User Manual for models 2000E, 2500E, 3200E .
Contents
1. If the machine is to be used for light gauge gag Lb A bending only up to mm then it may not be necessary to bolt it to the 1 jese floor however for heavy bending it is essential a Oo A si a SS ee 17 Remove the clear protective coating from the top surface of the machine KL and from the underside of the clampbar A suitable solvent is mineral So 5 turps or petrol gasoline g 2 18 Place the clampbar on the backstop bars of the machine and pull it S O forward to engage the heads of the retracted lifter pins Engage the Xa lifting mechanism by pushing hard back on one of the lifting handles and x W 8 yp 8 8 O then release forwards O o D 19 Your MAGNABEND is ready for use Please now read the Operating GE E i oS Instructions ES e S z lw S S NJE T S Hl N HLS SE d A ze A ot a YOLSINYA ui ER a o gt q 2 S z A e 3 e de 38 B DN SS z irs RB KE a S SB 2 a a S l e ES g Idd Wd Q THM ze jo Si Zoo Gi Z e lt E wo A A Tdd 8 oS i a rJ as i hg 9 2 ER m He a e x sl lz al Y E 2 a si o Ze 5 9 x O no G 9 9 Ee z zs es al SC TA Obbo a Si SI l S MN as E ee Nga RO 9 ES a SC a w 3 g T J MAINS TERMINAL 20A N BLU ay SPECIFICATIONS NOMINAL CAPACITY Machine Weight Model 2000E 2000 mm x 1 6 mm 6 ft x 16g 270 kg Model 2500E 2500 mm x 1 6 mm 8ft x 16g 315 kg Model 3200E 3200 mm x 1 2 mm 10 ft x 18g 380 kg CLAMPING FORCE Total force with2. The MAGNABEND is ideally suited to forming boxes especially complex ones because of the versatility of using short clampbars to form folds relatively unhindered by previous folds Plain Boxes 1 Make the first two bends using the long clampbar as for normal bending Select one or more of the shorter clampbars and position as shown It is not necessary to make up the exact length as the bend will carry over gaps of at least 20 mm between the clampbars For bends up to 70 mm long just select the largest clamp piece that will fit For longer lengths it may be necessary to use several clamp pieces Just select the longest clampbar that will fit in then the longest that will fit in the remain ing gap and possibly a third one thus making up the required length For repetitive bending the clamp pieces may be plugged together to make a sin gle unit with the required length Alternatively if the boxes have shallow sides and you have available a slotted clampbar then it may be quicker to make the boxes in the same manner as shallow trays See next section TRAYS Lipped boxes Lipped boxes can be made using the standard set of short clampbars provided one of the dimensions is greater than the width of the clampbar 98 mm 1 Using the full length clampbar form the length wise folds 1 2 3 amp 4 2 Select a short clampbar or possibly two or three plugged together with a length at least a lip width shorter than the width of th
3. taken right at the point where they are generated forces do not have to be transferred to support structures at the ends of the machine This in turn means that the clamping member does not need any structural bulk and hence can be made much more compact and less hindering The thickness of the clampbar is determined only by its requirement to carry sufficient magnetic flux and not by structural considerations at all Special centerless compound hinges have been developed for the Mag nabend and are distributed along the length of the bending beam and thus like the clampbar take bending loads close to where they are generated The combined effect of the magnetic clamping with the special centerless hinges means that the Magnabend is a very compact space saving machine with a very high strength to weight ratio To get the most out of your machine users are urged to read this man ual particularly the section titled USING THE MAGNABEND Please also return the WARRANTY REGISTRATION as this will simplify any claims under warranty and also it gives the manufacturer a record of your address which facilitates keeping customers informed of any developments which may benefit them ASSEMBLY ASSEMBLY INSTRUCTIONS k Unpack all items from the box except the main MAGNABEND machine Locate the packet of fasteners and the 6 mm Allen Key Using the slings provided lift up each end of the machine and rest it on pieces of wood
