MAGNABEND 650E User manual

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ELECTROMAGNETIC SHEETMETAL FOLDERS
MAGNABEND - USER MANUAL
for
MODELS 650E, 1000E & 1250E
Contents Page
INTRODUCTION ...............................................................................3
ASSEMBLY ........................................................................................4
SPECIFICATIONS ..............................................................................6
INSPECTION SHEET .......................................................................10
USING THE MAGNABEND:
BASIC OPERATION ..................................................................12
POWER SHEAR ACCESSORY .................................................13
FOLDED LIP (HEM) ..................................................................14
ROLLED EDGE ..........................................................................15
MAKING A TEST PIECE...........................................................16
BOXES (SHORT CLAMPBARS)...............................................18
TRAYS (SLOTTED CLAMPBAR) ............................................21
TOP-HAT PROFILES .................................................................22
MAKING VERY CLOSE REVERSE BENDS ..........................25
USING BACKSTOPS .................................................................26
ACCURACY .....................................................................................27
MAINTENANCE ..............................................................................28
TROUBLE SHOOTING....................................................................29
CIRCUIT DIAGRAMS .....................................................................31
WARRANTY ....................................................................................32
WARRANTY REGISTRATION.......................................................33
MAGNETIC ENGINEERING P/L
KINGSTON, TASMANIA
14/07/2019

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The Magnabend sheet met a l ben d ing ma ch ine is a high ly ver sa tile
and easy to use machine for bending all types of sheetmetal such as
aluminium, copper, steel, and stainless steel.
The electromagnetic clamping system p r ovid es mor e fr eed om to
form the workpiece into complex shapes. It is easy to form very deep
narrow channels, closed sections, and deep boxes that are difficult or
impossible on a conventional machine.
The unique hinging system u sed for t he ben d ing bea m p r ovid es a
completely open-ended machine thus greatly extending its versatility.
The single column stand design also contributes to the versatility of
the machine by providing a "free-arm" effect at the ends of the ma-
chine.
Ease of use flows fr om t he finger t ip cont r ol of t h e cla mping a n d
unclamping, the ease and accuracy of bend alignment, and the auto-
matic adjustment for sheetmetal thickness.
A two-handed interlock p r ovides sa fet y for t h e op er at or .
Fundamentally t he u se of ma gn et ic cla mp in g mea n s t h a t b end ing
loads are taken right at the point where they are generated; forces do
not have to be transferred to support structures at the ends of the ma-
chine. This in turn means that the clamping member does not need
any structural bulk and hence can be made much more compact and
less hindering. (The thickness of the clampbar is determined only by
its requirement to carry sufficient magnetic flux and not by structural
considerations at all).
Special centerless compound hinges have been d eveloped especial-
ly for the Magnabend, and are distributed along the length of the
bending beam and thus, like the clampbar, take bending loads close to
where they are generated.
The combined effect of the magnetic clamping with the special cen-
terless hinges means that the Magnabend is a very compact, space
saving, machine with a very high strength-to-weight ratio.
To get the most out of your machine, p lea se r ead t h is ma n ual,
particularly the section titled USING THE MAGNABEND.
Please also return the WARRANTY REGISTRATION as this will
simplify any claims under warranty and also it gives the manufacturer
a record of your address which facilitates keeping customers informed
of any developments which may benefit them.
MAGNABEND - INTRODUCTION

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ASSEMBLY ...
ASSEMBLY INSTRUCTIONS
1. Unpack the column and the feet and locate the packet of fasteners
and the 6 mm Allen key.
2. Attach the feet to the column. The pair of feet with the black and
yellow safety tape should point forwards from the column. (The
front face of the column is the side without a join in it.)
Use M10 x 16 button head screws to attach the feet.
3. Models 650E and 1000E: Attach the footplate under the tips of the
front feet. Use two M10 x 16 cap-head screws with washers.
Alignment of the screw holes will be made easier if the foot
mounting screws are left loose until after the footplate is fitted.
The M8 x 20 cap-head screws in the rear feet may be adjusted to
level the machine and suit any unevenness in the floor.
Model 1250E: A footplate is not supplied with this machine; it
must be bolted to the floor at the front feet.
4. With the aid of an assistant carefully place the Magnabend ma-
chine on the stand and secure it with M8 x 16 cap -head screws.
Models 650E & 1000E: Be sure to guide the wires and connector
down into the column as the machine is being lowered onto the
stand.
5. Models 650E & 1000E: Remove the rear electrical access panel
and plug-together the 3-pin connector. This connects the electro-
magnet in the body of the machine to the electrical unit in the col-
umn. Replace the panel.
Model 1250E: Fasten the mains-cable clip to the back of the col-
umn with an M6 x 10 pan-head screw.
6. Model 650E: Join the two halves of the tray using M6 pan -head
screws and nuts. Attach the tray (with rubber mat) to the rear of
the machine using two M8 x 12 cap -head screws. Fit two backstop
slides to the sides of the tray.
Models 1000E and 1250E: Attach the two backstop bars into the
back of the machine using two M8 x 16 screws for each bar. At-
tach the tray (with rubber mat) to the rear of the machine using
three M8 x 16 cap-head screws. Fit a stop collar onto each back-
stop bar.
7. Attach the handle(s) with M8 x 16 cap -head screws.
Models 650E and 1000E: The handle should be slipped down
through the angle indicating ring before attaching the handle.
Model 1250E: The handle with the angle scale must be fitted on
the left side, and a stop collar slipped onto it and clamped up near
the top of the handle.

