Baileigh RDB-250 Operator's Manual
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Baileigh RDB-250 Operator's Manual

Rotary draw bender
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OPERATOR'S MANUAL
ROTARY DRAW BENDER
MODEL: RDB-250
REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL, INC.
IS PROHIBITED. Baileigh Industrial, Inc. does not assume and hereby disclaims any liability for any damage or loss
caused by an omission or error in this Operator's Manual, resulting from accident, negligence, or other occurrence.
Rev. 03/2015
© 2015 Baileigh Industrial, Inc.

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Summary of Contents for Baileigh RDB-250

  • Page 1 REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL, INC. IS PROHIBITED. Baileigh Industrial, Inc. does not assume and hereby disclaims any liability for any damage or loss caused by an omission or error in this Operator’s Manual, resulting from accident, negligence, or other occurrence.

  • Page 2: Table Of Contents

    Table of Contents THANK YOU & WARRANTY ..................1 INTRODUCTION ......................3 GENERAL NOTES ......................3 SAFETY INSTRUCTIONS ....................4 SAFETY PRECAUTIONS ....................7 TECHNICAL SPECIFICATIONS ..................9 TECHNICAL SUPPORT ....................9 UNPACKING AND CHECKING CONTENTS ..............10 Cleaning ........................10 TRANSPORTING AND LIFTING ..................
  • Page 3 Large Size Square ..................... 40 INDEX TABLE ATTACHMENT (OPTIONAL EQUIPMENT) .......... 41 Introduction ........................ 41 Connection to Your Machine ..................41 Height Adjustment and Leveling ................41 Material Layout ......................42 Operation ........................42 INDEX TABLE LAYOUT DIAGRAM (OPTIONAL EQUIPMENT) ........43 LUBRICATION AND MAINTENANCE ................

  • Page 4: Thank You & Warranty

    THANK YOU & WARRANTY Thank you for your purchase of a machine from Baileigh Industrial. We hope that you find it productive and useful to you for a long time to come. Inspection & Acceptance. Buyer shall inspect all Goods within ten (10) days after receipt thereof. Buyer’s payment shall constitute final acceptance of the Goods and shall act as a waiver of the Buyer’s rights to inspect or...
  • Page 5 Baileigh Industrial makes every effort to ensure that our posted specifications, images, pricing and product availability are as correct and timely as possible. We apologize for any discrepancies that may occur. Baileigh Industrial reserves the right to make any and all changes deemed necessary in the course of business including but not limited to pricing, product specifications, quantities, and product availability.

  • Page 6: Introduction

    After receiving your equipment remove the protective container. Do a complete visual inspection, and if damage is noted, photograph it for insurance claims and contact your carrier at once, requesting inspection. Also contact Baileigh Industrial and inform them of the unexpected occurrence. Temporarily suspend installation.

  • Page 7: Safety Instructions

    IMPORTANT PLEASE READ THIS OPERATORS MANUAL CAREFULLY It contains important safety information, instructions, and necessary operating procedures. The continual observance of these procedures will help increase your production and extend the life of the equipment. SAFETY INSTRUCTIONS LEARN TO RECOGNIZE SAFETY INFORMATION This is the safety alert symbol.
  • Page 8 SAVE THESE INSTRUCTIONS. Refer to them often and use them to instruct others. PROTECT EYES Wear safety glasses or suitable eye protection when working on or around machinery. PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing.
  • Page 9 KEEP CLEAR OF MOVING OBJECTS Always be aware of the position of the material and the swing area in which the material will travel. The material will swing with significant force. This swing area will create pinch points and the force of the material movement may cause serious bodily injuries.

  • Page 10: Safety Precautions

    SAFETY PRECAUTIONS Metal working can be dangerous if safe and proper operating procedures are not followed. As with all machinery, there are certain hazards involved with the operation of the product. Using the machine with respect and caution will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result.
  • Page 11 11. Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or across a running machine. 12. Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or machine when you are tired. 13.

  • Page 12: Technical Specifications

    TECHNICAL SPECIFICATIONS Maximum Center Line Radius (CLR)* 9" (229mm) Minimum Center Line Radius (CLR)* .5" (12.7mm) Minimum OD .25" (6.35mm) Mild Steel Pipe (Schedule 40) Based on a material tensile strength of 60000 PSI – mild 2" (50.8mm) steel Aluminum Pipe (Schedule 40) 2"...

