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  5. Operator's Manual

Baileigh RDB-250 Operator's Manual

Manual is about: ROTARY DRAW BENDER

Summary of RDB-250

  • Page 1

    Operator’s manual rotary draw bender model: rdb-250 © 2015 baileigh industrial, inc. Reproduction of this manual in any form without written approval of baileigh industrial, inc. Is prohibited. Baileigh industrial, inc. Does not assume and hereby disclaims any liability for any damage or loss caused...

  • Page 2: Table Of Contents

    Table of contents thank you & warranty .......................................................................................... 1 introduction ............................................................................................................. 3 general notes ................................

  • Page 3

    Large size square ..................................................................................................... 40 index table attachment (optional equipment) .......................................... 41 introduction .............................................................................

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    1 1 thank you & warranty thank you for your purchase of a machine from baileigh industrial. We hope that you find it productive and useful to you for a long time to come. Inspection & acceptance. Buyer shall inspect all goods within ten (10) days after receipt thereof. Buyer’s payment shall constitu...

  • Page 5

    2 2 force majuere. Seller shall not be responsible for any delay in the delivery of, or failure to deliver, goods due to causes beyond seller’s reasonable control including, without limitation, acts of god, acts of war or terrorism, enemy actions, hostilities, strikes, labor difficulties, embargoes,...

  • Page 6

    3 3 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,...

  • Page 7: Important

    4 4 learn to recognize safety information this is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury! Follow recommended precautions and safe operating practices. Understand signal words a signal word – danger, warning, ...

  • Page 8

    5 5 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. Wear suitable hearing pro...

  • Page 9

    6 6 keep clear of moving objects always be aware of the position of the material and the swing area in which the material will travel. The material will swing with significant force. This swing area will create pinch points and the force of the material movement may cause serious bodily injuries. Hy...

  • Page 10: Warning:

    7 7 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...

  • Page 11

    8 8 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. Check for damaged parts. Before using any tool or machi...

  • Page 12

    9 9 technical specifications maximum center line radius (clr)* 9" (229mm) minimum center line radius (clr)* .5" (12.7mm) minimum od .25" (6.35mm) mild steel pipe (schedule 40) based on a material tensile strength of 60000 psi – mild steel 2" (50.8mm) aluminum pipe (schedule 40) 2" (50.8mm) stainless...

  • Page 13: Warning:

    10 10 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. Cleaning your machine may be shipped with a rustp...

  • Page 14: Caution:

    11 11 transporting and lifting follow these guidelines when lifting: • the lift truck must be able to lift at least 1.5 – 2 times the machines gross weight. • make sure the machine is balanced. While transporting, avoid rough or jerky motion, and maintain a safe clearance zone around the transport a...

  • Page 15: Warning:

    12 12 • 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. • leveli...

  • Page 16

    13 13 getting to know your machine a b c d e f g h i j k l m n.

  • Page 17

    14 14 item description function a grease zerk for greasing main spindle bearing b main spindle and drive pins for supporting the bend dies and driving the dies c center pin for aligning die onto spindle d hitch pin for mounting the counter die e quick release for pivoting counter die away from bend ...

  • Page 18: Caution:

    15 15 electrical motor specifications your tool is wired for 220 volt, 60hz alternating current. Before connecting the tool to the power source, make sure the machine is cut off from power source. Considerations • observe local electrical codes when connecting the machine. • the circuit should be pr...

  • Page 19

    16 16 • 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. If repair or replacement of the electric cord or plug is nec...

  • Page 20: Caution:

    17 17 operation programmer overview • this draw bender utilizes a fully programmable touch screen operator interface. The unique operator interface allows you to write and save 170 programs with 10 bends per program. Operation is extremely simple to learn. Simple foot pedal controls allow you to eas...

  • Page 21

    18 18 programmer display and key functions 1. The touch screen control is very self-explanatory. By touching the labeled touch boxes on the screen, the listed parameter or function will be selected. The exit box will return you to the previous screen and get you back to the rmd main screen. When ent...

  • Page 22

    19 19 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. B. From the program selector...

  • Page 23

    20 20 edit a program 1. Select this feature when you want to edit an existing program. A. From the program selector screen fig 5, choose the program number to be edited. Use the up and down arrows to move the screen up or down one line or one page at a time. Dashed lines in the name indicate that no...

  • Page 24: Caution:

    21 21 4. After selecting the program line. Touch the edit button and the program parameters will be displayed fig 6. Press the view button in the upper right corner to change to the edit mode. 5. On the edit screen enter the desired program name by touching the name field fig. 6. 6. The alpha key pa...

  • Page 25

    22 22 down one line or one page at a time. Dashed lines in the name indicate that no program is saved to that location. 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 di...

  • Page 26

    23 23 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. The speed is controlled with th...

  • Page 27

    24 24 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 nee...

  • Page 28

    25 25 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. • this machine is capable...

  • Page 29

    26 26 • 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 30

    27 27 oem screen figure 14 oem screen figure 15 oem screen figure 16 oem screen figure 17.