4. Measure resistance from mains plug earth pin to magnet body ELECTRICAL ISOLATION Megger from coil to magnet body MIN MAX SUPPLY VOLTAGE TESTS At 260v Pre clamp full clamp release ceceeeeeeeeee ees At 200v Pre clamp release Pre clamp full clamp release INTERLOCK SEQUENCE With power on pull HANDLE then press START button MAINS CABLE PLUG Check that plug is correct type Size 1 2 eee e ee ne eee neces FOOTSWITCH Does Footswitch activate light clamping TURN ON OFF ANGLES Movement of Bending Beam to activate full clamping measured at bottom of bending beam 4 mm to 6 mm Reverse motion to switch off machine Measure back from 90 Should be within the range 15 5 oe ANGLE SCALE Reading at edge of Indicator when bending beam is set MAGNET BODY Straightness of top surface along front pole max deviation 0 5 MM oo eee ee ceeeceeeeeeeeeeeeeee eens Flatness of top surface across the poles max deviation 0 1 mM oo eee ceeeeeeeeeee teen eee BENDING BEAM Straightness of working surface max deviation 0 25 mm Alignment of extension bar max deviation 0 25 mm Note Test straightness with precision straight edge onm L L 23 ACCURACY CHECKING THE ACCURACY OF YOUR MACHINE All functional surfaces of the Magnabend are manufactured to be straight and flat to within 0 2 mm over the en
5. retaining screw nuts been locked 00c0ccccceeceeeeees C BENDING TEST A maximum specification bend to 90 at minimum supply voltage Steel test piece thickness C mm Bend length mm Width of lip eee eens C mm Bend radius C mm Uniformity of bend angle maximum deviation 27 C deg LABELS Check for clarity adhesion to machine and proper alignment Nameplate amp Serial No C Clampbar Warning O Electrical warnmngs C Switch labelling C Safety tape on front legs C FINISH Check cleanliness freedom from rust blemishes ete O SIGNATURES ae 12 OPERATION OPERATING INSTRUCTIONS WARNING The Magnabend sheetmetal folder can exert a total clamping force of several tonnes see SPECIFICATIONS It is equipped with 2 safety interlocks The first requires that the safe pre clamping mode is engaged before full clamping can be activated And the second requires that the clampbar is lowered to within about 5 mm of the bed before the magnet will turn on These inter locks help ensure that fingers cannot be inadvertently caught under the clampbar when electro magnetic clamping is applied However it is most important that only one operator controls the machine and it is good practice to never place your fingers under the clampbar NORMAL BENDING Ensure power is ON at the power outlet and the ON OFF switch on the m
6. standard full length clamp bar Model 2000E 9 Tonne Model 2500E 12 Tonne Model 3200E 12 Tonne ELECTRICAL 1 Phase 220 240 V AC Current Model 2000E 12 Amp Model 2500E 16 Amp Model 3200E 16 Amp Duty Cycle 30 Protection Thermal cut out 70 C Control Start button pre clamping force Bending beam microswitch full clamping Interlock the start button and the bending beam must be oper ated in correct overlapping sequence to initiate full clamping force HINGES Special centerless design to provide a completely open ended machine Rotation angle 180 BENDING DIMENSIONS T 8 Wes JI min Eo min Standard Clampbar 49mm min Narrow Clampbar La 19mm min L to Chart Filler Piece TROUBLE SHOOTING NI Kl 27 lt Workpiece 26 TROUBLE SHOOTING need more clutching force Lack of clutching force usually relates to the two M8 cap head screws at either end of the actuator shaft not be ing tight If the actuator rotates and clutches OK but still does not click the microswitch then it may need adjusting To do this first un plug the machine from the power outlet and then remove the electrical access panel The turn on point can be adjusted by turning a screw which passes through the actuator The screw should be adjusted such that the switch clicks when the bottom edge of the bending beam has moved about 4 mm The same adjustment can also be achieved by bendi
7. 32 MAGNA BEND 8 ELECTROMAGNETIC SHEETMETAL FOLDERS MAGNABEND USER MANUAL for MODELS 2000E 2500E amp 3200E Contents Page INTRODUCTION WEE 3 ASSEMBLY E 4 Te E 6 INSPECTION SHEET E 10 USING THE MAGNABEND OPERATION EE 12 USING E KT 13 FOLDED LIP HEM Jinising iait 14 ee DIR DEE 15 MAKING A TEST PIECE preninte nirqa ONS 16 BOXES SHORT CLAMPBARS egegereeste ninna nna 18 TRAYS SLOT LED CLA MPBARS E 21 POWER SHEAR ACCESSOR E 22 A CURA Gs EE 23 MAINTENANCE EEN 24 TROUBLE SHOOTING ENEE n aa 25 CIRCUIT WARRANTY WARRANTY REGISTRATION MAGNETIC ENGINEERING P L 32 Browns Road Kingston Tasmania 7050 AUSTRALIA Phone 03 6229 7599 Fax 03 6229 7598 Sunday January 30 2011 Please Cut ebe GE deeg 31 WARRANTY REGISTRATION Model No Serial No Date Purchased Dealer s Name amp Address Customer s Name amp Address Your answers to the following questions would be appreciated Please underline the appropriate word or words How did you learn of the Magnabend Trade Fair Advertisement At a School or College Other Which is your category of use School Technical College University Plumber Maintenance workshop Automotive repair Electronics workshop Research support workshop Production workshop Sheetmetal shop Jobbing workshop Other What type of metal will you usually bend Mild Steel Aluminium Stainless Steel Copper Zinc Brass Other What thicknes
