BAYKAL APHS Series User Manual

Cnc hydraulic press brake

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BAYKAL

USER'S MANUAL

HYDRAULIC PRESS BRAKE

No part of this User's Manual may be reproduced or transmitted by any without Prior permission of Baykal

Makine Sanayi ve Ticaret A. .

EDITION NO

APHS

DATE OF ISSUE :

May-2011

CNC

MODEL APHS

PAGE

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Summary of Contents for BAYKAL APHS Series

Page 1 BAYKAL USER’S MANUAL HYDRAULIC PRESS BRAKE MODEL APHS No part of this User‘s Manual may be reproduced or transmitted by any without Prior permission of Baykal Makine Sanayi ve Ticaret A. . EDITION NO APHS DATE OF ISSUE : May-2011...
Page 2 BAYKAL MACHINE TYPE DESCRIPTION APHS XXXXX-xx SUPPLY HYDRAULIC STANDARD CONTROLLER SAFETY DEVICE ACCESSORIES VOLTAGE BLOCK APHS C – CE 1 – 220 1 – DELEM DW-66 1 – FISSLER AKAS 1-- HOERBIGER B – BASIC 2 – 230 2 – DELEM DM51 2 –...
Page 3 BAYKAL ! ATTENTION PUMP ROTATION MUST BE IN ARROW DIRECTION, OTHERWISE THE PUMP WILL BE DAMAGED ″ ″ ″ ″ ″ ″ ″ ″ CHECK THE MOTOR ROTATION BY PUSHING THE GREEN START, AND IMMEDIATELY AFTER, THE (RED) STOP BUTTONS ON THE ELECTRICAL PANEL.
Page 4 BAYKAL INFORMATION AND WARNING LABELS DESIGNATION PLATE Manufacturer BAYKAL Mak. San. Tic. A. . Bursa / TÜRK YE Machine Hydraulic Press Brake Type Model Serial No Capacity Bending length Main voltage V/Hz/Ph Motor Power System Pressure Min stroke Max stroke...
Page 5 BAYKAL C O N T E N T S: GENERAL MACHINE INFORMATION 1.1. Registered trademark 1.2. Machine type 1.3. Serial number 1.4. Year of manufacturer 1.5. Address of the manufacturer 1.6. Address of the authorized dealer IMPORTANT INFORMATION 2.1. Safety features of your Press brake 2.2.
Page 6 BAYKAL ELECTRIC CIRCUIT DIAGRAM ADDITIONAL MANUALS A.CYBELEC ModEva B.Wila Centrally Adjustable Crowning System (CVB/D) EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 7: General Machine Information
1.2. Machine type : APHS 1.3. Serial number 1.4. Year of manufacture 1.5. Address of manufacturer: BAYKAL Mak. San. Tic. A. Organize Sanayi Bölgesi Lacivert Cad. 2. Sokak No1/A 16140 Bursa/TÜRK YE Tel.int: 90-224-243 16 10 Fax int: 90-224-243 12 86 1.6.
Page 8 BAYKAL 2. IMPORTANT INFORMATION 2.1. Safety features of your press brake The electrical and hydraulic circuits of your press brake are designed to allow operation with maximum safety. The following precautions are installed on the machine for enhanced safety. Emergency stop buttons ( engaging type ) are available on the cybelec control •...
Page 9 BAYKAL Rear side of the machine Fig.1.2 In case of a power supply failure during operation, the beam will stop at a • standstill. When power supply is recovered, it is Not possible to start the machine without resetting. EDITION NO...
Page 10: Installation
BAYKAL 2.2. Important safety information & instructions The machine must NOT be operated before reading this User’s Manual. Operate the machine only if it is in a perfect condition and in accordance with the work regulations of your factory and operating instructions of this manual.
Page 11 BAYKAL Check the machine daily for recognisable external damages and defects and leakages. Operate the machine only will all protective devices and guardings Take notice of the warning labels on the machine and do not remove them. In case of malfunction immediately shut down and secure the machine.
Page 12 11. The machine is to be serviced and/or be repaired only by the authorised personnel of Baykal or its appointed representatives. EDITION NO APHS...
Page 13: Noise Measurement
BAYKAL 2.3. Noise measurement The sound pressure level of the press brake at operator’s working position is under 70 Db (A). 2.4. Stop time control The stopping time of this press brake is 80 ms and the corresponding miniumum safety distance for the two-hand control is 130 mm.
Page 14 BAYKAL 3. OVERALL DRAWING AND DIMENSIONS Fig.3.1. E MAX H-MAX H DROL K PRES APHS 1250x40 1250 1070 1470 1500 1000 1050 2550 APHS 2104x60 2100 1600 1580 1650 1000 1050 2550 APHS 2106x90 2100 1600 1580 1650 1000 1050...
Page 15 BAYKAL APHS 4109x240 4100 3550 1610 1680 1200 1350 2900 APHS 4112x300 4100 3550 1820 1920 1400 1400 3200 APHS 4116x440 4100 3550 2235 2355 1400 1400 1105 3500 APHS 6104x160 6100 5100 1960 2000 1400 1000 2850 APHS 6106x240...
Page 16 BAYKAL 4. LIFTING & TRANSPORTATION The following points should be taken into account : The lifting points are illustrated in Fig.4.1.The dimensions and the weight of the • machine are given in section 6.1.1.of this manual. Make sure that the lifting rope or chain are of sufficient capacity for the lifting •...
Page 17: Unpacking And Installation
BAYKAL 5. UNPACKING & INSTALLATION The press brake is covered in plastic, and is bolted on wooden crates. Prior to installation, remove the cover and wooden crate seperately and safely in accordance with environmental regulations. After unpacking, check the machine visually against any damage during transport.
