Di-Acro 6 Manuel utilisateur

DI-ACRO

NO. 6 & NO. 8 POWER BENDER

INSTRUCTION MANUAL

Toll Free: (855) 651-8948 - www.diacro.com - Fax: (651) 342-1293

12430 55th St. No. - Oak Park Heights, MN 55082 - USA

REV. B 12/16 2

TABLE OF CONTENTS

SECTION

PAGE

A. INTRODUCTION

B. SAFETY INFORMATION

C. SPECIFICATIONS

D. INSTALLATION

E. LUBRICATION

F. CONTROL DESCRIPTION AND OPERATION

G. SETUP & RUN –NO. 6 BENDER

H. SETUP & RUN –NO. 8 BENDER

I. CHANGING THE HOME POSITION

J. TABLE ASSEMBLY

K. 4” CYLINDER ASSEMBLY

L. BASE ASSEMBLY

M. NO. 6 TOOLING HEAD ASSEMBLY

N. HANGER ASSEMBLY

O. PRESSURE ROLLER ASSEMBLY

P. NO. 8 TOOLING HEAD ASSEMBLY

Q. NOSE HOLDER ASSEMBLY

R. GAUGE GROUP

S. FLOOR PLAN

T. HYDRAULIC DIAGRAM

U. ELECTRICAL DIAGRAM

V. WARRANTY

REV. B 12/16 3

A. Introduction

This instruction manual serves two purposes:

1. It outlines essential information for installation, operation, and maintenance of the PLC

controlled No. 6 and No. 8 Power Bender.

2. It gives a complete parts breakdown identified by number, should replacements be

required.

It is recommended that the operator become familiar with the bender’s instructions and

operating details. It is also recommended that the foreman or supervisor familiarize himself with

the operating details of the machine to insure its continued efficient service.

The Di-Acro Power Benders are designed to accommodate two different types of tooling.

The No. 6 Bender is designed to handle tubing to 1.125” diameter (.060” wall-mild steel) and

mild steel round bars up to .563” diameter.

The No. 8 Bender will handle mild steel round bar up to 1” diameter and tubing to 1.500”

diameter (.060” wall-mild steel)

B. Safety –Caution

Always read and understand this instruction manual before operating the No. 6 or No. 8 Bender.

Always make certain that other individuals are not in the working area of this machine before

operating.

Always keep fingers, hands, arms, elbows, head, feet, or other parts of the body clear of

swinging arm and out of tooling area when machine is in operation.

Always make certain power is off when installing, removing, or changing tooling.

Always make certain power is disconnected when servicing machine.

Never allow untrained personnel to operate this machine.

REV. B 12/16 4

C. Specifications

NO. 6 TOOLING HEAD

NO. 8 TOOLING HEAD

CAPACITY (MATERIAL)*

1-1/4” OD TUBE - .060”

WALL

1-1/2” OD TUBE - .060”

WALL

¾” I.P.S.

1” I.P.S.

5/8” DIA SOLID ROUND

1” DIA SOLID ROUND

½” SOLID SQUARE

7/8” SOLID SQUARE

¼” X 2” FLAT (EASY WAY)

3/8” X 4” FLAT (EASY WAY)

¼” X 1” FLAT (HARD WAY)

3/8” X 1” FLAT (HARD WAY)

MAXIMUM RADIUS

9”

24”

HYDRAULIC PRESSURE

1250 PSI

MOTOR

3 HP

CYLINDER BORE

4”

FLOOR SPACE

18” X 62”

SHIPPING WEIGHT

1,150 LBS

SPINDLE TORQUE

3487 FT*LBS

VOLTAGE REQUIREMENTS

208, 230, OR 460 VAC, 3 PH, 60HZ

*ALL MATERIAL (EXCEPT I.P.S.) IS SPECIFIED AS MILD STEEL (57 KSI YIELD STRENGTH) OR

EQUIVALENT.

REV. B 12/16 5

D. Installation

During shipment, the bender may have accumulated a coating of dust or grit. Remove all dirt

and rust preventative with cleaning solvent.

WARNING: To prevent serious bodily injury fasten machine to floor through four holes (5/8”

diameter) provided in the base of the machine.