  • Page 13: Unpacking And Checking Contents

    UNPACKING AND CHECKING CONTENTS Your Baileigh machine is shipped complete in one crate. Separate all parts from the packing material and check each item carefully. Make certain all items are accounted for before discarding any packing material. WARNING: SUFFOCATION HAZARD! Immediately discard any plastic bags and packing materials to eliminate choking and suffocation hazards to children and animals.

  • Page 14: Transporting And Lifting

    TRANSPORTING AND LIFTING CAUTION: Lifting and carrying operations should be carried out by skilled workers, such as a truck operator. Make sure the machine is well balanced. Choose a location that will keep the machine free from vibration and dust from other machinery.

  • Page 15: Assembly And Set Up

    • Keep the floor free of oil and make sure it is not slippery. • Remove scrap and waste materials regularly, and make sure the work area is free from obstructing objects. • If long lengths of material are to be fed into the machine, make sure that they will not extend into any aisles.

  • Page 16: Getting To Know Your Machine

    GETTING TO KNOW YOUR MACHINE...

  • Page 17: General Design Description

    The simplicity of design and minimum effort required to operate the machine contributes towards meeting schedules and producing greater profits. The RDB-250 is an electric powered “Rotary Draw” bending machine. To bend material, a bending die and counter die are required. The material is hooked by the bending dies’ hook arm and is powerfully rotated in the clockwise direction.

  • Page 18: Electrical

    ELECTRICAL CAUTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY A CERTIFIED ELECTRICIAN! Check if the available power supply is the same as listed on the machine nameplate. WARNING: Make sure the grounding wire (green) is properly connected to avoid electric shock. DO NOT switch the position of the green grounding wire if any electrical plug wires are switched during hookup.

  • Page 19: Plug Connection

    • Improper connection of the equipment-grounding conductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

  • Page 20: Operation

    OPERATION CAUTION: Always wear proper eye protection with side shields, safety footwear, and leather gloves to protect from burrs and sharp edges. CAUTION: Keep hands and fingers clear of the dies and swing arms. Stand to the front of the machine to avoid getting hit with the material during the bending process.

  • Page 21: Programmer Display And Key Functions

    Programmer Display and Key Functions 1. The touch screen control is very self-explanatory. By touching the labeled touch boxes on the screen, the listed parameter or function will be selected. The exit box will return you to the previous screen and get you back to the RMD MAIN SCREEN. When entering names and degrees, a keypad will be displayed Fig 2, 3, and 4 to allow switching between alpha and numeric keys.

  • Page 22: Main Menu Choices

    Main Menu Choices 1. "RUN, VIEW OR EDIT A PROGRAM" Select this Feature if you want to: Run a program View the settings of an existing program Edit or create a program. a. Up to 170 programs with 10 bends per program can be created using any alphanumeric characters.

  • Page 23: Edit A Program

    Edit a Program 1. Select this feature when you want to edit an existing program. a. From the Program selector screen Fig 5, choose the program number to be edited. Use the up and down arrows to move the screen up or down one line or one page at a time.

  • Page 24: Dry Running

    4. After selecting the program line. Touch the EDIT button and the program parameters will be displayed Fig 6. Press the View button in the upper right corner to change to the Edit mode. 5. On the edit screen enter the desired PROGRAM NAME by touching the name field Fig.

  • Page 25: Manual Bend

    down one line or one page at a time. Dashed lines in the name indicate that no program is saved to that location. 3. After selecting the program touch the RUN button and the program parameters will be displayed Fig 7. 4.
  • Page 26 5. When the angle and speed settings have been entered, the bend may be dry run or an actual bend may be performed. Full Manual Mode Full Manual Mode allows for bending to any angle between 0.0 and 200.0 degrees with only the operator controlling the stop point.

  • Page 27: Homing

    Homing IMPORTANT: Don’t Change the home position unless you are sure the position was lost, damage to the machine and tooling can occur if the home position is set incorrectly. 1. The machine has been homed from the factory and does not need to be re-homed unless the encoder or drive motor needs servicing.

  • Page 28: Oem Screens And Bending More Than 180 Degrees

    • Parameters in the OEM MENU should only be done after consulting the factory. Changing these parameters without consulting the factory will void the warranty. • This machine is capable of bending more than 180 degrees. Contact Baileigh Industrial about your application.

