Sb 48 Bender

Electric Metal Bending Machine

ERCOLINA by CML International S.p.A. ITALYTel. +39 0776 40281Fax +39 0776 404801

www.ercolina.it - www.ercolina.come-mail: [email protected]

USE AND MAINTENANCEINSTRUCTION MANUAL

This manual was written accordingto prescriptions of attachment I-

1.7.4. of :

EEC DIRECTIVE 89/392MACHINERY DIRECTIVEMODIFIED BY DIRECTIVE

91/368RECEIVED BY PRESIDENTIAL

DECREE NR. 459/1996

EEC Directive 89/392 published on theEuropean Community Official Journalnr. L183 dated June 29, 1989

EEC Directive 91/368 published on theEuropean Community Official Journalnr. L198 dated July 22, 1991

Presidential Decree 459/1996 published onthe Official Journal nr. 209 dated September6, 1996

We wish to thank you for your excellent choice in purchasing an Ercolina MediBender MB42. By following these instructions the Medi Bender will be a simple anduseful working tool.

Remember: after reading this manual, keep it in a safe place for future reference!

!!WARNING

Before using the machine read carefully this instructionmanual!

Any use of the machine which does notstrictly conform to the instructions of

this manual will immediately invalidatethe warranty and free the

Manufacturer of any responsibility.

!!WARNING: the use and maintenance instructionsof this manual apply to each of the following machines,unless otherwise specified: SB48 (single phase) edSB48T (three phase).

Rev. 00 Page 1

CML International S.p.A.

WARRANTY ............................................................................................................... 3WARRANTY CONDITIONS AND RESTRICTIONS ..................................................................3

PARTS IDENTIFICATION....................................................................................... 5GENERAL SAFETY RULES .................................................................................... 6APPLICATION FIELDS............................................................................................ 9TECHNICAL DATA ................................................................................................ 10

WORKING CAPACITY ...............................................................................................................11ELECTRIC AND ELECTRONIC COMPONENTS............................................. 12RISK PREVENTION SOLUTIONS ....................................................................... 13DIRECTIONS FOR RESIDUAL RISK LIMITATIONS..................................... 14IDENTIFICATION CE MARKING PLATE ........................................................ 16ECOLOGICAL INFORMATION........................................................................... 17

MACHINE DEMOLITION...........................................................................................................17INDICATION FOR CORRECT WASTE DISPOSAL.................................................................17

MACHINE TRANSPORTATION .......................................................................... 18LIFTING FROM BOTTOM WITH PACKING............................................................................18PACKING METHODS..................................................................................................................18TRANSPORTATION ON ROAD USING AUTHORIZED MEAN ............................................19CHANGE OF WORKING POSITION .........................................................................................19

INSTALLING THE MACHINE.............................................................................. 19USING THE MACHINE .......................................................................................... 20

CHOICE OF ACCESSORIES .......................................................................................................21INSTALLING THE TOOLING ....................................................................................................21SWITCHING MACHINE ON.......................................................................................................22MACHINE PREPARATION ........................................................................................................22TIGHTENING THE TUBE...........................................................................................................22PROGRAMMING THE MACHINE.............................................................................................23

PROGRAMMING MANUAL.................................................................................. 23INTRODUCTION .........................................................................................................................24KEY BOARD FUNCTIONS.........................................................................................................25LIGHT SIGNALS..........................................................................................................................26

PROGRAM PROCEDURES ................................................................................... 27PROCEDURES FOR BEND MAKING........................................................................................28HOW TO CORRECT THE SPRING-BACK ANGLE .................................................................30EDITING THE ACTUAL BEND ANGLE ...................................................................................31CHANGING THE LANGUAGE ..................................................................................................31

PRACTICAL USE OF THE MACHINE ............................................................... 32MAINTENANCE ...................................................................................................... 34

ORDINARY MAINTENANCE ....................................................................................................34EXTRAORDINARY MAINTENANCE.......................................................................................34

TUBE BENDING TROUBLESHOOTING............................................................ 35TROUBLESHOOTING............................................................................................ 36SB48 TROUBLESHOOTING.................................................................................. 37SB48T TROUBLESHOOTING ............................................................................... 39MACHINE CE CONFORMITY DECLARATION .............................................. 42

NOISE RATING MEASUREMENT ............................................................................................42MACHINE CONFORMITY DECLARATION..................................................... 43

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NOISE RATING MEASUREMENT ............................................................................................43TEST CARD .............................................................................................................. 44

SETTINGS OF SB48 ELECTRONIC BOARD............................................................................49SPARE PARTS ARTICLE CODES..............................................................................................51

REPLACEMENT PARTS REQUEST.................................................................... 54BENDING FILE ........................................................................................................ 55

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WARRANTY

Every machine is carefully controlled and tested before shipment. Machineinstallation is under customers responsibility, if qualified personnel is required forassistance and training, the cost of the operation will be charged.

WARRANTY CONDITIONS AND RESTRICTIONS

1. Each ERCOLINA bender has a 24 month warranty effective from delivery date,against any components defect. The company reserves the right to request a copyof the sale invoice.

2. Defects must be notified to us within 2 months from the date the defect has beenfound.

3. Defects are checked on our premises, so every ERCOLINA bender must besent, FREIGHT PREPAID, to our address or to authorized service centres. ANYFREIGHT COLLECT DELIVERY WILL BE REJECTED. If checking atcustomers premises is required, a cost for checking on site will be charged.

4. Warranty includes the defective components replacement or repair excludinglabour cost.

5. Electrical parts are not included in the warranty in case of incompatibility withpower supply ( caused by overvoltage and / or atmospheric events ).

6. Operations performed under warranty do not extend warranty terms.

7. Warranty does not respond to damages caused by wear.

8. The warranty does not apply if damages are a result of incorrect handling or of ause that does not conform with specifications described in this manual.

9. The warranty does not apply if the machine has been modified or tampered with.

10. The warranty certificate IS INVALID if dealer stamp with sales date is notincluded at the bottom of the document and in the attached coupon. Furthermore,the part to be sent to us must be mailed within 8 days following the invoice date.

