DUCTFORMER TDFC Reference guide

3991 Green Park Road ● St. Louis, MO 63125 ● Phone – 314.631.1416 Fax –314.631.3003
OPERATING and PROCEDURES
MANUAL
TDFC POWER BRAKE

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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OPERATOR SAFETY REMINDERS
This manual contains important instructions for the TDFC Power Brake, that must
be followed during installation, maintenance, and operation. The TDFC Power
Brake is designed and tested according to international safety requirements, but
as with all electrical equipment, certain precautions must be observed when
installing and/or operating the brake. To reduce the risk of personal injury and to
ensure the safe installation and operation of the TDFC Brake, you must carefully
read and follow all instructions and safety precautions in this manual. Only
personnel that have read and understand this manual should be allowed to
operate the equipment.
The National Safety Council reminds us that many accidents
are caused by the failure to follow fundamental safety or
precautions. For this reason, you as a careful operator are
the best insurance against an accident.
Unless otherwise noted. Do not make any adjustments or
lubricate the machine(s) while in motion.
All Machine Guarding must be in place and properly secured whenever the
Machine is running or under Power.
Disconnect POWER Before Servicing.
DO NOT ATTEMPT TO OPERATE THIS EQUIPMENT
BEFORE READING AND UNDERSTANDING THE
INFORMATION PRESENTED IN THIS MANUAL

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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If You Have Any Unresolved Questions You May Contact
Customer Service at Ductfomer
TABLE OF CONTENTS
Section Description Page Number
1. General Information 4
2. System Operation 4
3. Unloading and Installation 4,5
3.1 Receiving the Machine
3.2 Unloading Procedure
3.3 Electrical Procedures
4. Maintenance 5,6
5. General Construction, Factory Settings and Adjustments 6
6.1 General Notes and Cautions
6.2 Guide Settings
6. Set-up of the Equipment 7
7. Wiring & Plumbing of the System 7
8. Controls & Control Functions 7,8,9
9. Understanding the Machine 9
10.1 Press Bar Assembly
10.2 Folder Assembly
10. Procedure to Operate 10
11. Ordering Replacement Parts 10
12. Schematics
Pneumatic Schematic 11
Electrical Schematic (120 volt power) 12
Electrical Schematic (240 volt power) 13

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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1. General Information
The TDFC Power Brake is designed to operate in either Automatic or Manual Mode.
The Manual Mode is operated from a control box mounted on the front of the machine.
A foot operated switch operates the machine in Automatic Mode. A programmable logic
controller is mounted inside the electrical enclosure to control the machine operation
while in automatic mode. In either mode the machine is exclusively a one (1) man
operation. Unintended use, operator oversight and failure to operate in accordance with
these instructions can result in severe injuries.
2. System Operation
The Power Brake performs two operations. First the press bar with upper die is driven
down with pneumatic cylinders to clamp the part in place. Next the folding assembly
swings up to brake the part. The operation can be performed three times to produce a
full wrapper.
3. Unloading and Installation
3.1.Receiving the Machine
Visibly check machine for possible shipping damage.
If damage is evident, insist on a notation on the freight bill and photo
document the damage immediately along with a hand written description
of apparent damage.
If repairs are necessary, contact Ductformer by phone at 314-631-1416
you may be requested to E-Mail or Fax your damage documentation to
Ductformer.
Fax –314-631-3003
E-mail –[email protected]
Do Not place damaged equipment under power until proper repairs have
been made by a qualified service technician.

