Sayfa No 1

SERVO PRESS BRAKE

Doküman No KL.002
OPERATING, MAINTENANCE Yayın Tarihi 01.07.2020
AND USING MANUAL Rev. No / Rev. Tarih 0 / --

SERVO PRESS BRAKES

DD-M SERIES

SERVO PRESS BRAKES

PRESS BRAKE
OPERATING, MAINTENANCE
AND USING MANUAL
Table of Contents
INTRODUCTION ...................................................................................................................... 4
1. TOPIC AND PURPOSE OF BOOK ..................................................................................... 1
1.1. SERVO PRESS BRAKE(Drawing) and the Technical Specification ............................ 2
1.2.INFORMATION ABOUT THE MAXIMUM PRESSURE FORCE .............................. 2
1.3.Main Components ............................................................................................................ 4
2. LIFTING ................................................................................................................................ 5
2.1. Transportation of the Machine(Drawing)..........................................................................
3. INSTALLATION FOR PREPARED AND SECURITY CLEARANCES ........................... 8
4. ASSEMBLING OF MACHINE.......................................................................................... 11
4.1.Connection to the basic ground plan(Drawing) ...................................................................... 11
5.BEFORE STARTING THE MACHINE CAREFULLY FOLLOW THE LISTED POINTS
.................................................................................................................................................. 13
6. WHILE WORKING ............................................................................................................. 19
7. SERVO PRESS BRAKE GENERAL EQUIPMENT .......................................................... 20
8.STORAGE ............................................................................................................................ 21
8. 1. STORAGE OF THE POOLS: ...................................................................................................... 22
9.TECHNICAL PROPERTIES ................................................................................................ 23
10.ELECTRICAL INFORMATION FORM ........................................................................... 24
11.ACCESORIES LIST ........................................................................................................... 26
11.1 STANDART ACCESSORY ......................................................................................................... 26
11.2 OPTIONAL ACCESSORY .......................................................................................................... 26
12. EFFICIENCY CONDITIONS ........................................................................................... 27
13. BENDING TECHNOLOGY .............................................................................................. 28
13.1. USE OF BENDING CHART ...................................................................................................... 29
13.2 SHEET METAL BENDINGS IMPORTANT MATTERS : ............................................................... 34
13.3 PRESS WITH MOULD ............................................................................................................. 34
14.ELECTRIC CABINET ...................................................................................................... 35
14.1. Description of Using the machine in different modes ......................................................... 36
14.2.Buttons and Using Rules........................................................................................................ 37
14.3. OPERATING SERVO PRESS BRAKE......................................................................................... 38
15. ADJUSTMENT OF LOWER DIE AND UPPER PUNCH ............................................... 41
15.1- Servo Press Brake Punch Connection System ...................................................................... 43
15.2-SERVO PRESS BRAKE PUNCH CONNECTION SYSTEM (DRAWING) ........................................ 44
16 . ADJUSTMENT OF THE BACKGAUGE ........................................................................ 45
16.1. System of Adjustment .......................................................................................................... 45
16.2. The Backgauge System ......................................................................................................... 45
16.3.Points To Be Paid Attention To While Maintenance Of The Backgauge: .............................. 46
17. THE BACKGAUGE (DRAWING) ................................................................................... 48
18. FRONT SUPPORT SYSTEM ........................................................................................... 49
19. ADJUSTMENT OF THE PARALLELISM AND BENDING .......................................... 50
19.2 THE LIMITATION ADJUSTMENT OF DESCEND AND ASCENT ..................................... 51

Instruction Manual Page 2

20. ADJUSTMENT OF PRESSURE: .................................................................................... 52
21 . LUBRICATION ................................................................................................................ 53
21.1.LUBRICATION REQUIRED ONCE IN A MONTH OR 200 HOURS .............................................. 53
21.1.2.Upper beam guides ............................................................................................................ 54
21.2.LUBRICATION REQUIRED ONCE IN 3 MONTHS OR 200 HOURS ............................................ 54
21.3. LUBRICATION REQUIRED ONCE IN 2 YEARS OR 5000 HOURS .............................................. 54
22. SAFETY ............................................................................................................................. 56
22.1 SAFETY SYSTEM ..................................................................................................................... 56
22.2 SAFETY INSTRUCTIONS .......................................................................................................... 56
23. TROUBLE SHOOTING .................................................................................................... 58
23.1.Machine does not take commands ....................................................................................... 58
23.2.Machine receives command but there is no any functional motion .................................... 58
23.3.Machine is running but upper beam does not move upwards from the bottom point ....... 59
23.4.Machine is running but there is no pressure; ....................................................................... 59
23.5.Machine is working but there is bending defects; ................................................................ 60
24. RISK CAN NOT BE ANNULLED FOR SAFETY RULE ............................................... 61
25. MAINTENANCE............................................................................................................... 63
25. 1. GENERAL .............................................................................................................................. 63
25.2.Tighten Upper beam belts..................................................................................................... 64
25.4. MAINTENANCE SCHEDULE ................................................................................................... 66
26. SAFETY ............................................................................................................................. 69
26. 1. GENERAL POINTS : ............................................................................................................... 69
26. 2. SAFETY EQUIPMENT .......................................................................................................... 70
27. SAFETY LABEL AND MEANING ................................................................................. 71

Instruction Manual Page 3

 INTRODUCTION

Press Brake Industry is developing everyday for providing neccessity of Press Brake market.
And also is indispensability of technology and life. Our target is for provide neccesisty that use the
best tecnology and engineering technic for provindig high performance and capacity.

DENER has IFC GLOBAL ISO 9001 certificate of the quality system.

This book is a comprehensive document of transport of machine, foundation proporties of

functions, maintenance, safety and using of machine. If you run your machine according to this book,
will make your job many years.

We wish, use this machine with good days, and we wish you good success with machine.

NOTE: Inside this book; Nobody uses and copies and give somebody this book without written
aproval of DENER MAKİNA SANAYİ TİC.LTD. ŞTİ.

DENER MAK. SAN. TİC. LTD. ŞTİ

Semerkent Mah. Bölükler Sk. No:538 İncesu
KAYSERİ / TÜRKİYE
Telephone : + 90 352 321 13 50 ( Pbx. )
Fax : + 90 352 321 13 53
Web : www.denermakina.com
E-mail : denermakina@denermakina.com

Instruction Manual Page 4

 1. TOPIC AND PURPOSE OF BOOK

This manual is prepared of operator of DENER Servo Press Brake and maintenance officials
for giving information about functions of machine and maintenance.

DENER MAK. SAN. TİC. LTD. ŞTİ is not responsible for arising problems from using of this
book misunderstandingly or not using of this book.

Apply to following address, phone or e-mail address about this manual and technical problem of
machine.

DENER MAK. SAN. TİC. LTD. ŞTİ is not responsible for doing something except of explaning
which is inside of this manual.

After selling of machine, the service will be given by DENER MAKİNA or authoritative service of
DENER MAKİNA. DENER MAKİNA is not responsible about that the service of machine is given
by non-authorized people, further more the machine waranty ends.

DENER MAK. SAN. TİC.LTD. ŞTİ.

Semerkent Mah. Bölükler Sk. No:538 İncesu
KAYSERİ / TÜRKİYE
Telephone : + 90 352 321 13 50 ( Pbx. )
Fax : + 90 352 321 13 53
Web : www.denermakina.com
E-mail : denermakina@denermakina.com
1.1. SERVO PRESS BRAKE(Drawing) and the Technical
Specification

Figure 1.1.General Appearance of DENER Servo Press Brake

1.2.INFORMATION ABOUT THE MAXIMUM PRESSURE FORCE

The pressure possibilities for Dener Servo Press Brakes are shown in the figure below .

