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SafanDarley E-Brake 

Preliminaries 

Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019 

2 

 
 

 
 

All technical and technological information contained in this manual as well as 
any drawings and technical descriptions put at your disposal, remain our 

property and are not to be used further other than for the sake of the operation 
of this product, photocopied, reproduced, transmitted or brought to the notice of 

third parties without our prior written consent. 
 

 

SafanDarley B.V. 
Kwinkweerd 11 

Post-box 96 
7240 AB Lochem 

The Netherlands 
 

Phone +31(0)573 

222222 

Fax +31(0)573 

252057 

E-mail [email protected] 

Website www.safandarley.com 
 

 
 

 
 

 

 

Summary of Contents for E-Brake Premium 100-3100

Page 1: ...e Premium 100 3100 Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 1 RServo electronic press brake SafanDarley E Brake Premium 100 3100 Technology version MPB RD100 101 Instruction manual 100Pr 2019 En ...

Page 2: ...ptions put at your disposal remain our property and are not to be used further other than for the sake of the operation of this product photocopied reproduced transmitted or brought to the notice of third parties without our prior written consent SafanDarley B V Kwinkweerd 11 Post box 96 7240 AB Lochem The Netherlands Phone 31 0 573 222222 Fax 31 0 573 252057 E mail info safandarley com Website ww...

Page 3: ...SafanDarley E Brake Preliminaries Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 3 PRELIMINARIES Instruction manual ...

Page 4: ...SafanDarley E Brake Preliminaries Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 4 Notes ...

Page 5: ...N 9 1 Introduction 15 1 1 General 17 1 1 1 Application 17 1 2 Design 18 1 3 Dimensionsions and Tecnical Data 20 1 3 1 Main dimensions and foundation measurements 20 1 3 2 Technical data 21 1 4 Information about the noise interference of the machine 22 1 5 Information about the maximum pressure of the machine 23 1 6 Description of the bending process 25 1 7 The different axis of a press brake 28 2 ...

Page 6: ...ards or other maintenance in the electrical cabinet 66 4 1 8 Caution 66 4 2 Daily checking procedures 67 4 2 1 Regular testing of the safety device by experts 67 4 3 Rest risks 69 4 4 Examples of jamming hazards 70 5 Transport installation commissioning 71 5 1 Transportation 73 5 1 1 Internal transport in your company 73 5 1 2 Hoisting 73 5 1 3 Delivery 74 5 2 Installation Cleaning 75 5 2 1 Cleani...

Page 7: ... tools 107 9 3 4 Changing upper tools 109 9 3 5 Changing bottom tools 111 9 3 6 Checking top tool adaptation runs parallel to bottom tool adaptation 113 9 3 7 Upper beam in tilted position 114 9 3 8 Fan Filters electrical cabinet 114 9 3 9 Cleaning position sensors 114 9 3 10 Checking and re adjusting the position of the back gauge 115 9 3 11 Fan Filters electrical cabinet 115 9 4 Lubrication 116 ...

Page 8: ...ntrol panel 44 Figure 2 10 Survey of the various terms 46 Figure 4 12 Examples of jamming hazards 70 Figure 5 1 Transport and hoisting instructions press brake 73 Figure 5 2 No forklift truck 74 Figure 5 3 Required operating and maintenance space 77 Figure 5 4 Anchor the press brake side on two spots at the rear only 78 Figure 5 5 Attention At the front put the supports of the press brake exactly ...

Page 9: ...more with the use of the manual it makes an as safe and as carefree functioning of the press brake possible Please study this manual carefully before putting the press brake into active operation and get well acquainted with the way in which the press brake functions and is operated and strictly follow the instructions given Should you have any further questions or wish any further explanation con...

Page 10: ...onnel how the press brake works Chapter 4 Safety Is important for everyone who is involved with the press brake it is about safety Chapter 5 Transport installation commissioning Is to use by persons involved in setting up transporting and starting up the machine and preparations for these activities They should also take account of chapter 4 Safety Chapter 6 Accessories Offers information about ac...

Page 11: ...e A literal text on the screen or the product will be indicated by quotation marks A pointing finger in the margin indicates that this comment is important Danger of damage to the machine or the product will be indicated by an exclamation mark Personal danger will be indicated by a triangle incorporating an exclamation mark Danger of injury caused by electric current Wear hearing protection Wear p...

Page 12: ...d on the most recent information They are supplied under reservation of later alterations We reserve the right to modify the construction and or design of our products at any time without any obligation to modify previous models GUARANTEE The guarantee conditions as contained in our terms of delivery which you received apply to the product The guarantee on your machine lapses if Service and mainte...