When shipped, the gauge is removed for packing purposes. Install one of the two gauge groups

as shown below if desired.

Note: The Stop Rod Weldment is inserted through the table assembly from the Operator’s

Console side of the table. The appropriate Gauge Group is then installed onto this weldment

from the opposite side. The “pin” through the Stop Rod Weldment will engage a slot in the hole

of the knurled knob to allow the knob assembly to rotate the Gauge Group.

Note: Install gauge group “A” for short or single length bends. Install group “B” for longer or

multiple length bends.

Note: It is suggested that all four stop arms be placed at right angles to each other even if only

one or two are needed so that the knurled knob can be easily turned to position the stops. IF the

REV. B 12/16 6

stop arms are not located as above, the group will be out of balance and may cause binding of

the knurled knob.

Connect electricity to a three-phase input supply making certain that the transformer and motor

are connected properly for power being supplied. (208-230, or 460 VAC).

Check pump rotation. Power up the machine. Start the hydraulics by rotating the emergency

stop button clockwise, pressing the power on/reset button, and pressing the green start button

on the operator console. Open the door in the base and make sure that the pressure gauge

indicates a value around 1250 psi. If no pressure is indicated by the gauge, the motor is spinning

the wrong direction. Stop the pump by pressing the red stop button on the operator’s console

and disconnect power. Swap two of the input power leads at the machine disconnect to change

the motor direction.

Check the oil level in the sight glass on the tank in the base of the machine. If oil is required, use

the oil detailed in the lubrication section of this manual.

E. Lubrication

If the oil level is low in the sight glass on the side of the hydraulic tank, fill with Shell Tellus S2 M

32 or equivalent. Under no circumstances is a detergent motor oil to be used.

Lubricate the Grease Fitting (No. 29 in the Table Assembly parts breakdown) on the Cam

Follower (No. 29) every 500 hours or every 3 months. Use NLGI No 2 grease to lubricate this

component.

Bare metal surfaces on the tooling and slides can be lubricated with Boeshield T-9, or an

equivalent thin-film lubrication to prevent corrosion in high moisture environments. This can be

applied as needed.

F. Control Description and Operation

1. Initial Power Up

After providing the proper power source to the main electrical enclosure, rotate

the disconnect switch to the “on” position. This will provide power to the PLC

and control panel.

Rotate the Emergency Stop button on the control panel clockwise to deactivate.

Press the “Power on/Reset” button.

Press the “Start” button to start the hydraulic system. The “Stop” button will

shut down the hydraulic system. NOTE: Stop the pump if the machine will be

sitting for a long period. Allowing the pump to run idle can cause the hydraulic

oil to heat up and require replacement.

REV. B 12/16 7

2. HMI Screen Displays (Without Recipe Operation)

The HMI panel layout is shown in the photo below. Make note of the Function

Keys, Numeric Keypad, and Enter/Return key.

Two screen options are provided with the standard power bender HMI. The

Main Screen as shown below is used during production runs.

This screen displays the Bend Setpoint, Bend Value, and Parts Counter.

REV. B 12/16 8

The “Manual/Homing” Screen is used to run the machine manually and to home

the machine. This screen is shown below.

This screen displays the Bend Value, and indicates whether the machine is

Homing or Homed during the Homing procedure.

On either screen, the Function Keys are used to perform whatever functions are

displayed on the screen at the time, or toggle between different modes as

displayed. This is covered in detail in the Homing, Manual, and Automatic

Operation sections that follow.

3. Manual Operation

CAUTION: When operating the power bender in manual mode, it is possible to crash

the tooling setup more readily than when it is set up in automatic mode. Make sure

you are familiar with all the controls and the direction of travel prior to actuating the

machine.

When the machine is initially powered up, the Main Screen will be displayed.

Press F4 to advance to the Manual/Homing Screen display.

The Manual/Homing screen shows the Bend Value, Mode (Automatic or

Manual), direction of travel (Extend or Retract), and Homing/Home State.

The Function Keys will toggle the values shown above each function key

descriptor in each box (F1, F2, etc.)

The value displayed above F1 is what mode the bender is in. Use the F1 button

to toggle between Auto and Manual

The value displayed above F2 displays the direction of travel that the bender will

move when it is actuated. Extend moves the tooling head counter-clockwise

when viewed from above, and Retract moves the tooling head clockwise. Extend

will also increase the bend value displayed, while Retract decreases the bend

value.

