Electric Tube Bender User's Manual, (MS-13-138,R4)
Contents
1. Gain Factors for O to 90 Bends 0 1 2 3 4 5 6 7 8 9 0 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0001 0 0001 0 0003 0 0003 10 0 0005 0 0006 0 0008 0 0010 0 0013 0 0015 0 0018 0 0022 0 0026 0 0031 20 0 0036 0 0042 0 0048 0 0055 0 0062 0 0071 0 0079 0 0090 0 0100 0 0111 30 0 0126 0 0136 0 0150 0 0165 0 0181 0 0197 0 0215 0 0234 0 0254 0 0276 40 0 0298 0 0322 0 0347 0 0373 0 0400 0 0430 0 0461 0 0493 0 0527 0 0562 50 0 0600 0 0637 0 0679 0 0721 0 0766 0 0812 0 0860 0 0911 0 0963 0 1018 60 0 1075 0 1134 0 1196 0 1260 0 1327 0 1397 0 1469 0 1544 0 1622 0 1703 70 0 1787 0 1874 0 1964 0 2058 0 2156 0 2257 0 2361 0 2470 0 2582 0 2699 80 0 2819 0 2944 0 3074 0 3208 0 3347 0 3491 0 3640 0 3795 0 3955 0 4121 90 0 4292 a Example The gain factor for a 90 bend is 0 4292 To calculate the gain for 90 bend multiply the gain factor times the bend radius Example 0 4292 x 6 in 2 58 or about 2 9 16 in gain 9 Making Offset Bends NOTE Make all marks 360 around the tubing 1 Make a reference mark at the end of the tubing from which your measurement begins E 2 From the reference mark at the end of the tubing measure the desired length for the bend Make2. Distance 1 Follow Steps 1 to 4 above for a Single 90 Bend 2 Using the center line of the previous 90 bend as your second reference mark repeat Steps 2 to 4 for the second 90 bend ricas an EXAMPLE Using 1 1 2 in OD tubing make two 90 bends with measured length distances of 18 in between bend marks See Illustrations 2 and 3 1 1 2 in OD Tubing 1 From the reference mark at the end of the tubing measure 18 in and make a measurement mark 2 The bend deduction distance for 1 1 2 in OD tubing in Table 2 is 9 7 8 in 3 18 in 9 7 8 in 8 1 8 in Make the first bend mark at 8 1 8 in Illustration 2 First 90 Bend 4 Bend tubing Bend 5 From the center line of the first 90 bend measure 18 in is Second and make a measurement mark Measurerient 6 The bend deduction distance for 1 1 2 in OD tubing in Bend Deduction 18 in Table 2 is 9 7 8 in Distance 7 18 in 9 7 8 in 8 1 8 in Make the second bend mark at l 8 1 8 in from the center line of the first 90 bend 8 Bend tubing Note Follow the above steps when using metric measurements Illustration 3 Second 90 Bend Multiple 90 Bends The Premeasure Method 1 Follow Steps 1 to 3 for a Single 90 Bend See page 8 2 From the reference mark at the end of the tubing measure the desired length for the second bend and make a measurement mark 3 Subtract the bend deduction distance s
3. Insufficient roller quate cremene Uni ondio cleats pressure Ovality Undersize tubing Turn roller adjustment screws clockwise in as uarter turn increments until condition clears Insufficient roller eer Comer Wall Condi cleats pressure 12 Roller Adjustment Screws The two roller adjustment screws on the left side of the bender see Figure 10 change the pressure applied to the tubing The factory setting as viewed from the front for these screws is the gap measured between the top of the bender frame leg and the bottom of the screw blocks La E x ecic Woe pens YE Roller Adjustment Screws Original Factory Setting Figure 10 Notes When the roller adjustment is changed to compensate for under or oversized tubing return the roller screws to their original factory setting before bending a new length or lot of tubing e ZERO SET may need to be re established See Bending page 11 step 2 e Set the roller adjustment screws evenly to keep the bridge assembly level Roller Alignment The two roller alignment screws located on the rear side plate of the bridge assembly see Figure 11 allow adjustment of the bridge assembly to keep the roller towers and bend shoe aligned Misalignment can lead to sidemarking To Check Alignment e Viewing the bender from the side look between the roller towers and the bend shoe If the roller tower appears to be misaligned with the bend shoe loosen the lock nuts o
