Related Manuals for Baileigh Industrial B8105
Summary of Contents for Baileigh Industrial B8105
- Page 1 OPERATOR’S MANUAL ROTARY DRAW BENDER MODEL: RDB-500 (B8105) Rev. 08/2015 © 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 Adaptor Plate Assembly Parts Diagram ..............42 Parts List ........................43...
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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 10. Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a full- face shield if you are producing metal filings. 11. Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or across a running machine.
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Page 10: Technical Specifications
TECHNICAL SPECIFICATIONS Maximum Center Line Radius (CLR)* 20" (508mm) Minimum Center Line Radius (CLR)* .5" (12.7mm) Minimum OD .25" (6.35mm) Mild Steel Pipe (Schedule 40) 3" (76.2mm) Aluminum Pipe (Schedule 40) 3" (76.2mm) Stainless Steel Pipe (Schedule 40) 2.5" (63.5mm) 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
Item Description Function Forward Foot Pedal Will operate the machine in the cw direction Reverse Foot Pedal Will operate the machine in the ccw direction Power Switch For turning power on/off to the bender For programming bend angle and displaying the Bend Angle Controller bend angle position. -
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 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.
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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 7. The digital control and preset should only be used in whole degrees. For example 90, 91, 92 not 90.1 or 90.5. If any number is entered after the decimal the control will add 1 to the final degree. So it’s best to leave it at 0. 8.
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Page 20: 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 21 Spindle Die Drive Pins 1/2-13 Tapped holes for bolting down dies Center Pin 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” holes line up. 5.
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Page 22: Material Insertion
• 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. - Page 23 Important: Liberally apply lubricant along the counterdie and the 1/2 of the material that contacts the counter die (A) with a WD-40 style lubricant or equivalent. Do not lubricate the bending die. Lubricating the bending die will encourage slipping of material in the bending die.
- Page 24 Material Removal 1. After reaching the desired angle, the material needs to be removed. 2. Press the reverse (left) foot pedal. Both the die and the counter die will retract simultaneously. Run in reverse until all bending pressure is released from the bend. Activating the quick release lever 3.
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Page 25: Material Insertion Limitations
Material Insertion Limitations 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. -
Page 26: Bending More Than 180 Degrees
Bending More than 180 Degrees • This machine is capable of bending more than 180 degrees. Contact your distributor about your application. o It will require a password to make the machine go past 200 degrees. o Requires special tooling to allow removal of bent part. If standard tooling is used, the material will be locked onto the die. - Page 27 • 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”...
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Page 28: 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 29: 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 30: 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 31: 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 32: 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 33: Lubrication And Maintenance
1/2 full, fill to the top with AW-46 hydraulic fluid. Hydraulic fluid and the filter should be changed when the filter gauge reads “Change Filter”. • Check periodically for leaks. If a leak is detected, consult Baileigh Industrial. • There are four grease zerks on the machine, at the main spindle pivots. Grease these zerks every month with only two pumps from a standard grease gun. -
Page 34: Electrical Schematic
ELECTRICAL SCHEMATIC... -
Page 35: Troubleshooting
TROUBLESHOOTING WARNING: Make sure the electrical disconnect is OFF before working on the machine. Problem Solution Cylinders not retracting all the Do the dry run sequence as outlined in section 8 of the way or not in sequence manual under operation Check that the solenoid valve has its wires connected. -
Page 36: 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 37 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 38: Diagram 1
Diagram 1... -
Page 39: Diagram 2
Diagram 2... -
Page 40: Parts Diagram
PARTS DIAGRAM Base Assembly Parts Diagram... -
Page 41: Main Tube Assembly Parts Diagram
Main Tube Assembly Parts Diagram... -
Page 42: Swing Arm Assembly Parts Diagram
Swing Arm Assembly Parts Diagram... -
Page 43: Lead Screw Assembly Parts Diagram
Lead Screw Assembly Parts Diagram... -
Page 44: Encoder Assembly Parts Diagram
Encoder Assembly Parts Diagram... - Page 45 Adaptor Plate Assembly Parts Diagram...
- Page 46 Parts List Item Part Number Description Qty. M500-5A008 M500 Base Assembly BS-0323 Foot Pad Shaft M350-7A071 Leveling Foot 5/8-11 Hex Nut M500-6A040 Cabinet Assembly PP-0023 Cord Grip PP-0290 3/4" Cord Grip PP-0021 45 Degree Cord Grip PP-0549 Schneider Switch Assembly M12 X 1.75 X 30 Hex Flange M12 X 1.75...
- Page 47 Item Part Number Description Qty. M175-6A059 Box Cover M5 X 0.8 X 10 PPMS M500-7A023 Upper Bushing M500-7A022 Lower Bushing M500-7A010 Thrust Bearing (Top) M500-7A011 Thrust Bearing (Middle) M500-7A012 Thrust Bearing ME-M500-6A001 Swing Arm (Top) ME-M500-6A003 Tie Block (Long) ME-M500-6A004 Tie Block (Short) ME-M500-6A021 Tie Block (Front)
- Page 48 Item Part Number Description Qty. PP-1256 Encoder M500-6A038 Encoder Spacer M500-6A037 Encoder Mount M3 X .05 X 8 SHCS M6 X 1.0 X 80 SHCS ME-M500-6A007 Slide Block ME-M350-7A046 Lead Screw Nut PP-0209 Thrust Ball Bearing M500-5A006 Lead Screw Assembly ME-M350-7A047 Stop Nut M10 X 1.5 X 12...
- Page 49 Item Part Number Description Qty. PP-1424 M500 Power Unit M10 X 1.5 X 20 Hex Flange M10 X 1.5 Flange Nut...
- Page 50 NOTES...
- Page 51 NOTES...
- Page 53 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 54 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.