  • Page 29: Oem Screen Shots

    • Activation of bi directional option should only be done at the factory. Consult the factory for specific information. OEM Screen Shots OP Screen Figure 1 OEM Screen Figure 11 OEM Screen Figure 12 OEM Screen Figure 13...
  • Page 30 OEM Screen Figure 14 OEM Screen Figure 15 OEM Screen Figure 16 OEM Screen Figure 17...
  • Page 31 OEM Screen Figure 18 OEM Screen Figure 19 OEM Screen Figure 20 OEM Screen Figure 21...
  • Page 32 OEM Screen Figure 22...

  • Page 33: Understanding Springback

    UNDERSTANDING SPRINGBACK Springback can be difficult to understand. As material is bent, the materials yield strength resists being formed. As a final degree is reached, the machine will have enough power to hold the bend at a set degree, but as the pressure of the machine is released, the material has a resistance built in, so it “springs back”...

  • Page 34: Die Selection And Installation

    Bronze Counter Die Insert “0” Mark Note: Pipe and Tube are not the same, (see table 1) for nominal pipe sizes. All BAILEIGH INDUSTRIAL dies are color coded to avoid confusion between pipe and tube (see table 2). IMPORTANT: Damaged or worn tooling should be replaced before attempting to bend material.
  • Page 35 Spindle Die Drive Pins 1/2-13 Tapped holes for bolting down dies Center Pin At “0” position, this flat is parallel with the machine side Hitch Pin 4. To install the counter die, remove the hitch pin and insert the counter die in the opening in the counter die mount until the 3/4”...

  • Page 36: Material Insertion

    • Another program available is BEND-TECH which is a program specifically designed for tube bending and will give you all of the required data to make a part. This software is available from Baileigh Industrial. • Bending with a rotary draw bender requires determining the start of bend point which will line up with the “0”...
  • Page 37 6. With the counter die tight, document the number displayed on the Leadscrew counter, you will want to return to the same exact number every time to ensure exact counter die positioning and repeatable bends. This number can be entered in the control for programmed bends.

  • Page 38: Material Removal / Advancement

    Left Right • In the left figure, there is not enough material to complete the bend. This bend will damage the dies. • The right figure shows a correct bending orientation. IMPORTANT: Orienting your tubing in this fashion will cause damage to your tooling and machine!! DO NOT pull bent tubing into the counter die! Make sure you have enough straight material on the draw side of the tube to create your bend.

  • Page 39: Pipe And Tube Bending Diagrams

    PIPE AND TUBE BENDING DIAGRAMS L = Arc length (outside) R = Rise (inside) D = Tube outside diameter t = Tube wall thickness a = First bend arc angle H = Height of offset b = Second bend arc angle L = Length of offset A = First tangent R1 = First radius...

  • Page 40: Bending Glossary

    BENDING GLOSSARY Arc Length The length of material along the centerline of the tubing Distance in inches from the center of curvature to the centerline Centerline Radius (CLR) axis of the tube bending or pipe bending bends. Abbreviated as CLR. See Tube Bending and Pipe Bending Diagram Angle in degrees to which the tube/pipe bends are formed (i.e.

  • Page 41: Bending Suggestions

    • If using BAILEIGH INDUSTRIAL’s standard counterdie is not producing desired results, roller counter dies are also available. • BAILEIGH INDUSTRIAL has both steel rollers as well as plastic rollers. Plastic rollers are used primarily for polished aluminum. Steel rollers would be used for non-polished materials.

  • Page 42: Bending With Square Dies

    Bending With Square Dies • Die Parts Main Bending Die Die Cap Quick Release Handles Hook-Arm Hook-Arm Clamp Plastic Slide Slide Mount Quick Release Studs Square Tooling Setup 1. Install the bending die (1) on to the spindle. Be careful not to pinch your fingers as you lower the die on to the spindle.

  • Page 43: Large Size Square

    If the square material slips in the hook arm, use the supplied clamp and bolts to hold in place. BAILEIGH INDUSTRIAL offer crush bend dies to form a concave crease on the inside of square bends to reduce the possibility of wrinkling.

  • Page 44: Index Table Attachment (Optional Equipment)

    INDEX TABLE ATTACHMENT (OPTIONAL EQUIPMENT) Introduction The IDX-10 Indexing table was designed to allow you too accurately and repeatedly position distances between bends, by using the adjustable stops. Also the IDX-10 can be used to hold the material being bent perfectly level while bending, or altering the angles between bends. Connection to Your Machine 1.

