MetalMaster PB-440T User manual

EDITION NO :
PB-REV1
SECTION :
DATE OF ISSUE :
SEPTEMBER 2015
PAGE :
1
USER MANUAL
HYDRAULIC PANBRAKE
Machine Types: PB-440/T
PB-825A
PB-830A/T
PB-1030T
PB-860T

1
OPERATING MANUAL
QUALITY CERTIFICATE
is Metalmaster machine is in conformity with the norms, machine directive (89/392/
CE,91/368 EEC)
HYDRAULIC PANBRAKE
MACHINE
MODEL NO.
SERIAL NO.
DATE OF MANF.
Note: is manual is only for your reference. Owing to the continuous
improvement of the machine, changes may be made at any time
without obligation or notice. Please note the local voltage while
operating this electric machine.
Date 2016-04-22
Distributed by
www.machineryhouse.co.nz

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OPERATING MANUAL
MACHINE TYPE DESCRIPTION
Standard Supply
Voltage
Controller Backside
Safety
Backgauge
Adjustment
Hydraulic
Block
Accessories
PB CE 415V 1-NC89
2-NC Easy
Touch
NA Manual Jinhai
NOTE:
In order to see the type and model of the machine, please see the specication
plate. Usually found on the back of the machine. See example (Fig.1)
Fig.1

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OPERATING MANUAL
C O N T E N T S:
1. GENERAL MACHINE INFORMATION
1.1. Specications...............................................................4
1.2. Standard Equipment...................................................4
1.3. Overall Drawings........................................................5
2. IMPORTANT INFORMATION
2.1 Safety Requirements....................................................6
2.2 Liing Instructions......................................................8
3. INSTALLATION
3.1 Base Foundation and Securing Points.......................9
3.2 Machine Leveling........................................................10
3.3 Checking the Power Supply.......................................10
4. MACHINE SETUP
4.1 Setting e Clamp Gap...............................................11
5. MAINTENANCE AND INSPECTION
5.1 Type and frequency of Inspections...........................12
5.2 Lubrication Points.......................................................13
5.3 Changing Oil...............................................................14
5.4 Changing e Filter....................................................15
5.5 Troubleshooting..........................................................16
5.6 Storage..........................................................................17
6. MACHINE OPERATION
6.1 Start Up.........................................................................17
6.2 Bending.........................................................................17
APPENDIX
A. Spare Parts List.............................................................18
B. Hydraulic Circuit Diagram.........................................20
C. NC89 Electric Circuit Diagram.................................21
D. Ezy Touch Controller Electric Circuit Diagram......21
E. Electrical Parts.............................................................23
G. Modication For Loss Of Clamping Pressure.........24
H. NC89 Controller..........................................................25
Risk Assessment Sheets...................................................30

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OPERATING MANUAL
is METALMASTER Panbrake machine has been designed to operate safely and correctly
e machine must NOT be operated before reading this User‘s Manual. Operate the machine only
if it is in a perfect condition and in accordance with the work regulations of your factory and oper-
ating instructions of this manual.
1.1 Specications
1. GENERAL MACHINE INFORMATION
Machine Type PB-440A/T PB-825A/T PB-830A/T PB-1030T
Bending Length (mm) 1300 2500 2500 3050
Material Capacity Mild Steel (mm) 4 2.5 4 3.2
Stainless Steel (mm) 2 1.2 2 1.6
Bending Angle Indicator (deg) 0-120 0-120 0-120 0-120
Box Depth Of Fingers (mm) 230 215 205 205
Opening Height (mm) 140 140 140 140
Weight (kgs) 1250 1740 2900 3730
System Pressure (Mpa) 5 5 5 5
Pan Movement (mm/sec) 5 5 5 5
Clamp Movement (mm.sec) 10 10 10 10
Oil Tank Volume (ltr) 80 80 100 100
Back Gauge Range (mm) 1000 1000 1000 1000
Main Motor 3Ph 415v 50Hz 3.75 3.75 5.5 5.5
1.2. Standard Equipment
q Electric motor: 415V 3phase
q Top nger segments
q Back-gauge assembly
q Side guarding
q Oil tank level indicator
q Foot switch and control panel
e above specications were current at the time this manual was published, but because of our policy of
continuous improvement, Metalmaster reserves the right to change specications at any time and without
prior notice, without incurring obligations.

