ELECTRABRAKE EB0625 User manual

EB2500
Magnetic Panbrake (240V)
2500 x 1.6mm
INSTRUCTION MANUAL
S5321
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C O N T E N T S
Page number
Introduction 3
Risk assessment 4 – 6
Pace maker warning 7
Assembling the EB0625, EB1000 8
Assembling the EB1250 9
Assembling the EB2000, EB2500, EB3200 10
Operating procedures for the EB2000, EB2500 and EB3200 11
General cautionary important warnings 11
Safety procedures: 11
Standard bending 11
How to use the backstops 12
How to fold a lip 12
How to make a rolled edge 13
How to form a test piece 14
Basic boxes 15
Lipped boxes 15
Boxes with individual ends 16
Flanged boxes with plain corners 16
Flanged box with corner tabs 17
How to use a slotted clamp bar 18
Forming trays 18
How to check the accuracy of your machine 19
How to check using the machine. 19
Maintenance 20
Adjusters 20
Hinge lubrication 20
Working surfaces 20
Trouble shooting 20
Full clamping not operating 21
Clamp bar not being released 21
Problems with the bending of heavy gauge sheet metal. 22
EB 625 and EB1000 panel 23
EB 2000 EB3200 Wire panel 24
EB-0625 EB1250 Circuit diagram 25
EB 2000, EB2500 and EB3200 circuit diagram 26
Specification sheet 27
Dimensional specifications EB625 28
Dimensional specifications EB1000 28
Dimensional specifications EB1250 29
Dimensional specifications EB2000 30
Dimensional specifications EB2500 30
Dimensional specifications EB3200 31
Warranty 32
Warranty registration 33
ANEXURE 1
Basic Safety Precautions and Procedures: 34-35
FRAME ASSEMBLY AND PARTS LIST EB2000, EB2500, EB3200 36-37
Packing Lists for EB 625 – EB 3200 38-43
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INTRODUCTION
ELECTRABRAKE machines use an electromagnet, rather than a mechanical, clamping system.
The machine consists of a long electromagnet with a steel clamp bar located above it. The sheet
metal is clamped between the two by an electromagnet capable of clamping with a force range of
between 3 - 10 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; lift 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 centre less hinges means that the
ELECTRABRAKE is a very compact, space saving, machine with a very high strength-to-weight
ratio.
ELECTRABRAKE EB625, EB1000, EB1250, EB 2000, EB 2500 & EB3200
The ELECTRABRAKE EB625, EB1000, EB1250, EB2000, EB2500 & EB3200 are highly versatile
sheet metal folding machines used to bend mild steel and aluminium sheet metal. Thicknesses of
up to 1.2 mm thick can be folded on the EB3200, across the full length of the machine. The
EB625, EB1000, EB1250, EB2000 and EB2500 machines fold material of up 1.6mm thickness.
These multi-purpose machines bend sheet metal of lengths 625mm, 1000mm, 1250mm, 2000mm,
2500mm and 3200mm 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 a much greater versatility than conventional sheet metal benders. The machines
are ideal for use in industry, air-conditioning and building industries.
For the EB-2000, EB2500 and EB3200 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 foot switch is supplied as a standard accessory on the EB2000, EB2500 and EB3200 only. On
the EB1250 the foot switch is an optional extra.
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 Full 12 month warranty is offered that covers faulty materials and workmanship.
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SAFETY PRECAUTIONS
Please note: no person with a pacemaker should be closer than 6 FOOT OR 1.828 METRES to
an Electramagnetic machine or anything that has an electrical field.
1. Strong electromagnetic fields can cause electromagnetic interference.
2. EMI can stop the pacemaker from sensing your heart’s rhythm.
PACEMAKER PROTECTION
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ASSEMBLY
HOW TO ASSEMBLE YOUR ELECTRABRAKE
The EB625, EB1000
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. Use the 6mm Allen Key and the screws supplied.
3. Place packing between the body and the crate.
4. Attach the feet to the column using the eight M10 x 16 button-head screws provided. Note
that the seam on the column is at the back and the two feet with the yellow and black safety
tape are the front feet.
5. Fasten the foot plate under the front feet using the M10 x 16 cap-head screws with washers.
Alignment is easier if the foot mounting is not tightened until the foot plate is fitted. The rear
feet cap head screws can be adjusted to level the machine.
