Chiao-Sheng-Machinery - Manual Dobladora

CHIAO SHENG MACHINERY
50TBRE-P
OPERATION MANUAL
No.2 , Sec.2, Huandong Rd., Tainan Science Park Sinshih District,

Tainan City 74144, TAIWAN, R.O.C.
TEL:+886-6-5055800 FAX:+886-6-5055798
WEBSITE: http://www.tubebender.com.tw
E-MAIL: tubebend@ms24.hinet.net
CE305-GEF 50V000
Doc. No. CE305-GEF Chiao Sheng Machinery Co., Ltd. Version 50V000
WARNING!
 Do not modify any systems and components of machines without authorization and permission
from administrators in the Technology Department of CSM.
 Users who modify machines without authorization will loss the rights and the warranty from Chiao
Sheng Machinery Co., Ltd.
 Do not modify the safety system and electrical system of machines to ensure the safety of
operators.
 Operators must read this handbook first before operating or installing components of machines.
The inexactitude installation and operation would cause the danger of operators and the damage
to machines.
 Do not distribute this handbook to other individuals, companies or organizations.
 Do not copy this book in any forms.
Attention!
 Users have to inspect the parts and components of the machine right after receiving. If there are
any broken or missing parts caused by the delivery, please contact the shipping company
immediately to ask the indemnification of the damaged and the lost parts.
 This manual provides general operating instructions for delivery and installation, safety regulation,
explanation of operation, installation and adjustment of the molding tools, maintenance of benders,
special treatment for the abnormal bend of the tube, and clearing malfunctions of the automatic
tube bender.
The Usage of Automatic Tube Bender

 Please use the Automatic Tube Bender with rational and careful attitude to keep the safety of the
operators and prolong the life of machine.
 For the Automatic Tube Bender is manufactured with enhanced technologies, correct usage and
maintenance with good plans can keep the life of machine longer. Any human error and improper
maintenance would cause serious damage to the machine in operation, and also accelerate the
worn out of components, which would even threaten the safety of operators seriously.
 The Automatic Tube Bender presented in this manual can only be used to bend the metal tubes.
Please do not try to bend nonmetal material. If the operators use the bender for other uses, it
would be dangerous.
 If you do not follow the regulation and cause some damage, you will lose the rights and the
warranty from Chiao Sheng Machinery Co., Ltd.
Doc. No. CE305-GEF Chiao Sheng Machinery Co., Ltd. Version 50V000
Index
Page
Part Ⅰ Transportation and Installation
1 Packing and Transportation………..…….……………………………....…….…. Ⅰ- 3
2 Installing the Machine…………….….……………….………….………….…...... Ⅰ- 4
3 Choice of Oil Sorts……………………………….…………………..……..……… Ⅰ- 5
4 Cooling System (Not applicable for all electric model) …………...……………................. Ⅰ- 8
5 Electrical System ………..…………..…………………………..….…………...... Ⅰ- 9
Part Ⅱ Safety Section
1 Safety Warning Label…………………………………………………………........ Ⅱ-4
2 General Information……………………………………………………………..…. Ⅱ-11
3 Electrical, Safety Practices……………………………………………………...… Ⅱ-14
4 Hydraulics, Safety Practices (Not applicable for all electric model) …………………….... Ⅱ-15
5 Noise Levels………………………………………………………………..…...….. Ⅱ-16
6 AC Servo Driver, Safety Practices……………..……………………………….… Ⅱ-17
7 Tooling Setup……………………………………………………………………….. Ⅱ-19
8 Machine Operation ………………………………………………………….....….. Ⅱ-21
9 Maintenance……………………………………………………………...……….... Ⅱ-25
Part Ⅲ Machine Operation
1 Overview of Machine…………... …………….……..…………………………….. Ⅲ-3
2 Instructions of Machine Operation…………………..……………….…………... Ⅲ-11
3 Introductions for Bend Data Programming………...........………..…………..… Ⅲ-33
Part Ⅳ The Maintenance
1 Introduction of Machine Function………………………………………………… Ⅳ-3
2 Maintenance of Machine.………….…………………………………………..…. Ⅳ-6
3 Lubrication and Maintenance ………………………………………….…………. Ⅳ-7
4 Maintenance of Hydraulic Cooling System (Not applicable for all electric model) ……… Ⅳ-11
5 Maintenance of Machines' structure ……...……….…………………………... Ⅳ-13
6 Selection of Lubricants.……………………………………………………………. Ⅳ-14
Part Ⅴ Troubleshooting
1 Troubleshooting of the Normal Type Bender……..……………….…………..… Ⅴ-3
2 Special Treatment for the Abnormal Bend of Tube………..…………..……….. Ⅴ-8
Version 50V000 Chiao Sheng Machinery Co., Ltd. Doc. Page I-1
Part Ⅰ Transportation and Installation
Before installing this machine, please read:

" Transportation and Installation ".
Attention!
Why most accidents occur

is because of not following
safety regulations.
The operators should follow all the rules emphasized in this manual to
prevent accidents. If the tube bender needs maintenance, operators
should report this to the supervisor and stop working on the machine until
the problem is rectified.
This tube bender should be used for the stated tube capacity and
material resistance rated maximum bending. Never try to bend non-metal
material or use the bender to execute illegal usage. Noncompliance of
maintenance, safety and capacity will void all rights and warranty by CSM.
Part I Transportation and Installation

Index 1
1 Packing and Transportation ................................................................................... 3

1.1 Method of Packing .............................................................................................. 3
1.2 Method of Transportation .................................................................................... 3
1.3 Position ............................................................................................................... 3
2 Installing the Machine ............................................................................................. 4

2.1 Cleaning Machines ............................................................................................. 4
2.2 Operating Environment ....................................................................................... 4
2.3 Shock-Absorbing Pads ....................................................................................... 4
2.4 Leveling Machines .............................................................................................. 4
2.5 Toolbox ............................................................................................................... 4
3 Choices of Oil Sorts ................................................................................................ 5

3.1 Hydraulic Oil (Not applicable for all electric model)............................................. 5
3.2 Lubrication .......................................................................................................... 7
4 Cooling System (Not applicable for all electric model)........................................ 8

4.1 Connecting the Hydraulic System ....................................................................... 8
4.2 Suggestion! ......................................................................................................... 8
5 Electrical System .................................................................................................... 9

5.1 Warning! ............................................................................................................. 9
5.2 Connecting the Power Source ............................................................................ 9

1 Packing and Transportation

1.1 Method of Packing
There are two ways to pack, which are in a wooden case or containerization. Fix the position
of the machines inside the boxes, and mark the label outside the boxes.
1.2 Method of Transportation

Read the gross weight from the packing list. Then use a suitable crane or forklift to move the
machine to the preset position. The gross weight of this machine is listed in the Table T.1 of
Technical Document.
1.3 Position
Open the packing and then use suitable steel slings according to the local law that can endure
the weight of the machine to attach to all of the eyebolts on the tube bender. Use the derrick to
move the machine to the correct position. Use suitable lifting slings when a crane is used. If
using a forklift truck, use a suitable rated forklift truck.
The diagrams of operating range and hanging position are listed in the Technical Document.
Prepare adequate space before setting the machine.
 This manual book belongs to the original editor and CSM. CSM has the right to modify the
connection and copy it for the customers.
 No one can modify, copy, and use this book without the allowable of editor and CSM, or it
will break the wisdom property rights.

2 Installing the Machine

The method that we take on our machine is Complete Assemble Transport. When users begin to
setup the machines initially, follow the steps as follows:
2.1 Cleaning Machines

Use kerosene or similar fluid. Clean the oil and the rust from the machines. And take the effective
protective method to prevent the accessories of the die and the machines from damage.
2.2 Operating Environment

We suggest that the machine must be located in a dust-free area. The indoor temperature range
should be between 0°C and 38°C (32°F~99°F). At the bending section of the machine, provide
sufficient space for loading and unloading the tube. The detail information is enclosed in the
technical specification. Please refer to the technical document.
2.3 Shock-Absorbing Pads

For fastening the machine firmly on the floor, users need to drill holes on the floor so that the
machine base can be installed. Further, installing the shock-absorbing pads bought from local
markets could smooth the whole installation. (Vender provides four shock-absorbing pads for all
CNC series machines.)
2.4 Leveling Machines

Users should apply the leveling bolts and plates (packed in toolbox) to check the level of the
machines to ensure that the machines would not move and shake during the bending process.
Use the adjusting screws or the proper tools to fix and tighten the slack parts of the machine,
which get loosen from shaking or colliding during the transport process. The bend head and
carriage were fixed before transportation in all machine models. Be sure loose the fixed
plate and eye bolts before testing run to evade collision occurred during operation.
2.5 Toolbox
The tools in the toolbox are listed in the Technical Document. Prepare adequate space before
setting the machine.

3 Choices of Oil Sorts

3.1 Hydraulic Oil (Not applicable for all electric model)
3.1.1
Check before pouring oil. Open the lid on the hydraulic oil tank, and check inside the tank to
ensure that it has no water and rubbish. The hydraulic oil tank capacity of this machine is listed
in the Table T.1 of Technical Document.
3.1.2
We suggest using the high-quality hydraulic oil with wear-resistant additives. The viscosity
index of the oil is 150SUS at 100°F (or VGO-46).
Table 3.1 Suitable Oil
Brand Production Brand Pour Point(°C) Flash Point(°C)
Bartran 42 -33 222
HP
Bartran 68 -36 208
Rando HD 32 -33 220
CALTEX
Rando HD 68 -30 226
Hydraulic AW Series 46 -18 201
CALUB
Hydraulic AW Series 68 -18 204
46AW -30 242
CPC
68AW -30 246
Visga HP 46 -21 232
ELF
Visga HP 68 -18 242
Nuto H 46 -33 241
ESSO
Nuto H 68 -30 220
Hymax 32R -30 228
KINGUNION
Hymax 68R -27.5 236
Super Hyrandq 32 -25 236
NISSEK
Super Hyrandq 68 -25 258
FG-AW 46 -12 185
PENNZBELL
FG-AW 68 -12 185
Hrdro AW 46 240
SHELL
Hydro AW 68 240
3.1.3
Pump the hydraulic oil through the filter into the tank until the oil covers the top of the sight
gauge in the base. The oil level will drop as the hydraulic system fill when the machine is first
operated. After initial operation, add the oil to bring the reservoir oil level back to the gauge
level indicator.

3.1.4 Attention!
Some air may be stayed in the cylinders, which may cause the hydraulic system to have
irregular performance when the machine is operated initially. Cylinders are air-relievable with
continuous operation through 20 to 30 cycles, and automatically relieve air from the hydraulic
system.
3.1.5
Check the hydraulic oil level over 2/3 of the oil sight glass in front of the machine base, and
refill with the suitable hydraulic oil if it is necessary.
3.1.6
Keep the hydraulic oil reservoir cleanly.
3.1.7
Do not let the hydraulic hoses of bending arm rub the floor.
3.1.8
In order to achieve the best performance of hydraulic oil, choose the suitable oil for different
temperature.
Table 3.2 Suitable Oil for Different Temperatures
Range of
Type and Number of Oil
Temperature
Viscosity ISO 68 Viscosity ISO 68
25°C Above
China Petroleum AW68, LPS68 BP Energol SHF 68

10°C ~ 25°C

Under 10°C

3.2 Lubrication
3.2.1
The machine is equipped with an oil-type automatic lubricator. The reservoir of the lubricator
was initially set and filled at the factory with Machine Way Lubricant #68. Obtain good quality
Machine Way Lubricant and add to the lubricator as needed. See listing of recommended oils.
3.2.2
The Auto lubricator was set at the factory. The lubricated frequency was decided by the times
of clamp die. Refer to Part III - System Configuration - Numeric setting page (System lub.
frequency & System lub. time). The operator can change the setting time, as you need.
3.2.3
Note! The center lubricator was started by clamp’s frequency. Refer to Part III - System
Configuration - Numeric setting page (System lub. frequency & System lub. time). The
tank is equipped with reverse stop valve so that the oil pumped out cannot return. Fill the
lubricator reservoir weekly.

4 Cooling System (Not applicable for all electric model)

4.1 Connecting the Hydraulic System
Through the long time operating, the whole hydraulic oil will become hot. The hydraulic system
connected the cooling system and used the fan type cooler to reduce the whole system
temperature. Users must ensure that hydraulic oil temperature be kept below 55°C. The sensor
was installed in the tank and can be set from the controller on the tank. When the temperature
was over 55°C, the fan would be started to cool the hydraulic oil.
Attention! The radiator has a filter to prevent the dust. Be sure to keep the filter cleanly.
4.2 Suggestion!
If the weather in your country will freeze in the winter, you might choose the hydraulic oil with
antifreeze additive. This will make the bender to start easily. Attention! Clean the filter in a fixed
time. If it is necessary to wash with water, the motor and the wire must away from water. The
electric power must be cut off!

5 Electrical System
5.1 Warning!
Check the input electric voltage on the motor and the control cabinet. Make sure they are the
same. Be sure to keep the electric voltage at 3 ∮ HZ V 5%. (The actual
values according to the mark on the machine)
After installed and connected the power source, pressed the power “on”. If the buzzer was “on”,
the phase sequence or phase loss was incorrect. The inside of control box had installed a
monitoring relay for monitoring the phase sequence and phase loss.
5.2 Connecting the Power Source
19. Start button 1 2 1. Clamp die 10. Power on button

(Option) 2. Pressure die assist 11. Power off button
19 16 19 3. Tube support 12. Hydraulic system
4. Collet 13. Bend head
5. Carriage 14. Bend arm
6. B axis rotation 15. Touch screen
7. Mandrel base 16. Emergency stop button
14 1 13 2 8. Circuit breaker 17. Foot pedal-start
9. Power indicator 18. Foot pedal-temporary stop
Type EMB, EMR
Option
1 2 3 4 5 6 7
16 15
9
10
11
14 13 Electrical
connection
12 8
17 18 point
Fig-1
Connect the L1, L2, L3 power lines and the machine in the end of the control broad. Remember!
There is an on-off button to control the power. Use the cable to connect the ground according to
the country electric regulation.

Version 50V000 Chiao Sheng Machinery Co., Ltd. Doc. Page II-1
Part Ⅱ Safety Section

The tube bending machines
are potentially dangerous if they are not used correctly.
Please observe all information about the use, misuse and hazards
associated with these types of machines.
Before operating the machine,
please read "Safety Section".
Attention!
Why most accidents occur

Is because of not following
safety regulations.
Please read this safety section and the owner’s manual before tooling
setup, operation or maintenance. The operators should follow all rules
emphasized in this handbook to prevent accidents. If the tube bender
needs maintenance, operators should report this to the supervisor and
stop working this machine until the problem is rectified.
All factory and national safety precautions that are in force where the
equipment is located must be observed at all times. No practices can be
carried out on the machine that would result in unsafe, or that would
endanger the machine operators in any way. The machine must not be
operated in a manner that may cause immediate or long-term deterioration
to the environment.
The maintenance and repair should be executed by the professional
technicians. This is the best safety measure for both human and machines.
If the operators cannot understand the maintenance procedure, please
contact the service engineer from the agent. But do not try to repair the
machines by yourselves.
Part II Safety Section

Index 2
1 Safety Warning Label .............................................................................................. 4

1.1 Important Points.................................................................................................. 4
1.2 Meaning of Label Colors and Basic Sign ............................................................ 5
1.3 Diagrams of Symbols Position ............................................................................ 9
1.4 Potential Hazards ............................................................................................. 10
2 General Information .............................................................................................. 11

2.1 Introduction ....................................................................................................... 11
2.2 Usage of Bending Machines ............................................................................. 11
2.3 Prevent Overloading ......................................................................................... 12
2.4 Develop a Safety Project .................................................................................. 13
3 Electrical, Safety Practices ................................................................................... 14
4 Hydraulics, Safety Practices (Not applicable for all electric model) ................. 15
5 Noise Levels .......................................................................................................... 16
6 AC Servo Driver, Safety Practices ....................................................................... 17

6.1 AC Servo Drivers .............................................................................................. 17
6.2 Explanation of Fault Symbols ........................................................................... 17
6.3 Safety Practices ................................................................................................ 17
7 Tooling Setup......................................................................................................... 19
7.1 Overview ........................................................................................................... 19
7.2 Tool Setup Safety.............................................................................................. 19
8 Machine Operation ................................................................................................ 21

8.1 Machines Guards.............................................................................................. 21
8.2 Safety of Operator ............................................................................................ 21
8.3 Safe Operating Procedures .............................................................................. 23
8.4 Safety Precautions during Bending................................................................... 24

9 Maintenance .......................................................................................................... 25
9.1 Machine Longevity ........................................................................................... 25
9.2 Machine Cleanliness ........................................................................................ 25
9.3 Machine Upgrades ........................................................................................... 25
9.4 Safety of Maintenance...................................................................................... 26

1 Safety Warning Label

Labels are affixed on the machine and contain brief messages outlining the hazards associated
with that portion of the machine. It is important to note these labels and follow the precautions they
outline.
All signs, nameplates and legends that are attached to the machine are included as following
section with an explanation of their meanings.
Each sign is identified with a unique part number (P87-DW_____) in accordance with Chiao Sheng
Machinery Ltd. Procedures.
All the signs are language-specific for the shipping destination of the machine.
1.1 Important Points

A. The signs should be regularly checked to ensure that they remain clean and visible, and that
their meanings are still appropriate. The signs must not be obstructed in any way.
B. It is the responsibility of operators to report any condition or occurrence that there is a
warning sign or the correct sign is not correctly displayed. The operators must ensure that
the instruction on the warning signs is carried out, or has been complied with before
operating the machine.
C. It is customers’ responsibility to replace any warning signs that become damaged or illegible
at any time during the life cycle of machine. These signs can be provided from Chiao Sheng
Machinery Co., Ltd.
D. Chiao Sheng Machinery Co., Ltd. or their appointed representatives will not be held
responsibility for any accident that occurs on the machine as a result of a mandatory safety
or warning sign not being displayed in the designated position on the machine.
E. More and more people attach great importance to the quality of life and use holidays to
travel in Taiwan, the knowledge trip especially. However, the traditional guides can not satisfy
the needs of the common people. It is easy to provide a good solution with the wireless
positioning system and MMS.

1.2 Meaning of Label Colors and Basic Sign

1.2.1 Types of Warning Label Colors
Safety Color Meaning or Purpose
Red Stop, Prohibition
Yellow Caution, risk of danger
Blue Mandatory Action
Green Safe Condition
1.2.2 Types of Warning Basic Sign

Basic Signs Explanations
Background color is white. Circular band and cross bar is red.

The symbol is black.
Used in areas of serious danger.
Background color is yellow. Triangular band is black.

The symbol or text is black.
Used mainly to call attention to items during usage (when in
operation.)
Background color is blue. The symbol or text shall be white.

Used mainly to indicate a specific necessary procedure.
Background color is green. The symbol or text is white.

Used in areas of safety.

1.2.3 Meaning of Symbols

No. Diagram Warning Titles And Meaning
Danger of Pinching Warning Symbol
This symbol is used on warning label for areas at which there is a
danger of serious injury by having a body part pinched between
1
interior moving parts or rotating parts.
These caution items include the safety mechanism necessary for
avoiding a dangerous situation.
P87-DW009
Electric Shock Warning Symbol

There are areas of high voltage inside the control panel and
2 operating panel and the possibility of electric shock exists.
Anyone touching the interior should have a specialized knowledge
of electronics.
P87-DW001
Danger of Being Caught-Up Warning Symbol

There is a possibility of getting a body part caught up in a gear
3
resulting in serious injury.
Never touch this area during operation.
P87-DW002
Danger of Being Caught-Up Warning Symbol

There is a possibility of getting a body part caught up in roller
4
resulting in serious injury.
P87-DW010

There is a danger of having a body part pinched between interior
5
moving parts resulting serious injury.
P87-DW003


There is a danger of having a body part pinched between interior
6
moving parts or revolving parts resulting in light to medium injury.
P87-DW004
Use Guard
7 There is a possibility of getting a body part injured.
Use guard in operation.
P87-DW012
Emergency Stop Push Button

8
Push it while in danger. The machinery will stop.
P87-DW016
Hazardous Voltage!
It will shock, hum, or cause death.
9
Do not work in this enclosure unless familiar with these electrical
circuits and safe servicing procedures.
P87-DW005
Confirm The Power

Obey the procedures as following:
10
Before performing maintenance, pad lock main disconnects switch
in off position.
P87-DW006

Moving parts inside openings can crush hands or feet.

11 Do not put hands or feet in openings when the hydraulic motor is
running
P87-DW011
Prohibit Dismantling
To prevent from injury, the whole hydraulic system and any
12 components of hydraulic system can’t be separated and loose
when the hydraulic motor is running.
Before maintenance, make sure the motor is turned off.
P87-DW007
Keep safe distance when operating.

When loading the tubes, please keep 45° between the carriage and
13
the operators in order to avoid the damage from the action of the
servo motor.
P87-DW008
Swinging arm closes with great force.

It can cause severe crush injury
14
Do not stand between opening arms when the hydraulic motor is
running.
P87-DW013
Arm swings out with great force.

It can cause severe crush injury.
15
When the hydraulic motor is running, be careful of swinging arm
and the bent material.
P87-DW015

Space between dies may not be guarded.

To prevent your hands or fingers from injury, must keep your
16
hands out of pinch points as loading material.
Before installing or adjusting dies, make sure motor is turned off.
P87-DW017
17 Don’t enter the working area.
P87-DW014
1.3 Diagrams of Symbols Position

The diagram of safety position is attached in Technical Document. The number meanings which
were labeled on the machine please refer to 1.2 Meaning of Label Colors and Basic Sign.

1.4 Potential Hazards

The most potentially hazardous areas of the benders are:
1.4.1
The area defined by the total travel of the swinging arm. The area between the stationary arm
and the swinging arm is especially dangerous.
1.4.2
Die area.
1.4.3
Work area ahead of the machine nose swept out by the part being formed.
Note: When loading the tubes, please keep 45° between the carriage and the operators in
order to avoid the damage from the action of the servo motor.
Each of these areas is identified with a corresponding safety label. The labels are shown in the
Technical Document, along with a general diagram of a bender. The label areas are noted on
the diagram.

2 General Information
2.1 Introduction
Most accidents are caused by people failing to follow simple and fundamental safety rules or
precautions. Lack of attention to the instructions in this manual can result in a reduction of
efficiency, accidents and most importantly, personal injury.
As soon as an operator determines that a bender is malfunctioning or needs maintenance, he
should notify his supervisor and discontinue operation of the machine until the necessary repairs
are made.
2.2 Usage of Bending Machines

2.2.1 Bender Usage
The usage of the bender in a thoughtful and intelligent manner is of utmost importance. The
safety of operators and die setters, as well as the total useful life of the machine is involved.
The benders, by their nature, are ruggedly built. With proper use and maintenance the machine
will give you many years of service. However, through misuse or accident, the machine can be
severely damaged during a single operational cycle. The misuse of a bending machine may
not be intentional, but misuse does accelerate the wear and deterioration of component parts.
2.2.2 Safety Board

There is a safety board located near the inside of swinging arm. If operators come into the
range of the swinging arm action and touch the limit switch, the screen will show this special
situation and the machine will cut off the motor power by itself to prevent operators’ pinch injury
from unintentionally entering.
2.2.3 The Device of Emergency Touching Control Power Failure

When the machine gets in the emergency situation, you can press the emergency stop
button to break the action of motor to prevent from dangerous events. After hazards has
disappeared, you need to restart the motor.
2.2.4 The Location of Emergency Stop Button

A. On the Operating Board
When you press it, the power of all motors and servomotor will be cut.
B. Emergency Stop (At the top of foot pedal)
When you press it, you’ll cut off the power of the lubrication system.

2.3 Prevent Overloading

Abuse of bending equipment can result in the overloading of the machine’s components.
Overload may be unintentional and can occur simply because the tube or pipe used require more
torque than machine is designed to produce.
2.3.1 The Burden of Operation

Confirm the burden of the operation to prevent the machines from overloading, or it will
influence the using time limit and damage the operators' safety.
2.3.2 To Know the Burden of Bending

Warning! Maximum bending capacities are based on mild-steel tubing with a tensile strength
of 40 kg/m², and tube O.D.X W.T. (Outside Diameter × Wall Thickness) is listed in the Table
T.1 of Technical Document. Must obey these specifications, or it will cause machines get
serious damage and the company will have an expensive extra maintenance expense.

2.4 Develop a Safety Project

A continuous, supervised project of safety training and instruction can help you minimize the
possibility of injury. The safety project must have leadership and direction from management.
Effective safety training depends on the quality of supervision. Supervisors must be kept informed
in all areas of their job responsibility, including safety. Supervisors should make daily inspection
tours of their departments. Encourage supervisors to identify, report and correct any safety
hazard. Machine operators should be encouraged to regularly demonstrate and promote their
personal safety awareness.
2.4.1 Sense of Safety Training

To get the best protective effect, the suitable training is needed. it's necessary to notify the
employees about the personal safe sense, the suitable behavior and some important
regulations including the tooling setters, safe device, operating method, and individual safety.
2.4.2 Plan of Safety Training

Build up a safe training plan of executing and supervising. Then supervisors can direct and
lead the employees to follow the plan, and make sure the safe training be able to improve the
quality of the management.
2.4.3 Feedback
To consider the duty of work and safety, supervisors should go around to inspect every work
area everyday to promote the personal safe sense and the safe and dangerous knowledge of
the employees, then reflect the safe situation and improve or deal with it immediately.

3 Electrical, Safety Practices
Warning Lethal Voltages!
A. The incoming connections on the main isolator terminals will always be live. Do not touch. If
an external auxiliary power socket has been fitted, this will also be live at all times. Only allow
qualified personal to open the electrical enclosures.
B. Before using the machine, the connections at all transformers must be changed to match the
supply voltage of the country where the machine is to be operated.
C. Before any electrical cabinets are opened, the machine must be totally isolated. The main
three-phase power supply to the machine must be turned OFF and clearly marked that
personnel are working on the machine.
D. The main isolator switch must then be locked OFF by using a suitable device. The device
must be of such a design that allows individual padlocks to be inserted: one padlock for each
person working on the machine. It must be impossible for the main isolator to be turned ON
until all padlocks and the locking devices have been removed. Caution! The incoming main
power supply will always live even when the main isolator is turned OFF.
E. Additional signs should be displayed on the machine and the control cabinet, to warn that
personnel are working on the electrical system.
F. The electrical control cabinet door of the machine must be closed before the main isolator
switch is turned ON to restore power to the machine. Do not leave the door open and attempt
to restore power from inside the cabinet by overriding the switch.
G. The maintenance operators have to take the electrical specialized courses. Please check if
operators have the Circuit Diagrams before the maintenance.
H. Power Supply: ±5% Voltage.
I. The protective device like limit switch couldn’t be shorted or changed.
J. The install operation has to obey the last country electrical law, and be tested completely
according to the law.

4 Hydraulics, Safety Practices (Not applicable for all
electric model)
Warning High Pressure Fluids!
A. This pressure can be measured at a point on the main manifold using the gauge provided.
B. Never, under any circumstance, release any machine hydraulic fittings or assembles from
the system under any pressure. Check to ensure that all pump motors are OFF. When
accumulators are fitted, the system is in a discharged state.
C. Regular checkup must be conducted to all the hydraulic hoses on the machine to ensure that
they remain in a good condition. They should not have any severe abrasions. The machine
must never be used if any hydraulic hoses are split or fractured.
D. All hydraulic components fitted to the machine have been sized (in the case of the hoses
tested) to suit the maximum operating system pressure, as shown on the hydraulic circuits.
Any increase in pressure above the one shown will result in potentially dangerous operating
conditions, and it has to be avoided.
E. Ensure that lubricants and hydraulic oils are nontoxic when purchased from other suppliers,
and only use the products matched with the task.
F. Prolonged contact with mineral oils on bare flesh may remove the natural oil of the skin, and
cause dry out and possible local irritation of the skin. Always wear gloves when handling
hydraulic oil. Never swallow hydraulic oil under any circumstance and if accidentally swallow,
do induce vomiting.
G. For specific safety information regarding oils, please refer to the documentation from the
suppliers. All industrial oil suppliers are obliged to provide full safety information about their
products.
H. Always seek medical advice if oil is swallowed in large quantities.
I. Please clean the oil, which leaved on the ground during maintaining machine or adding the
hydraulic oil.
J. The nullification oil has to handle according to the local law.

5 Noise Levels
The machine is designed and tested to ensure that emission of airborne noise is reduced to the
lowest level, and fall under the acceptable range based on the type of machine.
Noise Levels Circumstance

The noise level read on the machine was measured at the operator
80dBA
workstation.
70dBA This reading was registered with a background noise level.
However, it is strongly recommended that the machine operator and other personnel in the direct
vicinity of the machine adopt the good working practice of wearing suitable ear defenders while the
machine is in operation.

6 AC Servo Driver, Safety Practices

6.1 AC Servo Drivers
The Servo Amplifiers are mounted on the control side of the electric cabinet. One servo amplifier
is fitted to control each AC servomotor driving one axis on the machine. e.g. feeding (Y Axis),
rotating (B Axis), bending (C Axis) and shifting horizontally (X Axis). Each servo amplifier is
monitored by a LED display mounted on the panel of the electrical cabinet to indicate that if it is
active. If the amplifier is not active or is overloaded, then LED monitoring that particular amplifier
will not be illuminated. Under this condition the machine will not run. The Operating and setting
Instruction manual published by the amplifier manufactures, is included with the machine
documentation. This instruction is therefore limited to immediate fault diagnosis.
6.2 Explanation of Fault Symbols

Each amplifier is equipped with a segmented LED display on its front plate, which serves as
status and fault symbols. The explanation of the symbols is enclosed within the technical
specification document.
6.3 Safety Practices

A. Never touch the interior of servo driver while running due to the high-voltage circuit in the
servo driver. Never perform overhaul by yourself, and always make request to our company
or agents appointed by our company.
B. Right after the power is turned off, the circuit may still be charged with high voltage for a while.
If you need to touch the terminals of the terminal board, or the inside of the driver, please turn
off the main power and control power externally and wait for 5 minutes or more.
C. Please put the cover on the terminal board to prevent electric shock while using the driver.
D. When motor and peripheral units are turned ON, do not touch the driver, for the temperatures
of these units are rising. Specifically, in attending the regenerative resistor, the temperature of
regenerative resistor becomes quite high. Never touch the resistor.
E. As to the driver radiator, the temperatures of regenerative resistor and motor are quite high
for a while, even after shutting off power supply. Do not touch these units.