Page 13: ...orm you as correctly and fully as possible concerning possible dangers when dealing with the machine You yourself are responsible for the observance of these rules of conduct The buyer user are obliged to make the operating cleaning and maintenance staff familiar with these instructions Check the shipment immediately on arrival for Possible damage and or defects due to transport Have the hauler dr...

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Page 15: ...SafanDarley E Brake Introduction Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 15 1 INTRODUCTION ...

Page 16: ...SafanDarley E Brake Introduction Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 16 Notes ...

Page 17: ...ample A SafanDarley E Brake press brake with a tonnage of 50 tons and a working length of 2050 mm fitted with a E Control control is given the type code SafanDarley E Brake 50 2050 1 1 1 APPLICATION A press brake can only be used for bending and punching sheet materials for example metal and sheets of synthetic material wire netting materials etc A bent profile must not be bent back flattened Duri...

Page 18: ...ght guard programmable fixed vertical with 28 5 mm blanking max bending speed 10 mm sec Process control Option not exploited Back gauge SafanDarley Type G with X axis R axis and Z1 Z2 axis independently adjustable DeltaX axis fully programmable Extra back gauge finger Option not exploited Bend aid Option not exploited Flattening tool Option not exploited Support arms Set 2 pcs Aluminium front shee...

Page 19: ... 19 Flip over stops Option not exploited Miscellaneous Splitscreen In this manual often is referred to SafanDarley numbers in addition to the usual trade names these numbers are used by SafanDarley B V in computerized systems Please state this number when ordering parts see also Chapter 9 Maintenance ...

Page 20: ...emium 100 3100 100Pr 2019 20 1 3 DIMENSIONSIONS AND TECNICAL DATA 1 3 1 MAIN DIMENSIONS AND FOUNDATION MEASUREMENTS 2510 4080 1775 1750 3224 1250 1775 1735 3528 4080 Figure 1 1 Main dimensions and foundation measurements Type SafanDarley E Brake Premium 100 3100 Q size 590 mm ...

Page 21: ... safety light guard 10 mm sec Max distance safety light guard 185 mm Return speed upper beam 75 mm sec Maximum stroke back gauge 550 mm Max speed back gauge 350 mm sec Pneumatic supply sheet thickness measurement 0 0002 m3 n per min 6 bar Supply voltage 3 x 400V 50 60Hz N PE Cable diameter 4 mm2 Fuse slow blow 35 Amps Max connected load 11 KW Weight 7500 kg See also Chapter 5 2 5 Electrical connec...

Page 22: ...istance of approx 1 meter there was a 1 70 m high wall of synthetic material Measuring took place at a distance of about 1 meter from the front of the press brake When unloaded a bending movement without sheet the press brake produced a sound level of 73 dB A When loaded bending a sheet the press brake produced a sound level of 73 dB A When measured at the rear of the machine during a movement of ...

Page 23: ... press brakes are described in the figure below Figure 1 2 Allowable bending force SafanDarley E Brake press brake As on all press brakes the SafanDarley E Brake doesn t have the same allowable bending force over the full working length of the machine In the table above the allowable bending force is described for the each machine type On next page there is an explanation in some examples of a 50 ...

Page 24: ...mm Bending position L H side Bending position L H side Max bending force 28 9 tons Max bending force 26 2 tons Example 3 Example 4 Type E Brake 50 2050 Type E Brake 50 2050 Bending length 500 mm Bending length 250 mm Bending position L H side Bending position L H side Max bending force 19 5 tons Max bending force 6 2 tons Figure 1 3 Examples allowable eccentric bending force SafanDarley E Brake pr...

Page 25: ...p of the sheet this is the so called material clamping point MCP is the zero point of the Y axis Figure 1 4 Preparation of a bending The back gauge holds the sheet into position so that it is ready for the bending process The back gauge can be moved backwards and forward horizontally the X direction Before loading the sheet the back gauge has to be positioned in the correct X direction Then the sh...

Page 26: ...nnot be moved again Should in the case of certain bending cycles the back gauge prove an obstructing factor the material clamping point can be used to move the back gauge backwards to the return position Bending The sheet can be bent starting at the material clamping point The upper tool is now moved down at the set bending speed causing the sheet to be bent The upper tool keeps moving down until ...

Page 27: ... speed decompression distance This restricted speed is used to guarantee a controlled rebound of machine and sheet material After the decompression distance the upper tool goes to the top dead point at maximum return speed Now the sheet can be taken out of the machine Figure 1 7 Removing the sheet Result The sheet that was removed from the tools can now be measured If the bending result deviates f...

Page 28: ...SafanDarley E Brake Introduction Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 28 1 7 THE DIFFERENT AXIS OF A PRESS BRAKE Figure 1 9 The different axis of a press brake ...