8. a chine The full length clampbar should be on the machine with the lifting pins engaging the holes in the ends of the clampbar If the lifting pins are locked down then release them by pushing hard back on either handle located under the machine near each column and releasing for wards This should elevate the clampbar slightly 1 Adjust for workpiece thickness by rotating the 2 screws in the rear edge of the clampbar To check the clearance lift the bending beam to the 90 position and observe the gap between the bending edge of the clampbar and the surface of the bending beam For optimum results the gap be tween the clampbar edge and the surface of the bending beam should be set to slightly greater than the metal thickness to be bent 2 Insert the workpiece under the clampbar Adjustable backstops may be set if required 3 Lower the clampbar onto the workpiece This may be done with the lifting handles or by simply pushing down the clampbar Note An interlock ensures that the machine will not turn ON unless the clampbar is lowered to within about 5 mm above the surface bed If the clampbar cannot be lowered sufficiently eg because it is resting on a buckled workpiece then the interlock can be operated by locking down the lifting system Push hard back on one of the lifting handles 4 Press and hold one of the 3 green START buttons or operate the foot switch This applies pre clamping force 5 With your other hand pu
9. amp bar and place it the test piece and the round i e Sa bar on the machine as shown under ROLLED EDGE earlier in this 1 Select a piece of 0 8 mm thick mild steel or aluminium sheet and cut it to manual 320 x 200 mm e Hold the round bar in position with the right hand and apply pre e Matk EES SSPE Beene below clamping by pressing and holding the START button with the left hand Now use your right hand to pull the handle as if doing an ordinary bend the START button may be released Wrap the workpiece as far as possible about 90 Reposition the workpiece as shown under Forming a Rolled Edge and wrap again Continue Bend 1 180 until the roll is closed Bend 2 90 reverse bend mark this line on the vend reverse side of the sheet Bend 3 90 Bend 4 90 The test shape is now complete Bend 5 90 This section to be rolled around 25mm round bar 3 Align Bend 1 and form a lip on the edge of the workpiece See FOLDED LIP 4 Turn the test piece over and slide it under the clampbar leaving the folded edge towards you Tilt the clampbar forward and line up Bend 2 Make this bend to 90 The test piece should now look like this
10. aspect of the machine and does not affect the bending accuracy The Magnabend can produce sharp folds in thinner gauges and in non ferrous materials such as aluminium and copper However in thicker gauges of steel and stainless steel do not expect to achieve a sharp fold see specifications Uniformity of the bend in thicker gauges can be enhanced by using scrap pieces of the workpiece to fill in the unused portions under the clampbar 22 POWER SHEAR Optional accessory INSTRUCTIONS FOR USING THE SHEAR The power shear based on the Makita Model JS 1660 provides a means for cutting sheetmetal in such a way that very little distortion is left in the workpiece This is possible because the shear removes a waste strip about 4 mm wide and most of the distortion inherent in shearing sheetmetal goes into this waste strip For use with a Magnabend the shear has been fitted with a special magnetic guide The shear works well in combination with a Magnabend Sheetmetal Folder the Magnabend provides both a means of holding the workpiece fixed while being cut and also a means for guiding the tool so that very straight cutting is possible Cuts of any length can be handled in steel up to 1 6 mm thick or aluminium up to 2 mm thick To use the tool first place the sheetmetal workpiece under the clampbar of the Magnabend and position it so that the cutting line is exactly 1 mm in front of the edge of the Bending Beam A toggle switch labell
