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Table O f C on t en t s
DESCRIPTION OF THE BENDING MACHINE
APPLICATIONS
UNSUITABLE APPLICATIONS
OPERATING PRINCIPLE
3
3
4
SAFETY INFORMATION
SAFETY CRITERIA
SAFETY FEATURES
OPERATOR SAFETY
NOISE
OTHER DANGERS AND PRECAUTIONS
PRECAUTIONS
5
5
5
5
6
7
TRANSPORT
INSTALLATION
9
9
10
10
USE
11
CONTROL PANEL
STARTING THE MACHINE
BENDING
BRACKET BENDING AND MEASURING ACCESSORIES
EMERGENCY STOP
SWITCHING OFF
11
12
13
14
15
15
16
APPLICATION
OPERATING PRINCIPLE
16
16
DIAGNOSTICS
17
MAINTENANCE
18
MAINTENANCE GUIDE
CLEANING
OILS
REMOVAL FROM SERVICE AND RECYCLING
Power Circuit Diagram
Control Circuit Diagram
AVAILABLE ACCESSORIES
18
19
19
19
20
21
22
WARRANTY
23
25
This document contains copyright material. All rights reserved. This document cannot be
reproduced, fully or partially, without the written consent of the manufacturer. Only the
user of the prod uct is permitted to use the document.
2
MODEL
RPM
MOTOR
H.P
Kg/mmsq45
Kg/mmsq65
Kg/mmsq80
28
36
42
52
55
16
20
25
32
26
8
10
12
20
16
25
32
36
42
46
12 6
16 8
20 10
25 16
24 16
20
25
32
36
44
10 6
12 6
16 8
20 12
22 14
NUMBER
OF ROD
IRONS
B28
B36
B42
B52
B55
12
9
8
6
5.6
3
5
5
7.5
7.5
Fe 415 45 kg/mm2)
Fe 500 65 kg/mm2
Un s u i t a b l e a p p l i ca t i o n s
The machine is unsuitable for all uses not explicitly stated in Applications, in particular:
The model of the purchased machine, serial number and the year of manufacture
are on the manufacturer's serial plate.
Op e r a t i n g p r i n c i p le
An electric motor rotates pulley 1, which provides rotation to pulley 2 via three belts.
The rotation of the bend wheel bends the rod iron using pins inserted in the locating holes.
Striker/Checking Block
S AF E T Y I N FO RM A T IO N
S a fe ty c rit e r ia
During the design and construction of this machine, precautions and safety criteria were adopted
that satisfy the essential safety requirements of Machine Directive .
S a fe ty f e a t u re s
The structure of the frame prevents access to gears, belts and moving parts of the
transmission.
Selector switch for Automatic or Continuously pressed safety controls (dead man) to allow the
bending of rod irons:
o a button on the control panel
o a guarded pedal to prevent accidental operation.
When a continuously pressed control is released, the bending action is stopped using DC
Injection brake.
The DC Injection brake stops the motor and the moving parts as soon as the machine is
stopped or the power to the motor is removed.
O p e r a t or sa f e ty
Use gloves to move rod irons to avoid abrasions and cuts caused by the material surface.
No i s e
Equivalent of continuous acoustic noise level : 75 dB (A).
Average figure at a distance of 1 m from the machine.
Emergency Stop
P r eca u t i on s
Never try to reach the bending area with hands, especially during the automatic return
movement.
Keep the rod iron in place using the striker, pins and bush supplied.
Carry out work on the machine and maintenance only when the machine is off, with the
power plug removed.
Check the rotation of the bend wheel before placing the striker and bend pins.
P r eca u t i on s
Protection from electric shock is based on correct connection to the protective earth: the
electrical system which the machinery is to be connected to must conform to current
legislation.
The socket that the machine is connected to must be protected upstream by the installer
with a residual current circuit breaker (operating threshold not more than 30mA).
Ensure that cables between the mains plug and the machine are not in areas of
movement and nevertheless, not damaged or trapped.
Carry out work on the machine and maintenance only when the machine is off, with the power
plug removed.
TRANSPORT
The machine is supplied on a wooden pallet covered in protective cover.
