Sb 48 Bender

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Electric Metal Bending

Electric Metal Bending Machine

Machine

ERCOLINA®

ERCOLINA® by

by CML International S.p.A.

CML International S.p.A.

ITALY

Tel. +39 0776 40281

Fax +39 0776 404801

www.ercolina.it - www.ercolina.com

e-mail: [email protected]

This manual was written according This manual was written according

to prescriptions of attachment to prescriptions of attachment I-1.7.4. of : 1.7.4. of : EEC DIRECTIVE 89/392 EEC DIRECTIVE 89/392 «MACHINERY DIRECTIVE» «MACHINERY DIRECTIVE» MODIFIED BY DIRECTIVE MODIFIED BY DIRECTIVE 91/368 91/368 RECEIVED BY PRESIDENTIAL RECEIVED BY PRESIDENTIAL DECREE NR. 459/1996 DECREE NR. 459/1996

EEC Directive 89/392 – published on the EEC Directive 89/392 – published on the European Community Official Journal

European Community Official Journal nr.

nr. L183 L183 dated dated June June 29, 29, 19891989

EEC Directive 91/368 – published on the EEC Directive 91/368 – published on the European Community Official Journal

European Community Official Journal nr. L198

nr. L198 dated dated July 22, July 22, 19911991

Presidential Decree 459/1996 – published on Presidential Decree 459/1996 – published on the Official Jour

the Official Journal nr. nal nr. 209 dated 209 dated SeptemberSeptember 6, 1996

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Remember:

Remember: after reading this manual, keep it in a safe place for future reference! after reading this manual, keep it in a safe place for future reference!

!!WARNING

Before using the machine read care

Before using the machine read carefully this instruction

fully this instruction

manual!

Any use of the machine which does not

strictly conform to the instructions of

this manual will immediately invalidate

the warranty and free the

Manufacturer of any responsibility.

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useful working tool. useful working tool.

Remember:

Remember: after reading this manual, keep it in a safe place for future reference! after reading this manual, keep it in a safe place for future reference!

!!WARNING

Before using the machine read care

Before using the machine read carefully this instruction

fully this instruction

manual!

Any use of the machine which does not

strictly conform to the instructions of

this manual will immediately invalidate

the warranty and free the

Manufacturer of any responsibility.

!!WARNING: the use and maintenance instructions

of this manual apply to each of the following machines,

unless otherwise specified: SB48 (single phase) ed

SB48T (three phase).

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WARRANTY CONDITIONS AND RESTRIC