Page 18 BAYKAL Intentially left in blank EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 19: Standard Equipment
BAYKAL 6. OPERATING AND MAINTENANCE INSTRUCTIONS 6.1.Technical Data 6.1.1. Specification Bending length Bending capacity - St.42 Bending force tons Length Width Heigth Weigth Approach speed mm / sec Bending speed mm / sec 10. Return speed mm / sec 11. Standard stroke 12.
Page 20 BAYKAL 6.1.3. List of parts subject to rapid wear Part name Size specification Bottom tool Top tool Piston seal (Busak+Shamban) O-ring (Piston seal) Rod seal (Busak+Shamban) O-ring (Rod seal) Scraper O-ring ( cylinder ) EDITION NO APHS DATE OF ISSUE :...
Page 21 BAYKAL 6.2. Description of press brake applications Your press brake is designed and constructed for press bending of flat metal materials up to 3100 mm. length through use of hydraulic pressure power of maximum 120 tons which is adjustable. At maximum tonnage, the material thickness that can be formed is 6 mm.
Page 22 BAYKAL 6.3. Prohibited uses of the press brake The press brake should not be used in the following circumstances : If there is ANYTHING OTHER THAN THE WORKPIECE, inserted, extended, put or placed in the working area between top and bottom bending tools.
Page 23 BAYKAL 6.4. Incorrect uses of the press brake During normal operation of the press brake, the following incorrect uses must be avoided. The likely consequences of such incorrect uses are also explained below : Incorrect use ( 1 ) : Top tool not centered on the bottom tool ″...
Page 24 BAYKAL 6.5. Using the press brake 6.5.1. Requirements for the initial test and examination • Check the machine visually against any transport damage. • Clean the oil tank. • Fill the oil tank up to the level indicator with one of the oil types recommended in the Lubrication Diagram.
Page 25: Electrical Connections
BAYKAL 6.5.2. Electrical connections All electrical connections, however simple, must be carried out by qualified electricians. Machine must be placed as close as possible to an electric power supply. In cases where this is not possible, it is recommended to bring an auxilary supply duct alongside the machine.
Page 26 BAYKAL 6.5.3. Electrical Cabinet and Control Units A. Pedal Connections: 2S22 3H13 3H12 SB23 2S21 6S43 3H14 4S11 4S17 4S10 6S44 EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 27 BAYKAL Label Name Description 2S22 It starts the main pump 3H13 Pump start (onlamp Pump stop It stops the main pump 2S21 When it illuminate, it has 4 indicator function; Safety Warning 1. Laser is interrupted 2. Stop module is active...
Page 28 BAYKAL Working Hour Indicator 1S25 SB10 3S18 SA500 FILTER 3H11 2S22 2S21 1S14 3H13 EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 29 BAYKAL Label Name Description Emergency Stop In case of emergency, it stops all the machine SB10 functionality Mode selector It has 4 funtions; Switch 0. Control OFF 1. Manual mode 3S18 2. Footswitch control 3. Two-hand control 4. Two-hand –Footswitch control Side Bar Safety It has two position;...
Page 30: Front Connections
BAYKAL B. Front Connections (c*) (d*) (g*) Mark Label Designation Description (Electr.Diag) Linear encoder and connection. This encoder supplies feedback of the Y1 axis position. Y Linear encoder axis consists of two independent axes Y1 and Linear encoder and connection. This encoder...
Page 31 BAYKAL opened, it sends a interrupt signal to the CNC control and thus pomp stop. Safety switch and connection. This is used for Side guard safety switch additional safety. When the side guard (door) is (Right side) opened, it sends a interrupt signal to the CNC control and thus all pump stop.
Page 32 BAYKAL C. Two axes backgauge connections R Axis X Axis Fig. All connections are covered by cover plates. When you need to see these connections, you NOTE 1: should remove the plates. This picture was taken from the front of the machine.
Page 33 BAYKAL Mark Label Designation Description (Electr.Diag) Limit position of X axis movement in the 4SX+ Limit switch positive direction Limit position of X axis movement in the 4SX- Limit switch negative direction and is also reference switch for X axis.
Page 34: Backside Connections
BAYKAL D. Backside connections (d*) (c*) This picture was taken from the back-left side of the machine. NOTE Mark Label Designation Description (Electr.Diag) Main motor or pump supplies hydraulic Main motor (Pump) and pressure for hydraulic circuit. 1M3 shows a...
Page 35 BAYKAL E. Valves Connections (l*) (m**) (i***) It is under the valve (g) and not seen in the picture. It is under the valve (h) and not seen in the picture. Mark Label Designation Description (Electr.Diag) Proportional closing valve for the left cylinder...
Page 36 BAYKAL Pressure relief valve SP03 Safety valve Directional valve control sensor for the left Sensor cylinder Directional valve control sensor for the right cylinder Sensor Sensor Approaching control sensor Approaching valve Fast closing control sensor for right cylinder Sensor Fast closing control sensor for left cylinder...