11. The buyer can not claim compensation for damages in any way.

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12. The warranty does not provide a replacement even temporarily of the machine.

13. The whole warranty declines if:

The machine has been repaired or maintained by personnel that has not beenauthorised by Ercolina;

Not original parts have been used; Damages or errors are due to connections not performed according to the using

instructions; Errors due to the machine wear.

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PARTS IDENTIFICATION

1 Emergency switch mushroombutton9 Counterbending die

2 Foot switch socket 10 Hexagonal shaft3 Handle for transport 11 Former4 Front door 12 Counterbending support bracket5 Machine Body 13 Counterbending support bracket arm6 Labels 14 Hand wheel attachment7 Bottom Casing 15 Control panel8 Counterbending die support 16 Two pedal foot switch with reinforced cable

3

4

5

6

7

8

9

10

11

12

13

14

1516

21

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GENERAL SAFETY RULES

The Ercolina Super Bender has been designed following high tecnology standardsand in accordance to the latest official safety regulations. The machine if improperlyused can be a source of risk for the user or other people.To avoid danger it is important to read and apply the following safety rules.

Use the machine only for the purpose for which it has been made andobserving the general safety rules. The Manufacturer will not be liable for anydamage or harm caused by improper use of the machine;

Do not switch on power supply and use the machine without readingcarefullythe instruction manual

Do not install and use the machine in environments containing: flammable fluids or gas; explosive materials;

Do not install the machine in a humid or wet environment;

Do not expose the machine to the rain ;

Do not touch moving parts of the machine;

Do not put hands on the tube during bending;

Avoid having more than one person working on the same machine;

Working area should not be restricted to a too limited space in proportion tothe tube lengths to be bent;

FORBIDDEN

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Do not use the machine beyond the maximum capacities indicated ;

Allow only qualified and authorised personnel to effect maintenance work orrepair on the machine ;

Do not clean the machine without switching off power supply;

For safety reasons and in order not to invalidate the machine guarantee nevermodify the electric or electronic circuitry of the machine;

Never transport the machine by pulling it by the cable;

Do not modify the machine structure.

!!Warning: Only use original Ercolina accessories made for this type ofmachine. Any modification will invalidate the machine guarantee. The Manufacturerreserves the right not to supply accessories or spare parts in case of alteration of themachine;

To avoid finger pinching never put fingers between formers and machinebody;

Do not leave the machine unattended with power supply switched on .

Check that the power supply is exactly the same required by the Super Benderbefore connecting the power cord to an outlet;

Allow only trained personnel to work on the machine;

! Allow only trained personnel to workon the machine.

MANDATORY

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Store the machine in a dry and safe location;

Delimit the machines working area with barriers and / or chains in order toavoid non authorised persons entering the working area of the machine whenboth in motion and switched off ;

Mark the working area with appropriate signals;

Always stand in a safe position during the functioning of the machine;

Never stand on the opposite side of the machine operating controls;

Before transporting the machine always disconnect main power plug cable;

Check wear of formers and counterbending dies;

Wear protective gloves while operating the machine;

Wear a protective helmet for upward moving or suspended tubes;

Wear safety shoes in case of fall of heavy parts;

Read carefully the warning labels and plates on the machine.

!! WARNING: other safety protections can be adoptedby the operator or by the person in charge of the machine.Our technical office is at complete disposal for any furtheradvice needed.

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APPLICATION FIELDS

The SB48 electric tube, pipe and profile bending machine can be used in thefollowing sectors:

mechanical, hydraulics, metal fabrication, marine engineering, electrical, general installation.

The SB48 machine can bend tubes and profiles of various dimensions, wall thicknessand type of materials such as:

steel, brass, copper, alluminium.

The SB48 electrical metal bending machine is provided with an induction motor andan electromagnetic brake, therefore is powerful and practically maintenance free;furthermore the microprocessor electronic control which is divided into 30 blocks of9 bends each, allows easy achievement of accurate and repeatable bends.

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TECHNICAL DATA

Min outside diameter 5 mm

Max ouside diameter 48 mm

Min bend (R) radius 2 x tube

Workingcapacity

Required time for toolchange 10 s

Maximum bend angle 180

SB48 2 rpmSpeed

SB48T 4 rpm

Weight of machine body with no accessories 110 kgWeight of greatest former which can be used 20 kgWidth 410 mmLength 570 mm

Dimensions andweight

Height 1000 mm

TECHNICAL NOTE: Design and machine specifications are subject to changewithout prior notice.

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WORKING CAPACITY

Section Material Max x wallthick. (mm)

Max x wallthick.

(inches)OD

Min radius(mm)

Boiler tubes* 48 x 3.5 1"1/2gasx0.134" 100

Standard steel tubes* 48 x 3.5 1"7/8x0.134" 100

Soft brass 60 x 3 2"3/8x0.118" 120

Stainless steel 48 x 2.5 1"7/8x0.095" 100

Welded tube for furniture* 54 x 1.5 2"1/8x0.059" 110

Hydraulic tube ST35 50 x 4 2"x0.157" 100Hydraulic 304L stainlesssteel tube 50 x 2.5

2"x0.095" 100

Hard copper & aluminium 64 x 2 2"1/2x0.065" 130

Mild steel* 32 1"1/4 60

Mild steel* 48 x 8 1/4"x1"7/8 100

Mild steel* 40 x 20 x 3 3/4"x1"5/8x0.118" 80

Mild steel* 40 x 40 x 3 1"5/8x1"5/8x0.118" 80

Mild steel* 30 x 30 1"1/4x1"1/4 60

Mild steel* 40 x 40 x 5 1"5/8x1"5/8x0.203" 80

Mild steel* 32 x 16 x 5 1"1/4x5/8"x0.203" 60

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*Note: capacity refers to materials with a resistance equal to 42 kg/mm2

ELECTRIC AND ELECTRONIC COMPONENTS

The SB48 machine is provided with the following electric and electroniccomponents:

electronic board microprocessor control core Zilog Z80, with 3 relay outputs,TA controlled power absorbtion of the motor and LCD display of 16 charactersdivided into 2 lines working with 10.5V AC and an incorporated rectifier;

power supply card, provided with a voltage transformer, AC transformer,machine setting bridges and relays for motor running and brake control;

electrical single phase motor with brake for former movement; red emergency switch button , for interrupting power supply to the machine in

case of danger;

the reset button ( not on SB48T), supplies power to the machine afterconnecting AC power cord to an outlet with main power switch on position (1),- or restores power supply after that emergency button has been pressed;

Two pedal foot switch (Bend Return), allows the operator to bend or toplace the former into position without using the manual controls;

Degree counter , reads out position of counterbending die in relation to theformer;

X axis read out system, reads former rotation angle .