WARRANTY CONDITIONS AND RESTRICTIONSTIONS ...33

PARTS

PARTS IDENTIFICATION...IDENTIFICATION... 55 GENERAL

GENERAL SAFETY SAFETY RULESRULES ... 66 APPLICATION

APPLICATION FIELDS...FIELDS... 99 TECHNICAL

TECHNICAL DATADATA ... 1010

WORKING CAPACITY

WORKING CAPACITY ...11...11

ELECTRIC AND

ELECTRIC AND ELECTRONIC COMPONENTS...ELECTRONIC COMPONENTS... 1212 RISK

RISK PREVENTION PREVENTION SOLUTIONSSOLUTIONS ... 1313 DIRECTIONS FOR RESIDUAL RISK LIMITATIONS

DIRECTIONS FOR RESIDUAL RISK LIMITATIONS ... 1414 IDENTIFICATION CE MARKING PLATE

IDENTIFICATION CE MARKING PLATE ... 1616 ECOLOGICAL

ECOLOGICAL INFORMATION...INFORMATION... 1717

MACHINE

MACHINE DEMOLITIONDEMOLITION...17...17 INDICATION FOR CORRECT WASTE DISPOSAL

INDICATION FOR CORRECT WASTE DISPOSAL ...17...17

MACHINE

MACHINE TRANSPORTATIONTRANSPORTATION ... 1818

LIFTING FROM

LIFTING FROM BOTTOM WITH BOTTOM WITH PACKING...PACKING...1818 PACKING

PACKING METHODS...METHODS...1818 TRANSPORTATION ON ROAD USING AUTHORIZED MEAN

TRANSPORTATION ON ROAD USING AUTHORIZED MEAN ...19...19 CHANGE OF WORKING POSITION

CHANGE OF WORKING POSITION ...1919

INSTALLING

INSTALLING THE THE MACHINE...MACHINE... 1919 USING

USING THE THE MACHINEMACHINE ... 2020

CHOICE

CHOICE OF OF ACCESSORIESACCESSORIES ...21...21 INSTALLING THE TOOLING

INSTALLING THE TOOLING ...2121 SWITCHING

SWITCHING MACHINE MACHINE ONON...22...22 MACHINE PREPARATION

MACHINE PREPARATION ...22...22 TIGHTENING THE

TIGHTENING THE TUBETUBE ...22...22 PROGRAMMING

PROGRAMMING THE THE MACHINE...MACHINE...2323

PROGRAMMING

PROGRAMMING MANUAL...MANUAL... 2323

INTRODUCTION

INTRODUCTION ...2424 KEY

KEY BOARD BOARD FUNCTIONSFUNCTIONS ...25...25 LIGHT

LIGHT SIGNALS...SIGNALS...26...26

PROGRAM

PROGRAM PROCEDURESPROCEDURES ... 2727

PROCEDURES FOR

PROCEDURES FOR BEND BEND MAKING...MAKING...2828 HOW TO CORRECT THE SPRING-BACK ANGL

HOW TO CORRECT THE SPRING-BACK ANGLEE ...30...30 EDITING THE ACTUAL BEND ANGLE

EDITING THE ACTUAL BEND ANGLE ...31...31 CHANGING THE LANGUAGE

CHANGING THE LANGUAGE ...31...31

PRACTICAL USE OF THE MACHINE

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R

Reevv..0000 PPaaggee 22 NOISE RATING MEASUREM

NOISE RATING MEASUREMENTENT ...4343

TEST

TEST CARDCARD ... 4444

SETTINGS OF SB48

SETTINGS OF SB48 ELECTRONIC BOARDELECTRONIC BOARD ...49...49 SPARE PARTS

SPARE PARTS ARTICLE CODESARTICLE CODES ...5151

REPLACEMENT

REPLACEMENT PARTS PARTS REQUEST...REQUEST... 5454 BENDING

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WARRANTY

Every machine is carefully controlled and tested before shipment. Machine Every machine is carefully controlled and tested before shipment. Machine installation is under customer’s responsibility, if qualified personnel is required for installation is under customer’s responsibility, if qualified personnel is required for assistance and training, the cost of the operation will be charged.

assistance and training, the cost of the operation will be charged. WARRANTY CONDITIONS AND RESTRICTIONS

WARRANTY CONDITIONS AND RESTRICTIONS 1.

1. Each ERCOLINA bender has a 24 month warranty effective from delivery date,Each ERCOLINA bender has a 24 month warranty effective from delivery date, against any component’s defect. The company reserves the right to request a

against any component’s defect. The company reserves the right to request a copycopy of the sale invoice.

of the sale invoice. 2.

2. Defects must be notified to us within 2 months from the date the defect has beenDefects must be notified to us within 2 months from the date the defect has been found.

found. 3.

3. Defects are checked on our premises, so every ERCOLINA® bender must beDefects are checked on our premises, so every ERCOLINA® bender must be sent, FREIGHT PREPAID, to our address or to authorized service centres. ANY sent, FREIGHT PREPAID, to our address or to authorized service centres. ANY FREIGHT COLLECT DELIVERY WILL BE REJECTED. If checking at FREIGHT COLLECT DELIVERY WILL BE REJECTED. If checking at customer’s premises is required, a cost for checking on site will be charged.

customer’s premises is required, a cost for checking on site will be charged. 4.

4. Warranty includes the defective component’s replacement or repair excludingWarranty includes the defective component’s replacement or repair excluding labour cost.

labour cost. 5.

5. Electrical parts are not included in the warranty in case of incompatibility withElectrical parts are not included in the warranty in case of incompatibility with power supply ( caused by overvoltage and / or atmospheric events ).

power supply ( caused by overvoltage and / or atmospheric events ). 6.

6. Operations performed under warranty do not extend warranty terms.Operations performed under warranty do not extend warranty terms. 7.

7. Warranty does not respond to damages caused by wear.Warranty does not respond to damages caused by wear. 8.

8. The warranty does not apply if damages are a result of incorrect handling or of aThe warranty does not apply if damages are a result of incorrect handling or of a use that does not conform with specifications described in this manual.

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Rev. 00 Page4

12. The warranty does not provide a replacement even temporarily of the machine. 13. The whole warranty declines if:

 The machine has been repaired or maintained by personnel that has not been authorised by Ercolina®;

 Not original parts have been used;

 Damages or errors are due to connections not performed according to the using instructions;

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PARTS IDENTIFICATION

1 Emergency switch mushroom_button 9 Counterbending die 2 Foot switch socket 10 Hexagonal shaft

3 4 5 6 7 8 9 10 11 12 13 14 15 16 2 1

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Rev. 00 Page6

GENERAL SAFETY RULES

The Ercolina® Super Bender has been designed following high tecnology standards and in accordance to the latest official safety regulations. The machine if improperly used can be a source of risk for the user or other people.

To avoid danger it is important to read and apply the following safety rules.

Use the machine only for the purpose for which it has been made and observing the general safety rules. The Manufacturer will not be liable for any damage or harm caused by improper use of the machine;

Do not switch on power supply and use the machine without reading carefullythe instruction manual

Do not install and use the machine in environments containing:  flammable fluids or gas;

 explosive materials;

Do not install the machine in a humid or wet environment; Do not expose the machine to the rain ;

Do not touch moving parts of the machine; Do not put hands on the tube during bending;

Avoid having more than one person working on the same machine;

Working area should not be restricted to a too limited space in proportion to the tube lengths to be bent;

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Do not use the machine beyond the maximum capacities indicated ;

Allow only qualified and authorised personnel to effect maintenance work or repair on the machine ;

Do not clean the machine without switching off power supply;

For safety reasons and in order not to invalidate the machine guarantee never modify the electric or electronic circuitry of the machine;

Never transport the machine by pulling it by the cable; Do not modify the machine structure.

!!Warning:

Only use original Ercolina® accessories made for this type of machine. Any modification will invalidate the machine guarantee. The Manufacturer reserves the right not to supply accessories or spare parts in case of alteration of the machine;

To avoid finger pinching never put fingers between formers and machine body;

Do not leave the machine unattended with power supply switched on .

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Rev. 00 Page8

Store the machine in a dry and safe location;

Delimit the machine’s working area with barriers and / or chains in order to avoid non authorised persons entering the working area of the machine when both in motion and switched off ;

Mark the working area with appropriate signals;

Always stand in a safe position during the functioning of the machine; Never stand on the opposite side of the machine operating controls;

Before transporting the machine always disconnect main power plug cable; Check wear of formers and counterbending dies;

Wear protective gloves while operating the machine;

Wear a protective helmet for upward moving or suspended tubes; Wear safety shoes in case of fall of heavy parts;

Read carefully the warning labels and plates on the machine.

