amada RG35S-100 Operator Manual
PRESS BRAKE (ZII)
RG35S–100
OPERATOR'S MANUAL
RG25-125-
E02
-200510
PREFACE Read this manual carefully to obtain a thorough knowledge of machine operation and maintenance.
Be sure to follow the instructions to ensure proper procedures and prevent injuries and accidents. Do not operate
the machine by guesswork. Keep the manual at hand
and refer to it whenever you are not sure of how to perform
any of the procedures.
Operator's Manual:
Press Brake (ZII) RG35S-100
© 2005 by AMADA CO., LTD.
No part of this publication may be photocopied or otherwise reproduced without the prior written permission of AMADA CO., LTD.
ii
Printed in Japan
CONTENTS
Part I Safety.................................................................................... I-1
1. Safety rules ............................................................................ I-2
2. DANGER and WARNING plates........................................... I-10
Part II Description.......................................................................... II-1
1. Functions ...............................................................................II-2
2. General view ..........................................................................II-3
3. Specifications......................................................................... II-5
4. Dimensions ............................................................................ II-6
5. Standard accessories ............................................................II-9
6. Options..................................................................................II-10
Part III Installation.......................................................................... III-1
1. Summary............................................................................... III-2
1-1. Environmental conditions............................................... III-2
1-2. Input power source......................................................... III-2
1-3. Things to be supplied by customer ................................ III-3
2. Installation procedures.......................................................... III-4
2-1. Location.......................................................................... III-4
2-2. Lifting.............................................................................. III-5
2-3. Foundation ..................................................................... III-6
2-4. Placing ........................................................................... III-6
2-5. Leveling.......................................................................... III-6
2-6. Supplying hydraulic oil ................................................... III-8
2-7. Supplying electric power ................................................ III-8
Part IV Controls..............................................................................IV-1
1. Controls on electrical enclosure............................................ IV-2
2. Controls on upper beam ....................................................... IV-3
3. Hydraulic equipment controls ............................................... IV-4
4. Other controls .......................................................................IV-6
(Continued on next page.)
iii
Part V Operation ............................................................................V-1
1. Inspection before start of day’s work .....................................V-3
2. Preparing for operation.......................................................... V-3
3. Turning on power...................................................................V-5
4. Removing tools ......................................................................V-6
4-1. Preparing for removing tools........................................... V-6
4-2. Removing punches .........................................................V-8
4-3. Removing dies ................................................................V-9
5. Installing tools .......................................................................V-11
5-1. Preparing for installing tools ..........................................V-11
5-2. Installing dies .................................................................V-12
5-3. Installing punches ..........................................................V-14
6. Preparing for special bending...............................................V-16
6-1. Installing and removing punch holders .......................... V-16
6-1-1. Removing punch holders ........................................V-16
6-1-2. Installing punch holders ..........................................V-17
6-2. Installing punches rearside front....................................V-18
6-3. Installing wide dies.........................................................V-19
7. Other uses ............................................................................ V-20
7-1. Adjusting punch holders.................................................V-20
7-2. Using one-touch punch holders (option)........................V-23
7-2-1. Installing and removing punches from front ............V-25
7-2-2. Installing and removing punches by sliding them
along groove of rear clamping plates .....................V-28
7-2-3. Installing and removing rear clamping plates..........V-29
8. Aligning tools ........................................................................V-32
8-1. RG35S ...........................................................................V-32
8-2. RG50, RG80, and RG100.............................................. V-34
9. Setting tool origin ..................................................................V-37
10. Bending operation...............................................................V-38
10-1. Setting rising speed change position ...........................V-38
10-2. Setting multiple opening limit .......................................V-39
10-3. Bending worksheet ......................................................V-40
10-3-1. Temporarily setting multiple closing limit...............V-40
10-3-2. Setting worksheet..................................................V-41
10-3-3. Setting bend angle ................................................V-42
11. Turning off power ................................................................V-44
12. Troubleshooting ..................................................................V-46
13. Clearing emergency stop condition .................................... V-48
iv
Part VI Maintenance.......................................................................VI-1
1. Inspection before start of day’s work .................................... VI-2
2. Maintaining hydraulic system................................................ VI-4
2-1. Checking hydraulic oil level............................................ VI-4
2-2. Changing hydraulic oil.................................................... VI-5
2-3. Maintaining tools ............................................................ VI-6
3. Lubrication ............................................................................ VI-7
4. Hydraulic circuit diagrams..................................................... VI-8
4-1. RG35S ........................................................................... VI-8
4-2. RG50, RG80, and RG100............................................. VI-10
5. Electric circuit diagrams....................................................... VI-13
v
vi
Part
I
Safety
1. Safety rules ..................................................................................I-2
2. DANGER and WARNING plates.................................................I-10
I-1
1. SAFETY RULES
Observe these safety rules to prevent injuries and accidents:
a) Never modify the machine. If the control circuit or other part of the machine
is modified, the ram may malfunction.