11. best performance apply clamping for no longer than is necessary to do the bend USING THE BACKSTOPS The backstops are useful when a large number of bends have to be made all of which are the same distance from the edge of the workpiece Once the back stops are correctly set any number of bends can be made without the need for any measuring or marking out on the workpiece Normally the backstops would be used with a bar laid against them so as to form a long surface on which to reference the edge of the workpiece No spe cial bar is supplied but the extension piece from the bending beam may be used if another suitable bar is not available NOTE If it is required to set a backstop under the clampbar then this can be done by using a strip of sheetmetal the same thickness as the workpiece in conjunction with the backstops 14 FOLDED LIP FOLDING A LIP HEM The technique used for folding lips depends on the workpiece thickness and to some extent on its length and breadth Thin Workpieces up to 0 8 mm 1 Proceed as for normal bending but continue the bend as far as possible 1357 2 Remove the clampbar and leave the workpiece on the machine but move it rearwards about 10 mm Now swing the bending beam over to compress the lip Clamping need not be applied Note Do not attempt to form narrow lips on thick workpieces 3 With thin workpieces and or where the lip is not too narrow a more com plete flattening can be a
12. chieved by following with magnetic clamping only 19 BOXES Boxes with separate ends A box made with separate ends has several advantages it saves material if the box has deep sides it does not require corner notching all cutting out can be done with a guillotine all folding can be done with a plain full length clampbar and some drawbacks more folds must be formed more corners must be joined and more metal edges and fasteners show on the finished box Making this kind of box is straight forward and the full length clampbar can be used for all folds 1 Prepare the blanks as shown below 2 First form the four folds in the main workpiece 3 Next form the 4 flanges on each end piece For each of these folds insert the narrow flange of the end piece under the clampbar 4 Join the box together oko e Flanged boxes with plain corners Plain cornered boxes with outside flanges are easy to make if the length and width are greater that the clampbar width of 98 mm Forming boxes with outside flanges is related to making TOP HAT SECTIONS described in a later section see Contents 4 Prepare the blank 5 Using the full length clampbar form folds 1 2 3 amp 4 6 Insert the flange under the clampbar to form fold 5 and then fold 6 7 Using ap 18 BOXES MAKING BOXES USING SHORT CLAMPBARS There are numerous ways of laying out boxes and numerous ways of folding them up
13. e box so that it may later be removed Form folds 5 6 7 amp 8 While forming the folds 6 amp 7 be careful to guide the corner tabs either inside or outside the sides of the box as desired 15 ROLLED EDGE FORMING A ROLLED EDGE Rolled edges are formed by wrapping the workpiece around a round steel bar or piece of thick walled pipe 1 Position the workpiece clampbar and rolling bar as shown a Ensure that the clampbar does not overlap the front pole of the machine at a as this would allow magnetic flux to bypass the rolling bar and hence clamping would be very weak b Make sure the rolling bar is resting on the steel front pole of the ma chine b and not further back on the aluminium part of the surface c The purpose of the clampbar is to provide a magnetic pathway c into the rolling bar 2 Wrap the workpiece as far as possible then re position as shown 3 Repeat step 2 as required 16 17 TEST PIECE TEST PIECE e E test pi ke B 3 B 4 B 5 h to 90 INSTRUCTIONS FOR FORMING TEST PIECE urn test piece over and make Bend end 4 and Bend 5 each to 9 6 To complete the shape the remaining piece is to be rolled around a 25mm diameter round bar of steel In order to gain familiarity with your machine and the type of operations that can be performed with it it is recommended that a test piece be formed as described below e Select the 280 mm cl
14. ed NORMAL AUX CLAMP will be found next to the main ON OFF switch Switch this to the AUX CLAMP position to hold the workpiece firmly in position Position the shear at the right hand end of the Magnabend and ensure that the magnetic guide attachment engages on the front edge of the Bending Beam Start the power shear and then push it evenly along until the cut is completed Notes 1 For optimum performance the blade clearance should be adjusted to suit the thickness of material to be cut Please read the Makita instructions supplied with the JS1660 shear 2 Ifthe Shear does not cut freely check that the blades are sharp MAKITA POWER SHEAR IN ACTION Note that the waste strip curls out in a continuous spiral leaving your workpiece distortion free INSPECTION SHEET MAIN CLAMPBAR Straightness of bending edge max deviation 0 25 mm O mm Height of lift with lifting handles up min 47 mi mm Do pins drop when the lifting mechanism is locked down With adjusters set at 1 and the bending beam at 90 is the bending edge parallel to and 1 mm from the beam SEENEN O With the bending beam at 90 can the clampbar be adjusted forward to touch and rearward by 2 mm L HINGES Check for lubrication on shafts C and sector blocks Check that hinges rotate through 180 freely and smoothly C Check hinge pins do not rotate C and are loctited C Have the