F. When any alarm has occurred, remove causes to assure safety, then reset alarm and restart.
(If the alarm number is 09, 10 or 11, read the message number on the display of servo driver
that is mounted on the inside of control box near the back end of the machine. To prevent any
accident, you must handle some processes according to the regulations of Technical
Document at once.)
G. When you do not want to use the motor and the machine for a long time, please turn off the
power.
H. Firmly set and install the equipment to prevent physical injuries caused by insufficient setting
ad installation in case of earthquake.
I. After earthquake, make sure to conduct safety checkup.
J. The inner parameter has been passed the safety test. Please don’t modify it without any
permission.
K. When you want to take apart the servo motor, please turn off the power.

7 Tooling Setup
7.1 Overview
Tooling setup is an extremely important job. The safety of the operator depends on the proper
execution of this job. The die setters should have a practical working knowledge of bending
machines, dies and material. He must know and remember the importance of proper die
adjustment. Tooling must be the proper size for the machine. Overloading a bender by attempting
to bend tubing larger than the rated capacity can result in mechanical failure and possible injury
to operating personnel. Along with their technical knowledge, die setters must develop a sense
of personal safety awareness. Die setting must be accomplished in a safe manner. All die setters
should recognize the necessity of doing their own job safety as well as providing a safe operation
environment for other.
7.2 Tool Setup Safety

The following precautions are listed as a guide to the development of safe tooling setup
procedures.
A. Never place hands, fingers or any parts of the body within the die area unless the hydraulic
pump motor is turned off.
B. Never install, adjust or remove dies without proper instruction and without first reading and
understanding the tooling instructions in the owner’s manual.
C. Never install, adjust and remove dies or service the machine when the hydraulic pump motor
is turned on.
D. Never wear a necktie, jewelry, or loose clothing while working on or near machinery.
E. Where the tooling is too heavy to be lifted by hand, suitable mechanical methods must be
used. Tooling of said size is provided with a point for screwing in a lifting bolt. Sling or chains
should only be attached to these lifting bolts as these points are determined for keeping the
tooling components stable during lifting.
F. Clean dies before installing. Misalignment caused by dies, chips of metal or other foreign
materials could result in injury to the operator or damage to the machine and dies.
G. The operator must wear personal protective clothing at all times when handling the tooling
components, especially with hands and feet. To avoid the possibility of trapped fingers, do not
physically guide the suspended tooling component onto a location, but preferably use a
suitable hand tool.
H. Lock the disconnect switch in the off position to prevent the hazard from unauthorized using
of the machine or an unintentional start.

I. Install tooling securely. Be sure bolts are in good condition so that vibration does not allow
dies to move out of position.
J. Use the proper die for the bender’s size to prevent overloading. Never install worn or
damaged dies.
K. After dies are installed, perform all necessary adjustments. Please execute it before running
the machine.
L. Be sure all people clean machines and dies before operating machines.
M. Be sure all people clean machines and dies before operating machines t no tools, nuts, bolts,
clamps and so on are left in these areas before cycling the machine.
N. Observe the machine operation long enough to determine that the machine, dies and
auxiliary equipment are working properly.
O. Report any questionable operation, unusual action, oil leaks, unsafe condition or safety
devices.
P. When changing setting of the bender controls for a different operation, make certain selector
switches are set correctly test cycle to be sure it operates correctly before bending tubes.
Q. Bending lubricant that would make the surrounding area slippery would contaminate the
tooling area. Handle the tooling carefully! While it is safe and practical to do so, it is good
practice to plug the end of the tube with absorbent material during bending, in order to
prevent the bending lubricant from dripping onto the safety mats and onto the machine, which
can keep the floor from being slippery to reduce the potential hazard to the operators.
R. When a bending machine has been in no space operative or left unattended, even for a brief
time, check the setting of all switches before starting the machine.
S. Develop a sense of personal safety awareness. Observe all safety regulations. Learn to spot
hazardous conditions and discuss ways to control them with your supervisor.

8 Machine Operation
8.1 Machines Guards
Due to the diverse nature of tube configurations, the variation in the number of the bends
required and the complexity of some part shapes, it is usually necessary to custom design
point-of-operation guards for each application.
The design and manufacture of point-of-operation machine guards adds to the cost of a machine
installation. However, because the machine owner takes responsibility for the safety of his
employees, the additional costs required to properly guard the dies should not be of primary
concern. Covers removed to gain access for service operations must be replaced before machine
operation is resumed.
8.2 Safety of Operator

The following list contains the practices that can minimize the chance of serious operator injury.
Adherence to these practices makes the operator’s job safety and more effective. Please read
and follow each practice carefully.
A. Never operate machine without first reading and understanding the operation instructions in
the owner’s manual.
B. Never place the hands, fingers or any parts of the body within the die area, without shutting
off the hydraulic pump motor.
C. Never wear a necktie, jewelry, or loose clothing when working on or near machinery.
D. At the beginning of each shift and after every break, cycle the machine several times.
Carefully observe the controls to be sure they are functioning properly.
E. Never talk with anyone while operating the machine. If it is necessary to talk, stop the
machine, turn off the motor and step aside until the conversation is completed.
F. Report any questionable operations, unusually actions, oil leaks, unsafe conditions or
improper maintenance to your supervisor.
G. Never attempt to pull a part out of the die with your hands. If a part sticks in the die, stop the
machine and call for your supervisor.
H. Keep all safety guards in place and in good condition.
I. Never reach over, under or around safety guards.
J. Observe machine operation for overloading. Accidental or intentional operation above the
maximum rated torque can result in excessive wear and abuse of the machine and dies. This
can create a hazardous condition.
K. When turned off the motor, check sight gauges for lubricator level in the lube system.

L. Never stack parts on or near the die area of a bender.

M. Turn off the hydraulic pump motor when no one uses the bender. Move the disconnect switch
to OFF to prevent unauthorized use of the machine or an unintentional start.
N. Clean the machine and inspect it carefully for loose, worn, broken or damaged parts.
O. If two or more people are around the machine during operation. Do make sure that
everyone stays for away from m/c before starting the machine.
P. While operating machine, be sure to position yourself. Don’t come into the scope of any
moving parts. Do not come into the scope when bend arm moving.
Q. The collision maybe created while rotating. The operator should away from it.
R. Develop a personal sense of awareness. Observe all safety regulations. Learn to stop
hazardous conditions and discuss control of them with your supervisor.

8.3 Safe Operating Procedures
Caution! Possibility of severe injury or entrapment in the machine!
A. The machine must not be operated with any part of the safety equipment inoperative or
ineffective. Neither must the machine be operated if any of the safety devices or safety
guarding have been overridden in any way.
B. Do not operate the machine if a fault is generated during production, which in any way
renders the machine unsafe.
C. The precautions must be taken if any of the following machine malfunctions occurs during or
after bending a tube.
a. If the tube can not be released from the tooling, or remains stuck between the tooling
during or after bending.
b. If the tube is damaged in any way during bending.
c. If the machine bending cycle is interrupted or is stopped in any way before a particular
bending or bending cycle has been completed. This could result in the tube stuck in the
machine.
D. Emergency, stop the machine as quickly as possible. Report the malfunction immediately and
make all personnel in the vicinity aware that the machine has malfunctioned.
E. If and only if power can be restored safely, switch to Manual mode and attempt to free the
tube from the machine by driving each element of the tooling in turn to the OFF position. Do
not allow anyone to approach the machine during operation.
F. While you operate the machine controls, never hold the tube yourself, or ask any other person
to hold the tube or any items of the tooling, and then physically try to force the tube free from
the machine
G. If the tube can not be released from the machine by operating in the manual mode, then
under Electrical Safety Approach totally isolate the system and the machine from the front,
and support the necessary parts, and carefully dismantle all the tooling components to release
the tube.
H. After the tube has been released, carry out a full and detailed inspection of the machine, and
report any damage in writing. Also investigate the cause of the malfunction and do not operate
the machine until the fault has been isolated and rectified. If necessary, leave the machine
totally isolated and request service assistance from Chiao Sheng Machinery Co., Ltd.
I. Carry out a full and detailed checkup of the safety guarding, after any malfunction has
occurred. Carry out a full startup procedure checkup on the machine, the tooling setup and
the bending program.
J. When assembling the tubes, please keep 45° between the carriage and the operators in order
to avoid the damage from the action of the servo motor.

8.4 Safety Precautions during Bending
A. Never, under any circumstances, hold the tube while the machine is still in sequence, even if
the sequence has been interrupted and the tube is trapped in the tooling. Do not carry out
any work inside the machine-guarded areas, with the main power switched ON.
B. Operators must communicate!! When the machine is handed over to an operator at the
start of a new shift, a proper handover procedure must be carried out. Always check the
machine configuration and record which options and features on the machine are active.
This is particularly important where Sequencing Options and Sequence Teach Facilities are
active.
C. Never presume or pre-empt what is going to happen during a bending sequence. If
necessary, select the Manual mode and run the machine through a full cycle before loading
any tube stock.
D. Always carry out a test bend using the Step mode on the “first part” of each new
configuration of a production run. This test bend must be done with the slowest speed.
E. Select the handing speed to produce the component safely. Take into account tube diameter;
tube length and overhang of the resultant bends. Start slowly and increase the speed and
accelerate gradually.
F. All operators must always be informed on each occasion when bending machine software is
changed. Sufficient training must be given to ensure that all operators become familiar with
safe operating procedures of the machine and with any changes to the machine sequence
and operation.

9 Maintenance
9.1 Machine Longevity
In order to retain the utility and the safety build into a bender, an effective program of machine
inspection and maintenance must be performed with regularity. Detailed information concerning
this program is presented in the maintenance section of the owner’s manual. It is difficult to
establish life figures for relays, solenoid valves and other electromechanical components.
Actual life may very, depending upon type of usage, environment conditions and thoroughness of
the preventive maintenance program. Because of wear or improper maintenance, it is important
to realize that a component failure could occur at any time.
However, frequent inspection and a good preventive maintenance program can reduce this
possibility. Immediate replacement of components that are worn or improperly maintained is
imperative.
9.2 Machine Cleanliness

Cleanliness makes any inspection and maintenance program easier. Trouble areas can be
spotted faster on a clean machine and workmen appreciate working in an area where good
housekeeping is practiced.
An occasional coat of paint with a thin film of light oil applied to unpainted finished surfaces can
prevent rusting and help maintain the appearance of the equipment.
It is also important to keep the floor area around the machine clean and free from obstructions.
9.3 Machine Upgrades

When the machine cannot be practically repaired, order a new machine. Continued operation of a
machine that is worn out is not only unsafe and inefficient, but also is the major cause of poor die
life and unsatisfactory product.
A bender that are old but still in good condition, it can be updated to be more efficient through
upgrades such as the latest hydraulic conversion units and new electrical controls.
Users may develop a thorough and objective system to evaluate all benders in operation,
And based on the results of evaluation, users may decide the systems to be updated, repaired or
replaced.

9.4 Safety of Maintenance

The following list contains precautions that can minimize the chance of serious injury during
maintenance. Read and follow these steps each time you perform maintenance on a bending
machine.
A. Read the service manual first before maintaining the bender.

B. Never place the hands, fingers or any parts of the body into the potentially hydraulic areas
of the bending machine unless the hydraulic pump motor is turned off and the main power
disconnect switch is in the OFF position and tagged.
C. Never wear a necktie, jewelry, or loose clothing when working on or near machinery.
D. Hand tools should be carried only in tool boxes or tool belts. Never put hand tools in
pockets or under trouser belt. Never leave tools on or around the machine after you finish
maintenance.
E. Move the power disconnect switch to the off position and lock it out, before performing
maintenance or repair. Make certain that no one can turn it on again without your
knowledge.
F. Make certain that all air, electrical and hydraulically actuated components are completely
assembled and properly attached to the bending machine before starting the motor.
G. Use only the proper sizes and types of tooling for the job.
H. After completing machine repairs or maintenance, replace all guards, remove all tools,
start the bending machine and check for proper operation.
I. Never release the machine for production operation until you are certain that it is
performing correctly.
J. Never leave machines with hydraulic pump motor on.
K. Clean up all oil and grease spills. Leave the entire area around the machine clean.
L. Never paint over any of the safety labels on the machine. Periodically inspect the safety
labels to be sure that they are legible and in place. If any labels are missing or illegible,
contact your supervisor.
M. If the machine does not work normally, turn off the power immediately.
N. Keep area around the machine tidy especially on the floor.
O. Confirm the data before auto process.
P. Do not use any sharp tools to poke the touch screen, to prevent the monitor from damage.
Q. System pressure should never exceed recommended maximum.

Version 50V000 Chiao Sheng Machinery Co., Ltd. Doc. Page III-1
Part Ⅲ Machine Operation
Before operating the machine,

please read " Operation Instructions".
Attention!
Reasons why most accidents occur,

are because of disobeying
safety regulations.
The operators should obey all regulations of this handbook to avoid

accidents. If the automatic tube bender needs maintenance, operators
should report this to the supervisor and stop working this machine until
the problem is rectified.
maintenance, safety and capacity will void all rights and warrantees by
CSM.
Part III Machine Operation

Index 3
1 Overview of Machine ......................................................................................................... 3

1.1 Machine Specification ................................................................................................... 4
1.2 Explanation of Machine’s Figure ................................................................................... 4
1.3 Description of Axes ....................................................................................................... 7
1.4 Function of Rolling Mode (Option) ................................................................................ 8
1.5 Explanation of Hydraulic Pressure Adjustment ............................................................. 9
1.6 The Adjustment for Limit Switch of Carriage ................................................................10
2 Instructions of Machine Operation.................................................................................. 11

2.1 Start Machine and Program ......................................................................................... 11
2.2 Manual Mode Operation ..............................................................................................13
2.3 Machine Specification – Manual Mode .........................................................................29
2.4 Tooling Specification – Manual Mode ...........................................................................31
3 Instructions for Bend Data Programming .......................................................................34

3.1 Search the Program ....................................................................................................34
3.2 Load the Program ........................................................................................................36
3.3 Create a Directory / File ...............................................................................................37
3.4 Delete a Directory / File ...............................................................................................39
3.5 Change Name .............................................................................................................41
3.6 Copy a Directory / File .................................................................................................43
3.7 Synchronous ...............................................................................................................45
3.8 Folder / Program Import...............................................................................................46
3.9 Folder / Program Export ..............................................................................................48
3.10 Operations for Bend Data Programming ....................................................................50
3.11 Calculate Length of Rolling and Bending Arc Curvature .............................................96
3.12 Operations in Auto Mode ...........................................................................................98
3.13 Pauses and Release................................................................................................ 114
3.14 Motion Process ........................................................................................................ 115
3.15 System Configuration .............................................................................................. 116
3.16 System Diagnostic ...................................................................................................130
3.17 User Login／Logout .................................................................................................131
3.18 Alarm Message and Troubleshooting .......................................................................133

1 Overview of Machine
CAUTION
We appreciate your patronage of automatic electrical-servo bending machine. In order to

help you operate the machine well and get perfect work result, you are invited to read the
manual carefully before operation.
FOREWORD
When you see the column as shown in Fig-1.1 on screen, press the column to bring up on-screen
keypad (as shown in Fig-1.2). User can input data by using this on-screen keypad.
####.#
Fig-1.1
****.*
The numerical range is set from 0 to 999999999.
0 ~ 99999999999 If user input the value is beyond the range or a sign error
with the value, the following message will be shown on
7 8 9 c screen:
“The value is out of range set.”

4 5 6 Del
to remind user the value should be corrected.

1 2 3 Max
0 . -/+ Exit
ENTER Fig-1.2

1.1 Machine Specification

Before operating the machine, the user must understand the capacity and the technical
specification of the machine prevent from overloading the machine and resulting in the damage for
both user and machine. Some capacity and technical specification documents that contain the
detail specification of the machine are enclosed within the Technical Document. If the operators
need to take the reference of the machine, refer to the Technical Document.
1.2 Explanation of Machine’s Figure

1.2.1 The Introduction of Machine’s Profile
19. Start button 1 2 1. Clamp die 10. Power on button
(Option) 2. Pressure die assist 11. Power off button
19 16 19 3. Tube support 12. Hydraulic system
4. Collet 13. Bend head
5. Carriage 14. Bend arm
6. B axis rotation 15. Touch screen
7. Mandrel base 16. Emergency stop button
14 1 13 2 8. Circuit breaker 17. Foot pedal-start
9. Power indicator 18. Foot pedal-temporary stop
Type EMB, EMR
Option
1 2 3 4 5 6 7
16 15
9
10
11
14 13 Electrical
connection
12 8
17 18 point
Fig-1.3
The inside of control box has a monitoring relay for monitoring the phase sequence and phase
loss. After connected the power source and pressed the Power on button (Fig-1.3○ 10 ), the relay
will inspect the states of the power source. If the phase sequence is incorrect or phase loss, the
buzzer will be on.

1.2.2 The Introduction of Control Panel

The drawing of control panel is introduced as below. The names of each button and explanation
of detailed usage are listed as follows. Before operating the machine, user should read this
description first to avoid the damage from the wrong usage.
E.M. STOP
Fig-1.4
3 4 5 7 6 8 9 10
Introduction of Control Panel

No Name Description
It provides the menus with the operating selection. When you
1 Touchscreen touch it, it will lead you to other menus or various control
functions of the bending machine.
Some buttons will present at this section. These buttons will

Function selection area change the screen display of the control panel to direct the
2
(touch-type) setup of the different machines. The user should operate as the
actual circumstance.
While pressing it, you will start an automatic cycle or other

3 Auto start button
operation according to the currently displayed menu.
4 Auto stop button While pressing it, you will stop the automatic cycle.
Press this button to increase moving speed of mandrel backward

5 Manual rapid button (the mandrel moving backward item must be selected) etc. If you
do not press this button, the speed of above actions will be slow.
While pressing it in manual mode, the tools will move forward

Manual
6 (or clockwise) until it is released. It is the manual operating
positive button
button for bend arm, clamp die, pressure die, mandrel etc.

No Name Description
It is the manual operating button for bend arm, clamp die,

Manual
7 pressure die, mandrel etc. While pressing it, the tools will move
negative button
backward (or counter-clockwise) until it is released.
8 Light of alarm When the machine gets the trouble alarm, the light will twinkle.
9 Alarm released button You can press this button to release the alarm warning.
While pressing it, you will remove the electrical power

10 Emergency stop button immediately from the hydraulic and electric motors and stop all
action of the machine.

1.3 Description of Axes

It is necessary to design 3-axes movement for 3-dimensions production. That is Y.B.C. The extent
of each Y, B, C axis movement on a bender could be determined by a specified numerical value.
These YBC values would provide all necessary data to notify a 3-dimensional tube shape. Fig1.5
shows as each axis and the direction of the movement.
Y axis: Feeding axis. It is the distance between 1st curve’s ending point and 2nd curve’s
beginning point, “＋” means carriage moves toward the bend die. “－” means carriage moves
away from bend die.
B axis: The angle of 1st curve to next curve. “＋” means B axis rotates clockwise, “－” means B
axis rotates counterclockwise.
C axis: Bending axis. The movement of angle of bend curve. “＋” means bend arm advances. “－”
means bend arm returns.
X axis: It is bend head horizontal movement. “＋” means bend head shifts outward. “－” means
bend head shifts inward.
Z axis: It is bend head vertical movement. “＋” means bend head shifts to lower stack , “－” means
bend head shifts to higher stack.
Y AXIS
_ B AXIS
Z AXIS
+
X AXIS
+
+ Fig-1.5
C AXIS

1.4 Function of Rolling Mode (Option)

The material rolling mode is included; depend upon bend arm’s position (C axis angle) that user
can get multiple radiuses at the same material and the same module. However, while you’d like
producing many curves at on tube, it’s not necessary to purchase plenty of tube bender. For more
this function supplies you smallest curvature up to six times (approx.) of tube’s diameter.
22 °
11 °
Fig-1.6

1.5 Explanation of Hydraulic Pressure Adjustment

This machine is based on a hydraulic system with some control knobs that the operators could
adjust the motion pressure for each part. Operators must refer to the following table to know
meanings of icons and learn how to adjust the control knobs according to actual situation.
To operate the machine with appropriate pressure could help the machine works more smoothly.
No Icons Explanation No Icons Explanation
1
P System pressure
9
P Pressure control knob
control knob for collet closing
P87-NB019 P87-NB027
P87-NB019 P87-NB027
2
P-L Low pressure setting
10
Speed control knob
control knob for collet closing
P87-NB020 P87-NB028
P87-NB020 P87-NB028
3
P-H High pressure setting
11
Speed control knob
for pressure die
control knob
P87-NB021 P87-NB029
P87-NB021 P87-NB029 closing
Speed control knob Speed control knob

4 P87-NB022 for tube support 12 P87-NB030 for pressure die
P87-NB022 opening P87-NB030 opening
Pressure die partial

Speed control knob
opening control knob
5 P87-NB023 for tube support 13 P87-NB031
(Applicable for
P87-NB023 closing P87-NB031 18MBE/MRE/TDRE/TSRE)
Speed control knob

Speed control knob
6 for A.M.R.U. 14
for clamp die closing
P87-NB024 P87-NB032
P87-NB024 (Optional) P87-NB032
P Pressure control knob

Speed control knob
7 for pressure die assist 15
for clamp die opening
P87-NB025 P87-NB033
P87-NB025 advancing P87-NB033
Speed control knob

8 P87-NB026 for pressure die assist
P87-NB026 advancing

1.6 The Adjustment for Limit Switch of Carriage

1.6.1 Limit Switch of Carriage Illustration
4 5 3 1
1. Front limit switch
2. Carriage
3. Block
4. Rear limit switch
5. Block
Fig-1.7
Adjusted distance of front limit switch
1.6.2 Adjustment of the Limit Switches of Carriage

There are two limit switches on the left side of carriage. The function of each limit switch is as
follows:
A. Front limit point: It is a safety design to avoid bumping. As the carriage (2) moves forward
till touching the limit switch (1) by the block (3), it is not allowed to move any more to keep
the carriage at a safe area. Front switch position is set as Fig-1.7 when the machine is
completed. The position can be set upon requirement with 100% sure no hazards and
bumps would incur by any moving objects.
B. Rear limit position: It is a safety design to avoid bumping. As the carriage (2) moves
backward till touching the limit switch (4) by the block (5), it is not allowed to move any
more to keep the carriage at a safe area. Rear switch position is fixed, not for adjusting.

2 Instructions of Machine Operation

2.1 Start Machine and Program
2.1.1 Operation Steps
A. Turn on Circuit breaker (Fig-1.3○
8 ), and press the Power on button (Fig-1.3○ 10 ).
B. When program is started, the operator is prompted to log in. A drop down list of the defined
users is available. User must select a username and input the password to enter the
Main page of program.
Note: Username and password are : Admin(1234)、PRGO(123)、USER(123).
Fig-2.1

2.1.2 Main Screen of Program

A. Operation Steps
The function selections are at the bottom line of main screen (as shown in Fig-2.2), and
click the function button according to your needs.
Fig-2.2
B. Explanation of Buttons and Functions (See Fig-2.2)
a. Manual mode: Tap on this button to enter the manual mode. (Refer to
2.2 Manual Mode Operation)
b. Auto mode: Tap on this button to enter the auto mode. (Refer to 3.12
Operations in auto mode)
c. Bend data programming: Tap on this button to enter editing pages and
set bend data for working program. (Refer to 3.1 Load the program)
d. System configuration: Tap on this button to enter system configuration

pages and it could help user to know basic information regarding the
machine, to select interface language, to set password and numeric
settings or system maintenance for service. (Refer to 3.15 System
configuration)
e. System diagnostic: Tap on this button to enter diagnostic pages and
judge signals of sensors if it is normal. (Refer to 3.16 System diagnostic)
f. User login / logout: Tap on this button and log out from program to
change username. (Refer to 3.17 User Login / Logout)

2.2 Manual Mode Operation

2.2.1 Manual Operation Buttons, Icons and Function Tabs
A. Operation Steps
Touch the Manual mode button on the Main page (Fig-2.2), then Manual
operation mode page will be shown on screen. (shown as below)
Manual Data Input

(M.D.I.)
Mode settings
Parameter settings
Fig-2.3
The left hand side of the screen shows options with settings
M.D.I, Mode or Parameter, and it will change for each manual
operation button when the button is pressed. For example,
pressing “Bending (C axis)”, the screen will show as above.

B. Explanation for Name of Manual Operation Buttons and Movement (See Fig-2.3)
a. Automatic mandrel lubrication (Optional, applicable for mandrel
unit)
Touch Automatic mandrel lubrication button on the Manual operation
mode page (Fig-2.3) to start spraying lubricants, or leave the button to
stop spraying.
b. Tube support (Optional, applicable for tube support is a hydraulic

/ pneumatic / servo device)
Occasion: If the shape of material is non-round, must be sure the tube
support has been opened before B axis is rotating.
1. Touch Tube support button on the Manual operation mode page
(Fig-2.3), then it becomes dimmed .

2. Press Manual positive button on the control panel, tube
support rises / moves inward to support material.
3. Press Manual negative button on the control panel, tube
support lowers / move outward to release material.
c. Mandrel rod (Optional, applicable for mandrel unit)

1. Touch Mandrel rod button on the Operations in manual mode page
(Fig-2.3), then it is dimmed .

2. Press Manual positive button on the control panel, mandrel
rod advances.
3. Press Manual negative button on the control panel, mandrel
rod returns.
※ Parameter setting
1. Mandrel forward position: Mandrel moves forward to the target
position by input value in this column. (Absolute position)
2. Mandrel back position: Mandrel moves backward to the target

d. Carriage (Y axis)
1. Touch Carriage button on the Manual operation mode page

2. Press Manual positive button on the control panel, carriage
moves toward the bend die.
3. Press Manual negative button on the control panel, carriage
moves away from bend die.
※ Manual data input for feeding moves
A
B
C
A: Current location of Y axis display
B: Manual speed input for feeding moves (Y axis): The

speed range is from 0 to 9.
C: Manual data input (M.D.I) for feeding moves (Y axis)
Note: If user keyin value in Manual data input column for Y axis, press
Auto start button on the control panel and release it at once,
then Y axis starts feeding until its feeding distance equals to the value,
motion of Y axis is halted automatically. In case user wants to stop
motion of Y axis in course of feeding, just press Auto stop button
on the control panel to halt.
1. Front limit position: The value in this column is the distance
between center of bend die and front end of carriage. If front limit
position has been changed, must readjust the data to keep it
correctly.

e. Tube rotation (B axis)

1. Touch Tube rotation button on the Manual operation mode page

2. Press Manual positive button on the control panel, B axis
rotates clockwise.
3. Press Manual negative button on the control panel, B axis
rotates counterclockwise.
※ Manual data input for rotation angle
A
B
C
A: Current angle of B axis display
B: Manual speed input for rotation angle (B axis): The

C: Manual data input (M.D.I) for rotation angle (B axis)

Note: If user keyin value in Manual data input column for B axis, press
then B axis starts rotating until its rotation angle equals to the value,
motion of B axis is halted automatically. In case user wants to stop
motion of B axis in course of rotating, just press Auto stop button
f. Collet
1. Touch Collet button on the Manual operation mode page (Fig-2.3),
then it is dimmed .
2. Press Manual positive button on the control panel, collet
closes.
3. Press Manual negative button on the control panel, collet
opens.
1. Collet close delay: Collet was closed by cylinder. Collet keeps
closing for a few seconds by input value in this column. Be sure the
position of collet is correct and avoid material slipping off.

g. Pressure die assist back (Optional)

1. Touch Pressure die assist back button on the Manual operation
mode page (Fig-2.3), then it is dimmed .

2. Press Manual negative button on the control panel, pressure
die assist returns.
Note: If PDA is a servo device, moves state will show columns below the
icon. The upper column represents the current position of
PDA; the bottom column represents PDA move forward to
Max. bend angle.
h. Pressure die
1. Touch Pressure die button on Manual operation mode page

2. Press Manual positive button on the control panel, pressure
die closes.
3. Press Manual negative button on the control panel, pressure
die opens.
Note: If pressure die is a servo device, moves state will show columns
below the icon. The upper column represents the current
position of pressure die; the middle column represents
absolute position for pressure die closing; the bottom column
represents absolute position for pressure die opening.
※ Manual data input for pressure die moves (Applicable for PD is

driven by servo)
A: Current location of pressure die display
B: Manual data input (M.D.I) for pressure die moves

Note: If user keyin value in Manual data input column for pressure die,
press Auto start button on the control panel and release it at
once, then pressure die starts moving until its moving distance equals to
the value, motion of pressure die is halted automatically. In case user
wants to stop motion of pressure die in course of moving, just press
Auto stop button on the control panel to halt.