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... ASSEMBLY
8. Model 1250E: Swing the bending beam up through 180°. Unpack
the angle indicator assembly and pass the Indicator Slide over the
left handle. Unscrew the two M8 cap -head screws from the indica-
tor anchor-block which is fastened to the base of the machine near
the left handle. Attach the Indicator Arms to the anchor -block and
tighten both M8 cap-head screws by hand and then, using the 6
mm Allen key, tighten both screws very firmly.
Note: The machine may not turn ON if these screws are not tight.
9. Using a chlorinated solvent (or petrol) clean off the clear wax -like
coating from the working surfaces of the machine.
10.Place the short clamp bars in the tray and the full-length clamp bar
on top of the machine with its locating balls sitting in the grooves
in the top surface of the machine.
11.Plug into a power outlet and turn ON the main switch. The ma-
chine is now ready for operation - please refer to "BASIC OPER-
ATION" in this manual.
Backstop Bar Tray
Angle Indicator
Stop Collar Handle
Column
Foot

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NOMINAL CAPACITY Machine Weight
Model 650E: 625 mm x 1.6 mm (2ft x 16g) 72 kg
Model 1000E: 1000 mm x 1.6 mm (3ft x 16g) 110 kg
Model 1250E: 1250 mm x 1.6 mm (4ft x 16g) 150 kg
CLAMPING FORCE
Total force with standard full-length clamp-bar (and zero non-magnetic gap
under the clampbar):
Model 650E: 3 Tonne
Model 1000E: 4.5 Tonne
Model 1250E: 6 Tonne
ELECTRICAL
1 Phase, 220/240 V AC
Current:
Model 650E: 4 Amp
Model 1000E: 6 Amp
Model 1250E: 8 Amp
Duty Cycle: 30%
Protection: Thermal cut-out, 70°C
Control: Start button ...pre-clamping force
Bending beam microswitch...full clamping
Interlock...the start button and the bending beam must be oper-
ated in correct overlapping sequence to initiate full -clamping force.
HINGES
Special centerless design to provide a completely open -ended machine.
Rotation angle: 180°
BENDING DIMENSIONS
SPECIFICATIONS ...
Refer to Chart
16mm (min)
98mm (min) Standard Clampbar
49mm (min) Narrow Clampbar
16mm (min)
16mm (min)
Unlimited

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BENDING CAPABILITY
(When using a standard full-length clamp-bar to bend a full-length work-
piece)
* With extension bar fitted to bending beam.
SHORT CLAMP-BAR SET
Lengths: Model 650E: 25, 38, 52, 70, 140, 280 mm
Models 1000E & 1250E: 25, 38, 52, 70, 140, 280, 597 mm
All sizes (except 597 mm) may be plugged together to form a bending edge
within 25 mm of any desired length up to 575 mm.
SLOTTED CLAMPBAR
When supplied, a special set of 8 mm wide slots provide for forming all tray
sizes in the range shown below:
* For deeper trays use the Short Clamp-bar set.
... SPECIFICATIONS ...
MODEL TRAY LENGTHS MAX. TRAY DEPTH
650E 15 to 635 mm 40 mm*
1000E 15 to 1015 mm 40 mm*
1250E 15 to 1265 mm 40 mm*
MATERIAL THICKNESS LIP WIDTH BEND RADIUS
(yield/ultimate) (minimum) (typical)
Mild-steel 1.6 mm 30 mm* 3.5 mm
(250/320 MPa) 1.2 mm 15 mm 2.2 mm
1.0 mm 10 mm 1.5 mm
Aluminium 1.6 mm 30 mm* 1.8 mm
Grade 5005 H34 1.2 mm 15 mm 1.2 mm
(140/160 MPa) 1.0 mm 10 mm 1.0 mm
Stainless Steel 1.0 mm 30 mm* 3.5 mm
Grades 304, 316 0.9 mm 15 mm 3.0 mm
(210/600 MPa) 0.8 mm 10 mm 1.8 mm