15. he finished folds 2 Now select two slots between which to fold up the remaining two sides This is actually very easy and surprisingly quick Just line up the left side of the partly made tray with the leftmost slot and see if there is a slot for the right side to push into if not slide the tray along till the left side is at the next slot and try again Typically it takes about 4 such tries to find two suitable slots 3 Finally with the edge of the tray under the clampbar and between the two chosen slots fold up the remaining sides The previously formed sides go into the selected slots as the final folds are completed With tray lengths that are nearly as long as the clampbar it may be necessary to use one end of the clampbar in lieu of a slot 20 BOXES Flanged Box with Corner Tabs When making an outside flanged box with corner tabs and without using separate end pieces it is important to form the folds in the correct sequence 1 Prepare the blank with corner tabs arranged as shown 2 At one end of the full length clampbar form all tab folds A to 90 It is best to do this by inserting the tab under the clampbar 3 At the same end of the full length clampbar form folds B to 45 only Do this by inserting the side of the box rather than the bottom of the box under the clampbar 4 At the other end of the full length clampbar form the flange folds C to 90 5 Using appropriate short clampbars comple
16. i rust such as CRC 5 56 or RP7 HINGE LUBRICATION If the Magnabend sheetmetal folder is in constant use then grease or oil the hinges once per month If the machine is used less then it may be lubri cated less frequently Lubrication holes are provided in the two lugs of the main hinge plate and the spherical bearing surface of the sector block should also have lubricant applied to it ADJUSTERS The adjuster screws at the ends of the main clampbar are to control the allow ance for the thickness of the workpiece between the bending edge and the bending beam Note that the heads for the screws are divided into 3 by one two and three centre pop marks These marks are a useful reference for repeat settings of the clampbar If the adjuster screws are both set so that the single pop mark is uppermost then the bending gap will be approximately 1 mm SPECIFICATIONS MODEL 3200E Bending edge length 3290 665 Dist between lifters 3228 d S 640 Max Backgauge 900 770 1310 centres FRONT amp SIDE ELEVATIONS mm Clampbar Standard Clampbar Stiffener raised position Lifting Pin at each end lt 36 gt is 7 A Bending beam Extension removable cl Magnetic flux path Cep Bending beam CROSS SECTION DETAIL mm 920 10 INSPECTION SHEET EARTHING CONNECTIONS
17. ll one of the bending handles This activates a microswitch which will now cause full clamping to be applied The START button or footswitch should now be released 6 Commence bending by pulling on both handles until the desired bend 21 SLOTTED CLAMPBAR FORMING TRAYS USING SLOTTED CLAMPBAR The Slotted Clampbar when supplied is ideal for making shallow trays and pans quickly and accurately The advantages of the slotted clampbar over the set of short clampbars for making trays are that the bending edge is automati cally aligned to the rest of the machine and the clampbar automatically lifts to facilitate the insertion or removal of the workpiece Never the less the short clampbars can be used to form trays of unlimited depth and of course are better for making complex shapes In use the slots are equivalent to gaps left between the fingers of a conven tional box amp pan folding machine The width of the slots is such that any two slots will fit trays over a size range of 10 mm and the number and locations of the slots are such that for all sizes of tray there can always be found two slots that will fit it The shortest and longest tray sizes the slotted clampbar will accommodate are listed under SPECIFICATIONS To fold up a shallow tray 1 Fold up the first two opposite sides and the corner tabs using the slotted clampbar but ignoring the presence of the slots These slots will not have any discernible effect on t
