ELECTRABRAKE EB0625 User manual

INSTRUCTION MANUAL
NSW Schools / TAFE - MB1250
Magnetic Panbrake (240V)
1300 x 1.6mm
K8303
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Instruction Manual for MB1250 (K8303)
01/12/2015

# S5251 EB625 4/6/08
# S5291 EB1000
# S5291 EB1250
ELECTRABRAKE
Electromagnetic sheetmetal bending machines
User Manual on the
EB 0625/1000/1250
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Instruction Manual for MB1250 (K8303)
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INTRODUCTION
ELECTRABRAKE machines use an electromagnet, rather than mechanical clamping. The
machine consists of a long electromagnet with a steel clamp bar located above it. The sheet
metal is clamped between the two surfaces by an electromagnet capable of clamping with a force
range of between 3 - 12 Tons. Rotating the bending beam then forms the bend. The sheet is bent
around the front edge of the clamp-bar.
Using the machine is simple, slide the sheet in under the clamp-bar; press the start-button to
initiate clamping; pull the handle to form the bend to the desired angle; and then return the handle
to automatically release the clamping force. The folded sheet can now be removed or
repositioned ready for another bend.
The special centre less compound hinges are distributed along the length of the bending beam
allowing bending loads close to where they are generated.
The combined effect of the magnetic clamping with the special center less hinges means that the
ELECTRABRAKE is a very compact, space saving, machine with a very high strength-to-weight
ratio.
ELECTRABRAKE EB0625 EB1000 & EB1250
The ELECTRABRAKE EB0625, EB1000 & EB1250 are highly versatile sheet metal folding
machines used to bend mild steel and aluminium sheet metal. Thicknesses of up to 1.6 mm thick
can be folded across the full length of these machines. These multi-purpose machines bend
sheet metal of lengths 625mm, 1000mm and 1250mm respectively.
The ELECTRABRAKE magnetic clamping system replaces the bulky clamping structure used in
conventional folding machines. The small compact clamp bar does not hinder or obstruct the
work piece. Automatic electromagnetic clamping and unclamping, means faster operation. These
machines have much greater versatility than conventional sheet metal benders. The machines
are ideal for use in the sheet metal industry, air-conditioning and building industries.
An electrical interlock is offered to enhance Operator Safety. This operation ensures that a safe
pre-clamping force must be applied before full-clamping can be engaged.
ACCESSORIES
Adjustable backstops, storage tray and a complete set of short-length clamp-bars are included
as Standard Accessories.
A narrow clamp bar, a slotted clamp bar for forming shallow boxes more quickly and a power
shear with guide for straight distortion-free cutting of up to 1.6 mm thick is all available as
Optional Extra Accessories. A further optional extra is a foot switch which is available for
theEB1250 unit only.
A Full 12 month Warranty is offered that covers faulty materials and workmanship.
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Instruction Manual for MB1250 (K8303)
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ASSEMBLY
HOW TO ASSEMBLE YOUR ELECTRABRAKE
Note: The machine is supplied upside down for assembly purposes.
1. Remove all parts from the crate with the exception of ELECTRABRAKE magnet body
assembly.
2. Find the 6mm Allen Key and fasteners supplied.
3. Use slings provided to remove the magnet body from the crate. Rest the body on wooden
blocks supplied.
4. Attach the feet to column by using the M10 x 16 button-head screws provided. Point the
pair of feet forwards ensuring that the safety tape is facing forwards. Ensure that the
joining seam on the column faces to the backwards.
5. On Models EB0625 and EB1000, fasten foot plate under front feet using M10 by 16 cap-
head screws with washers. Alignment is easier if foot mounting is not tightened until the
foot plate is fitted. The rear feet cap head screws can be adjusted to level the machine.
A foot plate is not supplied with the EB1250 machine. The machine is bolted directly to
the floor at the front feet.
6. Place the ELECTRABRAKE magnet body on the stand securing it with M8 x 16 cap head
screws. This would be best if lifted with a lifting facility or some assistance. On Models
EB0625 and EB1000 ensure that connector and wires are guided down the column as
the magnet body is lowered on to the stand.
7. On Models EB0625 and EB1000, connect the electromagnet to the electrical unit by
removing the rear access panel and plug the three pin connectors together. Refit access
panel.
8. On Model EB0625 using the M6 pan head screws and nuts, join the two halves of the
tray. Using M8 x 12 cap head screws attach tray to rear of machine. Fit rubber mat inside
tray. Attach backstop slides to the sides of tray. On Model EB1000 and EB1250, use two
M8 x 16 cap head screws to attach the two back stop bars. Slide the stop collars onto
each back stop bar. Fit rubber mat.
9. Using M8 x16 cap head screws attach the handle (s) to the bending beam. Before
attaching the handle on Models EB0625 and EB1000, slide it through the angle
indicating ring. On Model EB1250, slide stop collar to the top of the handle and tighten.
Fit the handle with angle scale to the right side.
10. On Model EB 1250 rotate the bending beam to 180°. Slide angle indicator unit on to
right handle. Attach the two arms to the indicator spindle at the anchor block. To ensure
correct operation, securely fasten screws to switch mechanism.
11. Use solvent i.e. turpentine to remove the clear protective coating from the top of the unit
and from the clamp bar.