6. Place the stand on its feet in a safe area so that the magnet body can be fastened to the
stand.
7. Place the magnet body on the stand securing it with two M8 x 16 cap head screws. This
would be best of you used a lifting device or got some assistance. Ensure that the magnet
wires are guided down the column as the magnet body is lowered onto the stand.
8. Remove the rear access cover to gain access to the electrical unit. By removing the four pan
head screws. Connect the adjoining matching plug leads from the magnetic coil and PC
board. Refit the rear access cover.
9. On the EB625 the tray is in two halves. First join the two halves of the tray using the two M6
pan head screws and nuts. Now using two M8 x 12 cap head screws attach the tray to the
back of the magnet body. Place the rubber mat in the tray. Attach the back stop slides to the
side of the tray.
10. On the EB1000 use four M8 x 12 cap head screws to attach the two back stop bars to the
back of the magnet body
11. On the EB1000 use three M8 x 12 cap head screws to attach the tray to the back of the
magnet body between the two back stop bars. Place the rubber mat in the tray.
12. Open the bending beam to gain access to the back of the bending beam so that you can
attach the handle.
13. Slide the handle through the angle indicating ring. Now using two M8 x 16 cap-head screws
to attach the handle to the bending beam.
14. Use solvent i.e. turpentine or methylated spirits to remove the clear protective coating from
the top of the unit and the clamp bar.
15. Place the clamp bar on the magnet body.
16. To obtain excellent results follow the operating instructions.
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ASSEMBLY
HOW TO ASSEMBLE YOUR ELECTRABRAKE
The EB1250
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 the screws supplied.
3. Lift the magnet body up from the crate. Place a plank between the body and the crate.
4. Attach the feet to the column using the eight M10 x 16 button-head screws provided. Note
that the seam on the column is at the back and the two feet with the yellow and black safety
tape are the front feet.
5. The rear feet cap head screws can be adjusted to level the machine.
6. Place the stand on its feet in a safe area so that the magnet body can be fastened to the
stand.
7. Place the magnet body on the stand securing it with two M8 x 16 cap head screws. This
would be best of you used a lifting device or got some assistance.
8. Use four M8 x 12 cap head screws to attach the two back stop bars to the back of the
magnet body
9. Use three M8 x 12 cap head screws to attach the tray to the back of the magnet body
between the two back stop bars. Place the rubber mat in the tray.
10. Open the bending beam to gain access to the back of the bending beam so that you can
attach the handle.
11. Use two M8 x 20 cap-head screws per handle to attach the handles to the bending beam.
12. The handle with the angle scale is attached on the left hand side of the bending beam.
Attach the other handle on the right hand side.
13. Slide the angle indicator unit onto the left handle. Attach the 2 arms to the indicator spindle.
To ensure correct operation securely fasten the screws to the switching mechanism.
14. Use the two M12 x 60 masonry bolts supplied to secure the Electrabrake machine to the
floor. Adjust the head levelling screws in the rear of each foot until the machine is stable and
level.
15. Use solvent i.e. turpentine or methylated spirits to remove the clear protective coating from
the top of the unit and the clamp bar.
16. Place the clamp bar on the magnet body.
17. To obtain excellent results follow the operating instructions.
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ASSEMBLY
HOW TO ASSEMBLE YOUR ELECTRABRAKE
The EB2000, EB2500, EB3200
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 the screws supplied.
3. Lift the magnet body up from the crate. Place a plank between the body and the crate.
4. Attach the columns to the magnet body by using four M8 x 16 cap-head screws per column.
Open-out the bending beam to gain access to insert the screws.
5. NB Check that the right and left columns are in the correct position with the foot mounting
holes facing to the outside.
6. Attach the feet to respective columns with the adjusting screws pointing backwards using
four M10 x 16 button-head screws per foot.
7. Place the machine the right way up. Assistance is required on the large units.
8. Use four M8 x 16 cap-head screws to attach shelf to the columns. Place the rubber mat in
the shelf.
9. Use three M8 x 12 cap-head screws to attach the tray to the magnet body. Place the rubber
mat in the tray.
10. Use two M8 x 12 screws per backstop to attach the four backstop bars to the back of the
magnet body.
