 1 2 28 29 57 17 18 35 30 34 35 68 22 24 46 45 43 47 90 31 36 67 60 51 60 39 49 88 75 57 76 45 65 90 59 95 47 84
30. es from the reference mark and make a measurement mark to indicate the first desired bend length 3 The bend deduction in the Fractional Tubing Bend Data table for a 90 bend using 5 8 in tubing and an aluminum bend shoe is 1 3 4 in ony Second desired bend length 4 Place the bend mark 1 3 4 in from the measurement x 12 in mark going towards the reference mark Bend deduction 5 Bend tube 90 according to the appropriate Operation te X section 6 Measure 12 inches from the vertex of the 90 bend and make a second measurement mark away from the reference mark 7 The bend deduction distance in the Fractional Tubing Bend Data table for a 45 bend using 5 8 in tubing and an aluminum bend shoe is 11 16 in 8 Place a second bend mark 11 16 in from the second measurement mark going towards the first bend Second Bend 45 9 Bend tube according to the appropriate Operation section Bench Top Bender User s Manual Reverse Bends The Measure Bend Method Sometimes a multiple bend layout will require that a bend be made in reverse A reverse bend is made with the end of the tube opposite the reference mark inserted into the bend shoe rather than the end with the reference mark 1 Measure from the vertex of the preceding bend and place a second measurement mark farther down the tube at a distance equal to the desired length of the leg 2 Measuring from that measurement mark place a bend
31. ess Steel carbon steel hydraulic tubing ASTM Bend Wall Thickness Wall Thickness Wall Thickness Wall Thickness Radius Min Max Min Max Min Max Min Max A179 or equivalent Hardness 72 HRB 130 HV or less Dimensions in 0 028 0 065 0 065 0 095 0 028 0 065 Fully annealed high quality Type 304 316 etc Seamless or welded and drawn stainless steel hydraulic tubing 0 035 0 083 0 083 0 188 0 049 0 109 ASTM A269 or A213 or equivalent 0 035 0 065 Hardness 80 HRB 180 HV or less 0 035 0 095 0 049 0 095 0 049 0 109 0 049 0 109 0 049 0 120 0 065 0 120 0 065 0 120 0 083 0 120 0 035 0 065 0 035 0 083 0 083 0 134 0 035 0 083 Metric Tubing Approx Carbon Steel Stainless Steel Suggested Tubing Ordering Information Bend Wall Thickness Wall Thickness High quality soft annealed carbon steel hydraulic Radius Min Max Min Max tubing DIN 2391 or equivalent Hardness 130 HV Dimensions mm 72 HRB or less Fully annealed high quality Type 304 316 etc stainless steel tubing EN ISO 1127 or equivalent Hardness 180 HV 80 HRB or less 4 Bench Top Bender User s Manual Bend Layout This bender can be used to form single offset and other bends This section contains information for measuring and marking the tube prior to bending Note Make all marks 360 around the tube Single Bend 1 Place a reference ma
32. he tube see Measuring the Bend Angle If the actual bend is smaller than the desired bend angle Subtract the actual bend angle from the desired bend angle The difference is the amount that must be added to the desired bend angle when setting the bend angle thumb wheels for all subsequent bends made with this tube For example The desired bend angle entered is 90 The resulting calibration sample measures 86 90 86 4 The bend angle thumb wheels must be set 4 more than the desired bend angle for subsequent bends with this size tube i e for a 90 bend the bend angle thumb wheels must be set at 94 Bend angle thumb wheels If the actual bend is larger than the desired bend angle Subtract the desired bend angle from the actual bend angle The difference is the amount that must be subtracted from the desired bend angle for all subsequent bends made with this tube For example The desired bend angle entered is 90 The resulting calibration sample measures 92 92 90 2 The bend angle thumb wheels must be set 2 less than the desired bend angle for subsequent bends with this size tube i e for a 90 bend the bend angle thumb wheels must be set at 88 8 Make note of this amount Note Tube springback is cumulative Depending on the tube variables a smaller bend angle builds up less tube springback during the bending process than a larger bend angle For example if a 30 bend is attempted