1. Pressure die (PD) thickness: Measure the PD thickness and input
the correct value in this column.
2. PD in delay: If machine installs PD in sensor, when PD closes until
check sensor is activated, PD will stay a few seconds by input value
in this column, then machine carry on the next motion. If machine
does not install PD in sensor, PD will closes for a few seconds by
input value in this column, then machine carry on the next motion. It
is to ensure that PD’s position is correct and avoid material slipping
off. (Applicable for PD hydraulic driven)
3. Pressure die (PD) clamping fine tune: It is for fine-tuning the
clamping distance of pressure die (PD) to move forward / backward.
When user input a positive value in this column, the PD clamping
forward. If user input a negative value in this column, the PD
clamping backward.
4. Pressure die (PD) length: Measure the PD length and input the
correct value in this column.
5. Pressure die base length for re-stroke: In case PD length (PD
length) was shorter than arc length, it’d lead to deformation on
straight part behind the arc. In such case user needs to calculate the
arc length beforehand, then check what shortage between arc length
and PD length, then offset the shortage by input value in this column.
In such case the PD will move to-and-fro twice to make up for the
shortage in between. For example, when bending OD20 x CLR50 x
180 degrees, the arc length should be 157 mm. If PD length = 120
mm, if you set 30 mm in this column, the PD will move forward 90
mm (120 - 90), then retrieve, then move forward again to finish this
bend.
6. Pressure die (PD) partial opening time: It is time for PD open
partially by input value in this column, then PD carry on the next
motion. This set is to save processing time and increase efficiency.
(Unit: sec) (Applicable for PD hydraulic driven)
Pressure die partial opening distance: It is distance for PD open
partially by input value in this column, then PD carry on next motion.
For example, if user input “10” into this column, PD will move
backward 10mm from current position, and then carry on next
motion. This set is to save processing time and increase efficiency.
(Unit: mm) (Applicable for PD servo device)

i. Clamp die
1. Touch the Clamp die button on Manual operation mode page

2. Press Manual positive button on the control panel, clamp die
closes.
3. Press Manual negative button on the control panel, clamp
die opens.
Note: If clamp die is a servo device, moves state will show columns
below the icon. The upper column represents the current
position of clamp die; the middle column represents
absolute position for clamp die closing; the bottom column
represents absolute position for clamp die opening.
※ Manual data input for clamp die moves (Applicable for CD is

driven by servo)
A: Current location of clamp die display
B: Manual data input (M.D.I) for clamp die moves
Note: If user keyin value in Manual data input column for clamp die,
press Auto start button on the control panel and release it at
once, then clamp die starts moving until its moving distance equals to the
value, motion of clamp die is halted automatically. In case user wants to
stop motion of clamp die in course of moving, just press Auto stop
button on the control panel to halt.
1. Clamp die (CD) in delay: If machine installs CD closing sensor,
when CD closes till check sensor is activated, CD will stay for a few
seconds by input value in this column, then machine carry on the
next motion. If machine does not install CD closing sensor, CD will
close for a few seconds by input value in this column, then machine
carry on the next motion. It is to ensure that CD’s position is correct
and avoid material slipping off. (For CD is a hydraulic device)

j. Bending (C axis)
1. Touch the Bending button on the Manual operation mode page

2. Press Manual positive button on the control panel, bend arm
advances.
3. Press Manual negative button on the control panel, bend arm
returns.
※ Manual data input for bending angle
A
B
C
A: Current angle of C axis display
B: Manual speed input for bending angle (C axis): The

C: Manual data input (M.D.I) for bending angle (C axis)

Note: If user keyin value in Manual data input column for C axis, press
then C axis starts bending until its bending angle equals to the value,
motion of C axis is halted automatically. In case user wants to stop
motion of C axis in course of bending, just press Auto stop button
1. Angle to end of bending that A.M.R.U. starts: Input the data, to
determine mandrel pull back timing by angle setting at the last
degrees of a bend. It depends on material, tubing OD and thickness
to set it properly. Generally, it is set by 5~10 degrees to start action.
For instance, if user wants to bend 90 degrees, and input 3° in this
column, when bend arm moves to 87° (90-3), mandrel starts
receding. (Optional, applicable for mandrel unit)
2. Distance that A.M.R.U. to retract: It is distance that A.M.R.U. to
retract by input value in this column. (Optional, applicable for
mandrel unit)
3. PDA stop running angle: To evade booster rushing out at the end of
bending, user can set booster ending stop angle by input value in this
column. Generally, it is set by 0 degree in this column. (For PDA is a
hydraulic device)
4. Elongation ratio (%): Elongation proportion is for a percentage of
material’s original length. The thinning and stretching of the extrados
of material while under the force of the bend forming process. If the
elongating force exceeds the elastic limit of the tubing material, the
tube will split or tear. The setting range of elongation proportion is
70~100 (%) in this column. (This value can be got by calculator.)
(Optional)
5. Elongation constant: This constant is used to correct for elongation
proportion of material. (This value can be got by calculator.)
(Optional)
6. PDA elongation ratio: It is distance for PDA. advanced movement.
For example, when bending OD20 x CLR100 x 90 degrees, the arc
length should be 157.08 mm. If user set 90 in this column, the PDA
will move forward 141.375 mm (157.08x0.9). (Optional, applicable
for PDA servo device)
7. PDA elongation costant: This constant is used to compenstae for
PDA elogation proportion. (Optional, applicable for PDA servo
device)
※ Mode setting
Y axis and C axis move simultaneously: To select this
option whether it activates or not. If mark this function, Y
axis and C axis will move simultaneously during bending,
and Y axis advance distance is equal to arc length.
(Optional)
Pressure die booster: To select pressure die booster
whether it enable or not. If machine free run, do not mark
this option. (Optional)
Mandrel function: If machine does not set up mandrel or
it is unnecessary to operate with mandrel during bending,
in such case user needs to cancel this option. (Optional,
applicable for mandrel unit)
A.M.R.U.: If user wants to execute this function, must
input “Angle to end of bending that A.M.R.U. starts”
and along with the function “Mandrel function”.
(Optional, applicable for mandrel unit)
※ Torque setting (Optional)
1. Tap this button , then Manual torque setting will be opened
up on screen (as shown below). Press this button

and all pressure are set as the 1st section column.

2. Bend degree range for each section pressure

Calculation: Bending degrees divided by 10 to get bending
degree range of each section pressure.
Example: If bending angle = 90°; 90÷10=9, thus bending degree
range of each section pressure are as follows.
Bend degree range
0~9
10~18
19~27
28~36
37~45
46~54
55~63
64~72
73~81
82~90
Explanation: If input “50” in the “The 3rd section pressure” column,

it means that RBE / PDA will output 50% pressure as bend angle is
between “19~27” degrees.
※ Material Characteristics for Rolling (Optional)
1. Tap this button , then Material characteristics for rolling

page will appear on screen. (as shown below).
2. User needs to input data in Reading on the radius meter columns

for bender test running.

Note: Rolling function will not be available to select in the 3.6.4 YBC data
settings page without Material characteristics for rolling page being set
(as shown in red frame above).
k. Bendhead vertical movement (Applicable for Multi-stacked)
1. Touch the Bendhead vertical movement button on the Manual
operation mode page (Fig-2.3), then it is dimmed .

2. Press Manual positive button on the control panel, bend
head shifts upward. For example, bend die shifted from R2 to R1.
3. Press Manual negative button on the control panel, bend
head shifts downward. For example, bend die shifted from R1 to R2
.
Note: For example, a column shows on the right side of the button
that it means bendhead stay on R2 stack currently. If “0” is shown in the
column, it represents bendhead is not positioning.
※ Manual data input for Z axis
A
B
C
A: Current stack position of Z axis display
B: Manual speed input for Z axis: The speed range is from

0 to 9.
C: Manual data input (M.D.I) for Z axis stack shift

Note: If user key-in value in Manual data input column for Z axis, press
then Z axis starts shifting to the stack which is set in the column, then
motion of Z axis is halted automatically. In case user wants to stop
motion of Z axis in course of bending, just press Auto stop button
Safety position for Z axis move down: It is safety position for Z axis
move down. User could evade bend head Colliding with tooling by input
value in this column, bend head will move down to the safety zone to
rotate.

l. Bendhead horizontal movement (Applicable for Multi-stacked)

1. Touch the Bendhead horizontal movement button on the Manual
operation mode page (Fig-2.3), then it is dimmed .

2. Press Manual positive button on the control panel, bendhead
shifts in towards the bend die.
3. Press Manual negative button on the control panel,
bendhead shifts out away from the bend die.
Note: If work-head horizontal movement is driven by servomotor, moves
state will show columns below the icon. The upper column
represents the current position of work-head; the middle column
represents absolute position for work-head shifting in; the
bottom column represents absolute position for work-head
shifting out.
1. Tool interference: bend die insert thickness. Please confirm the
centerline radius upon the specification on the tooling stack or
measure by user, and must be sure the unit (Millimeters or Inches)
you input is correct. (It set upon each stack)
2. Outside diameter: Input the outside diameter of material in this
column.
m. Punch (Optional)
1. Touch Punch button on Operations in manual mode page (Fig-2.3),
then it is dimmed .
2. Press Manual positive button on the control panel, punch
device moves forward to process. When user releases this button,
the punch device backward.
n.
Action rate adjustment
If user would like to change processing speed of movement, drag the scroll bar to
adjust on Manual operation mode page (Fig-2.3).
o. Manual mode settings

(Refer to 2.2 Manual Mode Operation)
p. Settings for machine specification in manual mode

(Refer to 2.3 Machine Specification－Manual Mode)
q. Settings for tooling specification in manual mode

(Refer to 2.4 Tooling Specification－Manual Mode)

MM
r. Unit: Select the unit as Millimeters or Inches.
s. Operation manual: Selecting this tab brings up a version of operation

manual displayed in the Adobe PDF On-Screen Viewer.

2.2.2 Calculator
Touch the Manual mode button on Main page (Fig-2.2), then Manual operation
mode page (Fig-2.3) will be shown on screen. Tap Calculator button on Manual
operation mode page (Fig-2.3), then screen will show as below. There are six tabs －
Calculator, Trigonometric, CLR, Elongation ratio, Springback and Arc radius introduced
below:
Calculator, Trigonometric & CLR calculation (See Fig-2.4~2.6)
Tap on Calculator, Trigonometric or CLR calculation tab, it can help user to do simple
mathematical operation, trigonometric or CLR calculation to get values.
Fig-2.4
Fig-2.5 Fig-2.6

Elongation ratio calculation (See Fig-2.7)
Input measured angle and press

Calculate, it will show the result of
1 calculation for Elongation ratio and
Elongation constant.
2
If check the result of calculation already,
press Save data to transfer data into
bend program.
Fig-2.7
Springback calculation (See Fig-2.8)
Input measured angle and press
Calculate, it will show the result of
1 calculation for Springback ratio and
Springback constant.
2
If check the result of calculation already,
press Save data to transfer data into
bend program.
Fig-2.8

Arc radius calculation (See Fig-2.9) (Optional)

When executing roll function, get a measured value by Radius meter, and this value needs to
be subtracted from 30, then input the result of calculation into Reading on the radius meter
column (shown as below). Also it needs to input value in the Outside diameter column, then
press Calculate button to get arc radius.
Fig-2.9
The measure range of radius meter (see below) is from 0 to 30 mm. Place the meter on the bent
tube to make the probe touches the tube, then read on the radius meter. When the meter probe
is fully extended and the reading on the meter is 0. When the meter probe is fully retracted and
the reading on the meter is 30mm.
For example:
STEP 1: Input value (30mm) into Outside diameter column.
STEP 2: Measure the bent tube by Radius meter to get value = 28.5mm.
STEP 3: 30-28.5=1.5mm
STEP 4: Input 1.5 into the Reading on radius meter column.
STEP 5: Press Calculate button to get arc radius = 1215.75mm.
Bent tube

2.3 Machine Specification – Manual Mode

A. Operation Steps
a. Touch the Manual mode button on Main page (Fig-2.2), then Manual
operation mode page (Fig-2.3) will be shown on screen.
b. Click the tab at the bottom of the screen, and then Manual machine
specification page will show on screen. (shown as below)
Fig-2.10
B. Function Explanation (See Fig-2.10)

Delay / Timer setting
a. Collet close delay: Collet was closed by cylinder. Collet keeps closing for
a few seconds by input value in this column. Be sure the position of collet
is correct and avoid material slipping off.
b. Clamp die in delay: If machine installs clamp die closing sensor, when
clamp die closes till check sensor is activated, clamp die will stay for a few
seconds by input value in this column, then machine will proceed to next.
If machine does not install clamp die closing sensor, clamp die will close
for a few seconds by input value in this column and machine will proceed
to next. It is to ensure the position of clamp die is correct and prevent
material slipping off.
c. Pressure die partial opening distance: It is distance for pressure die

open partially by input value in this column, then pressure die carry on the
next step. This set is to save processing time and increase efficiency.
(Unit: mm)

Tube parameter
d. Outside diameter: Input the outside diameter of material in this column.
e. Tube material: Input the material of tube in this column.
f. Material wall thickness: Input the wall thickness of a tube.
g. Elongation ratio (%): Elongation proportion is for a percentage of

material’s original length. The thinning and stretching of the extrados of
material while under the force of the bend forming process. If the
elongating force exceeds the elastic limit of the tubing material, the tube
will split or tear. The setting range of elongation proportion is 70~100 (%)
in this column.
Elongation constant: This constant is used to correct for elongation
proportion of material.
The above values can be got by calculator.
h. PDA elongation proportion (%): It is distance for PDA. advanced
movement. For example, when bending OD20 x CLR100 x 90 degrees,
the arc length should be 157.08 mm. If user set 90 in this column, the PDA
will move forward 141.375 mm (157.08x0.9). (Applicable for PDA servo
device)
PDA elongation constant: This constant is used to compenstae for PDA
elogation proportion. (Applicable for PDA servo device)
i. Springback ratio (%): This percentage is used to compensate for the

effects of material springback. For instance, if the programmed bend
angle is 90°and input 5% into this column, then it will get the actual bend
angle is 94.5° (90° x 1.05).
Springback constant: This constant is used to compensate for the
effects of material springback. Continue above example, if input 2° into
this column, then the actual bend angle will be 96.5° (94.5° + 2°).
j. Mandrel forward position: Mandrel moves forward to the target position
by input value in this column. (Absolute position)
k. Mandrel back position: Mandrel moves backward to the target position

by input value in this column. (Absolute position)
Button functions
l. Load a format: Press this button, program will load the settings which are already saved
as format before.
m. Save the format: Press this button, program will save the current settings as a format.

2.4 Tooling Specification – Manual Mode

A. Operation Steps
a. Touch the Manual mode button on Main page (Fig-2.2), then Operations in
manual mode page (Fig-2.3) will be shown on screen.
b. Click the tab at the bottom of the screen, and then Manual tooling
specification page will show on screen. (shown as below)
B. Data Input
To evade collision occurred during operation, please input correct data into the columns of
Manual tooling specification page (Fig-2.11), instructions are detailed as follows:
a. Touch a white column brings up the on-screen keypad.
b. Click figure squares of on-screen keypad to input correct data.
c. Then click Enter key to finish input operation.
Note! Please notice the limitation (which is displayed at the top of on-screen keypad) of
input data, if the input data required exceeds limitation allowed, a dialogue box “The
value is out of the range set.” will shows on screen to prompt user that data needs to
be fixed. To avoid bumping, be ensure that values in this page are correct.
Fig-2.11

C. Function Explanation (See Fig-2.11)

a. Collet depth: This is the distance from the face to the stop of collet. This
is the amount of material insert to collet as collet is closed.
b. X axis shift out offset: you can force X axis to shift out to avoid tube
scratch with tooling.
c. Tooling stack number (CW.): It is tooling stack number for clockwise

bending and numbers form upper to bottom stack are R6 to R1. User
could determine available tooling stack by input value in this column.
d. Tooling stack number (CCW.): It is tooling stack number for

counterclockwise bending and numbers form upper to bottom stack are
R-6 to R-1. User could determine available tooling stack by input value in
this column. (Applicable for rotary work-head)
e. Safety position for Z axis move down: It is safety position for Z axis
move down. User could evade bend head colliding with tooling by input
rotate. (Applicable for rotary work-head)
f. Process (Bending=0 / Rolling=1): User needs to select this column upon the tooling
characteristic. If process mode is bending, user has to select “0” in this column; if
process mode is rolling, choose “1” in this column. (It set upon each stack) (It is
available for use if machine is rolling model.)
g. Clamp roller radius: Measure clamp roller radius and input the value in this column.
Also, user needs to check the unit (Millimeters or Inches) if it is correct. (It set upon
each stack) (It is available for use if machine is rolling model.)
h. Bending CLR.: Please confirm the centerline radius upon the specification on the
tooling stack or measure by user, and must be sure the unit (Millimeters or Inches) you
input is correct. (It set upon each stack)
i. Tool interference: bend die insert thickness. Please confirm the centerline radius upon
the specification on the tooling stack or measure by user, and must be sure the unit
(Millimeters or Inches) you input is correct. (It set upon each stack)
j. Centerline height: Upon actual centerline height to input value in this column. (It set
upon each stack)
k. Pressure die (PD) length: Measure the pressure die length and input the correct value
in this column. (It set upon each stack)
l. Pressure die base length for re-stroke: In case pressure die length (PD length) was
shorter than arc length, it’d lead to deformation on straight part behind the arc. In such
case user needs to calculate the arc length beforehand, then check what shortage
between arc length and PD length, then offset the shortage by input value in this column.
In such case the pressure die will move to-and-fro twice to make up for the shortage in
between. For example, when bending OD20 x CLR50 x 180 degree, the arc
length should be 157 mm. If PD length = 120 mm, if you set 30 mm in this column,
the pressure die will move forward 90 mm (120 - 90), then retrieve, then move forward
again to finish this bend. (It set upon each stack)

m. Pressure die (PD) thickness: Measure the pressure die thickness and input the correct
value in this column. (It set upon each stack)
n. Pressure die (PD) clamping fine tune: It is for fine-tuning the clamping distance of
pressure die (PD) to move forward / backward. When user input a positive value in this
column, the PD clamping forward. If user input a negative value in this column, the PD
clamping backward. (It set upon each stack)
o. Max. bending angle: In general, we set 190 degrees in this column, or set this value
upon the max. bending angle of tooling to prevent tooling from being damaged with
machine. (It set upon each stack)
p. Front limit position: The value in this column is the distance between center of bend
die and front end of carriage. If front limit position has been changed, must readjust the
data to keep it correctly. (It set upon each stack)
q. Clamp die (CD) length / Clearance for bend arm return: Measure the clamp die length
and input the correct value in this column. This column is applicable for multi-stack
machine. Carriage pre-feeds length beforehand for bend arm return clearance, the value
in this column is usually clamp die length. (It set upon each stack)
r. Clamp die (CD) thickness: Measure the clamp die thickness and input the correct value
in this column. (It set upon each stack)
s. Clamp die (CD) clamping fine tune: (Applicable for CD is driven by servo)
It is for fine-tuning the clamping distance of clamp die (CD) to move forward / backward.
When user input a positive value in this column, the CD clamping forward. If user input a
negative value in this column, the CD clamping backward. (It set upon each stack)
t. Wiper die length: Measure the wiper die length and input the correct value in this
column. (It set upon each stack)
u. Wiper die thickness: Measure the wiper die thickness and input the correct value in this

3 Instructions for Bend Data Programming

3.1 Search the Program
Click the Bend data programming button on Main page (Fig-2.2), then Program
selection page (Fig-3.1) will be shown on screen. Operations for searching a program under the
directory are described below:
STEP 1: Select a directory on directory list box. Directory list is displayed in RED at this time, it
represents activated.
STEP 2: Press Search button to open Search for files page (Fig-3.1.1).
STEP 3: You can input keyword from the file name.
Search file from a file name. Search file from initial alphabet.
○
1
○
2
Fig-3.1

○
3
Fig-3.1.1

3.2 Load the Program

selection page (Fig-3.1) will be shown on screen. Operations for loading a program are described
below:
STEP 1: Select a directory on directory list box.
STEP 2: Select a bend program on file list box. File list is displayed in RED at this time, it
represents activated, and user can preview the material shape in Part feature frame.
STEP 3: Press Load this program button and screen will turn to YBC data input page (Refer to
3.10.5 YBC data - Editing), then user can start programming the bend data.
○
1
○
2
○
3
Fig-3.2

3.3 Create a Directory / File

selection page (Fig-3.1) will be shown on screen. Operations for creating a directory / a file are
described below:
A. Create a directory (See Fig-3.3)
STEP 1: Select a directory where the directory is to be created on directory list box.
STEP 2: Press Create a directory button to bring up on-screen keyboard and name the
new directory by typing in on-screen keyboard, then the new directory will appear under the
selected directory.
○
1
○
2 Fig-3.3

B. Create a file (See Fig-3.4)

STEP 1: Clicking on a directory where the file is to be created in the directory list tree.
STEP 2: Select a file on file list box.
STEP 3: Press Create a file button to bring up on-screen keyboard and name the new file
by typing in on-screen keyboard, then screen will turn to YBC data input page. (Refer to
3.10.5 YBC data - Editing)
○
1
○
2
○
3 Fig-3.4

3.4 Delete a Directory / File

selection page (Fig-3.1) will be shown on screen. Operations for deleting a directory / a file are
described below:
A. Delete a directory (See Fig-3.5)
STEP 1: Select a directory where the directory is to be deleted on directory list box.
STEP 2: Press Delete a directory button, then Check dialog box appears on screen to
prompt user if delete the directory or not. If clicking “Yes”, the directory and all files of this
directory will be deleted permanently. Note! The directory “Data” can not to be deleted.
○
1
Fig-3.5
○
2

B. Delete a file (See Fig-3.6)

STEP 1: Clicking on a directory where the file is to be deleted in the directory list tree.
STEP 3: Press Delete a file button, then Check dialog box appears on screen to prompt
user if delete the file or not. If clicking “Yes”, the file will be deleted permanently.
○
1
○
2
Fig-3.6
○
3

3.5 Change Name

selection page (Fig-3.1) will be shown on screen. Operations for renaming a directory / a file are
described below:
A. Rename a directory (See Fig-3.7)
STEP 1: Select a directory where the directory is to be renamed on directory list box.
STEP 2: Press Change name button, then Rename dialog box appears on screen. Clicking
on New filename column to bring up on-screen keyboard and rename the directory by
typing in on-screen keyboard.
○
1
Fig-3.7
○
2

B. Rename a file (See Fig-3.8)

STEP 1: Clicking on a directory where the file is to be named in the directory list tree.
STEP 3: Press Change name button, then Rename dialog box appears on screen. Click
New filename column to bring up on-screen keyboard and rename the file by typing in
on-screen keyboard.
○
1
○
2
Fig-3.8
○
3

3.6 Copy a Directory / File

selection page (Fig-3.1) will be shown on screen. Operations for copying a directory / a file are
described below:
A. Copy a directory (See Fig-3.9)
STEP 1: Select a directory where the directory is to be copied on directory list box.
Attention! All files of the CURRENT directory can be copied, not including the sub-directory.
STEP 2: Press Directory copy button to open Copy dialog box, then select a path location
of where to store the directory.
STEP 3: Click New filename column to bring up on-screen keyboard and name the
directory by typing in on-screen keyboard.
○
1
Fig-3.9
○
2
○
3

B. Copy a file (See Fig-3.10)

STEP 1: Clicking on a directory where the file is to be copied in the directory list tree.
STEP 3: Press File copy button to open Copy dialog box, then select a path location of
where to store the file.
STEP 4: Click New filename column to bring up on-screen keyboard and name the file by
typing in on-screen keyboard.
○
1
○
2
Fig-3.10
○
3
○
4

3.7 Synchronous
selection page (Fig-3.1) will be shown on screen. Operations for updating folders and bend data
are described below:
STEP 1: Clicking on directory list box. Directory list is displayed in RED at this time, it represents
activated. Select a directory where the directory is to be updated.
STEP 2: Press Synchronous button, all files in the file list box of the Selected directory will be
updated synchronously with the files of the Same directory which are saved on the local computer.
As shown below, select “KEN” on the directory list box and press Synchronous button, then all
files in the file list box of KEN directory will be updated synchronously with the files which are
saved on the local computer D:\CSM\Data\KEN.
○
1
○
2
Fig-3.11

3.8 Folder / Program Import

selection page (Fig-3.1) will be shown on screen. Operations for importing a folder / a file are
described below:
A. Import the entire folder (See Fig-3.12)
STEP 1: Select a directory of where to store the entire folder which is to be imported on
directory list box.
STEP 2: Press Program import button to open Browse for folder box. Select the location
from where the folder is to be imported, then press OK button to complete the import process.
○
1
Fig-3.12
○
2

B. Import single bending program (See Fig-3.13)

STEP 1: Select a directory of where to store the file which is to be imported on directory list
box.
STEP 2: Clicking on file list box.
STEP 3: Press Program import button to open Browse for folder box. Select the location
from where the file is to be imported, then press OK button to complete the import process.
○
1
○
2
○
3 Fig-3.13

3.9 Folder / Program Export

selection page (Fig-3.1) will be shown on screen. Operations for exporting a folder / a file are
described below:
A. Import the entire folder (See Fig-3.14)
STEP 1: Select a directory which is to be exported on directory list box.
STEP 2: Press Program export button to open Browse for folder box. Select the location
where the folder is to be exported, then press OK button to complete the export process.
○
1
○
.2 Fig-3.14

B. Import single bending program (See Fig-3.15)

STEP 1: Clicking on a directory where the file is to be exported in the directory list tree.
STEP 3: Press Program export button to open Browse for folder box. Select the location
where the file is to be exported, then press OK button to complete the export process.
○
1
○
2
Fig-3.15
○
3

3.10 Operations for Bend Data Programming

Bend data programming operations, parts of function explanation have been described in the
foregoing sections. Machine specification, operation mode, (XYZ) coordinate settings, YBC
data settings and motion sequence are explained as follows:
A. Settings for machine specification:

(Refer to 3.10.1 Machine specification - Editing)
B. Settings for tooling specification:

(Refer to 3.10.2 Tooling specification - Editing)
C. Settings for operation mode:

(Refer to 3.10.3 Operation mode - Editing)
D. (XYZ) Coordinate settings:

(Refer to 3.10.4 (XYZ) Coordinate - Editing)
E. YBC data settings:

(Refer to 3.10.5 YBC data - Editing)
F. Machine motion:
(Refer to 3.10.6 Machine motion - Editing)

3.10.1 Machine Specification – Editing

A. Operation steps
a. Touch the Bend data programming button on Main page (Fig-2.2), then
Program selection page (Fig-3.1) will be shown on screen.
b. Select a bending program and press Load this program button to enter YBC data
input page. (Refer to 3.10.5 YBC data - Editing)
c. Click the tab at the bottom of the screen, and then Machine specification
page will appear on screen. (shown as below)
Fig-3.16
a. Collet close delay: Collet was closed by cylinder. Collet keeps closing
for a few seconds by input value in this column. Be sure the position of
collet is correct and avoid material slipping off.
b. PD in delay: If machine installs PD in sensor, when PD closes until

check sensor is activated, PD will stay a few seconds by input value in
this column, then machine carry on the next motion. If machine does
not install PD in sensor, PD will closes for a few seconds by input value
in this column, then machine carry on the next motion. It is to ensure
that PD’s position is correct and avoid material slipping off. (Not
applicable for PD servo device)

c. Clamp die in delay: If machine installs clamp die closing sensor, when
clamp die closes till check sensor is activated, clamp die will stay for a
few seconds by input value in this column, then machine will proceed to
next. If machine does not install clamp die closing sensor, clamp die will
close for a few seconds by input value in this column and machine will
proceed to next. It is to ensure the position of clamp die is correct and
prevent material slipping off. (Not applicable for CD servo device)
d. Pressure die partial opening distance: It is distance for pressure die
open partially by input value in this column, then pressure die carry on
the next step. This set is to save processing time and increase
efficiency. (Unit: mm)
Tube parameter
e. Outside diameter: Input the outside diameter of material in this
column.
f. Tube material: Input the material of tube in this column.
g. Material wall thickness: Input the wall thickness of a tube.
h. Elongation ratio (%): Elongation proportion is for a percentage of

will split or tear. The setting range of elongation proportion is 70~100
(%) in this column.
i. PDA elongation ratio (%): It is distance for PDA. advanced movement.
For example, when bending OD20 x CLR100 x 90 degrees, the arc
length should be 157.08 mm. If set 90 into this column, the PDA will
move forward 141.375 mm (157.08x0.9). (Optional, applicable for
PDA servo device)
PDA elongation constant: This constant is used to compenstae for
PDA elogation proportion. (Optional, applicable for PDA servo
device)
j. Spring back ratio (%): This percentage is used to compensate for the
effects of material spring back. For instance, if the programmed bend
angle is 90°and input 5% into this column, then it will get the actual
bend angle is 94.5° (90° x 1.05).
Spring back constant: This constant is used to compensate for the
effects of material spring back. Continue above example, if input 2° into
this column, then the actual bend angle will be 96.5° (94.5° + 2°).