b) Whenever the machine is not in use, remove the key from the POWER
ON/OFF keyswitch, and hand it to the chief operator for custody.
c) Assign trained operators to the operation and maintenance of the machine.
d) Inspect the machine before the start of the day's work.
e) Install the machine with a rear clearance of at least 1000 mm {40 in.} where
it is not exposed to direct sunlight. If the electrical equipment of the
machine is overheated as a result, the machine may malfunction.
f) Before starting the operation of the machine, check that there are no
persons and obstacles around the machine. Pay particular attention to the
rear of the machine. Never place hand tools and parts on the installed dies
and the lower beam.
g) Never put your hand or hands between the punches and dies.
I-2
h) When changing the tools, strictly observe the following rules:
• Before installing and removing the
dies, turn the POWER ON/OFF
keyswitch to OFF, remove the key from
the keyswitch, and keep it by yourself.
(Install and remove the dies as
described in “4. Removing tools” and
“5. Installing tools” in Part V.)
• Before installing and removing the
punches, turn the multiple closing limit
setting handwheel to close the ram to
the desired position, turn the POWER
ON/OFF keyswitch to OFF, remove the
key from the keyswitch, and keep it by
yourself. Never put your hand or
hands between the punch and die to
support the punch. (Install and
remove the punches as described in
“4. Removing tools” and “5. Installing
tools” in Part V.)
• Securely fix the punches, dies, and die
holders before applying pressure to
them.
• When you install and remove the tools
with an assistant operator or
operators, be sure to coordinate your
work with them.
• Never put your hands between the
punches and dies to support a punch,
for example.
• When you install a tool by sliding it
sideways, take care not to get your
hand pinched between it and another
tool already installed.
I-3
If your machine is equipped with optional one-touch punch holders, keep the
following rules:
• When applying pressure to the
punches or bending the worksheet,
ONE-TOUCH PUNCH HOLDER
LEVER POSITIONS
POSITION POSITION POSITION
turn the punch holder levers to the
position ◯B.
POSITIONS FOR OPERATING
LEVER AND INSTALLING AND
REMOVING PUNCHES
• Install or remove the punch holder
levers only in the position ◯B.
• Affix the punch holder lever position
sticker in an easy-to-see place to
prevent procedural mistakes.
i) When you bend worksheets with an assistant operator or operators, you
must press the bar pedal after fully ensuring the safety of all of them.
I-4
j) Before adjusting the stoppers, turn the POWER ON/OFF keyswitch to OFF,
remove the key from the keyswitch, and keep it by yourself. Be sure to
adjust the stoppers from the rear of the machine.
k) Correctly set the position where the bending speed of the ram is to be
changed. If this position is not correctly set, the worksheet may start to
bend unexpectedly.
l) When bending a small worksheet, set the stroke length of the ram to 6 mm
{0.24 in.} or less, and hold the worksheet as shown on the next page. Take
care not to get your fingers pinched between the punches and dies or
between the punches and worksheet.
6 mm
{0.24 in.}
or less
I-5
Hold the worksheet as shown below.
m) If your machine is equipped with an optional backgauge, push the
worksheet against the stoppers of the backgauge after the backgauge is
properly positioned. Otherwise the worksheet may be pushed forward
when the backgauge moves forward.
n) Use Amada genuine punches and dies on the machine. The machine
performs various controls by reference to the Amada genuine punches and
dies. Non-genuine punches and dies are different in brittleness and
allowable tonnage from the genuine punches and dies. Use of such nongenuine tools may cause various troubles and detract from safety of the
machine.
o) Apply to the installed tools a pressure
that is not higher than the allowable
tonnage marked on them. Unless a
proper pressure is applied to them, the
tools may break and scatter in a
dangerous manner.
When 2V-dies are used, use the Vgroove toward the rear of the machine
for additional safety from breakage.
