Related Manuals for MetalMaster PB-GL Series
Summary of Contents for MetalMaster PB-GL Series
- Page 1 OPERATION MANUAL PB-GL SERIES HYDRAULIC PRESS BRAKE E21 CONTROLLER Models S970GL, S902GL, S906GL, S908GL, S909GL, S910GL, S912GL Edition No : PB-GL 004 Date of Issue : 01/2024...
- Page 2 This manual is only for your reference. Owing to the continuous improvement of the Metalmaster machine, changes may be made at any time without obligation or notice. Please ensure the local voltage is the same as listed on the specification plate before operating any electric machine.
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Page 3: Table Of Contents
OPERATION MANUAL PB-GL SERIES C O N T E N T S: 1. GENERAL MACHINE INFORMATION 1.1 Specifications............... 1.2 Standard Equipment..........1.3 Identification..............2. IMPORTANT INFORMATION 2.1 General Metalworking Machine Safety....2.2 Specific Safety for Press Brake Machines... 2.3 Lifting Instructions............. - Page 4 OPERATION MANUAL PB-GL SERIES 6. MAINTENANCE 6.1 Maintaining Hydraulic System....... 6.2 Lubrication..............6.3 System error list ............6.4 General Troubleshooting ........6.5 One Piece 4 Sided Die..........6.6 Segmented Top Punch..........APPENDIX A.1 Laser Setup & Calibration for old style spring type calibrator supplied prior to Nov 2023 ..
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Page 5: Specifications
OPERATION MANUAL PB-GL SERIES 1.1 SPECIFICATIONS Order Code S970GL S902GL S906GL S908GL Model PB-40A PB-70B PB-135B PB-135B Estun NC- Estun NC- Estun NC- Estun NC- Control Unit (Type) Laser Guarding System Nominal Pressure - Tonnage (Ton) Nominal Pressure - Kilo-newtons (kN) -
Page 6: Standard Equipment
OPERATION MANUAL PB-GL SERIES 1.1 SPECIFICATIONS CONT..Order Code S909GL S910GL S912GL Model PB-170B PB-170B PB-200B Control Unit (Type) Estun NC-E21 Estun NC-E21 Estun NC-E21 Laser Guarding System Nominal Pressure - Tonnage (Ton) Nominal Pressure - Kilo-newtons (kN) 1600 1600... -
Page 7: Identification
OPERATION MANUAL PB-GL SERIES 1.3 IDENTIFICATION ontrol endant e21 C ontrol enCe laMPS obile edal ront uPPortS ottoM ydrauliC ontrol endant enCe enCe onnage Hart leCtriCal abinet... -
Page 8: General Metalworking Machine Safety
OPERATION MANUAL PB-GL SERIES 2.1 GENERAL METALWORKING MACHINE SAFETY DO NOT use this machine unless you have read this manual or have been instructed in the use of this machine in its safe use and operation Exposure to the dust created by grinding, may... - Page 9 OPERATION MANUAL PB-GL SERIES 2.1 GENERAL METALWORKING MACHINE SAFETY Cont. Each machine should have only one operator at a time. However, everyone should know how to stop the machine in an emergency. Ensure that keys and adjusting wrenches have been removed from the machine before turning on the power.
- Page 10 OPERATION MANUAL PB-GL SERIES 2.1 GENERAL METALWORKING MACHINE SAFETY Cont. HAZARDS ASSOCIATED WITH MACHINES include, but are not limited to: • Being struck by ejected parts of the machinery • Being struck by material ejected from the machinery • Contact or entanglement with the machinery •...
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Page 11: Specific Safety For Press Brake Machines
OPERATION MANUAL PB-GL SERIES 2.2 HYDRAULIC PRESS BRAKE SAFETY PROCEDURE DO NOT use this machine unless you have been instructed in its safe use and operation and have read and understood this manual Safety glasses must be worn at all Long and loose hair must be times in work areas. - Page 12 OPERATION MANUAL PB-GL SERIES SAFETY SYMBOLS Fixed to the front of the press brake are safety symbols designed to make sure the machine is safely operated CENTRE WORKPIECE Hearing and eye protection are extremely important as the result of an injury to these parts of the body may cause permanent damage.