4. EFORE USING BENDER This device is electrically powered and must be operated in a safe environment to avoid risk of fire explosion or electric shock Grounding and Extension Cord Information Bender MUST be grounded to guard against electrical shock It is equipped with a three wire conductor and three prong plug to fit a grounded receptacle A NEVER CONNECT THE GREEN OR GREEN YELLOW WIRE TO A LIVE TERMINAL e Use only three wire extension cords that have three prong grounding type plugs and three pole receptacles The extension cord wire size must meet the following specifications For 0 to 50 ft 0 to 15 m the recommended minimum wire gauge is 12 AWG 2 5 mm For 50 to 100 ft 15 to 30 m the recommended minimum wire gauge is 10 AWG 4 0 mm Statements CAUTION Statements that identify conditions or practices that could result in damage to the equipment or other property WARNING Statements that identify conditions or practices that could result in personal injuries or loss of life Symbols CAUTION Indicates cautionary information WARNING Indicates that voltage greater than 30V ac is present WARNING PINCH POINTS Keep hands loose clothing and long hair away from moving parts Serious injury can occur WARNING KEEP DRY Do not expose the equipment to water or wet locations WARNING FIRE OR EXPLOSION Do not use equipment in a combustible or explosive atmosphere Flammable liquids or gases c
5. a measurement mark on the tubing 3 Subtract the clamp distance see Table 4 from the first Illustration 5 Tubing Length Offset measurement mark and make a bend mark 4 Determine the length of tubing L consumed in the offset Y Table 4 Clamp Distance See Table 5 or use one of the offset bend allowances Clamp Clamp referred to in Table 6 See Illustration 5 e Distance Distance In mm 5 From the first bend mark measure the distance required 2 1 4 57 for the offset bend allowance and make a second bend gt 3 4 70 mark mis 3 1 2 89 6 Check for proper bend direction and tube orientation To 4 bend tubing 36 Bending on page 11 Clamp distance only applies to offset bends 4 in ed First Measurement Mark eee Second Bend Mark Reference First Distance to Center Mark Bend Mark First Measurement Length Clamp Distance 3 1 2 in 1 ra Illustration 6 Offset Bends EXAMPLE Using 1 1 2 in OD tubing make an offset Table 5 Offset Bend Calculations bend beginning 14 in from the end of the tube with a E E E 20 in offset dimension O and a 30 offset angle E 30 Offset 45 Offset 60 Offset See Illustration 6 o Max E Max L Max L i Offset Tube Center Tube Center Tube Center 1 From the reference mark at the end of the tubing mencion Roba eese eo fo canter MOB S eT measure 14 in and make a measurement mark 2 The clamp distance
6. assemble the cover bridge assembly and bend shoe Lubrication e Chains do not require lubrication under normal work conditions For corrosive environmental conditions a 90 weight oil may be used e Lubricate rollers and pivot points with a light machine oil as necessary Adjusting Bolt Figure 16 A 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 hereby warrants to the purchaser of this Product that the non electrical components of the Product shall be free from defects in material and workmanship for the life of the Product 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 MANUFACTURER SPECIFICALLY DISAVOWS ANY OTHER REPRESENTATION EXPRESS OR IMPLIED WARRANTY OR LIABILITY RELATING TO THE CONDITION OF USE OF THE PRODUCT AND IN NO EVENT SHALL SWAGELOK BE LIABLE TO PURCHASER OR ANY THIRD PARTY FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES 15 Swagelok TM Swagelok Company 1999 2002 2004 Swagelok Company Printed in U S A October 2004 R4 MS 13 138
7. ed tubing is listed below in Table 1 bend radius wall thickness limits and minimum straight length required to make a 90 bend using the tail roller Table 1 Min Max Wall Thickness Dimensions in Dimensions mm Stainless i Bend Carbon Stainless Steel Radius Steel Steel A oe a onena 0 650 100 103 1280 1880 iva 2204 8 0650180 00830186 128 2040 2040 me 251 6 0 080 0 220 0050188 162 2245 2245 aa a omo onoo 203 3050 See the Swagelok Tubing Data catalog for suggested tubing wall thickness for use with Swagelok tube fittings READ AND BECOME FAMILIAR WITH OPERATING INSTRUCTIONS BEFORE BENDING TUBING This bender can be used in the vertical or horizontal position Before using bender make sure rollers and shoe grooves are in line See Roller Alignment page 13 5 Tube Bender Components Tube Clamps Bend Shoe Bend Shoe Retaining Pin Fixed Tail Roller Bridge Openin Adjustment ARE a Screws Handle Lock Eoc Mie Tura Ber ter BEND Rotates bend shoe clockwise JOG Rotates bend shoe clockwise in 1 increments UNLOAD Rotates bend shoe counterclockwise ZERO SET Resets pendant display to 0 BEND SET Stores a bend in memory Indicator light on display center decimal point will flash to confirm bend is stored AUTO BEND Rotates bend shoe to the angle s