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RISK PREVENTION SOLUTIONS

The SB48 electric metal bending machine is equipped with safety systems intendedto minimize risks, which operators are exposed to during use or maintenance of themachine.In the following table protection devices are listed associated to the main sources ofrisk they protect from.

Type of risk Safety devices

Mushroom emergency switch in front of machine which canbe easily reached by the operator. Once pressed the buttonremains in emergency position until it is manually released.

DANGERS OFMECHANICAL

NATUREPedal starting command purposefully designed to obstructunintentional activation with protection on three sides (cover)and internal protection. The foot must be deeply introduced inthe pedal cover to reach the pedal. In addition, the commandworks at low voltage.

Low tension command devices (24V).DANGERS OFELECTRICALNATURE DUE TO

DIRECT OR INDIRECTCONTACT Electrical circuit closed on a panel.

During bending there is no risk of projection of workpiece.

FALL AND/ORPROJECTION OF

BENT PIECE

The risk of injury due to fall of workpiece during insertion orextraction is prevented by the command position which obligesthe operator to stand in a safe position. Furthermore having alimited working area with confining barriers such as chains orprotective shields with safety labels would avoid third personscoming unintentionally into contact with the workpiece.

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DIRECTIONS FOR RESIDUAL RISK LIMITATIONS

To reduce uneliminable residual risks, due to the nature of working operations, wehave provided:

Individual protection systems and tags posted on the machineindicaring the correct operating methods.

In the following table mandatory individual protection devices are listed associated tothe risk they protect from.

TYPE OF RISK INDIVIDUAL PROTECTION DEVICESAbrasion, cutting, collisiondanger

Gloves

Falling objects danger Helmet, protective shoesDanger of entanglement ofclothes

Adequate apparel

The following labels with caution indications have been attached to the machine ;they also provide information on the red emergency button, foot switch socket andthe machine voltage.

SB48

SB48T

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Confining barriers: due to the technical and operating characteristics ofthe machine, installing rigid protection devices like protective shieldswould hinder its use, since the necessary operations would becomeimpossible to perform;

Precautions: Confine working space; Indicate danger using necessary

signals.

L tube + 1m L tube + 1m

SB48 positionTube position

!!WARNING:During bending theoperator must always standin the position indicated inthe picture.

SSSAAAFFFEEETTTYYY AAARRREEEAAA

Working space(Confined area access denied to unassigned

personnel)

!!MANDATORY: confine the working space using adequate barriers.

!!WARNING:Only no.1 person must operate within the working area (UNI EN 294).

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IDENTIFICATION CE MARKING PLATE

According to the rules in force ( Directive nr. CE/89/392 and presidential decree nr.459/1996), the SUPER BENDER SB48 has an identification plate with CE marking,where information on the machine characteristics that may be relevant in terms ofsafety is included. Refer to this information in case of doubt.The plate is placed on the lower side opposite to the controls where it can be easilyseen and it is not removable.If the idnetification plate for any reason is damaged, contact immediately themanufacturer for its replacement.

PLATE DATAYEAR 200_WEIGHT 110 KgMODEL SB48 SB48TMOTOR POWER SUPPLY 110V 230V 400VSERIAL NMOTOR POWER 1.5 KwMax RPM hexagonal shaft 2

!!WARRANTY:Whoever tampers with or removes the plate, can be prosecuted by law and

frees the Manufacturer from any warranty responsability.

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ECOLOGICAL INFORMATION

The disposal of the SB48 packing materials, replaced parts, lubricants, components orof the machine itself, must be performed respecting the environment, avoidingground, water and air pollution.It is the machine owners duty to perform this operation conforming to the rules inforce in the country where the machine is used.

MACHINE DEMOLITION

We recommend deactivating the machine, before proceeding to its demolition:

o disassembling its components;

o removing the motor

INDICATION FOR CORRECT WASTE DISPOSAL

o Ferrous materials, aluminium, copper: are recyclable materials that mustbe taken to the proper authorized collecting centre;

o Plastic and rubber materials: must be taken to a waste disposal site or tothe proper recycling centre.

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MACHINE TRANSPORTATION

Before proceeding, respect rules for use of lifting equipment and also verify:

Machine weight indicated in the Technical Characteristics table; Make sure that ropes used are suitable and in excellent conditions; Always check wear conditions of ropes and hooks used; Make sure load is safely fastened and balanced; Warn start of handling phase; Make sure machine and installed equipment to be lifted does not exceed the

ifting means maximum capacity; Do not abandon control place leaving suspended load unattaended.

LIFTING FROM BOTTOM WITH PACKING

Before proceeding verify:

Machine weight indicated in the Technical Characeristicstable ;

That the lifting mean used is suitable to lift the weight ofmachine and installed equipment;

Indicated zones of pallet where grabs should be inserted; That the grabs are well placed before lifting the machine on order to avoid

tipping it over.

PACKING METHODS

All machines, because of vibrations caused by transportation and particularly severeclimatic conditions are carefully packed using appropriate materials to guarantee atotal chemical and mechanical protection.

!!WARNING: during any machine handling adopt every safetymeasure and keep the necessary safety distance in case of load fall.

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TRANSPORTATION ON ROAD USING AUTHORIZED MEAN

The machine must be loaded with the maximum precautionsand in the way illustrated in the figure to guarantee stability.