I-6
p) When bending a large worksheet, be careful of its springing upward. Hold
one side of the worksheet or otherwise be ready for its springing upward.
q) Before bending each worksheet, check that the tools are securely installed
and tightened. With a sharp bend or U-bend, the punches and dies may
eat into the worksheet and fall together with the worksheet.
I-7
r) When rebending the same worksheet, align the nose line of the punches
with the bend line of the worksheet. If the worksheet is rebent without
aligning the lines, abnormal noise may be produced, and the tools may
break and scatter in a dangerous manner.
s) Whenever trouble occurs during the operation of the machine, press one of
the EMERGENCY STOP buttons, turn the POWER ON/OFF keyswitch to
OFF, remove the key from the keyswitch, keep it by yourself, and fix the
problem. When picking a worksheet that has fallen into the machine, be
sure to do so from the rear of the machine. As soon as the machine
develops trouble, report it to the chief operator.
I-8
t) If the machine suddenly loses its power due to a power failure, the ram may
open to the maximum opening limit. In such a case, hold the worksheet
over the ram so that it does not fall.
u) Before walking away from the machine, turn the POWER ON/OFF
keyswitch to OFF, remove the key from the keyswitch, and keep it by
yourself.
v) Before opening the electrical enclosure, be sure to turn off the machine
circuit breaker. You may receive an electric shock if you touch any parts in
the electrical enclosure.
w) Be sure to perform periodic maintenance on the machine. For the items of
maintenance to be performed, refer to Part VI, Maintenance.
x) Before maintaining or cleaning the machine, turn off the shop circuit breaker,
relieve the residual hydraulic pressure in the machine, and post a sign to
inform other workers that the machine is under maintenance.
y) When relocating the machine, ask AMADA about how to move the machine.
If moved incorrectly, the machine may turn over.
I-9
2. DANGER AND WARNING PLATES
Keep the DANGER and WARNING plates well noticeable and never remove
them.
I-10
Hazard seriousness level
DANGER
WARNING
CAUTION
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury.
I-11
I-12
Part
II
Description
1. Functions .................................................................................... II-2
2. General view ............................................................................... II-3
3. Specifications.............................................................................. II-5
4. Dimensions ................................................................................. II-6
5. Standard accessories .................................................................II-9
6. Options....................................................................................... II-10
II-1
1. FUNCTIONS
This machine is a hydraulic press brake of the central pressure
application and parallel rising type. It has the following features:
• The hydraulic circuit is simplified to minimize oil leakage and facilitate
maintenance.
• A main cylinder is installed at the center of the ram to minimize the
distortion produced in the upper and lower beams during pressure
application.
• Installed at the center of the ram, a bearing guide unit slides up and
down along the main cylinder surface that doubles as sliding surface,
in order to keep the upper and lower beams accurately parallel.
• A punch-to-die clearance setting unit allows the ram stroke length to
be set to a required minimum and the working efficiency to be
enhanced as a result.
• The bar pedal can be pressed as required to adjust the ram approach
speed or stop the ram mid-stroke. This is ideal for bending
worksheets on which scribed lines must be aligned with the punch
nose line.
• Punch holders and die holders are installed in the upper and lower
beams and provide for easy installation of punches and dies,
respectively.
• Standard tools are light in mass, easy to carry, available in many
types, and adaptable to a variety of bending operations. (For the
tools, refer to their catalogs.)
II-2
2. GENERAL VIEW
NOTE
O This drawing shows the general view of the RG50 machine.
REAR GUARD
HYDRAULIC UNIT
Hydraulic oil tank and hydraulic
drive unit are located at rear
of lower beam.
FRAME
ELECTRICAL ENCLOSURE
Power distribution and control circuits
are built in. Power and hydraulic pump
motor switches are located.
Shop's main power source is connected
to terminals in this enclosure.
HYDRAULIC
EQUIPMENT CONTROLS
Knobs and levers required for
operation of ram are located.
SUPPORTER
PEDAL STOPPER
Pressed to allow ram to be operated
only by single operator. Bar pedal can
be pressed only when foot is placed on
pedal stopper to disable pedal stopper.
STOPPER
EMERGENCY
STOP BUTTON
EMERGENCY
STOP BUTTON
UPPER BEAM
PUNCH HOLDER
LOWER BEAM
BAR PEDAL
Pressed as required to adjust ram approach
speed or stop ram mid-stroke.
