Baileigh RDB-480 Operator's Manual
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Baileigh RDB-480 Operator's Manual

Rotary draw bender
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OPERATOR'S MANUAL
ROTARY DRAW BENDER
MODEL: RDB-480
Baileigh Industrial Holdings LLC
P.O. Box 531
Manitowoc, WI 54221-0531
Phone: 920.684.4990
Fax: 920.684.3944
sales@baileigh.com
REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL
HOLDINGS LLC IS PROHIBITED. Baileigh Industrial Holdings LLC, 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. 08/2020
© 2020 Baileigh Industrial Holdings LLC

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Summary of Contents for Baileigh RDB-480

  • Page 1 REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL HOLDINGS LLC IS PROHIBITED. Baileigh Industrial Holdings LLC, 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 ....................6 Dear Valued Customer: ....................6 TECHNICAL SPECIFICATIONS ..................9 TECHNICAL SUPPORT ....................9 UNPACKING AND CHECKING CONTENTS ..............10 TRANSPORTING AND LIFTING ..................
  • Page 3 Large Size Square ..................... 37 LUBRICATION AND MAINTENANCE ................38 Gear Box Oil ......................38 ELECTRICAL SCHEMATIC ..................39 TROUBLESHOOTING ....................40 TABLES, CHARTS, & DIAGRAMS ................41 Diagram 1 ........................43 Diagram 2 ........................44 PARTS DIAGRAM ......................45 Cabinet Assembly ......................

  • Page 4: Thank You & Warranty

    THANK YOU & WARRANTY Thank you for your purchase of a machine from Baileigh Industrial Holdings LLC. 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 We apologize for any discrepancies that may occur. Baileigh Industrial Holdings LLC 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

    INTRODUCTION The quality and reliability of the components assembled on a Baileigh Industrial Holdings LLC 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 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: Safety Precautions

    Baileigh does not recommend or endorse making any modifications or alterations to a Baileigh machine. Modifications or alterations to a machine may pose a substantial risk of injury to the operator or others and may do substantial damage to the machine.
  • Page 10 ! ..P SAFELY! LEASE ENJOY YOUR AILEIGH MACHINE LEASE ENJOY IT 1. FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING THE MACHINE. Learn the machine’s application and limitations as well as the specific hazards. 2. Only trained and qualified personnel can operate this machine. 3.
  • Page 11 16. Keep children away. Children must never be allowed in the work area. DO NOT let them handle machines, tools, or extension cords. 17. Keep visitors a safe distance from the work area. 18. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust. Always lock up tools and keep them out of reach of children.

  • Page 12: Technical Specifications

    (other than die sets and blades). For specific application needs or future machine purchases contact the Sales Department at: sales@baileigh.com, Phone: 920.684.4990, or Fax: 920.684.3944. Note: The photos and illustrations used in this manual are representative only and may not depict the actual color, labeling or accessories and may be intended to illustrate technique only.

  • Page 13: Unpacking And Checking Contents

    UNPACKING AND CHECKING CONTENTS Your Baileigh machine is shipped complete. 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 NOTICE: Lifting and carrying operations should be carried out by skilled workers, such as a truck operator, crane operator, etc. If a crane is used to lift the machine, attach the lifting chain carefully, making sure the machine is well balanced. Follow these guidelines when lifting with truck or trolley: •...

  • Page 15: Installation

    INSTALLATION IMPORTANT: Consider the following when looking for a suitable location to place the machine: • Overall weight of the machine. • Weight of material being processed. • Sizes of material to be processed through the machine. • Space needed for auxiliary stands, worktables, or other machinery. •...

  • Page 16: Assembly And Set Up

    The simplicity of design and minimum effort required to operate the machine contributes towards meeting schedules and producing greater profits. The RDB-480 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 17: Getting To Know Your Machine

    GETTING TO KNOW YOUR MACHINE...
  • Page 18 Item Description Function This is the die which the material will form around. Forming Die This die will be specific to a material size and to a specific radius. Bolts used to secure the die down to the spindle drive. Die Retaining Bolts These MUST be installed and tightened during the bending process.