Machine specification
k. Recapture angle/advance distance: When carriage is at interference
zone of the pressure die, clamp die will move forward to grip tube and
collet open so that carriage could retract to “load position”, after then
pressure die move forward to grip tube. Carriage cannot grip material
exactly due to springback of workpiece, by setting this recapture angle
to cope with this situation, bend arm will return to this angle, carriage
advance and collet close, then clamp die move backward eventually.
l. Mandrel forward position: Mandrel moves forward to the target
m. Mandrel back position: Mandrel moves backward to the target

Button functions
n. Load a format: Press this button, program will load the settings which were already
saved as format before.
o. Save the format: Press this button, program will save the current settings as a format.
p. Roll offset setting: (It is available for use if machine is rolling model.)
Tap this button, then Material characteristics for rolling page will appear on screen
(as shown below). User needs to input data in Reading on the radius meter columns
for bender test running. Note: Rolling function will not be available to select in the 3.6.4
YBC data settings page without Material characteristics for rolling page being set (as
shown in red frame below).
q. Calculator: Press this button and calculator will be presented on

screen. Operator can use it to do simple mathematics. (refer to 2.2.2
Calculator)

r. Save as: Press this button, user can save a part as a different part
number. The command of this button on other page is the same.
s. Save: Press this button, user can save the active part. The command
of this button on other page is the same.
t. Exit: Click this button, and then Program selection page (Fig-3.1) will
be shown on screen. he command of this button on other page is the
same.
C. If Y axis feeding is longer than Rear limit position, Y axis will repeat moving to finish
feeding length. For example: (Applicable for Repeat feed Mode)
Rear limit position of Y= ‐1000mm

Load position=250mm
Feeding length=1000mm
The first feeding (a): Y axis returns distance a → Y axis advances distance a and move
to Load position → Clamp die close.
Tangent line Surface of collet

(Y=0) a = (1000‐2)‐250= 748mm
Note: 2mm is program reserved.
(‐998)
Load position
(‐250) Rear limit position
(‐1000)
The second feeding (b): Y axis returns distance b → Clamp die opens → Y axis
advances distance b and move to Load position to finish feeding length (1000mm).
Tangent line Surface of collet

(Y=0) (‐502)
b = 1000‐748= 252mm
Load position
(‐250) Rear limit position
(‐1000)

3.10.2 Tooling Specification – Editing

A. Operation steps
c. Click the tab at the bottom of the screen, and then Tooling Specification
page will appear on screen. (shown as below)
Fig-3.17
a. Collet depth: This is the distance from the face to the stop of collet.
This is the amount of material insert to collet as collet is closed.
b. X axis shift out offset: you can force X axis to shift out to avoid
tube scratch with tooling.
c. Tooling stack number (CW.): It is tooling stack number for clockwise

bending and numbers form upper to bottom stack are R6 to R1. User
could determine available tooling stack by input value in this column.

d. Tooling stack number (CCW.): It is tooling stack number for

counterclockwise bending and numbers form upper to bottom stack are
R-6 to R-1. User could determine available tooling stack by input value
in this column. (Applicable for rotary work-head machine)
e. Safety position for Z axis move down: It is safety position for Z axis
move down. User could evade bend head colliding with tooling by input
rotate. (Applicable for rotary work-head machine)
f. Process (Bending=0 / Rolling=1): User needs to select this column upon the tooling
g. Clamp roller radius: Measure clamp roller radius and input the value in this column.
each stack) (It is available for use if machine is rolling model.) (It is available for
use if machine is rolling model.)
h. Bending CLR.: Please confirm the centerline radius upon the specification on the
i. Tool interference: bend die insert thickness. Please confirm the centerline radius
upon the specification on the tooling stack or measure by user, and must be sure the
unit (Millimeters or Inches) you input is correct. (It set upon each stack)
j. Centerline height: Upon actual centerline height to input value in this column. (It set
upon each stack)
k. Pressure die (PD) length: Measure the pressure die length and input the correct
l. Pressure die base length for re-stroke: In case pressure die length (PD length) was
between arc length and PD length, then offset the shortage by input value in this
column. In such case the pressure die will move to-and-fro twice to make up for the
shortage in between. For example, when bending OD20 x CLR50 x 180 degree, the
arc length should be 157 mm. If PD length = 120 mm, if you set 30 mm in this column,
m. Pressure die (PD) thickness: Measure the pressure die thickness and input the
correct value in this column. (It set upon each stack)
n. Pressure die (PD) clamping fine tune: It is for fine-tuning the clamping distance of
Pressure die (PD) to move forward / backward. When user input a positive value in
this column, the PD clamping forward. If user input a negative value in this column, the
PD clamping backward. (It set upon each stack)

o. Max. bending angle: In general, we set 190 degrees in this column, or set this value
p. Front limit position: The value in this column is the distance between center of bend
die and front end of carriage. If front limit position has been changed, must readjust
the data to keep it correctly. (It set upon each stack)
q. Clamp die (CD) length / Clearance for bend arm return: Measure the clamp die
length and input the correct value in this column. This column is applicable for
multi-stack machine. Carriage pre-feeds length beforehand for bend arm return
clearance, the value in this column is usually clamp die length. (It set upon each
stack)
r. Clamp die (CD) thickness: Measure the clamp die thickness and input the correct
s. Clamp die (CD) clamping fine tune: It is for fine-tuning the clamping distance of
clamp die (CD) to move forward / backward. When user input a positive value in this
column, the CD clamping forward. If user input a negative value in this column, the CD
clamping backward. (It set upon each stack) (Applicable for CD is driven by
servo)
t. Wiper die length: Measure the wiper die length and input the correct value in this
u. Wiper die thickness: Measure the wiper die thickness and input the correct value in
this column. (It set upon each stack)

3.10.3 Operation Mode – Editing

A. Operation steps
c. Click the tab at the bottom of the screen, and then Operation mode page will
appear on screen. (shown as below)
Fig-3.18
Green area ※ The selected options in this area do not affect for machine motion of
editing page.
a. Step by step ／ Semi cycle ／ Full cycle: To select program
running mode as step by step, semi cycle, or full cycle.
b. Pedal start ／ Panel start ／ Button start (Optional, Applicable

for two-hand start buttons with machine)

c. Operation mode before bending: Set all steps of the bend program
whether it apply this function. (Refer to 3.10.3 Operation mode - Editing /
Part C)
d. Teach mode: Set all steps of the bend program whether it apply this
function. (Refer to 3.12.9 Teach mode)
e. Part examination: Select this button to determine whether part is

examined during auto mode operation. If user does not need to do this
function, cancel it. (Refer to 3.12.8 Examining part)
f. Tube support and collet simultaneous movement: If user marks this

option, tube support moves down as collet open; tube support moves
up as collet close. (For tube support is a hydraulic / pneumatic /
servo device)
g. Y axis and C axis move simultaneously: To select this option whether

it activates or not. If mark this function, Y axis and C axis will move
simultaneously during bending, and Y axis advance distance is equal to
arc length.
h. Pressure die booster: To select pressure die booster whether it

enable or not. If there are no materials on the machine, do not mark this
option. (Optional)
i. Welding line detection: To select this option whether it activates or

not. If mark this function, sensor is activated to check weld shut and
then start bending process. (Optional)
Blue area
※ Machine motion of editing page will be varied when options are marked in this area.
j. Circular tube ／ Non-circular tube (such as square, rectangular,

elliptic, etc.)
k. Feeding mode
Collet end stopped. In this mode, bend with collet closed. When collet
grips material end, carriage moves back and feeds for each bend.
Repeat feed. In this mode, bend with collet open and repeat feeding
enable. When bending action was carried on, the collet will be opened.
After the bending finished, the collet will close and feed again.
Note: As feeding mode is set “1”, the rolling function cannot be

executed; Y axis stand by position = Load position + (Pre-fed
length ‐ Clamp die length for loading)

l. Start one time ／ Start two times: If user selects “start one time”,
collet closes and starts feeding when user press Auto start button
. If user selects “start two times”, user needs to press Auto start
button to close collet, then press the button again to start
feeding.
Note: If there is Two-hand start device with machine, but without
Collet close / open buttons (external device), “start two times”
function will be forced activated. If it is with Collet close / open buttons
(external device), user can select “start one time” or “start two times”
function. (Optional)
m. X axis position when loading: It is position of X axis
(work-head/carriage/mandrel sliding base/work-platform) to move in /
out for loading material.
In: X axis (work-head/carriage/mandrel sliding base/work-platform)
moves in to stay for loading by input “0” in this column.
Out: X axis (work-head/carriage/mandrel sliding base/work-platform)
moves out to stay for loading by input “1” in this column.
n. Carriage backward position: To avoid interference between tube

and Carriage, you can set to force Carriage move back to this position.
o. With mandrel ／ Without mandrel: If machine does not set up

mandrel or it is unnecessary to operate with mandrel during bending, in
such case user needs to select “without mandrel”. (Optional,
p. Mandrel is located at front ／ Mandrel is located at back: It is to
select mandrel stay front or back before tube loading. (Optional,
q. Bend finished, clamp die close ／ Bend finished, clamp die open:
To control the clamp die open or close after the last bend finished when
the program was carried out completely.
r. Tool stack for loading: Before starting to bend, it is to determine Z axis

(carriage / tooling stack) stays on which tooling stack for loading by
input value in this column. For example, if input “0”, then Z axis
(carriage / tooling stack) will manipulate the first bend from default stack
for loading. If input “1”, it will start the first bend from R1 stack for
loading, and so on.
s. Load position: It is load position for carriage in auto mode.
t. B axis offset: For non-round tube bending, B axis has an offset rotation
to the home position first, then B axis rotates this offset angle to match
with the shape of mold.

C. Operation mode before bending
a. Check this icon on Operation mode page (Fig-3.18), when machine

motion runs to this line, it will pop up a dialog box to prompt user whether change
mode settings or not. (as shown in Fig-3.19)
b. If user applies the changes, it also applies into Operation mode page. (Refer to 3.10.3
Operation mode - Editing). This function is convenient for user to modify settings without
changing screen.
c. If do not need to modify any setting, select “No” into Mode settings column, and then
this dialog box will never show again in this step. (See an example below.)
Fig-3.19

3.10.4 (XYZ) Coordinate – Editing

A. Operation steps
input page (Refer to 3.10.5 YBC data - Editing)
c. Click the tab at the bottom of the screen, and then (XYZ) Coordinate
settings page will appear on screen. (shown as below)
B. Data input
Coordinate settings is a design for bending mode, not for rolling mode. If program is in
rolling mode, operator could input value to YBC data, and then convert the program.
Operations for data input are described below:
a. Touch a white column brings up the on screen keypad.
d. Repeat the above steps till all data are filled.
e. Roll scroll bar to view the coordinate steps.
Fig-3.20


a.
Field name: XYZ coordinate data shows on screen, user can input data in the
columns which are below field names.
b. Tooling stack number: Select tooling stack upon your needs to determine
which bend die works.
c. Step amount: It displays the total converting steps in the

bend program.
d. Igs/Stp: Press this button, user could import XYZ data to Bender from 3D file (in .igs
or .stp format) and view the part’s shape by pressing 3D Preview button. (Optional)
e. 3D Preview: Bend data will be switched into a 3D preview drawing on screen, in this
3D preview function, user can change the bend data to preview the material shape.
(Refer to 3.10.4 (XYZ) Coordinate - Editing / part E)
f. Clean data: Press this button, all data settings of XYZ data will be cleaned
permanently.
g. Convert to YBC: Click this button, the XYZ data will be converted into YBC data. The
details of operation steps will be described in 3.10.4 (XYZ) Coordinate - Editing / part D.
Note: In case the program is in the rolling mode, this function will not be executed.
h. Delete a line: Place cursor on a line which you want to delete, and then click Delete a
line button, the next step comes up to replace the deleted step.
i. Insert a line: Place cursor on a line and then click Insert a line button, the new step
will be inserted above. All columns of the new step are “zero”, user has input new data
up needs.

D. Result of Coordinate Data (X, Y, Z) to Bend Data (Y, B, C) Conversion

a. Complete data input onto (XYZ) Coordinate settings page (Fig-3.20), press Convert
to YBC button to show XYZ data on screen. (as shown in Fig-3.21)
b. Press button, and a dialogue box will be shown on screen to prompt user for
a confirmation whether the data are transferred or not, if press OK, the program will
start transferring the data. When transferring operation is done, the result of calculation
screen will show as below.
c. Press button to return on (XYZ) Coordinate settings page.
Fig-3.21

E. View The Part in XYZ page

a. Press 3D Preview button on the (XYZ) Coordinate settings page to open 3D Preview
tool. User can vary the value in the XYZ Step column which is located in the upper
right hand corner of the screen, it is to help user to view the shape of the part every
time XYZ Step is changed. (See an example below)
b. Press this button to exit this function.
1
2 3 6
4 5

3.10.5 YBC Data – Editing

A. Operating steps
input page. (shown as below)
B. Data input
a. Touch a white column brings up the on screen keypad.
d. Repeat the above steps till all data are filled.
Note! The bender only accepts the program of YBC data to drive the bending process. All
the programs of XYZ coordinate need to be transferred to YBC data.
Parameter
settings
Fig-3.22


a. Y axis/feeding axis: Input feeding length of Y-axis in “a”.
Offset: Input offset of feeding length in “b”, for instance, when Y
(a) =100, offset (b) = -2, so the actual processing value of Y is 98.
a
Speed: Input feeding speed in “c”. Setting number is from 0 to 9;
the greater figure selecting, the faster speed moving. Clicking on
b c
this icon , it can set all steps are all the same speed.
Attention! If the length of tubing is very long or the wall thickness

of tubing is very thin, please do not set the speed too fast, the
feeding position will be inexact.
1. Material blank length: Program will calculate material blank
length by YBC data and bending CLR.
2. Pre-feed length: It is blank length for pre-feeding before the
first bend. (For the first bend)
3. Load position: It is load position for carriage in auto mode.
(For the first bend)
4. Bending finish delay: When bending finished, C axis will
stay for a few seconds by input value in this column, then
machine carry on the next motion. It is to confirm that C axis’
position is correct and keep bending steadier.
5. Teach mode: If mark this option, it represents Teach mode
page will bring up on screen for this bend. (Refer to 3.12.9
Teach mode)
6. Clearance for bend arm return: This column is applicable for
multi-stack machine. Carriage pre-feeds length beforehand for
bend arm return clearance, the value in this column is usually
clamp die width.
7. Pressure die partial opening time: It is time for pressure die
open partially by input value in this column, then pressure die
carry on the next motion. This set is to save processing time
and increase efficiency. (Unit: sec) (Applicable for PD
hydraulic driven)
Pressure die partial opening distance: It is distance for
pressure die open partially by input value in this column, then
pressure die carry on next motion. For example, if user input
“10” into this column, pressure die will move backward 10mm
from current position, and then carry on next motion. This set
is to save processing time and increase efficiency. (Unit: mm)
(Applicable for PD servo device)

b. B axis/rotation axis: Input rotation degree of B-axis in “a”. When

you stand at the front of work-head, the direction of clockwise is
positive and counterclockwise is negative. (Refer to Fig-1.5)
a Offset: Input offset of rotation degree in “b”, for instance, when B
(a) = -300, offset (b) = 10, so the actual processing value of B is
-290.
b c
Speed: Input rotation speed in “c”. The setting number is from 0
to 9; the greater figure selecting, the faster speed moving. Clicking
on this icon , it can set all steps are all the same speed.
c. C axis/bending axis: Input bending degree in “a”.

Offset: Input offset of bending degree in “b”, for instance, when C
(a) = 100, offset (b) = -10, the actual processing value of Y is 90.
a Speed: Input bending speed in “c”. The setting number is from 0
to 9; the greater selecting, the faster speed moving. Clicking on
b c
this icon , it can set all steps are all the same speed.
d. Tooling stack number: It is to set stack number to determine which stack

works. (Applicable for Multi-stack machine model)

e. Bender type: Click this column to bring up the bender type list, user can
select bender process type as bend, roll or punch (optional) for this bend.
B=Bend
Select “B=Bend”, the following options will be shown on the right hand side
of the screen to provide user to check:
1. A.M.L: If mark this option, it represents that mandrel lubrication
activates for this bend. (Optional, applicable for mandrel unit)
2. Rear booster: If mark this option, it represents that RBE/RBH
activates for this bend. (Optional)
3. Pressure die assist: If mark this option, it represents that pressure
die assist activates for this bend. (Optional)
4. A.M.R.U.: If mark this option, it represents that A.M.R.U activates for
this bend. (Optional, applicable for mandrel unit)
R=Roll (It is available for use if machine is rolling model.)
Select “R=Roll”, the following columns will be shown on the right hand side
of the screen to provide user to set values:
1. Rolling pre-feed length: Input value in this column to determine
carriage forward distance as bend arm and carriage move
simultaneously. The curvature of workpice will become more smooth
and better by perform this function.
2. Arc length: It is to set arc length by input value in this column.
Offset: It is to set offset of arc length by input value in this column, for
instance, when arc length = 100, offset = -10, the actual arc length is
90.
3. Spiral angle: If user wants to bend tube into spiral, user can input
value in this column to control the pitch is the vertical rise for every 360
degrees of bend.
Offset: For example, the spiral angle = 100, offset = -10, the pitch of
every 360 degrees of bend = 90°(=100-10)
4. Speed: It is to set rolling speed by input value in this column. The
setting number is from 0 to 9; the greater selecting, the faster speed
moving.
5. Rolling CLR: If sets “0” into process column (refer to 3.10.2 Tooling
specification - Editing Process (Bending=0 / Rolling=1)), user can
input value in this column, then the relative bending angle will be
shown on the screen.
6. Rolling angle of tube: If sets “1” into process column (refer to 3.10.2
Tooling specification - Editing Process (Bending=0 / Rolling=1)),,
radius will be calculated automatically according to the value of
relative bending angle, and user can input value for rolling angle of
tube in this column. In case radius and arc length are changed, the
rolling angle of tube also be varied. For example, if bend die radius =
350R, and bend arm angle = 90, then arc length will be calculated
automatically = 549.9mm.

f. Motion sequence: Click this column to bring up the motion sequence list,
user can select movement progress for this bend. Tapping on this icon
, it can set all steps are all the same motion sequence.
1. Mandrel stays back: If mark this option, it represents that mandrel
stays back for this bend. (Optional, applicable for mandrel unit)
2. PD fully open: If mark this option, it represents that pressure die will
be full open when bending finished.
3. Shift out then next move (with pre feeding, C≧90 deg): If mark
this option, when bend angle is more than 90 degrees, Y axis will
move for pre-feeding length first and then X axis shift out.
4. Shift out then next move (without pre feeding, C＜90 deg): If mark
this option, when bend angle is less than 90 degrees, X axis will shift
out first and then Y axis move.
5. Bend back interference angle: This column shows on screen when
the option “C back → Y+B → Stk shift (3)” is selected. If user input
value in this column, C axis will return to the setting angle first, then Y
axis starts feeding until C axis return to 0, after then B axis is rotating
to proceed the next motion. It is to prevent moving device from
collision with tooling as bend arm is in course of returning.

g. Torque setting (Optional)
1. Tap this button , then Torque setting will be opened up on
screen (as shown below). Press this button and all

pressure are set as the 1st section column.
2. Bend degree range for each section pressure

Calculation: Bending degrees divided by 10 to get bending degree
range of each section pressure.
Example: If bending angle = 90°; 90÷10=9, thus bending degree range
of each section pressure are as follows.
Bend degree range

0~9
10~18
19~27
28~36
37~45
46~54
55~63
64~72
73~81
82~90
Explanation: If input “50” in the “The 3rd section pressure” column, it

means that RBE / PDA will output 50% pressure as bend angle is
between “19~27” degrees.
h. 3D Preview: Bend data will be switched into a 3D preview drawing on
screen, in this 3D preview function, user can change the bend data to
preview the material shape. (Refer to 3.10.5 YBC data - Editing / part G)

i. Insert: Place the cursor on a step and tap on Insert button, then the new step will be
created above and all columns of the new step are “zero”.
j. Delete: Place cursor on the step which you want to delete and tap on Delete button,
the next step comes up to replace the deleted step.
k. Clean data: Press this button, all data settings of YBC data will be cleaned
permanently.
l. Mirror: When user manipulates this function, it is to create a mirror image of the part
and be symmetric to original part.
m. Reverse: Press this button to determine this part is bent from back to front / from front
to back.
n. Dynamic 3D simulation: After inputting the program data, users can simulate the
bending process and preview the part. (Optional)
o. Tube length: Calculate Y axis receding length of step 1 by what you input. (Refer to
3.10.5 YBC data - Editing / part D)
p. Export: It is to export M4 bend program to the selected path.

Import: It is to import M3 / M4 bend program from the selected path.
q. Convert to XYZ: Click this button, the YBC data will be converted into XYZ data.
(Refer to 3.10.5 YBC data - Editing / part E)
Note: In case the program is in the rolling mode, this function will not be executed.

D. Calculate Tube Length

STEP 1: Press Tube length button on YBC data input page (Fig-3.22) to open up
Calculation options on screen. (as shown in Fig-3.23)
STEP 2: Select an item (calculate material blank length, pre-feed length or end-feed
length) in Calculation option field and input value in columns (as shown in Fig-3.23)
STEP 3: Press Calculate button and confirm data, then press Save data and exit button
(as shown in Fig-3.23) to get result of calculation.
Note: Calculation option field remembers the choice that you selected last time until the
choice is changed.
○
2
○
1
○
3 Fig-3.23
a. In repeat feed mode (refer to 3.10.3 Operation mode - Editing), “Y value of step 1” and
“Y-axis standby position” will be updated when pressing Save data and exit button.
b. In collet end stopped mode (refer to 3.10.3 Operation mode - Editing), “Y value of
step 1” will be updated when pressing Save data and exit button.

c. If End-feed length is smaller than Front limit position, Option suggesting (Fig-3.24)
will appear on screen to prompt user correct the value.
Note: If user does not correct or adopt the value that program suggested, the data will
not be calculated.
Fig-3.24
d. If Pre-feed length is less than zero, Option suggesting (Fig-3.25) will appear on
screen to prompt user correct the value.
Note: If user does not correct or adopt the value that program suggested, the data will
not be calculated.
Fig-3.25

E. Result of Bend Data (Y, B, C) to Coordinate Data (X, Y, Z) Conversion

a. Complete data input onto YBC data input page (Fig-3.22), press Convert to XYZ
button to show YBC data on screen. (See an example below)
b. Press button, and a dialogue box will be shown on screen to prompt user for
a confirmation whether the data are transferred or not, if press OK, the program will
start transferring the data. When transferring operation is done, the result of calculation
screen will show as below.
c. Press button to return on YBC data input page.

F. Y value (offset included) equals the total feeding values of the step
a. Y value (offset included) equals total feeding values of the step in motion sequence.
b. While changing Y value, program automatically modify (plus or minus) the difference at
the last feeding move.
c. For an example－Set Y=200 of the step, and the feeding moves are 50, 100, 50. As
changing Y=220, the feeding moves will be changed as 50, 100, 70. (as shown in the
following table)
Step Motion sequence Before After

Y=200 0001 Y=50 Y=50
00 (change) 0002 Y=100 Y=100
Y=220 0003 Y=50 Y=70 (50+20)
The increment of Y value is automatically plus the last feeding move

of the step.
G. View The Part in YBC page

a. Press 3D Preview button on the YBC data settings page to open 3D Preview tool.
User can vary the value in the No. of bends column which is located in the upper right
hand corner of the screen, it is to help user to view the shape of the part every time
Bend counts is changed. (See an example below)
b. Press this button to exit this function.
1 2
3 4

3.10.6 Machine Motion – Editing

A. Operation steps
c. Click the tab at the bottom of the screen, and then Machine motion page will
appear on screen. (shown as below)
Fig-3.26

a. “a” field is to show sequential steps.
“b” field is to show motion sequences of the step.
b
a
b. Step: Input step no. into “a” field to jump to the bend line of step.

c. Y axis/feeding axis: Input feeding length of Y-axis

a into “a” field.
Offset: Input offset of feeding length into “b” field,
for instance, when Y (a) =100, offset (b) = -2, so the
b c actual processing value of Y is 98.
Speed: Input feeding speed into “c” field. The
setting range is from 0 to 9; the greater figure
entering, the faster speed moving.
d. B axis/rotation axis: Input rotation degree of
a B-axis into “a” field. When you stand at the front of
work-head, the direction of clockwise is positive and
counterclockwise is negative. (Refer to Fig-1.5)
b c Offset: Input offset of rotation degree in “b” field, for
instance, when B (a) = -300, offset (b) = 10, so the
actual processing value of B is -290.
Speed: Input rotation speed in “c” field. The setting
range is from 0 to 9; the greater figure entering, the
faster speed moving.
e. C axis/bending axis: Input bending degree into “a”
a field.
Offset: Input offset of bending degree into “b” field,
for instance, when C (a) = 100, offset (b) = -10, the
b c actual processing value of Y is 90.
Speed: Input bending speed into “c” field. The
setting range is from 0 to 9; the greater figure
entering, the faster speed moving.
f. Working units: It is to show which device is working of the step.
g. Motion amount: It is to show all motions of the current bend program; 1200 motions
are available for a bend program.
C. Total feeding values of the step equals Y value (offset included)

a. Total feeding values of the step equals Y value (including offset).
b. While changing the feeding move of the step, program will automatically modify (plus
or minus) the difference with the last feeding move.
c. For an example－Set Y=200 of the step, and the feeing moves are 50, 100, 50. As
changing the first feeding move = 80, the feeding moves will be changed: 80, 100, 20.
(As shown in the following table)
Step Motion sequence Before After

0001 Y=50 Y=80 (50+30)
00 Y=200 0002 Y=100 Y=100
0003 Y=50 Y=20 (50-30)
Total feeding values of the step equals Y value (offset included) of YBC
data settings (refer to 3.10.5 YBC data - Editing).
The increment of Y value is automatically minus the last feeding move of the step.

3.10.7 Edit Menu for Motion Sequence – Editing

A. Operation steps
c. Click the tab at the bottom of the screen, and then Machine motion page will
appear on screen. (Fig-3.26)
d. Click the bend line you want to edit, and then Edit menu will be shown on screen.
(shown as below)
e. Select “Insert / delete a line” on bend line to insert, delete or set data for machine.
Fig-3.27
B. Function Explanation (Fig-3.27)

a. Insert a line: Place the cursor on a step and tap on Insert a line button, then the new
step will be created above and all columns of the new bend line are “zero”, it can input
new data for this bend line. (Refer to 3.10.7 Edit Menu for Motion Sequence / Part C)
b. Command change: Place cursor on a bend line and select Command change to
modify command for motion. (Refer to 3.10.7 Edit Menu for Motion Sequence / Part C)
c. Edit setting values: Place cursor on a bend line and select Edit setting values to
modify setting values. (Refer to 3.10.7 Edit Menu for Motion Sequence / Part C)

 Orientation: There are two options to set orientation: ABS and INC; the setting
instructions are described as follows:
ABS: Absolute position. To input the distance / angle of destination upon your
needs. For example, If Y axis moves to position “-500” with ABS, user has input
“ABS: -500” as setting. (as shown in Fig-3.28)
INC: It is an idea of relative position. To input the difference in distance / angle
between the present position and the destination. For example, if Y axis moves
to position “-500” with INC, the present position of Y axis is at “-200”, so the
difference in distance between the present position and the destination is
300mm, user has to input “INC: -300” as setting. (as shown in Fig-3.28)
If Y axis moves to position "-500",
the difference in setting methods between ABS and INC
Y
are as follows: ABS：-500　/　INC：-300
Tangent line
-100 -200 -300 -400 -500 -600 -700
Fig-3.28
 Movement: It is to set distance or angle of movement for motion device.
 Waiting: It is to set the working unit whether it waits for the device to complete a
motion before it starts running the next sequence.
d. Delete a line: Place cursor on the bend line which you want to delete and tap on
Delete a line button, the next bend line comes up to replace the deleted line.
e. Cut: Place cursor on the bend line and tap on Cut, the next bend line comes up to
replace the cut line.
f. Paste: Place cursor on the bend line and tap on Paste, the bend line will be inserted
above.

C. Insert a line / Command change

Click Insert a line or Command change on the Command menu (Fig-3.27) to create a
line or modify settings, then Machine motion setting box will open up on screen (shown
as below). There are three tabs Motion control, Cycle pause and External I/O (optional)
are introduced below:
Fig-3.29
Motion control (See Fig-3.30)

Select Motion control tab on Machine motion settings page (Fig-3.29) and click a button,
then screen will show as below, it can set orientation, direction, speed and waiting for
machine. The setting options of all devices are listed below, and users could set upon
actual situation.
Fig-3.30

Orientation Wait to
No Working units Direction options Speed
options complete
Mandrel lub. Yes

1. ------- Timer setting(sec) -------
(A.M.L.) No
Tube support Open Yes

2. ------- -------
(hor. / vert.) Close No
Absolute position
B-axis (ABS) Yes
3. Degree setting(deg) 0~9
rotation Relative position No
(INC)
Full out
Full in
Timer setting(sec)—for MD Yes
4. Mandrel (ABS) -------
is a hydraulic device. No
Distance setting(mm)—for
MD is a servo device.
Y-axis (ABS) Yes
5. Distance setting(mm) 0~9
feeding Relative position No
(INC)
Open Yes
6. Collet ------- -------
Close No
Pressure die In Yes

7. ------- -------
assist (PDA) Out No
Full out
Full in
Timer setting (sec)—for PD is
Absolute position a hydraulic device.
Pressure die (ABS) Distance setting (mm)—for Yes
8. 0~9
(PD) Relative position PD is a servo device. No
(INC)
※ When set “Full out” or
“Full in” for PD, its open will
be controlled with ABS.
Full out
Full in
Timer setting(sec)—for CD is
a hydraulic device.
Clamp die Yes
9. ------- Distance setting(mm)—for -------
(CD) No
CD is a servo device.
※ When set “Full out” or
“Full in” for CD, its open will
be controlled with ABS.

