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Summary of Contents for Baileigh Industrial RDB-350-TS
- Page 1 OPERATOR’S MANUAL ROTARY DRAW BENDER MODEL: RDB-350-TS (B8095) Rev. 04/2015 © 2015 Baileigh Industrial, Inc.
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Page 2: Table Of Contents
Table of Contents INTRODUCTION ......................1 GENERAL NOTES ......................1 SAFETY INSTRUCTIONS ....................2 SAFETY PRECAUTIONS ....................5 TECHNICAL SPECIFICATIONS ..................7 UNPACKING AND CHECKING CONTENTS ..............8 Cleaning ........................8 TRANSPORTING AND LIFTING ..................9 INSTALLATION ....................... 9 ASSEMBLY AND SET UP .................... 10 GETTING TO KNOW YOUR MACHINE ............... - Page 3 INDEX TABLE ATTACHMENT (OPTIONAL EQUIPMENT) .......... 36 Introduction ........................ 36 Connection to Your Machine ..................36 Height Adjustment and Leveling ................36 Material Layout ......................37 Operation ........................37 INDEX TABLE LAYOUT DIAGRAM (OPTIONAL EQUIPMENT) ........38 LUBRICATION AND MAINTENANCE ................39 Gear Box Oil ......................
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Page 4: Introduction
INTRODUCTION The quality and reliability of the components assembled on a Baileigh Industrial machine guarantee near perfect functioning, free from problems, even under the most demanding working conditions. However if a situation arises, refer to the manual first. If a solution cannot be found, contact the distributor where you purchased our product. -
Page 5: Safety Instructions
Note: This symbol refers to useful information throughout the manual. 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 6 General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. 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.
- Page 7 BEWARE OF PINCH POINTS Keep hands and fingers away from the drive mechanisms, cylinders, ratchets, and other moving linkage while the machine is in operation. KEEP CLEAR OF MOVING OBJECTS Always be aware of the position of the material and the swing area in which the material will travel.
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Page 8: 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 9 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.
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Page 10: Technical Specifications
TECHNICAL SPECIFICATIONS Maximum Center Line Radius (CLR)* 24" (610mm) Minimum Center Line Radius (CLR)* .5" (12.7mm) Minimum OD .25" (6.35mm) Mild Steel Pipe (Schedule 40) 2.5" (63.5mm) Aluminum Pipe (Schedule 40) 2" (50.8mm) Stainless Steel Pipe (Schedule 40) 2" (50.8mm) Mild Steel Round Tube (Wall) 3"... -
Page 11: 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 12: 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. Keep in mind that having a large clearance area around the machine is important for safe and efficient working conditions. -
Page 13: 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 14: Getting To Know Your Machine
GETTING TO KNOW YOUR MACHINE... -
Page 15: 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-350-TS 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 16: Electrical
ELECTRICAL WARNING: Baileigh Industrial is not responsible for any damage caused by wiring up to an alternative 3-phase power source other than direct 3-phase. If you are using an alternate power source, consult a certified electrician or contact Baileigh Industrial prior to energizing the machine. -
Page 17: Plug Connection
WARNING: In all cases, make certain the receptacle in question is properly grounded. If you are not sure, have a qualified electrician check the receptacle • 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. -
Page 18: 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 19: 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 20: Delete Program
3. At this point, pressing the forward foot pedal will start the bending process. The machine will rotate in the selected direction at the chosen speed to the desired degree totaling the bend angle plus the spring back degrees. 4. When at the final position, the control will prompt you to “Press REV Pedal to Home” Fig 8. Delete Program 1. -
Page 21: Dry Running
Dry Running • Once you are familiar with the machine and programming unit, it is important to dry run a few programs without any tooling or material installed. • Follow the steps in the Running a Program sections to dry run the program. •... -
Page 22: 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 23: Operation Screen Shots
Operation Screen Shots OP Screen Figure 1 OP Screen Figure 2 OP Screen Figure 3 OP Screen Figure 4 OP Screen Figure 5 OP Screen Figure 6... - Page 24 OP Screen Figure 7 OP Screen Figure 8 OP Screen Figure 9 OP Screen Figure 10 OP Screen Figure 11 OP Screen Figure 12...
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Page 25: Oem Screens And Bending More Than 180 Degrees
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 your distributor about your application. - Page 26 OEM Screen Figure 5 OEM Screen Figure 6 OEM Screen Figure 7 OEM Screen Figure 8 OEM Screen Figure 9 OEM Screen Figure 10...
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Page 27: 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 28: Die Selection And Installation
DIE SELECTION AND INSTALLATION Before any bending can take place, the proper die set must be chosen to match the material being bent. (EX) 1-1/2” diameter tubing requires a die set marked 1-1/2” tube. Hook Arm Bend Die Hold down Bolts Plastic Slide Counter Die Mount Bronze Counter Die Insert... - Page 29 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 holes line up.
