Page 1 SafanDarley E-Brake Premium 100-3100 Servo electronic press brake SafanDarley E-Brake Premium 100-3100 Technology version MPB-RD100/101 Instruction manual 100Pr 2019 En Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 2 SafanDarley B.V. Kwinkweerd 11 Post-box 96 7240 AB Lochem The Netherlands Phone +31(0)573 222222 +31(0)573 252057 E-mail info@safandarley.com Website www.safandarley.com Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 3: Preliminaries
SafanDarley E-Brake Preliminaries PRELIMINARIES Instruction manual Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 4 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ……………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 5: Table Of Contents
Machine identification 2.4.1. Description of the machine identification 2.5. Control panel 2.5.1. Description of the main controls on the control panel 2.6. Terminology Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 6 Back gauge E-Brake MPB-RD100/101 6.1.1. X axle 6.1.2. R axle 6.1.3. Z axle 6.1.4. Specifications Operation 7.1. Press brake control Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 7 Lubrication each two year/5000 hrs. 9.5. Maintenance- and lubrication chart 9.6. Drawings Electrical scheme 9.7. Mechanical scheme Register Register Annex Release notes Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 8: List Of Illustrations
LIST OF ILLUSTRATIONS Illustration page Figure 1-1 Main dimensions and foundation measurements Figure 1-2 Allowable bending force SafanDarley E-Brake press brake Figure 1-3 Examples allowable eccentric bending force SafanDarley E- Brake press brake Figure 1-4 Preparation of a bending ...
Page 9: Introduction
Keep this manual with all the scheme’s, diagrams, etc. with this machine as long as it is in use and keep this manual with all the scheme’s, diagrams, etc. available for servicing and maintenance personnel. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 10 In combination with the TS Control manual tells the operator how to operate the press brake. The operator should have a good knowledge of sheet handling Chapter 8 Troubleshooting Is about troubleshooting and remedies. Chapter 9 Maintenance Is meant for the authorized maintenance personnel. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 11 Personal danger will be indicated by a triangle incorporating an exclamation mark. Danger of injury caused by electric current. Wear hearing protection. Wear protective clothing: safety shoes, gloves, etc. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 12 These machines can be divided into two main categories:  Press brakes.  Guillotine shears These machines can vary from standard design to complete, fully automated installations. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 13 WORK SAFELY ! SafanDarley B.V. has taken all possible effort to inform 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.
Page 15: Introduction
SafanDarley E-Brake Introduction 1. INTRODUCTION Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 16 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 17: General
 EC10  EC20  EC3 Example: 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;...
Page 18: Design
SafanDarley E-Brake Introduction 1.2. DESIGN The SafanDarley press brakes can be carried out with a series of options. This press brake is delivered in the following design: Machine type: SafanDarley E-Brake Premium 100-3100 Technology version: MPB-RD100/101 Machine number: 100Pr Year of manufacture: 2019.
Page 19 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: 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 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 21: Technical Data
Fuse slow blow: 35 Amps Max. connected load: 11 KW Weight: 7500 kg *See also Chapter 5.2.5 Electrical connections. These technical data must be seen as purely informative; they have no binding force. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 22: Information About The Noise Interference Of The Machine
73 dB(A). When measured at the rear of the machine during a movement of the back gauge beam (over a longer distance) the press brake produced a sound level of 73 dB(A). Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 23: Information About The Maximum Pressure Of The Machine
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.
Page 24 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 SafanDarley Figure 1-3 Examples allowable eccentric bending force E-Brake press brake Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 25: Description Of The Bending Process
From this point the upper tool goes down at maximum bending speed to the material clamping point. Here the sheet is clamped between upper tool and die. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 26: Figure 1-5 Sheet Clamping
The upper tool keeps moving down until the bottom dead point is reached. The distance covered by the upper tool when it goes from the clamping point to the bottom dead point is the penetration depth. Figure 1-6 Bending Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 27: Figure 1-7 Removing The Sheet
The sheet that was removed from the tools can now be measured. If the bending result deviates from the desired bending result the various bending parameters can be corrected using the press brake control. Figure 1-8 Bending result Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 28: The Different Axis Of A Press Brake