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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3.2.Unloading Procedure
When unloading the machine off of the transport vehicle, the machine is
best handled by lifting the machine under the frame. Make sure Forks
extend through to the other side of the machine.
Move the machine to the desired location and visually inspect machine
thoroughly before installing power.
Never LIFT the machine by anything other than under the frame, this
would result in excessive damage to the machine and void warranty
After moving the machine to desired location, level and secure the
machine to the floor as required.
3.3.Electrical Connections
Supply 110 or 220 Volt single phase electrical service to the electrical
enclosure (Depending upon which model you have), in accordance with
National and Local Electrical Codes. This machine is offered in both 110
Volt and 220 Volt versions
ONLY UPON THE SATIFACTORY COMPLETION OF ALL THE ABOVE CHECKS
AND PERFORMANCE OF INITIAL INSTALLATION PROCEDURES SHOULD THE
MACHINE BE POWERED UP OR RELEASED FOR PRODUCTION USE.
4. Schematics
Pneumatic Schematic: See end of manual
Electrical Schematics: See end of manual
5. Maintenance
No repair or maintenance should be performed while the machine is running
or capable of running. Proper LOCKOUT/TAGOUT Procedures should be
followed. Turn all machine controls off before shutting off the Main Electrical
Disconnect to prevent startup when POWER is restored. Disconnect all
Electrical POWER at the Main Electrical Disconnect before performing any
maintenance or repairs to the Machine. It is important to realize that
cylinders will eventually bleed down and release or lower their loads. When

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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working around such items, blocks should be used to prevent unintentional
movements. After a repair remove the blocks and check the entire machine
carefully to determine proper reassembly before POWER is restored.
Note: The machine is supplied with bearings pre lubricated; however the
bearings should be lubricated after every 500 hours of running time.
The machine should be inspected for dirt and debris that may have
collected during Daily Usage.
All bolts should be checked for tightness every 6-months.
6. General Construction, Factory Settings and Adjustments
6.1.General Notes and Cautions:
This machine is designed for a maximum of 16 gauge Steel.
Do not exceed the maximum material thickness for the machine.
The machine has been adjusted at factory and should not require any
changes.
The TDFC Brake is exclusively designed as a one (1) man operation.
Failure to follow this precaution can result in serious injury.
6.2.Folder Adjustments
The Folder pivot position is located with pillow bearing blocks.
Adjustment bolts push the bearing blocks back toward the rear of the
machine, tightening the bend. To adjust, first remove the small guards
around the pivot mechanisms, then loosen the two bolts that fasten the
pillow block bearing to the table and rotate adjustment bolt to obtain
desired brake.
The Folder stop position is determined by the stop bolts located on the
overhead press bar. Loosen the jam nuts and adjust to set desired
brake angle.

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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7. Set-up of the Equipment
This system does not require any special flooring or grouting. The weight is evenly
distributed and there is a minimum amount of impact or shock load involved in the
operation. The area where the machine feet are located should be level and flat.
8. Wiring and Plumbing of the System
The electrical and pneumatic components have been pre-plumbed and wired for simple
installation. The Pneumatics and Electrical require (1) service drop each.
Electric: 110 Volt or 220 Volt single phase power (This machine is offered in either
110 Volt or 220 Volt versions)
Air: 5 CFM at 90 PSI
9. Controls and Control Functions
The controls consist of a variety of buttons, selector switches and a Micro Processor
Controller which all serve to control the functions of the machine.
NOTE: WHEN OPERATING ANY OF THE SELECTOR SWITCHES & PUSH
BUTTONS IT IS CRITICAL THAT THE OPERATOR FULLY UNDERSTAND THEIR
FUNCTION & VERIFIES THE MACHINE IS CLEAR FROM PERSONNEL OR ANY
OTHER HAZARDS.

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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Button Description
The electrical enclosure has all of the main control selectors and buttons to operate the
system. The following is a description of their individual functions.
POWER ON/OFF –This selector switch with green light indicates that power is supplied
to the machine and ready for operation
CYCLE START (FOOT PEDAL): –This foot switch controls the automatic feed cycle of
the Power Brake operation. When depressed, the press bar will come down to clamp
the part in place, next the folder will swing up. After this operation the folder will swing
back down and the press bar will retract. Machine must be selected to AUTO mode.
MANUAL/AUTO: - This selector switch will set the desired operation mode for the
machine. Manual mode must be selected for the various manual push button
operations. Automatic mode must be selected when running production.
PRESS DOWN –This push button operates simultaneously with the MANUAL CLAMP
button to operate the press bar. Press and hold the PRESS DOWN button until the
press is run all the way down; then without releasing simultaneously press the
MANUAL CLAMP button to hold the press in the clamping position. After releasing
both buttons press the PRESS DOWN button again to move the press back to the up
position. Machine must be selected to MANUAL mode.