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... SPECIFICATIONS ...
CROSS-SECTION DETAIL (mm)
FRONT & SIDE ELEVATIONS (mm)
MODELS 650E / 1000E

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... SPECIFICATIONS
FRONT & SIDE ELEVATIONS (mm)
CROSS-SECTION DETAIL (mm)
MODEL 1250E

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INSPECTION SHEET ...
SERIAL NO. DATE
EARTHING CONNECTIONS
Measure resistance from mains plug earth pin to magnet body .... ohm
ELECTRICAL ISOLATION
Megger from coil to magnet body .............................................
MIN/MAX SUPPLY VOLTAGE TESTS
At 260v: Pre-clamp.... full-clamp.... release .............................
At 200v: Pre-clamp.... release .................................................
Pre-clamp.... full-clamp.... release .............................
INTERLOCK SEQUENCE
With power on, pull HANDLE, then press START button.
Check that machine does NOT activate ....................................
ANGLE SCALE
Reading at edge of Indicator when bending beam is set
to 90° with an engineer's square. (min 89° , max 91° ) .............. deg
MAGNET BODY
Straightness of top surface, along front pole
(max deviation = 0.5 mm) .................................... mm
Flatness of top surface, across the poles
(max deviation = 0.1 mm) .................................... mm
TURN-ON/OFF ANGLES
Movement of Bending Beam to activate full-clamping,
measured at bottom of bending beam. (4 mm to 6 mm).............. mm
Reverse motion to switch-off machine. Measure back
from 90°. (Should be within the range 15° + 5° ) ...................... deg
BENDING BEAM
Straightness of working surface (max deviation =0.25 mm) ........ mm
Alignment of extension bar (max deviation = 0.25 mm) ............. mm
[Note: T est str aigh tness wit h pr ecision st r aight -edge.]
MODEL

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... INSPECTION SHEET
MAIN CLAMPBAR
Straightness of bending-edge (max deviation = 0.25 mm) ........... mm
Height of lift (with lifting balls in grooves) (min 3 mm) ............ mm
Can lifting balls be compressed flush with surface? ....................
With adjusters set at "1" and the bending beam at 90°
is the bending-edge parallel to, and 1 mm from, the beam? .........
With the bending beam at 90°, can the clampbar be adjusted
forward to touch and rearward by 2 mm? ...................................
BENDING TEST
(A maximum specification bend to 90°, at minimum supply voltage.)
Steel test piece thickness .......... mm, Bend length ........... mm
Width of lip ............................. mm, Bend radius ........... mm
Uniformity of bend angle (maximum deviation = 2°) .................. deg
LABELS
Check for clarity, adhesion to machine and proper alignment.
Nameplate & Serial No............. Clampbar Warning .......
Electrical warnings .................. Switch labelling ...........
Safety tape on front legs ...........
FINISH
Check cleanliness, freedom from rust, blemishes etc. .................
HINGES
Check for lubrication on shafts . and sector blocks..........
Check that hinges rotate through 180° freely and smoothly .........
Check hinge pins do not rotate .. and are loctited ............
Have the retaining screw nuts been locked? ...............................
SIGNATURES
Assembled & Tested .
Q. A. Inspection .......

