KAKA INDUSTRIAL RBM-50HV Round Bending Machine Instruction Manual

KAKA INDUSTRIAL RBM-50HV Round Bending Machine

Product Information

• Product Name: Round Bending Machine
• Model: RBM-50HV
• Operation Manual: Included

Product Usage Instructions

1. Keep the work area clean and free from clutter to prevent injuries.
2. Avoid using the machine in damp locations, and do not expose it to rain. Ensure the work area is well-lighted.
3. Keep children away from the work area and do not allow them to handle the machine or its accessories.
4. Store the machine in a dry location when not in use to prevent rust. Always lock it up and keep it out of reach of children.
5. Avoid forcing the tool beyond its intended capacity. Use  appropriate attachments and tools for the job
6. Ensure you are using the right tool for the specific task and do not attempt to use a small tool for industrial-sized work.
7. Dress properly for safety by avoiding loose clothing and jewelry that can get caught in moving parts. Wear protective, electrically non-conductive clothes and non-skid footwear. Use hair coverings to contain long hair.
8. Wear ISO-approved impact safety goggles and a full-face shield when producing metal filings or wood chips. Use an ISO-approved dust mask or respirator when working with metal or chemical dust and mists.
9. Maintain proper footing and balance while using the machine and avoid reaching over or across a running machine.
10. Maintain and care for the tools by keeping them sharp, clean, and properly lubricated. The handles should be kept clean, dry, and free from oil and grease.
11. Stay alert and use common sense while operating the machine. Do not use the tool when tired.
12. Before using the tool, carefully check for any damaged parts. Ensure proper alignment and movement of parts. Replace or repair any damaged parts before use.
13. Avoid body contact with grounded surfaces to guard against electric shock.
14. Only use identical replacement parts and approved accessories. The use of other parts may void the warranty.
15. Do not operate the tool under the influence of alcohol or drugs. Check warning labels on prescriptions for any impairments that may affect your judgment or reflexes.

SAVE THIS MANUAL: You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list, and diagram. Read all instructions before using this tool!

SAFETY INSTRUCTIONS

1. Keep the work area clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use machines or power tools in damp locations. Don’t be exposed to rain. Keep the work area well-lighted. Do not use electrically powered tools in the presence of flammable gases or liquids.
3. Keep children away. Children must never be allowed in the work area. Do not let them handle machines, tools, or extension cords.
4. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust. Always lock up tools and keep them out of reach of children.
5. Do not force tools. It will do the job better and more safely at the rate for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool’s capacity.
6. Use the right tool for the job. Do not attempt to force a small tool or attachment to do the work of a large industrial tool. Do not use a tool for a purpose for which it was not intended.
7. Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts. Protective, electrically non-conductive clothes and non-skid footwear are recommended when working. Wear restrictive hair covering to contain long hair.
8. Use eye and ear protection. Always wear ISO-approved impact safety goggles. Wear a full-face shield if you are producing metal filings or wood chips. Wear an ISO-approved dust mask or respirator when working around metal, and chemical dusts and mists.
9. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across the running machine.
10. Maintain tools with care. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. The handles must be kept clean, dry, and free from oil and grease at all times.
11. Stay alert. Watch what you are doing; use common sense. Do not operate any tool when you are tired.
12. Check for damaged parts. Before using any tool, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts; any broken parts or mounting fixtures; and any other condition that may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician.
13. Guard against electric shock. Prevent body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerator enclosures.
14. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any other parts will void the warranty. Only use accessories intended for use with this tool. Approved accessories are available from the distributor.
15. Do not operate the tool if under the influence of alcohol or drugs. Read warning labels on prescriptions to determine if your judgment of reflexes is impaired while taking drugs. If there is any doubt, do not operate the tool.
16. Don’t leave the machine until it comes to a complete stop.
17. Make sure the machine is disconnected from the power supply while making maintenance, adjustment, or repair
18. Always keep hands and fingers away from the rollers.
19. Avoid accidental starting. Make sure the switch is in the “OFF” position before plugging in the power cord
20. Ground all machines. Always make sure your machine is well connected to the earth. It may reduce electric shock hazards.
21. Don’t use it in a dangerous environment. Don’t use power machines in damp locations, or expose them to rain. Keep the work area well-lighted
22. Stop machine before servicing and when changing accessories such as rollers, etc
23. General Electrical Cautions: This machine should be grounded by the National Electrical Code and local codes and ordinances. This work should be done by a qualified electrician. The machine should be grounded to protect the user from electrical shock.
24. LABOUR PROTECTION RULES for Round bending machine
    • Take the machine from the mains for any repair or intervention.
    • It is forbidden to intervene in the gears during operation. They are protected by guards.—Check the fasting of the bending rollers on the shafts before starting the machine.
    • Do not use pinched or cracked bending rollers.