8. ee Table 2 and the adjustment factor see Table 3 from the second measurement mark and make the second bend mark Second Measurement Length 36 in First Measurement Gain Length 18 in _ gt gt Adjustment Factor Bend Deduction Bend Deduction Distance leo 16 in Distance 9 7 8 in gt lt 9 7 8 in gt Reference id Bend i Mark Mark Illustration 4 Multiple 90 Bends EXAMPLE Using 1 1 2 in OD tubing make two 90 Table 2 Bend Deduction Distance bends with a measured length distance of 18 in between RE aad bend marks See Illustration 4 Deduction Deduction 1 From the reference mark at the end of the tubing gt measure 18 in and make a measurement mark TE 2 The bend deduction distance for 1 1 2 in OD tubing in 247 Table 2 is 9 7 8 in 318 3 18 in 9 7 8 in 8 1 8 in Make the first bend mark at 8 1 8 in 4 Add the first and second measurement lengths PA AE A I ATS nd cad l 18 in 18 in 36 in 8 From the reference mark at the end of the tubing 5 From the reference mark at the end of the tubing measure 23 9 16 In and make a second bend mark measure 36 in and make a second measurement mark 9 Bend tubing 6 The bend deduction distance for 1 1 2 in OD tubing is Note Follow the above steps when using metric 9 7 8 in and the adjustment factor for a 90 bend in measurements Table 3 is 2 9 16 in Table 3
9. ey The AUTO BEND indicator light right decimal point will illuminate 5 Press and hold the BEND function key The bend shoe will rotate until the set angle is reached 6 Follow step 7 under Bending NOTE The auto bend function may be temporarily disabled to allow for bending of different angles while maintaining the pre set bend angle in memory To disengage the auto bend function either 1 Press the AUTO BEND function key The AUTO BEND indicator light will turn off and the auto bend is disengaged To reactivate the auto bend function press the AUTO BEND function key The indicator light will illuminate 2 Press the OVERRIDE AUTO BEND function key to temporarily override auto bend function The AUTO BEND indicator light will flash and the auto bend function is temporarily disengaged To reactivate the auto bend function press the OVERRIDE AUTO BEND function key The indicator light will stop flashing Troubleshooting Bender adjustments can be made if any of the following conditions are encountered See page 13 for specific instructions Potential Cause Solution Sidemarking Rollers not aligned Align rollers by turning roller alignment screws with bend shoe Oversize tubing Turn roller adjustment screws counterclockwise in quarter turn increments until condition clears y Excess roller pressure q Undersize tubing Turn roller adjustment screws clockwise in Ta uarter turn increments until condition clears
10. faceplate See Figures 5 and 6 Note the difference in appearance of the bend shoe in each figure The tube clamp should hang vertically from the bend shoe NOTE If the bend shoe stops at 110 or 99 reset the pendant display by pressing the ZERO SET function key Then press the BEND or UNLOAD function key to rotate bend shoe Insert tubing through tube clamp with reference mark toward the left see Tubing Layout page 8 making sure tubing is positioned over tower and tail rollers Press the JOG function key until tubing rests on tail roller and fits tightly Press the ZERO SET function key This process ensures the bender is set correctly for bending Press the UNLOAD function key until the tubing can be moved by hand Display will read approximately 2 Slide tubing to align the bend mark with the left edge of the tube clamp See Figure 7 Lock the roller tower by pushing the handle lock down until the roller tower stops firmly against bridge See Figure 8 To bend press and hold the BEND or JOG function key until the desired angle is displayed The JOG function key will bend in 1 increments Release the key to stop the bend shoe Add approximately 3 to allow for springback CAUTION Bending in excess of 110 may damage tubing and bender 7 To remove tubing stand clear of the handle lock and press and hold the UNLOAD function key approximately 5 until roller tower unlocks by lift