Instruction Manual Page 2

 Figure 1.2.Allowable bending force for DENER Servo Press Brake
In the above shown Figure 1.2 there is some examples for the sheet of length 1m at different positions for Dener Servo Press Brake 100-
3100.

Instruction Manual Page 3

1.3.Main Components

Figure 1. 3.Main Components of Dener Servo Brakes

Two Belts powered by the two Servo motors mo ve the upper beam of Press Brakes downwards. Developing a
maximum bending force of 400 kN up to 1000 kN. With the help of back gauge the sheets is exactly position in order to
create a precise product. By using the control panel the operator can adjust the working space.

Instruction Manual Page 4

 2. LIFTING

Before the machine comes, provide a crane which is enough to put down the machine from truck.
The machine should be lifted from the holes as shown in the Figures 2.2.a or Figure 2.2.b.You can choose either of them.

ATTENTION: Lifting force has to apply from this lifting holes. Do not lift the machine from under machine or
electrical cabinet or somewhere.

While lifting from fault of lifting, manufacturer of the machine is not responsible.

Follow the following points for all lifting of machine:

 Tie hawser or chain directly to lifting holes as the maximum\length ratio should not to exceed the load.

 While lifting the angle must be 90 degree between hawser or chain and the other side hawser or chain.

 While lifting be carefull not to damage the parts.

Instruction Manual Page 5

  While locating the machine lift from lifting jaw. Do not lift machine from under of machine or electrical cabinet or
somewhere.

The machine should not be lifted from Forklift. Because the center of gravity is not at the center.

Lifting of machine must be done like lifting explaning of this manual. And the ground must not be changable. The
machine is packed to cover from outside condition .

Instruction Manual Page 6

Figure 2.1.Dont use forklift truck Figure 2.2.Treading Label

NOTE : When treading some parts on the machine can not carry weight. Cause to damage something. Thi s label is
used not to apply load or treading for hiking to somewhere.

Instruction Manual Page 7

 Figure 2.3 LIFTING AND TRANSPORTATION

3. INSTALLATION FOR PREPARED AND SECURITY CLEARANCES

The press brake must be installed a stable ground. The working area requires 320 mm thickness concrete which is flat plane.
This surface has to have maximum tolarence 2 mm parameter.

Instruction Manual Page 8

The Press brake must be fixed to the ground only from two side on the rear side of the machine(Figure 4.1) and also there
must be support on the front side(on both the sides)

 You have to ensure a rear clearance of approximately for the machine from the wall that present behind the machine.
This is it was provided to allow the various maintenance operations that could be done by openinig t hat could be done
by opening the protection covers.

 You have to specify spaces between the sides in order to ensure a bending length area for you to make your bendings .

Instruction Manual Page 9

 Figure 3.1.Machine Installation distance

Instruction Manual Page 10

 4. ASSEMBLING OF MACHINE

1. The floor of the machine assembly must be rigid(concrete) and it must be extremely flat for the thickness of the please
refer to your foundation plan.

2. Please supply anchoring screws according to the assembly drawing which was given in the manual and fix them due to
the measurement and floor location layout.

3. The leveling of the machine has to be done by means of crane(winch, carrie crane etc..),and the machine has to be
located on the anchoring screws which were fixed on the given places in the figure.

4. Nuts of anchoring screws have to be tightened and the straight of machine has to be measured by an accurate balance,
by taking the lover table of the machine as base.

5. This balancing process must be done. If the machine location does not change longtime or anytime, you ca n concrete
deep of machine feet.

4.1.Connection to the basic ground plan (Drawing)

Instruction Manual Page 11

Figure 4.1.At the rear side anchor the machine on both the holes Figure 4.2.Chemical Anchor with Floor Plate

1. Adjusting Set Screw

2. Machine Anchoring Plate
3. Adjusting Plate (Not in our scope)
4. Threaded Rod and Fasteners (Not in our scope)

Figure 4.3.Put the support on both side in the front side

exactly on the foot

Instruction Manual Page 12

4.2 CALCULATION OF FLOOR

For the Calculation of the foundation for a press brake it must be assumed that
100% of the total weight rests on the two front base plates.

In practice this value equals and exceeds the sum of the static and load and
dynamic lod.

 The foundation thickness entirely depends on the base of the

foundation. Plase, contact the architect if there is any uncertainty
about this matter

Figure 4.5 Anchor the press brake side on two supports at the rear only.

Instruction Manual Page 13

 Figure 4.6 At the front side, put the 4 qty adjusting plate (150mm x 150 mm
dimensions) on both side

Instruction Manual Page 14

Machine M G (1) Static (1) Dynamic (2) Static (2) Dynamic
Code Load 1SL Load Load 2DL
(mm) (mm) Load 1DL
(kN) (kN)
(kN) 2SL (kN)

DDM 1532 1774 6,97 0,24 13,94 0,48

4015

DDM 1540 2284 8,02 0,27 16,04 0,54

5020

DDM 1512 2774 9,05 0,30 18,1 0,60

6525

DDM 1512 2774 9,04 0,30 18,08 0,60

8025

DDM 1533 3414 9,93 0,33 19,86 0,66

10030

DDM 1532 3334 12,50 0,42 25 0,84

13530

TABLE 1. Loads and Dimensions

Instruction Manual Page 15

4.3 ERECTING AND ANCHORING

As the press brake frame has a stable design, and to the two -point mounting of
the rear frame, the frame parts need not be a djusted to run parallel.

The electrical cabinet is fixed to te frame.

Fastening or loosening bolts is not necessary.

For the DENER press brakes it is necessary to anchor the rear machine foots to
the floor.

With the adjusting bolt(s) in the machine foot the cross direction of the machine
can be put in a water level position.

The machine must be anchored to the floor with two anchoring bolts M12x160

Erecting
The press brake must be placed on a good foundation and well anchored. Level
the press brake on the level surface in the side frame.

1. Make sure the press brake is put in its correct position straight away so
as to avoid having to shift it later.

2. Drill the foundation holes at the rear of the machine and fit the machi ne
to the floor.

3. Make sure tool nesting places of top beam and lower beam are parallel;

4. Make sure back gauge and tool nesting place are parallel;

5. Fit the control to the swivel arm of the press brake

Instruction Manual Page 16

 6. Adjust the height of the control to a comfortable position for the
operator

7. Then mount the various accessories (if supplied).

8. A qualified election must connect the mains.

9. Switch on the main voltage of the press brake.

10. Start the press brake

11. Check the proper working.

12. Make sure the various accessories (if supplied) are working proper.

Instruction Manual Page 17

 5.BEFORE STARTING THE MACHINE CAREFULLY
FOLLOW THE LISTED POINTS

1. This manual has to be observed properly and safety steps has to be

performed.

2. The electric connection must be showed at figure.5.1.Main voltage is 3

phase,1 notr and 1 ground cable.

3. Front side protection doors must be fixed and wright location .

4. The Electric cabinet door must be closed. Before opening the Electric
cabinet door Main switch position must be at 0.

5. Check the emergency stop buttons if closed, open them.

6. The lubrication areas have to be lubricated.

7. Any parts or anything which are interest with machine, are not located on
the machine.

8. Check the connections of punch and die.

9. For bending check the comformity of punch and die .

Figure 5.1.Electrical Connection

Instruction Manual Page 18

 6. WHILE WORKING

1. If the electricity connections is connected wrongly, the main motor can not
run.

2. The machine should be operated by trained people.

3. The machine should be used only by one operator.

4. DENER MAKİNA is not responsible for the damage if you dont use the
tools, which is provide by DENER MAKİNA, or the recommended tools.