!! WARNING: other safety protections can be adopted

by the operator or by the person in charge of the machine.

Our technical office is at complete disposal for any further

advice needed.

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APPLICATION FIELDS

The SB48 electric tube, pipe and profile bending machine can be used in the following sectors: ♦ mechanical, ♦ hydraulics, ♦ metal fabrication, ♦ marine engineering, ♦ electrical, ♦ general installation.

The SB48 machine can bend tubes and profiles of various dimensions, wall thickness and type of materials such as:

♦ steel, ♦ brass, ♦ copper, ♦ alluminium.

The SB48 electrical metal bending machine is provided with an induction motor and an electromagnetic brake, therefore is powerful and practically maintenance free; furthermore the microprocessor electronic control which is divided into 30 blocks of 9 bends each, allows easy achievement of accurate and repeatable bends.

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Rev. 00 Page 10

TECHNICAL DATA

Min outside diameter

Ø 5 mm

Max ouside diameter

Ø 48 mm

Min bend (R) radius 2 x tube Ø

Working capacity

Required time for tool

change 10 s

Maximum bend angle 180°

SB48 2 rpm

Speed

SB48T 4 rpm

Weight of machine body with no accessories 110 kg

Weight of greatest former which can be used 20 kg

Width 410 mm

Length 570 mm

Dimensions and weight

Height 1000 mm

TECHNICAL NOTE: Design and machine specifications are subject to change without prior notice.

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WORKING CAPACITY

Section Material Max ø x wall thick. (mm) Max ø x wall thick. (inches)OD Min radius (mm)

Boiler tubes* 48 x 3.5 1"1/2gasx0.134" 100

Standard steel tubes* 48 x 3.5 1"7/8x0.134" ₁₀₀

Soft brass 60 x 3 2"3/8x0.118" 120

Stainless steel 48 x 2.5 1"7/8x0.095" ₁₀₀

Welded tube for furniture* 54 x 1.5 2"1/8x0.059" 110

Hydraulic tube ST35 50 x 4 2"x0.157" 100

Hydraulic 304L stainless

steel tube 50 x 2.5 2"x0.095" 100

Hard copper & aluminium 64 x 2 2"1/2x0.065" ₁₃₀

Mild steel* 32 1"1/4 60 Mild steel* 48 x 8 1/4"x1"7/8 100 Mild steel* 40 x 20 x 3 3/4"x1"5/8x0.118_" 80 Mild steel* 40 x 40 x 3 1"5/8x1"5/8x0.11_8" 80 Mild steel* 30 x 30 1"1/4x1"1/4 ₆₀ Mild steel* 40 x 40 x 5 1"5/8x1"5/8x0.20_3" 80 Mild steel* 32 x 16 x 5 1"1/4x5/8"x0.203_" 60

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Rev. 00 Page 12

*Note: capacity refers to materials with a resistance equal to 42 kg/mm

ELECTRIC AND ELECTRONIC COMPONENTS

The SB48 machine is provided with the following electric and electronic components:

• electronic board microprocessor control core Zilog Z80, with 3 relay outputs,

TA controlled power absorbtion of the motor and LCD display of 16 characters divided into 2 lines working with 10.5V AC and an incorporated rectifier;

• power supply card, provided with a voltage transformer, AC transformer,

machine setting bridges and relays for motor running and brake control;

• electrical single phase motor with brake for former movement;

• red emergency switch button , for interrupting power supply to the machine in

case of danger;

• the r eset button ( not on SB48T), supplies power to the machine after

connecting AC power cord to an outlet with main power switch on position (1), - or – restores power supply after that emergency button has been pressed;

• Two pedal foot switch (Bend – Return), allows the operator to bend or to

place the former into position without using the manual controls;

• Degree counter , reads out position of counterbending die in relation to the

former;

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RISK PREVENTION SOLUTIONS

The SB48 electric metal bending machine is equipped with safety systems intended to minimize risks, which operators are exposed to during use or maintenance of the machine.

In the following table protection devices are listed associated to the main sources of risk they protect from.

Type of risk Safety devices

“Mushroom” emergency switch in front of machine which can be easily reached by the operator. Once pressed the button

remains in emergency position until it is manually released.

DANGERS OF MECHANICAL

NATURE

Pedal starting command purposefully designed to obstruct unintentional activation with protection on three sides (cover) and internal protection. The foot must be deeply introduced in the pedal cover to reach the pedal. In addition, the command works at low voltage.

Low tension command devices (24V).

DANGERS OF ELECTRICAL NATURE DUE TO DIRECT OR INDIRECT

CONTACT Electrical circuit closed on a panel.

During bending there is no risk of projection of workpiece.

FALL AND/OR PROJECTION OF

BENT PIECE

The risk of injury due to fall of workpiece during insertion or extraction is prevented by the command position which obliges the operator to stand in a safe position. Furthermore having a limited working area with confining barriers such as chains or protective shields with safety labels would avoid third persons

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Rev. 00 Page 14

DIRECTIONS FOR RESIDUAL RISK LIMITATIONS

To reduce uneliminable residual risks, due to the nature of working operations, we have provided:

• Individual protection systems and tags posted on the machine

indicaring the correct operating methods.

In the following table mandatory individual protection devices are listed associated to the risk they protect from.

