ef-35 form twist bend

CML International S.p.A.Piedimonte S. Germano (FR)Italy

EF35 ENGLISH INSTRUCTIONS MANUAL R3.0 19 11 03 1

EERRAAFFOORRMMEEFF3355

Hardware ver.: 1.0.0Software ver.:Man.Rel.: 3.0 date 19.11.2003



CONTENTS

1. GENERAL SAFETY WARNINGS ......................................................................................................... 3

2. ELECTRONIC CARD ............................................................................................................................. 5

3. CONTROL PANEL .................................................................................................................................. 6

4. EMERGENCY STOP AND RESET ....................................................................................................... 7

5. START UP OF MACHINE ...................................................................................................................... 8

6. OPERATION MODE SELECTION ....................................................................................................... 8

7. HOW TO SET UP BAR TWISTER / CURLER PARAMETERS ..................................................... 10

8. START UP OF BAR TWISTER OPERATION MODE ..................................................................... 12

9. START UP OF CURLER OPERATION MODE ................................................................................ 13

10. PRESS OPERATION MODE .............................................................................................................. 14

11. ELECTRICAL DRAWINGS ............................................................................................................... 15



1. GENERAL SAFETY WARNINGS

BEFORE MACHINE USEWARNINGS AND PRECAUTIONS

This symbol is a danger sign and warns you FOR YOUR SAFETY, that there is highand dangerous tension in the machine.

WARNING!

This signal is a danger sign and warns you FOR YOUR SAFETY that there arefundamental instructions to be followed.

This signal is a danger sign and warns you FOR YOUR SAFETY that there arefundamental instructions to be followed in order to avoid injury, and damage toobjects

INSTRUCTIONSTO AVOID INJURY AND DAMAGE TO

OBJECTS



GENERAL SAFETY NORMS

WARNINGThe ERAFORM EF35 has been manufactured according to state-of-the-art technology andin compliance with safety regulations officially accepted. Nevertheless the machine can bedangerous for the operator or a third person if used in a improper manner. It is importanttherefore to read the following safety norms.

WARNING• Use the machine only and specifically for the use which it has been manufactured for

and with full respect of the general safety norms. The Manufacturer will not be liable forany injury or damage to objects due to an incorrect use of the machine.

• Verify that the line voltage is always compatible with the power supply for which themachine has been manufactured for.

• Make sure that only trained personnel operates the machine.• Do not use the machine in an environment containing explosive material.• Do not use the machine in a humid or wet environment.• Do not expose the machine to the rain.• Store the machine in a dry and safe place.• Keep away unauthorised personnel when the machine is both in motion and switched

off.• Do not touch parts in motion.• Do not operate on mechanisms in motion.• Do not remove or tamper with safety devices.• Do not wear loose clothing.• Non authorised persons should be prohibited from entering the machine’s working

area.• Go to a safe position when the machine is in use.• Never stand next to the machine on the opposite side to the controls.• Avoid accidental start of the machine.• Electrical repair on the electrical panel of the machine is to be effected only by qualified

personnel.• Switch off power supply when operating on the electrical system.• Fix the machine to the ground by using the appropriate fixing points.• Do not tamper with electrical and electronic circuits in any way for safety reasons and

in order not to invalidate the warranty conditions.• Disconnect main power cable prior to transporting the machine.• Do not modify the machine structure. Use only era® accessories. Any alterations will

cause the invalidation of the warranty. The Manufacturer reserves the right to notsupply accessories or replacement parts in case the machine has been altered.



2. ELECTRONIC CARD

The ERAFORM machine has an electronic card (Fig. 1) which is easy to use and ensuresbetter and safer work.

- : Decreases parameter values.+ : Increases parameter values.FORWARD : Tool forward / Clockwise mandrel rotationRETURN : Tool return / Counter-clockwise mandrel rotationMENU/ESC : Menu / Esc scrollENTER : Confirmation

Fig. 1 – Electronic card



3. CONTROL PANEL

EMERGENCY : Mushroom head buttonR : Reset buttonSTART 1 : Start button 1START 2 : Start button 2MAX PRESS : Maximum pressure selection switch (ON with Press operation mode only )SELETT. VEL. : Low (1) / high (2) speed selection switchSEL.MACC. : Bar Twister (1) / Bar Curler (2) machine selection

R

MAXPRESSUREOFF ON

START 1

SELETTOREVELOCITA'1 2

START 2



4. EMERGENCY STOP AND RESET

In dangerous situations for the operator’s health or if there is risk of breakage of anymechanical component of the machine, press immediately the emergency mushroom headbutton.Such operation interrupts immediately the electrical power supply to the machine and anymotion in course.

When danger has ceased, reset the mushroom head button by turning it in the samedirection of the arrow, in order to reset the normal working conditions of the machine andthen press reset button R.



5. START UP OF MACHINE

The plug of the main power cable can be inserted after checking the exactcorrespondence between the voltage of the machine and the line voltage.Select 1 (ON) on the main switch near the door of the electrical cabinet for electrical powersupply of the machine ( each time a working cycle ends, switch off the machine selecting0 (OFF) on the main switch ).Check that the mushroom head emergency button has not been pressed. In case theemergency button is pressed, turn it in the opposite sense to the direction of the arrow untilresetting it.Press button R (machine reset) to supply power to the electrical devices of the machine.