Orientation Wait to
No Working units Direction options Speed
options complete
Bendhead
rotation
Absolute position CW. Yes

10. (Applicable 0~9
(ABS) CCW. No
for rotary
work-head
machine)
C-axis Absolute position Yes

11. Degree setting (deg) 0~9
Bending (ABS) No
Tangent line
Z-axis (bend
Timer setting(sec)—for
head/carriage
Z-axis is a hydraulic device.
& mandrel
Distance setting(mm)—for
sliding base)
Absolute position Z-axis is a servo device.
vert.
(ABS) Yes
12. movement 0~9
Relative position ※ Select which tooling stack No
(INC) works.
(Applicable
※ When set “Tangent line /
for
Safety position” for Z-axis, its
multi-stacked
moves will be controlled with
machine)
ABS.
X-axis (bend Move in

head/carriage Move out
& mandrel Timer setting(sec)—for
sliding X-axis is a hydraulic device.
base/work-pl Absolute position Distance setting(mm)—for
atform) hor. (ABS) X-axis is a servo device. Yes
13. 0~9
Movement Relative position No
(INC) ※ Select which tooling stack
(Applicable works.
for ※ When set “Move in / Move
multi-stacked out” for X-axis, its moves
machine) will be controlled with ABS.
Punching
(Applicable In Yes
14. ------- -------
for punched Out No
machine)

Cycle pause (See Fig-3.31)

Select Cycle pause tab on Machine motion settings page, then screen will show as
below. Button meanings of this page are introduced as follows:
Fig-3.31
a. Create a loop: It is to set the step as the beginning of a loop.

b. Back to the beginning of cycle: It is to set the step backs to the beginning of a loop.
c. Jump to line “N”: It is to set the bend line jumps to the appointed bend line.
d. Pause: It is to set temporary stop duration for the device. (Unit: sec)
Button#1(SB15): Press Auto start button on the control panel / step foot switch /
press Two hands start buttons to start bending.
Button#2(SB18): Collet close. (Optional)
Button#3(SB19): Clamp die open. (Optional)

e. Waiting control: In case interference would be occur in course of bending, user can
manipulate this function to cope with this situation. Not only avoid collision but save
processing time. For example, pressing Wait for C-axis button, set “＜30 deg” into
Direction column and press Apply. See an example below.
Fig-3.32
Step Motion
Working units (& explanations)
sequence sequence
C axis-[ABS][90deg][Speed 9][Wait to complete]
02 0025
Explanation: C axis completes 90 degrees bending.
C axis -[ABS][0deg][Speed 9]
02 0026
Explanation: C axis starts returning to 0 degree.
Wait for C axis-[<30deg]
02 0027 Explanation: When C axis returns less than 30 degrees,
“Sequence 0028” is activating.
Y axis-[INC][20mm][Speed 9]
02 0028
Explanation: Y axis starts to advance 20mm.

f. Create a sub loop

STEP 1: Press Create a sub loop-1 button on Cycle pause page (Fig-3.31), screen
will show as below.
Fig-3.33
STEP 2: Press Apply button on Create a sub loop-1 screen (Fig-3.33), then click
. The complete screen is shown as below.
Fig-3.34

g. Loop the device

STEP 1: Press Loop Y-axis button on Cycle pause page (Fig-3.31), screen will show
as below.
Fig-3.35
STEP 2: Set “< -800 mm” into Direction column of Loop Y-axis screen (Fig-3.35), it
represents “When Y value ≦ -800mm, the motion sequence will return to [Create
a sub loop-1]”. If Y value is more than -800mm (0~-799), then machine continues the
next motion. See an example below.
Fig-3.36

tangent line
Y= 0 Y= -800
proceed the next motion
sub loop cycle (Y ≦ -800)
(Y > -800)
-200 -400 -600 -800 -1000 -1200 -1400 -1600 -1800 -2000 -2200 -2600
Fig-3.37
STEP 3: Press Apply button on Loop Y-axis screen (Fig-3.33), then click .
The complete setting is shown as below.
Fig-3.38

External I/O (Optional) (See Fig-3.39)

a. Purpose: Input and output signals in this screen are applicable for bender to connect
peripherals like robot, loader, etc. There are eight buttons for input signals (I/P) /
outputs signals (O/P) on External I/O page. (See an example below)
I/P
O/P
Fig-3.39
Step Motion
sequence sequence
Notify to loading(O/P1)-[ON]
00 0013 Explanation: Bender sends a signal to O/P1 point, when
loader receives the signal and starts loading.
C axis -[ABS][0deg][Speed 9]
Explanation: When loading is done, loader sends a signal
00 0014
to I/P1 point for bender. Bender receives the signal, it
starts bending.

b. Example for loading process (green area) (Fig-3.40)
Fig-3.40
Step Motion
sequence sequence
Notify to loading(O/P1)-[ON]
Explanation: Bender output a signal to O/P1 point (I/O
00 0013
module), when robot receives the signal and starts
loading.
Loading completed(I/P1)-[ON]
Explanation: When loading is done, robot sends a signal
00 0014 to I/P1 point (I/O module) for bender. Bender receives
the signal ON, motion sequences 0015~0016 are
activating.
Notify to loading(O/P1)-[OFF]
00 0015
Explanation: Turn off O/P1 signal “Notify to loading”.
Loading completed(I/P1)-[OFF]
00 0016
Explanation: Turn off I/P1 signal “Loading completed”.
Collet-[Close][Wait to complete]
00 0017
Explanation: Collet close.
Notify to loading completed (O/P2)-[ON]
00 0018 Explanation: Bender output a signal to O/P2 to inform
robot for loading.
Loading arm reset completed (I/P2)-[ON]
Explanation: When unloading is done, robot sends a
00 0019 signal to I/P2 point (I/O module) for bender. Bender
receives the signal ON, motion sequences 0020~0021
are activating, then bender is going to bend.
Notify to loading completed (O/P2)-[OFF]
00 0020 Explanation: Turn off O/P2 signal “Notify to loading
completed”.
Loading arm reset completed (I/P2)-[OFF]
00 0021 Explanation: Turn off I/P2 signal “Loading arm reset
completed”.

c. Example for unloading process (green area) (Fig-3.41)
Fig-3.41
Step Motion
sequence sequence
Notify to unloading (O/P3)-[ON]
Explanation: Bender output a signal to O/P3 point (I/O
99 0130 module), when robot receives the signal and starts
unloading.
Unloading completed (I/P3)-[ON]
are activating.
Notify to unloading (O/P3)-[OFF]
99 0132 Explanation: Turn off O/P3 signal “Notify to
unloading”.
Unloading completed (I/P3)-[OFF]
99 0133 Explanation: Turn off I/P3 signal “Unloading
completed”.
Clamp die-[ABS][Full out] [Speed 9][Wait to
99 0134 complete]
Explanation: Clamp die fully open.
Notify to unloading completed (O/P4)-[ON]
99 0135 Explanation: Bender output a signal to O/P4 to inform
robot for unloading.
Unloading arm reset completed (I/P4)-[ON]
are activating, then bender is going to bend.
Notify to unloading completed (O/P4)-[OFF]
99 0137 Explanation: Turn off O/P4 signal “Notify to unloading
completed”.
Unloading arm reset completed (I/P4)-[OFF]
99 0138 Explanation: Turn off I/P4 signal “Unloading arm reset
completed”.

3.10.8 Part 3D Preview

A. Operation steps
b. Touch 3D Preview button on Program selection page (Fig-3.1); bend data will be
convert into a 3D preview drawing on screen (shown as below). User can change the
bend data to preview the material shape with this function.
c. Press this button to exit this function.
Fig-3.42
a. Reset viewport: Touch this button to activate the viewport and it
resets/reorients the part to match the orientation in the model space.
b. Zoom in: It can enlarge the part in the viewport by tapping on this button.
c. Zoom out: It can reduce the part in the viewport by tapping on this button.
d. 3-D Rotation: Tapping on this button and it can rotate the part with 360° in
the viewport.

e. Move: Tapping on this button and it can move the part up / down / left / right
in the viewport.
f. 3-D Rotation of X: It can rotate the part with 3-D rotation of X in the
viewport by tapping on this button.
g. 3-D Rotation of Y: It can rotate the part with 3-D rotation of Y in the
h. 3-D Rotation of Z: It can rotate the part with 3-D rotation of Z in the
i. Multi-viewpoints: Press this button to view the part with multi-viewpoints in

the model space.
j. Find: Tapping on this button and it will show details about the part on
screen.
k. Exit: Press this button to quit 3-D preview window.

3.10.9 Dynamic 3D Simulation (Optional)

A. Operation steps
a. Purpose: When bend data input is complete and it can start simulating the process
and previewing the workpiece. It is not only to preview working process, but also evade
collision incurring in course of bending by manipulating dynamic view simulation.
d. Press Dynamic 3D simulation button on YBC data input page (Refer to 3.10.5 YBC
data - Editing), then screen will be shown as below.
b. Just pressing Collision button at first, then touching Play button to start
simulation.
Fig-3.43

a. Zoom in: It can enlarge the object in the viewport by tapping on this button.
b. Zoom out: It can reduce the object in the viewport by tapping on this button.
c. Move: Tapping on this button and it can move the object up / down / left /
right in the viewport.
d. 3-D Rotation: Tapping on this button and it can rotate the object with 360° in
the viewport.
e. Last step: It can view the last motion of machine in the viewport by tapping
on this button.

f. Next step: It can view the next motion of machine in the viewport by tapping
on this button.
g. 3D Wireframe: It will display all lines of object to represent the boundaries.
h. Collision check: Press this button, it will start to check the simulation
whether collisions between tube and bending machine or tooling.
i. Play: Press this button and perform dynamic view simulation.
j. Pause: Press this button and halt simulation.
k. Axes: Touch this button and show the vector of axes.
l. Find: Tapping on this button and it will show details about object on screen.
m. Exit: Press this button to quit dynamic 3D simulation.

3.11 Calculate Length of Rolling and Bending Arc Curvature

3.11.1 Calculate the prearrangement length for bending
A. Someone would like prearrange the machine to carry out a tube which is with centerline
bending radius 50mm. (Fig-3.44)
B. Calculate the overall length of bending with the following formula and refer to Fig-3.45:
The arc length of curvature A = 0.0174532 x CLR x B
0.0174532 is a constant.
CLR = The unit of centerline radius of bend die in mm.
B = The actual bending angle.
L6
Θ5
Θ
5
L1
Θ4
Θ4
1
Θ
B
R
L2
L4
CL
Θ1
Θ3
Θ
3
A
2
Θ
Θ2
Fig-3.44 L3
Fig-3.45
C. Calculate the length of the five bends

1st bend = 0.0174532 x 50 x 90 = 78.52 mm
2nd bend = 0.0174532 x 50 x 90 = 78.52 mm
3rd bend = 0.0174532 x 50 x 90 = 78.52 mm
4th bend = 0.0174532 x 50 x 20.5= 17.88 mm
5th bend = 0.0174532 x 50 x 90 = 78.52 mm
D. Determine the suitable length of the tube.
L = 200+78.52+350+78.52+400+78.52+350+17.88+220+78.52+250 = 2101.9 mm
Note: The formula is theoretical only, because it does not consider other factors, such as
elongation, properties of material, etc.

3.11.2 Example: Example for Program Design (Single bend)

Refer to the drawing of Fig-3.46
TUBE TOTAL LENGTH=2102mm TUBE OUTSIDE DIAMETER=25.4mm
FEED LENGTH ROTATION DEG. BENDING DEG.
L1=200mm R1=0º Q1=90º
L2=350mm R2=90º Q2=90º
L3=400mm R3=0º Q3=90º
L4=350mm R4=90.5º Q4=20.5º
L5=220mm R5=-90º Q5=90º
L6=250mm
Program table filled according to drawing is as follows Fig-3.46
STEP Y B C.
0 REMARK 0 90
1 350 90 90
2 400 0 90
3 350 90.5 20.5
4 220 -90 90
Note: We suppose the loading position is 300mm.The value of Y step 0 is calculated by the way
as follows (Fig-3.46).
Because the total length of tube is 2102mm, so the value of Y. step 0 is
– (2102 – 300 – 200) = –1602
Note! Because the value is negative, so the direction of the carriage (Y) is backward. On the
other hand, it is forward.
D = The distance from Y axis load position to tangent

The bend position
Y axis load position (work point)
The first bend position

D
Fig-3.46

3.12 Operations in Auto Mode

3.12.1 Bend Program Selection – Auto Mode
Touch the Auto mode button on Main page (Fig-2.2), then Program selection page
will show as below.
Add a program
Select a program in the File list box and press Add a program button to move the bend
program into Work list box. Attention! 2 programs are allowed to work at a time.
Remove a program
Select a program in the Work list box and press Remove a program button to move the bend
program into File list box. Note! Bend programs will not be changed by adding / removing in
Program selection page.

3.12.2 Machine Motion – Auto Mode

A. Operation steps
a. When finish selecting bend programs in Program selection page (Fig-3.47) and press
Go to auto button, then Machine motion-auto mode page (Fig-3.48) will show on
screen.
b. Pressing Auto start button on the control panel (or depend on mode settings to
step on the start footswitch / press two hands start buttons) to start auto process.
Machine will run full automatically upon the bend data that user programming.
Attention! If alarm message shows on screen to prompt user, it needs to be shot
before restarting machine.
c. Programming instructions in auto mode refer to 3.10.7 Edit Menu for Motion Sequence –
Editing.
d. Flow charts of machine motion refer to 3.14 Motion process.
Fig-3.47
 Clicking on the
Modify button in
Machine motion-auto
mode page, it can
program the bend data,
but varying the
running bend
program and entering
into Manual mode
page are not allowed.
Fig-3.48

a. Data show for Y axis (feeding): It is to display the current position
of Y axis.
b. Data show for B axis (rotation): It is to display the current angle
of B axis.
c. Data show for C axis (bending): It is to display the current angle
of C axis.
d. Data show for X axis (tooling stack/carriage/mandrel sliding
base/work-platform) horizontal movement: It is to display the
current position of X axis.
e. Data show for Z axis (pressure die/carriage/mandrel sliding
base) vertical movement: It is to display the current position of Z
axis.
f. Data show for M axis (Mandrel): It is to display the current
position of M axis.
g. Data show for Q axis (Pressure die): It is to display the current
position of Q axis.
h. Data show for P axis (Clamp die): It is to display the current
Position of P axis.
i. Filename: It is to display the running bend program in auto mode.
j. Current sequence: It is to show the motion sequence number of bend line is running
in auto mode currently.
k. Mode settings: It is to select operation mode for machine running in auto mode.
(Meanings of icon please refer to 3.10.3 Operation mode - Editing)
l. Position of each axis: It is to display working status of each check sensor in auto
mode. (Refer to 3.12.3 Position of each axis in auto mode)
m. Counter: It is to count workpiece quantity and record processing time for the bend
program. (Refer to 3.12.4 Counter)
n. Numerical settings: It is to set timer and tube parameters in auto mode. (Refer to
3.12.5 Numerical settings in auto mode)
o. Tooling data: It is to set tooling data in auto mode. (Refer to 3.12.6 Tooling data in auto
mode)
p.
Modify: Clicking on the Modify button and vary commands for machine
motion in auto mode. If modification is complete, press Done button to save
changes.
q. Save to database: Press this button, the modified values are saved to database and
the previous values will be covered.
r. Save as: Press this button to save a part as different filename.

3.12.3 Mode Settings – Auto Mode

Press Mode settings button on Machine motion-auto mode page (Fig-3.48), then Mode
settings-auto mode page will show on screen (see below). This page is to select operation
mode for machine running in auto mode. Meanings of each icon refer to 3.10.3 Operation mode -
Editing.
Fig-3.49
3.12.4 Axes Position – Auto Mode

Press Position of each axis button on Machine motion-auto mode page (Fig-3.48), then
Axes position-auto mode page will show on screen (see below). This page will help user to
know all sensors’ positions and their states. Meanings of each icon refer to 2.2 Manual Mode
Operation.
Fig-3.50

3.12.5 Running Time & Quantity – Auto Mode

A. Operation steps
Press Counter button on Machine motion-auto mode page (Fig-3.48), then Running
time quantity-auto mode page will show on screen (see below).
Fig-3.51
B. Explanation of functions (See Fig-3.51)

a. Set counts: It is to set material quantity which needs to be processed.
b. Batch: It is for two programs working at a time. When a batch of workpiece is complete,
machine will proceed the next batch. See an example below, when the first program
completes 6 workpiece, then the second program complete 4 workpiece, after then
back to the first program proceed the next batch (6 workpiece) until set counts is
complete.
Sequence Filname Set counts Batch
#1 Data\0916-5.MBF 600 6
#2 Data\TEST.MBF 400 4
c. Workpiece counts: It is to display material quantity which was processed.

d. Revise counts: If there are some bad workpiece during the process, user can revise
the quantity in this column to correct the total quantity of workpiece.

e. Total: It is to show total quantity of workpiece. If check on the “Show the working
piece counts complete” item, when Total = Set counts, the following message will
be shown on screen to prompt user that processed counts is complete. If it does not
need to present this message next time, just cancel this check.
f. Reset (N=0): Pressing on this button and values in Workpiece counts and Total
columns will be reset to zero.
g. Total running time: It is to count total running time of all workpiece in auto mode.
h. Single part running time: It is to count running time of all steps of single part.
i. Average running time: It is to count average running time of per workpiece.
j. Total running time (loading / unloading included): It is to count total running time of
all workpiece in auto mode, loading / unloading time is included.
k. Single part running time (loading / unloading included): It is to count running time
of all steps of single part, loading / unloading time is included.
l. Average running time (loading / unloading included): It is to count average running
time of per workpiece, loading / unloading time is included.
m. Reset (time): Pressing on this button and all time will be reset to zero.

3.12.6 Numerical Settings – Auto Mode

A. Operation steps
Press Numerical settings button on Machine motion-auto mode page (Fig-3.48), then
Numeric setting-auto mode page appears on screen (shown as below).
Fig-3.52

a.
Collet close delay: Collet was closed by cylinder. Collet keeps closing
for a few seconds by input value in this column. Be sure the position of
collet is correct and avoid material slipping off.
b. PD in delay: If machine installs PD in sensor, when PD closes until

check sensor is activated, PD will stay a few seconds by input value in
this column, then machine carry on the next motion. If machine does
not install PD in sensor, PD will closes for a few seconds by input value
in this column, then machine carry on the next motion. It is to ensure
that PD’s position is correct and avoid material slipping off. (Not
applicable for PD servo device)
c. Clamp die in delay: If machine installs clamp die closing sensor, when
clamp die closes till check sensor is activated, clamp die will stay for a
few seconds by input value in this column, then machine will proceed to
next. If machine does not install clamp die closing sensor, clamp die will
close for a few seconds by input value in this column and machine will
proceed to next. It is to ensure the position of clamp die is correct and
prevent material slipping off. (Applicable for CD hydraulic device)

Tube parameter
d. Outside diameter: Input the outside diameter of material in this

column.
e. Elongation ratio (%): Elongation proportion is for a percentage of

will split or tear. The setting range of elongation proportion is 70~100
(%) in this column.
f. PDA elongation proportion (%): It is distance for PDA. advanced

movement. For example, when bending OD20 x CLR100 x 90 degrees,
the arc length should be 157.08 mm. If user set 90 in this column, the
PDA will move forward 141.375 mm (157.08x0.9). (Applicable for
PDA servo device)
PDA elongation constant: This constant is used to compenstae for
PDA elogation proportion. (Applicable for PDA servo device)
g. Mandrel forward position: Mandrel moves forward to the target

h. Mandrel back position: Mandrel moves backward to the target


3.12.7 Tooling Data – Auto Mode

A. Operation steps
a. Press Tooling data button on Machine motion-auto mode page (Fig-3.48), then
Tooling data-auto mode page appears on screen (as shown in Fig-3.53).
b. Columns display values in GRAY are not allowed to modify.
Fig-3.53
a. Process (Bending=0 / Rolling=1): User needs to select this column upon the tooling
b. Clamp roller radius: Measure clamp roller radius and input the value in this column.
each stack) (It is available for use if machine is rolling model.)
c. Bending CLR.: Please confirm the centerline radius upon the specification on the
d. Tool interference: Bend die insert thickness. Please confirm the centerline radius
upon the specification on the tooling stack or measure by user, and must be sure the
unit (Millimeters or Inches) you input is correct. (It set upon each stack)
e. Centerline height: Upon actual centerline height to input value in this column. (It set
upon each stack)
f. Pressure die (PD) length: Measure the pressure die length and input the correct

g. Pressure die base length for re-stroke: In case pressure die length (PD length) was
between arc length and PD length, then offset the shortage by input value in this
column. In such case the pressure die will move to-and-fro twice to make up for the
shortage in between. For example, when bending OD20 x CLR50 x 180 degree, the
arc length should be 157 mm. If PD length = 120 mm, if you set 30 mm in this column,
h. Pressure die (PD) thickness: Measure the pressure die thickness and input the
correct value in this column. (It set upon each stack)
i. Max. bending angle: In general, we set 190 degrees in this column, or set this value
j. Pressure die (PD) clamping fine tune: It is for fine-tuning the clamping distance of
Pressure die (PD) to move forward / backward. When user input a positive value in
this column, the PD clamping forward. If user input a negative value in this column, the
PD clamping backward. (It set upon each stack)
k. Front limit position: The value in this column is the distance between center of bend
die and front end of carriage. If front limit position has been changed, must readjust
the data to keep it correctly. (It set upon each stack)
l. Clamp die (CD) length / Clearance for bend arm return: Measure the clamp die
length and input the correct value in this column. This column is applicable for
multi-stack machine. Carriage pre-feeds length beforehand for bend arm return
clearance, the value in this column is usually clamp die length. (It set upon each
stack)
m. Clamp die (CD) thickness: Measure the clamp die thickness and input the correct
n. Clamp die (CD) clamping fine tune: It is for fine-tuning the clamping distance of
clamp die (CD) to move forward / backward. When user input a positive value in this
column, the CD clamping forward. If user input a negative value in this column, the CD
clamping backward. (It set upon each stack) (Applicable for CD is driven by
servo)

3.12.8 Examining Part

A. Purpose: It is to examine the stability of workpiece by checking the tolerance of Y position
and the user can determine whether Y axis tolerance examination is set. For example, if
input “1.00” into Y axis tolerance examination column, system will check tolerance of Y to
within ±1.0mm. When tolerance goes beyond ±1.0mm, the following screen will pop to
remind users whether the tolerance needs to be changed. The accuracy of examining
function is usually caused by the welding and elongation ratio of tubing.
Attention! Examining tolerance can not be zero.
Fig-3.54
B. Operation steps
STEP 1: Check Part examination on the Mode settings-auto mode page

(Fig-3.49) (see an example below). Meanings of each icon please refer to 3.10.3 Operation
mode - Editing.
Fig-3.55

STEP 2: Press Modify button on the Machine motion-auto mode page (Fig-3.48)
and the button turn to Done button . Insert a bend line which will be part examining
point. (see an example below)
Fig-3.56
STEP 3: Click Cycle pause tab, press Y axis reference point button. (see an example
below)
Fig-3.57

STEP 4: Set “Yes” into Wait to complete column, press Apply and Exit to quit this setting
box and screen will back to Machine motion-auto mode page (Fig-3.48), then press
Done button to complete settings. (see an example below)
Fig-3.58
3.12.9 Teach Mode

A. Operation steps
Check “Teach mode” onto the YBC data input page (Fig-3.22) for the bend. When motion
sequence runs to this step, screen will pop the Teach mode page. (shown as below)
Fig-3.59


a. Axis name: It is to show the device name and user can select devices to teach.
b. Current position: It is to show the current position for teachable devices.
c. Destination: It is to display destination for device.
d. To go: It is to show distance / angle that the device has to move to reach destination.
e. Direction: It is to display move direction of the device.
f. Move to target: Clicking on this column and a movement teach option list will show on
screen. It is to set movement teach for the device.
g. Machine motion: It is to record taught steps of machine motion.
h. Undo: Click Undo and press and simultaneously on the control panel
to un-teach the last move until the movement stop, then press Undo done to finish
moving.
i. Cancel undo: Cancel “Undo”. If user would like to cancel “Undo”, but the device has
been moved, it needs to press and simultaneously on the control panel
to cancel the last un-teach move until the movement stop, then press Cancel undo
button to save changes.
j. Memorize motion: When complete teaching the device and press Memorize motion
button to record teach steps into the box of the left hand side of the screen.
k. Abort: It is to abandon the taught device. If the device has been moved, it needs to
press and simultaneously on the control panel to give up the last taught
move until the movement stop, then press Abort to abandon the taught device.
l. Start: It is to teach device for motion. As setting is complete, tap on Start button and
press and simultaneously on the control panel to start teaching device
move.
m. Save motions: The error of To go column must within tolerance, or Save motions
button will be unavailable. The saved motion will cover the range of motion sequences
from clamp die and pressure die open in this bend to the next bend before.
C. Teach devices (See Fig-3.59)

a. Select Axis name column to teach device and more than one device can be taught.
b. Press and simultaneously on the control panel to jog the teachable
device to destination (forward / close / up or rotate clockwise).
c. Press and simultaneously on the control panel to jog the teachable
device to destination (backward / open / down or rotate counterclockwise).
d. To go column is to show distance / angle that the device has to move to reach
destination. A blue box in the To go column represents the device reached destination
already. For example, in Fig-3.59, when To go of Y axis (Feeding) = 0 and Current
position = Destination.
e. Figures with plus sign (+) or minus sign (–) in the To go column shows a red box, it
represents the device has not been reached destination, and it has to move the device
to reach its destination. For example, in Fig-3.59, B axis (Rotation) has to rotate
(+92.37) degrees to reach its destination.

D. Direction settings
a. Click Move to target column of the teachable device to open up list of teaching
direction options (see an example below). Options of each teachable device are
listed below, user can set Move to target column upon needs.
Fig-3.60

b. List for movement teach options (See Fig-3.60)

No Axis name Move to target Note
(1) Target
(2) Front limit position
1. Y (Feeding)
(3) Rear limit position
(4) Keyin values (INC)
(1) Target
(2) INC359 (rotate 359° CW.)
2. B (Rotation)
(3) INC-359 (rotate 359° CCW.)
(1) Target
3. C (Bending) (2) Max. bend angle
If teachable device is driven by
Select tooling stack number
(1) Shift in position hydraulic servo, it will no list for
(2) Shift out position (Right-hand movement teach options, in
X (Work-head / Carriage &
bending)
Mandrel sliding base / such case, user needs to press
4. (3) Min.
Work-platform) hor.
(4) Max and
movement
(5) Shift out position (Left-hand simultaneously
bending)
(forward/close/up or rotate
Select tooling stack number clockwise) or press and

(1) Centerline height simultaneously
Z (Work-head / Carriage & (2) Min.
(backward/open/down or rotate
5. Mandrel sliding base) vert. (3) Max.
counterclockwise) on the control
movement) (4) Safety position for Z axis move
down panel to jog the device to
destination.
(1) Full in
6. Q (Pressure die) (2) Full out
(1) Clockwise bending

7. R (Bendhead rotation)
(2) Counterclockwise bending
(1) Full in
8. P (Clamp die)
(2) Full out
(1) Full in
9. M (Mandrel) (2) Full out

3.13 Pauses and Release

If user would like to suspend or stop hydraulic system when machine is running in auto mode,
please find the ways below.
3.13.1 Pause
There are two pause switches with machine. One button (Auto stop button ) is on the
control panel and another is red footswitch which is labeled SB6. When pressing Auto stop
button on the control panel or stepping Footswitch (SB6), machine will suspend all
motions, and screen will pop the following message (Fig-3.61) immediately. If user would like to
resume the cycle, press Continue button for 3 seconds to remain the cycle in auto mode and
machine will proceed to next. Attention! Please check there is no person on the working
area before restarting the machine.
Fig-3.61
3.13.2 Emergency Stop

There are two emergency stops with machine. One button is on the control panel (Fig-1.4○ 12 )
and another is on the top of the foot pedestal which is labeled SB17. When pressing any
Emergency stop button, machine will cut hydraulic power off and halt all motions, and screen
will pop the above message (Fig-3.61) immediately. If user would like to resume the cycle, it has
to press Hydraulic motor start button (Fig-1.4○ 8 ) on the control panel first, or “Motor is not
on.” will show on screen to prompt user, then press Continue button for 3 seconds to remain
the cycle in auto mode and machine will proceed to next.
Attention! Please check there is no person on the working area before restarting the
machine.

3.14 Motion Process
Put material
Press the Manual rapid button (as shown in Fig-1.4(5))

on the control panel or Collet close button (external button)
(As mode settings)
Collet closes
Press Auto start button on the control panel, step start footswitch
or press Two hand start buttons (external button)
(As mode settings)
Bender works
(set upon Machine motion page)
Bending complete
Collet opens
Pressure die opens
Y axis returns to load position
Press Clamp die open button (external button)
Clamp die opens
Take out workpiece
Press Auto start button on the control panel, step start footswitch
or press Two hand start buttons (external button)
(As mode settings)
All devices reset

3.15 System Configuration

3.15.1 System Information – System Configuration
It is to prevent the program is changed by others, it has to input password before entering
System information page. In System information page, user can check the basic information
of system, such as software version, running time or bend counts, etc.
A. Operation steps
a. Clicking System configuration button on the Main page (Fig-2.2), then Input
password (the default password is 12345678) to enter System configuration page.
(shown as below)
b. Click System information tab on the System configuration (Fig-3.62), and then
System information page will show on screen. (as shown in Fig-3.63)
Fig-3.62

Fig-3.63
a. PLC software version: It is to display PLC software version.
b. Servo system software version: It is to show the software version of servo system.
c. Touchscreen software version: It is to show the software version of program.
d. System no.: This number is registration for bender software.
e. Total running time(min.): It is to record total running time for machine.
f. Running time in auto(min): It is to record total running time for machine in auto mode.
g. Bend counts: It is to record total bend counts for machine.
h. Serial number: It is serial number for machine.
i. Working record: Press this button and user can see the working event logs about
machine. (Refer to 3.15.4 Working record)
j. Format management: User can confirm the format which is saved, and also can
delete the format in this page. (Refer to 3.15.5 Format management)
k. Alarm record: Press this button and user can view the alarm event logs about
machine. (Refer to 3.15.6 Alarm record)
l. User management: It is to set privilege of program editor. (Refer to 3.15.7 User
management)
m. Export information: If there is any problem with the machine, user can press this
button to export information (such as PLC software version, servo system software
version, touchscreen software version, etc.) in .txt format, then send it to CSM for
solution.

3.15.2 Numerical Settings – System Configuration

A. Operation steps
b. Click Numerical settings tab on the System configuration (Fig-3.62), and then
Numerical settings page will show on screen. (shown as below)
Fig-3.64
a. Click Password setting column to change password of System configuration. Click
on-screen keypad to set new password and touch Enter key to finish change. From
now on, key in this new password to enter System configuration screen.
b. Rear limit position: It is rear limit position of carriage to avoid bumping. The value in
this column is the distance from tangent to the face of collet.
c. Unit (mm/inch): In this page, unit can be selected as Millimeters or Inches. User
also needs confirm and set the basic data for bender.
d. System lub. frequency: It is upon action times of clamp die to determine the
frequency of system lubrication. For example, if input 100 into this column, system
lubricating performs one time when clamp die moves 100 times.
e. System lub. time: It is to set lubricator running time for machine by input value in this
column. (Unit: second) Continue above example, if input 10 into this column, when
clamp die move 100 times and lubricator will start lubricating for 10 seconds.
f. Power save setting: If machine does not run within the setting time by input value in
“Time to power save (min)” column, motor will be turned off automatically.
g. Login without password required next time: If user marks this item, it will not need
to input password as entering System configuration page.
h. Default settings: Touch this button and all data will be applied to original company
settings.