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WARNING
The Magnabend sheetmetal folder can exert a total clamping force of
several tonnes (see SPECIFICATIONS). It is equipped with a two -
handed interlock to help ensure that fingers cannot be inadvertently
caught under the clampbar when electro -magnetic clamping is ap-
plied.
However, it is most important that only one operator use the machine
at a time. I t is p ot ent ia lly danger ou s for on e per son to in ser t t he
workpiece and handle the clampbars while another person operates
the switches !
NORMAL BENDING
Ensure power is ON at the power outlet and the full-length clampbar is posi-
tioned on the machine with its lifting balls resting in the locating grooves at
each end.
1. Adjust for workpiece thickness by r ot at in g t h e eccen t r ic a dj uster s at
either end of the clampbar. Lift the bending beam up to the 90° position
and check that it is parallel to the edge of the clampbar - if necessary re-
adjust the eccentric lifters.
(For optimum results the gap between the clampbar edge and the surface
of the bending beam should be set to slightly greater than the metal thick-
ness to be bent.)
2. Insert the workpiece t h en t ilt t h e fr ont ed ge of t h e cla mp ba r down
and align the bend line to the bending edge.
3. Press and hold the START button. T his a p plies p r e-clamping.
4. With the other hand pull on the handle. F u ll cla mping is n ow a ut o-
matically applied and the START button should now be released.
Continue bending until the required angle is reached.
5. The bending beam may be reversed about 10° to 15° to take pressure off
the workpiece for checking the bend angle. Reversing by more than 15°
automatically turns the machine off and releases the workpiece.
CAUTION
 To avoid the risk of damaging the bending edge of the clampbar or of
denting the top surface of the magnet body, do not put small objects under
the clampbar. The r ecom m en ded minimu m bend len gt h u sin g t h e
standard clampbar is 15 mm, except when the workpiece is very thin or
soft.
 The clamping force of the magnet is less when it is hot. Therefore to get
the best performance apply clamping for no longer than is necessary to do
the bend.
BASIC OPERATION

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INSTRUCTIONS FOR USE
The power shear (based on the Makita Model JS 1660) provides a
means for cutting sheetmetal in such a way that very little distortion
is left in the workpiece. This is possible because the shear removes a
waste strip, about 4 mm wide, and most of the distortion inherent in
shearing sheetmetal goes into this waste strip. For use with a
Magnabend the shear has been fitted with a special magnetic guide.
The shear works well in combination with a Magnabend Sheetmetal
Folder; the Magnabend provides both a means of holding the
workpiece fixed while being cut and also a means for guiding the tool
so that very straight cutting is possible. Cuts of any length can be
handled in steel up to 1.6 mm thick or aluminium up to 2 mm thick.
To use the tool first place the sheetmetal workpiece under the
clampbar of the Magnabend and position it so that the cutting line is
exactly 1 mm in front of the edge of the Bending Beam.
A toggle switch labelled “NORMAL / AUX CLAMP” will be found
next to the main ON/OFF switch. Switch this to the AUX CLAMP
position to hold the workpiece firmly in position.
Position the shear at the right-hand end of the Magnabend and ensure
that the magnetic guide attachment engages on the front edge of the
Bending Beam. Start the power shear and then push it evenly along
until the cut is completed.
Notes:
1. For optimum performance the blade clearance should be adjusted
to suit the thickness of material to be cut. Please read the Makita
instructions supplied with the JS1660 shear.
2. If the Shear does not cut freely check that the blades are sharp.
POWER SHEAR (Optional accessory)
MAKITA POWER SHEAR
IN ACTION
Note that the waste strip
curls out in a continuous
spiral leaving your
workpiece distortion-free.

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FOLDING A LIP (HEM)
The technique used for folding lips depends on the workpiece thick-
ness and to some extent, on its length and breadth.
Thin Workpieces (up to 0.8 mm)
1. Proceed as for normal bending but continue the bend as far as pos-
sible (135°).
2. Remove the clampbar and leave the workpiece on the machine but
move it rearwards about 10 mm. Now swing the bending beam
over to compress the lip. (Clamping need not be applied). [Note:
Do not attempt to form narrow lips on thick workpieces].
3. With thin workpieces, and/or where the lip is not too narrow, a
more complete flattening can be achieved by following with mag-
netic clamping only:
FOLDED LIP

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FORMING A ROLLED EDGE
Rolled edges are formed by wrapping the workpiece around a round
steel bar or piece of thick-walled pipe.
1. Position the workpiece, clampbar and rolling bar as shown.
a) Ensure that the clampbar does not overlap the front pole of the
machine at “a” as this would allow magnetic flux to bypass the
rolling bar and hence clamping would be very weak.
b) Make sure the rolling bar is resting on the steel front pole of
the machine (“b”) and not further back on the aluminium part
of the surface.
c) The purpose of the clampbar is to provide a magnetic pathway
(“c”) into the rolling bar.
2. Wrap the workpiece as far as possible then re -position as shown.
3. Repeat step 2 as required.
ROLLED EDGE