- Page 30 • Bending some thicker or harder material may require the use of a special counterdie with a 1-1/4” pin mounting hole. To install the counterdie with the larger hole the two reducer collars (N) must be removed. • To do this loosen the (2) set screw (casting type counter die mount) or the 5/16 socket head screws (welded type counterdie mount) and slip them out of the holes.
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Page 31: Material Insertion
This software is available from Baileigh Industrial. Contact your distributor for availability. • Bending with a rotary draw bender requires determining the start of bend point which will line up with the “0”... - Page 32 4. Tighten the counter die assembly applying moderate pressure on the material. 5. 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.
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Page 33: 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 34: 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 35: 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 36: Bending Suggestions
BENDING SUGGESTIONS Aluminum Bending If bending aluminum, lubrication is very important, if the results are less than desirable with WD- 40 other lubricants can be used such as: • Johnson Paste Wax (seems to work the best) • High Pressure grease •... -
Page 37: 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 38: Large Size Square
6. If the material slips during the bending operation, install the hook arm clamp (5). Do not use it unless you have to. 7. Activate the bender and bend to the desired angle. 8. To remove the material, open the counter die and return bender to the “home position”. Using a soft mallet, gently tap the cap clamps open and the material will spring out of the die (1). -
Page 39: 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 40: Material Layout
HEIGHT ADJUSTMENT CCW TO RAISE TURNS CCW DIE THICKNESS 0.0= 1.50 2.5= 2.00 5.0= 2.50 7.5= 3.00 10.0= 3.50 Material Layout Before you can use the IDX table, the bend positions of your first piece of material needs to be laid out. -
Page 41: Index Table Layout Diagram (Optional Equipment)
INDEX TABLE LAYOUT DIAGRAM (OPTIONAL EQUIPMENT) -
Page 42: 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 43: Electrical Schematic
ELECTRICAL SCHEMATIC... -
Page 44: Troubleshooting
TROUBLESHOOTING 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. Always follow proper safety precautions when working on or around any machinery. -
Page 45: 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 46 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...
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Page 47: Diagram 1
Diagram 1... -
Page 48: Diagram 2
Diagram 2... -
Page 49: Parts Diagram
PARTS DIAGRAM Base Assembly Parts Diagram... -
Page 50: Control Box Parts Diagram
Control Box Parts Diagram... -
Page 51: Drive Assembly Parts Diagram
Drive Assembly Parts Diagram... -
Page 52: Main Bending Assembly Parts Diagram
Main Bending Assembly Parts Diagram... -
Page 53: Quick Release Assembly Parts Diagram
Quick Release Assembly Parts Diagram... -
Page 54: Parts List
Parts List Item Part Number Description Qty. M350-5A032 Cabinet, Assembly M350-7A071 Leveling Foot ME-M200-7A005 Stand Off M6 X 1.0 X 14 Hex Flange NONE Me-M350 Electrical Panel Imperial 5/8-11 Hex Nut M6 X 1.0 X 14 SHCS PP-0304 On/Off 2 Pole Switch PP-0454 M350 Gearbox Imperial... - Page 55 Item Part Number Description Qty. .25-28 GREASE ZERK Straight Grease Zerk M400-7A012 Large Thrust Washer M400-7A013 Small Thrust Washer ME-M325-7A001 M325/M350 Spindle M16 X 2.0 X 55 Hex Flange M12 X 1.75 X 35 Hex Flange PP-0118 3.0" Clamp Collar M20 X 2.5 X 110 SHCS M8 X 1.25 X 10...
- Page 56 Item Part Number Description Qty. ME-M350-5A012 Quick Release Lever Assy. M10 X 1.5 X 30 SHCS ME-M400-6A012-V2 Counter Mount PP-0137-V2 Fiama Counter M350-7A010 Guide Shaft ME-M400-7A003-3 Spider Hub M150-7A013 Quick Release Shaft PP-0133 Black Ball Knob Imperial .25 X .25 X 1.0 Key M10 X 1.5 X 40 SHCS M8 X 1.25 X 10...
- Page 57 NOTES...
- Page 58 NOTES...
- Page 59 NOTES...
- Page 61 General Machinery Safety Instructions Machinery House requires you to read this entire Manual before using this machine. 1. Read the entire Manual before starting 14. Use correct amperage extension cords. machinery. Machinery may cause serious injury if Undersized extension cords overheat and lose not correctly used.
- Page 62 Elec/Mech Pipe/Tube Bender Safety Instructions Machinery House requires you to read this entire Manual before using this machine. 1. Maintenance. 10. Avoiding Entanglement. Make sure the Pipe/Tube Bender Pipe/Tube Bender guards is turned off and disconnect from the main power must be used at all times.
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