MetalMaster PB-CL Series User manual

OPERATION MANUAL
Edition No : PB-CL 001
Date of Issue : 01/2024
Models
PB-CL SERIES HYDRAULIC PRESS BRAKE
CYBELEC CT12 CNC CONTROLLER
S970CL, S902CL, S906CL, S908CL, S909CL, S910CL, S912CL

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OPERATION MANUAL PB-CL SERIES
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
HYDRAULIC PRESS BRAKE
MACHINE
MODEL NO.
SERIAL NO.
DATE OF MANF.
Note:
This manual is only for your reference. Owing to the continuous improvement of the
Metalmaster machine, changes may be made at any time without obligation or notice.
Please ensure the local voltage is the same as listed on the specication plate before
operating any electric machine.
Distributed by
www.machineryhouse.co.nz
MACHINE DETAILS

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OPERATION MANUAL PB-CL SERIES
C O N T E N T S:
1. GENERAL MACHINE INFORMATION
1.1 Specications............................................................... 5
1.2 Standard Equipment................................................. 6
1.3 Identication................................................................ 7
2. IMPORTANT INFORMATION
2.1 General Metalworking Machine Safety.............. 8
2.2 Specic Safety for Press Brake Machines........... 11
2.3 Lifting Instructions..................................................... 13
3. INSTALLATION
3.1 Site Selection and Preparation.............................. 14
3.2 Machine Leveling....................................................... 15
3.3 Electrical Installation................................................. 15
3.4 Full Load Current........................................................ 16
3.5 Checking The Power Supply................................... 16
3.6 Attaching The Accessories...................................... 17
4. COMMISSIONING
4.1 Press Brake Guarding - Laser Guarding ............. 18
4.2 Laser Guarding Safety Controller ........................ 19
4.3 Laser Safety Controller - Layout ........................... 20
4.4 Laser Safety Controller - Operating modes....... 21
4.5 Laser Setup & Calibration - Magnet Type Calibrator ..... 22
4.6 Stopping test - Magnet Type Calibrator ............................. 23
4.7 Laser Safety Periodical check ................................ 25
4.8 Controls.......................................................................... 26
5. OPERATION
5.1 Starting The Machine For The First Time............ 27
5.2 Testing The Emergency Stops................................ 28
5.3 Setting The Height Stops......................................... 28
5.4 Cybelec CT12 Controller Operation..................... 29
5.5 Press Brake Calibration: X Axis............................... 31
Press Brake Calibration: Y Axis............................... 32
5.6 Removing & Replacing Tools.................................. 33
5.7 Aligning The Punch And Die................................... 34
5.8 Adjusting The Backgauge........................................ 34
5.9 Bending Techniques.................................................. 35
5.10 Tonnage Chart .......................................................... 36
5.11 Adjusting The Tonnage........................................... 37
5.12 Top Tool Holder Wedge Adjustment.................. 37

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OPERATION MANUAL PB-CL SERIES
6. MAINTENANCE
6.1 Maintaining Hydraulic System............................... 38
6.2 Lubrication.................................................................... 42
6.3 System error list .......................................................... 43
6.4 General Troubleshooting ....................................... 44
6.5 One Piece 4 Sided Die............................................... 46
6.6 Segmented Top Punch............................................. 48
APPENDIX
A.1 Laser Setup & Calibration for old style spring
type calibrator supplied prior to Nov 2023 ...... 51
A.2 Laser Stopping test for old style spring type
calibrator supplied prior to Nov 2023 ................ 52
A.3 Electrical Diagrams .................................................... 53
A.4 Safety & Risk Assessment Sheets .......................... 61

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OPERATION MANUAL PB-CL SERIES
1.1 SPECIFICATIONS
Order Code S970CL S902CL S906CL S908CL
Model PB-40A PB-70B PB-135B PB-135B
Control Unit (Type) CYBELEC
CT12
CYBELEC
CT12
CYBELEC
CT12
CYBELEC
CT12
Laser Guarding System Yes Yes Yes Yes
Nominal Pressure - Tonnage (Ton) 44 70 135 135
Nominal Pressure - Kilo-newtons (kN) 400 630 1250 1250
Machine Axis (No) 2 2 2 2
Length of Work Table (mm) 2000 3200 3200 4000
Distance Between Columns (mm) 1615 2600 2600 3200
Maximum Open Height (mm) 330 360 390 390
Backgauge Travel (mm) 520 520 520 520
Throat Depth (mm) 200 250 415 415
Ram Stroke (mm) 100 100 130 130
Motor Power (kW / hp) 4 5.5 7.5 7.5
Motor Voltage (v) 415 415 415 415
Dimensions (L x W) (cm) 270 x 180 390 x 190 390 x 200 470 x 200
Height (cm) 240 240 270 270
Nett Weight (kg) 3800 5740 8600 10350