TYPE OF RISK INDIVIDUAL PROTECTION DEVICES

Abrasion, cutting, collision danger

Gloves

Falling objects danger Helmet, protective shoes Danger of entanglement of

clothes

Adequate apparel

The following labels with caution indications have been attached to the machine ; they also provide information on the red emergency button, foot switch socket and the machine voltage.

SB48

SB48T

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• Confining barriers: due to the technical and operating characteristics of

the machine, installing rigid protection devices like protective shields would hinder its use, since the necessary operations would become impossible to perform;

Precautions:

 Confine working space;

 Indicate danger using necessary signals.

SB48 position

Tube position

!!WARNING:

During bending the

operator must always stand in the position indicated in the picture.

S

_SA

A

_AF

F

_FE

E

_ET

T

_TY

Y

_{Y A}

A

_AR

R

_R E

E

_EA

A

Working space

(Confined area – access denied to unassigned personnel)

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Rev. 00 Page 16

IDENTIFICATION CE MARKING PLATE

According to the rules in force ( Directive nr. CE/89/392 and presidential decree nr. 459/1996), the SUPER BENDER SB48 has an identification plate with CE marking, where information on the machine characteristics that may be relevant in terms of safety is included. Refer to this information in case of doubt.

The plate is placed on the lower side opposite to the controls where it can be easily seen and it is not removable.

If the idnetification plate for any reason is damaged, contact immediately the manufacturer for its replacement.

PLATE DATA

YEAR 200_

WEIGHT 110Kg

MODEL SB48 – SB48T

MOTOR POWER SUPPLY 110V – 230V – 400V

SERIAL N°

MOTOR POWER 1.5 Kw

Max RPM hexagonal shaft 2

!!WARRANTY:

Whoever tampers with or removes the plate, can be prosecuted by law and frees the Manufacturer from any warranty responsability.

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ECOLOGICAL INFORMATION

The disposal of the SB48 packing materials, replaced parts, lubricants, components or of the machine itself, must be performed respecting the environment, avoiding ground, water and air pollution.

It is the machine owner’s duty to perform this operation conforming to the rules in force in the country where the machine is used.

MACHINE DEMOLITION

We recommend deactivating the machine, before proceeding to its demolition:

o disassembling its components;

o removing the motor

INDICATION FOR CORRECT WASTE DISPOSAL

o Ferrous materials, aluminium, copper: are recyclable materials that must

be taken to the proper authorized collecting centre;

o Plastic and rubber materials: must be taken to a waste disposal site or to

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Rev. 00 Page 18

MACHINE TRANSPORTATION

Before proceeding, respect rules for use of lifting equipment and also verify:

♦ Machine weight indicated in the “Technical Characteristics” table; ♦ Make sure that ropes used are suitable and in excellent conditions; ♦ Always check wear conditions of ropes and hooks used;

♦ Make sure load is safely fastened and balanced; ♦ Warn start of handling phase;

♦ Make sure machine and installed equipment to be lifted does not exceed the

ifting mean’s maximum capacity;

♦ Do not abandon control place leaving suspended load unattaended.

LIFTING FROM BOTTOM WITH PACKING Before proceeding verify:

 Machine weight indicated in the “Technical Characeristics” table ;

 That the lifting mean used is suitable to lift the weight of machine and installed equipment;

 Indicated zones of pallet where grabs should be inserted;

 That the grabs are well placed before lifting the machine on order to avoid tipping it over.

PACKING METHODS

All machines, because of vibrations caused by transportation and particularly severe climatic conditions are carefully packed using appropriate materials to guarantee a total chemical and mechanical protection.

!!WARNING: during any machine handling adopt every safety measure and keep the necessary safety distance in case of load fall.

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TRANSPORTATION ON ROAD USING AUTHORIZED MEAN The machine must be loaded with the maximum precautions

and in the way illustrated in the figure to guarantee stability.

CHANGE OF WORKING POSITION

If you need to change the machine’s working space, before transporting the machine be sure you:

o Disconnect main power cable; o Disconnect foot switch;

o Remove all accessories

While transporting:

o Beware of machine weight indicated in “Technical Characteristics” table; o Keep feet away from machine.

INSTALLING THE MACHINE

Place the machine in a safe and stable position.

Connect the machine to a power supply circuit provided with a main switch to enable interruption of power supply.

The above must be performed by specialized personnel and after verifying that: Main switch is in position (0);

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Rev. 00 Page 20

USING THE MACHINE

The important concepts that need to be known for an optimal use of the SB48 machine are as follows:

• Bending angle, is the degree

value of the bend you wish to achieve;

• Spring back angle α, is the

difference between the required bend angle and the bend angle

which would be actually

achieved if the Ercolina system would not be adopted to eliminate it. The spring back angle is due to elasticity of the materials, when bent they tend to “spring back” towards their original shape;

β

Required bend angle.

γ

Bend angle achieved without adpoting Ercolina system to correct spring back angle.

Difference between two bends : one with spring back angle correction, the other with no spring back angle correction.

α = β-γ

Note: the scope of this section is to outline the fundamental concepts for bending. The procedure for correcting spring back angle is explained in the SB48 PROGRAMMING MANUAL - “Editing the actual bend an le”.

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tube or profile and the centre of the hexagonal shaft.

Follow these steps for proper use of the machine: CHOICE OF ACCESSORIES

Choose the correct former and counterbending die to bend your tube or profile. Always make sure that the external diameter and wall thickness of the workpiece, match the sizes marked on the former and counterbending die.

INSTALLING THE TOOLING

Former

Counterbend.die

Place the counterbending die on its support bracket.