5. The operators have to work with safety tools.

Instruction Manual Page 19

 7. SERVO PRESS BRAKE GENERAL EQUIPMENT

The machine planning is manufactured for w orking dynamic working

condition. The following parts is used it press brake.

ELECTRICAL UNITS :SIEMENS/LENZE/FIESSLER

SERVO MOTOR :LENZE

LIGHT CURTAIN : SICK / FIESSLER /DSP LASER

CNC CONTROLlER UNITS : DELEM/DENER

BACK GAUGE :UNIMEC/DENER

TOOLS :WILA/EUROSTAMP/DENER

Backgauge system; The backgauge is controlled by control unit (DELEM) with

good positioning. And position tolarance is 0,1 mm

DENER MAKİNA machines have all safety equipments and the ris k of danger is
minimized.

Instruction Manual Page 20

 8.STORAGE

Servo Press brakes have been stored in DENER MAKİNA facilities

without exposing to any kind of environmental effects and loading and delivery
are made in this form.

Before the Servo press brake, if store the machine;

1. Machine must be stored under the normal operating conditions. If these

conditions could not be ensured; in the conditions where is a damp
environment, damp removing meterials ought to be placed on the electric
panel, cable connections cable canals, Servo block, by means of this
application electrical parts shall be protected from moisture .
2. During the storage period in D ENER facilities, and before the
transportation machine was prepared in a form that the punch on the
machine is located at the split of the dies ‘’V’’ dith .
3. Machine must be protected carefully to prevent from exposure to high
sunlight, storage must never be carried out in open air (wet environment).
Defects may ocur in the valve sockets or electric or electronic parts .
4. In order to prevent the unpainted metal equipments from rusting protective oil must be
used periodically. After this process the machine has to be brought to it original
protection position.
5. Storage ground must be stable and rigid.

STORAGE CONDITIONS CONDITIONS

OF LISTED COMPANY DAMAGES ARISING VIOLATIONS
WILL REGARDING MACHINES.

Instruction Manual Page 21

8. 1. STORAGE OF THE POOLS:

To prevent the wear of the sharp edges of the dies and punches, these tools
should be carried by board tracks and sto red in the rubber boxes, and they have
to be lubricated by protective oil. The tools must not be carried by means of
hands; qualited and trained personel should carry out the assembly remeval and
adjustment operations.

Instruction Manual Page 22

 9.TECHNICAL PROPERTIES

MAXIMUM
CAPACITY
BENDING

BENDING
LENGTH

STROKE

MOTOR
MAIN
ton mm mm kW
DD-M 25 1250 300 11
1225
DD-M 35 1250 300 11
1235
DD-M 40 1530 300 11
4015
DD-M 50 2040 300 11
2050
DD-M 65 2550 300 11
6525
DD-M 80 2550 300 11
2580
DD-M 100 3060 300 11
30100
DDM 100 3060 300 12,5
30130
DDM 135 3050 300 12.5
30135
DD-M 135 4050 300 12.5
40135
DD-M 150 3050 300 22
30150
DD-M 175 3650 300 22
36175
DD-M 200 3050 300 22
30200
DD-M 200 4050 300 22
40200
DD-M 300 3050 300 22
30300
DD-M 300 4050 300 22
40300

Instruction Manual Page 23

 PAINT

RED
RAL 7035

CREAM RAL 5015

WHITE RAL 1018

TABLE 3 – COLOUR LIST

10.ELECTRICAL INFORMATION FORM

FREQUENCY
CONTROL
VOLTAGE

VOLTAGE
CURRENT

CURRENT
CABINET

SECTION
SUPPLY

SUPPLY
MOTOR
SUPPLY

SUPPLY

CABLE

PANEL

Volt (V) Amper (A) Amper (A) Q/mm² Volt (V) hz

DD-M 380 80 63 4x10 24 DC 50-60
40-15
DD-M 380 80 63 4x10 24 DC 50-60
50-20
DD-M 380 80 63 4x10 24 DC 50-60
65-25
DD-M 380 80 63 4x10 24 DC 50-60
80-25
DD-M 380 80 63 4x10 24 DC 50-60
100-30
DD-M 380 100 95 4x10 24 DC 50-60
130-30

Instruction Manual Page 24

 11.ACCESORIES LIST

11.1 STANDART ACCESSORY

SEQUENCE PART NAME UNIT

1 ESA S525 CNC CONTROLER 1

2 PROMECAM TYPE PUNCH CLAMPING SYSTEM 1 SET

3 STANDART HARDENED,GRINDED SECTIONED 1 SET

TOP TOOL AND BOTTOM TOOL

4 BALLSCREWS ON THE BACKGAUGE STANDART 1

X AXİS

5 REMOTE FOOT CONTROL PEDAL WITH 1

EMERGENCY STOP BUTTON
6 MOVABLE BACKGAUGE FINGERS 2

7 MOVABLE FRONT SUPPORT 2

8 DIE HOLDERS 1 SET

TABLE 3 – SMART STANDART ACCESSORY LIST

11.2 OPTIONAL ACCESSORY

SEQUENCE PART NAME UNIT

1 ESA 530 CNC CONTROLER 1

2 X,R TYPE BACKGAUGE 1

3 MANUAL CROWNING SYSTEM 1

4 MOTORIZED CROWNING SYSTEM 1

5 LASER PROTECTION 1 SET

6 LIGHT CURTAIN 1 SET

7 PANEL COOLING UNIT 1

TABLE 4 – SMART OPTIONAL ASSESSORY

Instruction Manual Page 26

 12. EFFICIENCY CONDITIONS

Follow the recommended range in the table given below in order to

maximize the life time of the electronic parts.

Minimum Maximum

Storage heat -10 C + 50 C

Operation heat + 5 C + 35 C

Relative wet 20 % 75 %

TABLE 5 – MINUMUM AND MAXIMUM WORKING VALUE

 Under + 5C, to isolate electric cabinet, control panel.

 Up to +60C to isolate electric cabinet, control panel.

Instruction Manual Page 27

 13. BENDING TECHNOLOGY

Press Brake Machine is using for bending, dutching fo lding, striking, hammering
to material.

There are two ways of bending. One is Bending on air and the other is
Hammering.

A- BENDING ON AIR:

It usually is used to need low ton or pressure. Angle sensitiwity depends on

material of resistance.First put the meterial on the V-die, after write the angle
which you want as 100 , 120  , 150 , 175 bend of meterial.

 There are two ways for air bending.

a) Punch like seated: This type is for more than 2 mm thickness.

The rulers are for this bending style;

R > S (yawning) R is equal to V\10

So; V
R = -------
10

For example: From 90 bending table

S: thickness meterial

V die open = s ( thickness ) x 7-8 times the ( less than 4 mm thickness )

Instruction Manual Page 28

s ( thickness ) x 8-10 times ( more than 4 mm thickness )

V die opening = “ V “Openinig 30 mm. And 88

V –die opeining is more than 30 mm and 86

b) Party air bending :

Not to reach deep of V-die

At air bending, you can adjust your angle from 90 to 180.

B - HAMMERING:

R > S The punch break meterial radius you have to use special type for this
bending.

V -die opening = 10 x s ( thickness )

13.1. USE OF BENDING CHART

EXAMPLE: s=4 mm thickness

Lenght=1000 mm

Resistance=st 42 kg\mm^2

Instruction Manual Page 29

V-DIE OPENING =v-die opening 3mm to 8-12
4 mm to 10=42
s: thickness.

The width of tightest sheet is to be bended B=29 mm(on bending chart),iner

radius is R=4,2 mm (on bending chart) required force is 23 ton isdetermined on
the chart.

For example: St 42 sheet at the thickness:4 mm, at the lenght:1000 mm

1,42 x  x s x L
P = --------------------- (Ton )
1000 V

Example: V-die opening;

V= 10 x s

V= 10 x 4 mm= 40 mm, nearly 42 mm

St 42 resistance is 42 kg / mm².