33. iameter and thin wall tube 2 Insert the tube carefully into the grooved section of the bend shoe past the clamp arm A CAUTION The end of the tube must extend past the right edge of the clamp arm to prevent potential damage to the tube during bending Clamp arm 3 Align the bend mark on the tube with the reference mark on the bend shoe Reference mark Bend mark 4 Turn the roller bracket lever clockwise until the roller bracket assembly stop and the bracket post stop make contact Roller bracket pec assembly p p stop Note Do not turn the roller knob or bend consistency will be affected Note If the rollers touch the tube and prevent the stops from making contact gently turn the roller bracket lever clockwise while rotating the hand crank Hand crank Roller bracket lever 5 Check the following before continuing m The bend mark remains aligned with the reference mark on the bend shoe m The tube is positioned in the correct plane for bend m The tube will not contact the bender housing during the bend operation for a multiple bend Undesired tube contact 6 Rotate the hand crank until you reach the desired bend angle on the bend degree wheel m On low 1 and high 3 bend speeds rotate the hand crank clockwise to bend the tube m On medium 2 bend speed rotate the hand crank counter clockwise to bend the tube 7 Unload the tube from the bender See Unloading the
34. imilar tool rotate the spring away from the motor brush and remove the motor brush from the housing Note Complete replacement of one brush then replace the second brush Spring Releasing motor brush 4 Inspect the brushes for wear Replace when the length is 1 4 in 6 4 mm or less a in Replace brush New brush 5 Reverse steps 1 through 3 to install the new motor brush Ensure that the brush spring is secured properly in the housing Proper brush installation Improper brush installation Bench Top Bender User s Manual 37 Replacement Parts Tube Bender Components Description Ordering Numbe MS BTB M Metal box with trays manual model MS BTB CC M en Metal box with trays electric model MS BTB CC E Roller bracket MS BTB RS G pin MS BTB GR PIN D pin MS BTB DR PIN Roller bracket lever MS BTB RAH Support bracket MS BTB B SB Hand crank manual models only MS BTB HC Grease gun MS BTB A GG MS BTB 1 or Power cord electric models only MS BTB CORD MS BTB 2 Tooling kit carrying case MS BTT CC ss hal aluminum bend shoes only Does not include pin and pivot See Tools and Accessories MS 01 169 for country and voltage designators Tooling Sets Ordering Number Description Fractional 1 2 to 1 1 4 in Metric 12 to 25 mm Bend shoe set MS BTT B FSET MS BTT B MSET Guide deformation rollers set MS BTTI R FSET MS BTT R MSET Bend shoes
35. inkles on the inside bend of the tube but too much will leave heavy roller forming marks on the back of the bend Troubleshooting Problem Cause Solution Wrinkles occur on inside surface of the bend Forming pressure is insufficient Apply more pressure on the tube by turning the roller knob clockwise then recalibrate Bend shoe is contacting roller Bend shoe may be worn Rollers or bend shoe may be the wrong size for the tube Bend shoe radius may be too small Change to a larger radius bend shoe Excessive tube deformation occurs on back surface of the bend Forming pressure is excessive Reduce forming pressure by turning the roller knob counterclockwise then recalibrate Bend angle is not consistent from bend to bend Roller knob has been rotated between bends Do not rotate the roller knob after Setup is completed Tube ovality is not acceptable Forming pressure is either too high or too low Adjust the pressure to achieve proper results by turning the roller adjustment knob Check bend shoe for proper size Check bend shoe for excessive wear Tube kinks Excessive gap between the clamp arm and rollers Bend with gap of approximately 3 8 in or 10 mm between clamp arm and rollers Machine fails to bend tube overload indicator illuminates electric model only Tube wall thickness or hardness is beyond the capacity of the machine Use s
36. mark on the tube at the bend allowance for the angle being bent See Bend Data tables beginning on page 17 m If the bend allowance is positive place the bend mark away from the preceding bend m If the bend allowance is negative place the bend mark in the direction towards the preceding bend 3 Bend tube according to the appropriate Operation section Note When loading the tube into the bender to make a reverse bend ensure that the end with the reference mark is not inserted into the bend shoe Offset Calculations When offset exists determine the length of offset L before calculating for the adjustment from the tube bend To determine the length of offset select the offset angle E Then multiply the offset dimension O by the offset bend allowance Angle Offset Bend Offset O Length of Offset L E Allowance 22 5 2 613 MW eee oe 30 2 000 Me 45 1 414 RM Ma 60 1 154 x 5 6 Bench Top Bender User s Manual Manual Bender Roller bracket Product Information assembly Roller pins Bend shoe Roller bracket lever f Roller knob Carrying handle Bend degree wheel High bend 2 1 2 increments speed selector Medium bend ow bend speed selector Drill AN Hand erank speed selector suppor Bend shoe Zero reference mark Hex drive shaft D pin D roller Reference mark G pin pi Clamp G roller arm Support bracket Aluminum only