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OPERATING MANUAL
1.3 Overall Drawings

6
OPERATING MANUAL
SAFETY CHECKS BEFORE OPERATING
qLocate and ensure you are familiar with all machine operations and controls.
q Take notice of any warning labels on the machine and do not remove them.
qEnsure all guards are tted, secure and functional.
qEnsure working parts are well lubricated and the jaws and ngers free of rust and dirt.
qCheck workspaces and walkways to ensure no slip/trip hazards are present
qBe aware of other people in the area. Ensure the area is clear before using equipment.
SAFETY CHECKS WHEN OPERATING
q Operate the machine only if all protective devices and guarding are mounted and eective.
qRemove the pan brake ngers that are in the way. Use only the pan brake ngers required to
make the bend.
q Check that the material to be bent is the correct thickness.
qEnsure the pan brake ngers that are not removed for an operation are securely seated and
rmly tightened before the machine is used.
qEnsure your ngers and limbs are clear before operating the pan brake.
qLower nger clamps to work. Do not drop.
qCheck workpiece is secure.
qKeep clear of moving counterweight (where tted).
POTENTIAL HAZARDS AND INJURIES
qSharp edges and burrs.
qSquash/crush and pinch points.
qImpact from counterweight.
2.1 SAFETY REQUIREMENTS
Safety glasses must be worn at
all times in work areas. Earmus
should be worn if the work area is
noisy.
Sturdy footwear must be worn at
all times in work areas.
Gloves must be worn when han-
dling the material..
Long and loose hair must be con-
tained with a net or under a hat
2. IMPORTANT INFORMATION
e purpose of the safety section of this manual is to inform operators and maintenance
personnel of the precautions to be taken while operating or servicing the machine.
e following are a few basic guidelines to follow, but as with any type of machinery good judg-
ment and a safe attitude should be applied at all times.

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OPERATING MANUAL
DO NOT
qDo not use faulty equipment. Immediately report suspect machinery.
qDo not use a panbrake for bending metal that is beyond its capacity for thickness, or type.
qDo not attempt to bend rod, wire, strap or spring steel sheets.
q Do not remove the guards in front of the machine under any circumstances while the
machine is in an operational mode.
q Do not operate the machine without proper material adjustment according to sheet thickness.
q Do not bend material which has been welded or deformed.
q Do not use clamp ngers which are excessively damaged.
2.1 SAFETY REQUIREMENTS
q Use the right tool for the job
q Identify possible pinch point hazards in your work area
q Concentrate on objects that move or are capable of moving.
q Ask yourself, “What will happen if this moves? Will I be in
the path of that movement?”
qBe aware of pinch points created by objects that move and
come into direct or close contact with xed objects
q Be on guard whenever you put your hands, ngers, toes, or
feet “between” anything.
qDiscuss and point out pinch point hazards as part of your
risk assessment.
q Make sure your hands are placed where you can see them
PINCH POINT SAFETY WARNING
Machinery can pose a hazard with moving parts, conveyors, rollers and rotating shas. Never reach
into a moving machine. e machine must always be properly maintained. Always use the machine
tool guards provided with your equipment. ey act as a barrier between the moving parts and your
body.
In order to prevent accidents involving pinch points, the points listed below must be followed when
using machinery
WHEN MAINTAINING THE MACHINE
q Shut o the machine completely before any repair work is carried out.
q Disconnect and tag the power supply if not required while doing maintenance
q e machine is to be serviced and/or be repaired only by the authorized personnel

8
OPERATING MANUAL
2.2 LIFTING INSTRUCTIONS
On the day that the machine arrives, make sure that a crane with sucient capacity is available to
unload the Panbrake from the vehicle. Make sure access to the chosen site is clear and that doors
and ceilings are suciently high and wide enough to receive the machine.
To handle the Panbrake, use only the four sling holes located on the top of the end plates. (Fig. 2.3)
e slings should be positioned so the machine is level when lied.
When using slings please take note of the sling angle and the loads that apply
When the slings are at a 45° angle then each sling will carry
the equivalent of 50% of load weight. (Fig.2.1).
When the slings are at a 90° angle then each sling will carry
the equivalent of 75% of the load weight on each sling.
(Fig 2.2)
Note! Metalmaster recommend not to exceed 90° angle
Fig 2.2
Fig 2.1.
Fig. 2.3