Page 29: ...SafanDarley E Brake Description Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 29 2 DESCRIPTION ...

Page 30: ...SafanDarley E Brake Description Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 30 Notes ...

Page 31: ...ic combination of mechanics and electronics The press bake has been designed in order to perform as safe as possible Furthermore the press brake has been provided with safety devices Nevertheless there is a rest risk during operating the press brake the operator has to look out for hazards On the front of the upper beam 3 pictograms has been attached which warn the operator for these hazards Jammi...

Page 32: ...Top tool 5 Lower tool 6 Press brake table 7 Lower beam lower tool adaptation 8 Safety light guard 9 Press brake Control panel on adjustable swivel arm 10 Electrical cabinet main control units 11 Operators console 12 Electrical cabinet 13 USB drives 14 Rear guard with entrance with trellis 15 Side protective covers 2 2 1 DESCRIPTION OF THE MAIN COMPONENTS 1 Upper beam The upper beam is that moving ...

Page 33: ...d table with T slot single V tool table flattening tool combination lower tool change equipment Various accessories can be mounted on the standard table such as angled guide for bending narrow strips of sheet at right angles support arms for better supporting the sheet front stop for bending the sheet to a preset front stop size 7 Lower beam The bottom beam has been mounted to the machine frame in...

Page 34: ...m zone the upper beam will stop immediately the downward movement Furthermore the control is developed to use the light guard as an operator button So there is the possibility to operate the upper beam by means of a one break or two break interrupt of the light guard This can result in a highly efficient way of working with certain products In what way the possibilities are used is mechanically se...

Page 35: ...e third position every time before he starts operating E g there might be material under the foot pedal which blocks the pedal Figure 2 4 Operators console with HTR device 13 Electrical cabinet The electrical cabinet has been mounted on the right hand side of the press brake it is possible however that it has been moved to the left hand side frame at the request of the customer 14 USB drives Behin...

Page 36: ...iption Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 36 In the side protective covers are at each side a trap door through witch tools can be exchanged Also these trap doors are fitted with safety switches ...

Page 37: ...ABINET Selector mode switch The selector mode switch is needed to choose the control mode This control as far as major controls are concerned switches on the required operating mechanism The control can be locked in any position by the selector key lock The selector mode switch has 6 positions Their functions are explained in Chapter 3 Working of the SafanDarley E Brake Selector key lock With the ...

Page 38: ...a padlock Caution high voltage sign This danger sign indicates the possible danger of high voltage when the control box door is opened 2 3 3 VENTILATOR The electrical cabinet is equipped with a fan to control the temperature inside the cabinet In the electrical cabinet are three vents with filters for the supply and removal of air The filters should be regularly cleaned replaced See Chapter 9 Main...

Page 39: ...4 IPC The IPC in this machine has the following configuration Part Description Chassis Mini ITX embedded chassis black Power supply ACE A627A RS 270W ATX power supply Main board Mini ITX dual VGA dual HDMI HD 2500 graphics Dual GbE LAN SATA 3Gb s HD Audio Pocessor Intel Core i5 355oS 6M Cache up to3 70 GHz 3rd Generation Intel Core i5 Processor Memory 4GB DDR3 RAM 2x2GB Storage 64 GB industrial SS...

Page 40: ...Control software supplied is E Control version 1 0 1 5 or higher The TS software supplied is TS version 9 19 or higher The CPU c software is version 7 36 or higher The CPU y software is version 7 83 or higher The AUX software is version 6 00 or higher The Easy2D software is 1 1 23 or higher if ordered Windows software license A unique license sticker is attached to each PC casing Figure 2 6 Licens...

Page 41: ...SafanDarley E Brake Description Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 41 HDD Flash LED red Power LED green Figure 2 7 Overview IPC with wired Image Back up USB ...

Page 42: ...hine identification 2 4 1 DESCRIPTION OF THE MACHINE IDENTIFICATION Machine type In this field type and size of the machine are indicated SafanDarley E Brake 50 2050 means machine type SafanDarley E Brake maximum pressure force 50 ton nominal working length 2050 mm Machine number In this field the production number of the machine is indicated ...

Page 43: ...s brake is indicated Indication maximum stroke In this field the maximum stroke of the upper beam is indicated Weight indication In this field the total weight of the press brake is indicated Connected power In this field the connected power of the press brake is indicated Supply voltage In this field the supply voltage of the machine is indicated Indication stopping time upper beam In this field ...

Page 44: ... panel 1 Push button indicator light main drive on off 2 Reset push button indicator light 3 Mute push button indicator light 4 Push button indicator light tool clamping optional 5 Emergency stop 6 Teaching knob 7 Lower part Touch screen for control purposes 8 Upper part Touch screen for graphical purposes 9 Optional 10 Height adjustment ...