Danger! Remove the accessories from the drawer, to avoid them accidentally falling out
and check it is closed when lifting
Model
Dimensions
Weight
B28
721X671X889mm
550kgs
B36
852X860C882mm
600kgs
B42
1000X975X891mm
700kgs
B52
1100X1037X891mm
780kgs
B55
1100X1037X891mm
820kgs
Use ropes or chains of sufficient strength for the model to be lifted, using hooks in the holes
or the eye bolts, depending on the version ordered.
Initially, only lift a few centimetres from the ground and ensure the machine is raised level
with the ground and the load is balanced.
Only use the wheels for short movements and for positioning the machine on an even
and smooth surface.
When transporting and when positioning check the machine's wheels to avoid unwanted
movements.
Danger! Do not attempt to move the machine up or down slopes as the weight of
the machine can cause loss of control.
INS T ALL AT IO N
D e s c r i p t i on o f t h e s u p p l y
The following are supplied, in the drawer inside the machine:
1. control pedal
2. striker
3. square pin, the correct size for the supplied model
4. bracket bending pin, the correct size for the supplied model
5. three pins and various bushes, the correct size for the supplied model
6. Allen keys for maintenance
7. user manual.
Before positioning and after each time the machine is transported, check that no
damage has occurred to the machine structure as a result of knocks or falls during
transportation, that could affect the operation and reliability of the machine.
P o s i t i o n i ng
As well as the actual area required for the machine the following requirements must be satisfied:
The electric power source must be near to the location of the machine.
The surface for the machine must be strong enough to support its weight and smooth and
level to allow stable positioning.
The environment must be well lit to allow safe use and maintenance of the machine
The area must be sufficient for the machine and the material which is to be loaded and
processed. A distance of at least 1 m from a wall must be maintained to safely carry out
normal operation and maintenance . It must always be possible to reach the control panel and
the bending area.
The area must be protected from the elements; in particular, rain and snow.
C h eck i ng t h e e l ec t r i ca l s p ec i f i ca t i o n
The machine is supplied with the electrical system requested by the customer.
Always check the figures on the plate on the motor are compatible with the electrical system
before connecting the power supply. The voltage (in Volts), the frequency (in Hz), the current (in
A) or power (in kW) must correspond with the electrical power supply.
E l ec t r i ca l c onn ec t i o n s
The power cable and power plug provide connection to a protective earth.
The use of an separate earth is required when the power cable's resistance to earth is
excessive or there is doubt over this value.
Connect the end of a length of bare copper (a section of at least 16 mm2) to the screw
inside the frame using a nut to clamp it in position.
Connect the other end to an earth. The earth must be fixed deep in the ground and
somewhere fairly humid and conductive, or it can be a strip of copper, buried very deep in
the ground.
For connection to the electrical system, use a cable with the following characteristics:
Connect Sufficiently isolated from the surrounding environment. Connect the control pedal
to the control socket on the control side.
USE
C on t r o l p a n e l
Emergency
Stop
Name
Plate
Auto - Inch
Selector
Switch
Forward Button
Phase 1 Ind.
Reverse Button
Phase 2 ind.
Phase 3
Indicator
Trip Indicator
Forward
Reverse Main
Switch
Power ON/OFF Selector F/R Switch gives power supply to the motor and control
Switch
panel whilst selecting the rotational direction of the motor
S t a r t i ng t h e mac h i n e
S t a r t up p r o ce du r e
Turn the main switch to position 1 or 2 to select the rotation of the motor and start the machine
Check all three Indicators for supply of 3 Phase power to the machine.
Check the rotation of the bend wheel and ensure corresponding rotations to position 1 and
2 on the bend wheel
Press the Forward button to turn the bend wheel to desired position. If one of the
emergency stop buttons is pressed or the control guard is open, it is impossible to
operate the controls.
Bending Mandrel
Bend Pin with Bush
Bend Wheel
Bending Pin
C h eck i n g d i r ec ti on o f r o ta ti on
The main forward reverse switch on the control panel allows the user to select the direction of
rotation of the Bend Wheel without having to alter the electrical connection. The arrows on the
switch are for indication only because the actual direction of rotation depends on the electrical
phase connected to the machine.
B e nd i ng
Check the central plate is at the zero point. If necessary return it to the zero point by
pressing the R button.
