KRB 11 Radius Bender User manual

#11 Radius Bender
#11 Radius Bender
MANUAL

#11 Radius Bender
www.krbmachinery.com
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V1.12.09.21
This owner’s manual is compiled from the latest specifications and product information available at the
time of publication. We reserve the right to make changes as they become necessary. Any changes to
our products may cause slight variations between the illustrations and explanations in this manual and
the product you have purchased.
COPYRIGHT ©2022 KRB MACHINERY

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Table of Contents
Warranty........................................................................................................................................................3
Safety ............................................................................................................................................................ 4
Read And Understand This Manual ..........................................................................................................5
Machine Operation Hazards...................................................................................................................... 6
Machine Installation.......................................................................................................................................7
Locating And Anchoring The Machine....................................................................................................... 7
Electric ...................................................................................................................................................... 8
#11 Radius Bender – Proximity Switch Assembly Instruction ................................................................... 9
Operation..................................................................................................................................................... 10
General Description ................................................................................................................................ 10
Machine Controls .................................................................................................................................... 12
Machine Operation.................................................................................................................................. 13
#11 Radius Bender Minimum Diameters Capacity.................................................................................. 15
Controller Set Up And Operation ................................................................................................................. 16
Homing Instructions ................................................................................................................................ 17
Main Operation Screen ........................................................................................................................... 18
Stored Setup Screen............................................................................................................................... 19
Controller Configuration Screen .............................................................................................................. 20
How To Accomplish Multiple-Radii On A Bar .......................................................................................... 21
Preventive Maintenance And Servicing ....................................................................................................... 22
Electrical Replacement Parts....................................................................................................................... 38
Mechanical Replacement Parts ................................................................................................................... 41
Manual Revisions By Date........................................................................................................................... 55

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WARRANTY
KRB Machinery Corporation (“KRB”) warrants to ____________________________ (“buyer”), for its
#11 Radius Bender, Serial Number ___________________.
The warranty starts from the receipt of goods and is valid for 13 months or 2,000 working hours, whichever
occurs first.
• The warranty only covers the replacement of defective components.
• The original component must be returned to KRB within 30 days of notice to KRB regarding
defective component.
• The warranty does not cover components that are unusable due to normal wear.
• The warranty does not cover components damaged by improper use or lack of maintenance.
• The warranty does not cover electronic components (ie: controls, boards, drives, etc.) on
machinery connected to generators unless machinery is protected at its power source by a power
conditioner.
• KRB DISCLAIMS ALL OTHER WARRANTIES, EXPRESS, IMPLIED, OR STATUTORY AND
SPECIFICALLY DISCLAIMS ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
KRB shall not be liable to the Buyer for any failure to perform any obligations due to causes which are
beyond its reasonable control.
KRB is not responsible, under any circumstances whatsoever, for buyer's lost or anticipated profits,
diminution of goodwill, loss of use, incidental, special, or consequential damages in regard to purchasing
and using KRB equipment.
Contact Information
–
KRB Machinery Co.
1058 Cool Creek Road
Wrightsville, PA USA 17368
717-252-3667
1-800-367-5727

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SAFETY
This operator’s manual is for a #11 Radius Bender.
Read this manual before setup and operating the machine.
The safety information in this manual is denoted by the safety alert symbol: ^
The level of risk is indicated by the following signal words:
DANGER – Indicates a hazardous situation, which, if not avoided, will result in death or
serious injury.
WARNING – Indicates a hazardous situation, which, if not avoided, could result in death or
serious injury.
CAUTION – Indicates a hazardous situation, which, if not avoided, could result in minor or
moderate injury.
NOTICE – Indicates a situation that could result in damage to the machine or other property.
^ DANGER
^ WARNING
^ CAUTION
NOTICE

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Read and Understand This Manual
Carefully read and understand this manual and all safety signs on the machine before operating the
machine. Safety signs must be in good condition and legible at all times. Replace missing or damaged
safety signs.
Never allow anyone to operate this machine without proper instruction, while fatigued or under the influence
of alcohol, prescription or non-prescription medication.
Keep your machine in proper working condition. Modifications to the machine may impair the function
and/or safety and affect the machine life and warranty.
If you do not understand any part of this manual, contact KRB Machinery.
Read All Instructions
1. Read Operators Manual before operating equipment.
2. Do not operate machine unless you are fully qualified, and properly trained.
3. Do not work on machine unless disconnect switch is turned off. Pad lock disconnect switch to avoid
unwanted start-up.
4. All bolts must be tight before machine is operated.
5. Do not operate machine with any guards or covers removed or open.
6. Always wear protective gear when operating machine i.e.: safety glasses, hard hat, steel tip shoes,
gloves, arm sleeves, etc.
7. Do not insert body parts into any part of equipment while it is running, or power is turned on.
8. Do not make any adjustments on equipment while machine is turned on or running.
9. Always stay alert while operating equipment.
10. Do not operate equipment in or around water i.e.: puddles, rain, etc.
11. Only qualified technicians should work on equipment.
12. Make sure all local and state codes are met with your electrical installation.
13. Keep area clean from debris at all times.
14. Equipment must be properly secured to floor.
15. Work stations and unauthorized people should remain a safe distance from the machine at all times.