18. ng the arm of the microswitch b If the microswitch does not click ON and OFF even though the actuator is working properly then the switch itself may be fused inside and will need to be replaced c If your machine is fitted with an auxiliary switch then make sure it is switched to the NORMAL position Only light clamping will be available if the switch is in the AUX CLAMP position 3 Clamping is OK but Clampbars do not release when the machine switches OFF This indicates a failure of the reverse pulse demagnetising circuit The most likely cause would be a blown 6 8 Q power resistor Also check all diodes and also the possibility of sticking contacts in the relay 4 Machine will not bend heavy gauge sheet a Check that the job is within the specifications of the machine In par ticular note that for 1 6 mm 16 gauge bending the extension bar must be fitted to the bending beam and that the minimum lip width is 30 mm This means that at least 30 mm of material must project out from the bending edge of the clampbar This applies to both alumin ium and steel Narrower lips are possible if the bend is not the full length of the ma chine b Also if the workpiece does not fill up the space under the clampbar then performance may be affected For best results always fill up the space under the clampbar with a scrap piece of steel the same thickness as the workpiece For best magnetic clamping the filler piece should be s
19. s 0 6 mm or less 0 8mm 1 0mm 1 2mm 1 6mm Comments Eg Does the machine do what you expected After completing please post this form to the address on page 1 30 WARRANTY PIII III AI III IIIISISII SSIS SSIS SSS IS SS SS SSA The Manufacturer hereby warrants this Magnabend bending machine to be free from defects in materials and or workmanship for a period of 12 months Our obligation under this Warranty is limited to repairing or replac ing faulty parts or materials and does not extend to consequential loss or damage arising from the use of the machine This Warranty does not cover faults that are due to misuse abuse negligence accident or caused during transportation Also excluded are faults arising from unauthorised repair use not according to instructions and normal wear and tear Returns under Warranty must be freight prepaid and if the Warranty Registration has not been previously returned must be accompanied by proof of the purchase date The rights and conditions under this warranty are additional to any rights that may be conferred under the Trade Practices Act JOO OR OE ER Ob bb I bt bb tb bt gt tt tt L Ebb Ob bb bbb bt tb bt bt tb bot bt FI III II III III II III II IAAI AIA IAA AAA ACK IK IK Please fill in for your own reference Model Serial No Date Purchased Dealer s Name and Address Before returning your machine for repair under warranty plea
20. se contact the Manufacturer to discuss the most efficient means of transport and packaging and whether the whole or only a part of the machine needs to be returned to the factory To establish proof of purchase date please return the Warranty Registration on the following page You are advised to contact the Manufacturer before any repairs are under taken especially when using outside contractors The Warranty does not cover the costs of these contractors unless prior arrangements have been made MAGNABEND INTRODUCTION The Magnabend sheetmetal bending machine is a highly versatile and easy to use machine for bending all types of sheetmetal such as aluminium cop per steel and stainless steel The electromagnetic clamping system provides more freedom to form the workpiece into complex shapes It is easy to form very deep narrow channels closed sections and deep boxes that are difficult or impossible on a conventional machine The unique hinging system used for the bending beam provides a com pletely open ended machine thus greatly extending its versatility The stand design also contributes to the versatility of the machine by providing a free arm effect at the ends of the machine Ease of use comes from the fingertip control of the clamping and unclamp ing the ease and accuracy of bend alignment and the automatic adjustment for sheetmetal thickness Fundamentally the use of magnetic clamping means that bending loads are