Install former on upper part of hexagonal shaft as indicated .

!!WARNING: Always align the zero mark of former with the zero mark on the hexagonal shaft and body of machine.

!!WARNING: for a correct choice of tooling , we recommend to use our former and counterbending die charts in our catalogue.

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Rev. 00 Page 22

SWITCHING MACHINE ON

Switch on machine using main power switch turning it on position (1) and pressing set button.

MACHINE PREPARATION

TIGHTENING THE TUBE

Lubricate adequately counterbending die before insertin tube.

Insert tubeo into former.

Approach counterbending die turning bracket.

Tighten the tube between the former and counterbending die turning hand wheel.

!!WARNING: apply adequate tightening pressure , in order to avoid wrinkles on inside of bend and tube ovalization.

Screw the counterbending die to the support bracket .

!!WARNING: Screwing the counterbending die to its bracket is necessary only if counterbending die has not the quick “slide” engagement system.

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PROGRAMMING THE MACHINE

For programming of Ercolina Super Bender, follow instructions of “SB48 SUPER BENDER - PROGRAMMING MANUAL”.

Programming Manual

Hardware ver. RC0063 rev. C Software ver. E198

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Rev. 00 Page 24

INTRODUCTION

The microprocessor controlinstalled on the Super Bender SB48 board is equipped with a lithium back up battery able to store date fro over 10 years.

The autodiagnostic electronic system allows a reliable and accurate process of all its functions throughout all the use of its features.

The soft touch keypad simplifies the use of the machine and helps data insertion during the programming procedures.

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All the program functions can be executed with the use of the few simple keys described below:

• Confirms all data.

• Starts work program block . • Ends data storage.

• Bending alternative key to move the shaft of the machine (alternative to foot

pedal).

• In the data entry mode this key can be used to insert 90° directly in the

program in a quicker way.

• Return alternative key to move the shaft of the machine backwards

(alternative to foot pedal).

• During the data entry mode allows the insertion of new data or changes in

old data stored .

• When doing the spring back angle it allows to change the previous set

value.

• Program key for increasing bend angle value. • Enables data entry.

• Allows work block selection.

• Program key for decreasing bend angle value.

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Rev. 00 Page 26

LIGHT SIGNALS

On the main electronic card, there are a number of light signals which will appear accordingly to the machine position as follows:

OVERLOAD:

• Excessive power absorbed

• Connections to the main motor have been interrupted • Emergency stop button activated

• Magneto thermic switch in the off position

WARNING: • Low tension • High tension • Error 86* • Error 87* • Error 88* SYNCRO:

• Reset return phase

BEND:

• Machine is ready to bend

• (flashing) bend is accomplished

POWER:

• Power supply going in main electronic board

*Note: information concerning ERRORS 87-88 on the SB48 is on page 37 e 38 of this manual; information concerning ERRORS 86-87-88 on the SB48T is on page 39, 40, 41.

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PROGRAM PROCEDURES

1. Activate data entry mode:

• Switch on power supply (by using main switch) and press set up button ; • Press the button ; the display should show as follows:

Program Start

2. Press the or keys to continue or not the data entry mode;

3. If you have chosen to insert new data pressing the plus , you will have to choose the block in which you would like to work with using again the plus button to select a group to work with from P0 to P9.

By pressing minus button for 4 seconds while the program number is displayed, all the previous stored data will be lost and new data can be memorised.

4. Once the group has been selected and it is ready to be programmed, the display will show as below ; you may now insert the bend angle value and store it with

the button.

Insert bend angle

5. To insert the bend angle values press and buttons to increase or decrease

DATA ENTRY MODE +=YES ENTER = NO

INSERT BEND 1(1…P) 000

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Rev. 00 Page 28

Stored bend angle

7. Once the first bend angle has been inserted, the program will automatically ask for the second bend angle which can be inserted in the same way as the first. The same can be done for the third, the fourth and so on until the ninth of the same group by repeating steps 5 and 6. If instead you wish to end the data entry you must press the button without inserting any angle value the display will show :

End of data storage

8. For programming new groups press button and repeat steps from 3 to 7. To end data storage press .

PROCEDURES FOR BEND MAKING

After the full data entry will be finished the machine will be in stand by mode with the following message :

Stand by mode

In this position if the bend angles memorised are more than one, with the use of the button you may scroll through and choose the bend angle you would like to use . Set all tooling on the machine, former and counterbending die of the same size of the material to be bent. Set in position the support bracket and adjust initial pressure on tube against the former. With the use of the keys, and you will need to memorize the cursor counterbending die postion :

STORED

END OF DATA ENTRY

FORWARD C.BEND DIE Mm - … PR … 1

FORWARD C.BEND DIE Mm - … PRX1

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Setting the electronic counterbending die position

The position of the counterbending die (mm 000.0) is controlled by the microprocessor which enables the machine to carry out the following bends repeating exactly the position of the cursor and counterbending die with a tolerance of + 0.2mm.

It will be possible to begin the first bend now by pressing the button; the tube will begin to move in the tools until it will be possible that it will visibly begin to bend the angle moved will be our spring-back angle. See example in the bottom indicating what the display will show:

Spring back

Press the button to memorise the spring back angle (see below).

Spring back storage

It will be possible now to bend by continuing to press the button.

Once the bend angle will be achieved, the machine will stop automatically and the yellow light will flash.

Press the button to bring the machine back to the 0 origin point.

BEND 1 0° 090° Mm 000.0 0° 008° BEND 1 8° 090° Mm 000.0 8° 000°

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Rev. 00 Page 30

• The machine shaft should be without any kind of tools;

• Keeping the button or pressed by turning on the machine simultaneously,

you will enter the shaft reset mode.