11. Use one M8 x 20 cap-head screw with lock nut per lifter handle to attach lifter handles to the
back of the shaft located at the outside of the columns.
12. Open the bending beam to gain access to the back of the bending beam so that you can
attach the handles
13. Use two M8 x 20 cap-head screws per handle to attach the handles to the bending beam.
14. The handle with the angle scale is attached to the right of the bending beam. Attach the
other handle on the left hand side.
15. Slide the angle indicator unit onto the right handle. Attach the 2 arms to the indicator spindle.
To ensure correct operation securely fasten the screws to the switching mechanism.
16. Use the two M12 x 60 masonry bolts supplied to secure the Electrabrake machine to the
floor. Adjust the head levelling screws in the rear of each foot until the machine is stable and
level.
17. Use solvent i.e. turpentine or methylated spirits to remove the clear protective coating from
the top of the unit and the clamp bar.
18. Place the clamp bar on the magnet body. To engage the heads of the lifter pins push lifter
handle back and then pull the handle forward.
19. To obtain excellent results follow the operating instructions.
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OPERATING PROCEDURES
GENERAL CAUTIONARY IMPORTANT WARNINGS
Electrabrake machines are designed for ONE operator only, which includes the inserting 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 engage
STANDARD BENDING
Preparation: Switch on power. Check that the clamp bar is correctly positioned and that locating
pins are in place at each end of the clamp bar.
For bigger models EB-2000, EB-2500 and EB-3200
Should lifting pins be locked – locate handles below the machine, push hard back and release
forward to lift the clamp bar slightly.
 Set the machine to suit the sheet metal thickness by rotating the 2 screws situated on the
back edge 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 depth
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.
 Lift handles or push down the clamp bar onto the sheet metal. The machine will not turn ON
until the clamp bar is within 5mm above the surface bed due to the interlock. The interlock
can be operated by locking down the lifting system if the clamp bar is unable to be lowered
to 5mm. This can occur when sheet metal is buckled.
 To apply pre-claming force use the foot-switch or depress and hold any of the green start
buttons.
 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 till the angle required is achieved. Assistance will be
necessary when carrying out heavy duty bending. The right handle has a beam angle, 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 at the OFF stage allowing the
clamp bar to release immediately.
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 To release the sheet metal, flick the material upwards, which will lift the clamp bar to make
ready for the next bend. It may be necessary to lift the clamp bar by using one of the lifting
handles.
CAUTION
Do not insert small items under the clamp bar – a minimum bend of 15mm is essential except
when bending very lightweight soft metal. This will prevent damage to the clamp bar.
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 at the size required.
Backstops can be used with a bar (not supplied) laid against them, making a long surface to
use as a reference. The extension pies from the bending beam could be used.
Use a strip of sheet metal of the same thickness as the work piece if a backstop is required
under the clamp bar.
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. Move
the angle stop collar up to the top of the handle, and tighten the Allen head screw to
keep it there.
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 © for the rolling bar.
Folding round a pipe
2. Wrap the sheet metal around the rolling bar as far as possible –
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3. Repeat step 2 until rolled edge to requirement.
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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For ease of folding, make use of the short clamp bars to the shape folds into 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.
Fitting the short clamp bar
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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BOXES WITH INDIVIDUAL ENDS
Advantages:
Material saving
No corner notching
Cut without a guillotine
Fold with the regular full length clamp bar.
Disadvantages:
Extra folds to be carried out
Extra corners to join
The finished product shows more joins
Use the full length clamp bar for all folding.
1. Set up sheet metal as per drawing below
2. Form four folds in the sheet metal as shown on drawing.
3. For folds on side panels, as per drawing, use the narrow flange of the end piece of the
clamp bar
4. Join the box
FLANGED BOXES WITH PLAIN CORNERS
To make plain cornered boxes, the length and width should not exceed the clamp bar width of
98mm. Outside flanges are also used when making top hat sections.
1. Mark up sheet metal as per drawing below.
2. Use the full length clamp bar and fold sections marked 1, 2, 3 & 4.
3. Form fold 5 by inserting the flange under clamp bar follow by folding 6.
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4. Using slotted clamp bar form folds 3, 4, 7 and 8.