21. slipped in across the open top of the box Two suitable pieces of wood are supplied While the machine is in this up side down position attach the columns using four M8 x 16 cap head screws You will need to open out the bending beam to gain access to insert two of these screws Ensure left and right columns are not interchanged Columns are correct if the foot mounting holes are facing outwards Attach the feet to their respective columns The end with the threaded screw holes should point towards the rear Use four M10 x 16 Button head screws for each foot Rotate the machine until the tips of the feet are touching the floor and then with the aid of an assistant lift the machine up onto its feet Install an M10 x 25 cap head jacking screw into the rear of each foot Screw the jacking screws in until the machine is stable 7 Attach the shelf using four M8 x 16 cap head screws 8 Fasten the mains cable clip to the rear of the right column using an M6 x 10 11 12 13 14 15 10 Phillips head screw Attach the tray with rubber mat to the centre rear of the magnet bed using three M8 x 16 cap head screws Install the 4 backstop bars using two M8 x 17 screws for each bar Fit a Stop Collar onto each backstop bar Attach the left and right lifter handles to the rear of the shaft visible next to the rear side of the columns Use one M8 x 20 cap head screws for each handle Ro
22. tate the bending beam fully up and attach the handle with the angle scale in the right position using two M8 x 20 cap head screws Attach the other handle in the left position Install a stop collar on the right handle and lightly clamp it near the top of the handle Slip the angle indicator unit onto the right handle Remove the screws from both ends of the indicator spindle attach the 2 arms and re tighten both screws Note If these screws are not properly tightened then the switching mechanism will not work correctly Install the Footswitch Remove the rear access panel 8 off M6 x 10 Phillips head screws Insert the footswitch cable end through the hole in the centre of the panel and plug into the spare socket Install the footswitch mounting block to the access panel using two M6 x 30 screws 29 CIRCUIT SSES RSC rex fa fe e e e 240 25 25 25 LIGHT Clamping 300 condition V de V de V de FULL Clamping 240 240 215 215 340 condition V ac V ac V de V dc V dc 28 CIRCUIT ASSEMBLY These screws may be already loosely installed in the panel Re install the access panel 16 Bolt the machine to the floor using two M12 x 60 masonry bolts supplied Using a 12 mm masonry bit drill two holes at least 60 mm Zs E sl G SES gt 28 58 g deep through the holes in the front of each foot Insert the masonry bolts aTa Q o S p 8 y III wos H 3 S and tighten the nuts Note
23. te folds B to 90 6 Join the corners Remember that for deep boxes it may be better to make the box with separate end pieces 13 OPERATION angle is reached For heavy bending work an assistant will be required The beam angle is continuously indicated on a graduated scale on the front of the right hand handle Normally it is necessary to bend to a few degrees beyond the desired bend angle to allow for spring back of the ma terial being bent For repetitive work a stop may be set at the desired angle The machine will turn OFF when the bending beam motion is reversed At the moment of turn OFF the electrical circuit of the machine releases a re verse pulse of current through the electro magnet which removes most of the residual magnetism and allows immediate release of the clampbar When removing the workpiece a slight upward flick will elevate the clampbar sufficiently for the insertion of the workpiece for the next bend If it is re quired to lift the clampbar right up then this is most easily accomplished by using one of the lifting handles CAUTION e To avoid the risk of damaging the bending edge of the clampbar or of denting the top surface of the magnet body do not put small objects un der the clampbar The recommended minimum bend length using the standard clampbar is 15 mm except when the workpiece is very thin or soft e The clamping force of the magnet is less when it is hot Therefore to get the
24. teel even if the workpiece is not steel This is also the best method to use if it is required to make a very narrow lip on the workpiece SPECIFICATIONS BENDING CAPABILITY When using a standard full length clamp bar to bend a full length work piece MATERIAL THICKNESS LIP WIDTH BEND RADIUS yield ultimate stress minimum typical Mild steel 1 6 mm 250 320 MPa 1 2 mm 1 0 mm Aluminium 1 6 mm Grade 5005 H34 1 2 mm 140 160 MPa 1 0 mm Stainless Steel 1 0 mm Grades 304 316 0 9 mm 210 600 MPa 0 8 mm With extension bar fitted to bending beam SHORT CLAMP BAR SET Lengths 25 38 52 70 140 280 597 1160 mm All sizes except 597 mm amp 1160 mm may be plugged together to form a bending edge within 25 mm of any desired length up to 575 mm SLOTTED CLAMPBAR Supplied as an optional extra for forming shallow pans Has a special set of 8 mm wide by 40 mm deep slots which provide for forming all tray sizes in the range 15 to 1265 mm For deeper trays use the Short Clamp bar set SPECIFICATIONS MODELS 2000E amp 2500E A Bending edge length 2090 2590 J k Dist between lifters 2028 2528 1310 centres Standard Clampbar A raised position Be e ec ES EE Lifting Pin Ss at each end 665 640 Max Backgauge a 920 D Bending beam Extension removable Bending beam Magnetic fl