• When the mode is entered the display should show the following message:

Shaft (axis C) reset mode

In this mode press the or pedals, to move the hexagonal shaft base aligned with the mark, placed on the aluminium body of the machine itself.

• To store the new origin or 0 point, you need to press the button and the

display will show as follows:

New position of the shaft stored ( Axis C )

HOW TO CORRECT THE SPRING-BACK ANGLE

If while working you notice that the required bend angle achieved is not conforming to the desired angle you may adjust the spring-back angle to correct the angle in the machine program.

To correct the bend angle, while working you need to :

• stop the machine from working by releasing all keys;

• press the button _, then a flashing cursor will appear on the spring-back angle

value;

• the value of the spring-back angle can be changed with the use of the buttons

and ;

• The new set value will be stored only after having the button pressed, the

following message will then be displayed :

Spring-back angle change storage 0

SHAFT RESET MODE

SHAFT RESET STORED

BEND 1 12° 090°

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In the example shown in the above picture the new spring-back value (12°) has been stored on the first 90° bend.

• After the new angle has been stored you may proceed continuing the bend until completed.

EDITING THE ACTUAL BEND ANGLE

As the spring-back angle you may also modify the bend angle without changing a whole program. To edit a single bend angle you must:

• interrupt bending ;

• press the button until the flashing cursor is on the bend angle value;

• at this point with the use of the and buttons you may add or subtract

degrees to your original stored angle;

• Once the bend angle has been changed you will need to store it by pressing the

button.

CHANGING THE LANGUAGE

In order to change the machine language on the display please act as follows:

• Place the machine in the off position and then press the , ,

simultaneously while turning on the machine;

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Rev. 00 Page 32

PRACTICAL USE OF THE MACHINE

Main points to keep in mind for bending correctly with the Ercolina® system:

♦ Before bending make sure that the outside diameter of the tube is of the same

size as the one printed on the former and the counterbending die.

!!Note: if you measure the former groove with a calibre, do not be surprised to find it a few mm smaller ( if the wall thickness of the tube is smaller than 2,5mm ) or a decimal part of a mm smaller ( if the wall thickness of the tube is greater than 2,5mm ) than the actual marked diameter size. It is perfectly normal and it is part of the Ercolina® bending technology.

♦ Remember that the minimum bend radius depends on the material to be

bent, the tube external diameter and the wall thickness of the tube.

♦ Correct pressure between

former and counterbending die. You must apply just enough pressure to avoid wrinkles on the inside bend of the tube.

!!Note: If even with a higher pressure there are still wrinkles in the inside bend use a former with a larger radius.

♦ In case of excessive

constriction of the tube on its inside radius use the special screw on support bracket: as soon as tube starts visibly bending tighten screw so that the screw touches the back of the counterbending support bracket. After this continue the bending process as normal. Fine adjustment of this screw will further improve the bend quality.

Special screw

Results achieved after bending with no special screw or by using it in a too backward position

Improvement of bend quality achieved by fine adjustment of special screw

Results achieved after bending with no special screw or by using it in a too forward position.

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materials.

♦ Former and counterbending die must never touch otherwise the tube may break

or have wrinkles on the inside bend and the machine can be damaged.

♦ Do not keep tubes in dusty/dirty places, in these conditions the counterbending

dies will wear out faster due to increased friction between the dirty tube and counterbending die

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Rev. 00 Page 34

MAINTENANCE

ORDINARY MAINTENANCE

Lubrication. In order to always guarantee optimal functioning of the SB48 machine , grease upper gear box with a grease gun every 40 hours of work.

How to replace the hexagonal shaft (former holder ). Act as follows:

a. _{unscrew all the bolts which hold the shaft ;} b. _{extract the hexagonal shaft ;}

c. _{insert new hexagonal shaft so that the zero} marked on the machine body match ( only one fitting position is possible );

d. _{screw the bolts firmly back into place} following a cross section order.

EXTRAORDINARY MAINTENANCE

Any repair or replacement of internal and exernal parts of the machine must be made only by personnel trained/authorised by the Manufacturer.

The Manufacturer reserves the right not to supply accessories or spare parts if the machine has been modified.

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TUBE BENDING TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Wrinkles on internal surface of bend

Bending pressure is too low

Apply more pressure on tube ( the maximum pressure is achieved when former and counterbending die are almost touching ).

Wrinkles on internal surface of bend

Counterbending die and

former are touching Act so that these two parts do not touch Wrinkles on internal

surface of bend

Former radius is too

small Use former with larger radius. Excessive tube

deformation (ovalisation)

Bending pressure is too high

Diminish bending pressure or use former with a larger radius.

Excessive tube deformation at beginning and end of bend

Bending pressure is too high

Diminish bending pressure or use former with a larger radius.

Excessive tube deformation on internal radius at beginning and end of bend

Bending pressure is too

high Use special screw on support bracket . Machine fails to bend

since machine goes into overload

Tube wall thickness and/or chemical composition of tube is beyond machine bending capacity

Try to bend by using the special Ercolina® roll instead of counterbending die.

For any other technical problem on bending, contact your nearest Ercolina® dealer.

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Rev. 00 Page 36

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Does not switch on Electrical

connections in plug Check plug

Does not switch on Electrical connection Check power cable making sure it is not damaged

Display is completely off

Missing phase Check plug and phases on QS1 M a c h i n e Display is completely off

Burnt fuse Check fuses and if blown replace

Pushing pedal machine does not start

Support bracket datum position not stored

Store bracket position

“Low tension” Low voltage power supply

Switch off machine immediately and connect it to suitable power supply.