37. r bracket assembly stop must be to the right of the bracket post stop Bracket post Roller bracket Bracket assembly post stop stop 6 Place the roller bracket lever on the bracket pin Note The lever must be fully bottomed on the pin 7 Lift the roller pins place the G and D rollers in the marked locations on the roller bracket and replace the roller pins Note The roller pins must be fully engaged into the roller bracket assembly G roller pin D roller pin 4 D roller G roller Roller Bracket bracket pin lever Roller bracket assembly 8 Carefully insert the tube into the bend shoe past the clamp arm A CAUTION The end of the tube must extend past the right edge of the clamp arm to prevent potential damage to the tube during bending Bend shoe Clamp arm 9 Turn the roller bracket lever clockwise until the roller bracket assembly stop makes contact with the bracket post stop Roller bracket Bracket ost st assembly P p stop 10 Hold the tube in the bend shoe and turn the roller knob clockwise until both the G and D rollers make contact with the tube Note Smaller diameter tube may need to be guided into the rollers 11 Once the roller knob is tight the following conditions must be met E The roller bracket assembly stop and the bracket post stop must maintain contact E Both rollers must make contact with the tube E There must be approximately 3 8 in or 10 mm clearance
38. recommended when Bracket pin using 1 in or 25 mm bend shoe Roller bracket assembly Bracket post Bracket assembly stop Roller bracket lever 4 Bracket post stop Roller knob A CAUTION When lifting the bender first place one hand under the bender then pick up the unit by grabbing the carrying handle with your other hand Setup 1 Place the hand crank on the high bend speed selector 2 Rotate the hand crank until the zero reference mark on the hex drive shaft is between the 2 and 3 o clock position when viewed from the operating position z 2 o clock Hex drive shaft 3 o clock Zero reference mark Roller knob 4 Place the appropriate bend shoe on the hex drive shaft aligning the zero reference marks on the shoe and the shaft The bend shoe must be fully bottomed on the hex drive shaft Zero reference Bend shoe marks Hex drive shaft Bench Top Bender User s Manual 7 5 Install the roller bracket assembly on the bracket post Note The roller bracket assembly stop must be to the right of the bracket post stop Roller bracket Bracket assembly post Roller bracket Bracket assembly post stop stop 6 Place the roller bracket lever on the bracket pin Note The lever must be fully bottomed on the pin 7 Lift the roller pins place the appropriate rollers in the marked locations on the roller bracket and replace the roller pins G roller pin D roller pin D
39. rk at the end of the tube from which you are beginning the measurements 2 Measure from the reference mark and make a measurement mark on the tube at a distance equal to the desired bend length This mark is the vertex of the bend 3 Measure the bend deduction distance for the angle being bent from the measurement mark see Bend Data Tables beginning on page 17 and make a bend mark on the tube m f the bend deduction is positive place the bend mark toward the reference mark m f the bend deduction is negative place the bend mark away from the reference mark 4 Refer to the appropriate Operation section to bend the tube Desired bend length Measurement mark mark mark Reference Bend Bend deduction gt Single Bend Multiple Bends The Measure Bend Method 1 Follow Single Bend steps 1 through 4 First desired bend length Bend deduction 1 3 4 in 2 Using the vertex of the previous bend as the reference mark repeat steps 2 through 4 for the next bend The vertex is where the center lines of the two legs of the angle intersect Example Reference Center line Using 5 8 in OD tube and an aluminum bend shoe make a aie TIES 90 bend 12 inches from the reference mark followed by a 45 bend with 12 inches between bends 5 8 in OD 1 Place a reference mark at the end of the tube from tube which you are beginning the measurements i First Bend 90 2 Measure 12 inch