II-3
II-4
3. SPECIFICATIONS
Metric unit system (International system of units)
Item
Maximum bend length (mm) 1250 2085 2505 3100
Press capacity (kN) 343 490 784 980
Stroke length (mm) 100 100 100 100
Open height without punch holders (mm) 370 370 370 370
Approach speed at 50/60 Hz (mm/sec) 46/55 38/45 38/45 49/59
Bending speed at 50/60 Hz (mm/sec) 8/9.5 7/8.5 7/8.5 8.3/10.1
Moving-down speed (mm/sec) 40 35 52 52
Number of main cylinders
(number of auxiliary cylinders)
Hydraulic pump motor output (kW) 2.2 3.7 5.5 7.5
Hydraulic oil tank capacity (L) 26 51 51 65
Machine mass (kg) 1600 2900 5100 6400
RG35S RG50 RG80 RG100
1 1 (2) 1 (2) 1 (2)
Model
Power supply of 380/400/460 V
Item
RG35S RG50 RG80 RG100
Primary power cable (mm2)223.58
Load current (A) 9.1 13.2 23.0 30.0
Model
Power supply of 200/230 V
Item
Primary power cable (mm2) 3.5 3.5 8 14
Load current (A) 17.0 22.3 38.0 49.1
RG35S RG50 RG80 RG100
Model
II-5
English unit system
Item
Maximum bend length (in.) 49.2 82.1 98.6 122.0
Press capacity (US tonf) 38.6 55.1 88.2 110.2
Stroke length (in.) 3.9 3.9 3.9 3.9
Open height without punch holders (in.) 14.6 14.6 14.6 14.6
Approach speed at 50/60 Hz (ips) 1.8/2.2 1.5/1.8 1.5/1.8 1.9/2.3
Bending speed at 50/60 Hz (ips) 0.31/0.37 0.28/0.33 0.28/0.33 0.33/0.40
Moving-down speed (ips) 1.6 1.4 2.0 2.0
Number of main cylinders
(number of auxiliary cylinders)
Hydraulic pump motor output (HP) 3.0 5.0 7.4 10.1
Hydraulic oil tank capacity (US gal) 6.9 13.5 13.5 17.2
Machine mass (lb) 3530 6390 11250 14110
RG35S RG50 RG80 RG100
1 1 (2) 1 (2) 1 (2)
Model
Power supply of 380/400/460 V
Item
RG35S RG50 RG80 RG100
Primary power cable (mm2)223.58
Load current (A) 9.1 13.2 23.0 30.0
Model
Power supply of 200/230 V
Item
Primary power cable (mm2) 3.5 3.5 8 14
Load current (A) 17.0 22.3 38.0 49.1
RG35S RG50 RG80 RG100
Model
II-6
4. DIMENSIONS
400 mm
{15.7 in.}
390 mm
{15.4 in.}
225 mm
{8.9 in.}
F*
F**
60 mm
{2.4 in.}
60 mm
{2.4 in.}
*Depth of RG35S, RG50, RG80
**Depth of RG100
II-7
Unit: mm
Model A B C (D) E F G H I J K L M N O P
RG35S 1200 1020 935 370 1955 1495 1800 650 920 1355 25 445 250 1745 200 60
RG50 2000 1520 940 370 1910 1495 1820 600 1670 2025 40 970 250 2410 400 60
RG80 2400 2050 945 370 2065 1495 1920 750 2240 2515 60 970 250 2895 400 60
RG100 3000 2550 1035 370 2305 1555 2110 900 2750 3065 60 1090 250 3445 400 90
Unit: in.
Model A B C (D) E F G H I J K L M N O P
RG35S 47.2 40.2 36.8 14.6 77 58.9 70.9 25.6 36.2 53.3 0.98 17.5 9.8 68.7 7.9 2.4
RG50 78.7 59.8 37.0 14.6 75.2 58.9 71.7 23.6 65.7 79.7 1.57 38.2 9.8 94.9 15.7 2.4
RG80 94.5 80.7 37.2 14.6 81.3 58.9 75.6 29.5 88.2 99.0 2.36 38.2 9.8 114.0 15.7 2.4
RG100 118.1 100.4 40.7 14.6 90.7 61.2 83.1 35.4 108.3 120.7 2.36 42.9 9.8 135.6 15.7 3.5
II-8
5. STANDARD ACCESSORIES
No. Item Description Qty Applicable model
Tool box
Single-ended
wrench
45° offset box
1 Tool set
2 Hydraulic oil Super Hydraulic oil 56 (Nippon oil)
3 Stopper 2 (0) ALL
4 Supporter 4 (2) ALL
5 2V-die holder
6 Punch holder
7 Bulb LS-6 2 ALL
Note: Quantity values enclosed in parentheses apply when machine is equipped with optional
backgauge.