“High tension” High voltage power supply

Switch off machine immediately and connect it to suitable power supply

“Error 87” Faulty T.A. Check phases

“Error 87” C axis beyond 210° Reset heaxagonal shaft ( C axis )

“Error 88” C axis beyond 210° Reset heaxagonal shaft ( C axis ).

“Error 88” Faulty axis C encoder Check connections on electronic card ( 4 pin connector marked with a C ) with a screwdriver making sure connections are not faulty. D i s p l a y s h o w s :

“Error 88” Faulty axis C encoder.

Check integrity of encoder star wheel next to motor shaft, making sure it is not dirty ( clean with air jet ). Also make sure that star is not loose. Make sure that star wheel is at the centre of the degree reader.

Overload light on Machine overloaded. Switch off machine. Use within its capacity. Use correct tooling and materials.

Overload light on Faulty motor. Check motor connections.

Warning light on Faulty motor. Turn emergency button, switch machine off and reswitch on QS1.

I f :

Overload light on Faulty axis C encoder.

Check C axis encoder and its connections.

The machine works but shows Error 88 every now and then

Broken or dirty axis C encoder.

Clean encoder with an air jet from beneath the hexagonal shaft holder. Check integrity of the encoder and of star wheel.

TROUBLESHOOTING (only for SB48T) “Incorrect rotation direction

reverse switch”

Inverted phase Reverse main switch QS1.

“Error 86” Missing phase Check plug.

“Error 88” and when pedals are pressed the machine clicks

Faulty TR1 or rectifier.

Press on KM’s and check outlets 101-102 (100 V), if there is no power on replace TV1, if there is power press on KM’s and check outlets 200-201 (110 V), if there is no power replace rectifier. D i s p l a y s h o w s :

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If when pressing on the pedal the motor does not start and “ERROR 87” appears on the display

ERROR 87

Cause

AXIS “C” HAS HIT THE

LIMIT MICROSWITCH INTERRUPTED T.A.

REMEDY T.A. JP2 Setting End of operation at 210° Origin axis C indicator REMEDY See “ERROR 88”

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Rev. 00 Page 38

Premendo il pedale il motore accenna a partire ma si ferma immediatamente e sul

display appare: ERRORE 88.

Premendo un pedale il motore non parte e sul display appare: ERRORE 88. ERROR 88 Cause “AXIS C “ AT LIMIT MICROSWITCH INTERRUPTED T.A. Cause

If when pressing on the pedal the motor appears to want to start, but then stops immediately and “ERROR 88” appears on the display

If, when pressing on the pedal the motor does not start and “ERROR 88” apperas on the display

End of operating at 210°

Origin “Axis C” indicator

1. If, the machine is at the end of operations stage at 210°, you have to switch machine off and then back on and return. 2. If, the machine

passes the “0” point indicator you must reset the origin “Axis C” REMEDY Special key Cap Connector Motor Star Electronic board Lower plate Encoder REMEDY 1.Open the window on the microprocessor and lift the microprocessor. Disconnect the microprocessor from the connector “degree counter” identifiable by a “C” on the cap, and with a special key push on the 4 wires to make sure that there is not a faulty connection.

2.Check the encoder which can be found near the motor and make sure all is in order as shown on the drawing. If the fault remains, replace the encoder.

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ERROR 86

If, when pressing on the pedal the motor does not start and “ERROR 86” appears on the display

MISSING PHASE BURNT FUSE

Plug On/Off Switch Magneto thermical switch REMEDY Replace fuse

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Rev. 00 Page 40

ERROR 87

If, when pressing on the pedal the motor does not start and “ERROR 87” appears on the display

“AXIS C” HAS HIT THE LIMIT MICROSWITCH INTERRUPTED T.A. MISSING PHASE Plug On/Off switch Magneto thermical switch REMEDY See “ERROR 88” REMEDY

Check the phases in the T.A. nos. 400 and 403 End of operation at 210° Origin axis C indicator REMEDY See “ERROR 88”

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If, when pressing on the pedal the motor does not start and “ERROR” 88 appears on the display

If when pressing on the pedal the motor appears to want to start, but then stops immediately and “ERROR 88 “ appears on the display

Damage to encoder “Axis C” Emergency button pressed “Axis C” at limit microswitch Missing phase Special key Cap Connector Encoder Lower plate REMEDY Motor

1.Open the window on the microprocessor and lift the microprocessor. Disconnect the microprocessor from the connector “degree

Emergency stop button is pressed Electronic board Release before pressing again on foot switch REMEDY

1. If, the machine is at the end of operations stage at 210°, you have to switch machine off and then back on and return.

2. If, the machine passes the “0” point indicator you must reset the origin “Axis C” REMEDY End of operating at 210° Origin “Axis C” indicator Plug On/Off Switch Magneto thermical switch REMEDY 1.Check the electrical plug socket.

ERROR 88

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Rev. 00 Page 42

MACHINE CE CONFORMITY DECLARATION

(Directive n. 89/392 CE, Attachment II, part A).

