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Summary of Contents for Baileigh Industrial RDB-250
- Page 1 OPERATOR’S MANUAL ROTARY DRAW BENDER MODEL: RDB-250 (B8085) Rev. 03/2015 © 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) .......... 40 Introduction ........................ 40 Connection to Your Machine ..................40 Height Adjustment and Leveling ................40 Material Layout ......................41 Operation ........................41 INDEX TABLE LAYOUT DIAGRAM (OPTIONAL EQUIPMENT) ........42 LUBRICATION AND MAINTENANCE ................43 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 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 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)* 9" (229mm) Minimum Center Line Radius (CLR)* .5" (13mm) Minimum OD .25" (6mm) Mild Steel Pipe (Schedule 40) Based on a material tensile strength of 60000 PSI – mild 2" (60mm x 4mm) steel Aluminum Pipe (Schedule 40) 2"... -
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-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 16: Electrical
ELECTRICAL ATTENTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY A CERTIFIED ELECTRICIAN! Your Baileigh Machine is Certified Check if the available power supply is the same as required by the machine (consult nameplate on machine) WARNING: Make sure the grounding wire (green) is properly connected to avoid electric shock. - 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: Plug Connection
Plug Connection 1. Have an electrician install the correct plug for the application. 2. Once hooked up, turn on the power supply and start the machine. 3. For three phase applications, check that the motor is running in the correct direction. 4. -
Page 19: Machine Start Up And Homing
Machine Start up and Homing 1. Tum the main power switch to the "ON" position. 2. It takes about 1 minute for the programmer to boot up. 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 20: Main Menu Choices
OP Screen Figure 4 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 21: Edit A Program
c. After selecting the program. Touch the EDIT button (Fig 5) and the program parameters will be displayed Fig 6. Press the View button at the top of the screen to change to the Edit mode. d. Verify that the bend to be edited is selected. -
Page 22: Delete Program
2. After selecting the program touch the RUN button (Fig 5) and the program parameters will be displayed Fig 7. 3. At this point, the display reads “Press FWD Pedal to Bend”. 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. -
Page 23: Dry Running
5. On the edit screen enter the desired PROGRAM NAME by touching the name field Fig. 6. 6. The alpha key pad (Fig. 2 and 3) will open. Name the file for future reference, (There is an 8 character limit) and press enter to save the name and return to the previous screen. -
Page 24: Manual Bend
3. After selecting the program touch the RUN button and the program parameters will be displayed Fig 7. 4. Verify the spindle is clear and ready to perform a dry run or that the die is secure and material properly loaded. 5. - Page 25 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.
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Page 26: 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 27: Oem Screens And Bending More Than 180 Degrees
OEM Screen Figure 11 OEM Screen Figure 12 OEM Screen Figure 13 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. •... -
Page 28: 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 29 OEM Screen Figure 14 OEM Screen Figure 15 OEM Screen Figure 16 OEM Screen Figure 17...
- Page 30 OEM Screen Figure 18 OEM Screen Figure 19 OEM Screen Figure 20 OEM Screen Figure 21...
- Page 31 OEM Screen Figure 22...
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Page 32: 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 33: 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 34 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”...
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Page 35: 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 36 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.
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Page 37: 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 38: 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 39: 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 40: 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 41: 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 42: 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 43: 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 44: Material Layout
Material Layout Before you can use the IDX table, the bend positions of your first piece of material needs to be laid out. Using Diagram1 and Table1 you can determine all of the bend start points, these points should be transferred to the material using a fine point sharpie marker. This diagram is a generic two bend scenario, for more complex parts the steps are generally the same. -
Page 45: Index Table Layout Diagram (Optional Equipment)
INDEX TABLE LAYOUT DIAGRAM (OPTIONAL EQUIPMENT) -
Page 46: 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 47: Electrical Schematic
ELECTRICAL SCHEMATIC Horner ( XLE or XLT) Hexle 102 or HE-XT102 Programmer Black J2 Connector Orange J1 Connector... -
Page 48: 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 49: 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 50: 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 51 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 52: Diagram 1
Diagram 1... -
Page 53: Diagram 2
Diagram 2... -
Page 54: Parts Diagram
PARTS DIAGRAM Base Assembly Parts Diagram... -
Page 55: Control Box Parts Diagram
Control Box Parts Diagram... -
Page 56: Drive Assembly Parts Diagram
Drive Assembly Parts Diagram... -
Page 57: Main Bending Assembly Parts Diagram
Main Bending Assembly Parts Diagram... -
Page 58: 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 59 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 60 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 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 63 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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