FLANGED BOX WITH CORNER TABS
Important Note: Folds must be formed in the correct sequence using one piece of sheet metal. It is
suggested the deep boxes are manufactured with separate end pieces.
1. Mark up sheet metal as be drawing below
2. Form all tab folds to 90deg. marked A at the one end of the full length clamp bar by inserting
the tab under the clamp bar.
3. Use the same end of the clamp bar and fold B to 45deg. by inserting the side of the box
instead of the bottom of the box under the clamp bar.
4. Form the flange fold C to 90deg. at the other end of the clamp bar.
5. Complete folds B to 90deg. By using suitable short clamp bars.
6. Complete the box by joining the corners.
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HOW TO USE A SLOTTED CLAMPBAR
FORMING TRAYS
The slotted clamp bar is perfect for manufacturing shallow trays and pans.
Advantages:
The Bending edges are aligned automatically to the front edge of the magnet body. The clamp bar
automatically lifts to facilitate insertion and removal of the sheet metal whereas with the short set
each section must be lifted individually.
The slotted clamp bar folds shallow trays, however trays of unlimited depth and complex shapes
can be manufactured with a short clamp bar.
The pitch of the slots has been calculated to enable the folding of various sizes of trays.
Specification sheet indicate shortest and longest tray sizes that can be accommodated by the
slotted clamp bar
To fold shallow tray
1. First fold two opposite sides and the corner tabs by using the slotted clamp bar – ignore the
slots they will have no effect on the finished folds.
2. Select two slots to fold the remaining two sides. Line up the left side of the tray with the left
slot and check if there is a slot for the right side. Slide the tray along the left and try the next
slot until a suitable slot is found. The edge of the tray should be under the clamp bar and
between the two chosen slots.
3. To complete, fold the remaining sides.
Note: Trays that are almost as long as the clamp bar may need to use the end of the clamp bar in
lieu of a slot.
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Measuring the slotted clamp bar
Folding a tray note that the folded sides fit into the slots
HOW TO CHECK THE ACCURACY OF YOUR MACHINE
Critical aspects of Electrabrake are that working surfaces of the bending beam, the bending edge
clamp bar are straight and that both of these surfaces are parallel. This can be checked with a
precision straight edge.
How to check using the machine.
Swing bending beam up to 90deg. and hold or lock it in position with a back stop clamp collar at
the back of the angle slide on the handle. Check the gap between the working surface of the
bending beam and the edge of the clamp bar. Set the gap at 1mm on each side by using the clamp
bar adjusters. A feeler gauge or scrap piece of metal can be used.
The gap must be the same along the edge of the clamp bar. Variations can be within +/-0.2mm.
The gap must not exceed 1.2mm and be less than 0.8mm. Should the adjustors not be the same at
each end, they will have to be reset – see Maintenance page 16.
Notes
The straightness of the elevated clamp bar is not important as this is flattened out in magnetic
clamping when in use.
The gap between the magnet body and bending beam is about 2 to 3mm. This does not affect the
bending accuracy.
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Electrabrake produces folds on thinner gauges and non-ferrous metals such as aluminium,
however, check the specification for heavier gauges.
To fill in unused portion under the clamp bar, make use of scrap pieces of sheet metal to create
uniformity of the bends in thicker gauges.
MAINTENANCE
ADJUSTERS
The adjuster screws at the end of the clamp bar control the thickness of the sheet metal between
the bending beam and its edge.
The heads for the screws are divided into 3 by centre pop marks. Use these marks as a reference
for repeat setting of the clamp bar. The bending gap will be approx. 1mm if adjuster screws are
both set so that the single pop mark is uppermost.
Adjuster set to 1mm
HINGE LUBRICATION
Grease all hinges once per month .
Hinge
WORKING SURFACES
Bare working surface may become rusty or tarnished. Recondition by filling off and clean up
surfaces with emery paper. Use an anti-rust spray.
TROUBLE SHOOTING
Prior to ordering a replacement electrical unit from the manufacturer please check the
following:
 If the machine does not operate at all, check the pilot light in the ON/OFF switch.
 If the machine is hot and power is available, leave the machine to cool and try again.
 Do not pull the handle prior to starting – the start button must be pressed first.
 If the bending beam is moved prior pressing the start button begin again and make sure the
handle is pushed fully back.
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