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INSTRUCTIONS FOR FORMING TEST PIECE
In order to gain familiarity with your machine and the type of opera-
tions that can be performed with it, it is recommended that a test -
piece be formed as described below:
1. Select a piece of 0.8 mm thick mild steel or aluminium sheet and
cut it to 335 x 200 mm.
2. Mark lines on the sheet as shown below:
3. Align Bend 1 and form a lip on the edge of the workpiece. (See
"FOLDED LIP")
4. Turn the test piece over and slide it under the clampbar, leaving
the folded edge towards you. Tilt the clampbar forward and line
up Bend 2. Make this bend to 90°. The test piece should now
look like this:
TEST PIECE ...
PAGE16B.DOC 30/03/98
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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5. Turn test piece over and make Bend 3, Bend 4 and Bend 5 each to
90°
6. To complete the shape, the remaining piece is to be rolled around a
25mm diameter round bar of steel.
 Select the 280 mm clamp-bar and place it, the test piece and the
round bar on the machine as shown under “ROLLED EDGE”
earlier in this manual.
 Hold the round bar in position with the right hand and apply
pre-clamping by pressing and holding the START button with
the left hand.
Now use your right hand to pull the handle as if doing an
ordinary bend (the START button may be released). Wrap the
workpiece as far as possible (about 90°). Reposition the
workpiece (as shown under “Forming a Rolled Edge”) and wrap
again. Continue until the roll is closed.
The test shape is now complete.
... TEST PIECE

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MAKING BOXES (USING SHORT CLAMPBARS)
There are numerous ways of laying-out boxes and numerous ways of folding
them up. The MAGNABEND is ideally suited to forming boxes, especially
complex ones, because of the versatility of using short clampbars to form
folds relatively unhindered by previous folds.
Plain Boxes
1. Make the first two bends using the long clampbar as for normal bending.
2. Select one or more of the shorter clampbars and position as shown. (It is
not necessary to make up the exact length as the bend will carry over gaps
of at least 20 mm between the clampbars.)
For bends up to 70 mm long, just select the largest clamp piece that will fit.
For longer lengths it may be necessary to use several clamp pieces. Just se-
lect the longest clampbar that will fit in, then the longest that will fit in the
remaining gap, and possibly a third one, thus making up the required length.
For repetitive bending the clamp pieces may be plugged together to make a
single unit with the required length. Alternatively, if the boxes have shallow
sides and you have available a slotted clampbar, then it may be quicker to
make the boxes in the same manner as shallow trays. (See next section:
TRAYS)
Lipped boxes
Lipped boxes can be made using the standard set of short clampbars provided
one of the dimensions is greater than the width of the clampbar (98 mm).
1. Using the full-length clampbar, form the length wise folds 1, 2, 3, &4.
2. Select a short clampbar (or possibly two or three plugged together) with a
length at least a lip-width shorter than the width of the box (so that it may
later be removed). Form folds 5, 6, 7 & 8. While forming the folds 6 &
7, be careful to guide the corner tabs either inside or outside the sides of
the box, as desired.
BOXES ...

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Boxes with separate ends
A box made with separate ends has several advantages:
- it saves material if the box has deep sides,
- it does not require corner notching,
- all cutting-out can be done with a guillotine,
- all folding can be done with a plain full-length clampbar;
and some drawbacks:
- more folds must be formed,
- more corners must be joined, and
- more metal edges and fasteners show on the finished box.
Making this kind of box is straight forward and the full -length clampbar can
be used for all folds.
1. Prepare the blanks as shown below.
2. First form the four folds in the main workpiece.
3. Next, form the 4 flanges on each end piece. For each of these folds, insert
the narrow flange of the end piece under the clampbar.
4. Join the box together.
Flanged boxes with plain corners
Plain cornered boxes with outside flanges are easy to make if the length and
width are greater than the clampbar width of 98 mm. Forming boxes with
outside flanges is related to making TOP-HAT SECTIONS (described in a
later section - see Contents).
4. Prepare the blank.
5. Using the full-length clampbar, form folds 1, 2, 3 & 4.
6. Insert the flange under the clampbar to form fold 5, and then fold 6.
7. Using appropriate short clampbars, complete folds 7 & 8.
... BOXES ...

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Flanged Box with Corner Tabs
When making an outside flanged box with corner tabs and without
using separate end pieces, it is important to form the folds in the
correct sequence.
1. Prepare the blank with corner tabs arranged as shown.
2. At one end of the full-length clampbar, form all tab folds "A" to
90. It is best to do this by inserting the tab under the clampbar.
3. At the same end of the full-length clampbar, form folds "B" to 45°
only. Do this by inserting the side of the box, rather than the
bottom of the box, under the clampbar.
4. At the other end of the full -length clampbar, form the flange folds
"C" to 90°.
5. Using appropriate short clampbars, complete folds "B" to 90.
6. Join the corners.
Remember that for deep boxes it may be better to make the box with
separate end pieces.
... BOXES