CHANGE OF WORKING POSITION

If you need to change the machines working space, before transporting the machinebe sure you:

o Disconnect main power cable;o Disconnect foot switch;o Remove all accessories

While transporting:

o Beware of machine weight indicated in Technical Characteristics table;o Keep feet away from machine.

INSTALLING THE MACHINE

Place the machine in a safe and stable position.Connect the machine to a power supply circuit provided with a main switch to enableinterruption of power supply.The above must be performed by specialized personnel and after verifying that:

a. Main switch is in position (0);

b. Power supply is exactly the same required by themachine as indicated on the label;

c. Conductors connected to power cord have an adequate section forabsorbing same or more power as indicated on the label.

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USING THE MACHINE

The important concepts that need to be known for an optimal use of the SB48machine are as follows:

Bending angle, is the degreevalue of the bend you wish toachieve;

Spring back angle , is thedifference between the requiredbend angle and the bend anglewhich would be actuallyachieved if the Ercolina systemwould not be adopted toeliminate it. The spring backangle is due to elasticity of thematerials, when bent they tendto spring back towards theiroriginal shape;

Required bend angle.

Bend angle achieved withoutadpoting Ercolina system to correctspring back angle.

Difference between two bends : one withspring back angle correction, the other withno spring back angle correction.

= -

Note: the scope of this section is to outlinethe fundamental concepts for bending. Theprocedure for correcting spring back angleis explained in the SB48PROGRAMMING MANUAL - Editingthe actual bend angle.

Bending radius R

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bending radius, it is the radius of the bend measured from the centre of thetube or profile and the centre of the hexagonal shaft.

Follow these steps for proper use of the machine:

CHOICE OF ACCESSORIES

Choose the correct former and counterbending die to bend yourtube or profile. Always make sure that the external diameter andwall thickness of the workpiece, match the sizes marked on theformer and counterbending die.

INSTALLING THE TOOLING

Former

Counterbend.die

Place the counterbending die on its support bracket.

!!WARNING: fix thecounterbending die on itssupport bracket by the wingas indicated in the figure.

Wing

Install former on upper part of hexagonal shaft as indicated .

!!WARNING: Always align the zero mark of former with the zeromark on the hexagonal shaft and body of machine.

!!WARNING: for a correct choice of tooling , we recommend to useour former and counterbending die charts in our catalogue.

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SWITCHING MACHINE ON

Switch on machine using main power switch turning it on position (1) and pressingset button.

MACHINE PREPARATION

TIGHTENING THE TUBE

Lubricate adequately counterbending die beforeinserting tube.

Insert tubeo into former.

Approach counterbending die turning bracket.

Tighten the tube between the former andcounterbending die turning hand wheel.

!!WARNING: apply adequate tightening pressure , inorder to avoid wrinkles on inside of bend and tubeovalization.

Screw the counterbending die to the support bracket .

!!WARNING: Screwing the counterbending die to itsbracket is necessary only if counterbending die has not thequick slide engagement system.

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PROGRAMMING THE MACHINE

For programming of Ercolina Super Bender, follow instructions of SB48 SUPERBENDER - PROGRAMMING MANUAL.

Programming Manual

Hardware ver. RC0063 rev. CSoftware ver. E198

Edition 1.0Date 26.04.2000

SUPER BENDER SB48

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INTRODUCTION

The microprocessor controlinstalled on the Super Bender SB48 board is equippedwith a lithium back up battery able to store date fro over 10 years.The autodiagnostic electronic system allows a reliable and accurate process of all itsfunctions throughout all the use of its features.The soft touch keypad simplifies the use of the machine and helps data insertionduring the programming procedures.

Control Board

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KEY BOARD FUNCTIONS

All the program functions can be executed with the use of the few simple keysdescribed below:

Confirms all data. Starts work program block . Ends data storage. Bending alternative key to move the shaft of the machine (alternative to foot

pedal). In the data entry mode this key can be used to insert 90 directly in the

program in a quicker way.

Return alternative key to move the shaft of the machine backwards(alternative to foot pedal).

In the data entry mode this key can be used to insert 45 directly in theprogram in a quicker way.

During the data entry mode allows the insertion of new data or changes inold data stored .

In the data entry mode this key can be used to insert 135 directly in theprogram in a quicker way.

When doing the spring back angle it allows to change the previous setvalue.

Program key for increasing bend angle value. Enables data entry. Allows work block selection. Program key for decreasing bend angle value. Erases bend angle values stored in program blocks.

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LIGHT SIGNALS

On the main electronic card, there are a number of light signals which will appearaccordingly to the machine position as follows:

OVERLOAD: Excessive power absorbed Connections to the main motor have been interrupted Emergency stop button activated Magneto thermic switch in the off position

WARNING: Low tension High tension Error 86* Error 87* Error 88*

SYNCRO: Reset return phase

BEND: Machine is ready to bend (flashing) bend is accomplished

POWER: Power supply going in main electronic board

*Note: information concerning ERRORS 87-88 on the SB48 is on page 37 e38 of this manual; information concerning ERRORS 86-87-88 onthe SB48T is on page 39, 40, 41.

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PROGRAM PROCEDURES

1. Activate data entry mode: Switch on power supply (by using main switch) and press set up button ; Press the button ; the display should show as follows:

Program Start

2. Press the or keys to continue or not the data entry mode;

3. If you have chosen to insert new data pressing the plus , you will have tochoose the block in which you would like to work with using again the plusbutton to select a group to work with from P0 to P9.By pressing minus button for 4 seconds while the program number isdisplayed, all the previous stored data will be lost and new data can bememorised.

4. Once the group has been selected and it is ready to be programmed, the displaywill show as below ; you may now insert the bend angle value and store it withthe button.

Insert bend angle

5. To insert the bend angle values press and buttons to increase or decreasethe value of the bend angle values or it will be possible with the use of the , , to insert quick bend angle values such as 135, 90 e 45.