SafanDarley E-Brake Introduction 1.7. THE DIFFERENT AXIS OF A PRESS BRAKE Figure 1-9 The different axis of a press brake Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 29: Description
SafanDarley E-Brake Description 2. DESCRIPTION Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 30 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ……………………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 31: General
Jamming of body parts between upper beam and lower beam Jamming of body parts between upper beam and sheet material Danger of being hurt by raising or descending sheet material. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 32: The Main Components
SafanDarley E-Brake Description 2.2. THE MAIN COMPONENTS Figure 2-2 The main components of the SafanDarley E-Brake press brake 1. Upper beam 2. Intermediate beam 3. Clamping plates 4. Top tool 5. Lower tool 6. Press brake table 7. Lower beam / lower tool adaptation 8.
Page 33 If the light guard is interrupted during the approach speed, the upper beam will stop immediately and return to TDP. If the light guard is interrupted during bending speed, the operator should Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 34: Figure 2-3 Examples Of Blanking Of The Safety Light Guard
The press brake control is in height adjustable to meet a comfortable working height for the operator. The press brake control is discussed in a separate control manual; it controls the movements of the top beam and back gauge movements, if Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 35: Figure 2-4 Operators Console With Htr Device
Side protective covers The side protective covers prevent the danger of clamping between the drive system of the press brake. They also prevent the measuring system for being damaged. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 36 SafanDarley E-Brake Description 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 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 37: Electrical Cabinet
With the selector key lock the selector mode switch can be locked. USB-drive USB -drive for exchanging files. During start-up of the machine there must not be any memory sticks in the USB drive. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 38: Ventilator
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 Maintenance. 1. Fan 2. Lead-through for the supply cable from the floor 3. Seal plug Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 39: Ipc
64 GB industrial SSD 2,5” MLC flash 4x RS232 port, 2x PS/2 port Software W7 Pro 32 bit USB Key Sandisk 64Gb USB 2.0 key + image The HDMI connections are not used Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 40: Figure 2-6 License Sticker
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 License sticker Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 41: Figure 2-7, Overview Ipc With Wired Image Back-Up Usb
SafanDarley E-Brake Description HDD/Flash LED red Power LED green Figure 2-7, Overview IPC with wired Image Back-up USB Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 42: Machine Identification
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. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 43 SafanDarley E-Brake Description In the case of SafanDarley E-Brake \ this number is always prefixed by “M”.  Please, always state machine number and machine type in your correspondence with SafanDarley.  Year of manufacture In this field the year of manufacture is indicated.
Page 44: Control Panel
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 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 45: Description Of The Main Controls On The Control Panel
Use the USB-drive on the electrical cabinet to enter a memory stick, to connect a keyboard or the like. Attention: When using the keyboard you must observe the rules of notation for software, E.g. in filename enter no point, slash or the like. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 46: Terminology
Figure 2-10 Survey of the various terms X-WITHDR. Withdrawal distance back gauge X-AXIS Back gauge position Mechanical Stop Position Speed Changing Position (mute) Material Clamping Position Programmable End Position Maximum stroke Maximum stroke upper beam Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 47: Description Of The Various Terms
Maximum Maximum stroke length of the upper beam; This is the stroke maximum vertical movement the upper beam is capable of making. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 49: Working
SafanDarley E-Brake Working 3. WORKING Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 50 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 51: General
GENERAL Two belts powered by two electro motors move the upper beam 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.
Page 52: Working Of The Mode Switch
In this position the light guard is not active, in this position all the movements (back gauge and upper beam) start when the foot pedal is pressed. The light guard may be interrupted during the whole movement of the upper beam. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 53 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 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 54 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. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 55 10 mm/s. In this position the light guard is only active as safeguard during the first part of the stroke of the upper beam (as far as the mute point) Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 56 In this way the belt will not come loose. Position 5: Service position In this position the main drive is switched off. The brakes of the motors are released. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 57: Upper Beam In Tilted Position