Note : The warning and instructions contained in this instruction manual cannot cover all possible conditions and situations that may occur when using this product. It must be understood that common sense and caution are factors, which cannot be built into this product. These factors must be supplied by the person who operating this piece of equipment.

MAIN SPECIFICATION

USE RANGE

OPERATION:

This machine can work both in the horizontal and the vertical position. After you choose the desired working position, put the material to be bending between rollers. To get the desired bending act upon the leading roller in the bending direction by hand. The desired profile bending is obtained by turning the upright driving shaft of the slide war gradually, as well as the position of the main roller shaft. The guiding rollers are driven by the bending mechanism activated by the electric motor. It allows repeated travels in both directions. The starting of the electric motor in both directions is made using the double pedal.

Standard and Optional rollers:
The Round bending machine RBM50HV is used for bending steel profiles by rolling. The machine is equipped with a set of standard rollers used for bending profiles of the parallelepipedal sections. For other types of profiles, there are special sets of rollers. These rollers are to be found in the table below and delivered on demand.

MAINTENANCE

• Clean, grease and make the necessary adjustments before each operation.
• Check the temperature of bearings(touching them by hand) during operation. The temperature must not exceed 50°.

ELECTRIC INSTALLATION

Technical conditions

1. Supply with electrical power is made according to EN 60204-1,§4.3. The machine is wired up to a three-phase supply network:3-50HZ; 400V; equipped with working earthing (PE). The feed circuit will be protected against short circuits and amperages exceeding the permitted values.
2. Electric installation is made under the IP44 protection degree.
3. Electric installation works under the following conditions:
   • maximum altitude: 1000mm
   • environment temperature: 15℃ up to +40℃
   • relative humidity of environment: 40% up to 80% at 25℃
4. Electric installation works normally at:
   • voltage between (0.9-1.1) Un
   • frequency between (0.99-1.01)Fn

The main parts of the electric installation

• instruments plate for control and driving
• three-phase induction motor M for machine driving
• pedal(with micro-switch JK1, JK2)-for START/STOP control

**Operation instruments

**

After the machine is assembled and fixed in its place, make the operations below in the order prescribed.

1. Check if all metallic parts of the machine are well-earthed, according to the electric diagram. Checking is made visually for the beginning, and then an ohmmeter to measure the resistance of the earthing circuit. Inside, the earthings must have a resistance of ＜0.1Ω, and between the machine and the ground clamp of the power unit, it is ＜0.4Ω.
2. Check the condition of electric instruments, junction wires, cables, and electrical connections.
3. After all checkings are made, connect the machine to the mains:
   • supply is made respecting all conditions in §1.
   • to protect the feed circuit it is recommended to equip the power unit with fusible:3 X 10A for the 3 phases(L1, L2, L3);
4. Check if the machine is correctly supplied after it is connected to the mains.
5. After all, checkings are made and the machine is connected to the mains, start the machine on idle running to determine the correct sense of rotation of the roller: when pushing the pedal on the right side, the sense of rotation is to the right, and then push the left pedal, it is to the left.
6. Let the machine idle for one hour. Meanwhile check if abnormal noises to the electric motor, overheatings to the electric motor, or electric instruments do not appear.
7. Start the machine under load and repeat all checkings.