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OPERATION MANUAL PB-CL SERIES
1.2 STANDARD EQUIPMENT
Front Sheet Supports
Mobile Foot Pedal Control
Instruction Manual
1.1 SPECIFICATIONS CONT.....
Order Code S909CL S910CL S912CL
Model PB-170B PB-170B PB-200B
Control Unit (Type) CYBELEC CT12 CYBELEC CT12 CYBELEC CT12
Laser Guarding System Yes Yes Yes
Nominal Pressure - Tonnage (Ton) 176 176 220
Nominal Pressure - Kilo-newtons (kN) 1600 1600 2000
Machine Axis (No) 2 2 2
Length of Work Table (mm) 3200 4000 4000
Distance Between Columns (mm) 2600 3200 3200
Maximum Open Height (mm) 470 470 450
Backgauge Travel (mm) 550 550 550
Throat Depth (mm) 420 420 420
Ram Stroke (mm) 200 200 200
Motor Power (kW / hp) 11/15 11/15 15/20
Motor Voltage (v) 415 415 415
Dimensions (L x W) (cm) 390 x 220 470 x 220 470 x 230
Height (cm) 290 290 300
Nett Weight (kg) 11100 14100 16500

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OPERATION MANUAL PB-CL SERIES
1.3 IDENTIFICATION
Control Pendant
Mobile Foot Pedal
Side FenCe
toP die
bottoM die
toP beaM
Front SuPPortS
CybeleC Ct12
ClaMPS
baCk FenCe
eleCtriCal Cabinet
HydrauliC PuMP
Control Pendant arM
Side FenCe
tonnage CHart

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OPERATION MANUAL PB-CL SERIES
DO NOT use this machine unless you have read this manual or have been instructed in the use
of this machine in its safe use and operation
2.1 GENERAL METALWORKING MACHINE SAFETY
Always wear safety glasses or goggles.
Wear appropriate safety footwear.
Wear respiratory protection where required.
Gloves should never be worn while operating the machine, and only worn when
handling the workpiece.
Wear hearing protection in areas > 85 dBA. If you have trouble hearing someone speak
from one metre (three feet) away, the noise level from the machine may be hazardous.
DISCONNECTION THE MACHINE FROM POWER when making adjustments or servicing.
Check and adjust all safety devices before each job.
Ensure that guards are in position and in good working condition before operating.
Ensure that all stationary equipment is anchored securely to the oor.
Ensure all machines have a start/stop button within easy reach of the operator.
RESPIRATORY
PROTECTION
Exposure to the dust created by grinding, may
cause serious and permanent respiratory or
other injury, including silicosis (a serious lung
disease), cancer, and death.
GLOVES
DO NOT wear gloves near moving parts of the
machines. Operator’s hands can be caught and
drawn into the rotating dies.
EYE & EAR
PROTECTION
ALWAYS wear eye protection. Any machine can
throw debris into the eyes during operations,
which could cause severe and permanent eye
damage.
SAFETY
FOOTWEAR
Safety footwear must be worn when operating
this equipment
READ & UNDERSTAND
THE MANUAL
This manual provides safety instructions on the
proper setup, operation, maintenance, and
service of this machine. Save this manual, refer
to it often, and use it to instruct other operators.

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OPERATION MANUAL PB-CL SERIES
Each machine should have only one operator at a time. However, everyone should know
how to stop the machine in an emergency.
Ensure that keys and adjusting wrenches have been removed from the machine before
turning on the power. Appropriate storage for tooling should be provided.
Ensure that all cutting tools and blades are clean and sharp. They should be able to cut freely
without being forced.
Stop the machine before measuring, cleaning or making any adjustments.
Wait until the machine has stopped running to clear cuttings with a vacuum, brush or rake.
Keep hands away from the cutting head and all moving parts.
Avoid awkward operations and hand positions. A sudden slip could cause the hand to move
into the cutting tool or blade.
Return all portable tooling to their proper storage place after use.
Clean all tools after use.
Keep work area clean. Floors should be level and have a non-slip surface.
Use good lighting so that the work piece, cutting blades, and machine controls can be seen
clearly. Position any shade lighting sources so that they do not cause any glare or reections.
Ensure there is enough room around the machine to do the job safely.
Understand that the health and re hazards can vary from material to material. Make sure all
appropriate precautions are taken.
Clean machines and the surrounding area when the operation is nished.
Use proper lock out procedures when servicing or cleaning the machines or power tools.
DO NOT
×Do not distract an operator. Horseplay can lead to injuries and should be strictly prohibited.
×Do not wear loose clothing, gloves, necktie’s, rings, bracelets or other jewellery that can be
come entangled in moving parts. Conne long hair.
×Do not handle cuttings by hand because they are very sharp. Do not free a stalled cutter
without turning the power o rst. Do not clean hands with cutting uids.
×Do not use rags or wear gloves near moving parts of machines.
×Do not use compressed air to blow debris from machines or to clean dirt from clothes.
×Do not force the machine. It will do the job safer and better at the rate for which it was
designed.
2.1 GENERAL METALWORKING MACHINE SAFETY Cont.
BEFORE OPERATING ANY MACHINE, TAKE TIME TO READ
AND UNDERSTAND ALL SAFETY SIGNS AND SYMBOLS.
IF NOT UNDERSTOOD SEEK EXPLANATION FROM YOUR
SUPERVISOR.