Page 45: ...uge axis in position See for an extended explanation the E Control manual 7 Touch screen lower part for control purposes Touching the lower part of this screen commands are given to the E control system See for an extended explanation the E Control manual 8 Touch screen On this screen on the upper part you can read graphical applications as PDF files drawing files images etc 9 Optional This button...

Page 46: ...NOLOGY SURVEY OF THE VARIOUS TERMS IN USE Figure 2 10 Survey of the various terms X WITHDR Withdrawal distance back gauge X AXIS Back gauge position TDP Mechanical Stop Position SCP Speed Changing Position mute MCP Material Clamping Position BDP Programmable End Position Maximum stroke Maximum stroke upper beam ...

Page 47: ...the point of the upper tool during a bend During the run of a program PSP is the programmed Top Dead Point Mechanical Stop Position is reached when selector mode switch is turned into Service Tilt position SCP Speed Changeover Point This is the point at which the upper beam switches from high speed to low speed MCP Material Clamping Position This is the spot where the sheet to be bent has just bee...

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Page 49: ...SafanDarley E Brake Working Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 49 3 WORKING ...

Page 50: ...SafanDarley E Brake Working Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 50 Notes ...

Page 51: ...eam of the SafanDarley E Brake downwards Developing a maximum bending force of 200 kN up to 3000 kN See also figure 2 1 of this manual With several back gauge axis the product is exactly positioned in order to create a precise product See also Chapter 6 Accessories On the Touch screen the operator can program the size the way of working See also the E Control manual ...

Page 52: ...this position can be chosen for one of the 3 following procedures In this position the light guard is during the whole stroke of the upper beam active as safeguard In this position all the movements back gauge and upper beam start when the foot pedal is pressed If the foot pedal is pressed the upper beam will move downwards with high speed approach speed At the mute point will be switched over to ...

Page 53: ...he upper beam will immediately stop and return to TDP At the mute point the movement of the upper beam will stop and the light guard will be switched off If the foot pedal is pressed again the movement downwards of the upper beam will start again but the speed is low now The light guard may be interrupted during this part of the movement Because the light guard is not active as safeguard during th...

Page 54: ...as safeguard during the first part of the stroke of the upper beam as far as the mute point At the mute point the light guard will be switched off In this position all the movements of the back gauge and upper beam start when the light guard is interrupted and left 1x When switched into One break mode the X axis should at the first time be set in position by operating the foot pedal Even when the ...

Page 55: ... it to be the first and or second break Autoretour See TS manual has to be on If the light guard is interrupted and left 2x the upper beam will move downwards with high speed approach speed At the mute point will be switched over to bending speed At BDP the upper beam will return to TDP The light guard may not be interrupted during the whole downwards movement of the upper beam Because the light g...

Page 56: ...w The light guard may be interrupted during this part of the movement Because the light guard is not active as safeguard during this part of the stroke of the upper beam the maximum closing speed is not allowed to be higher than 10 mm s Position 4 Foot control with safe speed In this position all the movements of the back gauge and upper beam start when the foot pedal is pressed Maximum closing sp...

Page 57: ...or light main drive on will light up when the drive is powered Emergency stop and interlocking are engaged and all axes are under power After the main drive is switched off it takes 9 seconds before the main drive can be switched on again 2 Reset push button indicator light This element is button and indicator light together The button function is a reset function The light indicates the status of...

Page 58: ... 1 mm and turning slow with steps of 0 1mm R axis Turning clockwise the R axis will move up Turning anticlockwise the R axis will move down Turning fast the axis will move with steps of 10 mm turning moderate fast with steps of 01 mm and turning slow with steps of 0 1mm Z1 and Z2 axes Turning clockwise the X axis will move to the right Turning anticlockwise the X axis will move to the left Turning...

Page 59: ...e Working Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 59 10 Height adjustment not visible Height adjustment gives the operator the possibility to adjust the control to the most convenient position ...

Page 60: ...e back ups auxiliary equipment is required such as memory sticks and USB drives No memory sticks should be in the IPC while starting up the machine or the IPC Image back up and restore system When using a PC system situations can arise that damage the memory system HDD or SSD For that reason this IPC is equipped with a wire fixed image back up USB stick With this system the IPC can be brought back...

Page 61: ...virus scanner and updates If the machine is part of a computer network it is strongly advised to use a virus scanner and NOT to update MS Windows software Third party applications It is permissible to expand the PC of this machine with software for virus checking and backup software Because there are so many programs in this area SafanDarley cannot exclude that any of these programs have a negativ...