6. To store the bend angle values press the button and the following messagewill appear on the display:

DATA ENTRY MODE+=YES ENTER = NO

INSERT BEND 1(1P) 000

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Stored bend angle

7. Once the first bend angle has been inserted, the program will automatically askfor the second bend angle which can be inserted in the same way as the first. Thesame can be done for the third, the fourth and so on until the ninth of the samegroup by repeating steps 5 and 6. If instead you wish to end the data entry youmust press the button without inserting any angle value the display will show:

End of data storage

8. For programming new groups press button and repeat steps from 3 to 7.To end data storage press .

PROCEDURES FOR BEND MAKING

After the full data entry will be finished the machine will be in stand by mode withthe following message :

Stand by mode

In this position if the bend angles memorised are more than one, with the use of the button you may scroll through and choose the bend angle you would like to use .Set all tooling on the machine, former and counterbending die of the same size of thematerial to be bent. Set in position the support bracket and adjust initial pressure ontube against the former. With the use of the keys, and you will need tomemorize the cursor counterbending die postion :

STORED

END OF DATA ENTRY

FORWARD C.BEND DIEMm - PR 1

FORWARD C.BEND DIEMm - PRX1

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Setting the electronic counterbending die position

The position of the counterbending die (mm 000.0) is controlled by themicroprocessor which enables the machine to carry out the following bends repeatingexactly the position of the cursor and counterbending die with a tolerance of +0.2mm.It will be possible to begin the first bend now by pressing the button; the tube willbegin to move in the tools until it will be possible that it will visibly begin to bend theangle moved will be our spring-back angle. See example in the bottom indicatingwhat the display will show:

Spring back

Press the button to memorise the spring back angle (see below).

Spring back storage

It will be possible now to bend by continuing to press the button.Once the bend angle will be achieved, the machine will stop automatically and theyellow light will flash.Press the button to bring the machine back to the 0 origin point.

Completed memorised bend

Should the (0) position of the machine shaft be lost or offset it will be necessary to setthe machine in the shaft reset mode to bring the hexagonal shaft (axis C) back in itsoriginal position.The shaft reset procedure can be accomplished as follows:

BEND 1 0 090Mm 000.0 0

008

BEND 1 8 090Mm 000.0 8

000

BEND 1 8 090Mm 000.0 8 090

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The machine shaft should be without any kind of tools; Keeping the button or pressed by turning on the machine simultaneously,

you will enter the shaft reset mode. When the mode is entered the display should show the following message:

Shaft (axis C) reset mode

In this mode press the or pedals, to move the hexagonal shaft basealigned with the mark, placed on the aluminium body of the machineitself.

To store the new origin or 0 point, you need to press the button and thedisplay will show as follows:

New position of the shaft stored ( Axis C )

HOW TO CORRECT THE SPRING-BACK ANGLE

If while working you notice that the required bend angle achieved is not conformingto the desired angle you may adjust the spring-back angle to correct the angle in themachine program.To correct the bend angle, while working you need to :

stop the machine from working by releasing all keys; press the button , then a flashing cursor will appear on the spring-back angle

value;

the value of the spring-back angle can be changed with the use of the buttons and ;

The new set value will be stored only after having the button pressed, thefollowing message will then be displayed :

Spring-back angle change storage

0

SHAFT RESET MODE

SHAFT RESET STORED

BEND 1 12 090 STORED

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In the example shown in the above picture the new spring-back value (12)has been stored on the first 90 bend.

After the new angle has been stored you may proceed continuing the bend untilcompleted.

EDITING THE ACTUAL BEND ANGLE

As the spring-back angle you may also modify the bend angle without changing awhole program. To edit a single bend angle you must:

interrupt bending ; press the button until the flashing cursor is on the bend angle value; at this point with the use of the and buttons you may add or subtract

degrees to your original stored angle; Once the bend angle has been changed you will need to store it by pressing the

button.

CHANGING THE LANGUAGE

In order to change the machine language on the display please act as follows:

Place the machine in the off position and then press the , , simultaneously while turning on the machine;

On the display the following message should be shown:

Language selection

By pressing the button you may scroll through all the available languages; Make your selection then store with the use of the button.

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PRACTICAL USE OF THE MACHINE

Main points to keep in mind for bending correctly with the Ercolina system:

Before bending make sure that the outside diameter of the tube is of the samesize as the one printed on the former and the counterbending die.

!!Note: if you measure the former groove with a calibre, do not be surprisedto find it a few mm smaller ( if the wall thickness of the tube is smaller than2,5mm ) or a decimal part of a mm smaller ( if the wall thickness of the tubeis greater than 2,5mm ) than the actual marked diameter size. It is perfectlynormal and it is part of the Ercolina bending technology.

Remember that the minimum bend radius depends on the material to bebent, the tube external diameter and the wall thickness of the tube.

Correct pressure betweenformer and counterbendingdie. You must apply justenough pressure to avoidwrinkles on the inside bendof the tube.

!!Note: If even with ahigher pressure there are stillwrinkles in the inside benduse a former with a largerradius.

In case of excessiveconstriction of the tube on itsinside radius use the specialscrew on support bracket: assoon as tube starts visiblybending tighten screw sothat the screw touches theback of the counterbendingsupport bracket. After thiscontinue the bending processas normal. Fine adjustmentof this screw will furtherimprove the bend quality.

Special screw

Results achievedafter bending withno special screw orby using it in a toobackward position

Improvement of bend qualityachieved by fine adjustmentof special screw

Results achieved after bendingwith no special screw or byusing it in a too forwardposition.

Rev. 00 Page 33


!!Remember to adjust the position of this screw for different tube sizes /materials.

Former and counterbending die must never touch otherwise the tube may breakor have wrinkles on the inside bend and the machine can be damaged.

Do not keep tubes in dusty/dirty places, in these conditions the counterbendingdies will wear out faster due to increased friction between the dirty tube andcounterbending die

Rev. 00 Page 34


MAINTENANCE

ORDINARY MAINTENANCE

Lubrication. In order to always guarantee optimalfunctioning of the SB48 machine , grease upper gear boxwith a grease gun every 40 hours of work.

How to replace the hexagonal shaft (formerholder ). Act as follows:a. unscrew all the bolts which hold the shaft ;b. extract the hexagonal shaft ;c. insert new hexagonal shaft so that the zero

marked on the machine body match ( only onefitting position is possible );

d. screw the bolts firmly back into placefollowing a cross section order.