Operation of electric equipment

To start the machine switch the SA power switch, which is to be found on the machine frame, in the “I” position (shut):

• the SA on position: “O”- machine uncoupled

“I”  machine coupled

• Push the peal R.H. for starting with the sense of direction to the right. The pedal acts the JK1 micros-witch making its contact; it controls the connection of the KM1 contactor which supplies the M motor. The motor starts with the sense of rotation to the left.
• Push the pedal L.H. to start with the sense of direction to the left. The pedal acts as the JK2 micro-switch making its contact; it controls the connection of the KM2 contactor which supplies the M motor. The motor starts with the sense of rotation to the left.
• When the pedal is not pushed, the contract of the micro-switch(JK1 or JK2) opens, and the contactor (KM1 or KM2) turns rotation to the left.

The motor runs as long as one of the pedals is pushed. The machine is equipped with a TA stop button, which can be used for an emergency or when repairs, adjustments, etc. take place. After the stop button is pushed, it is necessary to pull it out when you want to restart the machine, because it is a retaining button and stays pushed.

Maintenance and repair of electric installation

Trouble and remedies:

1. In case all those indicated in the previous chapters were respected and the machine does not start when pressing one of the pedals and KMcontactor (KM1 or KM2) does not connect, make the following operations:

   • Check if the machine is correctly supplied:3-50Hz;400V

   • Check if the thermal protection of the M motor (FR thermal relay) was activated and look for the cause that determined it.
     The reasons could be:

   • supply of M electric motor is made only in two phases or with a lower voltage than 360V/50Hz

   • thermal repay is not correctly set- at 2.3A.

   • M electric is locked or turns hard owing to friction

   • M electric motor out of order

   • FR thermal relay out of order

     • Make corrections and reset the thermal relay with the help of the resetting lever.

   • Check the breaker: QF2 in the transformer primary circuit and QF3 in the control circuit. In case one of the breakers is broken, remove the fault and change the replacing piece.

   • Attention : Use only calibrated replacing pieces and at the parameters indicated.

   • Check if the TC transformer for the 24V supply voltage of the control circuit is in order:

   • check if the T transformer is fed correctly in the primary with a 400V voltage.

   • check if in secondary the transformer supplies the 24V voltage

   • Check if the control circuit has continuity:

   • screws for connections to be well-tightened.

   • contacts of instruments (JK1, JK2, SB, FR) in the control circuit to close correctly.

   • Check if the KM contactor is in order.

2. If pressing the pedal contactor makes the connection, the M electric motor does not start. There should be two situations.

   • If the M motor is correctly fed from 3-50Hz,400V voltage.
   • check if the electric motor is in order: stator winding not to be broken, connections at the terminal box to be perfect, etc.
   • If the M motor is not correctly fed from 3-50Hz;400V voltage, check the motor force circuit: Attention: Use only calibrated replacing pieces and at the parameters indicated.
   • check if the electric stress circuit of the FR thermal relay is not broken.
   • check all junction wires and cables of the electric stress circuit not to be broken.

All necessary checks can be made with a general instrument (multi-meter) which measures: V, A, Ω.

Maintenance operations

• Weekly checking:
  

  • make visual checking of electric apparatus condition and in case they are damaged will be replaced with others at the same parameters;
  • tighten the screws of electric connections and the holdings screws of electric apparatus;
  • check the condition of the feeder cable, jack, and connection socket to the mains, and in case they are damaged will be replaced with others at the same parameters;
  • check if the earthing circuit has continuity and its ohmic resistance;
  • wipe the dust on the electric apparatus and connecting elements. Cleaning can be made with an air jet of a maximum of 2 atm. or with a brush.

• Labor protection rules

  • Respect all instructions and norms in force when mounting, putting into service, repairing, and maintaining the electric installation.
  • Stop the machine and release it from the mains before any intervention to the electric installation to before the periodical checking of electric equipment and motor.

All operations that ask for the electric installation under voltage (measuring the energy, voltage, determining succession of phases) will be effected only by skilled people with legal authority. They must have proper tools equipped with non-conducting handles and non-conductive protection equipment. It is forbidden any modification, of the electric installation if it is certificated by the manufacturer. It could be dangerous. Measures indicated by the manufacturer to protect people against electric shock.