The hydraulic tool clamping (option) is switched off. After an emergency stop the brakes will keep the upper beam in the emergency position. When the situation allows, unlock the emergency Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 58 The control can be fitted with a keyboard in combination with a graphical control program. Touch screen Touching this screen commands are given to the TS control system. See for an extended explanation the TS manual Optional Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 59 SafanDarley E-Brake Working Height adjustment (not visible) Height adjustment gives the operator the possibility to adjust the control to the most convenient position. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 60: Working Of The Ipc
Keep in mind that an image restore does not recover the application files and production files. So backup you production files daily. Files relating to the SafanDarley application can usually be repaired quickly, Parameter and setting files have been saved on the USB-stick that comes with the manual.
Page 61 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 negative impact on the operation of the machine.
Page 62: Working Of The Back Gauge
SafanDarley E-Brake Working 3.4. WORKING OF THE BACK GAUGE The working of the back gauge is explained in chapter 6 “Accessories” Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 63: Safety
SafanDarley E-Brake Safety 4. SAFETY Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 64 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ……………………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 65: Work Safely
4.1. WORK SAFELY ! SafanDarley B.V. has made every effort to inform you about any dangers inherent in the use of this machine as accurately and fully as possible. You are responsible for ensuring that you follow this code of conduct.
Page 66: Use Of Virus Scanner
4.1.8. CAUTION ! OBSERVE A WAITING TIME OF AT LEAST 5 MINUTES BEFORE STARTING ASSEMBLY WORK ON THE AMPLIFIERS. AFTER SWITCHING OFF RESIDUAL VOLTAGE REMAINS IN SOME LIVE PARTS OF THE AMPLIFIERS. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 67: Daily Checking Procedures
This is necessary to detect any modifications to the mounting of the system since the last test. It could then be possible for the hazardous area to become unprotected and allow for example reach over or under. When used with Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 68 Then check the diagram on the right to make sure there is no risk that anyone may be able to reach over or under the danger zone. During this test procedure, only the red LED should be illuminated. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 69: Rest Risks
When insert tools through the 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. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 70: Examples Of Jamming Hazards
SafanDarley E-Brake Safety 4.4. EXAMPLES OF JAMMING HAZARDS In the illustration examples of jamming hazards are shown. Figure 4-12 Examples of jamming hazards Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 71: Transport, Installation, Commissioning
SafanDarley E-Brake Transport, installation, commissioning 5. TRANSPORT, INSTALLATION, COMMISSIONING Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
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Page 73: Transportation
SafanDarley E-Brake Transport, installation, commissioning 5.1. TRANSPORTATION The SafanDarley E-Brake press brake has been packed properly for transportation by truck or for overseas transportation. 5.1.1. INTERNAL TRANSPORT IN YOUR COMPANY Observe the following rules for transport inside the building  The way of handling ...
Page 74: Delivery
Ask the forwarder to compile a transport damage report on delivery if necessary. full supply of all parts and accessories ordered.  Always contact SafanDarley B.V. directly in case of damage or faults. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 75: Installation Cleaning
A qualified electrician must connect the press brake. For the specifications of supply voltage, fuse and cable diameter see chapter 1.2.2 Technical data If necessary due to local circumstances, use a RCCB Type B Differential switch Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 76 The connection – R1/4 x 100 mm - for the pneumatic supply is left above the electrical cabinet behind the protective cover Check list: Transformers : is the input voltage (TRAFO - IN) correctly set for the mains voltage? Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 77: Required Operating And Maintenance Space And Area Lighting
This does not apply if only short tools are used. Take care of sufficient work area lighting. Preferred is natural light or, as alternative, artificial light. Both require the minimum light intensity of 500 Lux. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 78: Calculation Of Floor
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 foot the cross direction of the machine can be put in a water level position.
Page 79: Figure 5-5 Attention: At The Front Put The Supports Of The Press Brake Exactly On The Foot Plates
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. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 80: Figure 5-8 Chemical Anchor With Steel Foundation Plate