Insert the safety pin behind the reversing pin, leaving two free holes between the two.
13
10. If the button or pedal is released the machine is stopped immediately when running in
Inch mode.
11. When the safety pin activates the motor reverse limit switch, the direction of rotation
reverses and it automatically returns to the zero point.
12. To make corrections move the pin one or more holes forward if the angle is too large, one
or more holes backwards if the angle is too small.
It is advisable to use the striker to bend bars up to a diameter of 25 mm. For greater diameters it
is better to use a pin with a bush to avoid friction during bending.
When a bush is used on the pin in the central hole of the rotating plate (to create slow curves) a
bush should be chosen with an external diameter 3 to 5 times greater than the diameter of the bar
to be bent..
To bend stirrups, insert the bracket bending pin in the central hole of the rotating plate.
B r acke t b e nd i ng a nd mea s u r i n g acce ss o r i e s
Installation of bracket
measuring and bending
tools
2nd measurement
1st measurement
14
E me r g e n c y s t op
There are two red emergency stop buttons for stopping the machine in an emergency:
1. one on the control panel
2. one on the side of the machine opposite the control panel, which with machines fitted
with a shear unit, corresponds to the shear unit side.
Emergency stop buttons only halt the moving parts of the machine, they do
not disconnect the electric current. To electrically isolate the whole machine, turn the
main switch to 0 and remove the plug.
R e s t a r t i ng a f t e r a n e me r g e n c y s t op
1. Pull the button out by twisting it clockwise.
2. If necessary, return the central plate to the zero point by pressing the Reverse button.
S w i t c h i ng o f f
At the end of each working day, disconnect the machine from the site's electrical supply.
If the machine is not located under cover, protect it from the elements with a waterproof
sheet.
15
Operating Principle
The brake works on a DC magnetic injection, for which, a rectifier is installed inside the control panel. DC
current with 24V is applied to the motor winding thus stopping the motor instantly (braking). Two timers
have been installed inside the control panel which assist in the braking and reversing action of the motor.
Timer 1 : is required for setting the time for DC injection into the motor.
Timer 2: is required for breaking interval timer (Start-Stop)
Both Timers are factory set and must not be tampered with. Any changes in time
To ensure accurate braking check for loose connections on rectifier and timer regularly.
16
DIAG NOSTICS
Problem
The machine does not work when the start
button or the pedal are pressed. The button
indicator is lit and the voltage and power
supply indicators are lit.
Action
Check that the guards are lowered. If the
guards are lowered one of the micro switches
may be faulty.
17
MAINTENANCE
Maintenance operations must be carried out by qualified personnel in accordance with all
current legislation.
Electrocution risk !
Carry out work on the machine and maintenance only when the machine is off, with
the power plug removed.
Switch off the machine and disconnect the power plug before changing a fuse or resetting of the magneto-thermal safety plug
Ma i n t e n a n c e g u i d e
SL.
NO.
DESCRIPTION
DAILY
MONTHLY
YEARLY
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
18.
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
19.
C l ea n i ng
Danger! Turn off the machine and unplug from the electrical supply.
Unscrew the four screws fitted to the frame and the four screws on the box using the
Allen keys supplied in the toolbox.
Check the condition of the limit switches and remove the scale deposit on the reduction gear.
Afterwards, replace the frame plate in the correct position using the eight screws.
Oi l s
Oil
Litre
s
5
8
1
3
Models
B - 28
B - 36
B 42, B- 52, B - 55
Usage of Grease
Use EP-2 grade grease for greasing all rotating parts
R e mo v a l f r o m s e r v i ce a nd r e c y c l i n g
When the technical and operating life of the machine is finished, the machine must be deactivated.
Although removing it from service so it can no longer be used for what it was intended, it should
still be possible to recycle the primary materials.
To safely deactivate the machine follow this procedure:
Turn off the machine and remove the power plug. Cut the power plug from
the cable.
Empty the lubricating oil. Collect the oil from the drain plug under the machine in a suitable
container.
Remove the wheels. Follow the procedures given in Transport if the machine is to be
moved.
Do not release oil and grease into the environment. Dispose of by contacting the
service authorised to deal with used oil.