1,42 x 42 kg / mm² x 4 mm x 1000 mm

P = ------------------------------------------------
1000 x 42 mm

P = 22, 72 tons

P = 23 Tons

Instruction Manual Page 30

13.1.1. DEHLER CHART

B

Figure.13.1.1.Dehler Chart
Up shape is for practical calculation
DEHLER CHART

THICKNESS RADIUS
MATERIAL PROPERTIES B
s mm r mm
STEEL 1s 4
0,8 1s ........ 5 s 5
5s 6
ALUMINIUM
1s 2
0,8 ........ 2 1s ........ 5 s 3
COPPER 5s 4

1s 0
BRASS 2 1s ........ 5 s 1
5s 2
B = 22 kg/mm
STEEL(NORMAL STRENGTH ) 1s 5
0,8 1s ........ 5 s 6
B = 40 kg/ mm  5s 8

BRASS 1s 2
0,8 ........ 2 1s ........ 5 s 3
HIGH STRENGHT 5s 5
B = 35 kg/ mm
1s 0
2 1s ........ 5 s 1
BRONZE 5s 3
1s 7
0,8 1s ........ 5 s 9
5s 12
STEEL 1s 4
0,8 ........ 2 1s ........ 5 s 5
5s 7
B = 60 kg/ mm 1s 2
2 1s ........ 5 s 3
5s 5

Instruction Manual Page 31

13.1.2. DIFFERENCES OF DEGREE
DIFFERENCES OF DEGREE CHART
Δα 1 1.5 2 2.5 3 3.5 4 4.5 5
V
mm.
6 0.031 0.046 0.061 0.076 0.09 0.106 0.121 0.136 0,151
8 0.041 0.061 0.081 0.101 0.121 0.141 0.161 0.181 0.201
9.5 0.048 0.072 0.096 0.120 0.144 0.166 0.192 0.215 0.239
10 0.051 0.076 0.101 0.127 0.152 0.177 0.202 0.226 0.251
12 0.061 0.091 0.122 0.152 0.182 0.212 0.242 0.272 0.301
13 0.066 0.100 0.132 0.185 0.197 0.230 0.262 0.294 0.327
15 0.076 0.114 0.152 0.190 0.228 0.265 0.302 0.340 0.377
16 0.081 0.122 0.162 0.203 0.243 0.283 0.323 0.362 0.402
19 0.097 0.145 0.193 0.241 0.288 0.336 0.383 0.430 0.477
20 0.11 0.152 0.203 0.253 0.304 0.354 0.403 0.453 0.502
24 0.122 0.183 0.244 0.304 0.364 0.424 0.484 0.544 0.603
25 0.127 0.190 0.254 0.317 0.379 0.442 0.504 0.566 0.628
30 0.153 0.230 0.305 0.380 0.455 0.530 0.605 0.679 0.754
32 0.163 0.244 0.325 0.405 0.486 0.566 0.645 0.725 0.804
35 0.173 0.267 0.355 0.443 0.530 0.619 0.706 0.793 0.849
38 0.194 0.299 0.386 0.481 0.577 0.672 0.766 0.861 0.995
40 0.204 0.305 0.406 0.507 0.607 0.707 0.807 0.906 1.005
50 0.255 0.381 0.508 0.633 0.759 0.884 1.010 1.132 1.256
52 0.265 0.400 0.530 0.660 0.789 0.919 1.050 1.178 1.306
55 0.28 0.420 0.560 0.700 0.835 0.972 1.109 1.246 1.382
60 0.306 0.460 0.610 0.760 0.911 1.060 1.210 1.360 1.510
63 0.321 0.480 0.640 0.800 0.960 1.110 1.270 1.430 1.580
70 0.357 0.540 0.710 0.890 1.060 1.240 1.410 1.590 1.760
76 0.387 0.580 0.770 0.960 1.150 1.340 1.530 1.720 1.910
80 0.41 0.610 0.810 1.010 1.210 1.420 1.610 1.810 2.010
100 0.509 0.760 1.000 1.270 1.520 1.770 2.020 2.260 2.510
125 0.637 0.950 1.270 1.580 1.900 2.210 2.520 2.830 3.140
160 0.815 1.220 1.620 2.030 2.430 2.830 3.230 3.620 4.020
200 1.02 1.520 2.030 2.530 3.030 3.530 4.030 4.530 5.020
250 1.27 1.900 2.530 3.170 3.800 4.420 5.040 5.660 6.280
320 1.63 2.400 3.250 4.100 4.900 5.700 6.450 7.250 8.040
400 2.03 3.000 4.010 5.100 6.100 7.100 8.100 9.100 10.000
500 2.55 3.800 5.010 6.400 7.600 8.800 10.100 11.300 12.600
630 3.2 4.800 6.400 8.000 9.600 11.000 12.700 14.300 15.800
Width of bending of the material which
the material designated channel to be bent
angle of release, may occur due to 

differences (Δα) as given in the table
(Approximately) based on the calculations
can be made.

Figure 13.1.2.Differences of degree

Instruction Manual Page 32

13.1.3 BENDING DIAGRAM
V B S ( mm. )
R
(min.) 0,5 0,8 1 1,2 1,5 1,8 2 2,5 3 3,5 4 4,5 5 6 7 8 9 10 12 15 18 20
6 5 1 2,5 6,4 10
8 6 1,3 1,9 4,9 7,6 10,8
10 7 1,7 1,5 3,9 6 8,8 13,8 1.42 x  x s x s L
12 9 2 3,1 5 7,1 11,1 16,1 P= (TON)
15 12 2,7 4 5,8 9 12,9 16 1000 V
20 15 3,3 4,3 6,8 9,8 12 18,8
26 18 4,2 5,2 7,5 9,2 14,5 20,8
30 22 5 6,5 8 12,5 18 24,5
32 23 5,4 7,5 11,7 16,9 23 30
37 25 5,8 10,1 14,6 20 26 32,8
42 29 6,7 12,8 17,5 23 29 35,8
45 32 7,5 16,4 21,4 27 33,2 48
50 36 8,3 19,1 24,2 30 43 60
60 43 10 20,2 25 35,9 48,9 63,8
70 50 11,5 21,5 30,8 41,9 54,8 69,2
80 57 13,5 27 36,7 48 60,5 74,7
90 64 15 32,6 42,6 53,8 66,4 95,6
100 71 17 38,3 48,5 59,8 86 134,4
130 93 22 37,3 46 66,2 103,4 148,8
180 130 30 33,3 47,9 74,8 107,6 132,8
200 145 33 43,1 67,2 96,8 119,5
250 180 42 53,9 77,5 95,7

P : Capacity ( ton )  : Tensile strength ( 42 kg/mm ) B :The minimum length of sheet metal bending
L : Length (1000 mm.) V : V-DIE
s : Thickness (mm) R : internal diameter
TABLE 13– BENDING DIAGRAMS

Instruction Manual Page 33

13.2 SHEET METAL BENDINGS IMPORTANT MATTERS :

1. At air bending A, B and C points is important

2. Press to sheet to deep of the V-die And press, both side. This is important for following points;
 You do not need work with max pressure.
 Provide normal tools for good bending.
 There is tolarance for air bending.

i. With pointed punch ± 0,2 degree

ii. With standart punch ± 0,3 degree
iii. With wide punch ± 0,5 degree

B
A

V=4 ve 5s
C

Figure 13.2.Bending with the punch

13.3 PRESS WITH MOULD

Using punches and dies must have a sensitivity surface to prevent to

damage sheet. Neccessary pressure is more then air bending pressure. At this
bending tolarance is -+0.6’

v-die opening is linearly proportional to bended part .

r = 16 V calculation can be used.