25. tire length of the machine The most critical aspects are l 2 3 the straightness of the working surface of the bending beam the straightness of the bending edge of the clampbar and the parallelism of these two surfaces These surfaces can be checked with a precision straight edge but another good method of checking is to reference the surfaces to each other To do this L Swing the bending beam up to the 90 position and hold it there The beam can be locked in this position by placing a back stop clamp collar behind the angle slide on the handle Observe the gap between the bending edge of the clamp bar and the work ing surface of the bending beam Using the clampbar adjusters set this gap to 1 mm at each end use a scrap piece of sheetmetal or a feeler gauge Check that the gap is the same all the way along the clampbar Any varia tions should be within 0 2 mm That is the gap should not exceed 1 2 mm and should not be less than 0 8 mm If the adjustors do not read the same at each end then reset them as described under MAINTENANCE Notes a The straightness of the clampbar as observed in elevation from the front is not important as this gets flattened out by magnetic clamping as soon as the machine is activated The gap between the bending beam and the magnet body as observed in plan view with the bending beam in its home position is normally about 2 to 3 mm This gap is not a functional
26. trical module with the magnet coil f If clamping does not operate but the clampbar snaps down on release of the START button then this indicates that the 15 microfarad capacitor is faulty and will need to be replaced g If the machine blows external fuses or trips circuit breakers when oper ated then the most likely cause is a blown bridge rectifier 2 Light clamping operates but full clamping does not a Check that the Angle Microswtich is being actuated correctly This switch is operated by a square brass piece which is attached to the angle indicating mechanism When the handle is pulled the bending beam rotates which imparts a rotation to the brass actuator The ac tuator in turn operates a microswitch inside the electrical assembly Pull the handle out and in You should be able to hear the microswitch clicking ON and OFF provided there is not too much background noise If the switch does not click ON and OFF then swing the bending beam right up so that the brass actuator can be observed Rotate the bending beam up and down The actuator should rotate in response to the bend ing beam until it clutches against its stops If it does not then it may 24 MAINTENANCE WORKING SURFACES If the bare working surfaces of the machine become rusty tarnished or dam aged they may be readily reconditioned Any raised burrs should be filed off flush and the surfaces rubbed with P200 emery paper Finally apply a spray on ant
27. ux path Standard Full length Clampbar Short Clampbars 15mm thick CROSS SECTION DETAIL mm 25 TROUBLE SHOOTING The easiest way to fix electrical problems is to order a replacement electrical module from the manufacturer This is supplied on an exchange basis and therefore is quite reasonably priced Before sending for an exchange module you may like to check the following 1 Machine does not operate at all a Check that power is available at the machine by observing the pilot light in the ON OFF switch b If power is available but the machine is still dead but feels very hot then the thermal cut out may have tripped In this case wait until the machine cools down about an hour and then try it again c The two handed starting interlock requires that the START button is pressed before the handle is pulled If the handle is pulled first then the machine will not operate Also it may happen that the bending beam moves or is bumped sufficiently to operate the angle mi croswitch before the START button is pressed If this happens make sure the handle is pushed fully back first If this is a persistent problem then it indicates that the turn on point of the microswitch actuator needs adjustment see below d Another possibility is that the START button may be faulty See if the machine can be started with one of the alternative START buttons or the footswitch e Also check the connector which connects the elec
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