Manufacturer: C.M.L. International S.p.A. Address: 03030 Località Annunziata snc

Piedimonte S. Germano (FR), Italy

declares that:

The ELECTRICAL TUBE, PIPE AND PROFILE BENDING MACHINE SB48, Series N° ________________ is:

− _{In confirmity with the Machine Directive (Directive n. 89/392 CE), as modified with the}

legislation that transposes it;

− In conformity with conditions of the following CE directives: − directive 73/23/CEE regarding low voltage electrical material; − directive 89/336/EEG regarding electromagnetic compatibility ;

− _{directive 89/392/CEE regarding member countries approaching on machine legislation ;}

− directive 85/374/CEE regarding member countries approaching on legislation for

responsabilities for damages caused by defective products;

NOISE RATING MEASUREMENT

TYPE OF

MEASUREMENT NOISE RATING dB <78

Measurements performed according to machine directives.

Made in __________ Date _____________

Signatory’s name Signature

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Rev. 00 Page 44

TEST CARD

MACHINE / COMPONENT TEST

CARD NUMBER: N°………. MACHINE / COMPONENT:

TEST INSPECTOR : TEST DESCRIPTION:

DATE OFTEST START END

/ /200__ CHECK DESCRIPTION MODEL: MATERIAL: TYPE OF WORK: ANOMALY/IES FOUND DIAGNOSIS REMEDIES SUGGESTIONS TEST RESULTS CONCLUSION NOTES

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Rev. 00 Page 46

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FUSES

F1: 1A 250V ( Trasformer protection TV1) F2: 1A 250V (Motor brake protection) F3: 25A 250V (Power supply protection) F4: 1A 250V (Start circuit)

ELECTRONIC BOARD CONFIGURATION

Before connecting the machine to power supply, set voltages on the JP1 bridge and the TA values on the JP2 bridge in the following manner:

Machine Voltage JP1 JP2

SB48 110V 104V 104 16

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Rev. 00 Page 50 72 80 93 87 29 5 121 90 89 88 36 35 112 6 1 60 33 xxx 12 92 59 81 48 12 32 37 120 36 78 76 36 119 60 110 117 43 118 61 62 63 66 12 16 67 70 65 xxx 91 44 69 57 56 19 51 50 18 40 48 xxx 15 2 55 39 25 ₆₈ 84 101 97 85 34 27 102 30 26 34 31 28 104 73 71 11 3 24 106 105 108 109 13 14 17 107 103 115 116 10 113 83 4 41 23 xxx 37 21 38 82 45 94 46 20 54 53 95 47 52 42 111 68 74 77 79 75 9 49 98 38 96 99 64 100 22 114 58 “

“EER R CCOOLLIINNAA”” SSUUPPEER R BBEENNDDEER R SSBB4488 – – EExxppllooddeedd vviieeww f f oorr ppaarrttss iiddeennttiif f iiccaattiioonn

Complete bracket Complete instr. board _(425mm) (550mm) (Z90) (Z44) (Z32) (Z36) (40mm) (50mm)

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CHART OF SPARE PARTS ARTICLE CODES

POSIT. COMP. ART. DESCRIPTION

1 810P GREASE SPRAY

2 AD001 ERCOLINA “BIG” ADHESIVE LABEL

AD001/11 SB48 SUPER BENDER ADHESIVE LABEL

3 AP162 SCREW

4 CPM101 MOTOR KW1,5 - 230V - Hz50

5 MP202A/1 ELECTRONIC CARD

6 P010 PLASTIC GREASE GUN 150ml

7 P050A HEXAGONAL SHAFT 40MM

8 P050B HEXAGONAL SHAFT 50MM

P050/D ADHESIVE LABEL “GREASE EVERY 40 HOURS”

9 P050D/1 COMPLETE SUPPORT BRACKET

10 P050G 4 SPOKE HAND WHEEL

11 P050H FOOT SWITCH

12 P103 CONICAL HEAD PHILIPS SCREW

13 P107/2 FUSE

14 P108 FUSE HOLDER

15 P112 FOOT SWITCH SOCKET

16 P184 SPRING WASHER 17 P190S SCREW 18 P191J/1 3 PIN PLUG 19 P229 KEY 20 P244 KEY 21 P352 MICROSWITCH 22 P352A MICROSWITCH 23 P365 SCREW 24 P378 SCREW 25 P502 GRAB HANDLE 26 P503 RUBBER WHEEL 27 P504 SCREW 28 P507 WASHER 29 P508 NUT 30 P511 LOCK

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92 P705/4

P705/6 AXIS C READER AXIS

93 P706A BUSHING 94 P707A PINION 95 P710 OIL SEAL 96 P722B PULLEY 97 P722C PULLEY 98 P723C PULLEY 99 P723D PULLEY 100 P724A1 BELT 101 P724C TOOTHED BELT 102 P725/2 SUPERBENDER SB48 CABINET

103 P725A CABLE GLAND

104 P725/B BRASS BUSH

105 P725C POWER CABLE

106 P725D/2 SINGLE PHASE 2 PLUG

107 P725L PLATE PANEL

108 P725T SERIAL NUMBER PLATE

109 P725T1 RIVETS

110 P728NS COMPLETE SUPER SB48 ELECTRONIC CARD

111 P730A SCREW

112 P731 HEXAGONAL SHAFT COVER

113 P732 SCREW

114 P735 BUTTON

P735/1 BLOC. P9B10VN

116 P737 RELAY SWITCH UNIT P737/2 RELAY SWITCH UNIT 117 P738 BLACK PLASTIC CAP

118 P738A BLACK PLASTIC CAP

119 P741 FLEX PLATE

120 P742 FIXING PLATE

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Rev. 00 Page 54

REPLACEMENT PARTS REQUEST

In order to achieve a perfect identification of a particular required component please specify:

MODEL: Serial N°: Sub-group: Component position N°: Code N° Description Quantity