Page 62: ...SafanDarley E Brake Working Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 62 3 4 WORKING OF THE BACK GAUGE The working of the back gauge is explained in chapter 6 Accessories ...

Page 63: ...SafanDarley E Brake Safety Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 63 4 SAFETY ...

Page 64: ...SafanDarley E Brake Safety Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 64 Notes ...

Page 65: ...cation as well as incorrect and improper use operation and maintenance may render the full or partial responsibility of the producer or its authorized agent in respect of non compliance with requirements damage and accidents null and void 4 1 1 PROTECTIVE CLOTHING Wear the right clothing Sheet edges can be sharp sturdy work gloves boots with steel caps to prevent injury from falling sheets ear pro...

Page 66: ...ed in section 9 3 3 CHANGING TOOLS based on the type of tool clamping your machine is equipped with Tools must be handled in such a way that hands or part of a hand never get between the underside of the top tool and the top of the bottom tool Tools may not protrude at both sides from the tool clamping device Protruding tools may cause damage or danger of jamming 4 1 7 CHANGING PRINT CARDS OR OTHE...

Page 67: ...ods The inspection should be carried out in accordance with valid national regulations at the intervals defined in the regulations The intention of these inspections is to detect any changes or manipulations of the protective devices since the original commissioning The inspections should also be carried out whenever major modifications are made to the machine or protection equipment as well as af...

Page 68: ...vice and the mechanical guarding is not possible 1 Close to sender Access opening at protective field limits protective field markings Move the test rod diameter 14 or 30 mm as appropriate slowly through the guarded access opening following the direction of the arrows as shown in the diagram on the left Then check the diagram on the right to make sure there is no risk that anyone may be able to re...

Page 69: ... aid table rises towards the TS control panel Position the TS control panel outside the bend aid movement If a bend aid is used there is a danger when the bend aid returns from top position to start position Stay away from the area of the bend aid table movement Changing upper tools through the side frame When insert tools through the side frame be aware to insert the tool completely even with the...

Page 70: ...E Brake Safety Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 70 4 4 EXAMPLES OF JAMMING HAZARDS In the illustration examples of jamming hazards are shown Figure 4 12 Examples of jamming hazards ...

Page 71: ...SafanDarley E Brake Transport installation commissioning Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 71 5 TRANSPORT INSTALLATION COMMISSIONING ...

Page 72: ...SafanDarley E Brake Transport installation commissioning Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 72 Notes ...

Page 73: ...eight refer to technical specifications 1 2 1 Dimensions refer to main measurements and foundation measurements 1 2 2 5 1 2 HOISTING Use the crane holes in the back bridge next to the electro cabin and from that point the third hole In case of a machine with a tool cabinet use the holes next to the electro cabinet and next to the tool cabinet Figure 5 1 Transport and hoisting instructions press br...

Page 74: ...ks in the rear and the front of the frames to fasten the machine The center of gravity is directly behind the top beam of the machine This may cause the machine to topple forward during transport Consequently the press brake must never be lifted from the underside by means of a forklift truck Figure 5 2 No forklift truck 5 1 3 DELIVERY Delivery report Check the machine on arrival for Damage and fa...

Page 75: ...AL CONNECTIONS ATTENTION ONLY QUALIFIED MAINTENANCE PERSONEL MAY USE THIS SWITCH The lead through for the supply cable is a hole at the right in the bottom of the electrical cabinet The cable shall be fixed with tie wraps towards the main switch For cable from the sealing knock the knock out hole at the right on top of the cabinet use the gland nut from the bottom and seal the bottom hole with the...

Page 76: ...earth connection The cable is suitable for the maximum main motor current The listed fuse slow blow is the maximum permitted for this type of cable Maximum cable length is not to exceed 20 meters If a longer cable is required consult our service department Maximum allowable variation of supply voltage or 10 of nominal Damage caused by incorrect installation of electric supplies is not covered by t...

Page 77: ...000 3528 1000 Longueur bras support 1000 4080 1000 Figure 5 3 Required operating and maintenance space The gray shaded area in the drawing shows the required operating space around the press brake On the left hand side and on the right hand side of the press brake there should be a minimum space which exceeds the working length of the machine by approximately 1 meter This space is required in orde...

Page 78: ...press brake frame has a stable design and thanks to the two point mounting of the rear frame the frame parts need not be adjusted to run parallel The electrical cabinet is fixed to the frame Fastening or loosening bolts is not necessary For the SafanDarley E Brake press brake Premium 100 3100 it is necessary to anchor the rear machine foots to the floor With the adjusting bolt s in the machine foo...

Page 79: ...ng Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 79 Figure 5 5 Attention At the front put the supports of the press brake exactly on the foot plates Figure 5 6 Support view from front Figure 5 7 Support view with protective cover open ...