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Machine Operation Hazards
Pinching or Severing Hazard
Keep hands away from pinch points while operating this machine.
•Pinching hazard.
•The rollers may pinch or sever fingers.
•Keep away from rollers.
Safety Devices
Never override any safety device on this machine. Overriding a safety device may cause the machine to
operate unintentionally and uncontrollable, which may result in injury or death.
•Prevent serious injury or death.
•Never override safety devices on this machine.
Wear Appropriate Clothing
Wear close fitting clothing. Do not wear a neck tie, scarf, jewelry or necklace while operating this machine.
These items may get caught in the machine, resulting in injury or death.
Do Not Touch Bar
Do not touch bar while machine is in operation.
•Pinching and severing hazard.
•Do not touch bar while machine is in operation.
Maintenance
•Improper disposal of waste can harm the environment.
•Use leak proof container when draining fluids. Do not use food or beverage
containers.
Contact your local environmental or recycling center for the proper way to recycle or dispose of waste.
^ WARNING
^ WARNING
^ WARNING
NOTICE

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MACHINE INSTALLATION
Locating and Anchoring the Machine
Approximate Weight:
1. Locate machine on level concrete floor with ample space to radius bars, and for production
storage. A minimum 5”-6” thick concrete floor is adequate to support the machine.
2. The manufacturer recommends bolting the machine to the floor in order to maintain its position.
Usually (4) ½” x 4” long anchor bolts will be adequate.
Anchor Bolt Locations
4,014
lbs. (1,821 kg).

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Electric
3. Be sure all wiring is done by a qualified electrician and conforms to local codes and specification.
Electrical requirements: 460VAC, 3 PHASE, 60HZ, 20 AMPERES
4. Connect the main disconnect (furnished) to the proper power supply (as noted in Part II above).
Before finalizing connections, verify the correct rotation of the drive rolls by setting drive roll
selector switch in forward and pressing the foot pedal. Rotation should be clockwise to feed
material right to left.
^ WARNING

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#11 Radius Bender – Proximity Switch Assembly Instruction
For Use at assembly for field retrofit Revised October 2, 2001
1. Pre-assemble the proximity switch to the mounting bracket. Be careful to locate it in the center of
the elongated slot.
2. Turn the machine on and using the manual control, move the bend roll out to allow for the easy
insertion of an approximate 3 foot length of 1 ½” diameter steel rod.
3. Note: It may be necessary to slightly readjust the forward over-travel micro-switch located on the
right forward side.
4. Place the 1 ½” diameter bar between the two drive rolls and the bend roll. This should be fairly
loose and easy to accomplish. Be sure all areas are clean and free of rust or scale build-up.
5. Carefully, using the manual control, adjust the bend roll in so that it barely touches the 1 ½” bar.
You should be able to turn the bar but not pull it in or out. (Turning the bar at this point proves that
the bar is straight – this is very important.)
6. Locate the pre-assembled bracket and proximity switch along the left side slide guide so that the
center of the switch top is centered on the small ¼” thick tab. Note: It may be necessary to adjust
the switch in or out slightly on the bracket to avoid contacting the tab. The bracket must be
positioned both vertically and horizontally along the slide guide.
7. Clamp the bracket in place.
8. Remove the Proximity switch to avoid damage during the welding.
9. Weld the bracket to the slide guide.
10. Remove the 1 ½” bar.
11. Touch up paint as required.
12. Reassembly the Proximity switch to the bracket.
13. Readjust the right side over-travel micro-switch if necessary.
14. Connect Proximity switch leads.
15. Adjust the location of the proximity switch in the elongated slot. Set it all the way out and slowly
move it in until the yellow led comes on. Tighten the adjusting screw. Don’t move the bend roller at all
from its setting in Step #5.