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OPERATING MANUAL
e machine is delivered in complete assembled execution. It must be leveled and rmly
stationed on the oor where it is to be used, according to the Installation Diagram attached.
Indoor installation and a dry working environment without danger of re and explosion is
necessary.
e oor load, where the machine is to be installed, must be suitable for the weight of the ma-
chine.
3. INSTALLATION
3.1 Base Foundation and Securing Points
Before securing the machine a solid concrete base must be prepared to the specication of the
machine.
e sizes for the bolt holes position are listed as A-B.
Fig. 2.5

10
OPERATING MANUAL
3.3 Checking e Power Supply
METALMASTER machines are supplied wired ready to run. Check the specication plate on the
machine to conrm the correct voltage of the power supply.
e machine must be connected to the power by a qualied and licensed electrician. Warranty
could be voided if it is found that the connection was not carried out by a qualied electrician.
Start the pump by turning the key selector to the right.
Compare the direction of rotation of the motor. e blades need to rotate clockwise
If the direction does not match, stop the pump rotation by turning the key and make changes to
the wiring
3.2 Machine Leveling
To set your machine up so that it operates to optimum performance, apply the following procedure
Aer your panbrake has be anchored to a concrete slab oor, it then needs to be leveled. e level-
ing is performed using each of the screws on each pad.(Fig. 3.1). Loosen the hold down bolts and
place a level on the surface of the working table. Tolerances: 1000:0.30mm, for both axis.
Metal plates need to be placed under each jacking screw to distribute the load. Once level then
tighten the hold down bolts.
Metal Plate
Jacking Screw
e machine must not rest on supports other
than those dened in Fig. 3.1
Fig. 3.1

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OPERATING MANUAL
4.1 Setting e Clamp Gap
Before operating the machine the clamp gap needs
to be set to match the material thickness
e Clamp gap must be set to a minimum of 1.5 x
material thickness.
Example: If the material that is to be bent is 4mm
then the clamp gap must be set to a minimum of
6mm.
Each panbrake may have dierent mechanisms for
adjusting the clamp gap but the formula of 1.5 x
Material ickness must be maintained to prevent
overload and possible damage
4. MACHINE SETUP
Some machines have a quick adjusting arm with
pin positions marked 0-6. is should represent
your material thickness.
Example: If the material to bend is 6mm then place
the pin in position 6.
Note ! is must be done on both sides.
You may have to use a combination of top clamp
adjustment and apron adjustment.
Example: If bending 6mm aluminium with the
clamping position 4, the apron must be dropped
down 3mm to make the total gap of 9mm (1.5 x
6mm = 9mm)
Note ! e locking bolts on the apron must be re-
leased before adjusting, then tightened when the
correct height is reached.
RETURN LENGTH - LIMITATION
Caution - ere is a minimum “Return Length”
of 15 x ickness of Material when bending
thicker material over 1mm. Damage could occur
to the machine if the return is too short.
Example: If bending 4mm the minimum return
length must be 60mm

12
OPERATING MANUAL
5.1 Type and frequency of Inspections
5. MAINTENANCE AND INSPECTION
Inspection Frequency Responsible
Lubrication of all grease
points
See Lubrication points
(Section 5.2) Operator
Lubrication of clamp ngers
and machine surfaces Daily Operator
Guards for physical damage Daily Operator
Machine xing bolts against
loosening Weekly Operator
Oil Leakage in cylinders Week ly Operator
Oil leakages in hoses, pipes
and hydraulic parts Week ly Operator
Hydraulic uid levels Week ly Operator
Cylinder connecting bolts
against loosening Week ly Operator
Safety and limit switches
against loosening Week ly Operator
Electrical terminal connec-
tions Annually Electrician

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OPERATING MANUAL
GREASE POINTS X 2 EVERY 8HRS
GREASE POINTS X 2 EVERY 8HRS
GREASE POINTS X 2 EVERY 8HRS
GREASE POINTS X 2 EVERY 8HRS
5.2 Lubrication Points

14
OPERATING MANUAL
5.3 Changing Oil
Cover
Oil Level Indicator
1. Remove the oil tank cover aer pulling out the screws
2. Using an appropriate pump, drain out the old oil completely. Be sure nothing is le
3. Using a pump or proper equipment, ll with new oil. Oil level must be seen in the middle of the
oil indicator. Observe the oil level from this indicator. Always keep the oil at the same level.
4. When changing oil, keep the oil thank clean.
5. Oil must be changed aer rst 200 working hours of use, and then every 1000 working hours.
(See: Lubrication Diagram)
.
e eciency of the Metalmaster machine relies on the hydraulic system being well maintained
All precautions must be taken to keep the hydraulic system clean at all times.