40. roller G roller Roller Roller bracket bracket lever Note The roller pins must be fully engaged with the roller bracket assembly 8 Mark tube according to Bend Layout 9 Carefully insert the tube into the bend shoe past the clamp arm A Caution The end of the tube must extend past the right edge of the clamp arm to prevent potential damage to the tube during bending Clamp arm 8 Bench Top Bender User s Manual 10 Align the bend mark on the tube with the reference mark on the bend shoe Bend shoe Reference mark 11 Turn the roller bracket lever clockwise until the roller bracket assembly stop makes contact with the bracket post stop Roller bracket hale assembly stop 12 Hold the tube and turn the roller knob clockwise until the G and D rollers both make contact with the tube and the roller knob is tight Note The rollers may need to be guided onto smaller diameter tubing 13 Ensure there is approximately 3 8 in or 10 mm clearance between the D roller and the clamp arm of the bend shoe D roller To increase clearance Rotate the roller knob counterclockwise while slowly rotating the hand crank clockwise and maintaining straight tube To decrease clearance Rotate the roller knob clockwise while slowly rotating the hand crank counterclockwise Note The roller knob must be tight Note Do not turn the roller knob after this point or bend consistency will be affected
41. teel Bend Shoe Angle Bend Bend Bend Degrees Allowance Deduction Length 15 11 12 23 22 1 2 18 20 37 30 24 28 51 45 36 44 80 60 46 62 75 53 83 90 55 50 30 17 30 mm OD 112 mm Bend Radius 112 mm Bend Shoe Carbon Steel and Stainless Steel Tubing Bend Steel Bend Shoe Angle Bend Bend Bend Degrees Allowance Deduction Length 15 9 10 18 22 1 2 15 17 32 30 22 25 47 45 34 41 75 60 44 60 75 51 81 90 53 48 29 18 28 Bench Top Bender User s Manual Fractional Tubing with Metric Dimensions Tube OD is in inches Bend radius bend shoe and bend dimensions are in millimeters 1 4 in OD 36 mm Bend Radius 36 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Aluminum Bend Shoe Steel Bend Shoe Medium Pressure Tubing Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 1 2 3 8 8 16 9 10 19 22 1 2 3 4 7 10 10 20 12 12 24 30 5 6 12 12 13 25 14 14 28 45 9 12 21 16 18 34 18 20 38 60 13 18 30 19 24 43 21 26 47 75 15 25 40 21 31 52 24 33 56 90 33 49
42. the direction opposite that used to bend the tube 2 As the hand crank is rotated gently push the roller bracket lever counter clockwise until the rollers swing away from the tube and the tube can be removed from 7 Rotate the hand crank until the bend degree wheel the bender reads the angle from step 4 in example 85 6 Reload the tube into the bender lining up the bend mark and the reference mark Note Do not force the roller bracket lever Hand crank Roller bracket 8 Keep the hand crank still and rotate the bend degree lever wheel to the measurement noted in step 5 in example 88 This calibrates the bend degree wheel by setting it to display the actual bend angle being produced 9 Continue to rotate the hand crank until the bend degree wheel reads the desired bend angle 10 Unload the bender see Unloading the Bender and measure the bend angle of the tube 10 Bench Top Bender User s Manual Operation Before operating the bender mark the tube see Bend Layout and follow the Setup and Calibration procedures A CAUTION PINCH POINTS 1 With the zero reference mark between the 2 and 3 o clock position place the hand crank on the desired speed selector m Low bend speed selector 1 is suggested for large diameter or heavy wall tube m Medium bend speed selector 2 is suggested for intermediate size and medium wall tube m High bend speed selector 3 is suggested for small d
43. uctor and three prong plug to fit a grounded receptacle Never connect the green or green yellow wire to a live terminal A WARNING For safe operation of the electric bender the extension cord wire size must meet the following specifications For 0 to 25 ft 0 to 7 5 m the recommended minimum wire gauge is 14 AWG or 1 5 mm For 25 to 50 ft 7 5 to 15 m the recommended minimum wire gauge is 12 AWG or 2 5 mm A CAUTION When lifting the bender first place one hand under the bender then pick up the unit by grabbing the carrying handle with your other hand Setup It is recommended that scrap tube be used during setup and calibration of the Electric Bench Top Tube Bender 1 Plug in the power cord 2 Hold the toggle switch in the unload direction until the motor stops The zero reference mark on the hex drive shaft should now be between the 2 and 3 o clock position Note The toggle switch is programmed to have a safety time delay of approximately two seconds between operations 2 o clock Hex drive shaft 3 o clock Zero reference mark 3 Rotate the roller knob counterclockwise until it stops Roller knob 4 Place the appropriate bend shoe on the hex drive shaft aligning the zero reference marks on the shoe and the shaft The bend shoe must be fully bottomed on the hex drive shaft Bend shoe Hex drive shaft 5 Install the roller bracket assembly on the bracket post Note The rolle