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OPERATION MANUAL PB-CL SERIES
2.1 GENERAL METALWORKING MACHINE SAFETY Cont.
HAZARDS ASSOCIATED WITH MACHINES include, but are not limited to:
• Being struck by ejected parts of the machinery
• Being struck by material ejected from the machinery
• Contact or entanglement with the machinery
• Contact or entanglement with any material in motion
Health Hazards (other than physical injury caused by moving parts)
• Chemicals hazards that can irritate, burn, or pass through the skin
• Airborne items that can be inhaled, such as oil mist, metal fumes, solvents, and dust
• Heat, noise, and vibration
• Ionizing or non-ionizing radiation (X-ray, lasers, etc.)
• Biological contamination and waste
• Soft tissue injuries (for example, to the hands, arms, shoulders, back, or neck) resulting
from repetitive motion, awkward posture, extended lifting, and pressure grip)
Other Hazards
• Slips and falls from and around machinery during maintenance
• Unstable equipment that is not secured against falling over
• Safe access to/from machines (access, egress)
• Fire or explosion
• Pressure injection injuries from the release of uids and gases under high pressure
• Electrical Hazards, such as electrocution from faulty or ungrounded electrical
components
• Environment in which the machine is used (in a machine shop, or in a work site)
Machines are safeguarded to protect the operator from injury or death with the placement of
guards. Machines must not be operated with the guards removed or damaged.

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OPERATION MANUAL PB-CL SERIES
2.2 HYDRAULIC PRESS BRAKE SAFETY PROCEDURE
DO NOT use this machine unless you have been instructed in its safe use and
operation and have read and understood this manual
Long and loose hair must be
contained or restrained
Safety glasses must be worn at all
times in work areas.
Appropriate protective footwear with
substantial uppers must be worn
Coveralls, protective clothing, or a
workshop apron, is recommended
Rings and jewelery must not be worn. DO NOT wear large leather gloves
when operating this machinery
PRE-OPERATIONAL SAFETY CHECKS
1. Ensure that all guards and safety devices are in position and secured.
2. Adjust all guards to minimum practicable clearances for the material to be pressed.
3. Note: any guards and safety devices should NEVER be removed, except for maintenance
purposes, and only by an authorised sta member.
4. Working parts should be well lubricated and all jaws, ngers, ‘V’ blocks and blades be free of
rust and other foreign matter.
5. Adjust the head rams to suit the material thickness.
6. Adjust and check that the‘v’ forming blocks and/or knife blades are aligned correctly.
7. Be aware of any other personnel in the immediate vicinity and ensure the area is clear
before using this equipment.
8. Familiarize yourself with all electrical, hydraulic and mechanical operations and controls,
including the roving foot pedal control.
OPERATIONAL SAFETY CHECKS
1. Strictly only one operator is to use this heavy duty press brake, and, when necessary, with a
safety observer present.
2. Never use any press or pan brake to bend or fold beyond the capacity of the machine.
3. Ensure that both hands are positioned away from any possible pinch point
4. Particular preparation and caution is to be observed when bending rod, strap or spring
steel.
5. This heavy duty press brake is likely to be tted with infra-red safety beams or electronic
sensors to detect hazardous circumstances. If so, this machine should NOT operate if these
safety devices are breached in any way, either by materials or by the operator.
6. Never leave the machine in operational mode while unattended.
POTENTIAL HAZARDS
Entanglement and entrapment Striking and shearing
Pinch, crush and squash Manual handling
Electrical and hydraulic components  Eye injury

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OPERATION MANUAL PB-CL SERIES