EXTRAORDINARY MAINTENANCE

Any repair or replacement of internal and exernal parts of the machine must be madeonly by personnel trained/authorised by the Manufacturer.

The Manufacturer reserves the right not to supply accessories or spare parts if themachine has been modified.

Rev. 00 Page 35


TUBE BENDING TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Wrinkles on internalsurface of bend

Bending pressure is toolow

Apply more pressure on tube ( themaximum pressure is achieved whenformer and counterbending die arealmost touching ).


Counterbending die andformer are touching Act so that these two parts do not touch


Former radius is toosmall Use former with larger radius.

Excessive tubedeformation (ovalisation)

Bending pressure is toohigh

Diminish bending pressure or useformer with a larger radius.

Excessive tubedeformation at beginningand end of bend

Bending pressure is toohigh

Diminish bending pressure or useformer with a larger radius.

Excessive tubedeformation on internalradius at beginning andend of bend

Bending pressure is toohigh Use special screw on support bracket .

Machine fails to bendsince machine goes intooverload

Tube wall thicknessand/or chemicalcomposition of tube isbeyond machine bendingcapacity

Try to bend by using the specialErcolina roll instead ofcounterbending die.

For any other technical problem on bending, contact your nearest Ercolinadealer.

Rev. 00 Page 36


TROUBLESHOOTING

PROBLEM CAUSE SOLUTION Does not switch on Electrical

connections in plugCheck plug

Does not switch on Electrical connection Check power cable making sure it is not damaged

Display is completelyoff

Missing phase Check plug and phases on QS1

Mac

hine

Display is completelyoff

Burnt fuse Check fuses and if blown replace

Pushing pedal machine doesnot start

Support bracketdatum position notstored

Store bracket position

Low tension Low voltage powersupply

Switch off machine immediately and connect it to suitable powersupply.

High tension High voltage powersupply

Switch off machine immediately and connect it to suitable powersupply

Error 87 Faulty T.A. Check phasesError 87 C axis beyond 210 Reset heaxagonal shaft ( C axis )Error 88 C axis beyond 210 Reset heaxagonal shaft ( C axis ).Error 88 Faulty axis C encoder Check connections on electronic card ( 4 pin connector marked

with a C ) with a screwdriver making sure connections are notfaulty.D

ispl

ay s

how

s:

Error 88 Faulty axis Cencoder.

Check integrity of encoder star wheel next to motor shaft, makingsure it is not dirty ( clean with air jet ). Also make sure that star isnot loose. Make sure that star wheel is at the centre of the degreereader.

Overload light on Machine overloaded. Switch off machine. Use within its capacity. Use correct toolingand materials.

Overload light on Faulty motor. Check motor connections.

Warning light on Faulty motor. Turn emergency button, switch machine off and reswitch on QS1.

If:

Overload light on Faulty axis Cencoder.

Check C axis encoder and its connections.

The machine works butshows Error 88 every nowand then

Broken or dirty axisC encoder.

Clean encoder with an air jet from beneath the hexagonal shaftholder. Check integrity of the encoder and of star wheel.

TROUBLESHOOTING (only for SB48T)

Incorrect rotation directionreverse switch

Inverted phase Reverse main switch QS1.

Error 86 Missing phase Check plug.

Error 88 and when pedalsare pressed the machineclicks

Faulty TR1 orrectifier.

Press on KMs and check outlets 101-102 (100 V), if there isno power on replace TV1, if there is power press on KMsand check outlets 200-201 (110 V), if there is no powerreplace rectifier.

Dis

play

show

s:

Error 87 Faulty T.A. Check phases on T.A. n.400,403

Rev. 00 Page 37


SB48 TROUBLESHOOTING

If when pressing on the pedalthe motor does not start andERROR 87 appears on thedisplay

ERROR 87

Cause

AXIS C HAS HIT THELIMIT MICROSWITCH

INTERRUPTED T.A.

REMEDY

T.A. JP2 Setting

End ofoperationat 210

Originaxis Cindicator

REMEDY

See ERROR 88

Rev. 00 Page 38


Premendo il pedale il motore accenna apartire ma si ferma immediatamente e suldisplay appare: ERRORE 88.

Premendo un pedale il motorenon parte e sul display appare:ERRORE 88.

ERROR 88

Cause

AXIS C AT LIMITMICROSWITCH

INTERRUPTED T.A.

Cause

If when pressing on the pedal the motorappears to want to start, but then stopsimmediately and ERROR 88 appears onthe display

If, when pressing on the pedal themotor does not start and ERROR88 apperas on the display

End of operating at210

Origin AxisC indicator

1. If, the machine isat the end ofoperations stageat 210, you haveto switch machineoff and then backon and return.

2. If, the machinepasses the 0point indicator youmust reset theorigin Axis C

REMEDY

Special key

Cap

Connector

Motor

Star

Electronicboard

Lowerplate

Encoder

REMEDY

1.Open the window on themicroprocessor and lift themicroprocessor. Disconnectthe microprocessor from theconnector degree counteridentifiable by a C on thecap, and with a special keypush on the 4 wires to makesure that there is not a faultyconnection.2.Check the encoder whichcan be found near the motorand make sure all is in orderas shown on the drawing. Ifthe fault remains, replace theencoder.