Instruction Manual Page 34

 ATTENTION: After long time using, the punches and dies can be
detrital. You can understand the detrital, the tools should be
proccessed.

14.ELECTRIC CABINET

Figure 14.1.Electric cabinet

Instruction Manual Page 35

14.1. Description of Using the machine in different modes

Figure 14.2.Operating mode and the Security mode of the machine

3
Operation
mode/ 1 2 3 4 Description
4 Security
mode
1 x Manual Mode
1 x Automatic Mode
x Single brake(Lazer light need to detect the movement of hand for
1 one time in order to start bending and will run without the food
pedal )
x Double brake(Lazer light need to detect the movement of hand for
1 two times in order to start bending and will run without the food
pedal )
2 x
2 x If the operation mode is in 2 then it doesnt depend on the whatever
2 x the security mode is,the speed of the upper beam will be slow.
2 x
3 x Manual Mode Will work as same as the operation
3 x Automatic Mode mode 1 the only difference after
3 x Single Brake reaching the MUTE point the machine
3 x Double Brake will start working with the food pedal.

Note : If there is 0 in either of the two modes the machine will not work.

Instruction Manual Page 36

14.2.Buttons and Using Rules

ROBOTS ACTIVE: Activates the Robot

function(OPTIONAL)

UP LIFTING: For lifting the upper beam up.

OVERRUN TEST OK: If the light blinks it means that overrun

test is not completed.After the overrun test this light must be
ON.

MUTE INDICATOR: It means that machine in Manual Mode

or the Upper beam teached the mute point.

Instruction Manual Page 37

 GENERAL RESET: It reset safety PLC.If all the safety
condition are satisfied then this button will be pressed.

EMERGENCY BUTTON: Press this button in case of

emergency this will stops all the movements of the
machine.After releasing this button the machine must be
reset again.

ANTI-PANIC BUTTON:To stop the machine

immediately.

14.3. OPERATING SERVO PRESS BRAKE

1. On the Dener Servo Press Brakes, after the specified assemblies, the
system is fed by a 4x10 mm² cable connected to ground and energy can ve
given to the clipboard.

2. After power on, the board control is performed and energy is measured. If
3-Phase, notr and ground connection are OK, change the main switch
position from (0) to (1). When the key on the panel is turned clockwise
direction, 24V DC voltage is given to the control circuit and STOP lamp

Instruction Manual Page 38

 on the control panel lights up (due to the machine is not running). In order
to make bending on the machine, you must press START button on the
panel after the following checks have been completed. If the emergency
buttons are not active the machine will work.

3. The main electric motor rotation direction must be checked. If the lamp
of the PSR ( Phase Sequence Relay) inside clipboard lights up gren it
means motor rotation direction is correct. If the lamp of PSR doesn’t light
up it means motor rotation direction is reverse and 24V DC voltage doesn’t
reach control curcuit and because of that moto r and machine won’t work.
In this case interchange L1 and L3 phase on PSR. Thus the direction of the
motor rotation is achieved in correct way. During this process, the control
panel switch position must be (0) and must be performed only by
authorized persons .

4. Operation of the motor and Servo pump and therefore the introduction of
the machine with START button on the control panel; turn off the motor
and Servo pump is provided with STOP button on the control panel.

5. A short time after starting the motor, the lamp inside the STOP button
going off and the lamp inside the START button going on mean the
machine is ready for the action.

6. After the end of the day is finished working with the machine, the ram
must move down (punch must move down until die level ) and is left in this
state until the next work.

Instruction Manual Page 39

If the Upper beam is in up position;

To take reference on the machine the ram souldn’ t be up position. The

ram position must have down level or must have at least one position down from
the top level.

Press Manual button on the computerized controller of the ESA or

Cybelec or Delem. After that press the foot pedal and move down the ram at a
certain distance with slow speed.

The reference process must be completed in manual mode on the ESA

and Delem controller also in semi-automatic mode on the Cybelec controller. For
this on the ESA and Delem controller you need to press up button on the foot
pedal for the ram reference and you need press START button on the cont roller
for backgauge axes’ reference. On the Cybelec controller firstly you must reach
semi-automatic mode and then you need to press up button on the foot pedal for
ram reference; you need to press START button on the controller for the
backgauge axes’ reference.

If the Upper Beam is down position;

The reference process must be completed in manual mode on the ESA and
Delem controller also in semi-automatic mode on the Cybelec controller. For this
on the ESA and Delem controller you need to press up button on the foot pedal
for the ram reference and you need press START button on the controller for
backgauge axes’ reference. On the Cybelec controller firstly you must reach
semi-automatic mode and then you need to press up button on the foot pedal for
ram reference; you need to press START button on the controller for the
backgauge axes’ reference .

NOTE: The ram position should be on die level when you finish to work with
machine.

Instruction Manual Page 40

 15. ADJUSTMENT OF LOWER DIE AND UPPER PUNCH

One of the important points must be taken into consideration in order to

obtain an accurate bending is that the axis of punches and dies must be at the
same direction and this position must be kept while pressing. For this reason the
adjustment of the die and punch must be done and this adjustment must be
repeated every time you tie a working part, which is going to bended, is
connected to the machine. This adjustment has to be repeated in the first bending
of every new work. Again this adjustment must be done while t he machine is in
manual position. The process order necessary for this condition is given as
follows;

1. Press Manual mode on the controller.

2. The die tightening arms that are located on the lower table has to be
loosened completely and they are brought to f ree position.

3. While the upper beam of the Servo press brake is in down position (it will
be in a distance of 10-15mm from the lower die’s upper surface). Firstly
the lifting chains have to be connected to the bolts that were located on the
lower die’s both ends and the other side of the chains have to be connected
to the bolts from both sides that were located on the ram, where the
pressing punch was located on. By raising the ram upwards, the die will be
raising by means of the chains. The adjustment of t he demanded V width
could be done by turning the lifted die. The bending part of the lifted die
has to be brought under the punch after it was lifted.

Don’t hold the punches with bare hand, despite the possibility of slip always wear
appropriate gloves and be very careful!!

Instruction Manual Page 41

 4. The canal surface of the die, which is dwelled on the lower table, and the
edge point of the upper punch that realizes bending must be carefully
cleaned.

5. The tip point of the punch is placed to the V center of the die stably by
means of command panel (manual position).

6. In this condition by means of the lower die, tightening arms and lower die
connection part, and the lower die fixing part is leaned to die then the is
fixed slowly.

7. The punch is raised to a specific distance then by m eans of a measurement

device the distance between the right and the left edges of the punches and
the right and the left deep point of the V -die, is measured. If it is possible
this measuruments can be increased at various points so parallelism
between the die and punch is ensured.

8. After adjustment pressing process is carried out.

NOT: In the course of the time, angle differences can be seen in

the bended sheet. In this situation the section that the angle
difference occurs is determined;

1. In this section the armed pressing screw is loosened.

2. The punches become free.

3. Then all the punches are descended on a thin sheet metal that was located
on the die slowly

4. There should not be any light leakage between punch tip point and sheet
metal.

5. At this position the punches are tightened one by one.

Instruction Manual Page 42

 Figure 15.0.1.Adjustment of die and the punch

In addition, you can use manual or motorized crowning system to

remove angle diversity. This is an optinal system for Servo Press Brakes.

15.1- Servo Press Brake Punch Connection System

The purpose of the system , the machine may occur in the bending points out
differences of degree and fixing of the blades twist to provide the most appropriate
way .