15
OPERATING MANUAL
5.4 Changing the Filter
1. Remove the cover on the oil tank aer loosening and removing the screws.
2. Remove the old lter from its place inside the oil tank by turning in a clock wise direction.
3. Fix the new lter into its place by turning it in counter clock wise direction.
Note ! e suction lter element must be cleaned aer rst 200 hours of use, and then every 1000
working hours. Replace if damaged.

16
OPERATING MANUAL
PROBLEM POSSIBLE CAUSES CORRECTION
Material bend is uneven
1. Clamp setting wrong for
the material thickness.
2. Finger edges are uneven
Re-adjust cam settings
Adjust pan clearance
Adjust ngers
Panbrake Clamp does not
work
Pressure relief valve is
blocked
Failure in the pressure relief
valve
Directional valve is blocked
Failure of directional valve
Suction lter is blocked
Pump failure
Leakage in the pipes or cyl-
inder
* Clean valve
*Change valve
* Clean valve
* Change valve
* Clean lter
* Check pump and change
if necessary
* Find the leaks and repair
Pan does not ascend Low pressure in liing
cylinders
Leakage in liing cylinders
* Check system pressure
*Replace piston seal
Oil leaking from cylinder Gland seal is damaged *Change seal
Oil leaking from ttings Loose ttings *Tighten ttings
5.5 Troubleshooting

17
OPERATING MANUAL
In cases where the machine is not to be used for a long period of time, the following precautions
must be taken:
Disconnect electrical supply to the machine, and place a disconnect tag on the electric panel as a
reminder for future use.
e storage place of the machine must be indoor with protection against humidity, dust, and dan-
ger of re.
Lubricate top and bottom working surfaces with anti-rust lubricant.
Empty the oil from the tank.
Lubricate pistons and all metal surfaces with anti-rust lubricant
Lubricate plastic hoses against cracking.
Cover the machine with a nylon cover to protect against dust.
5.6 Storage
Take the following steps if the machine is to be re-utilized aer a long period of storage:
To use the old machine oil, make sure that the physical and chemical properties of the liquid is
intact. is should be veried by an expert body. Otherwise, ll the tank with new oil.
All electrical components must be checked by a qualied electrician to make sure that all of them
are properly functional. Replace the faulty components.
e machine body and mechanical parts must be checked through by authorized and qualied
personnel, and the machine must be prepared for operation according to the operating instruc-
tions.
Re-utilization aer storage
6. Machine Operation.
a. Check that the electrical supply has been connected.
b. Check that the hydraulic reservoir has been lled with hydraulic oil.
c. Ensure that the emergency stop button is in the released position.
d. Press the start button and check that all the indicator lights are ON.
e. Press the hydraulic pump button to start the electric motor.
e. Adjust the bend angle adjuster according to your requirements.
f. Once the steel plate is in position for bending then the choice of inching or automatic can be
selected.
6.2 Bending
6.2 Start Up
a. Before operating the machine check that the blade settings are correct.
b. Check that the material to be bent is the correct thickness.
c. Do not bend material which has been welded or deformed.
d. Adjust the bend angle adjuster according to your requirements.
e. Once the steel plate is in position for bending then the choice of inching or automatic
bending can be chosen.

18
OPERATING MANUAL
APPENDIX
A. Spare Parts List
No. Name Specication
1 Dust Seal ADA 17-0450-N90
2Seal U321 45.53.8
3Seal WRI45
4 O Ring G70 O-RING 69.4x3.1
5Seal KDAS 070-058
6 O Ring G35 O-RING 34.4x3.1
HYDRAULIC RAM CYLINDER ARM

19
OPERATING MANUAL
Top Hydraulic Cylinder and Seal
No. Name Specication
1Seal KDAS 140-115
2 O Ring G35 O-RING 35.4x3.1
3Seal U321 70 78.8
4Seal WRI 70
5 O Ring G135 O-RING 134.4x3.1