C. A Program associated when jumping out of auto.

It is to set “The program was running at the SN1 in auto” OR “The last program being
edited (not run in auto)” as default when entering Program selection page (Fig-3.1).
Select one on the list of “A program associated when jumping out of auto”. (See an
example below)
When “The program was running at the SN1 in auto” is selected…

a. The part program will be associated with the one was running in auto when jumping
out of auto. See an example below…D:\CSM\Data\KEN\TEST.MBF.

b. The part program will be associated with the one was running in auto as default when
entering Program selection page. See an example below…
D:\CSM\Data\KEN\TEST.MBF
Default program:
D:\CSM\Data\KEN\TEST.MBF

When “The last program being edited (not run in auto) is selected…
a. The part program will be associated with the last one being edited on Editing page
when jumping out of auto.
b. The part program will be associated with the last one being edited on Editing page as
default when entering Program selection page. See an example
below…D:\CSM\Data\123\TEST2.MBF
Default program:
D:\CSM\Data\123\TEST2.MBF

D. Romer set up (Optional)

To setup Romer data transmission function.
a. Transmission path: The exchange folder, must be set in the same directory on Bender
and Romer.
b. Station No.: The exchange folder, must be set in the same directory on Bender and
Romer.
c. Romer data version: Romer (supravision)

3.15.3 Delay / Timer Settings – System Configuration

A. Operation steps
a. Clicking System configuration button on the Main page (Fig-2.2), then

Input password (the default password is 12345678) to enter System configuration
page.
b. Click Timer settings tab on the System configuration (Fig-3.62), and then Timer
settings page will show on screen. (shown as below)
Fig-3.65
B. Data input
a. Clicking on a white column to brings up the on-screen keypad and key in data into
column, then click Enter to finish input operation. Please note the limit of input data.
a. If set 0.00 in the column, machine will proceed to next without any delay. (Unit: sec)
b. Collet open delay: It is for collet keeps opening for a few seconds by input value in
this column. It is to confirm the position of collet is correct and it fully open.
c. Mandrel forward delay: After check sensor confirms the forward position of mandrel
is correct, then action will delay for a few seconds by input value in this column. This
delay setting is to ensure the mandrel’s position is true. (Optional, applicable for
mandrel unit)
d. Mandrel lub. time: It is to set working time for mandrel lubrication pump in this
column. The oil volume is up to size and material of tubing. (Optional, applicable for
mandrel unit)
e. Punch in time: It is to set time that punch die move inward to process for a few
seconds by input value in this column. (Optional, applicable for Punch unit)
f. Punch out time: It is to set time that punch die move outward for a few seconds by

input value in this column, then machine will carry on the next motion. (Optional,
applicable for Punch unit)

3.15.4 Working Record

A. Purpose: It is to view the working event logs for machine from this page.
B. Operation steps

page.
b. Click Working record button on the System configuration (Fig-3.62), and then
Working record page will show on screen. (shown as below)
Fig-3.66
C. Explanation for columns (See Fig-3.66)

a. Analysis by－
Record: It is to show every bend data records on screen.
Date: This record will determine on date and filename to count total workpiece and sort
bend data by date to show on screen.
b. Record count: A drop down list of record count is available. User can select 100, 500
or All records to be shown on screen.

3.15.5 Format Management

A. Purpose: User can confirm the format which is saved, and also can delete a format from
this page.
B. Operation steps

page.
b. Click Format management button on the System configuration (Fig-3.62), then
Format management page will show on screen and a drop down list of format name
is available. (shown as below)
Fig-3.67

3.15.6 Alarm Record

A. Purpose: User can view the alarm event logs for machine from this page.
B. Operation steps

page.
b. Click Alarm record button on the System configuration (Fig-3.62), and then Alarm
record page will show on screen. (shown as below)
Fig-3.68

3.15.7 User management

A. Purpose: In order to manage the program editing privilege, it has to create a username
with a private password to modify program.
B. Operation steps
b. Click Alarm record button on the System configuration (Fig-3.62), and then User
management page will show on screen. (shown as below)
c. Create: Clicking on Create button  Add a username, password and select a level 
Press Save button to finish creating the username. Note: If user would like to abandon,
just press Abort button.
d. Edit: Select a username  Press Edit button  Modify the username, password or
level  Press Save button to save changes. Note: If user would like to abandon
changes, just press Abort button.
e. Delete: Select a username  Press Delete button  Remove the username from
away user list
Fig-3.69

3.15.8 Backup database

A. Purpose:
1. The database in C:\\Tube can be backup in the IPC.
2. The Parameter, Bending program and Work record in D:\\CSM can be backup in the
IPC.
B. Operation steps:
b. Click Backup database button on the System configuration (Fig-3.62), and then
Browse folder icon will show on screen. (shown as below)
Fig-3.70
c. Choose a storage location  click OK button or Create button to create a new
folder  Done
d. You can see backup file name in zip file, default file name is "yyyymmdd".

3.16 System Diagnostic

A. Purpose: System diagnostic is to help user to judge signals of sensors if it is normal.
B. Operation Steps
a. Touch the System diagnostic button on the Main page (Fig-2.2), then System
diagnostic page will shows on screen. (shown as below)
b. Click the tab at the top of the screen, signals of each unit whether it is activated by
checking in Input board / Output board / Control panel diagnostic pages. For digital
outputs and inputs, represents an ON state; represents an OFF state.
(shown as below)
Fig-3.70 Fig-3.71
Fig-3.72 Fig-3.73
Fig-3.74

3.17 User Login／Logout

A. Purpose
It is for user to change username and authority by logging out / logging in the program.
B. Operation steps
a. Touch the User login / logout button on the Main page (Fig-2.2), then Login /
Logout box will pop on screen. (shown as below)
b. If user would like to change password, just press Change password button on Login
box (shown as below). If user forgets personal password, it can set a new on in User
management page. (Refer to 3.15.7 User management)
Fig-3.75
Fig-3.76

C. User Privilege
In the program, there are 3 levels for user privilege: System manager (Admin/default
password:1234), Supervisor (PROG/default password:123) and Operator (USER / default
password:123). Privileges of each level are listed as below:
No Using Privileges Admin PROG USER

1. Perform manual operations   
2. Run automatic cycle   
3. Edit machine motion in auto mode  
4. Save bend program to database in auto mode  
5. Save bend program as another in auto mode  
6. Edit program  
7. Load the program   
8. Part 3D preview   
9. Create / delete a directory  
10. Create / copy / delete bend file  
11. Export programs  
12. Import programs  
13. Save programs  
14. Print bend data  
15. Convert to machine motion  
16. Perform dynamic 3D simulation   
17. Perform calculator   
18. Edit system configuration (for service) 
19. Clear working records 
20. Clear alarm event logs 
21. Edit format management 
22. Save the format  
23. Load a format  
24. User management 

3.18 Alarm Message and Troubleshooting

To avoid the illogical and error operation damaging the machine and even causing human's injury,
the alarm and troubleshooting will appear on the screen in time.
3.18.1 Alarm messages

When you execute the illogical and error operation, the bender will make the bell alarm. Then,
the malfunction reason will appear on the screen and teach you how to solve this problem.
Fig-3.77
3.18.2 Table of Alarm and Troubleshooting

When the machine starts to operate, the malfunction reason will appear on screen and advise
operators where it is out of order as some trouble happenings. The following table indicates that
how to solve the problem and the statements of trouble-shooting.
No Trouble Point Solutions

Check if the clamp die cylinder moves normally. If not, please
Clamp die Fwr. sensor (SNR4) or valve (SOL2)
01 check/change its solenoid valve (SOL-2). If it runs normally,
breaks down.
check/change if just the sensor (SNR-4) slips away or is broken.
Check if the clamp die cylinder moves normally. If not, please
Clamp die back sensor (SNR7) or valve
(SOL2) breaks down.
Check if the pressure die cylinder moves normally. If not, please
Pressure die Fwr. sensor (SNR5) or valve
(SOL5) breaks down.
Check if the pressure die cylinder moves normally. If not, please
Pressure die back sensor (SNR8) or valve
(SOL5) breaks down.
Check if the cylinder of mandrel moves normally. If not, please
Mandrel Fwr. sensor (SNR3) or valve (SOL4)
breaks down.


Check if the cylinder of mandrel moves normally. If not, please
Mandrel back sensor (SNR1) or valve (SOL4)
breaks down.
Check if the cylinder of booster moves normally. If not, please
Booster back sensor (SNR10) or valve (SOL6)
breaks down.
Check if the cylinder of bend arm moves normally. If not, please
Bend arm back sensor (SNR2) or valve
(SOL3) breaks down.
If something wrong on the servomotor, please find the figure which

is shown on the servo driver (in the control box of machine’s back
09 Feeding servo motor is abnormal. side) and contact with supplier or engineer. If you want to cancel
the alarm, please wait for 30 seconds and then turn off the power.
Also wait for another 30 seconds to turn on the power.

10 Rotation servo motor is abnormal. side) and contact with supplier or engineer. If you want to cancel
11 Work-head servo motor is abnormal. side) and contact with supplier or engineer. If you want to cancel
12 Please check air pressure. Please check the air pressure, and keep it at least over 3kg/cm2.
Motor turns off ascribe to left safety plate is crashed, please press
13 Safety plate (Left) is in action. alarm released button as Fig-1.4(11) on the control panel to clear
alarm.
Motor turns off ascribe to right safety plate is crashed, please press
14 Safety plate (Right) is in action. alarm released button as Fig-1.4(11) on the control panel to clear
alarm.
Being overloading, please check the hydraulic motor and voltage of
15 Hydraulic motor is overloaded.
power.
Being overloading, please check the servomotor and voltage of
16 Servo driver is overloaded
power.
Check if the cylinder of collet moves normally. If not, please
Collet open sensor (SNR26) or valve (SOL8)
breaks down.
Check if the cylinder of bendhead moves normally. If not, please
Work-head move up sensor (SNR18) or valve
(SOL10) breaks down.
Work-head move down sensor (SNR17) or
valve (SOL10) breaks down.
Check if the cylinder of R1 moves normally. If not, please
R1 shift in sensor (SNR20) or valve (SOL11)
breaks down.
Check if the cylinder of R0 moves normally. If not, please
R0 shift in sensor (SNR20) or valve (SOL11)
breaks down.


Work-head shift-out sensor (SNR20) or valve
(SOL11) is broken.
Check if the cylinder of mandrel base moves normally. If not, please
Mandrel base up movement sensor
(SNR-13) or valve (SOL-10) breaks down.
Mandrel base down movement sensor
(SNR-12) or valve (SOL-10) breaks down.
Mandrel base shift-in (R1) sensor (SNR-15)
or valve (SOL-11) breaks down.
Mandrel base shift-in (R0) sensor (SNR-14)
Mandrel base shift-out sensor (SNR-11) or
valve (SOL-11) breaks down.
Check if the feeding length is correct or if the front limit point is set
28 Feeding Fwr. distance will exceed front limit.
correctly.
Check the fuse whether it blows or not. If yes, change the same
29 24V DC power is abnormal. (63,62) specification fuse. If the fuse often blows, please contact with
supplier or engineer.
Check the fuse whether it blows or not. If yes, change the same
30 24V DC power is abnormal. specification fuse. If the fuse often blows, please contact with
supplier or engineer.
Check the interference dot whether it is correct or not. If carriage

Carriage has crashed with pressure die.
31 crashes with pressure die, please move interference dot backward,
(SNR23 active).
or check the sensor (SNR-23) works normally.
Check if the feeding length is correct or the rear limit is set

32 Feeding back distance will exceed rear limit.
correctly.
Check if the cylinder of front booster clamp moves normally. If not,
Front booster clamp close sensor (SNR-24)
33 please check/change its solenoid valve (SOL-15). If it runs normally,
Check if the cylinder of front booster clamp moves normally. If not,
Front booster clamp close sensor (SNR-25)
Check if the cylinder of bend die moves normally. If not, please
Bend die back sensor (SNR-6) or valve
(SOL-18) breaks down.
There is an object in the danger area, and Remove the object from danger area, and then press reset button
36
the safety guard is active. of safety guard to clear alarm.
Check if the cylinder of tube support moves normally. If not, please
Tube support up sensor (SNR-29) or valve
Check if the cylinder of tube support moves normally. If not, please
Tube support down sensor (SNR-30) or valve
Check the volume of mandrel lubricant whether it is enough. If not,
39 Lack of mandrel lubricant.
please fill with the same spec. oil.


Check the volume of system lubricant whether it is enough. If not,
40 Lack of system lubricant.
please fill with the same spec. oil.
The last stay position is unmatched with Please check the fallowing situation: 1. Is clamp die slipped away?
41
standard check value. 2. Is program data correct? 3. With tube bending?
Please check the power line specification whether it is correct or
42 The power line phase is incorrect.
not.
43 X axis servo motor is abnormal. side) and contact with supplier or engineer. If you want to cancel
44 Z axis servo motor is abnormal. side) and contact with supplier or engineer. If you want to cancel
45 PLC back-up battery is low. Replace the battery.
Please check the bending value is correct or bending axis front limit
47 C axis is over front limit.
sensor (SNR-39) works normally.
Please check the bending value is correct or bending axis front limit
48 C axis is over rear limit.
sensor (SNR-39) works normally.

Servo motor of pressure die assist is
49 side) and contact with supplier or engineer. If you want to cancel
abnormal.
Check if the cylinder of center clamp base moves normally. If not,
Center clamp close sensor (SNR-49) or valve
Check if the cylinder of center clamp base moves normally. If not,
Center clamp close sensor (SNR-50) or valve
Servo motor of pressure die positioning is

52 Please check the positioning of pressure die is correct.
abnormal.
Bendhead shift in distance will exceed shift Please check the X axis value is correct or X axis shift in limit sensor
53
in limit. works normally.
Bendhead shift out distance will exceed shift Please check the X axis value is correct or X axis shift out limit
54
out limit. sensor works normally.
Z axis vertical distance exceeds downward Please check the Z axis value is correct or Z axis up limit sensor
55
distance. (LS11) works normally.
Z axis vertical distance exceeds upward Please check the Z axis value is correct or Z axis up limit sensor
56
distance. (LS12) works normally.
Y axis could not advance to interference dot Please check program, before Y axis advanced movement, to set
57
because pressure die does not full open. pressure die “full open”.
Pressure die could not advance because Y

58 Retract carriage to get away the interfere area.
axis enter interference dot.


Please check values of CLR and pressure die thickness that you
59 Alarm for servomotor of pressure die. input are correct, and check the servomotor whether it is running
normally.
Movement distance of pressure die exceed Be sure the values of CLR and pressure die thickness that you input
60
front limit. are correct.
Movement distance of pressure die exceed Be sure the values of CLR and pressure die thickness that you input
61
rear limit. are correct.
Check if PDA moves (CW.) are correct or if the front limit point is set
62 Movement of PDA (CW.) exceed front limit.
correctly.
Check if PDA moves (CW.) are correct or if the rear limit point is set
63 Movement of PDA (CW.) exceed rear limit.
correctly.
Check if PDA moves (CCW.) are correct or if the front limit point is
64 Movement of PDA (CCW.) exceed front limit.
set correctly.
Check if PDA moves (CCW.) are correct or if the rear limit point is
65 Movement of PDA (CCW.) exceed rear limit.
set correctly.
Check if rotation of R axis is correct or if the front limit point is set

66 Rotation of R axis exceed front limit.
correctly.
Check if rotation of R axis is correct or if the rear limit point is set

67 Rotation of R axis exceed rear limit
correctly.
Pressure die vertical movement (CW.) Check if pressure die vertical moves (CW.) are correct or if the front
68
exceed front limit. limit point is set correctly.
Pressure die vertical movement (CW.) Check if pressure die vertical moves (CW) are correct or if the rear
69
exceed rear limit. limit point is set correctly.
Pressure die vertical movement (CCW.) Check if pressure die vertical moves (CCW.) are correct or if the
70
exceed front limit. front limit point is set correctly.
Pressure die vertical movement (CCW.) Check if pressure die vertical moves (CCW) are correct or if the rear
71
exceed rear limit. limit point is set correctly.
Check if clamp die moves are correct or if the front limit point is set
72 Clamp die movement exceed front limit.
correctly.
Check if clamp die moves are correct or if the rear limit point is set
73 Clamp die movement exceed rear limit.
correctly.
Check if mandrel moves are correct or if the front limit point is set
74 Mandrel movement exceed front limit.
correctly.
Check if mandrel moves are correct or if the rear limit point is set
75 Mandrel movement exceed rear limit.
correctly.
Check if clamp die offset moves are correct or if the front limit point
76 Safety protection is on.
is set correctly.
Failure on either bendhead positioning Check if clamp die offset moves are correct or if the rear limit point
77
lower sensor (SNR-177) or valve (SOL-125). is set correctly.


If something wrong on the servomotor, please find the code which
78 S axis servomotor is abnormal. side) and contact with supplier or engineer. If you want to cancel
80 PDA. servomotor (CCW.) is abnormal. side) and contact with supplier or engineer. If you want to cancel
81 R axis servomotor is abnormal. side) and contact with supplier or engineer. If you want to cancel
Servomotor for pressure die vertical
movement is abnormal.
83 Servomotor for clamp die is abnormal. side) and contact with supplier or engineer. If you want to cancel
84 Servomotor for mandrel is abnormal. side) and contact with supplier or engineer. If you want to cancel
85 Servomotor for clamp die offset is abnormal. side) and contact with supplier or engineer. If you want to cancel
Servomotor for carriage positioning is
abnormal.
Servomotor for bend arm positioning is
abnormal.
89 Sawing motor is abnormal. side) and contact with supplier or engineer. If you want to cancel
R axis could not rotate because Z axis does Be sure the values of R axis’ position correspond with safety
90
not move downward to the safety position. position, or it is unable to rotate.

X axis cannot move because its position is

91 Be sure the position of X axis is correct, or it is unable to move.
not at safety zone.
Mandrel sliding base shift in distance Please check the X axis value is correct or X axis shift in limit sensor
94
exceeds limit. works normally.
Mandrel sliding base shift out distance Please check the X axis value is correct or X axis shift out limit
95
exceeds limit. sensor works normally.
Check if rotation of R axis is correct or if the rear limit point is set

124 Loading arm servo motor alarm
correctly.
125 No tubes for loading arm to grab Please check sensor (SNR103) or tubes on loading arm.
126 Carriage is in the loading interference zone Load position is not correct
Failure on loading arm extending sensor or

127 Please check sensor(SNR) or solenoid(SOL)
pneumatic valve.

Version 50V000 Chiao Sheng Machinery Co., Ltd. Doc. Page IV-1
Part Ⅳ Maintenance Description of Tube Bender
Before maintaining the machine,

please read " The Maintenance Instruction".
Attention!
Reasons why most accidents occur,

is because of disobeying
safety regulations.
To keep the tube bender working normally and safely, it is necessary

to maintain the machine periodically and build an effective maintenance
plan according to the user application, and environment.
The operators should obey all recommendations of this handbook to
avoid accidents. If the tube bender needs maintenance, operators should
report this to the supervisor and stop working this machine until the
problem is rectified.
maintenance, safety and capacity will void all rights and warrantees by
CSM.
Part IV Maintenance Description of Tube Bender

Index 4
1 Introduction of Machine Function.......................................................................... 3

1.1 Lubrication System ............................................................................................. 3
1.2 Hydraulic Oil System (Not applicable for all electric model) ................................ 3
1.3 Electric System ................................................................................................... 4
1.4 Cooling System (Not applicable for all electric model) ........................................ 4
1.5 Microplate Heat Exchanger (Optional, not applicable for all electrical model) .... 5
1.6 Heater (Optional, not applicable for all electrical model) ..................................... 5
2 Machine Maintenance ............................................................................................. 6
3 Lubrication and Maintenance ................................................................................. 7

3.1 Lubrication Period ............................................................................................... 7
3.2 Automatic Lubricator ........................................................................................... 8
3.3 Mandrel Lubricator (Optional) ............................................................................. 9
3.4 Hydraulic Oil (Not applicable for all electric model)........................................... 10
4 Maintenance of Hydraulic Cooling System (Not applicable for all electric model)
................................................................................................................................... 11
4.1 Water Cooler..................................................................................................... 11
4.2 Periodical Inspection......................................................................................... 11
4.3 Fan Cooler ........................................................................................................ 12
4.4 Periodical Inspection......................................................................................... 12
5 Maintenance of Machines' Structure ................................................................... 13
6 Selection of Lubricants ......................................................................................... 14

1 Introduction of Machine Function

The Automatic Tube Bender, which is produced by Chiao Sheng Machinery Co., Ltd. is a hydraulic
operated machine. It is designed to produce to bent many kinds of material and tubing (i.e. steel
tube and non-steel tube) very efficiently and precisely under the different modes. If you need
special dies like square tube, oval tube, rectangle tube, and other shape sections, please inquire
and contact with CSM.
The main system of the tube bender is introduced as follows:
1.1 Lubrication System

Automatic Lubricator
On Electrical CNC series (TSRE, TDRE, TBRE, TMRE etc.) tube benders, an adjustable
automatic lubrication system includes the supply time and the oil volume, which is fitted as
standard. The operator can set the lubrication timing according to clamp action times if it is
necessary. We suggest the oil viscosity is 30 cST ~ 50 cST. (The working temperature range is
25°C~40°C). Besides, the controller of lubrication system should keep away from dust, water and
oil.
1.2 Hydraulic Oil System (Not applicable for all electric model)
1.2.1 Vane Pump
The hydraulic oil is sent with the vane-driven hydraulic pump.
1.2.2 Hydraulic System

The device and function of the hydraulic oil system are as following:
A. Hydraulic Pump
It is fitted on the machine oil tank. There is a filter setup on the oil-bore to avoid dust and
metal particles falling into the oil tank.
B. Power Motor
It is positioned outside the tank. The main shaft, which is inside the coupling, connects the
electrical motor and the hydraulic pump.
C. Components of Hydraulic System
For example, the release valve can adjust and set to the highest hydraulic pressure, which
the system needs to protect the pump from overload.

1.3 Electric System

1.3.1 Correct Electrical Power Cable Supply
Operator has to Install correct electric power cable according to the machine specification.
Before connecting the electric power, inspect the main electric voltage number on the motor
plate to confirm that the correct electrical wire gauge is used. The main voltage numbers are
listed in Technical Document.
1.3.2 Equipped Function of Electric System

Use the "On" and "OFF" buttons to start the motor. The setup device of the motor is
electromagnetic which can increase the starting capability of the motor. The inner
temperature-overload relay protects the motor coil from ultra high temperature. (The control
power of the electromagnetic valve is 24 DC volts.)
1.3.3 Control Box Heater Exchanger

The power supply of heater exchanger was connected by AC 220 volt. Keep the water and the
oil away from that. Be sure to clean the air strainer at least once a week with air gun or water
after dismounting air filter.
1.3.4 Warning!
When people come into the safe operating area or other collision areas, the alarm will ring and
the DC electric voltage will auto-turn off also the hydraulic system will stop.
1.4 Cooling System (Not applicable for all electric model)

1.4.1
The temperature of the hydraulic oil increases follows the operating time. The whole hydraulic
system has to be connected to a cooling system (water cooling or fan cooling) to stabilize the
oil temperature. This will extend both oil and hydraulic components life.
1.4.2
The cooling system can keep the temperature of the hydraulic oil at 55°C. It may make the
components of the hydraulic system be used for longer time, and also keep the accuracy of the
bending angle.

1.5 Microplate Heat Exchanger (Optional, not applicable for all

electrical model)
1.5.1 Water Requirement
Soft water is required to heat exchanger. Soft water is the term used to describe types of water
that contain few or no calcium or magnesium ions. If use hard water to heat exchanger, it will
cause limescale deposits in heat exchanger and decrease heat exchanger efficiency.
1.5.2 Strainer
If any of the media contain particles of 1 mm or larger, we recommend that a strainer (16-20
mesh) be installed before the heat exchanger.
1.5.3 Maintenance
To avoid obstruction occurring during operation, user must do back flow cleaning for heat
exchanger periodically. Use a 5% solution of a weak acid such as phosphoric or citric acid.
Reverse the normal flow direction, and increase the flow rate to 1.5 times normal.
1.6 Heater (Optional, not applicable for all electrical model)

1.6.1 Maintenance for Hydraulic Motor
When temperature of hydraulic oil is too low, heater will hot oil up automatically until it arrives
at the minimum temperature setting. If it is not arrived at the minimum temperature setting,
please do not start up the hydraulic motor for preventing from damage.

2 Machine Maintenance
2.1 Before maintaining the machines, read "The Maintenance Instruction" first.
2.2 If the main power source and the hydraulic pump not be turned off, don't put your hands,
fingers, or any parts of your body into the tube bender.
2.3 While you're near the machines or the operation is going on, don't wear ties, jewelry slack
clothes etc.
2.4 To avoid damage from using the machines without the permission, turn off the electric
power and lock the switch on the "OFF" position.
2.5 Use the gauge die to execute the adjustment, machine testing, and die testing.
2.6 Don't leave the machine while the pump is working.
2.7 Put small tools into the toolbox or the tool-waist-pocket. Don’t put these tools into your
pocket. After maintenance, don't leave any tools near the machine.
2.8 Before starting the machines, confirm all components of compressed air; electricity, and the
hydraulic system are connected. Then the machine can be started after confirming the
value of the power voltage requirement.
2.9 After completion of maintenance, identify and confirm the related parameters and pick up all
tools. Then, start the tube bender and make sure it works smoothly.
2.10 Clean out all debris, and clean the area around the machines.
2.11 When you repaint the machines, don't cover the safe labels on the machines, and
periodically inspect if those labels are visual. If the marks are not recognizable, replace with
new ones by contacting the supplier.

3 Lubrication and Maintenance

3.1 Lubrication Period
The correct and periodical lubrication can extend the life of machines. If machines work without
interruption, they need to be lubricated once every eight hours. If machines are used
disconnected, then they need to be lubricated once every week or the accumulative time is eight
hours. Every time when you lubricate machines, notice as follows:
3.1.1 Main Points of Using Lubricators

A. Before lubricating, erase the machines with the clear clout to avoid the foul or dust
dropping into the shaft.
B. After working the machines in a period, it is suggested to use the high-quality lubricants
according to lubrication period labels, such as L-2 or L-1 multi-purpose lubricants to
paint or add on the parts, which need to be lubricated.
C. This bending machine has auto lubricator system and it starts up according to the clamp
action times. Refer to Part III - System Configuration - Numeric setting page
(System lub. frequency & System lub. time) with the more detail instruction. Note the
oil volume to fill oil on time. (The oil is the slide way oil under S.A.E.# 68.)
D. Main lubrication points of the machine were written in the Technical Document. The
suitable lubricants were listed in it, too.
3.1.2 Attention!
If you want to lubricate the machine head and the bending arm with grease, you should close
the clamp die and the pressure die first, and then let the swinging arm to about 90°. Then
lubricate to every nipple.
3.1.3 Bendhead Periodical Lubrication of E Series

Table 3.1 The Table for Bendhead Periodical Lubrication of E Series
Machine Specification 25/30 38 50 65 80 100
Lubricating Cycle
10000 10000 5000 5000 2000 1000
(Bend Times)
Grease Volume (cc.) 20 32 31 32 27 24
Note: This table is applicable for normal working status, user could increase grease volume
according to the actual working condition.

3.2 Automatic Lubricator

3.2.1 Daily Work of Periodical Inspection
Inspect the oil level of the automatic lubricator. If it is not enough, select the high-quality
lubricants according to the temperature of the working environment and fill up it. (It is
suggested to use the lubricants under ISO 68 or the viscosity 30 ~ 50 cSt. Read the lubricant
instruction to get more detail.)
3.2.2 Yearly Work of Periodical Inspection

Replace the filter of the automatic lubricator. Inspect if the wire of the lubricating system
connects well or the ducts get lose and worn.
3.2.3 Trouble Shooting

Fault Cause Solution
Lamps are shining but Oil-level switch does not work. Change oil-level switch.
no discharge of oil.
Oil insufficient. Add oil to proper level.
Pump-motor does not run. Change pump-motor.
Pump is working but Air stay in the pump hose. Wait for 1 minute. It still no
no discharge. discharge of oil, relax the thimble
nut and start the pump till
remove all air inside of the pipe,
and then screw the nut.
Disassemble piping, switch power Clean the pump or change the
on and check the oil could be new pump.
charged. If not, the gear pump
might be blocked.
If the pump does work, the Find the crashed section and
lubricator is OK; the oil pipe might charge new pipe.
be choked or crashed.
Oil discharged Filter is blocked. Clean the oil suction set.

insufficiently.
Wrong viscosity of the oil. Use the correct oil.
The motor doesn’t run. The power source faults. Check the power source.
The motor contacts with humidity Clean the pump unless change the
or water. new pump.
Gear pumps faults. Change the new pump and use

the accurate oil

3.3 Mandrel Lubricator (Optional)

3.3.1 Mandrel Lubricator
It’s a kind of electric working pump and it’s mounted at the rear of the machine. The purpose of
the function is automatic supply the lubricants when the bender feeds the material every time
with automatic bending. It also can control per volume of the supply lubricants with manual
lubricator switch.
3.3.2 Adjustment of Supply Lubricant

The function of the indicator, which is set at the exit pipeline of the pump, is to adjust the
lubricant volume of the pump valve stroke. When the lubricant supply decreases, turn the main
screen to System Configuration page. When the operator went into time setting, you can
change the time of lubrication. (Please refer to Part III - System Configuration - Numeric
setting page (System lub. frequency & System lub. time))
3.3.3 Caution!
After filling up the tank, close the lid of the tank. Put on the mark to avoid damage of the tank
and parts from the high pressure.