CENTRE
WORKPIECE
SAFETY SYMBOLS
Fixed to the front of the press brake are safety symbols
designed to make sure the machine is safely operated

CENTRE
WORKPIECE
Hearing and eye protection are extremely important as the result of
an injury to these parts of the body may cause permanent damage.
Safety glasses and hearing protection must be approved
When operating the press-bake hands and arms must at all times
be kept from between the top and bottom die.
Failure to do so may cause severe crushing.
With all hydraulic press brakes it is important that pressing takes
place between the two rams in the center of the beam.
This ensures equal pressure is applied to both rams.
Never attempt to support the end of the workpiece by holding it
on either side of the tools. No part of your body must enter the
hazardous area during bending operations. Beware of sudden
movements of the worksheet during bending
Never hold the sheet by its folded edge; hold it from the sides

CENTRE
WORKPIECE

CENTRE
WORKPIECE

CENTRE
WORKPIECE

CENTRE
WORKPIECE

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OPERATION MANUAL PB-CL SERIES
2.3 LIFTING INSTRUCTIONS
On the day that the machine arrives, make sure that a crane with sucient capacity is available
to unload the machine from the vehicle. Ensure 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 machine, the slings should be positioned so the machine is level when lifted.
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 is
carrying the equivalent of 50% of load weight. (Fig.2.1).
When the slings are at a 90° angle then each sling will
have a weight equal to 75% of the load on each sling.
(Fig 2.2)
Note! The manufacturer recommends not to exceed 90°
angle
Fig 2.2
Fig 2.1.
When lifting the machine only certied lifting slings should be used.
Ensure that when lifting, the machine does not tip over.
Check that the lifting slings do not interfere with the hydraulic pipes or electrical conduits.
Failure to follow these instructions could cause damage to the machine
LIFTING POINTS
Fig. 2.3
Fig.2.3

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OPERATION MANUAL PB-CL SERIES
3. INSTALLATION
3.1 SITE SELECTION AND PREPARATION
The METALMASTER Press Brake must be installed on a rigid and stable oor such as a concrete
slab 150 - 200mm thick. The press brake will be more stable if it sits on one slab and does not
straddle slabs. Due to the design of the Press Brake with a high center of gravity bolting down to
the oor is preferable.
The site must allow for access to the machine from all sides leaving enough room to cover any
maintenance programs that need to be done. The rear and front of the machine must allow for
clearance of the work parts.
If no solid foundation can be found prepare the following foundation. (Fig.3.1)
Install the machine on the prepared foundation, and then x using the foundation bolts. Once
attached to the bolts do the nal second grouting. After the cement has been solidied, check
and correct the level of the machine. Check the bolt hole dimensions on the machine.
100-150
200x200
150x150
600
700
SECOND GROUTING
B
A
200
430
120 X120 X 20 - Upper surface should be at
the same level as the ground
Screw Support Plate
75
Fig.3.1

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OPERATION MANUAL PB-CL SERIES
3.2 MACHINE LEVELING
To set your machine up so that it operates to optimum performance, apply the following
leveling procedure
After your machine has been anchored to a concrete slab oor, it then needs to be leveled. The
leveling is performed using the screws on each pad.(Fig. 3.2). Loosen the hold down bolts and
place a level on the surface of the working table. Tolerances: 1000:0.30mm, for both longitudi-
nal and transverse.
Metal plates need to be placed under each jacking screw to distribute the load. Once level then
tighten the hold down bolts.
The machine must not rest on supports
other than those dened in Fig. 3.2
Place the machine near an existing power source. Make sure all power cords are protected from
trac, material handling, moisture, chemicals, or other hazards. Make sure there is access to a
means of disconnecting the power source. The electrical circuit must meet the requirements for
415V. To minimize the risk of electrocution, re, or equipment damage, these machines should
be hard wired with installation work and electrical wiring done by a qualied electrician.
NOTE : The use of an extension cord is not recommended as it may decrease the life of electrical
components on your machine.
3.3 ELECTRICAL INSTALLATION
ELECTRICAL REQUIREMENTS
Nominal Voltage.........................................415V
Cycle............................................................50 Hz
Phase...............................................Three Phase
(Full load current rating is on the specication plate on the motor.)
Fig.3.2
JaCking SCrew
Metal Plate