  • Page 19: Electrical

    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 Holdings LLC prior to energizing the machine. 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.
  • Page 20 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 21: 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 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: 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 24: 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 25: Homing

    Homing Don’t Change the home position unless you are sure the position was IMPORTANT: 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 26: 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 27 OP Screen Figure 7 OP Screen Figure 8 OP Screen Figure 9 OP Screen Figure 10 OP Screen Figure 11 OP Screen Figure 12...

  • 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 Figure 5 OEM Screen Figure 6 OEM Screen Figure 7 OEM Screen Figure 8 OEM Screen Figure 9 OEM Screen Figure 10...

  • Page 30: 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 31: Die Selection And Installation

    (EX) 1-1/2” diameter tubing requires a die set marked 1-1/2” tube. 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).
  • Page 32 • 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 33: Material Insertion

    Material Insertion Note: The photos and illustrations used in this manual are representative and may not depict the actual color, labeling or accessories and may be intended to illustrate technique only. 1. At the start page, choose “RUN PROGRAM” and choose program to run following screen instructions.
  • Page 34 Left Right • The left figure shows the recommended minimum / correct amount of material remaining to be fully supported in plastic slide. • The right figure shows the maximum amount the material can be pulled through the counterdie. Pulling the material further than shown into the counter die, it will destroy the plastic slide.

  • Page 35: Material Removal / Advancement

    Material Removal / Advancement 1. After the die stops at the desired angle, the material needs to be removed or advanced. 2. Activate the reverse foot pedal. As the die starts going backwards, the counter die and its quick release will swing out of the way allowing for easy material removal. 3.

  • Page 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42: Electrical Schematic

    ELECTRICAL SCHEMATIC...

  • Page 43: 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 44: 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 45 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 46: Diagram 1

    Diagram 1...

  • Page 47: Diagram 2

    Diagram 2...

  • Page 48: Parts Diagram

    PARTS DIAGRAM Cabinet Assembly...

  • Page 49: Electrical Panel

    Electrical Panel...

  • Page 50: Controller And Arm Assembly

    Controller and Arm Assembly...

  • Page 51: Motor And Gearbox

    Motor and Gearbox...

  • Page 52: Top Plate Assembly

    Top Plate Assembly...

  • Page 53: Spindle Assembly

    Spindle Assembly...

  • Page 54: Lead Screw Assembly

    Lead Screw Assembly...

  • Page 55: Strut Rods

    Strut Rods...

  • Page 56: Parts List

    Parts List Item Part Number Description Qty. M480-6A014 Bottom Plate M480-7A001 Main Bearing Hub M480-6A002 Top Plate M480-6A003 Side Frame M480-6A004 Side Frame (L.H.) M480-5A005 Cabinet Assy M480-7A011 Spindle (Dynamic Oil) PP-1629 220 x 160 x 60 Roller Bearing M480-7A003 Bearing Hub M480-6A008 End Bar...
  • Page 57 Item Part Number Description Qty. ME-M400-7A003-3 Spider Hub M150-7A013 Quick Release Shaft PP-0133 Black Ball Knob PP-0060 Grip ME-M200-7A005 Stand Off BSM-0279 M6 x 1.0 x 16 Hex FLG BSM-0001 M6 x 1.0 x 14 SHCS PP-0023 Cord Grip PP-0290 Cord Grip PP-0453-A Housing Cover...
  • Page 58 Item Part Number Description Qty. M480-7A026 Stop Pin BSM-0022 M12 x 1.75 x 25 SHCS BSM-0239 M12 x 1.75 x 16 Set Screw M480-7A029 Foot Pad BSM-0292 M24 x 3.0 x 90 HHCS Fully Threaded BSM-0109 M24 x 3.0 Jam Nut BSM-0138 M6 x 1.0 x 12 BHCS PP-0587...
  • Page 59 Item Part Number Description Qty. BS-0398 6-32 x .25 Machine Screw M480-6A028 .25 x .25 x 1.0 Key BSM-0294 M4 x 0.7 x 6 Set Screw NOTES...
  • Page 60 BAILEIGH INDUSTRIAL HOLDINGS LLC 1625 D , WI 54220 UFEK RIVE ANITOWOC : 920. 684. 4990 F : 920. 684. 3944 HONE www.baileigh.com BAILEIGH INDUSTRIAL HOLDINGS LTD. U WIFT OINT WIFT ALLEY NDUSTRIAL STATE UGBY , CV21 1QH U IDLANDS...

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