3.4 Hydraulic Oil (Not applicable for all electric model)

3.4.1
We suggest that use the following high-quality hydraulic oil, which almost include anti-wear
additives. The viscosity index of the oil is 150SUS at 100°F (or VGO-46).
Table 3.2 Suitable Oil for Different Temperatures

Range of Temperature Type and Number of Oil
25°C Above

10°C ~ 25°C

Under 10°C
3.4.2
Everyday the operators should inspect the change of the oil volume. Confirm and keep the oil
surface at the 2/3 position of the indicator. If it needs to add oil, please confirm the oil sort and
use the same sort of oil. And then, operator adds oil to delivery it through the filter into the
hydraulic system.
3.4.3
If the machine works over half year or one year, you find that the oil is polluted or overheated
emulsification, please drain off the oil in the hydraulic tank clearly. And then, wash or change
the filter or the strainer. At last, add the clear hydraulic oil.

4 Maintenance of Hydraulic Cooling System
(Not applicable for all electric model)

4.1 Water Cooler
4.1.1
Use the clean water to clean the foul on the filter net inside the filter periodically. Maximum
pressure of water inlet is 7 kg/cm2. the minimum flow rate is 15 l/min.
4.1.2
You can add some chemical agent into the cooling water to avoid the water rust forming.
4.1.3
Please open the lid of the cooler every next 3 ~ 6 months, and use the steel-brush to clean the
inner foul. At the same time, please inspect for corrosion.
4.2 Periodical Inspection

4.2.1 Inspection
Inspect if components of the water cooler get worn, or loose every 6 months to keep the best
cooling efficiency. Change the new parts if it’s necessary.
4.2.2 Temperature
Observe the temperature of the hydraulic oil carefully. User must ensure that hydraulic oil
temperature be kept below 55°C. If the temperature is too high, please inspect the water cooler
to handle this problem.
4.2.3 Warning!
If the water in your country will freeze in the winter, you must observe the list as follows:
A. Fill up ISO-VG68 hydraulic oil containing with anti-freezing mixture in oil tank or change to
fill up ISO-VG46 hydraulic oil containing with anti-freezing mixture in freezing area.
B. Contact the warm water about 40°- 50℃ and stop to increase temperature depend on its
condition, instead of cooling water in freezing area.
C. Please release the filter water from cooler after using in the area which temperature is
below 4℃ because it can avoid to cause cooler’s damage result from freezing.

4.3 Fan Cooler

4.3.1 Clean
The hydraulic oil was delivered to the cooler with a pump, and then the fans cooled the oil.
Clean the radiator by small-pressured air (2~4 kg/cm2) a time every three months. When you
finished the cleaning fans, you can add some detergent or sodium bicarbonate into the water to
clean the cells. After washing the fans, used small-pressured air (2~4 kg/cm2) to blow the water
and the dirt away.
4.3.2 Caution
Before washing the fans, turn off the electrical power. Do not let the water into the fan motor.
Make sure the fan motor was dried and supply the electrical source.
4.4 Periodical Inspection

4.4.1 Inspection
Inspect if components of the water cooler get worn, or loose. Change the new parts if it‘s
necessary.
4.4.2 Temperature
Observe the temperature of the hydraulic oil carefully. Operator must ensure that hydraulic oil
temperature kept below 55°C. If the temperature is too high, inspect the water cooler to handle
this problem.
4.2.3 Warning!
If it will be frozen in the winter in your country, obey our suggestion as follows:
Fill up the hydraulic oil ISO-VG68 or ISO-VG46 with anti-frozen addition.

5 Maintenance of Machines' Structure

Table 5.1 Table for Periodical Inspection and Machine Maintenance
Per Per Per Half
No. Note Item
Daily Week Month Year
Use the manual control system to inspect the supply and
1 X
drip situation of the auto-lubricator.
Inspect the function of the safety guard plate on the bend
2 X
arm.
Inspect the function of the safety guard plate on the fixed
3 X
arm.
4 Inspect the function of the leak of the hydraulic system. X
5 Inspect the function of the supply of the hydraulic system. X
Inspect the function of the limit switch and adjust it to the
6 X
most suitable position.
Inspect the clamp die and the pressure die on the bending
7 X
arm. They have to be level and perpendicular.
8 Inspect if the screw nuts and the bolts are fixed and tight. X
9 Inspect if the high pressed hydraulic tubes are worn or leak. X
10 Inspect if the hydraulic oil flows smoothly. X
Inspect the distance between sensors and objects.(4 ~ 5
11 X
mm)
12 Inspect the action of the cylinders. X
13 Inspect if the bearings of the bending arm are drawing tight. X
14 Inspect the setup device and the keys of the wheel gear. X
15 Inspect if the bender base are worn or lack of lubricating. X
16 Inspect the oil volume of the decelerator. X
17 Inspect the suitable pressure of the system. X
Inspect if the slideway need to be adjusted. If they are too
18 X
perpendicular and leaning, change them.
19 Inspect the base of the machines. X
20 Inspect if cylinders are leaking. X
21 Inspect the main rod of all cylinders. X
Inspect the degree of tightness of the arm bearings. If they
22 are leaning, maybe the base is loose or worn. Open the lid X
of the device to inspect the gear and the trough.
There are three recording charts, i.e. the records per day, per season, and per year. They could be
the standard charts for ISO9000 verification. You can copy them for each machine. Put the charts
near the machines. After checkup, note down the actual situation, and do not forget to sign your
name.

6 Selection of Lubricants
We suggest some lubricants are listed as Table 6.1. The diagrams that describe the details of
lubrication position for machine are enclosed within Technical document. Before lubricating
machines, operators must refer to the Technical document.
Table 6.1 Lubrication Equivalents
Lubricated Position of Production Brand Suggestion
Machines Castrol Shell China Petroleum Mobil
Hyspin AWH Tellua T AW32.46.68
Hydraulic Oil Tank DTE 15
32.46.68 32.46.68 LPS32.46.68
B or Y or C Axis Extreme Pressure Glygoyle
Alpha Gel SAG-EP2
Gear Cabinet (Grease) Grease No.0 00
B or Y or C Axis SEA Mobil gear
Alpha SP68 Omala 220
Gear Cabinet (Gear Oil) 250 630
Air Line Super Spindle Velocite
Hyspin AWS 32 Tellus 22
Lubricator Oil R22 10
Slideway Oils Vactra
General Oil Magna BD 68 Tonna TX 68
68 No.2
Extreme Pressure Mobilux
General Grease Spheerol AP 2 Calithia EPT 2
Grease EP2 EP2
Strucovice BHD
Cardium Open Gear Lubricant
Bend Bevel Gear (Open Gear Dorcia 2
Compound No.3
Lubricant)
Made by CSM
Mandrel Lubricant
Viscosity: @20°C:300 m2/s
Note 1: If the lubrication had any problems, please contact located agent or supplier to get more
detailed information. The specification of lubrication had changed; we shall be done without notice.
Note 2: Please fill up the lubricating points with lubricants for appropriate volume.

Version 50V000 Chiao Sheng Machinery Co., Ltd. Doc. Page IV
(Per Day) CNC Bender Maintenance Record

Model: Supervisor: Year Month
NO Item Description \ Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Safety
1 Check the functions such as Emergency
Stop button, Pedal, Safety board for
operator, etc.
Machinery
1 Clean touch-screen, and check the
visibility and sensitivity of screen.
2 Clean the filter of cooling fan.
3 Check the bevel gear below the bending
head is tight enough, or not?
Electrical
1 Clean touch-screen, and check if the
response is in exactly correct.
Hydraulic
1 Hydraulic oil is enough.
2 Lubrication is enough.
3 Hydraulic Pump is normal.
Operator signature:
Conductor confirmed:
Remarks: 1. Maintain and record actual records, V → good △→ air X → bad.
2. The bender shut down or out of order to display a notice on machine and reported to the supervisor promptly to find the solutions.
3. Please refer to operation manual for trouble shooting.
4. Put this chart by the machine. You can use it to record the situation of the machine. It could be used for the ISO9000 verification.

(Season) CNC Bender Maintenance Record

Model: Supervisor: Year
No Item Description \ Date 1( M ) 2( M ) 3( M ) 4( M )
Safety
1 Check the functions such as Emergency Stop button, Pedal,
Safety board for operator, etc.
Machinery
1 Check the clearance between two arms.
2 Clean and lubricate the slide moving parts.
Electrical
1 Clean touch-screen, and check if the sensitivity is in exact.
2 Clean the filter of cooling fan.
3 Clean Micro-switch and Limit-Switch.
Hydraulic
1 Check if the level of oil is as required quantity.
2 Check if the pressure is set in regular.
3 Check if the temperature of oil below is as requirement.
Function test
1 Check if each axis’ action is smooth, and did not vibrate
moving.
2 Check if each cylinder action and its bumper are correct
function, also no noise.
3 Check if the connector was leaks, or not.
4 Record the operating hours. Hr min Hr min Hr min Hr min
Operator signature:
Conductor confirmed:
Remarks: 1. Maintain and record actual records, V → good △ → fair X → bad.
4. Put this chart by the machine. You can use it to record the situation of the machine. It could be used for ISO9000 verification.
(Year) CNC Bender Maintenance Record

Model: Supervisor: Year
No Item description Record filter NO Item description Record filter
Safety Function test
1 Check the functions such as 1 Check if each axial action is smooth,
Emergency Stop button, Pedal, Safety and does not vibrate while moving.
board for operator, etc.
Machinery 2 Operating hours Hr min
1 Check the clearance between two 3 Check if hydraulic connector has no
sliders and arms. leaks.
2 Clean and lubricate the slide moving
Check if each cylinder action and its
parts.
4 bumper are correctly functioning, and
3 Clean and lubricate air- regulator
also have no noise.
equipment.
Electrical Hydraulic
1 Clean touch-screen, and check if the 1 Change hydraulic oil filter and
actuality is in exact. cartridge replacement.
2 Clean the filter of cooling fan. 2 Change hydraulic oil.
3 Clean Micro-switch and Limit-Switch. 3 Clean oil tank.
4 Check if electrical connectors were
fixed and in good condition.
5 Clean controller inside and check if
cable or wiring is tight.
Operator signature: Operator signature:
Conductor confirmed: Conductor confirmed:
Remarks: 1. Maintain and record actual records, V → good △ → fair X → bad.
4. Put this chart by the machine. You can use it to record the situation of the machine. It could be used for ISO9000 verification.

Version 50V000 Chiao Sheng Machinery Co., Ltd. Doc. Page V-1
Part Ⅴ Troubleshooting
After the operators have

finished the setup and all adjustments,
they can start operating bending machine.
Before executing the bender operation,
please read "Troubleshooting".
Attention!
Why most accidents occur,

Is because of not following
safety regulations.
To read "Troubleshooting" can predict, prevent, or improve the

problems, which may occur during the bender operation cycle.
Maintenance and repair of the bender should be executed by
professional technicians. This is the safest way for people and machines.
If the operators cannot understand the maintenance procedure, please
contact the service engineer from the agents. Do not try to repair the
machines by yourselves.
material or use the bender to execute illegal application. Noncompliance of
Part V Troubleshooting
Index 5
1 Troubleshooting of the Normal Type Bender ........................................................ 3

1.1 Machine Startup and Test ................................................................................... 3
1.2 Hydraulic Pump (Not applicable for all electric model) ........................................ 4
1.3 Mechanical Situation of the Bending Arm ........................................................... 5
1.4 Mechanical Situation of the Mandrel ................................................................... 6
1.5 Mechanical Situation of the Clamp Die and Pressure Die .................................. 7
2 Special Treatment for the Abnormal Bend of Tube .............................................. 8

2.1 Clamp Marks Generated in the Clamp Die Action .............................................. 8
2.2 Scratches Generated in the Wiper Die Action ..................................................... 9
2.3 Clamp Marks of the Pressure Die Action .......................................................... 10
2.4 Wrinkles of the Tube ......................................................................................... 11
2.5 Flattening of the Bend....................................................................................... 14
2.6 Tube Break or Rupture While Bending ............................................................. 15
1 Troubleshooting of the Normal Type Bender

1.1 Machine Startup and Test
Table 1.1 Problems and Solutions
Problems Causes Solutions
The pump 1. The electric power is cut 1. Recheck the power source and push the ‘START’
and the off or supply voltage is button if there are no any problems.
driving motor cut off spontaneously.
can not be 2. Motor is overloaded and 2. Check the overload protection switch. Restart the
started or is the overload protection machine in three minutes. If the switch trips again, it
abruptly switch trips. indicates that wiring or electrical elements are out of
stopped in order. Only restart the machine after all the
operation. malfunctions are cleared.
3. The electromagnetic 3. Change the coils or the electromagnetic contacts.
contact is overloaded to
trip the coils.
4. The control loop fuse is 4. Inspect the broken points correctly.
burned out. After repairing/replacing the fuse, start the machine
again.
5. The safety switch does 5. Replace the safety switch.
not function or trips. Restore the bending arm, (for the safety switch can
be used for monitoring the returning motion of
bending arm.).
6. The transformer is 6. Replace the transformer.
burned or broken.
7. The spontaneous 7. Improve the power source or install the power
voltage is unstable (over stabilizing device.
10%).
Machine 1. The solenoid valve is 1. Clean up the valve to remove blockage. Replace
does not broken. with a new valve, if there are leaks
work even 2. Inspect the wiring and check the input direct-current
with good voltage (24V). If the coil is burned, replace it.
driving force 3. Tear off the valve to inspect if the spring or the oil
from pump ring is broken, change or repair them if necessary.
and driving 4. Check the light on the valve. If it is broken, test the
motor circuit broad and repair it.
While the 1. Check the oil level 1. When it is too low, add the hydraulic oil.
motor is indication.
working, the 2. Check if the oil filter is 2. Clean or change the oil filter.
action of the jammed. After draining out the oil in the tank, clean the tank
machine is and install the oil filter net.
very slow. Then, add the new hydraulic oil.
3. The hydraulic pump is 3. Refer to the troubleshooting of the hydraulic pump.
broken.
4. Check if the hydraulic 4. Use the pressure control bar to adjust the pressure
pressure is too high. back to normal.
5. Check if the hydraulic 5. Clean or replace the hydraulic relief valve.
relief valve is broken.
1.2 Hydraulic Pump (Not applicable for all electric model)

The pump 1. The oil level of the tank is 1. Add the hydraulic oil.
could not too low.
deliver the 2. The oil filter is jammed. 2. Clean or change the oil filter.
rated pressure. After draining out the clean oil in the tank,
cleanse the tank and install a new oil filter.
Then, add the new hydraulic oil.
3. The viscosity of the 3.Choose the suitable oil according to the work
hydraulic oil is too high environment temperature
and it causes the pump (Refer to PartⅣ Maintenance)
cannot push out the oil.
While the pump 1. The oil sealing of pump is 1. Use the 500 Inch/Pond torque to tighten the
is running, broken. flange jointer evenly (do not over-tighten).
abnormal noise (The air enters when the After tightening the flanges, change the oil
is generated or oil is sucked into the sealing if the noise still exists or the hydraulic
the oil pressure pump.) pressure is not enough.
is too low. 2. The suction lines of the 2. Fill in the hydraulic oil from the suction side
pump are leaking. for searching the leakage location.
Tighten or replace the leakage parts.
1.3 Mechanical Situation of the Bending Arm

The clamp die and the The flow control valve, Open and adjust the flow control valve.
pressure die are locked. which controls the speed of
The bending arm could not the clamp die or the
execute the bending pressure die, is closed.
action.
The angle of the bending The voltage delivery or the Inspect the voltage and the element as
arm is inaccurate. electric element is broken. follows;
The returning motion of replace the broken elements after
bending arm is not smooth. inspection.
There is some strange A. The condition of the connections
noise while the bending in the electric circuit.
arm is moving. B. The low voltage control loop.
Note! If the inaccurate C. The responding of the micro
bending angle is caused switch.
by the pressure die, refer
to “The Installation of
Troubleshooting for
Bender.”
1.4 Mechanical Situation of the Mandrel

The mandrel 1 The solenoid valve is 1. A. Dismantle the valve and clean it to take out the
has no broken and the blockage. If there are leaks, change it.
backward mandrel cannot move. B. Test the coil and check the input DC voltage
retraction (24V). If the coil is burned, change a new one
motion. or replace the whole set.
C. Dismantle the solenoid valve to inspect the
(Only applied O-rings and the spring.
to only the D. Check the indication light on the valve. If it is
bender broken, test the circuit broad and repair/or
equipped with replace it
hydraulic 2.There are leaks inside 2. Inspect the cylinder. Change/or replace the oil
mandrel of the cylinder of the seals, the piston rings, and the wood pads.
cylinder.) mandrel system.
3.The operating pressure 3. Adjust the pressure delivered from pressure die
of pressure die is too cylinder.
large.
After bending 1.A. The sensors of the 1. A. Cleanup the dirt, which would influence the
the tube and mandrel cylinder do detection of the sensors.
retracting the not detect. B. Adjust the position of the sensor. (Keep the
mandrel, the B. The alignment distance in 2~3 mm with the object.)
clamp die and sensor in front of the C. Inspect the proximity switch and its wiring. If
the pressure clamp die cylinder is they are broken, change it. (Use the ferrous
die do not broken. block to test the function of the sensor.)
retract. C. The proximity sensor
of the mandrel is
broken.
2. The solenoid valves for 2. A. Dismantle the valves and clean them to take
retracting dies are out the blockage. If there are leaks, replace
broken. with new ones.
B. Test the coil ensures the input DC voltage
(24V).
If the coils are burned, change the burned ones
or replace the whole set.
C. Dismantle the solenoid valve to inspect the
O-rings and the spring. Replace/repair the
damaged ones.
D. Check the indicator lights on the valve. If they
are broken, test the circuit broad and
repair/replace it.
1.5 Mechanical Situation of the Clamp Die and Pressure Die

The openings of the 1. The proximity-sensing 1. Adjust the sensing distance of the
clamp die and the switch for retracting the proximity switch to complete the
pressure die are not clamp die does not operation. If the sensor was broken,
big enough to insert work. change a new one.
the tube. 2. The transmission bar 2. Inspect the wearing situation of the
and the central shaft of connecting bar and the central shaft.
the clamp die and the Replace them. If necessary.
pressure die move After dismantling the device, apply with
stagnantly. the lubrication grease.
3.The hydraulic system is 3. Find out the leakage points of the system
leaking or the pressure and replace the leakage parts or enforce
is not large enough and the leakage-resistant process.
the stroke of the clamp
die cylinder is effected.
2 Special Treatment for the Abnormal Bend of Tube

2.1 Clamp Marks Generated in the Clamp Die Action
2.1.1 Wrinkles throughout Bend Area and Scratches in Grip
Fig-2.1
2.1.2 Explanation

When the tube is bent, There is some dust or small metal Clean the clamp area before
the clamp marks and pieces adhering on the clamp die bending.
the scratches are groove position or the c-shaped
generated at the clamp groove of bend die. .
die area.
When the tube is bent, The pressure of the clamp die is Adjust the pressure of the
imprints are formed at too big. clamp die cylinder. If the tube
the clamp die area. gets slippery, operators should
increase a few clamp pressure
When the tube is bent, The position of the mandrel is too Adjust the mandrel position a
burnish marks are deep into the tube. The inner little bit backward.
formed on the outer supporting force and the clamping
diameter of the tube at force during the bending
the clamp area. procedure cause the material to
get the polished pressure marks.
When the tube is bent, 1. The oversized diameter of the 1. The diameter of the tube
the top and bottom of tube causes the grooved marks should match the size of the
the material have generated at the clamp die c-shaped groove of clamp
grooves at the clamp position. Too small c-shaped die. Further, the ductility of
area. groove of the die causes the tube need to be taken into
clamp trace generated on the consideration for the die
tube. design specification and the
bend operation.
2. The joint motion of the clamp 2. Adjust the joint motion of the
die, the bending die and the clamp die, the bend die and
wheel clamp loses the tangent the wheel clamp, and make it
position in the vertical direction. be the motion of
perpendicular lines.
2.2 Scratches Generated in the Wiper Die Action

2.2.1 Scratches Generated in the Wiper Die Action
Fig-2.2
2.2.2 Explanation

When the tube is 1. The wiper die is worn out. 1. Repair the wiper die.
bent die, the
scratches are 2 The position of the wiper die 2. Adjust the wiper die position.
(Flatten the end of wiper die and
generated on the is wrong.
keep it from touching the tube
inside diameter of by approximately 2mm).
the tube at the wiper 3 The material of the wiper die 3 Change a new suitable wiper die for
die area. is not suitable enough. the tube.
4 The lubrication of the wiper 4 Use high quality lubricant.
die is not enough. Before bending, clean both the
tube and groove of die; also
lubricate the wiper die.
2.3 Clamp Marks of the Pressure Die Action

2.3.1 Tool Marks On Centerline of Bend
Clamp Area Clamp Area
Fig-2.3 Fig-2.4
2.3.2 Explanation

When the tube is bent, the 1. The central heights of the 1. Adjust the centers of the
top and bottom of the tube pressure die and the pressure die and the bending die
get the clamp trace and bending die are not to be the same.
the scratches at the matched Re-adjust vertical alignment of
pressure die area. (The die groove is oversize clamp dies and/or pressure die.
or undersize).
2. The size of the tube is too 2 Use the tube in accordance
big (Not the size of the tube with the original die design
allowed in the original specification and also pay
specification of die design). attention to the material
characteristic of the tube for
bending and stretching.
When the tube is bent, There are some dust or Clean the adhering stuff on the
scratches and small metal pieces adhering surface of the pressure die and
concave-convex marks are to the pressure die. the bending die.
formed on the outer
diameter of the bend.
2.4 Wrinkles of the Tube

2.4.1 Hump at the End of Tube
Clamp Area Fig-2.5

When the tube is 1. The position of the mandrel 1. Making position of the
bent, protrusion is not correct or the mandrel is correct.
is formed at the mandrel function is not turn Add the mandrel function or
exterior of the on. turn on the mandrel function.
end of the bend
tube. 2 The wiper die position is too 2. Move the wiper die forward.
behind the tube.
3 The welding line of the tube is 3 The welding line of the tube
positioned incorrectly. cannot be put at the outside
and the inside of the bending
plane.
2.4.2 Wrinkles throughout All Bend Area
Fig-2.6

The starting 1. The clamping force of 1. Adjust the clamp die cylinder to increase
point of the the clamp die is the clamp die pressure. Increase the
bend gets the sufficient and the length of the clamping surface if
inner concavity slippery is thus caused. necessary.
marks and Increase pressure die force only after
wrinkles. checking the wiper die assembly and the
position of mandrel.
2. The position or the size 2. Adjust the position of the mandrel and
of the mandrel is not make it correctly.
correct. Check the remedy of the tube and the
mandrel if it is correct.
2.4.3 Wrinkles throughout the Tube and Even Extending to Wiper Die
Fig-2.7

When the tube is 1. The mandrel in the 1. Adjust the position of mandrel and make it
bent, wrinkles are tube does not reach correctly.
formed at the bend. the supporting
position.
2. Wiper is frayed 2. Repair the wiper die or change the new
The positions of the one.
wiper die and the Advance wiper die toward tangency.
bending die are not Decrease rake of wiper die so that it can
correct. Missing the be closed to the tube.
tangent direction for Repair the wiper die groove.
bending, the worn If its length is not long enough, change a
wiper die or new one.
insufficient length of
dies causes the
incorrect match.
2.5 Flattening of the Bend
Fig-2.8

The bending cross 1. Without mandrel 1.Increase the pressure die pressure and
section of the tube is function, the pressure of adjust it’s position.
too flat. the pressure die is not
enough.
The position of the
pressure die is not
correct.
2. With mandrel function, 2. Adjust the mandrel toward the tangency.
the position of the Increase the outer diameter of the mandrel
mandrel is not proper. ball bearing to fill up the tube for support or
The number of the increase the number of ball bearings
mandrel ball is not (maximum is 5 balls.).
enough.
2.6 Tube Break or Rupture While Bending

The tubes get 1 Insufficient lubrication for the 1 Choose the suitable lubricant to
broken or mandrel increases the friction lubricate the mandrel, the pressure die
ruptured while inside the tube. and the inner wall of the tube.
bending. 2 The speed of the booster is
2 Adjust the speed of the booster.
too slow.
3 The position of mandrel is not
3 Adjust the position of the mandrel.
correct.
4 Choose a proper tube material for
4 The tube ductility is too small.
bending.
5 Re-check the positions of the clamp die
5 The tube slips while bending.
and the bending die.
6 The pressure die pressure is 6 Decrease the pressure die pressure.
too large. (Loosen the pressure die.)
7 The radian of the mandrel is 7 Use the smaller mandrel ball.
bigger than the radius of the Reassemble the mandrel balls.
bending die.
The quality of assembling
mandrel is not good.
Note! Recording the actual situation of the machines could help user to understand the
problems more clearly. Periodical inspection could find problems earlier.
喬陞機器股份有限公司
CHIAO SHENG MACHINERY
50TBRE-P
模具安裝作業說明
Instructions for Tooling Assembly
台南市新市區環東路二段 2 號
TEL:06-5055800 FAX:06-5055798
網頁: http://www.tubebender.com.tw
電子郵件信箱: tubebend@ms24.hinet.net
No.2 , Sec.2, Huandong Rd., Tainan Science Park Sinshih District,

Tainan City 74144, TAIWAN, R.O.C.
TEL:+886-6-5055800 FAX:+886-6-5055798
WEBSITE: http://www.tubebender.com.tw
E-MAIL: tubebend@ms24.hinet.net
文件編號文件頁數
Doc. No. CE305-GEF 喬陞機器股份有限公司 Doc. Page 1
發行月份 Chiao Sheng Machinery Co., Ltd. 版次
Issuing month
Aug-2017 Version 50V000
1 模具安裝作業的說明
1.輪模
2.夾模
3.導模
4.後導模
5.穿心
6.束管夾
6
4
1
2
3
Fig-2.1
Issuing month
1.1 輪模
1 彎 1 捲 (如
如 Fig-2.2 所示)
所示
輪夾○
a. 將第一層輪夾螺栓○
輪夾 4 以螺栓輪模○
螺栓 5 固定於輪模鍵○
輪模 2 後，再將鍵螺栓○
6 以螺栓輪模○
螺栓 7 固定於輪模
輪模 2 局部
輪模○
組合。將第一層輪模
輪模 2 固定於曲手凸鍵上。
主滾輪○
b. 將第二層主滾輪滾針軸承○
主滾輪 3 裝入滾針軸承止推滾針軸承○
滾針軸承 8 與止推滾針軸承輪模○
止推滾針軸承 9 局部組合,放置輪模
輪模 2 後，再
主軸上螺母○
取主軸上螺母主軸上段○
主軸上螺母 10 鎖緊於主軸上段
主軸上段 1 即可。
10
10
8
7
6
4 2
5
Fig-2.2
Issuing month
2 彎 (如
如 Fig-2.3 所示)
所示
輪夾○
a. 將下層輪夾螺栓○
螺栓 4 固定於輪模鍵○
輪模 2 中，再將鍵螺栓○
5 以螺栓輪模○
螺栓 6 固定於輪模
輪模 2 局部組
輪模○
合。將第一層輪模
輪模 2 固定於曲手凸鍵上。
輪夾○
b. 將上層輪夾螺栓○
螺栓 9 固定於輪模輪模○
輪模 7 中。再將上層輪模輪模○
輪模 7 固定於下層輪模
輪模 2 凸鍵
上。
主軸上段螺母○
c. 取主軸上段螺母主軸上段○
主軸上段螺母 10 鎖至主軸上段
主軸上段 1 鎖緊即可。
10
10
8 7
9
6
5
3 2
4
Fig-2.3
Issuing month
1.2 夾模
1 彎 1 捲 (如
如 Fig-2.4 所示)
所示
A. 安裝
平鍵○
a. 將平鍵衝頭墊塊○
平鍵 5 放置於衝頭墊塊
衝頭墊塊 3 之鍵槽。
衝頭○
b. 再將衝頭衝頭墊塊○
衝頭 4 放入衝頭墊塊止浮螺絲○
衝頭墊塊 3 衝孔內，以止浮螺絲衝頭○
止浮螺絲 6 將衝頭
衝頭 4 鎖緊。
夾模○
c. 將組件放入夾模定位珠○
夾模 2 內，以定位珠止浮螺絲○
定位珠 8 與止浮螺絲
止浮螺絲 7 將其鎖緊固定。
型塊○
d. 將T型塊夾模○
型塊 9 放入夾模螺栓○
螺栓 10 固定鎖緊。
夾模 2 T溝內，以螺栓
型塊○
e. 將上層T型塊轉接塊○
型塊 13 放入轉接塊轉接塊○
轉接塊 12 鍵槽內，再將轉接塊夾輪座○
轉接塊 12 放入夾輪座螺
夾輪座 11 鍵槽內，以螺
栓○ 夾輪○
14 固定鎖緊，再將夾輪滾針軸承○
夾輪 15 依序裝入滾針軸承夾輪座○
滾針軸承 16 局部組合後,裝入夾輪座
夾輪座 11 內,
心軸○
以心軸夾輪座○
心軸 20 組於夾輪座止浮螺絲○
夾輪座 11 內，取止浮螺絲心軸○
止浮螺絲 19 逼緊心軸固定片○
心軸 20 ，再取固定片螺栓○
固定片 17 與螺栓
螺栓 18 鎖
夾輪座○
夾輪座 11 即可。
緊於夾輪座
夾模○
f. 將下層夾模夾輪座○
夾模 2 與上層夾輪座夾模座○
夾輪座 11 對齊夾模座止浮螺絲○
夾模座 1 T槽內後,再將止浮螺絲夾模
止浮螺絲 21 鎖入夾模
座○ T型塊○
1 螺栓固定孔內逼緊T型塊 9 ○ 六角螺帽○
13 後,鎖上六角螺帽
六角螺帽 22 固定鎖緊即可。
18
16
17
19
11
15
12
16 13
14
20
2
9
7 10
8 5
6
3
4 1
21
22
23
24
25
Fig-2.4
Issuing month
B. 調整說明
止浮螺絲○
a. 將止浮螺絲六角螺
六角螺帽○
止浮螺絲 23 、六角螺母○
24 放鬆，並調整螺母夾模座○
螺母 25 使夾模座
夾模座 1 至適當位置。
b. 切換操作畫面至手動模式頁面（參照操作手冊第三部份 2.2 節），並在觸控螢幕