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OPERATION
The KRB #11 Radius Bender is designed to radius up to 1-#11, 35mm piece of rebar.
General Description
The machine has a 16 station preset counter. This counter can be set up to do multi radii in
one piece of rebar. You can also store up to 16 preprogrammed positions of the “Metering Roll” / Pressure
Roll.This counter will allow you to return the metering roll to an exact position each time. The control
also features a manual in/out switch for positioning the metering roll. The drive rolls are controlled by
selector switch. They can be controlled by a foot switch.There are two e-stops which may
be moved as desired.
The radius bender has 2 driven rolls. The entry drive roll is the roll that allows the operator to start
a radius without pre-bending the bar. The drive roll is a serrated roll providing the second driven roll.
These rolls are chain driven from a gear reducer. The gear reducer is driven by a 5HP brake motor and is
coupled by a flexible coupling.
The metering roll applies pressure against the rebar thus creating the radius desired. The metering
roll moves in/out on the slide assembly. The slide assembly is moved by the worm gear screw jack. The
worm gear screw jack is chain driven by the brake motor.
A
B
C
D
E
F

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B
C
D
E
A
F
F

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Machine Controls
Controller Head Pedestal
Foot Switch
Starter Box Controls
Front of Machine Controls

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Machine Operation
1. Prior to operating the machine make sure all safety guards are in place, and read and understand
all safety instructions in the machine manual.
2. Turn on the main power, handle on the starter box located on the right side of the machine; make
sure the emergency stop (“e-stop”) push buttons are pulled out.
3. Turn the control power on switch to the on position. The controller will come on to the startup
screen. Press the reset button on the front of the starter box located on the right side of the
machine. Press ENT/RET on the control key pad. The measuring bend roll will automatically
home itself.
4. At this point do not start the drive rolls. Slide the bar you want to put a radius on between the drive
rolls and the measuring bend roll. Using the bend roll in/out switch. Run the measuring roll in until
it just touches the bar. This will be the starting point for determining the count needed to bend the
desired radius.
5. Remove the bar. Manually move the measuring bend roll in a few counts. Start the drive rolls and
run the bar through. Bar goes into the right and comes out of the left. Check the radius. If it’s not
correct keep repeating moving the bend roll and running the bar thru until you have the correct
radius.
6. When bending overlapping circles, bar may be manually guided above the guard, or back under
the guard. The guard is attached to a cylinder which allows it to open or close when pushing the
“Guard Open”/”Guard Close” buttons.
Note: If the guard is open, drive rolls will not turn.

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Note: When adjusting counts for incorrect radii on bends:
Tight radius bent parts-
A large change in the number of counts will produce a small
change in radius.
Slight radius bent parts-
A small change in the number of counts will produce a large
change in radius.
7. Bend a fresh bar. The measuring bend roll will probably need some fine adjustments when a new
bar that had no previous radius on it is bent.
8. When you get the correct radius with your fresh bar. Note: the count value is POS. This is the
count you want to save to memory for that bar size and radius.

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#11 Radius Bender Minimum Diameters Capacity
Capacity (Hard Grade)
DO NOT EXCEED MAXIMUM CAPACITY
Single Bar
Imperial Bar Size Grade 60
Bar 3 4 5 6 7 8 9 10 11
Min Dia 1’-3” 1’-4” 1’-6” 1’-9” 1’-11” 3’-6” 6’-8” 12’-10” 28’-0”
Soft Metric Bar Size Grade 60
Bar 10 13 16 19 22 25 29 32 36
Min Dia mm 380 400 460 530 580 1060 2030 3900 8500mm
Hard Metric Bar Size Grade 60
Bar 10 15 20 25 30 35
Min Dia mm 380 460 530 1060 2030 8500mm
Metric Bar Size 413 mpa
Bar 10 12 16 19 22 25 29 32 35
Min Dia mm 380 400 460 530 580 1060 2030 3900 8500mm
Multiple Bar
Imperial Bar Size Grade 60
Bar 3 4 5 6 7
Qty 4 4 3 2 2
Min Dia 2’-0” 2’-5” 2’-9” 2’-7” 3’-8”
Soft Metric Bar Size Grade 60
Bar 10 13 16 19 22
Qty 4 4 3 2 2
Min Dia mm 600 740 840 790 1120mm
Hard Metric Bar Size Grade 60
Bar 10 15 20 25
Qty 4 3 2 2
Min Dia mm 600 840 790 1120mm
Metric Bar Size 413 mpa
Bar 10 12 16 19 22
Qty 4 4 3 2 2
Min Dia mm 600 740 840 790 1120mm
Quality and hardness of bar will cause variation of minimum bar diameters.