• All active metallic parts are inside cases. In this war, people are protected against dangers that can exist by touching the parts directly according to EN60204§6.2.1
• All active metallic parts are insulated against inactive metallic parts that the people could come in touch with, according to EN60204§6.2.2
• External connecting elements, which the people could come in touch with have the active parts entirely insulated, according to EN60204,§6.2.2
• Galvanic separation of control circuit by transformer, according to EN60204§6.3.3
• Use of reduced voltage(PELV) OF 24 V for the supply of control circuit, according to EN20204§6.4
• To avoid undesired acting owing to insulation damage, breaking or detaching of connections of conductors in the control circuit, a branch of this circuit is connected to the protection circuit, according to EN60204§60204§8.4

All inactive metallic parts of the machine are earthed according to EN60204-1§5.2,§8.2, and EN 60445 to protect people against dangers caused by fault of insulation or accidental touching between active and inactive metallic parts. The earth link between the machine and the ground clamp of the mains is made using a feeder cable and must be checked to be correctly executed. It is forbidden to put the machine under voltage before connecting it to the ground clamp of the mains and before verifying the earth circuit according to instructions from §8.2.1 From time to time it is necessary to check if the continuity of earthings is assured and all instructions from §8.2.1 are respected.

ELECTRIC DRAWING

Parts drawing and Parts list

Part #| Description| Q’ty| Part #| Description| Q’ty
---|---|---|---|---|---
1| Check ring| 1| 37| Frame| 1
2| Bearing| 1| 38| Washer| 10
3| Check ring| 1| 39| Bolt| 6
4| Gear| 1| 40| Screw| 4
5| Key| 1| 41| Bolt| 4
6| Shaft| 1| 42| Rotating shaft stand| 4
7| Bolt| 4| 43| Shaft| 4
8| Reducer| 1| 44| Rotating shaft| 2
9| Motor| 1| 45| Rotating shaft cover| 2
10| Nut| 3| 46| Screw| 3
11| Pressure Pad| 3| 47| Cover| 1
12| Roller| 2| 49| Plate| 4
13| Adjusting gasket| 3| 50| Screw| 12
14| Protecting cover| 3| 51| Screw| 4
15| Conical bearing| 2| 52| Washer| 4
16| Bearing bushing| 2| 53| Nut| 1
17| Key| 2| 54| Screw Rod| 1
18| Key| 2| 56| Rod| 1
19| Shaft| 2| 57| Handle ball| 2
20| Check ring| 2| 58| Screw| 4
21| Gear| 2| 59| Pallet| 1
22| Check ring| 2| 60| Pin roll| 1
23| Bearing bushing| 2| 61| Spring| 1
24| Conical bearing| 4| 62| Screw| 4
25| Nut| 3| 63| Plate| 2
26| End cover| 3| 64| Plate| 2
27| Screw| 3| 65| Nut| 4
28| Shaft| 2| 66| Screw| 4
29| Check ring| 1| 67| Sliding base| 1
30| Gear| 1| 68| Shaft| 1
31| Shock insulator| 1| 69| Roller| 1
32| Gear| 1| 70| Angle iron| 2
33| Check ring| 1| 71| Screw| 4
34| Middle shaft| 1| 72| Bolt| 2
35| key| 1|  |  |
36| Gear| 4|  |  |

Part #| Description| Q’ty| Part #| Description| Q’ty
---|---|---|---|---|---
1| Underpants| 1| 17| Screw| 4
2| Screw| 4| 18| Plate| 1
3| Side plate| 1| 19| Screw| 4
4| Screw| 4| 20| Protective cover| 1
5| Electroplate| 1| 21| Screw| 6
6| Base| 1| 22| Nut| 4
7| Nut| 4| 23| Washer| 4
8| Washer| 4| 24| Washer| 4
9| Bottom Plate| 1| 25| Bolt| 4
10| Washer| 4| 26| Emergency Stop Switch| 1
11| Bolt| 4| 27| Footswitch| 1
12| Screw| 2| 28| Damping iron| 6
13| Protective cover| 1| 29| Iron mat| 6
14| Screw| 2| 30| Nut| 6
15| Support bor| 2| 31| Washer| 6
16| Protective cover| 1|  |  |

Note: This manual is only for your reference. Owing to the continuous improvement of the machine, changes may be made at any time without obligation on notice. And please note the local voltage while operating this electric machine.

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