  • Page 45: Material Layout

    5. The previous steps are just examples how to set stops and produce various bends; it is up to the user to define exactly how their IDX will be set up. BAILEIGH INDUSTRIAL will be glad to offer any suggestions for your application.

  • Page 46: Index Table Layout Diagram (Optional Equipment)

    INDEX TABLE LAYOUT DIAGRAM (OPTIONAL EQUIPMENT)

  • Page 47: Lubrication And Maintenance

    LUBRICATION AND MAINTENANCE WARNING: Make sure the electrical disconnect is OFF before working on the machine. Maintenance should be performed on a regular basis by qualified personnel. Always follow proper safety precautions when working on or around any machinery. • Check daily for any unsafe conditions and fix immediately. •...

  • Page 48: Electrical Schematic

    ELECTRICAL SCHEMATIC Horner ( XLE or XLT) Hexle 102 or HE-XT102 Programmer Black J2 Connector Orange J1 Connector...

  • Page 49: Electrical Components

    Electrical Components WARNING: Make sure the electrical disconnect is OFF before working on the machine. Use the lockout provided on the main disconnect switch. Wait at least 1 min before working on any circuit, because the VFD capacitors may have energy stored. Maintenance should be performed on a regular basis by qualified personnel.

  • Page 50: Troubleshooting

    TROUBLESHOOTING FAULT PROBABLE CAUSE REMEDY Check input power and verify Wrong or non-existent input Machine does not power voltage power source. Blown fuse or Check and replace fuses. Reset tripped circuit breaker. circuit breakers Let oil purge from gearbox and Oil leaking from breather Normal expansion of gearbox oil take no further action.

  • Page 51: Tables, Charts, & Diagrams

    TABLES, CHARTS, & DIAGRAMS Table 1 Standard Pipe Sizes and Schedules PIPE O.D. Pipe Schedules and Wall Thickness SIZES XX STRONG 0.405 0.400 0.050 0.068 0.095 0.540 0.500 0.070 0.088 0.119 0.675 0.500 0.070 0.091 0.126 0.840 0.700 0.080 0.109 0.147 0.188 0.294...
  • Page 52 Table 3 ARC LENGTH TABLE EXAMPLE: Arc Length = Constant x Bend Radius. Example: 90deg bend with 6” clr EXAMPLE: 1.575 (from table) x 6” (clr) = 9.45” (Arc Length) For bends more than 90deg, Constants can be added together. Degrees Constant Degrees...

  • Page 53: Diagram 1

    Diagram 1...

  • Page 54: Diagram 2

    Diagram 2...

  • Page 55: Parts Diagram

    PARTS DIAGRAM Base Assembly Parts Diagram...

  • Page 56: Control Box Parts Diagram

    Control Box Parts Diagram...

  • Page 57: Drive Assembly Parts Diagram

    Drive Assembly Parts Diagram...

  • Page 58: Main Bending Assembly Parts Diagram

    Main Bending Assembly Parts Diagram...

  • Page 59: Parts List

    Parts List Item Part Number Description Qty. PP-0043 1.0 ID X 1.1875 OD X 0.75 LG BUSHING PP-0035 1" SET SCREW COLLAR PP-0064 8" RUBBER WHEEL PP-0048 4.0 INCH CASTER STD. 3/8-16 X 1 CARRIAGE BOLT STD. 3/8 FLAT WASHER STD.
  • Page 60 Item Part Number Description Qty. ME-M250-6A017 CENTER SLIDE BLOCK (INSERTED) M250-7A006 PIVOT PIN ME-M250-7A010 LEAD SCREW NUT INSERT M5 X 0.8 X 12 SHCS M20 X 2.5 X 40 SHCS M250-7A009 LEAD SCREW STOP NUT M200-7A023 LEAD SCREW PP-0913 1.0 ID X 1.25 OD X 0.75LG PP-0056 1.0 ID X 1.5 OD X .125 THK PP-0036...
  • Page 61 Item Part Number Description Qty. M300-7A032 THRUST WASHER M300-7A031 THRUST WASHER PP-1071 3/4" DOWEL PIN STD. 3/8 LOCK WASHER STD. 3/8-16 X 16 HHCS M200-COVER COVER, M325 FRONT M250-7A002 BEARING HUB ME-M250-7A008 M250 SPINDLE (METRIC) STD. M20 X 2.5 X 120 HEX FLANGE SCREW PP-0666 FOOT PEDAL STD.
  • Page 62 NOTES...
  • Page 63 NOTES...

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