上選擇夾模動作鍵。
c. 把管件放入，再按下操作面板上的正向手動操作鍵，使夾模前進夾住管材，此
時需保持夾模和管材留有空隙。
螺母○
d. 調整螺母
螺母 25 直至夾模與管材緊緊密合，接著確保管材在彎管過程中不會滑落。
e. 按下操作面板上的負向手動操作鍵，使其夾模後退，此時依管材質與管厚度的
螺母○
條件以順時針調整螺母
螺母 25 1/4 圈或 1/2 圈為適當預壓。
止浮螺絲○
f. 再將止浮螺絲六角螺帽
六角螺帽○
止浮螺絲 23 、六角螺帽 24 鎖緊，即完成調整動作。
Issuing month
2 彎 (如
如 Fig-2.5 所示)
所示
A. 安裝
平鍵○
a. 將平鍵衝頭墊塊○
平鍵 5 放置於衝頭墊塊
衝頭墊塊 3 之鍵槽。
衝頭○
b. 再將衝頭衝頭墊塊○
衝頭 4 放入衝頭墊塊止浮螺絲○
衝頭墊塊 3 衝孔內，以止浮螺絲衝頭○
止浮螺絲 6 將衝頭
衝頭 4 鎖緊。
夾模○
c. 將組件放入夾模定位珠○
夾模 2 內，以定位珠止浮螺絲○
定位珠 8 與止浮螺絲
止浮螺絲 7 將其鎖緊固定。
型塊○
d. 將T型塊夾模○
型塊 9 放入夾模螺栓○
螺栓 10 固定鎖緊。
夾模 2 T溝內，以螺栓
e. 下層模具組裝順序同步驟 a ~ d。
夾模○
f. 將上、下層夾模夾模座○
夾模 2 對齊夾模座止浮螺絲○ 夾模座○
止浮螺絲 11 鎖入夾模座
夾模座 1 T槽內，再將止浮螺絲夾模座 1 螺栓固定
型塊○
孔內逼緊T型塊六角螺帽○
型塊 9 後,鎖上六角螺帽
六角螺帽 12 固定鎖緊即可。
2
9
7 10
8 5
6
3
4
11
12
13
14
15
Fig-2.5
Issuing month
B. 調整說明
止浮螺絲○
a. 將止浮螺絲六角螺
六角螺帽○
止浮螺絲 13 、六角螺母○
14 放鬆，並調整螺母夾模座○
螺母 15 使夾模座
夾模座 1 至適當位置。
b. 切換操作畫面至手動模式頁面（參照操作手冊第三部份 2.2 節），並在觸控螢幕

上選擇夾模動作鍵。
c. 把管件放入，再按下操作面板上的正向手動操作鍵，使夾模前進夾住管材，此
時需保持夾模和管材留有空隙。
螺母○
d. 調整螺母
螺母 15 直至夾模與管材緊緊密合，接著確保管材在彎管過程中不會滑落。
e. 按下操作面板上的負向手動操作鍵，使其夾模後退，此時依管材質與管厚度的
螺母○
條件以順時針調整螺母
螺母 15 1/4 圈或 1/2 圈為適當預壓。
止浮螺絲○
f. 再將止浮螺絲六角螺帽○
止浮螺絲 13 、六角螺帽
六角螺帽 14 鎖緊，即完成調整動作。
Issuing month
1.3 導模
1 彎 1 捲 (如
如 Fig-2.6 所示)
所示
A. 安裝
螺栓○
a. 將螺栓導模吊塊○
螺栓 2 放入導模吊塊導模○
導模吊塊 1 後,鎖緊於導模導模○
導模 3 中,將導模
導模 3 組合對齊鍵槽吊塊掛於
導模座○
導模座 4 上。
導輪○
b. 將導輪滾針軸承○
導輪 6 裝入滾針軸承導輪座○
滾針軸承 7 局部組合後,裝入導輪座心軸○
導輪座 8 內,以心軸導輪座○
心軸 9 組於導輪座
導輪座 8
固定片○
上,取固定片螺栓○
固定片 10 與螺栓導輪座○
螺栓 11 鎖緊於導輪座導輪座○
導輪座 8 ,導輪座螺栓○
導輪座 8 局部組合後,取螺栓
螺栓 12 鎖固
輔推滑板○
於輔推滑板
輔推滑板 5 即可。
B. 調整
螺桿座調整螺絲
螺桿座調整螺絲○
a. 將螺桿螺桿○
座調整螺絲 12 先行放鬆，並調整螺桿
螺桿 13 使其至適當位置。
b. 切換操作畫面至手動模式頁面（參考操作手冊第三部份 2.2 節），並在觸控螢幕
上選擇導模動作鍵。
c. 把管件放入，再按下操作面板上的正向手動操作鍵，使導模前進夾住管材，此
時須保持導模和管材留有空隙。
導模座調整螺桿○
d. 調整導模座調整螺桿
導模座調整螺桿 13 直至導模與管材緊緊密合。接著確保管材在彎管過程中
不會滑落。
e. 按下操作面板上的負向手動操作鍵，使其導模後退，此時依管材質與管厚度的
螺桿○
條件以順時針調整螺桿
螺桿 13 1/4 圈或 1/2 圈為適當預壓。
螺桿座
螺桿座調整螺絲
f. 將螺桿調整螺絲○
螺絲 12 鎖緊，即完成調整動作。
11
7
10
6
8
7 9
1 2
1
2
1
4
12
13
Fig-2.6
Issuing month
2 彎 (如
如 Fig-2.7 所示)
所示
A. 安裝
螺栓○
將螺栓導模吊塊○
螺栓 2 放入導模吊塊導模○
導模吊塊 1 後，鎖緊於導模導模座
導模 3 中，將導模組合對齊鍵槽吊掛於導模座
○
4 即可。
B. 調整
a. 將螺桿座調整螺絲螺桿○
螺桿座調整螺絲 5 先行放鬆，並調整螺桿
螺桿 6 使其至適當位置。
b. 切換操作畫面至手動模式頁面（參考操作手冊第三部份 2.2 節），並在觸控螢幕
上選擇導模動作鍵。
c. 把管件放入，再按下操作面板上的正向手動操作鍵，使導模前進夾住管材，此
時須保持導模和管材留有空隙。
導模座調整螺桿
導模座調整螺桿○
d. 調整導模座調整螺桿 6 直至導模與管材緊緊密合。接著確保管材在彎管過程中
不會滑落。
e. 按下操作面板上的負向手動操作鍵，使其導模後退，此時依管材質與管厚度的
螺桿○
螺桿 6 1/4 圈或 1/2 圈為適當預壓。
條件以順時針調整螺桿
f. 將螺桿座調整螺絲
螺桿座調整螺絲 5 鎖緊，即完成調整動作。
2
1
2
1
4
5
6
Fig-2.7
Issuing month
油壓輔助推進裝置
調整
A. 速度：
速度：油壓輔助推進裝置可藉由輔推
輔推前進
輔推前進速度調整鈕操作手冊第三部份／
操作手冊第三部份／
前進速度調整鈕（參照操作手冊第三部份
速度調整鈕
油壓調整解說
油壓調整解說）
解說）注意：
注意：當無加工管件彎管
，依輪模大小不同及管徑大小來調整。注意
模式選擇畫面（參照操作手冊第三部份
時，須在模式選擇
模式選擇操作手冊第三部份）選擇無輔推
操作手冊第三部份無輔推功能
無輔推功能，以免輔推裝
功能
置移動與夾模相撞。
B. 行程距離：
行程距離：當進行自動彎管動作而導模長度不足時，則有下列動作產生：
a. 彎管停止
b. 導模退夾
c. 輔推後退
d. 導模上夾
e. 繼續彎管
導模長度偵測開關(如
所以需依照導模之長度，來設定導模長度偵測開關
導模長度偵測開關 Fig-2.8 所示)，使輔推能正常
注意：
注意：在捲圓模式下，
作用。其適當的位置，須調整在導模接近末端時，才能偵測到。注意
無法選擇輔推功能運作。
偵測開關
SENSOR
Fig-2.8
Issuing month
1.4 後導模
2彎
A. 安裝 (如
如 Fig-2.9 所示)
所示
螺栓○
a. 取螺栓後導模座○
螺栓 1 將後導模座機頭○
後導模座 2 鎖緊於機頭
機頭 3 。
襯塊○
b. 將下層襯塊轉接塊○
襯塊 4 和轉接塊螺栓○
轉接塊 5 以螺栓襯塊○
螺栓 7 固定鎖緊，再將襯塊螺栓○
襯塊 4 組合件以螺栓
螺栓 8 和墊
後導模○
圈鎖緊於後導模
後導模 6 。
螺栓○
c. 取螺栓襯塊○
螺栓 9 與墊圈將襯塊調整塊○
襯塊 4 組合件鎖緊於調整塊
調整塊 12 上。
螺栓○
d. 取螺栓調整塊○
螺栓 13 與墊圈將調整塊旋轉座○
調整塊 12 組合件鎖緊於旋轉座
旋轉座 11 上。
後導模○
e. 將後導模旋轉座○
後導模 6 組合和旋轉座後導模座○
旋轉座 11 組合定位於後導模座螺栓○
後導模座 2 上，再將螺栓旋轉座
螺栓 10 鎖入旋轉座
○
11 。
f. 上層模具組裝順序同步驟 a ~ e。
B. 調整 (如
如 Fig-2.10 所示)
所示
將後導模儘可能靠近輪模，與導模形成切線方向 1°~2°之夾角。
10
9 11
12
13 4
7 5
8 6
2
1
3
1°~2°
Fig-2.9 Fig-2.10
Issuing month
1.5 穿心
A. 安裝 (如
所示
穿心本體○
a. 將穿心本體穿心拉桿○
穿心本體 7 以順時針方向旋入穿心拉桿穿心拉桿接頭○
穿心拉桿 8 。將穿心拉桿接頭油缸接頭
油缸接頭
穿心拉桿接頭 5 插入油缸
○ 固定片○
1 內，再插入固定片
固定片 2 即可防止穿心拉桿脫落。
防旋定位銷○
b. 當穿心不需要自由旋轉時，請將防旋定位銷防旋定位銷○
防旋定位銷 3 插入 A 孔，反之則將防旋定位銷
防旋定位銷 3
插入 B 孔。
旋鈕(○
c. 轉動旋鈕
旋鈕 4 )，可控制穿心自潤油脂之流量，順時針流量變小，逆時針流量變大。
注意！
穿心本體超出模具中心 2~3mm 為較易調整區域(如 Fig-2.12 所示)，操作人員依據

模具成型之要求，進行前後適當位置之調整。
B. 調整
螺母○
調整螺母穿心本體○
螺母 6 使穿心本體
穿心本體 7 至適當位置。在手動模式頁面（參照操作手冊第三部份
Fig-2.2 節）選擇穿心動作鍵，再按下操作面板上的正向手動操作鍵或負向手動操
作鍵，使穿心前進或後退。
6
3
B孔
Hole B
1
A孔
Hole A
5
8
7
Fig-2.11
2~3mm
Fig-2.12
Issuing month
1.6 束管夾
A. 筒夾一般型 / 快拆式安裝 (如
所示
在手動操作模式打開束管夾，將夾管夾模依照下圖之編號 1、2、3、4，以順時針方
向逐一鎖緊。在手動操作模式將束管夾閉合，確認可將管件夾緊。若要換新的零件，
則鬆開束管夾上的固定螺栓，換新之後再將它鎖緊。
4 4
3 3 1
1
2 2
※ 一般型 Typical ※ 快拆式 Quick change
Fig-2.13
B. 三爪式安裝 (如
所示
依照每一個夾爪上所標示的數字順序，將夾爪以順時針方向上螺絲固定鎖緊即可。若
要換新的零件，則鬆開束管夾上的固定螺栓，換新之後再將它鎖緊。
1
3
2
Fig-2.14
Issuing month
1.7 管支撐
A. 安裝 (如
所示
滾輪○
將滾輪滾輪心軸○
滾輪 2 放入滾輪心軸滾輪心軸○
滾輪心軸 1 中，再將滾輪心軸滾輪○ 滾輪座○
滾輪 2 放置於滾輪座
滾輪心軸 1 跟滾輪滾輪座 3 之 T 型螺帽
中。
B. 調整
用板手工具將整組滾輪鬆動，調整滾輪位置使滾輪恰好支撐夾住管件，再鎖緊整組
滾輪。
1.滾輪心軸
2.滾輪
3.左右凸輪座
1
2 1
3 2
Fig-2.15
Issuing month
1.8 模具上下層調整機構
A. 由下層模具移動至上層模具路徑： A → B → C → D
路徑：
管件位於
下層模具機頭向外移動機頭向下移動機頭向內移動
A B
C D
路徑： a → b → c → d
B. 由上層模具移動至下層模具路徑：
管件位於機頭向外移動機頭向上移動機頭向內移動
上層模具
c d
a b
C. 手動操作
手動模式畫面上的按鈕
a. 觸摸手動模式
手動模式手動模具規格畫面
，進入手動模具規格
手動模具規格，進行 R0 與 R1 的正確 CLR
值輸入。
手動操作按鈕畫面上的機頭水平位移
b. 手指觸摸手動操作按鈕
手動操作按鈕機頭水平位移按鈕，按面板上的負向手動操作
機頭水平位移負向手動操作按
負向手動操作
鈕，機頭往外側移出。
手動操作按鈕畫面上的機頭垂直位移
c. 手指觸摸手動操作按鈕
手動操作按鈕機頭垂直位移按鈕，按面板上的正向手動操作
機頭垂直位移正向手動操作按
正向手動操作
鈕，機頭移至上層。
d. 手指觸摸手動操作按鈕
手動操作按鈕機頭水平位移按鈕，按面板上的正向手動操作
機頭水平位移正向手動操作按
正向手動操作
鈕，機頭往內側移入。
程式輸入-模具規格設定頁面輸入，進行
e. 在自動模式中，CLR 值在程式輸入模具規格設定 R0 與 R1 的正
確 CLR 值輸入。
D. 機頭之運動路徑需注意事項
a. 手動操作按鈕畫面中，機頭模具欲更換上下模層時，務必將先選定機頭水平位移
手動操作按鈕機頭水平位移
按鈕，按面板上的負向手動操作
負向手動操作按鈕
負向手動操作，機頭往外側移出。
手動操作按鈕畫面上的機頭垂直位移
b. 手指觸摸手動操作按鈕
手動操作按鈕機頭垂直位移按鈕，按面板上的正向手動操作
機頭垂直位移正向手動操作按
正向手動操作
鈕或負向手動操作
負向手動操作，機頭移至上層或下層。
c. 手指觸摸手動操作按鈕
手動操作按鈕機頭水平位移按鈕，按面板上的正向手動操作
機頭水平位移正向手動操作按
正向手動操作
鈕或負向手動操作
負向手動操作，機頭整個往內側移動達到定位。
d. 若機頭未操作至定位，則會有提示功能出現，請按照指示操作。
E. 停機需注意事項
停機時位置需注意機頭務必置放於上層模具位置，以確保機器之壽命與安全。
Issuing month
1 Instructions for Tooling Assembly
1. Bend die
2. Clamp die
3. Pressure die
4. Wiper die
5. Mandrel
6. Collet
6
4
1
2
3
Fig-2.1
Issuing month
1.1 Bend die
Draw bend + Push bend (as shown in Fig-2.2)

a. The first tooling stack: Put bend die insert ○
4 with bend die ○
2 with screws
○
5 .Tighten keys ○
6 onto bend die ○
2 with screws ○
7 . Then put bend die ○
2 into
keyway of die boss plate.
b. Put the needle bearing ○

8 and ball bearings ○
9 in the bend roller ○
3 and put the
3 in the bend die ○

bend roller ○ 2 , then tighten them onto bend die post ○
1 with nuts
○
10 .
10
10
8
7
6
4 2
5
Fig-2.2
Issuing month
Draw bend x2 (as shown in Fig-2.3)

a. The first tooling stack: Put bend die insert ○
3 with bend die ○
2 with screws ○
4 .
Tighten keys ○
5 onto bend die ○
2 with screws ○
6 .Then put bend die ○
2 into
keyway of die boss plate.
b. The second tooling stack: Put bend die insert ○

8 with bend die ○
7 with screws ○
9 .
Put bend die ○

7 into keyway of the first bend die ○
2 .
2 ○
c. Tighten bend die ○ 7 onto bend die post ○
1 with nuts ○
10 .
10
10
8 7
9
6
5
3 2
4
Fig-2.3
Issuing month
1.2 Clamp die

A. Installation
a. Put the key ○
5 in the punch pin base ○
3 .
b. Put punch pin ○

4 into punch pin base ○
3 by set screw ○
6 .
4 ○
c. Put the punch pin ○ 8 assembly in the clamp die ○
2 and tighten it by the
positioning steel ball ○

8 and set screw ○
7 .
d. Put the T key ○

9 together with the clamp die ○
2 and tighten them with screws ○
10 .
e. The upper tooling stack: Put the T key ○

13 together with the adapter ○
12 and clamp
roller base ○
11 , tighten them with screw ○
14 . Put the needle bearings ○
16 in the
clamp roller ○
15 and put the clamp roller ○
15 in the clamp roller base ○
11 , then use
shaft ○
20 to fix them, and by the set screw ○
19 . Tighten clamp roller ○
15 and clamp
11 with fixing block ○

roller base ○ 17 and screw ○
18 .
f. Put the clamp die ○

2 (bottom stack) and clamp roller base ○
11 (top stack) in the
T slot of clamp die holder ○ 9 ○

1 , then tighten the T key ○ 13 by the set screws
○
21 and nuts ○
22 into the clamp die holder ○
1 .Installation complete.
18
16
17
19
11
15
12
16 13
14
20
2
9
7 10
8 5
6
3
4 1
21
22
23
24
25
Fig-2.4
Issuing month
B. Adjustment
a. Loosen the set screw ○

23 and the hex nut ○
24 and adjust nut ○
25 to set clamp die
holder ○
1 to a proper position.
b. Change the operation screen to manual mode page (Refer to Section 2.2 of Part III
in Operation manual) and touch the Clamp die icon.
c. Put a tube in the bend die, then press Manual “+” button on the control panel to
move clamp die inward for gripping the tube. At this time, it is needed to keep some
clearance between the tube and clamp die for the tube to be moveable.
d. Adjust the nut ○

25 until clamp die approaches the tube closely till the tube does not
slip during bend process.
e. Press Manual “–” button on the control panel to move clamp die outward, set the
nut ○
25 by quarter or half turn in as a preset.
f. Tighten all set screw ○

23 and the nut ○
24 up complete the adjustment.
Issuing month

A. Installation
a. Put the key ○
5 in the punch pin base ○
3 .
b. Put punch pin ○ 3 by set screw ○

4 into punch pin base ○ 6 .
c. Put the punch pin ○

4 assembly in the clamp die ○
2 and tighten it by the
8 and set screw ○

positioning steel ball ○ 7 .
d. Put the T key ○

9 together with the clamp die ○
2 and tighten them with screws ○
10 .
e. Follow step a ~ d to get the lower stack clamp die assembled.
f. Put the clamp die ○

2 in the T slot of clamp die holder ○
1 , then tighten the T key
○
9 by the set screws ○
11 and nuts ○
12 into the clamp die holder ○
1 . Installation
complete.
9
7 10
8 5
6
3
4
11
12
13
14
15
Fig-2.5
Issuing month
B. Adjustment
a. Loosen the set screw ○

13 and the hex nut ○
14 and adjust nut ○
15 to set clamp die
holder ○
in Operation manual) and touch the Clamp die icon.
move clamp die inward for gripping the tube. At this time, it is needed to keep some
clearance between the tube and clamp die for the tube to be moveable.
d. Adjust the nut ○

15 until clamp die approaches the tube closely till the tube does not
slip during bend process.
e. Press Manual “–” button on the control panel to move clamp die outward, set the
nut by quarter or half turn in as a preset..

13 and the nut ○
14 up complete the adjustment.
Issuing month
1.3 Pressure die

A. Installation
a. Tighten pressure die hangers ○
1 onto the pressure die ○
3 with screws ○
2 , then
put components ○
1 ○
2 ○
3 together and put the entire pressure die ○
3 on the
pressure die bar ○

4 .
b. Put the needle bearings ○

7 in the pressure roller ○
6 and put the pressure roller
○
6 in the pressure roller base ○
8 , then use shafts ○
9 to fix them. Tighten
pressure roller ○
6 and pressure roller base ○
8 with fixing block ○
10 and screws
○
11 , after then tighten pressure roller base ○
8 onto the pressure die slide ○
5 with
screws○
14 .
11
7
10
6
8
7 9
14 2
1
2
1
4
12
13
Fig-2.6
Issuing month
B. Adjustment
a. Loosen screws ○
12 , and adjust the bolt ○
in operation manual) and click the pressure die icon.
move pressure die inward for gripping the tube. At this time, it is needed to keep
some clearance between the tube and Pressure die for the tube to be moveable.
d. Adjust the bolt ○

13 until pressure die approaches the tube closely till the tube does
not slip during bend process.
e. Press Manual “–” button on the control panel to move pressure die outward, set the
nut by quarter or half turn in as a preset.

12 to finish adjustment.
Issuing month

A. Installation
Tighten pressure die hangers ○
1 onto the pressure die ○
3 with screws ○
2 , then put
components ○
1 ○
2 ○
3 together and put the entire pressure die ○
3 on the pressure
die bar ○
4 .
B. Adjustment
a. Loosen screws ○
5 , and adjust the bolt ○
in operation manual) and click the pressure die icon.
move pressure die inward for gripping the tube. At this time, it is needed to keep
some clearance between the tube and Pressure die for the tube to be moveable.
d. Adjust the bolt ○

6 until pressure die approaches the tube closely till the tube does
not slip during bend process.
e. Press Manual “–” button on the control panel to move pressure die outward, set the
nut by quarter or half turn in as a preset.

5 to finish adjustment.
2
1
2
1
4
5
6
Fig-2.7
Issuing month
Hydraulic Booster Device

A. Speed: Booster can be adjusted by turning the speed control knob according to
bending criteria ex. CLR, tube OD… (Refer to Part III / Explanation of hydraulic
pressure adjustment in operation manual). Note: If machine runs without any the
tube, user needs to select “without booster function” in mode settings page (Refer
to Part III in operation manual) to prevent collision between booster and clamp die.
B. Stroke: If booster moves to its end of stroke in automatic mode, then the following
situation will happen:
a. Bending stops.
b. Pressure die opens
c. Booster retracts to the beginning postition.
d. Pressure die re clamps.
e. Continue bending
Sensor position is set by PD (pressure die) length (Fig-2.8). The proper position is at the
end of pressure die cylinder stroke.
Note: When rolling is applied, the booster will not work even “with booster function” is
marked in mode settings page (Refer to Part III in operation manual).
偵測開關
SENSOR
Fig-2.8
Issuing month
1.4 Wiper die
Draw bend x 2
A. Installation (as shown in Fig-2.9)
a. Put wiper die bar ○
2 in place ○
3 with screws ○
1 .
b. Put the wiper die holder ○ 4 and wiper die adapter ○

5 together with
screws ○ 7 , and put the wiper die ○

6 on with screws ○
8 and washers.
c. Put wiper die holder ○

4 with the adjustment block ○
12 with screws ○
9
and washers.
d. Put the adjustment block ○
12 with the wiper die block ○
11 with screws ○
13 .
e. Tighten wiper die ○

6 , the wiper die block ○
11 components on the wiper die
bar ○2 with screws ○ 10 .
f. Follow the step a ~ e to get upper stack wiper assembled.
B. Adjustment (as shown in Fig-2.10)
Move the wiper die against the bend die as close as possible, and the tangent angle
from the pressure die hall be 1°~2°.
10
9 11
12
13 4
7 5
8 6
2
1
3
1°~2°
Fig-2.9 Fig-2.10
Issuing month
1.5 Mandrel
A. Installation (as shown in Fig-2.11)
a. Put the mandrel ○

7 into mandrel rod ○
8 . Put the mandrel rod connector ○
5 in
the mandrel retractor ○

1 then put the fixing piece ○
2 in the mandrel retractor ○
1
to prevent mandrel rod slipping off.

b. When mandrel revolving is not required ex. non round tube bending, put the pin ○
3
in the hole A. When mandrel revolving is required ex. round tube bending, put the
pin ○
3 in the hole B.
c. The knob ○
4 is to control grease flow of the mandrel lubrication. Turn knob ○
4
clockwise to get less lubrication; counterclockwise to get more lubrication..
Note! Mandrel position to go beyond the tangent line by 2~3mm is suggested for regular
bending (Fig-2.12).
Mandrel position varies upon part fabrication requirement.
B. Adjustment
Adjust the nuts ○

6 to move mandrel ○
7 at suitable position. Move mandrel advances
by pressing mandrel rod button in manual mode.
6
3
B孔
Hole B
1
A孔
Hole A
5
8
7
Fig-2.11
2~3mm
Fig-2.12
Issuing month
1.6 Collet
A. Installation – typical / quick-change (as shown in Fig-2.13)
Open the collet in the manual mode and tighten collet fingers with screws by number in
order. Close collet and be sure the collet set grips the tube properly. If it needs to install
new collet, loosen the screws of collet, then change the new one and re-fixed it.
4 4
3 3 1
1
2 2
※ 一般型 Typical ※ 快拆式 Quick change
Fig-2.13
B. Installation – finger type (as shown in Fig-2.14)
Put the collet fingers by number in order. If user wants to install new collet, loosen the
fixed bolts of collet, and then change the new one, finally, re-fixed it to complete
Installation.
1
3
2
Fig-2.14
Issuing month
1.7 Tube Support

A. Installation (如 Fig-2.15 所示)
Assemble the rollers ○
2 into the roller shaft ○
1 . Then install roller shaft ○
1
and rollers ○
2 on the roller bases ○
3 .
B. Adjustment
Loosen the parts of the rollers with spanner. Adjust the position of rollers and the
rollers support the tube. Then fasten the parts.
1. Roller shaft
2. Roller
3. Right & Left Roller Base
1
2 1
3 2
Fig-2.15
Issuing month
1.8 Machinery of C.L.R. Adjustment

A. Shifts tube from lower stack to higher stack Path: A → B → C → D
Tube on the Bend head Bend head Bend head
lower stack shifts out move shifts in
A B downward
C D
B. Shifts tube from higher stack to lower stack Path: a → b → c → d
Tube on the Bend head Bend head Bend head
higher stack shifts out move shifts in
upward
c d
a b
C. Manual Operation
a. Enter M.D.I. (Manual Data Input) and confirm the CLR of R0 and R1 stack.
b. Touch the Bend head horizontal movement icon in Manual mode page and press Manual
negative button on the control panel, bend head shifts out.
c. Touch the Bend head vertical movement icon in Manual mode page and press Manual
positive button on the control panel, bend head moves up.
d. Touch the Bend head horizontal movement icon in Manual mode page and press Manual
positive button on the control panel, bend head moves in.
e. In auto mode, the CLR data is set in Tooling specification – Editing page. User has to input
the correct CLR for R0 & R1 stack.
D. Note of the path of bend head movement
a. In manual mode, before moving bend head up or down, it needs to select Bend head horizontal
movement icon and press Manual negative button on the control panel to shift bend
head out.
b. Touch the Bend head vertical movement button in Manual mode page, press Manual
positive button or Manual negative button on the control panel to move bend
head upward or downward.
c. Touch the bend head horizontal movement button in Manual mode page, then press Manual
positive button or Manual negative button on the control panel to shift bend head
inward or outward.
d. If bend head is not positioning, a message will be shown on screen, user needs to follow the
instructions to operate.
E. Machine stop shall be notice
When machine finishes the job every day, user needs to move the bend head to the top stack. It will
extend longevity of machine.

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CHIAO SHENG MACHINERY

No.2 , Sec.2, Huandong Rd., Tainan Science Park Sinshih District,

The Usage of Automatic Tube Bender

Part Ⅰ Transportation and Installation

Before installing this machine, please read:

Why most accidents occur

Part I Transportation and Installation

1 Packing and Transportation ................................................................................... 3

2 Installing the Machine ............................................................................................. 4

3 Choices of Oil Sorts ................................................................................................ 5

4 Cooling System (Not applicable for all electric model)........................................ 8

5 Electrical System .................................................................................................... 9

Part I Transportation and Installation

1 Packing and Transportation

1.2 Method of Transportation

Part I Transportation and Installation

2 Installing the Machine

2.1 Cleaning Machines

2.2 Operating Environment

2.3 Shock-Absorbing Pads

2.4 Leveling Machines

Part I Transportation and Installation

3 Choices of Oil Sorts

Part I Transportation and Installation

Viscosity ISO 46 Viscosity ISO 46

Viscosity ISO 32 Viscosity ISO 32

Part I Transportation and Installation

Part I Transportation and Installation

4 Cooling System (Not applicable for all electric model)

Part I Transportation and Installation

5.2 Connecting the Power Source

19. Start button 1 2 1. Clamp die 10. Power on button

Part I Transportation and Installation

Part Ⅱ Safety Section

Why most accidents occur

Part II Safety Section

1 Safety Warning Label .............................................................................................. 4

2 General Information .............................................................................................. 11

3 Electrical, Safety Practices ................................................................................... 14

5 Noise Levels .......................................................................................................... 16

6 AC Servo Driver, Safety Practices ....................................................................... 17

8 Machine Operation ................................................................................................ 21

Part II Safety Section

Part II Safety Section

1 Safety Warning Label

1.1 Important Points

Part II Safety Section

1.2 Meaning of Label Colors and Basic Sign

1.2.2 Types of Warning Basic Sign

Background color is white. Circular band and cross bar is red.

Background color is yellow. Triangular band is black.

Background color is blue. The symbol or text shall be white.

Background color is green. The symbol or text is white.

Part II Safety Section

1.2.3 Meaning of Symbols

Electric Shock Warning Symbol

Danger of Being Caught-Up Warning Symbol

Danger of Being Caught-Up Warning Symbol