System consist of 5 main parts:

1- Connection part
2- Adjustment cutter
3- Top Pressure part
4- Punch Pressure part
5- Connection Plate

Instruction Manual Page 43

15.2-SERVO PRESS BRAKE PUNCH CONNECTION SYSTEM
(DRAWING)

Figure 15.0.2.Servo Press Brake Punch connection system

Instruction Manual Page 44

 16 . ADJUSTMENT OF THE BACKGAUGE

16.1. System of Adjustment

Position of the backgauge can be read with 0.1 mm accuracy on the

control panel of the CNC. The backgauge will move au tomatically the position
you entered on the controller. After this process the current position of the
backgauge is measured with a measuring device and verifies that the same value
on the controller screen. If there is some diff erences that value you must
calibrate the position on the adjustment page inside the controller. For more
information kindly check the CNC controller manual.

16.2. The Backgauge System

All units that all components of the backgauge unit is placed, were
protected by switched rear protection guard. The entrance to the back gauge
system could be done only during maintenance period while the machine was
stopped and every kind of defect, repair have to be done during this period.

Dener Servo Press Brakes designed with safety guards on the back side
which are control the backside. But if someone enters to backside, then, if the
guards were shut by someone else while the other was in this situation could
originate big dangers. You must pat a lot of attentio n to this situation and you
must hang a warning when you or someone else enters to the back side for any
kind of maintenance and repair.

Instruction Manual Page 45

16.3.Points To Be Paid Attention To While Maintenance Of The
Backgauge:

During the maintenance the machine must be stopped and its energy must be
switch off. Because of the low height of the backgauge system, the movement all
kinds of should be taken to stand bending.

All parts should be removed after taking the necessary measures and the
maintenance.

1. Timing belt and pulley system for maintenance purposes during control,
(before the housing front, plates should be removed) to be dialed manually
with the power belt and pulleys, timing belt pulleys hand trapped between
the pulley and timing belt should be considered and approached the
junction where the conversion should not be done here. Plates must be kept
here, not executing the machine being installed .

2. Weight-bearing instruments should be used if the system is completly

removed.

3. Limit switches of the backgauge must be checked. If these switches don’t

working properly this is possible that the backga uge may crash into bottom
table.

Instruction Manual Page 46

 17. THE BACKGAUGE (DRAWING)

Figure 17.1.Four Axis Backgauge

Instruction Manual Page 48

 18. FRONT SUPPORT SYSTEM

The aim of the system is to carry the remaining parts of the items that are going
to be bended with the machine, an to provide a moderate support for accurate
bending.

 Front support system parts:

1. Connection Part
2. Carrier Profile
3. Adjustment Spindle on X axis
4. Adjustment spindle on R axis

Figure 18.1.Front Support

Instruction Manual Page 49

 19. ADJUSTMENT OF THE PARALLELISM AND BENDING

The parallelism of Dener Servo Press Brakes are ensured by;

1. Deflection apparatus locates back side on the ram.

2. Five separate sledge system.

Advantage of System:

1. Ensures usage facility in working.

2. Ensures easy oiling during maintenance.

3. Ensures stroke adjustment in high velocity and minimum time.

19.1. A Sample for The Procedure To Bending

In order to make bending in Dener Servo Press Brakes;

After starting the machine;

1. The machine is adjusted according to the location of the process that will
be made and then the machine is brought ready for bending process.

2. The ”V” channel is adjusted according to the sheet metal that is going to
be bended. (This channel width could be chosen from the bending chart.

3. The punch and die adjustment is done as mentioned before.

4. The pressing operation is started.

5. When the pressing process finishes, the ram is raised manually with up
botton on the pedal foot pedal.

Instruction Manual Page 50

 6. By means of an angle measurement device the angle of bended sheet is
read off and this value is compared with the one in the CNC co ntroller.

7. If the angle is greater or smaller than the expected one, then the CNC
controller parameter values are adjusted according to these values.

The measurement of the sheet metal, which is going to be bended, is related

to some parameters;

1. The material quality of die and punches ;

2. The width of V-die;

3. The thickness of sheet;

4. The quality of material is that is going to be bended.

The measurement system should be applied with the considerations of

these parameters.

19.2 THE LIMITATION ADJUSTMENT OF DESCEND AND ASCENT

The descending and ascending adjustment of the machine is ensured by

the linear scales which are located on both sides of the ram. Owing to these
linear scales the CNC controller can read off the needed values. During the
machine working these linear scales transmits all the values of the ram while it
descends or ascents.

Instruction Manual Page 51

 20. ADJUSTMENT OF PRESSURE:

Different bending operations require, different programming and different

pressure adjustment for the sheet metal at different thickness. The pressure
adjustment and programming is done by the CNC control unit. The initially
entered values to the CNC control unit such as sheet thickness, sheet lenght,
material type, material streght are the criterion v alues which has a role in this
adjustment of pressure.

* An example about pressure adjustment for various thicknesses bending :

For 1mm sheet: From the bending chart

Length:1000mm, St 42 sheet
( V ) width = 10 mm , ( P ) Pressre = 6 tone = 6000 kg
X
P = ------
Y

X=P= pressure force Y =170 (fixed value for 100 ton press brake)
6000
P= --------- = 35,2 bar considered approximately 40 bar. The same method is applied for .
170
Other thickness.

Instruction Manual Page 52

 21 . LUBRICATION

GREASE
NR GREASE CODE
1 B.P. ENERGREASE LS2
2 MOBIL MOBILUX 2
3 SHELL ALVANIA R-2
4 TURCAS SPHEEROL AP-2

For Lubricating the parts,______ lubricants are recommended.It is

allowed to substitute the recommended lubricants by other brands of similar or higher quality.
In the suggested lubricating frequency one should look at the
length of time that is achieved first.
Most lubricating points of the press brake were provided with
sufficient grease or oil when the machine was assembled.
During normal use these lubricating points need only be provided
with clean grease at a major overhaul

21.1.LUBRICATION REQUIRED ONCE IN A MONTH OR 200 HOURS

21.1.1.Linear guides’s carriers

Linear guide’s Guide Carrier (mounted inside the back gauge
supports) must be greased by means of an oiler on the lubricating nipples. Pour
in so much oil that it comes out again at the wiper seals of the guide carrier
(remove superfluous oil with a rag).(Use for example SHELL Alvania 2R).

Instruction Manual Page 53

21.1.2.Upper beam guiding strip

These guiding strip must be checked once in every month for excessive
wear and if necessary clean it. These guiding strip don't need any maintenance.

21.2.LUBRICATION REQUIRED ONCE IN 3 MONTHS OR 200 HOURS

21.2.1. Ball screws

The ball screws (mounted inside the back gauge supports) must be
lubricated with thin lubricating oil. If the nut has a lubricating n ipple, the ball
screws must be lubricated by means of an oiler on the lubricating nipples. Pour in
so much oil that it comes out again at the wiper seals.(Use for example SHELL
Alvania 2R).

21.2.2. Spring packet

Clean and check the spring moun ts, bushings and check for wear or
damage. Use Teflon based products for lubricating the guiding parts such as the
plastic bushes and guiding steel shafts. Do not lubricate with oil or grease. These
products will harden and are sticky and consequently dust and dirt absorbing. For
the same reason do not use preservatives or spray on moving guiding parts.

21.3. LUBRICATION REQUIRED ONCE IN 2 YEARS OR 5000 HOURS

21.3.1. Reduction gear unit of the top beam drives

Drain the oil, preferably warm, of the reduction gear units by removing
the drain plug. The drain plug is mounted on the underside in the connecting
flange of the driving-motor. After having drained the oil, put back drain plug and

Instruction Manual Page 54

fill the reduction gear units with new oil at the top of the reduction gear units.
(Fill up with e.g.: High performance gear oil CLP HC 320 ).