  • Page 31

    28 28 oem screen figure 18 oem screen figure 19 oem screen figure 20 oem screen figure 21.

  • Page 32

    29 29 oem screen figure 22.

  • Page 33: Caution:

    30 30 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 mat...

  • Page 34

    31 31 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. A hook arm b bend die c hold down bolts d plastic slide e counter die mount f bronze counter ...

  • Page 35

    32 32 h spindle i die drive pins j 1/2-13 tapped holes for bolting down dies k center pin l at “0” position, this flat is parallel with the machine side m 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” h...

  • Page 36

    33 33 • 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 wh...

  • Page 37

    34 34 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. Leadscrew counter, do...

  • Page 38

    35 35 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 i...

  • Page 39

    36 36 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 b = straight between bends r2 = second ra...

  • Page 40

    37 37 bending glossary arc length the length of material along the centerline of the tubing centerline radius (clr) distance in inches from the center of curvature to the centerline axis of the tube bending or pipe bending bends. Abbreviated as clr. See tube bending and pipe bending diagram degree a...

  • Page 41

    38 38 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 • highly rich dish soap • the bronze counter die...

  • Page 42

    39 39 bending with square dies • die parts 1 main bending die 2 die cap 3 quick release handles 4 hook-arm 5 hook-arm clamp 6 plastic slide 7 slide mount 8 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...

  • Page 43

    40 40 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 t...

  • Page 44

    41 41 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,...

  • Page 45

    42 42 8. The chuck/gearbox assembly is designed to pivot on its mount, tension is adjusted with spring washers beneath the (2) ½-13 mounting bolts. For small light weight material, the swivel will need to be loosened so it pivots easily, for heavy material, the swivel should be tightened to increase...

  • Page 46

    43 43 index table layout diagram (optional equipment).

  • Page 47: Warning:

    44 44 lubrication and maintenance • check daily for any unsafe conditions and fix immediately. • check that all nuts and bolts are properly tightened. • on a weekly basis clean the machine and the area around it. • lubricate threaded components and sliding devices. • apply rust inhibitive lubricant ...

  • Page 48

    45 45 electrical schematic black j2 connector orange j1 connector horner ( xle or xlt) hexle 102 or he-xt102 programmer.

  • Page 49: Warning:

    46 46 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...

  • Page 50

    47 47 troubleshooting fault probable cause remedy machine does not power up wrong or non-existent input power source. Blown fuse or tripped circuit breaker. Check input power and verify voltage check and replace fuses. Reset circuit breakers oil leaking from breather normal expansion of gearbox oil ...

  • Page 51

    48 48 tables, charts, & diagrams table 1 standard pipe sizes and schedules pipe sizes o.D. Pipe schedules and wall thickness 5 10 40 80 160 xx strong 1/8 0.405 0.400 0.050 0.068 0.095 1/4 0.540 0.500 0.070 0.088 0.119 3/8 0.675 0.500 0.070 0.091 0.126 1/2 0.840 0.700 0.080 0.109 0.147 0.188 0.294 3/...

  • Page 52

    49 49 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 constant degrees constant 1 0.0175 31 0.5410 6...

  • Page 53

    50 50 diagram 1.

  • Page 54

    51 51 diagram 2.

  • Page 55

    52 52 parts diagram base assembly parts diagram.

  • Page 56

    53 53 control box parts diagram.

  • Page 57

    54 54 drive assembly parts diagram.

  • Page 58

    55 55 main bending assembly parts diagram.

  • Page 59

    56 56 parts list item part number description qty. 3 pp-0043 1.0 id x 1.1875 od x 0.75 lg bushing 4 4 pp-0035 1" set screw collar 4 5 pp-0064 8" rubber wheel 2 6 pp-0048 4.0 inch caster 2 7 std. 3/8-16 x 1 carriage bolt 8 8 std. 3/8 flat washer 12 9 std. 3/8 lock washer 8 10 std. 3/8-16 hex nut 8 11...

  • Page 60

    57 57 item part number description qty. 41 me-m250-6a017 center slide block (inserted) 1 42 m250-7a006 pivot pin 1 43 me-m250-7a010 lead screw nut insert 1 44 m5 x 0.8 x 12 shcs 3 45 m20 x 2.5 x 40 shcs 1 46 m250-7a009 lead screw stop nut 1 47 m200-7a023 lead screw 1 48 pp-0913 1.0 id x 1.25 od x 0....

  • Page 61

    58 58 item part number description qty. 76 m300-7a032 thrust washer 1 77 m300-7a031 thrust washer 1 78 pp-1071 3/4" dowel pin 3 79 std. 3/8 lock washer 4 80 std. 3/8-16 x 16 hhcs 4 81 m200-cover cover, m325 front 1 82 m250-7a002 bearing hub 1 83 me-m250-7a008 m250 spindle (metric) 1 84 std. M20 x 2....

  • Page 62

    59 59 notes.

  • Page 63

    60 60 notes.