Note that neither the Home Position Proximity Switch nor the Bend Setpoint will

stop the bender when in Manual Mode.

REV. B 12/16 9

Once the desired bend has been set up, place your fingers in the two-hand

safety switches located on either side of the Operator’s Console. Note that the

machine will begin moving when your fingers enter these switches. It will not

stop until your fingers are removed or the machine runs out of travel.

When the desired travel has been reached, take your fingers off the safety

switches. Press F2 to reverse the travel if desired. Actuate the safety switches to

move the bender back to the point you started.

4. Homing the Bender

When the machine is initially powered up, the Main Screen will be displayed.

Press F4 to advance to the Manual/Homing Screen display.

Once in the Manual/Homing Screen, note that the Homing and Homed indicator

circles are initially unfilled. This is normal, and should be the case regardless of

the Bend Value. This is because any time that the hydraulic system is powered

down, the PLC unlatches the home position.

Ensure that the Bend Value displayed is a positive number or zero. If the Bend

Value displayed is a negative number, refer to the Manual Operation section

and extend the bender until the Bend Value is zero or positive.

Press F1 until Auto is displayed in the box above F1.

Press F2 to put the machine in Retract Mode if it is in Extend Mode.

Press F3 to begin the Homing Sequence. If the Bend Value is 0.0, the indicator

circle next to Homing will briefly flash, then the circle next to Homed will be

filled. If the Bend Value is not 0.0, the indicator circle next to Homing will be

filled.

Actuate the machine by putting your fingers into the safety switches on the

sides of the operator console. The bender will then retract to 0.0, and the

indicator circles will show that the machine has been homed.

NOTE: The machine will only retract during the Homing sequence. If you happen to

begin this sequence from a negative Bend Value, and cannot move the machine in

Manual Mode, you will need to shut off the hydraulic system. You may then restart

the hydraulics and extend the machine in Manual Mode until the Bend Value is

positive prior to attempting to home the machine.

5. Automatic Operation

NOTE: The machine will not operate in Automatic Mode without being homed. Follow

the procedure outlined above for Homing the Bender to home the machine prior to

Automatic Operation.

NOTE: Most ductile materials will exhibit some spring back when bending. Parts can be

overbent to compensate for spring back. Spring back is determined by material type,

part geometry, and even grain direction. Because of this, you will need to determine the

amount of overbending required experimentally in manual mode. This will allow you to

determine the exact bend set point for your specific application.

The Automatic Mode of operation allows the operator to set a desired bend set

point for the machine to repeat. To set up this mode of operation from the

REV. B 12/16 10

Manual/Homing Screen, press F4 (Return). This will toggle the HMI display back

to the Main Screen.

In the Main Screen, press F1 to enter the Bend Set Point. The Bend Set Point

value should be highlighted on the HMI. Use the numeric keypad to enter the

desired Bend Set Point. Save the Bend Set Point by pressing Enter/Return.

Press F1 to exit the Bend Set Point mode.

If desired, the production counter can be reset in this screen by pressing F2.

Activate the bender by actuating the two-hand safety switches on the sides of

the operator console. The bender will then extend until the safety switches are

not actuated or the bend set point is reached, whichever comes first.

Once the bend set point is reached, remove your hands from the switches.

To retract the machine, return your hands to the safety switches. The Bender

will automatically change directions and retract home so long as the switches

are actuated.

NOTE: During Automatic Operation, the bender extends to the Bend Set Point. Once

it reaches the set point, the PLC switches to Homing mode internally, and will re-

home upon retraction. The machine is coded this way to combat any drift

introduced by delays in the mechanical or hydraulic system.

6. Recipe Operation (If Installed)

The optional Recipe Operation function allows the user to save recipes of up to

4 consecutive bends in a recipe that may be recalled when needed for

production. Up to 75 unique recipes can be saved in the internal memory.

HMI Screen Displays

The Manual/Homing Screen Display is unchanged from the screen shown

above. Homing and manual operation is also the same as listed above.

The Main Screen is shown below.

Autres manuels pour 6

Ce manuel convient aux modèles suivants

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