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Page 13: Lifting Instructions
OPERATION MANUAL PB-GL SERIES 2.3 LIFTING INSTRUCTIONS On the day that the machine arrives, make sure that a crane with sufficient capacity is available to unload the machine from the vehicle. Ensure access to the chosen site is clear and that doors and ceilings are sufficiently high and wide enough to receive the machine. -
Page 14: Installation
3.1 SITE SELECTION AND PREPARATION The METALMASTER Press Brake must be installed on a rigid and stable floor such as a concrete slab 150 - 200mm thick. The press brake will be more stable if it sits on one slab and does not straddle slabs. -
Page 15: Machine Leveling
OPERATION MANUAL PB-GL SERIES 3.2 MACHINE LEVELING To set your machine up so that it operates to optimum performance, apply the following leveling procedure After your guillotine has been anchored to a concrete slab floor, it then needs to be leveled. The leveling is performed using the screws on each pad.(Fig. -
Page 16: Full Load Current
3.5 CHECKING THE POWER SUPPLY METALMASTER machines are supplied wired ready to run. Check the specification plate on the machine to confirm the local voltage is the correct voltage for the machine. -
Page 17: Attaching The Accessories
OPERATION MANUAL PB-GL SERIES 3.6 ATTACHING THE ACCESSORIES. q Bolt the support arms onto the feed table. Ensure they are level and square to the table. (Fig.3.3) .3.3 q Unpack and attach both the side guards to the machine making sure they are square with the machine. (Fig3.4) . -
Page 18: Commissioning
OPERATION MANUAL PB-GL SERIES 4. COMMISSIONING 4.1 PRESS BRAKE GUARDING SYSTEM - LASER GUARDING Australian Legislation - Machine parts traveling at more than 10mm/second need physical or electronic guarding. Laser Guarding - This press brake top beam has an elec- tronic guarding system, when seutp &... -
Page 19: Laser Guarding Safety Controller
OPERATION MANUAL PB-GL SERIES 4.2 LASER GUARDING SAFETY CONTROLER On power up the laser safety controller per- forms a self test and checks and also checks the emitter & receiver for errors, if a safety fault is found the laser safety controller enters a fault state and can not be reset unless the fault is retified. -
Page 20: Laser Safety Controller - Layout
OPERATION MANUAL PB-GL SERIES 4.3 LASER SAFETY CONTROLER - LAYOUT on i oFF i aFety ndiCator aFety ndiCator reen orMal Mode ndiCator reen ault ndiCator ox Mode ndiCator ellow ower ndiCator range ute Mode ndiCator ellow witCH uarding Power SwitCH... -
Page 21: Laser Safety Controller - Operating Modes
OPERATION MANUAL PB-GL SERIES 4.4 LASER SAFETY CONTROLER - OPERATING MODES The laser safety controller provides three operating modes selected via the self resetting mode switch, rotate the mode switch to toggle between each mode, at machine or guarding system power on the mode is always reset to NORMAL mode. -
Page 22: Magnet Type Calibrator
OPERATION MANUAL PB-GL SERIES 4.5 LASER GUARDING SETUP & CALIBRATION - (Magnet type) ** Aiming aid types have been updated over time, if this procedure does not match your supplied aiming aid, please refer to Appendix A.1 for the old style procedure. -
Page 23: Stopping Test
OPERATION MANUAL PB-GL SERIES 4.6 LASER GUARDING STOPPING TEST - (Magnet type) Option 1 : Small V Method Use this method if you are using a smaller V size where you can easily place the Aiming Aid on the end of the die block. - Page 24 OPERATION MANUAL PB-GL SERIES Option 2 : Large V Method Use this method if you are using a large V size where you can not easily place the Aiming Aid on the end of the die block. Setup : a) Before proceding please ensure the Laser setup &...