Page 80: ...e Figure 5 8 Chemical anchor with steel foundation plate Part SafanDarley E Brake Premium 100 3100 1 Machine adjusting bolt 2 Machine foot 3 Steel foundation plate Dim 130x150x10 SafanDarley number 663 000 170 4 Foundation bolt Dim M12x160 SafanDarley number 210 650 172 Injection mortar SafanDarley number 210 650 012 Equivalent anchoring with wedge bolt etc is allowed ...

Page 81: ...ious accessories if supplied 8 A qualified electrician must connect the mains 9 Switch on the main voltage of the press brake 10 Start the press brake 11 Check the proper working 12 Make sure the various accessories if supplied are working properly 13 Make an image back up and restore system 5 3 1 COMMISSIONING REPORT Fill in the full commissioning report COMMISSIONING REPORT SafanDarley B V or he...

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Page 83: ...SafanDarley E Brake Accessories Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 83 6 ACCESSORIES ...

Page 84: ...SafanDarley E Brake Accessories Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 84 Notes ...

Page 85: ...le and a CNC operated R axle The X axle is driven by a gear wheel and positioned by tolerance free ball circulating spindles The height adjustment of the R axle is driven and positioned by a belt assembly This standard version has tip up fingers which can be moved manually parallel to the bending line Z axis Other options are CNC operated Z1 Z2 and Delta X axles Figure 6 2 Tip up fingers The frame...

Page 86: ...etween fingers X1 and X2 is obtained by moving the tension roll that is closest to the motor Figure 6 4 Zero setting X axle Moving the tension roll set will only change the position of the X1 finger When the tension roll set is moved up the X1 measurement will become bigger Moving the set 1mm will result in an X1 measurement shift of 0 1mm The X axle position is set during the start up of the mach...

Page 87: ...the gauge assembly any tolerance that may occur in the components is automatically corrected By horizontally moving the drive as a whole the R axle can be set at equal height left and right By moving the drive 1mm to the R1 side the R1 side will drop 1mm and the R2 side will rise 1mm Figure 6 5 Belt tension R axle The height position of the R axle is set during start up by detecting the height of ...

Page 88: ... by moving the tension roll at the ends of the gauge beam Figure 6 6 Belt tension Z axle The Z axle position is set during the start up of the machine by stopping against a mechanical limiter using a reduced torque control Next the initialization point is set on the motor s resolver 6 1 4 SPECIFICATIONS Reach X axis 550 mm X axis lay on 575 mm X axis lay on large 1000 mm Speed 350 mm sec Precision...

Page 89: ...SafanDarley E Brake Operation Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 89 7 OPERATION ...

Page 90: ...SafanDarley E Brake Operation Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 90 Notes ...

Page 91: ...f the press brake control mounted on this machine The manual covers the following types of press brake control SafanDarley EC 10 EC 20 EC 3 All safety regulations as specified in chapter 4 Safety are to be strictly observed It is for this reason that the press brake must not be operated by unauthorized persons but by operators who are familiar with the operating instructions and safety regulations...

Page 92: ...T key on the screen of the control The following text will appear on the screen START MACHINE DRIVE THEN INITIALIZE 5 Start the machine drive by pressing the drive on push button on the control panel 6 Touch somewhere in the screen 7 Press the RUN button in the Touch Screen 8 Press the foot pedal The back gauge will move to its programmed position 9 Make your choice with the selector switch and pr...

Page 93: ... Brake Premium 100 3100 100Pr 2019 93 7 3 CHOOSING THE EASIEST OPERATING MODE With the possibilities of selector safety switch the operator can choose for the most fast and convenient way of working The possibilities are extensively explained in chapter 3 Working ...

Page 94: ...xis page of the Touch screen after the last production handling and shut down the control The screen will turn black This means the PC is off 2 Press the main drive button 3 Switch off the supply voltage with the main switch 4 Clean up the machine and surroundings Do not use support arms or bend auxiliary as stock table Put just one product on these auxiliaries ...

Page 95: ...SafanDarley E Brake Troubleshooting Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 95 8 TROUBLESHOOTING ...

Page 96: ...SafanDarley E Brake Troubleshooting Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 96 Notes ...

Page 97: ...sh the main drive on push button Main drive does not start Selector safety switch is in position 0 or Service Bring the selector switch in another position than 0 and SERVICE Main motor does not start Emergency stop switch on control panel has been used Unlock emergency stop switch When the situation allows put the selector safety switch to and fro in position SERVICE until upper beam is in TDP Pu...