12. Place the clamp bar on the magnet body.
13. To obtain excellent results follow the operating instructions.
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Instruction Manual for MB1250 (K8303)
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OPERATING PROCEDURES
GENERAL CAUTIONARY IMPORTANT WARNINGS
Electrabrake machines are designed for ONE operator only, which includes the inserting of the
sheet metal and operating the switches.
See specifications for clamping strength – please note that the force is several tonnes. All units
are fitted with a two-handed interlocking system to prevent hands being accidentally trapped
when clamping.
Safety procedures:
1. Safe pre-clamping is engaged
2. Full clamping is activated
3. Lower clamp bar to 5mm of the bed
4. Magnet will disengage
STANDARD BENDING
Preparation: Switch on power. Check that the clamp bar is correctly positioned.
♦Set the machine to suit the sheet metal thickness by rotating the 2 adjuster pins situated
on top of the clamp bar. Check the clearance by lifting the bending beam at 90 deg. and
examine the gap. To achieve and perfect bend, set a fractionally larger gap than the
thickness of the sheet metal between the edge of the clamp bar and the face of the
bending beam.
♦Place sheet metal under clamp bar – the backstop can be used if needed.
♦To apply pre-claming force use start button or the foot-switch to activate the magnet.
♦To activate the micro-switch for full clamping, pull one of the bending handles with your
free hand. Release footswitch or start button.
♦Pull on both handles and begin bending until the angle required is achieved. The right
handle has a angle scale, which graduates continuously. To allow for spring back of the
sheet metal, bend a few degrees more than the angle that is required.
♦The electrical circuit of the machine releases a reverse pulse as soon as the bending
beam starts its journey to the home position, allowing the clamp bar to release
immediately.
CAUTION
Do not insert small items under the clamp bar – a minimum lip bend of 15mm is required
except when bending very lightweight soft metal.
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To get the best performance do not clamp longer than is necessary due to the magnet having
less clamping force when heated.
HOW TO USE THE BACKSTOPS
Make use of the backstops when handling volume bends that are all the same size. Set the
backstops to the depth required.
Backstops can be used with a bar (not supplied) laid against them, making a long surface to
use as a reference.
Use a strip of sheet metal of the same thickness as the work piece if a backstop is required
under the clamp bar.
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HOW TO FOLD A LIP
Folding the lip will depend on the sheet metal thickness and the length and width.
Lightweight sheet metal up to 0.8mm.
1. Carry out instruction for standard bending and continue to bend as far as possible.
2. Take away the clamp bar, leave the sheet metal on the machine and move 10mm
backwards, bring over the bending beam and compress the lip. No clamping is
required. Thick sheet metal is not suitable for this application.
3. Further flattening can be accomplished when using thin lightweight material by
following up with magnetic clamping
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HOW TO MAKE A ROLLED EDGE
Wrap sheet metal around a round steel bar or pipe.
1. Position sheet metal clamp bar and round pipe/bar as indicated on drawing.
i) To avoid weak clamping make sure that the clamp bar does not overlap the
machines front pole (A).
ii) Ensure that the rolling pipe is resting on the front pole of the machine (B). It
must not sit on the aluminium surface of the machine.
iii) The clamp bar provides a magnetic pathway (C) for the rolling bar.
2. Wrap the sheet metal around the rolling bar as far as possible –
3. Repeat step 2 until rolled edge is formed to required diameter.
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HOW TO FORM A TEST PIECE
To learn how to work the Electrabrake with confidence it is recommended that test pieces are
made.
Use a piece of 0.8 mm thick x 320 x 200mm aluminium or mild steel sheet. Mark sheet as per
drawing
Form a lip on the edge of the sheet metal (see: How to form a lip)
Turn sheet metal over and insert under the clamp bar with the folded lip end toward you. Tilt
clamp bar and line up bend marked 2. Bend to 90 degrees as shown in drawing below.
Turn sheet metal over and continue with steps marked 3, 4 and 5 bent to 90 degrees.
Roll the remaining piece around a 25 mm diameter round bar (see How to make a rolled edge)
See drawing below for completed job.
200
8
45
95
117
190
335
Bend 2
Bend 4 90°
Bend 3 90°
Bend 1 180°
This section to be rolled around Ø25mm
round bar
90° reverse bend (mark this line on the
reverse side of the sheet)
Bend 5 90°
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Instruction Manual for MB1250 (K8303)
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HOW TO MAKE A BOX USING SHORT CLAMP BARS
For ease of folding, make use of the short clamp bars which are able to be attached to each
other. Electrabrake is designed to assist you in the manufacture of a vast variety of box shapes.
BASIC BOXES
Use the long bar clamp to make the first two bends. Choose and insert one or two of the short
clamp bars as indicated on drawing.
Select the largest clamp piece for bends up to 70mm and for longer lengths use several clamp
pieces to fit the required length.
Clamp pieces can be plugged together for repeat bending when making a single unit. A slotted
clamp bar must be used for boxes or trays with shallow sides. Refer to HOW TO MAKE TRAYS.
LIPPED BOXES
1. Use the set of standard short clamp bars to make rectangular lipped boxes i.e. 98mm.
2. Choose the short clamp bar with at least a lip-width shorter than that of the box (Two or
three may be necessary – depending on length). Make folds 5, 6, 7 and 8. Take care to
guide the corner tabs on inside or outside of the box.
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Instruction Manual for MB1250 (K8303)
01/12/2015