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CONTROLLER SET UP AND OPERATION
THERE ARE (2) METHODS TO AUTOMATICALLY POSITION THE MEASURING ROLL.
1. From the main operation screen, select a preset 1 thru 6 by pressing the ↑or ↓arrow. (The flashing _and
the →indicate the selected preset) Type in a count. When you press the “ENT/RET” key the count will load
into REF. and the measuring bend roll will move from POS 000 (Home) to the new location called for by the
count you loaded into REF.
See machine operation for instruction on determining counts.
2. On the main operation screen select a preset 1 thru 6 by pressing the ↑or ↓arrow. (The flashing _and the
→indicate the selected preset), This will be the preset that the stored setup will be loaded into. Now press
F4. This will bring up the stored setup screen.
a. To Prove Out a Setup:
By using the method set out in #1 above, test bend bar and keep adjusting the count
+ or – and re-run a new bar until you get the desired radius. Store this proven setup.
b. To Retrieve a Stored Setup:
From the stored setup screen, Press F4 or F3 to select a bar size. Now select the desired stored setup
by pressing F2 or F3 to change pages and then the ↑or ↓arrow to select the number. Press the
“ENT/RET” key and that setup will load into the main screen preset you previously selected. Press
“ENT/RET” again to load the count to REF and to move the measuring roll into position.
You will notice that there are some setups already in from the factory.
Note: Due to the wide variances in the tensile strength of manufactured rebar, it is likely that these
predetermined counts for a given radius will not produce the desired part. You should alter the factory presets to
more accurately represent the proper count for your rebar.
c. To Store a Proven Setup:
From the stored setup screen. Press F4 or F3 to select a bar size. Now select the desired number you
want to store a setup in. Press F2 or F3 to change pages and then the ↑or ↓arrow to select the
desired number. Type in the radius. Example: 02-04 would be a 2 foot 4inch radius. Press the TAB key
to be able to enter the count number. Type in your desired count.
Helpful Hints:
1. Prior to moving on to a new job or before the control is turned off, store your proven setup.
2. Clear factory setups. This will eliminate getting your proven setups mixed up with the factory setups that may
or may not produce good parts.
3. Store your smallest radiuses in the lowest numbered setup numbers. This will aid in more easily finding
stored setups.
•To clear all setups, hold in the ESC and 0 keys while you power on the control.
•To reset all setups to factory settings, hold in the ESC and ENT keys while you power on the control.

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Start-Up Screen
Homing Instructions
Every time the control power is turned on, this screen comes up. Have the auto/manual switch in “AUTO”
and press the “RESET” button on the front of the starter box that is located on the right side of the machine.
Press “ENT” on the keypad and the measuring bend roll will automatically home itself. The main operation
screen will then appear. When the bend roll is at home position the readout POS on the main screen
should be 000 counts within a few numbers
KRB Machinery Company
WARNING
UNIT MUST BE HOMED PRIOR TO USE
PRESS <ENT>KEY TO HOME
1058 Cool Creek Rd.
Wrightsville, PA 17368
Ver. 09. 25. 01

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Main Operation Screen
*Press ESC from any screen to return to the Main Operation screen.*
1. Preset number 1 to 6 or it is the set bar size and radius in feet and inches or when set to metric
the read out is in meters and .00 meters (centimeters).
Example: 7 (# 7 Bar)
02 – 04 ( #7 bar with a 2 foot 4 inch radius)
or when set up for Metric
22 (22 millimeter Bar)
00.71 (71 centimeter radius or a .71 Meter radius)
2. Count. This is the value that the control will use to position the measuring roll to achieve a given
radius.
3. REF. This is the count value being used to position the measure roll.
4. POS. This is the actual position of the measuring roll. This should read 000 within a few numbers
when the measuring roll is at its home position. When the measuring bend roll is positioning this
number will be changing. This fact indicates that the signals from the pulse coder are reaching the
controller.
5. Set F4. Press F4 to view or retrieve radius setups stored in the memory on the stored setup
screens.
6. CFG F1. Press F1 to go to Controller Configuration screen.
KRB Radius Bender
275
→
REF
2 000 275
3 000
4 000 POS
5 000 000
6 000
<ENT>TO POSITION
[inch]POSITIONING
SET
F4 →
7
02
-04
CFG
F1 →
2
3
4
1
5
6

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Stored Setup Screen
*Press ESC to return to Main Operation screen.*
1. There are 32 possible memory locations to store setups for each bar size #3 bar to #11 bar or
when set for Metric 10mm bar to 36mm bar. Press F1 or F2 to select the different pages.
2. Radius (I) 00-00 this is the radius in feet and inches. (2 feet 4 inches: 02-04)
Or when set to Metric
00.00 this is the radius in meters and .00 meters. (1 meter 12 centimeters: 01.12)
3. Count is what will be entered on the Main Screen to position the measuring roll. The number in
counts does not directly represent any particular measurement.
4. F4 + Bar F3 -. Press F4 or F3 to access stored radius setups for different bar sizes.
5. F2 + PAG F1 - . Press F2 or F1 to change the page to get to all 32 memory locations of each
bar size.
BAR 7
RADIUS <I>COUNT
1 00-00 000
2 →02-04 275
3 00-00 000
4 00-00 000
5 03-01 250
6 00-00 000
7 04-01 220
8 00-00 000
F4 +
→
BAR
F3 -
F2 +
→
PAG
1
5
4
2
3