11. for 1 1 2 in OD tubing in Table 4 is 3 1 2 in 3 14 in 3 1 2 in 10 1 2 in Make the first bend mark at 10 1 2 in 4 The 20 in offset bend is not in Table 5 Calculate the center to center distance by multiplying 20 in by the factor in Table 6 for a 30 offset 2 000 20 in xX 2 000 40 in 5 From the first bend mark measure 40 in and make the second bend mark in in in in in in in E 6 Bend tubing 30 Offset 45 Offset 60 Offset Max L Max L Max L Note Follow the above steps when using metric Offset Tube Center Tube Center Tube Center measurements Dimension OD to Center OD to Center OD to Center mm mm mm mm mm mm mm Table 6 Offset Bend Allowance 150 300 38 212 25 173 200 400 283 38 231 250 500 353 288 300 600 424 346 350 700 495 404 400 800 566 462 450 900 636 519 L Length 2 000 x O offset 1 414 x O offset 1 154 x O offset 10 Springback Bending the tubing approximately 3 beyond the desired angle is necessary to compensate for tubing springback NOTE This is an approximate value Tubing springback characteristics differ due to size wall thickness and material WARNING MOVING PARTS Bending de Press the BEND or UNLOAD function key Rotate the bend shoe until the proper reference notch on the bend shoe is aligned with the pointer on the
12. ing slightly Lift the handle lock and allow roller tower to lean against tail roller Remove tube clamp and tubing Inspect the tubing bend if wrinkling ovality or sidemarking has occurred see Troubleshooting on page 12 445 Figure 5 1 1 4 and 2 in 32 and 50 mm Reference Notch C Figure 6 1 and 1 1 2 in 25 and 38 mm Reference Notch Bend Mark Aligned with Left Edge of Clamp Figure 7 Roller Tower Stops Against Bridge Figure 8 Bending Using Auto Bend Use the auto bend feature to program a bend angle into the bender s memory for applications where a single bend angle must be repeated NOTE A bend setting will be stored in memory until power is disconnected or a new bend is set 1 Follow steps 1 3 under Bending see page 11 then slide tubing completely away from tube clamp and bend shoe 2 Press the BEND or JOG function key until the desired angle is displayed Add approximately 3 to allow for springback Press the BEND SET function key to store the bend angle The BEND SET light center decimal point on the display pendant will flash momentarily Press the UNLOAD function key until the display reads f approximately 2 Figure 9 3 Slide tubing through tube clamp and align the bend mark with the left edge of the tube clamp See Figure 9 4 Lock the roller tower by pushing the handle lock down until the roller tower stops firmly against bridge Press the AUTO BEND function k
13. n the roller alignment screws Roller Alignment with a 9 16 in wrench gt Screws e Using a 3 16 in hex key turn the roller alignment screws until the roller tower aligns with the bend shoe Tighten the lock nuts Always set the roller alignment screws evenly to keep the bridge assembly parallel with the bend shoe Figure 11 13 Maintenance If this bender is subjected to flooding severe impact fire or other extreme conditions it should be inspected thoroughly by a trained technician before use Front Chain The front chain requires no routine adjustment However it will stretch slightly after making the first 10 to 20 bends of 1 1 2 or 2 in or 38 or 50 mm OD heavy wall tubing If there is any slack in the chain 1 Disconnect the bender from the power source and remove the roller tower 2 Remove the bend shoe retaining pin See Figure 12 3 Rock the bend shoe gently and pull forward until it clears drive lugs Remove the bend shoe CAUTION Bend shoe weight is 33 Ib 15 kg 4 Remove the long pin on the right side of the bridge assembly See Figure 13 5 Unhook both springs from the left side of the bridge assembly and Figure 13 remove the bridge assembly See Figure 14 6 Remove the front cover exposing the front chain See Figure 15 7 Loosen the adjusting bolt and rotate cam clockwise until the chain is free of slack Retighten the adjusting bolt See Figure 16 8 Re
14. ould ignite WARNING EYE PROTECTION Eye protection must be worn while operating or working near the equipment gt gt PEE Safety Features Emergency Stop Button tt Stops rotation of bend shoe and clears all settings Auto bend function will require reprogramming Circuit Breaker SS Disconnects power from outside source Clears all settings Receptacle with Cord Socket Lock Plug in power cord Tighten screw on cord socket lock to secure power cord Tube Bender Technical Data BENDING RANGE 1 to 110 in 1 increments Bending in excess of 110 may damage bender DIMENSIONS Vertical Position 44 in 112 cm high 29 in 74 cm wide 30 in 76 cm deep WEIGHT 420 lb 191 kg POWER REQUIREMENTS MS TBE 1 MS TBE 2 115 V ac 50 60 Hz 230 V ac 50 60 Hz Maximum current 13 A Maximum current 7 A Tubing Information All tubing should be free of scratches and suitable for bending Bends 1 1 1 4 1 1 2 and 2 in 25 32 38 and 50 mm OD tubing in a variety of wall thicknesses e Carbon steel tubing should be soft annealed seamless ASTM A179 or welded and drawn DIN 2391 1 and DIN 2391 2 or equivalent with a hardness of 72 HRB HV VPN 130 or less Stainless steel tubing should be fully annealed seamless or welded and drawn meeting ASTM A269 ASTM A213 EN ISO 1127 or equivalent specification with a hardness of 90 HRB HV VPN 180 or less The following information for bending anneal