Page 98: ...the main drive on button Incorrect size of product Back gauge position does not correspond with back gauge control value Re adjust back gauge fingers By shifting or by means of micro adjustment X axis does not position All kind of causes Analyze the problem Consult SafanDarley or agent IPC Machine will not startup Memory stick in the IPC Remove the memory and restart Temposonic R series position s...

Page 99: ...SafanDarley E Brake Troubleshooting Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 99 8 2 EXPLANATION OF THE INDICATOR LIGHT SIGNALS ...

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Page 101: ...SafanDarley E Brake Maintenance Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 101 9 MAINTENANCE ...

Page 102: ...SafanDarley E Brake Maintenance Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 102 Notes ...

Page 103: ...ous procedures should be executed Please first read the section about maintenance and lubricating before starting If you are in doubt about any procedures please contact your agent or if necessary SafanDarley s service department When readjusting TOOL ALIGNMENT and BACK GAUGE the readjustment of the upper beam guides is of great importance First check and if necessary readjust the guides prior to ...

Page 104: ...nd good service it is essential that the IPC components are not removed and replaced separately All casings are of the EBC 3100 R11 KH ACE A627A type but they all have a unique number on the back Figure 9 1 Unique IPC number Please state this number in all your correspondence For proper repairs and check ups you should therefore always return the entire PC and not just separate components ...

Page 105: ... interrupt the press brake control Turn the mode selector switch into position Service In this position the brakes of the main motors are released After that the belts can be tautened with a hex key size 17 mm See the sticker next to the motors for the correct turning direction The drive belts are tautened by turning the shafts of the gearbox above the motor The belts have to run properly between ...

Page 106: ... beam protecting cover of the press brake 4 Check the clearance with a feeler gauge between the guide face on the rear side of the upper beam and the guide face on the rear guide strip between the guide face on the front side of the upper beam and the guide face on the front guide strip The total clearance per machine side should be between 0 05 mm and 0 10 mm A feeler gauge of 0 05 mm goes betwee...

Page 107: ...y and remove it to prevent machine operation while the tools are being changed or adjusted Once the tooling is changed or adjusted re insert the key unlock the mode switch then reset the mode switch to the proper type of operation and begin safe machine operation On a press brake equipped with hydraulic clamping To change the tooling or adjust the installed tooling position press the unclamp butto...

Page 108: ...OFF hydraulic upper tool and lower tool clamping optional Depending on the design of the press brake it can be that upper and lower tool clamping are operated with one button the left button Figure 9 4 Mode Switch Note that the mode switch can be locked using a key This will lock the mode switch in the position it is in The mode switch cannot be changed after removal of the locking key Note the mo...

Page 109: ...Figure 9 5 Upper tool adaptation 1 Upper beam 2 Clamping plate 3 Safety key upper beam 4 Intermediate beam 5 Clamping plate 6 Safety key intermediate beam 7 Upper tool If the top tool has to be replaced the clamping plates with which the top tool is clamped to the upper beam or intermediate beam must be loosened a little causing the top tool to go down a little until it rests on the safety key The...

Page 110: ...brake to the left hand or right hand side of the press brake Keep upper limbs out of the machine as long as the top tool is still in it The top tool may be sharp wear leather working gloves A top tool is fragile handle with care 6 Put back again the top tool moved it through the side frame of the press brake and then push over the safety key of upper beam Make sure that the surfaces of the tool ad...

Page 111: ... side frame be aware to insert the tool completely even with the end of the tool clamping device Keep upper limbs out of the machine as long as the top tool is not yet placed correctly 9 3 5 CHANGING BOTTOM TOOLS The lower beam table is a standard accessory of SafanDarley press brakes As an extra option they may have been fitted with a so called single V tool table adjustable crowning system or fl...

Page 112: ...ool on its side out of the press brake to the left hand or right hand side of the lower beam 5 When the single V tool is put back again it must be pushed into the lower tool adaptation from the side of the press brake Make sure that the surfaces of the tool adaptation of both bottom tool and the table are clean and undamaged A single V tool usually has a marking running along the entire length of ...

Page 113: ...r side of top tool adaptation runs parallel to the upper side of bottom tool adaptation must be checked by bending test sheets under the left hand side of the upper beam and bending identical sheets under the right hand side of the upper beam Make sure that the tool adaptations are clean and undamaged the tool adaptations are aligned correctly the tools are undamaged the sheet to be bent is of a g...

Page 114: ... can be restarted as follows 1 by putting the safety selector switch Pos 4 of 2 3 1 to and fro on Service Tilted position the force of the upper beam springs will cause the upper beam to go upwards slowly In this way the belt will not come loose 2 in the mechanical top dead point the upper beam will be re aligned again 3 press the yellow reset button 4 press the drive on button Pos 1 of 2 3 1 5 ma...