CHART FOR LUBRICATION AND MAINTENANCE

PART LOCATION PERIOD ACTIVITY MATERIAL
Once in a month
Guide Carrier of the
or 200 working
linear guide
hours Use oil on E.g. SHELL
Back Gauge
Once in 3 months lubricating nipples Alvania 2R
Ball Circulating
or 600 working
Spindles
hours
Depends on Cleaning or E.g. SHELL
Computer Filter
Environment replacement of filter Alvania 2R
Electrical 2000 working Replace filters
Cooling Fan
Cabinet hours
Press Brake Control panel and
Once in a week Cleaning Cleaning cloth
Control controls
Clean and check the
spring mounts,
Cleaning cloth
bushings and check
Use Teflon based
Once in 3 month for wear or damage.
Spring Spring packet upper products
or 600 working Lubricating the
Packet beam Do not lubricate
hours guiding parts such as
with oil or
the plastic bushes
grease.
and guiding steel
shafts.
Once in 10 Check for excessive
Upper Beam Guiding
months or 2000 wear and clean if Cleaning cloth
strip
Upper working hours necessary
Beam Once in 2 years or
Gear Units of the Upper Drain oil then fill it
5000 working E.g. CLP HC 320
beam again
hours

Table 25.1.Chart for Lubrication and Maintenance

Instruction Manual Page 55

 22. SAFETY

22.1 SAFETY SYSTEM

1. At any kind of dangerous condition; in order to stop the machine there are emergency
buttons.

2. The sides of dies and punches were protected with switched guard doors.

3. The belt- pulley system that exists was protected with square pro files and
protective sheets.

4. The linear scales were protected with side guard doors.

5. The electrical unit is equipped with every kind of safety system.

22.2 SAFETY INSTRUCTIONS

1. While feeding is done, it must be obeyed to the values that are provided in
the electrical introduction card which are given in this manual and that
were located on the machine.

2. No part of the body should penetrate in the dangerous area during bending
operation.

Instruction Manual Page 56

 3. It must not be attempted to change any part of machin e, service,
maintenance or operating without reading the manu al or without any aware
of your superior.

4. Never make service or maintenance while the machine is working.

5. The service and the maintenance of the machine must be done by DENER
MACHINERY or by qualified and well-informed employee.

6. It must not be exceed above the max. pressure values that were given in
the introduction label, pressure label and user hand manual. Refer to the
technical properties(Chapter 9)

7. For the aspect of emergency the “EMERGENCY BUTTONS” are located

on the foot pedal and the control panel. In case of emergency situation
those buttons must be used.

8. The electric current warning labels were put on the machine’s electrical
panel and motor connection part. While working, attention must be paid to
these warnings.

9. While changing the die, die changing chain must be used and this
operation must not be done while the machine is working. While changing
the die and the punch use your protective gloves and shoes.

Instruction Manual Page 57

 23. TROUBLE SHOOTING

23.1.Machine does not take commands

The rotation direction of the main motor that activates the pump should be
controlled whether it has the same rotation direction with rotation direction that
was determined on the motor or not.

1. The R.S.T. phases that are found in the input of the panel should be
checked according to electric sheme.

2. The power curcuit, which was located in the electrical panel, should be
controlled according to the electric sheme.

3. The emergency stop button mi ght have been remained open (pressed) so
this must be controlled.

23.2.Machine receives command but there is no any functional motion

1. The coupling system that was mounted between the motor and the pump
have be controlled.

2. The CNC control panel and foot pedal system processes have to be
controlled.

Instruction Manual Page 58

 3. There may not be a mechanical warning in the Servo valves, so the
location of valve socket inputs in their places have to be controlled, and
control whether the needed voltage come or not (See Servo and electronic
circuit scheme).

4. The pressure switch may be kept pressing, this must be controlled (See
Servo and electronic circuit scheme).

5. The bending program that was made in CNC controller might be wrong.

23.3.Machine is running but upper beam does not move upwards from the
bottom point

1. Pressure switch may be adjusted over its max. limit so this should be
adjusted to its normal value (See Servo scheme)..

2. Main pressure valve should be controlled (See Servo scheme).

3. The bending program that was made in CNC controller might be wrong.

23.4.Machine is running but there is no pressure;

1. The pressure switch may be adjusted to lower values so this adjustment should be
controlled.

2. Main pressure safety valve may be adjusted to very low values so this adjustment
should be controlled.

ATTENTION: While this process the machine must not be working . If it is

necesaary start the machine for a shot time.

Instruction Manual Page 59

23.5.Machine is working but there is bending defects;

1. Machine may not be balanced well so balan ce should be controlled.

2. The die may not be in center you have to adjust.

3. Punch holder wenges maybe non-adjusted. You have to adjust.

4. You may make error at program from controller.

5. Punches or die may be detrital.

6. Crowning system value may not be right . (ıf you have)

Instruction Manual Page 60

 24. RISK CAN NOT BE ANNULLED FOR SAFETY
RULE

A ) At press brake most common accident is to remain employee of any limb between punch
and die. To prevent these accident employee must be careful while working with machine and
comply with rules which are on the machine. The machine should not be used by multiple
people. Hands must be far from bending area. For short pieces bending the sheet should be
holded with sheet metal pliers.

B ) safety doors is maked to prevent the accident because this door projection is for prevent to
reach to punch, die and slayt of ram.

C ) the back datasensor projection is for prevent to enter back of the machine because the
backgauge area is dangerous area.

E ) machine stroke value is adjusted necessary value and also you can change your machine
from cnc unit.

F ) the backgauge has limit switch for prevent to hit mechanical part to mechanical part.

G ) the electric cabinet projection is make for not to open while the machine is working. If
employee open the electric cabinet while the machine is working, ıt cause very big accident
and also the electric parts can be broken.

H ) There are emerency buttons for the emergency condition. One of the emergency button is
available on the foot pedal the other emerceny button is on the control panel. In emergency
condition you can use this button.

I ) Block and the installation has to be completely resistant to pressureServo system is

designed. The pressure relief valve and safety valves in the system due to other pressures have
been secured. One of the dangerous situations that may arise due to failure ofvalves to (eg as a

Instruction Manual Page 61

result of failure by the coach itself in danger of stalling) the dangers of this type have been
prevented by applying a second valve system

J ) ıf you connect to wrong phase electricity the phase squence relay prevent to give voltage
to machine.

K ) If low or high voltage come the thermic save the motor.

L ) the button have lamp. And also there is a lamp which is 24 DC voltage at back of the
machine.

M ) Control curcuits have cover to prevent accident.

N ) the common accident is between punch and die. To prevent this,the employee have to be
careful everytime.

O ) main ground cable connection give static voltage which pile up on the machine

P ) there is spiral snout for foot pedal. Be careful with this spiral snout.

Instruction Manual Page 62

 25. MAINTENANCE

25. 1. GENERAL

1. The dies and the punches must be always kept clean. And they have to be covered with
protective oil when they are not in use

2. The electric motors might get dusty because of environment conditions fort his reason,

3. The bolt connections that are found on the machine have to be tightened periodically.

4. Because of the sheet processing the oxit or slag residues could remain on the dies or punches.
In order to prevent these kinds of conditions if possible the dies, punches and clamping system
have to be cleaned before every work.

5. Regularly cleaning of uncovered parts and oil these parts lightly after cleaning

 Back Gauge beam and back gauge fingers

 Bottom tool adaptation
 Top tool adaptation
 Press brake table
 Tools
 Grips and handles
 Front Support system

Replace the faulty parts in time.

Properly adjust the machine before bending process. Make a regular round around the
machine for maintenance.