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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MANUAL CLAMP –This push button allows the press to stay down when the press is
moved to the lowest position. Press and hold the PRESS DOWN button until the press
is run all the way down; then without releasing simultaneously press the MANUAL
CLAMP button to hold the clamp press in the clamping position. After releasing both
buttons press the PRESS DOWN button again to move the press back to the up
position. Machine must be selected to MANUAL mode.
FOLDER UP –This push button operates the folder mechanism. When pressed the
folder assembly will swing up to brake the part. Machine must be selected to MANUAL
mode and Press in the down clamp position to operate folder manually.
FOLDER DOWN –This push button operates the folder mechanism. When pressed
the folder assembly will swing down off of the part. Machine must be selected to
MANUAL mode and Press in the down clamp position to operate folder manually.
10. Understanding the machine
10.1 Press Assembly: The Press Assembly is driven up and down with a
large pneumatic cylinder. In manual mode the Press Assembly can be
raised or lowered with the push buttons on the front control panel. In
Automatic mode the Press Assembly will lower at the beginning of the
machine cycle and rise at the end.
10.1 Folder Assembly: The Folder Assembly is moved up and down with a
large pneumatic cylinder. In manual mode the Folder Assembly can be
raised or lowered with the push buttons on the front control panel. In
Automatic mode the Folder Assembly will rise up at the beginning of the
machine cycle and down at the end.

OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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11. Procedure to operate
To operate the Power Brake in AUTO mode, first place part in machine with flanges
down. A Notch Locator Blade is located in the brake area of the table to locate the
flange notches. Once the part is in the correct location and table is clear of any other
obstructions the operator can cycle the foot pedal. At this point the Press Bar assembly
will lower to clamp the part to table. Next the folder will swing up to brake the part. The
Folder will now swing down and the Press Bar will rise up off of the part. The part can
now be removed or repositioned for another brake. At any time during the sequence
the operator removes his foot from the pedal, the upper press bar and folding beam will
automatically return to its home position. Again it is imperative that the machine is set-
up and controlled with a single operator. Failure to do so can result in severe injury.
The brake is to be operated in compliance with its intended use. Any other purpose
does not constitute intended use. The manufacturer is not responsible for any damages
or injuries resulting from unintended use.
To operate the Power Brake in MANUAL mode, place the part in machine and operate
either the Press Bar or Folder assembly independently to set up the machine. Once the
part is located within the press the operator cycles the Press Down button. After
confirming the part location the operator will then cycle the Manual Clamp button (while
still holding down the Press Down button). The Press Bar is operated manually up and
down with two buttons on the control box (Folder Up and Folder Down). Again it is
imperative that the machine is set-up and controlled with a single operator. Failure to
do so can result in severe injury. The brake is to be operated in compliance with its
intended use. Any other purpose does not constitute intended use. The manufacturer
is not responsible for any damages or injuries resulting from unintended use.
12. Ordering Replacement Machine PARTS
Replacement Machine PARTS may be ordered directly from Ductformer. All of the
following information is necessary to ensure the correct replacement PARTS are
provided:
Machine Model Number
Machine Serial Number
Replacement PART Number(s) –Description(s)
Quantity of PARTS (each)
Shipping and Billing Information
Contact Name, Company Name, Address and Phone Number
(PO Boxes are not acceptable addresses for shipment)
Preferred Shipping Method

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TDFC POWER BRAKE
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OPERATING and PROCEDURES MANUAL
TDFC POWER BRAKE
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