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OPERATION MANUAL PB-CL SERIES
The full-load current rating is the amperage a machine draws when running at 100% of the out-
put power. Where machines have more than one motor, the full load current is the
amperage drawn by the largest motor or a total of all the motors and electrical devices that
might operate at one time during normal operations.
It should be noted that the full-load current is not the maximum amount of amps that the
machine will draw. If the machine is overloaded, it will draw additional amps beyond the
full-load rating and if the machine is overloaded for a long period of time, damage, overheating,
or re may be caused to the motor and circuitry.
This is especially true if connected to an undersized circuit or a long extension lead. To reduce
the risk of these hazards, avoid overloading the machine during operation and make
sure it is connected to a power supply circuit that meets the requirements.
3.4 FULLLOAD CURRENT RATING
3.5 CHECKING THE POWER SUPPLY
METALMASTER machines are supplied wired ready to run. Check the specication plate on the
machine to conrm the local voltage is the correct voltage for the machine.
The machine must be connected to the power by a qualied and licensed electrician.
The motor direction must be checked as indicated below, to make sure the motor runs in the
correct direction.
NOTE: Warranty may be voided if it is found that the connection was not carried out by a
qualied electrician.

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OPERATION MANUAL PB-CL SERIES
qUnpack and attach both the side guards to the machine
making sure they are square with the machine. (Fig3.4)
3.6 ATTACHING THE ACCESSORIES.
qBolt the support arms onto the feed table. Ensure they are level and square to the table.
(Fig.3.3)
qUnpack the mobile foot control (Fig.3.5)
Fig. 3.4
Fig.3.3
Fig. 3.5
Fig. 3.6
qPlug the mobile foot control it into the socket provided
on the machine under the electrical cabinet. (Fig.3.6)

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OPERATION MANUAL PB-CL SERIES
4.1 PRESS BRAKE GUARDING SYSTEM  LASER GUARDING
Australian Legislation - Machine parts traveling at more than 10mm/second need physical or
electronic guarding.
Laser Guarding - This press brake top beam has an elec-
tronic guarding system, when setup & calibrated correctly it
is designed for the protection of the ngers and arms of the
operator in close proximity to the pressbrake tooling.
There is a laser emitter, a receiver (Fig.4.5) and a laser safety
controller in a Laser set. These are an electronic safety device
that can detect obstuctions in the working area as well as
monitor relay status. The safety guarding system reacts de-
pending on what signals it gets from all these components.
Emitter - The LINK LED on the emitter will be green to advise the emitter is linked with the
receiver (Fig.4.6)
Receiver- Has a green“ON”LED (Fig.4.5) to indicate all 3 protection zones of the laser are
aligned and linked. Protection zone E1, E2 & E3 lights turn RED when there is an obstruction
(Fig.4.6)
The laser system serves two functions
• If the beam is traveling down fast and an obstruction is introduced, the laser system sends a
signal to the laser safety controller so it will stop the beam travel.
• If any laser protection zone is obstructed before the beam is moving, they send a signal to
the laser controller so it will restrict the beam travel to slow speed.
* Lasers must never be disabled. Machines must not be used if the laser system is faulty.
Fig.4.5
Fig.4.6
4. COMMISSIONING

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OPERATION MANUAL PB-CL SERIES
On power up the laser safety controller per-
forms a self test and checks and also checks
the emitter & receiver for errors, if a safety
fault is found the laser safety controller enters
a fault state and can not be reset unless the
fault is retied.
Types of errors detected Emitter Receiver Controller
Broken or short circuit cable
Communication failure
Failure of safety output circuit
Internal circuit failure
Note: Checked, Not Checked
Laser Safety Controller Self check & Monitoring function -
E1, E2, E3 laser sensors - The laser safety controller monitors the output control signals of the
sensors and detects eective beam transmission.
Fault detection & indication - Detects the failure of the controller or laser sensors when any
failure in the above table occurs, and indicates the error at the same time.
Fast down stroke - The laser safety controller monitors the state of the NC contacts of the relay
which controls the fast down stroke to ensure the switching occurs in relation to the safety
logic.
Slow down stroke - The laser safety controller monitors the state of the NO contacts of the relay
which controls the slow down stroke to ensure the switching occurs in relation to the safety
logic.
OSSD outputs of controller - A Type 4 safety circuit is built in to the laser safety controller circuit
to monitor the state of the safety relay contacts to prevent welding due to arcing.
4.2 LASER GUARDING SAFETY CONTROLER

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OPERATION MANUAL PB-CL SERIES
Power indiCator
(orange)
Fault indiCator
(red)
SaFety on indiCator
(green)
SaFety oFF indiCator
(red)
norMal Mode indiCator
(green)
Mute Mode indiCator
(yellow)
box Mode indiCator
(yellow)
Mode SwitCH guarding Power
SwitCH
4.3 LASER SAFETY CONTROLER  LAYOUT