Rev. 00 Page 39


SB48T TROUBLESHOOTING

ERROR 86

If, when pressing on the pedal the motor does not startand ERROR 86 appears on the display

MISSING PHASE BURNT FUSE

Plug

On/OffSwitch

Magnetothermical switch

REMEDY

See ERROR 88

REMEDY

Replace fuse

Rev. 00 Page 40


ERROR 87

If, when pressing on the pedal themotor does not start and ERROR87 appears on the display

AXIS C HAS HIT THE LIMIT MICROSWITCHINTERRUPTED T.A.MISSING PHASE

Plug

On/Offswitch

Magnetothermicalswitch

REMEDY

See ERROR 88

REMEDY

Check the phases in the T.A.nos. 400 and 403

End of operation at210

Origin axisC indicator

REMEDYSee ERROR 88

Rev. 00 Page 41


If, when pressing on the pedalthe motor does not start andERROR 88 appears on thedisplay

If when pressing on the pedal themotor appears to want to start,but then stops immediately andERROR 88 appears on thedisplay

Damage to encoder AxisC

Emergencybutton pressed

Axis C at limitmicroswitch

Missing phase

Special key

Cap

Connector

Encoder

Lower plate

REMEDY

Motor

1.Open the window on the microprocessorand lift the microprocessor. Disconnect themicroprocessor from the connector degreecounter identifiable by a C on the cap, andwith a special key push on the 4 wires tomake sure that there is not a faultyconnection.

2. Check the encoder which can be foundnear the motor and make sure all is in orderas shown on the drawing. If the fault remains,replace the encoder.

Emergencystop buttonis pressed

Electronicboard

Release beforepressing again onfoot switch

REMEDY

1. If, the machine is at the endof operations stage at 210,you have to switch machineoff and then back on andreturn.

2. If, the machine passes the 0point indicator you must reset theorigin Axis C

REMEDY

End ofoperating at210 Origin AxisC indicator

Plug

On/OffSwitch

Magnetothermicalswitch

REMEDY

1.Check the electrical plug socket.

2. Open the door which gives you accessto the electrical panel, and switch themachine on by using the main switch tobe found in the panel. This operation isnecessary to check whether all threephases are working. Check no. L1, L2, L3on the magneto thermical switch arereceiving power supply ( as indicated inthe above drawing )

ERROR 88

CAUSE

Rev. 00 Page 42


MACHINE CE CONFORMITY DECLARATION(Directive n. 89/392 CE, Attachment II, part A).

Manufacturer: C.M.L. International S.p.A.Address: 03030 Localit Annunziata snc

Piedimonte S. Germano (FR), Italy

declares that:

The ELECTRICAL TUBE, PIPE AND PROFILE BENDING MACHINE SB48, Series N________________ is:

In confirmity with the Machine Directive (Directive n. 89/392 CE), as modified with thelegislation that transposes it;

In conformity with conditions of the following CE directives: directive 73/23/CEE regarding low voltage electrical material; directive 89/336/EEG regarding electromagnetic compatibility ; directive 89/392/CEE regarding member countries approaching on machine legislation ; directive 85/374/CEE regarding member countries approaching on legislation for

responsabilities for damages caused by defective products;

NOISE RATING MEASUREMENT

TYPE OFMEASUREMENT NOISE RATING

dB < 78

Measurements performed according to machine directives.

Made in __________Date _____________

Signatorys nameSignature

___________________________

Rev. 00 Page 43


MACHINE CONFORMITY DECLARATION(Directive no. 89/392 CE, Attachment II, part A).

Manufacturer: C.M.L. International S.p.A.Address: 03030 Localit Annunziata snc

Piedimonte S. Germano (FR), Italy

declares that:The ELECTRICAL TUBE, PIPE AND PROFILE BENDING MACHINE SB48T, Series N________________ is:

In conformity with the machine directive (Directive nr. 89/392 CE), as modified with thelegislation that transposes it;

In conformity with the conditions of the following CE directives: directive 73/23/CEE regarding low voltage electrical material; directive 89/336/EEG regarding electromagnetic compatibility; directive 89/392/CEE regarding member countries approaching on machine legislation; directive 85/374/CEE regarding member countries approaching on legislation for

responsabilities for damages caused by defective products;

NOISE RATING MEASUREMENT

TYPE OFMEASUREMENT NOISE RATING

dB < 70

Measurements performed according to machine directives.

Made in __________Date _____________

Signatorys nameSignature

___________________________

Rev. 00 Page 44


TEST CARD

MACHINE / COMPONENT TESTCARD NUMBER: N.

MACHINE / COMPONENT:

TEST INSPECTOR :

TEST DESCRIPTION:

DATE OF TEST START END / /200__

CHECK DESCRIPTION

MODEL:

MATERIAL:

TYPE OF WORK:

ANOMALY/IES FOUND

DIAGNOSIS

REMEDIES

SUGGESTIONS

TEST RESULTS

CONCLUSION NOTES

Rev. 00 Page 45


SB48 ELECTRICAL DRAWINGS

Rev. 00 Page 46


SB48T ELECTRICAL DRAWINGS

Rev. 00 Page 47


Rev. 00 Page 48


SB48T TOPOGRAPHICAL DIAGRAM

Rev. 00 Page 49


SETTINGS OF SB48 ELECTRONIC BOARD

FUSESF1: 1A 250V ( Trasformer protection TV1)F2: 1A 250V (Motor brake protection)F3: 25A 250V (Power supply protection)F4: 1A 250V (Start circuit)

ELECTRONIC BOARD CONFIGURATIONBefore connecting the machine to power supply, set voltages on the JP1 bridge and the TA valueson the JP2 bridge in the following manner:

Machine Voltage JP1 JP2SB48 110V 104V 104 16SB48 110V 110V 110 16SB48 110V 127V 127 16SB48 110V 145V 145 16 8K6SB48 220V 208V 200 7.5SB48 220V 220V 220 7.5SB48 220V 240V 250 7.5 4K2SB48 220V 260V 250 7.5 2K2

Furthermore set, frequency value on JP2 bridge, in the following manner:50Hz OFF; 60Hz ON

Rev. 00 Page 50


72

80

93 87

29

5

121

90 89

88 36 35

112

6

1

60

33xxx

12 92 59

81

48

12

32

37

120

36

78

76

36

119

60

110117

43

118

61

62

63

66

12

16

67

70

65

xxx

91

44

69

57

56

19

51

50

18

40 48

xxx

15 2

55

39

25 68

84

101

97

85

34

27

102 30

26

34

31

28

104

73

71

11

3

24

106

105108109

13

14

17

107

103

115116

10

113

83

4

41 23

xxx 37

21 38 82 45

94 46

20

54

53

95

47

52

42

111

68

74

77

79

75

9

49

98

38

96

99

64

100

22

114

58

EERRCCOOLLIINNAA SSUUPPEERR BBEENNDDEERR SSBB4488 EExxppllooddeedd vviieeww ffoorr ppaarrttss iiddeennttiiffiiccaattiioonn