Page 37 BAYKAL ADJUSTABLE SUPPORT 6.5.4. Centrally Adjustable Crowning System (Optional) When the hydraulic cylinders of the press brake are mounted at either end, the centre is not supported. This leads to the curvature which a crowning table can even out. A press brake deflects slightly during bending (concave sagging). This causes...
Page 38 BAYKAL These methods of crowning are, however, very labor-intensive, not very flexible, difficult to repeat, and result in a significant loss of production time. These problems can be eliminated by the centrally operated anti-deflection device developed by Wila. The Wila crowning devices (See fig.6.5.6.2 and fig 6.5.6.3) compensate the deflection of the press brake quickly and accurately.
Page 39 BAYKAL 6.5.5. Check- list of the finished product Prior to despatch, your press brake has been checked with respect to the following safety and operational functions, and verified O.K. : Safety guards Electric circuit diagram Hydraulic circuit diagram Top beam speed...
Page 40 BAYKAL 6.6. Maintenance & spection Genaral maintenance and cleaning of the press brake requires careful attention. Therefore the machine must be shut-off before starting any maintenance vork. 6.6.1. Type and frequency of inspections Inspection Period Responsibility • Lubrication Operator See : Lubrication Diagram •...
Page 41: Hydraulic System
BAYKAL 6.6.2. Hydraulic System All precautions must be taken to keep the hydralic system clean at all circumstances. A. Changing oil Oil must be changed after first 200 working hours of use, and then every 1000 working hours. a. Filling up cap b.
Page 42: Changing The Filter
BAYKAL B. Changing the filter The return filter element must be changed when the Oil Filter Lamp on the electrical panel cover lights up. NOTE 1: Return filter is at the top of the machine, between the hydraulic block and the main pump.
Page 43 BAYKAL RETURN FILTERS LIST The filters listed below, which are produced by different companies, can be used. APH/APHS 40-200 TON MANUFACTURER TYPE FILTER ELEMENT MP (Italy) MPF-100 1AG2D MPF-100 1A25HB HYDAC (Germany) RFM ECO/N 165 BD20W 1.1 0165 R 020 BN 3 HC...
Page 44 BAYKAL 6.7. Conditions of storage, re-utilisation and scrapping 6.7.1. Storage In cases where the machine is not be used for a long period of time, the following precautions must be taken: • Disconnect electrical supply to the machine, and write so on the electric panel as a reminder for future use.
Page 45 BAYKAL 6.7.3. Scrapping If the press brake has completed its normal operating life, prior to scrapping all the oil in the tank and cylinders should be drained off, and the machine should be dismantled. EDITION NO APHS DATE OF ISSUE :...
Page 46: Lubrication Points
BAYKAL 7. LUBRICATION POINTS EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 47 BAYKAL In order to lubricate points 3 and 4, remove the protection plates. PLACE OF NUMBER OF OIL TYPE EQUIVALENT LUBRICATION LUBRICATION LUBRICATION PREFILLED OIL TYPES PERIOD SPOTS AT FACTORY SLIDES KAPGRES 2 2 - 7 DAYS • MUST BE CHANGED t<10°...
Page 48 BAYKAL 8.BENDING CHART A bending chart is provided in this file to determine the following with respect to material thickness: • Selecting the correct vee. • Bending force required to bend material of 1 meter length. • Minimum flange that can be bent.
Page 49 BAYKAL 9. FOLDING FACILITIES You can see some bending examples according to the different tools below. EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 50 BAYKAL 10.PRINCIPLES OF PRESS BRAKE BENDING TECHNOLOGY Sheetmetal bending is effected by using two basic procedures: Air Bending: Widely used because of the relatively small tonnage required, but as regards to angular precision, it is subject to the residual elasticity inherent in the material after bending.
Page 51 BAYKAL ii. Partial Air Bending: This method of bending is in fact a limited case of air bending, as the forming of the metal sheet is interrupted before it bottoms in the vee. The plate is in contact with the tooling along the lines ABC. This method calls for a larger Vee opening (12 to 15 times) to maintain good bending quality.
Page 52: Spare Part List
BAYKAL 11. SPARE PART LIST EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 53 BAYKAL EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 54: Hydraulic Circuit Diagram
BAYKAL 12. HYDRAULIC CIRCUIT DIAGRAM EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 55 BAYKAL EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 56: Electric Circuit Diagram
BAYKAL 13. ELECTRIC CIRCUIT DIAGRAM EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 57 BAYKAL EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...
Page 58: Additional Manuals
BAYKAL 14 .ADDITIONAL MANUALS EDITION NO APHS DATE OF ISSUE : May-2011 PAGE...