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 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 81: Commissioning
When the machine is transferred to the customer’s care the report must be signed by both the commissioning agent and the customer. The original is to be retained in the records of SafanDarley B.V., and the copy is for the customer.
Page 83: Accessories
SafanDarley E-Brake Accessories 6. ACCESSORIES Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 84 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ……………………………………………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 85: Back Gauge E-Brake Mpb-Rd100/101
The frame structure allows for using finger stops along the entire working length. The fingers are equipped with replaceable stop pins. There is also an extra gauge option by which the gauge range can be extended up to 1,000mm. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 86: Axle
The X 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. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 87: R Axle
The height position of the R axle is set during start-up by detecting the height of the R axle by means of a proximity switch and a measuring point on the wind-up roll. Next, the initialization point is set on the motor’s resolver. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 88: Z Axle
Reach X-axis: 550 mm X-axis lay-on: 575 mm X-axis lay-on large: 1000 mm Speed: 350 mm/sec. Precision X-axis: +/-0,02 mm Reach R-axis: 150 mm Reach Z-axis: Working length Reach Delta X-axis: 100 mm Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 89: Operation
SafanDarley E-Brake Operation 7. OPERATION Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 90 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 91: Press Brake Control
Operation 7.1. PRESS BRAKE CONTROL One of the distinguishing features of SafanDarley press brakes is that they are easy and safe to operate. The press brake operating instructions are described in a separate manual. These operating instructions are based on the specific characteristics of the press brake control mounted on this machine.
Page 92: Starting The Machine
A bent profile must not be bent back (flattened). During a bending back procedure the material to be flattened may tilt causing hazardous situations causing the material to get jammed in the machine. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 93: Choosing The Easiest Operating Mode
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” Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 94: Stopping The Machine
Switch off the supply voltage with the main switch, Clean up the machine and surroundings Do not use support arms or bend auxiliary as stock table. Put just one product on these auxiliaries Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 95: Troubleshooting
SafanDarley E-Brake Troubleshooting 8. TROUBLESHOOTING Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 96 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 97: Trouble Shooting Chart
SERVICE so the brakes of the main motors are released. After that both belts can be tautened with a hex key (size: 12 mm or 17 mm). Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 98 Remove the memory and restart will not startup Temposonic R-series position sensors Power Error Description Normal function Magnet not detected Wrong quantity of magnets Out of range (Analog) Flashing Out of synchronisation Flashing Programming mode Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 99: Explanation Of The Indicator Light Signals
SafanDarley E-Brake Troubleshooting 8.2. EXPLANATION OF THE INDICATOR LIGHT SIGNALS Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 101: Maintenance
SafanDarley E-Brake Maintenance 9. MAINTENANCE Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 102 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ……………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 103: General
SafanDarley E-Brake Maintenance 9.1. GENERAL One of the distinguishing features of the SafanDarley press brakes is that they require little maintenance. However, the little maintenance that has to be done must be carried out thoroughly and with care. In view of the safety regulations applying to this machine, please, first read chapter 4 "SAFETY"...
Page 104: Maintenance Ipc
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. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 105: Maintenance
9.3.2. CHECKING AND RE-ADJUSTING THE UPPER BEAM GUIDES When checking the tool alignment or the back gauge adjustment errors may be found that make it necessary to re-adjust the upper beam guides. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 106 Make sure that no other persons are in the immediate vicinity of the machine. A SafanDarley trained service engineer should perform these activities be by or someone who has been trained to carry out this work properly. When (re)adjusting the upper beam guides always observe the following...
Page 107: Changing Tools
This deactivates the machine operation making tool change or adjustment safe. Once the tool change or tool position adjustments are complete select “clamp” bottom for the appropriate tool set, top, bottom or both to re-enable safe machine operation. verbiage Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 108: Figure 9-3 Tool Clamping Buttons On The Control Panel