Page 115: ...the mains power supply by means of the main switch 11 Open the side covers 12 Clean the left over part of the wearing surface of the position sensors with a cloth and Isopropanol or meths 13 Close the upper side protective covers and fasten the socket screws 14 Close the lower side protective covers at both sides 9 3 10 CHECKING AND RE ADJUSTING THE POSITION OF THE BACK GAUGE See chapter 6 Accesso...

Page 116: ...of the linear guides Guide cars of the linear guides mounted inside the back gauge supports must be greased by means of an oiler on the lubricating nipples Squirt in so much oil that it comes out again at the wiper seals of the guide cars remove superfluous oil with a rag KWEVE 25 B SL contains 2 3 gr grease KWEVE 30 B SL contains 3 8 gr grease refill with 50 Use for example Rhenus Norlith STM2 Th...

Page 117: ...tly dust and dirt absorbing For the same reason do not use preservatives or spray on moving guiding parts 9 4 3 LUBRICATION EACH TWO YEAR 5000 HRS Reduction gear unit of the top beam drives Drain the oil preferably warm of the reduction gear units by removing the drain plug The drain plug is mounted on the underside in the connecting flange of the driving motor After having drained the oil put bac...

Page 118: ...cket upper beam Clean and check the spring mounts bushings and check for wear or damage Lubricating the guiding parts such as the plastic bushes and guiding steel shafts Cleaning cloth Use Teflon products Do not lubricate with oil or grease Back gauge 1 x per 200 working hours Guide cars of the linear guide Use oiler on lubricating nipples E g Rhenus Norlith STM2 1 x per 600 working hours Ball cir...

Page 119: ...SafanDarley E Brake Premium 100 3100 100Pr 2019 119 Each year 2000 Hours Grease with Rhenus Norlith STM2 Both sides of the machine Each month 200 Hours Clean Both sides of the machine Each quarter 600 Hours Lubricate with Teflon product No oil or grease ...

Page 120: ...ake Premium 100 3100 100Pr 2019 120 Remove lid 4 Screws Each month 200 Hours Grease with Rhenus Norlith STM2 Both sides of the machine Each quarter 600 Hours Grease with Rhenus Norlith STM2 Both sides of the machine Each month 200 Hours Grease with Rhenus Norlith STM2 ...

Page 121: ...SafanDarley E Brake Maintenance Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 121 Frequently Clean with a blow pistol Both sides of the machine ...

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Page 123: ...SafanDarley E Brake Maintenance Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 123 9 6 DRAWINGS ELECTRICAL SCHEME ...

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Page 125: ...EME Drawings of spare parts How to order spare parts THE FOLLOWING INFORMATION SHOULD BE GIVEN ON YOUR ORDERS 1 Machine type 2 Machine serial number Year of production 3 Page and date of the handbook showing the part 4 SafanDarley number s from the part and if possible the name of the part 5 The quantity of parts required ...

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Page 127: ...SafanDarley E Brake Register Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 127 REGISTER ...

Page 128: ...SafanDarley E Brake Register Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 128 Notes ...

Page 129: ...mergency stop 45 58 Emergency stop 57 fast and convenient 93 Flattening tool 18 floor 77 foundation 78 Fuse 21 Guide cars 116 How to order spare parts 125 HTR foot pedal 35 INIT 92 interlocking 57 interrupted 52 53 interrupted and left 1x 52 53 jamming 31 Keep this manual 9 103 keyboard 45 58 lead through 76 level 78 linear encoder 114 Lower tool clamping 18 Machine number 18 Machine type 18 Maxim...

Page 130: ...Supply voltage 21 Support arms 18 swivel arm 81 TDP 25 tonnage 21 TOOL ALIGNMENT 103 tool nesting places 81 Touch screen 45 58 transformer 21 75 76 trap door 35 two break 34 two break mode 52 55 unauthorized 52 upper beam guides 105 116 Upper tool clamping 18 USB drive 35 valid legislation 65 warning pictograms 12 Weight 21 working length 21 written consent 2 X AXIS 46 X direction 25 X POS RET X 2...

Page 131: ...SafanDarley E Brake Annex Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 131 ANNEX Release notes Release document Conform CE ...

Page 132: ...SafanDarley E Brake Annex Instruction manual SafanDarley E Brake Premium 100 3100 100Pr 2019 132 Notes ...

Page 133: ...ged oil type from Shell into Rhenus Version 16 Electrical cabinet RD50 Cleaning position sensors Troubleshooting position sensors Version 17 Connecting supply cable added Version 18 Instruction for use of the press brake in combination with robot Version 19 Cleaning potentiometer Changing hydraulic tool clamping Version 20 Control panel added for Ultra Premium and Econic ...

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