Complete bracket

Completeinstr. board (425mm)

(550mm)

(Z90)(Z44)

(Z32)

(Z36)

(40mm)

(50mm)

Rev. 00 Page 51


SPARE PARTS ARTICLE CODES

CHART OF SPARE PARTS ARTICLE CODESPOSIT. COMP. ART. DESCRIPTION

1 810P GREASE SPRAY2 AD001 ERCOLINA BIG ADHESIVE LABEL

AD001/11 SB48 SUPER BENDER ADHESIVE LABEL3 AP162 SCREW4 CPM101 MOTOR KW1,5 - 230V - Hz505 MP202A/1 ELECTRONIC CARD6 P010 PLASTIC GREASE GUN 150ml7 P050A HEXAGONAL SHAFT 40MM8 P050B HEXAGONAL SHAFT 50MM

P050/D ADHESIVE LABEL GREASE EVERY 40 HOURS9 P050D/1 COMPLETE SUPPORT BRACKET10 P050G 4 SPOKE HAND WHEEL11 P050H FOOT SWITCH12 P103 CONICAL HEAD PHILIPS SCREW13 P107/2 FUSE14 P108 FUSE HOLDER15 P112 FOOT SWITCH SOCKET16 P184 SPRING WASHER17 P190S SCREW18 P191J/1 3 PIN PLUG19 P229 KEY20 P244 KEY21 P352 MICROSWITCH22 P352A MICROSWITCH23 P365 SCREW24 P378 SCREW25 P502 GRAB HANDLE26 P503 RUBBER WHEEL27 P504 SCREW28 P507 WASHER29 P508 NUT30 P511 LOCK31 P514 KEY FOR CABINET DOOR32 P514A T WRENCH 33 P521 GREASE NIPPLE34 P525 NUT35 P526 SPRING WASHER36 P527 BLOCKING RING37 P531A SCREW38 P532A CAM SHAFT39 P534 MICROSWITCH PROTECTION COVER40 P535 PHILIPS SCREW41 P535N SCREW42 P536 SCREW

Rev. 00 Page 52


43 P536A SCREW44 P538 BEARING45 P538A BEARING46 P540 BEARING47 P542 BUSHING48 P543 BEARING49 P545A BUSHING50 P547A PINION51 P548A KEY52 P551A GEAR WHEEL53 P553A KEY54 P554A GEAR WHEEL55 P559 DOWEL PIN56 P560/1 MUSHRROM HEAD EMERGENCY SWITCH57 P560Z EMERGENCY STOP ADHESIVE LABEL58 P561/1 BLOC. P9B01VN59 P565 SCREW60 P573 SCREW61 P575/1 SLIDER62 P576 STEEL SCREW63 P578 SPRING WASHER64 P579 SCREW SUPPORT65 P580 SCREW66 P581 METAL RING67 P582 WHEEL FOR SLIDER SCREW68 P583 METAL RING69 P584 Axis C SLIDER ENCODER

P584T DEGREE COUNTER PRINTED CIRCUIT70 P585 SLIDER SCREW SUPPORT BRACKET71 P587 SCREW72 P588 BOLT73 P589 WASHER74 P591N BRASS SUPPORT75 P592 BRACKET PIN76 P593/1 NEW EXTENDED SUPPORT BRACKET77 P593A LEVER ARM78 P593G1 NUT79 P593H2 GRUB SCREW80 P611D GRUB SCREW M8x20 PP 12,9 UNI592381 P701 TOP CASING82 P702 BOTTOM CASING83 P702A MOTOR SUPPORT84 P702B PULLEY SPACER85 P702C WASHER86 P703 GEAR WHEEL87 P704A NEW PINION 060U88 P705/1 DEGREE COUNTER DISC89 P705/2 WASHER90 P705/3 SCREW

Rev. 00 Page 53


91 P705B PINION92 P705/4 SPACER FOR READER DISC SUPPORT

P705/6 AXIS C READER AXIS93 P706A BUSHING94 P707A PINION95 P710 OIL SEAL96 P722B PULLEY97 P722C PULLEY98 P723C PULLEY99 P723D PULLEY

100 P724A1 BELT101 P724C TOOTHED BELT102 P725/2 SUPERBENDER SB48 CABINET103 P725A CABLE GLAND104 P725/B BRASS BUSH105 P725C POWER CABLE106 P725D/2 SINGLE PHASE 2 PLUG107 P725L PLATE PANEL108 P725T SERIAL NUMBER PLATE109 P725T1 RIVETS110 P728NS COMPLETE SUPER SB48 ELECTRONIC CARD111 P730A SCREW112 P731 HEXAGONAL SHAFT COVER113 P732 SCREW114 P735 BUTTON

P735/1 BLOC. P9B10VN116 P737 RELAY SWITCH UNIT

P737/2 RELAY SWITCH UNIT117 P738 BLACK PLASTIC CAP118 P738A BLACK PLASTIC CAP119 P741 FLEX PLATE120 P742 FIXING PLATE121 TP029 (PLASTIC) STAR CAP

Rev. 00 Page 54


REPLACEMENT PARTS REQUESTIn order to achieve a perfect identification of a particular required component please specify:

MODEL:

Serial N:

Sub-group:

Component position N:

Code N

Description

Quantity

Note.: If electrical components are requested please specify voltage in use.

Rev. 00 Page 55


BENDING FILE

Tube sizes Bend data StorageType of tube Wallthickness

Springback angle

Bendingradius Group N Bend N

1._____________

2._____________

3._____________

4._____________

5._____________

6._____________

7._____________

8._____________

9._____________

10._____________

11._____________

12._____________

13._____________

14._____________

15._____________

16._____________

17._____________

18._____________

19._____________

20._____________

21._____________

Date post:	16-Oct-2015
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Sb 48 Bender

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