The mode switch cannot be changed after removal of the locking key. Note the mode switch can have less positions, depending on whether or not the machine has a light guard. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 109: Changing Upper Tools
Maintenance 9.3.4. CHANGING UPPER TOOLS A standard feature of the SafanDarley press brakes is that the upper beams, intermediate beams and top tools have been fitted with the SafanDarley top tool adaptation. The adaptation has a so-called safety key. The safety key prevents the top tool from falling out of the tool adaptation when...
Page 110  The maximum moment of torque is approx. 50 Nm. Finally the top tool must be pushed well home in the tool adaptation. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 111: Changing Bottom Tools
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 flattening tool.
Page 112: Figure 9-6 Bottom Tool Adaptation (Single V Tools)
Figure 9-6 Bottom tool adaptation (single V tools) 1. Bottom tool (single V tool) 2. Bottom tool clamping bolt 3. Table for single V tool 4. Lower beam 5. Marking front side Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 113: Checking Top Tool Adaptation Runs Parallel To Bottom Tool Adaptation
If there is a difference between the angles produced by the left-hand side and the right-hand side of the machine (different penetration depths), the parallelism of the upper beam in relation to the lower beam must be adjusted correctly. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 114: Upper Beam In Tilted Position
Use the press brake control to make the upper beam go to its bottom dead point. Switch off the mains power supply by means of the main switch (Pos. 1 of chapter 2.5) on the electrical cabinet. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 115: Checking And Re-Adjusting The Position Of The Back Gauge
Filters of the electrical cabinet have to be cleaned regularly with water – not hotter than 40°C – or replaced. Frequency is due to circumstances. Filter AM 435P SafanDarley partnr. 38720000050. Put the filter with the rough side towards the inside of the cabinet. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 116: Lubrication
Squirt in so much oil that it comes out again at the wiper seals (remove superfluous oil with a rag) (Use for example Rhenus-Norlith-STM2). Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 117: Lubrication Each Two Year/5000 Hrs
After having drained the oil, put back drain plug and fill the reduction gear units with new oil at the top of the reduction gear units. (Fill up with e.g.: High performance gear oil CLP HC 320) Gear box type Oil quantity GFL07 appr. 4 liter Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 118: Maintenance- And Lubrication Chart
HTR foot pedal Clean and check Check the function of console the third position every time before starts operating. E.g. there might be material under the foot pedal, which blocks the pedal. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 119 Maintenance 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 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 120 Each month/200 Hours: Grease with Rhenus-Norlith-STM2 Both sides of the machine. Remove lid ( 4 Screws) Each quarter/600 Hours: Grease with Rhenus-Norlith-STM2 Both sides of the machine. Each month/200 Hours: Grease with Rhenus-Norlith-STM2 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 121 SafanDarley E-Brake Maintenance Frequently: Clean with a blow pistol. Both sides of the machine. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 123: Drawings Electrical Scheme
SafanDarley E-Brake Maintenance 9.6. DRAWINGS ELECTRICAL SCHEME Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 125: Mechanical Scheme
Machine type. Machine serial number.+ Year of production Page and date of the handbook showing the part. SafanDarley number(s) from the part and if possible the name of the part. The quantity of parts required. Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 127: Register
SafanDarley E-Brake Register REGISTER Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 128 …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………………………… ……………………………………………………………………………………………… Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 129: Register
........45, 57 foundation ........ 78 RESIDUAL VOLTAGE....66 Fuse ........21 responsible ....... 65 Guide cars ......116 rest risk ........31 How to order spare parts ..125 return cycle ......27 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 130 X-WITHDR........ 46 TDP ......... 25 Y-direction ........ 25 tonnage ........21 Year of manufacture ....18 TOOL ALIGNMENT ....103 Year of manufacturing ....9 tool nesting places ..... 81 zero-point ........ 25 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
Page 131: Annex
SafanDarley E-Brake Annex ANNEX Release notes Release document Conform CE Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...
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Page 133: Release Notes
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 Instruction manual SafanDarley E-Brake Premium 100-3100 100Pr 2019...

SafanDarley E-Brake Premium 100-3100 Instruction Manual

1 Introduction

2 Description

3 Working

4 Safety

5 Transport, Installation, Commissioning

Figure 5-5 Attention: at the Front Put the Supports of the Press Brake Exactly on the Foot Plates

6 Accessories

7 Operation

8 Troubleshooting

9 Maintenance

Quick Links

Troubleshooting

Need help?

Questions and answers

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