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Page 25: Laser Safety Periodical Check
OPERATION MANUAL PB-GL SERIES 4.7 LASER SAFETY DEVICE PERIODICAL CHECK The alignment & calibration of the laser system emitter & receiver along with the machines punch tooling shall be checked using the supplied calibration & testing aids. Section 4.5 “Laser guarding setup and Calibration” shall be used for the setup & calibration Refer Page 22 of this manual. -
Page 26: Controls
OPERATION MANUAL PB-GL SERIES 4.8 CONTROLS The purpose of this control overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, and the machine controls and what they do. It also helps the operator to understand if they are discussed later in this manual. -
Page 27: Operation
OPERATION MANUAL PB-GL SERIES 5. OPERATION The Model PB-135E will perform many types of operations that are beyond the scope of this manual. Many of these operations can be dangerous or deadly if performed incorrectly. The instructions in this section are written with the understanding that the operator has the necessary knowledge and skills to operate this machine. -
Page 28: Testing The Emergency Stops
PB-GL SERIES 5.2 TESTING THE EMERGENCY STOPS The Metalmaster Press Brake model PB-135B is fitted with two emergency stop buttons. One is on the mobile foot pedal and the other is on the pendant control panel. They should be tested one at a time to ensure they are working correctly. -
Page 29: Estun E21 Controller Operation
OPERATION MANUAL PB-GL SERIES 5.4 ESTUN E21 CONTROLLER OPERATION SINGLE: Common page that is used by anyone who wants to re-write a job. X - (X Back gauge actual position) Y - (Y Ram stoke actual position) XP - (X Program Position) - Back gauge distance from the blade YP - (Y Program Position) - Ram stroke depth. - Page 30 OPERATION MANUAL PB-GL SERIES 5.4 E21 CONTROLLER OPERATION PROG: Product Information Page This page lets you enter parameters for the pieces to be bent. ST - (Steps) There are 3 steps in this program PP - (Programed Pieces) - 5 jobs to be bent...
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Page 31: Pb-135E E21 Press Brake Calibration: X Axis
PB-GL SERIES 5.5 E21 PRESS BRAKE CALIBRATION: X AXIS The Metalmaster Press Brake is calibrated before the machine leaves the factory and should not need to be calibrated. However should the machine at any time need to be calibrated, the following is the procedure. -
Page 32: Pb-135E E21 Press Brake Calibration: Y Axis
OPERATION MANUAL PB-GL SERIES 5.5 E21 PRESS BRAKE CALIBRATION: Y AXIS The model PB-135E Press Brake has no hard limit micro switches fitted to the machine. It relies simply on the soft limits. The Soft limit is a Software limit that is set on the controller 1. -
Page 33: Removing & Replacing Tools
OPERATION MANUAL PB-GL SERIES 5.6 REMOVING & REPLACING TOOLS Installing and Removing The Die: To remove the die, loosen the clamp screws (Fig.5.8) and lift the die off the machine. NOTE: Please use safe lifting practices when removing or replacing the die. -
Page 34: Aligning The Punch And Die
OPERATION MANUAL PB-GL SERIES 5.7 ALIGNING THE PUNCH AND DIE When you reinstall the dies after removing them together with the die holders, align them again. To Align the Tools: 1. Start the machine. 2. Set the mode to “INCH”. -
Page 35: Bending Techniques
OPERATION MANUAL PB-GL SERIES 5.9 BENDING TECHNIQUES There are two basic bending techniques: - AIR BENDING This method is commonly performed because relatively low bending forces are required - COINING This method requires forces approximately three to five times those of air bending. It allows the inside radius to be coined. -
Page 36: Tonnage Chart
OPERATION MANUAL PB-GL SERIES 5.10 TONNAGE BENDING CHART .5.16... -
Page 37: Adjusting The Tonnage
Metalmaster advise that shimming the bottom die is quicker and will save the operator time. NOTE: If at any time the wedges need to be adjusted we recommend that this be carried out by a Metalmaster service engineer . 6.3... -
Page 38: Maintenance
OPERATION MANUAL PB-GL SERIES 6. MAINTENANCE 6.1 MAINTAINING HYDRAULIC SYSTEM When dirt, dust, and other foreign matter are deposited in large amounts in the hydraulic cir- cuit, the hydraulic pump may produce abnormal noise and decrease in discharge capacity, and the ram may decrease in bending speed and vibrate. - Page 39 OPERATION MANUAL PB-GL SERIES HYDRAULIC SYSTEM OF THE MACHINE The hydraulic system working principles are displayed in Fig.1. INACTIVE: When the oil pump is running, the oil feeds out, through an oil pipe and into the valve plate and solenoid valve, then returns into the oil tank. At this time the solenoid valve isn’t working, The No.12 valve is closed and the top beam is stationary .
- Page 40 OPERATION MANUAL PB-GL SERIES HYDRAULIC DIAGRAM...