15. the tube clamp with pin making sure the size identification faces out See Figure 4 Make sure the circuit breaker is switched to the ON position and the EMERGENCY STOP button is not engaged Plug the unit into an appropriate power source The display on the pendant will illuminate Up Position 1 1 2 in 38 mm Down Position a gt 2 in Upper Pin Hole 1 1 4 in 32 mm Roller Tower y Size if indicator Roller Tower Label Location Handle Lock Tubing Layout With this bender you can form single offset and other bends This section contains information for measuring and marking the tubing prior to bending NOTE Make all marks 360 around the tubing A Measurement Length Measurement Mark Reference ye Bend a x Bend Deduction gt Mark Mark Distance Illustration 1 Single Bend 90 Single 90 Bend 1 Place a reference mark at the end of the tubing from which your measurement begins 2 From the reference mark at the end of the tubing measure the desired length for the bend Make a measurement mark on the tubing 3 Subtract the bend deduction distance see Table 2 on page 9 from the measurement mark and make a bend mark The bend deduction distance is a length that compensates for the bender and tube clamp design 4 To bend tubing see Bending on page 11 First Measurement Mark lt Multiple 90 Bends 18 in gt Bend Deduction The Measure Bend Method
16. tored in memory Auto bend indicator light right decimal point remains on when bending with memory OVERRIDE Overrides the AUTO BEND mode without erasing memory Roller Towers Digital Display Pendant Error Message An E1 in pendant display indicates that the motor has stopped Remove LED DISPLAY Displays degrees of rotation any obstruction in bend shoe and retry the BEND or UNLOAD function CAUTION Pressing color key pad functions on the pendant causes bend shoe to rotate Assembling Components 1 Select and install proper tail rollers To bend 1 1 2 in 38 mm OD tubing use the fixed tail roller in the up position For 2 in 50 mm OD tubing use the fixed tail roller in the down position See Figure 1 To bend 1 in 25 mm OD tubing use the 1 in 25 mm removable tail roller securing pin in lower pin hole up position For 1 1 4 in 32 mm OD tubing use the 1 1 4 in 32 mm removable tail roller securing pin in upper pin hole Align roller with the inside of the unit See Figure 2 Select proper roller tower the size is indicated on roller tower To install lift and hold the handle lock Insert the roller tower into proper bridge opening so that the size indicator faces you Allow roller tower to lean against tail roller See Figure 3 Select proper tube clamp the size is indicated on clamp face Locate the tube size on the bend shoe and attach
17. www swagelok com Electric lube Bender User s Manual OwA Table of Contents Operators Safety Summary Grounding and Extension Cord Information oococcccccccoo Statements ai A A a a A adn ies SMA ia A A iio Safety ROQUES ici A ia a a eid doer Tube Bender Technical Data o ooooocoornrr eee tee Tubing Information ii de Tube Bender Components 000 ccc eens Digital Display Pendant cocos a ok Rie ere dia Pe ee ote dg ee eee Error Message x sai a a dd thd a eed died aga Shs dena dled cis Assembling Components sssaaa 000 ccc ttt Tubing Layout Single 90 Bendy iii A bed wide beeches tee Pdi aed ee hades Multiple 90 Bends Measure Bend Method oococcccccc tees Multiple 90 Bends Premeasure Method 0 000 c ccc te eee Making Offset Bends misonerien tenet eee 10 SPFINQDACK zra Paid Mead hee tah od tee id dee AA Re te an eae 11 BENN cic tiene Sect adink ie wench anh ien a aea aetna eet gated ene Staten ace ht eats 11 Bending Using Auto Bend 12 TrOUBIGSNOOLING ie eo seri he A de eee hd ted ode eed dete ad Rate 12 Roller Adjustment Screws o 13 Roller Alignment a gt bared a E ne ignore aia tated peated anand and eee Pee eee gd tee ea na dr etd 13 Mainitenanee aur aero teeth a A eae dls beeen gh eee hatch 14 Warranty Information aretina dae ee A we dew de ste aes tae said S 15 SAVE THESE INSTRUCTIONS Operator s Safety Summary READ AND UNDERSTAND THIS MANUAL B
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