wrench
Allen wrench
Brass bar
Hammer 1/2 pound
Size L: 830 mm {32.7 in.} long,
75 mm {3.0 in.} high
Size S: 412 mm {16.2 in.} long,
75 mm {3.0 in.} high
30 mm
13 mm
14 × 17 mm
8 mm, long type
5 mm
φ20 × 200 mm
1ALL
26 L
{6.9 US gal}
51 L
{13.5 US gal}
65 L
{17.2 US gal}
1RG35S
2RG50
3RG80
4RG100
1 RG35S, 50
6RG35S
10 RG50
12 RG80
15 RG100
RG35S
RG50, 80
RG100
II-9
6. OPTIONS
Name Function
Auto-backgauge system
Remote foot pedals
RR-type front gauge
Worksheet follower
One-touch punch holders*
Dial-type punch holders*
Double-side punch
holders*
Optical safety device
• Can set worksheet contact positions (bending positions) for up
to 99 processes.
• Allows continuous bending by programmed operation.
• Displays set values and current position of backgauge by LEDs.
• Has such functions as elongation compensation, backlash
compensation, and timing.
• Like bar pedal, open and close ram.
• Installed at front of machine to support worksheet with stoppers
and used for positioning worksheet at front of machine.
• Supports large worksheet during bending while following bend
angle.
• Allow punches to be installed and removed by levers without
use of any other tool.
• Allow height of punches to be adjusted with dials.
• Allow punches to be installed on both of front and rear sides.
• Emits light beams at front of installed punches and dies and
automatically stops machine as soon as two or more light
beams are interrupted by operator’s body parts or other objects.
Side guards
Two-hand control buttons
Two-person foot pedals
*Standard option
• Close up gaps in left and right frames and prevent operator’s
body parts from entering machine.
• Simultaneously pressed to open and close ram in place of bar
pedal.
• Simultaneously pressed by two persons to open and close ram
in place of bar pedal.
II-10
Part
III
Installation
1. Summary.....................................................................................III-2
1-1. Environmental conditions.....................................................III-2
1-2. Input power source...............................................................III-2
1-3. Things to be supplied by customer ......................................III-3
2. Installation procedures................................................................III-4
2-1. Location................................................................................III-4
2-2. Lifting....................................................................................III-5
2-3. Foundation ...........................................................................III-6
2-4. Placing .................................................................................III-6
2-5. Leveling................................................................................III-6
2-6. Supplying hydraulic oil .........................................................III-8
2-7. Supplying electric power ......................................................III-8
When the machine is delivered to you directly from AMADA, it is usually
transported by the specialized carrier. Instruct them where to install the
machine.
Select such a machine installation place where the space required for
worksheet loading, part unloading and machine maintenance can be
secured and where the machine can be installed on a flat surface
without ground subsidence. For details, refer to “2. Installation
procedures”.
WARNING
O Moving or carrying the machine may not only
damage the machine, but also is dangerous. Ask
a qualified contractor to perform this work.
III-1
1. SUMMARY
1-1. Environmental conditions
• Keep the machine at least 10 m {33 ft} away from a welder or any
other equipment that may produce electrical noise and magnetic
fields.
• Where the ambient temperature is not higher than 5 °C {41 °F}, keep
the machine and hydraulic pump motor energized during the day's
work.
• The higher the humidity in the place where the machine is installed,
the lower the insulation performance of its electric parts becomes.
This results in the premature degradation of the electric parts. Do
not install the machine in such a humid place.
• Install the machine in a place where it is not subjected to dust, dirt,
and organic or corrosive gases.
1-2. Input power source
Power requirement: 200/230/380/400/460 VAC±10% (transformer tap
and motor wiring is required), 3 phases, 50/60 Hz±1 Hz
NOTICE
O Supply the machine from a power source independent of a welder or any
other equipment that may produce line voltage variations. Otherwise the
machine may misoperate.
III-2
Loading...