6. OPERATION MODE SELECTION

The ERAFORM EF35 machine can work in 3 operation modes:

BAR TWISTER CURLER PRESS

WARNING: MAKE SURE THE MACHINE IS USED ONLY IN NORMAL WORKING CONDITIONS ANDWITH THE MANDREL PROTECTION COVER.

The machine can be used in Bar Twister operation mode by pressing button for 4seconds. The operation mode is displayed as in Fig.2

Check that maximum pressure selection is switched off ( OFF ) with Bar Twister operationmode, otherwise motor will not be able to start up. Also check that machine selection is seton position 1 - TORC. ( bar twister ).

02 010° 01 123°

Bar Twister mode Fig.2 – Bar Twister operation mode



To set the CURLER operation mode, press for four seconds plus buttonuntil the following data are displayed (Fig.3)

Check that maximum pressure selection is switch off (OFF) with Curler operation mode,otherwise motor will not be able to start up. Also check that machine selection is set onposition 2-RICC. (bar curler).

PRESS operation mode can be set by pressing + until the following isdisplayed (Fig. 4):

To go back to the bar twister or curler operation mode after selection of press operationmode, press menu/esc button (this step is not necessary if Bar twister or Curler operationmodes have been selected before).

.

02 200° 01 123°

Curler operat.mode Fig.3 – Curler operation mode

Press modeFig.4 – Press mode



7. HOW TO SET UP BAR TWISTER / CURLER PARAMETERSThe BAR TWISTER or CURLER operation mode work parameters can be set in the followingmanner :

after setting operation mode ( Bar twister or Curler ) , press once the menu/escbutton to display the first figure on the left (Fig.5) which indicates the number of rotationsthat are to be effected.

To set the number of rotations, use buttons:

Press enter button to go to the next figure (Fig.6) indicating number ofdegrees.

The degree setting can be effected by pressing plus and minusbuttons ( same procedure applying to number of rotations setting).

To confirm set values press enter again.

Fig. 6 shows a setting for 3 rotations and 180 degrees .

02 010° 00 000°

Rota.n° Fig.5 – Number of rotations setting

03 180° 00 000°

Degrees Fig.6 – Degree setting



It is possible to follow the progress of the working stages by checking the values on theright side of the display Fig.7:

03 180° 00 000°

Current positionFig.7 – Current position



8. START UP OF BAR TWISTER OPERATION MODE

BEFORE SETTING BAR TWISTER OPERATION MODE, REMOVE TRANSMISSION SHAFT AND/ORCHAIN FOR CURLING IF CURLER OPERATION MODE HAS BEEN SET PREVIOUSLY.

Before selecting Bar twister operation mode work parameters, check that mandrelprotection cover is shut.

Before starting a job cycle , set up the rotation sense of the bar holder mandrel by pressingthe appropriate buttons:

The rotation sense will be displayed in the following manner (Fig. 8 and 9):

Furthermore, it is also possible to select the rotation speed of the bar holder mandrelthrough the appropriate selection switch.Press START 1 + START 2 buttons to start working cycle. The mandrel stops when it hasmoved into position. Release buttons and press once more START 1 + START 2 for anelastic return of the material. Remove workpiece and press START1 + START2 again tillstart position (zero) is reached.Whilst working, job cycle can be stopped by replacing the set values with the new valuesof the current position.If the value displayed at end of the working cycle is different from 00 000° and thereforedoes not enable to set a different mandrel rotation sense, press enter tozero display.By releasing one of the two buttons, the working cycle will be immediately interrupted.

02 010° 01 123°

Clockwise rotation Fig.8 – Clockwise rotation

02 010° 01 123°

Anticlockwise rotat. Fig.9 –Anticlockwise rotation



9. START UP OF CURLER OPERATION MODE

Before starting a job cycle after setting up work parameters, make sure that mandrelprotection cover is shut and that the hexagonal transmission shaft has been insertedcorrectly.

You can set the rotation speed of the chain for curling, through the appropriate selectionswitch as well as the advanced position of the cursor through the end of stroke camplaced on the cylinder protection cover.

To start the working cycle press START 1 + START 2. The cursor advances and moves intoposition, whereas the chain for curling starts to turn .When into position, release buttons and re-press them to enable double release of thebrake and discharge of the workpiece.When the material is released, press START 1 + START 2 again to withdraw cursor to theinitial position and place the chain for curling on the starting point.

The pressure of the cursor can be regulated through the appropriate pressure-gauge ofthe machine.

The chain for curling could not be in start position (zero) when Curler operation mode isactivated. Therefore it is important to press START 1 + START 2 to turn the hexagonal toolholder into position.



10. PRESS OPERATION MODESetting up of work parameters is not possible with the press operation mode . Thestopping position of the cursor can be regulated through the cam on the cylinder protectioncover.

The cursor goes forward by pressing forward button + START 2 (press FORWARDbutton first), whereas the tool returns by pressing return button + START 1 (pressRETURN button first).

Before effecting any job with press operation mode, set maximum pressure electro-valve by selecting ON on MAX PRESSIONE selection switch (right knob).



11. ELECTRICAL DRAWINGS

ef-35 form twist bend

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