44. uitable material for proper machine operation Machine makes excessive noise Tube wall thickness is beyond the capacity of the machine Use suitable material for proper machine operation Gearbox requires lubrication Lubricate gearbox Both rollers do not remain on tube or end of tube is damaged during last bend Last leg of bend is too short See Minimum Length of Last Leg SWAGELOK COMPANY 29500 Solon Road Solon Ohio 44139 3492 U S A Telephone 1 440 248 4600 FAX 1 440 349 5970 The Swagelok Limited Lifetime Warranty Swagelok and its authorized distributors hereby warrant to the purchaser of their Products that the nonelectrical components shall be free from defects in material and workmanship for the life of the Products All electrical components installed in or on the Product are warranted to be free from defects in material and workmanship for twelve months from the date of purchase The purchaser s remedies shall be limited to replacement and installation of any parts that fail through a defect in material or workmanship All customer specified components carry the applicable manufacturer s warranty ALL OTHER REPRESENTATIONS EXPRESS OR IMPLIED WARRANTY OR LIABILITY RELATING TO THE CONDITION OR USE OF THE PRODUCT ARE SPECIFICALLY DISAVOWED AND IN NO EVENT SHALL SWAGELOK AND ITS AUTHORIZED DISTRIBUTORS BE LIABLE TO PURCHASER OR ANY THIRD PARTY FOR ANY DIRECT OR INDIRECT CONSEQUENT
45. uring reverse bends Fractional Tubing Dimensions are in inches 1 4 in OD 1 42 in Bend Radius 36 mm Bend Shoe Bend Angle Degrees Carbon Steel and Stainless Steel Tubing Bench Top Bender User s Manual Medium Pressure Tubing Aluminum Bend Shoe Steel Bend Shoe Steel Bend Shoe Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length Bend Allowance Bend Deduction Bend Length 15 1 16 1 16 1 8 5 16 5 16 5 8 3 8 3 8 3 4 22 1 2 1 8 3 16 5 16 3 8 7 16 13 16 7 16 1 2 15 16 30 3 16 1 4 1 2 7 16 1 2 1 9 16 9 16 1 1 8 45 3 8 7 16 13 16 5 8 11 16 15 16 11 16 3 4 1 1 2 60 1 2 11 16 13 16 3 4 15 16 111 16 13 16 1 1 13 16 75 9 16 15 16 1 9 16 13 16 13 16 2 1 16 15 16 11 4 2 3 16 90 5 8 1 5 16 1 15 16 7 8 1 9 16 2 7 16 15 16 1 5 8 2 9 16 9 16 111 16 2 1 4 13 16 2 2 3 4 7 8 2 1 16 2 15 16 3 8 2 5 16 2 5 8 1 2 2 5 8 3 1 8 5 8 2 11 16 3 5 16 1 4 3 1 4 3 1 8 3 5 8 3 1 2 1 16 3 11 16 3 11 16 1 3 4 5 1 16 3 3 8 1 5 8 5 1 2 3 7 8 1 9 16 5 5 8 4 1 16 6 13 16 10 9 16 3 3 4 6 13 16 11 41 4 6 3 4 11 1 8 47 16
46. wheel to zero now be very close to the bend angle produced If further A Caution adjustment is desired repeat steps 6 through 10 Releasing the hand crank while tube is under Note Tube springback is cumulative Depending on the tube load may cause the hand crank to spin possibly variables a smaller bend angle builds up less tube leading to injury springback during the bending process than a larger bend angle For example if a 30 bend is attempted using a bender that was calibrated to make a 90 bend the resulting bend may be larger than desired Conversely if a 150 bend is attempted on the same Example For a desired bend angle of 90 rotate the hand bender the resulting bend may be smaller than crank until the bend degree wheel reads 85 desired It is advised to verify each bend angle 4 Rotate the hand crank until the bend wheel displays 5 less than the desired bend angle This will prevent setup scrap due to overbending Unloading the Bender Note Do not turn the roller knob to unload the bender Doing so will affect bend consistency A Caution Releasing the hand crank while the tube is under load may cause the hand crank to spin possibly leading to injury 5 Unload the bender see Unloading the Bender and measure the bend angle of the tube see Measuring the Bend Angle Make note of this measurement as it is likely to be different than the angle displayed on the bend wheel 1 Rotate the hand crank in
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