Instruction Manual Page 63

25.2.Tighten Upper beam belts

The belts of the upper beam are checked by a sensor. If the belts got loose the
sensor will stop the press brake control.
Turn the selector safety switch into position “Service”. In this position the brakes
of the main motors are released. After that, the belts can be tautened with a hex key (size: 17
mm).See the sticker next to the motors for the correct turning direction. The drive belts are
tautened by turning the shafts of the gearbox(above the motor). The belts have to run properly
between the belt guiding edges of the rolls.

Verify whether the belts runs properly between the belt guiding edges of the rolls
or not. If it runs properly put the selector safety switch into position for production. Press the
reset button and then press the machine drive-on button.

25.3.Checking and Re-arranging the upper beam guides

When checking the tool alignment or the back gauge adjustment errors may occur that
makes it necessary to re-arrange the upper beam guides.
For the operations mentioned below it is required that the voltage should be kept
on. The sides and upper beam protective covers should be removed, this can give rise to
dangerous situations for the maintenance engineer and third parties:

Ensure that there is noone in the surrounding area of the machine.

A DENER MAKINA trained service engineer should execute the procedure that are
mentioned below or by someone who has been trained to execute this work properly. When
re-adjusting the upper beam guides always observe the following procedure:

Instruction Manual Page 64

 1. Use the press brake control to make the press brake assume such a position that the
guiding parts that are mounted to the machine frame and those parts that have been
mounted to the upper beam are coinciding.
2. Switch off the main power supply from the main switch
3. Remove the Side and the upper beam
protecting covers
4. Check the clearance between
 The guide face of the front side
of the upper beam and the guide
face on the front guide strip.
 The guide face of the front side
of the upper beam and the guide
face on the front guide strip.
The total clearance must be
between 0.05 mm and 0.1 mm.
Figure 25.3.Cross section of Press Brake

1. Upper beam
2. Front guiding strip
3. Rear guiding strip
4. Rear Adjustment bolt with locknut
5. Front Adjustment bolt with locknut
6. Front guiding bolts

7. Rear guiding bolts

8,9 and 10 are the Machine Frames

5. If required adjust the guides. In order to this there is two option, one is to loosen the
front guiding bolts that is located on the front guiding strip a little,then loosen the front
adjustment bolts and the other is to loosen the rear guiding bolts that is located on the
rear guiding strip a little then loosen the front adjustment bolts.
6. Then adjust the upper and lower adjustment bolts such that the clearance ranges
between the value that is mentioned above. If the guiding is adjusted correctly then the
upper and lower adjustment bolts must be secured again with the use of locknuts.

Instruction Manual Page 65

 7. Then the front guiding bolts or rear guiding bolts(Depend on which guiding bolts
loosened) can be tighten again.
8. The operations that are mentioned above must be carried on both sides of the machine.
9. Then put on the side and upper beam protecting covers and start the machine.

25.4. MAINTENANCE SCHEDULE

25.4.1.DAILY MAINTENANCE :

Daily maintenance should be carried out regularly everyday.

1. The general control of all equipments of the machine has to be done by sight.

2. As result of daily working, some parts that have to be cleaned occur on the machine

3. While the beam moves downards freely, a material(but it must not be made from glass and
glass derivates) is appoached to the bending area of the pres brake 2-3 mm far away from the
light curtain and a test is made. In this situation the stop of the functional properties of the
machine has to be observed. Thus it can be sure that the light curtain fulfills its functions.

25. 4. 2 . WEEKLY MAINTENANCE:

Weekly maintenance should be done regularly every week.

1. Any kind of slag, metal pieces, or dust particles that could originate from the working
environment or working metarial have to be cleaned with a vacuumed dust puller.

2. The fixing of all connection equipments(bolt,nut,record etc..)have to be controlled

3. The soft cleaning substances should be used to clean the parts given below.

- Backgauge parts
- Support arm group

Instruction Manual Page 66

 - Punches, dies, and the table group
4. The advised greases should be used to lubricate all parts, which were indicated on the
lubrication chart.

25. 3. 3. MONTHLY MAINTENANCE:

Monthly maintenance should be done every month regularly .

1. The protective oil should be used to lubricate unpainted metal parts.

2. By using a cleaner that does not include abrading materials the command panel and the by
dismantling the protective sheet in front of Servo piston, the nuts that are found under the
piston spindle have to be fixed(there is a special key for this)

25. 3. 4. 2 MONTHS :

Maintenance after two months should be carried out regularly every two months.

1. The filter in the electric cabinet has to cleaned with pressured air.

25.3.5. 3 MONTHS:

Quarterly maintenance carried out regularly in every three months.

1. The electrical boards and electric installation must be cleaned periodically by dry substances,
which do not contain anything that causes the wear.

2. The connection parts must be dismantled in order to be protected by chemical substances,

which prevents oxidation.

Instruction Manual Page 67

25.3. 6. 2000 HOURS :

This must be done in every 2000 hours periodically.

There is a group of sensitive valve systems of orifices in Servo press brakes. The safety of Servo
system is related to the clean this Servo system and consequently the clean of Servo oil

1. The bearings of the control panel handle, back gauge upper beam sledge system,
support arms must be checked. In case it is determined that there are some problems in
the bearings then these should be changed.

NOTE 1: For safety working appropriate spare parts have to be utilized.

Instruction Manual Page 68

 26. SAFETY

26. 1. GENERAL POINTS :

While installing, working and maintenace, follow the safety rules

1. Not to start working on the machine before reading Instruction manual.

2. Not to alter anything in the electric connection.

3. Not to work on the machine without protective covers.

4. Not to step to foot pedal cable.

5. There must not be any pieces which will become dangerous.

6. Put only sheet on the front support.

7. Not to wear plenty clothes.

8. Only one employee must work with machine

9. Before maintenance turn off the electricity.

10. Follow the rules and safety rules which are at label..

11. To prevent accident read this manual carefully.

12. Bending meterial side is only on the front side.

13. Not to put your hands or other limbs on the material which will be bended.

14. Not enter back of the machine except for maintenance.

Instruction Manual Page 69

 15. Make maintenance periodically. The machine life is 10 years. If not make
maintenance the machine life will decrease.

16. Dener Makina is not responsible when any of safety equipment is taken off.

17. Not to change any electric or mechanical parts from anywhere so the machine
warranty will be finished.

18. Not to enter dangeraous area.

19. If you weld something on the machine you will damage electric and electronic parts.

20. Not to use any chemical things on the machine.

21. There must not be any slippy liquid near the machine on the other hand you may fall
down and broke somewhere because of sharp surface of machine.

22. Wear safety clothes and shoes.

26. 2. SAFETY EQUIPMENT

1. Emercency button on foot pedal

2. Foot pedal
3. Back and front cover
4. Electric circuit which is controlled automatically

Instruction Manual Page 70

 27. SAFETY LABEL AND MEANING

NOT STEP WITH FOOT: Some parts on the machine may can not carry
the load because of this when you see this label not to step.

GROUND CONNECTION: when you see this label connect to ground

cable.

MAIN SWITCH ON/OFF: It shows main switch handle position.

CARRY BARB: It shows where you carry the machine

Instruction Manual Page 71

 ELECTRIC AMPERE: It shows dangerous area for electricity

HEADPHONE: you have to use headphone

BE CAREFUL WITH HAND: While using the machine be careful with your hand.

GENERAL DATA: You can see general data about the machine(located at the backside of machine)

ELECTRICAL DATA: You can see Electrical data of the

machine

Instruction Manual Page 72

 SAFETY INSTRUCTION: While working the machine
you have to adapt this rule for safety

OPEN DOOR: First turn off electricity with main switch handle
then open the door.

Instruction Manual Page 73

 WORK AT WET GROUND: you need to open electric cabinet for
service or maintenance first turn off electricity and also check the
ground is wet or not

BENDING CHART: For mechanical value check

this table

Instruction Manual Page 74