- Page 41 OPERATION MANUAL PB-GL SERIES HYDRAULIC PARTS LIST Name Type Specification Qty. Remarks Oil Tank Mesh Filter Gear Pump Motor Solenoid Overflow Valve Manometer Solenoid Reverse Valve Throttle Valve Valve 10 Solenoid Reverse Valve 11 Solenoid Reverse Valve 12 Hydraulic Control Check Valve...
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Page 42: Lubrication
OPERATION MANUAL PB-GL SERIES 6.2 LUBRICATION Before maintaining or cleaning the machine, turn off the circuit breaker, and relieve the residual hydraulic pressure in the machine. Post a sign to inform other workers that the machine is under maintenance Lubrication is very important to maintain bending accuracy and avoid machine troubles. Be sure to appropriately lubricate the machine according to the Lubrication chart below and s also found on the side of the machine. -
Page 43: System Error List
PB-GL SERIES 6.3 SYSTEM ERROR LIST PB-GL Series machines incorporate internal functional monitoring, this allows easier diagnostics of non mechanical errors that may inhibhit the use of the Pressbrake, These errors are often not seen by the user and generally require an experenced serivce techncian to resolve. -
Page 44: General Troubleshooting
OPERATION MANUAL PB-GL SERIES 6.4 GENERAL TROUBLESHOOTING Problem Cause Solution Power switched off Turn disconnect switch ON. The emergency STOP push Turn Emergency STOP push- button is pushed in. button clockwise to release, then push START button. Hydraulic Press Brake Pump Control circuit fuse is blown. - Page 45 OPERATION MANUAL PB-GL SERIES Problem Cause Solution Tooling is worn in the center Re machine forming surfaces of due to continuous forming tooling. Shim the die to compen- of small parts in one location. sate for worn areas. Under bending in the...
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Page 46: One Piece 4 Sided Die
OPERATION MANUAL PB-GL SERIES 6.5 ONE PIECE 4 SIDED DIE Models S970GL, S902GL Models S906GL, S908GL... - Page 47 OPERATION MANUAL PB-GL SERIES Models S909GL, S910GL S912GL...
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Page 48: Segmented Top Punch
OPERATION MANUAL PB-GL SERIES 6.6 SEGMENTED TOP PUNCH Models S970GL Models S902GL... - Page 49 OPERATION MANUAL PB-GL SERIES Models S906GL, S908GL, S909GL, S910GL, S912GL...
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Page 50: Appendix
OPERATION MANUAL PB-GL SERIES APPENDIX... -
Page 51: Laser Setup & Calibration For Old Style Spring Type Calibrator Supplied Prior To Nov 2023
OPERATION MANUAL PB-GL SERIES A.1 LASER GUARDING SETUP & CALIBRATION - (Spring Type Supplied Pre Nov 2023) Aiming aids - • Used to align the lasers to the punch. • Spring loaded to allow the punch to lightly press into V opening •... -
Page 52: Laser Stopping Test For Old Style Spring Type Calibrator Supplied Prior To Nov 2023
OPERATION MANUAL PB-GL SERIES A.2 LASER GUARD STOPPING TESTING - (Spring Type Supplied Pre Nov 2023) NEVER PLACE YOUR LIMBS IN BETWEEN THE PUNCH AND DIE Inspection at start-up, shift change or after laser adjustment. The laser optical lenses must be free of any dust, ingress, and damage. -
Page 53: Electrical Diagrams
OPERATION MANUAL PB-GL SERIES A.3 WIRING DIAGRAM... - Page 54 OPERATION MANUAL PB-GL SERIES...
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Page 62: Safety & Risk Assessment Sheets
OPERATION MANUAL PB-GL SERIES A.4 SAFETY & RISK ASSESMENT General Machinery Safety Instructions Machinery House requires you to read this entire Manual before using this machine. 1. Read the entire Manual before starting 14. Use correct amperage extension cords. machinery. - Page 63 OPERATION MANUAL PB-GL SERIES Hydraulic Pressbrake Safety Instructions Machinery House requires you to read this entire Manual before using this machine. 1. Maintenance. Make sure the Pressbrake is turned sensing safeguarding used must have regular off and disconnect from the main power supply Safety integrity tests and records kept.
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