19
Ava i l a b l e acce ss o r i e s
This page may also be used to order any accessories required. Specify the model for
which the part is required when ordering, as parts are mechanically different.
Accessory
Quantity
B 28
B 36
B 42
B 52
B 55
150
180
228
256
288
336
400
500
22
WARRANTY
Terms and Conditions
Jaypee India Limited warrants each shearing/ bending machine and its aggregates and components
there of manufactured by Jaypee India Limited & distributed or sold through their approved agents to be
free from defect in material and workmanship under subject to the following conditions.
1. Warranty shall be force until the expiry of a period of twelve months from the date of delivery/ invoice to the
customer entered in the warranty or 3750 running hours, whichever is earlier.
2. This warranty shall be applicable to the first registered owner only.
3. During the stated period of warranty, obligation of Jaypee India Limited shall be limited to repairing/
replacing free of charge such parts of the supplied Shearing/ Bending which on examination shall be
deemed defective in the opinion of Jaypee India Limited or its authorized representatives. Such defective
part or parts which have been replaced shall become the property of Jaypee India Limited.
4. Parts not manufactured by Jaypee India Limited but supplied as equipment, components such as Electric
Motor, V Belts, Electrical Accessories and all such proprietary items shall be governed by the warranty
terms & conditions offered by their manufacturer. Jaypee India Limited shall refer any defects thereof to the
respective manufacture & assist the owner of the Shearing/ Bending machine to prefer claims for repair/
replacement. In all cases, the manufacturers decision shall be deemed as final in this matter.
5. The warranty is against all defects in material & workmanship and is limited to making good of the defects
arising solely from the use of faculty material or manufacturer, and developing under proper/ recommended
use of the Shearing/ Bending machine as per service manual and maintenance schedule.
6. The right to determine the nature of defect and whether the component requires repair replacement will be
solely with Jaypee India Limited.
7. This warranty shall not be applied to:
A. Defects arising out of faculty use, application or maintenance by the user. As we are not getting back to
back warranty from the manufactures.
B. Parts replaced as a results of normal wear, such as Blades, Springs, V- Belt, Brake unit Gear oil (top up)
and other consumable items.
C. Normal periodic replacement parts and routine maintenance services.
D. Damages due to use of replacement parts, other than those & recommended by Jaypee India Limited
particularly Blades, Springs, Pins & Bushes etc.
E. Incidental or consequential damages such as downtime, inconvenience damage to personal property,
commercial losses such as ideal downtime during periodic when the Cutting and Bending machine are
undergoing repair/ service, or scheduled maintenance.
F. Any damage or loss due to accident during operation in the field. Fire, Floods, Natural calamities or 5
reasons beyond the control of the manufacture.
8. Jaypee India Limited reserves the right to make modification in design of the machine, as a result of
continuous development in technology & updating the performance of the product from time to time.
23
GENERAL: Customers are requested to contact the manufacturer/ authorized dealers in the event of any
premature failure or component deficiencies and we shall take immediate steps to depute our engineers or
approved representatives to investigate & rectify the complaints.
Jaypee India Limited lays maximum stress on quality control and efficiency and performance of product. After sales
service team is always available to promptly attend to any unlikely problems that may arise to maintain the quality
or service of the equipment. Our team of engineers is at hand to offer you prompt service without obligation,
so that you get optimum performance from the Jaypee Shearing/ Bending Machine.
THIS WARRANTY IS ISUED SUBJECT TO THE JURISDICTION OF CIVIL COURTS OF KOLKATA. WEST
BENGAL ONLY.
Customers are deemed to have read, understood and agreed to the terms of warranty once the warranty is issued.
24
SERVICE TECHNICIAN
FIELD R E P O R T
CONGRATULATIONS!!
Machine Name
Location
Model No.
Machine No.
Date of Visit
Job Start Time
End Time
Remarks
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Dated:
Service Technician Sign:
SERVICE HELPLINE
+91 9674515151
Call now for Troubleshooting
25
SERVICE TECHNICIAN
FIELD R E P O R T
CONGRATULATIONS!!
Machine Name
Location
Model No.
Machine No.
Date of Visit
Job Start Time
End Time
Remarks
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Dated:
Service Technician Sign:
SERVICE HELPLINE
+91 9674515151
Call now for Troubleshooting
26