SafanDarley MiniCell EN

SafanDarley E-Brake Mini Cell
35-1250 Premium
APS Bending Cell
SafanDarley E-Brake Mini Cell 35-1250
Technology Version MPB-RD100/101
Operating Instructions M7143 2023 En
Operating Instructions SafanDarley 35-1250 Premium M7143 2023 1

SafanDarley E—Brake Mini Cell
Introduction
This handbook is the version translated into English.
SafanDarley Lochem B.V.

Kwinkweerd 11
PO Box 96
7240 AB Lochem
Netherlands
Tel. +31(0)573 222222

Fax +31(0)573 252057
Email info@safandarley.com
Website www.safandarley.com
The technical and technological information contained in these operating

instructions and, if applicable, the drawings and technical descriptions that we
provide, remain our property and must not be used (other than for the operation
of this product), copied, reproduced, disclosed, or advised to third parties
without our prior written approval.
© 2022 SafanDarley B.V.

Introduction
TITLE AND PREFACE

Introduction
CONTENTS
Subject Page
Title and Preface 3

Contents 4
List of Illustrations 7
INTRODUCTION 8
1. Introduction 13
1.1. General 14
1.1.1. Applications 14
1.2. Execution and Data 15
1.2.1. Main Dimensions and Foundation Dimensions 17
1.2.2. Technical Data 17
1.3. Information About Machine Noise Level 19
1.4. Information About Loading Possibilities 20
1.5. Representation of the Bending Process 22
1.5.1. The Various Axes on a Press Brake 25
2. Description 27
2.1. General 28
2.2. The Main Components of the Bending Cell 30
2.2.1. 2.2.1. THE ROBOT CONTROL BOX 31
2.2.2. The Main Components of the Press Brake 33
2.2.3. Description of the Main Components 34
2.2.4. Robot Switchgear Cabinet 37
2.2.5. Signalisation 39
2.2.6. The swivel arm on the press brake 39
2.3. Electrical switchgear cabinet 40
2.3.1. The Operating Parts on the Electrical Switchgear Cabinet 40
2.3.2. Functions of the Operating Parts on the Electrical Switchgear
Cabinet 41
2.4. Overview of the Instruction Symbols on the Electrical Switchgear
Cabinet 42
2.4.1. Description of the Markings on the Electrical Switchgear Cabinet 43
2.5. Electrical switchgear cabinet 45
2.5.1. The Operating Parts on the Electrical Switchgear Cabinet 45
2.5.2. Functions of the Operating Parts on the Electrical Switchgear
Cabinet 45
2.5.3. Fan 46
2.5.4. IPC 47
2.6. Control Panel 50
2.6.1. Description of the Operating Parts on the Control Panel 51
2.7. Terms 53
2.7.1. Description of the Various Different Terms 54
3. Functionalities 55

Introduction
3.1. General 56
3.2. Safety Selection Switch 57
3.2.1. The Control Panel 62
3.3. The Backstop 64
4. Safety 65
4.1. Work Safe ! 66
4.1.1. For repairs / maintenance (lubrication) 66
4.1.2. Limitations To Use 66
4.1.3. Daily Check 67
4.1.4. Safety Parts and Instructions 67
4.1.5. Tool Replacement 67
4.1.6. Replacement of PCBs and Other Work in the Electrical
Switchgear Cabinet 67
4.1.7. Caution 67
4.1.8. Warning of Trap Hazard 68
5. Transport, Installation, Commissioning 69
5.1. Transport 70
5.1.1. Indoor Transport in Your Company 70
5.1.2. Lifting 70
5.1.3. Delivery 71
5.2. Installation 72
5.2.1. Cleaning 72
5.2.2. Connections 72
5.2.3. Required Working and Maintenance Space 73
5.2.4. Floor Calculation 74
5.2.5. Erection and Anchoring 75
5.2.6. Example of Foundations 75
5.3. Commissioning 76
5.3.1. Erection 76
5.3.2. Commissioning Report 76
6. Special Accessories 77
6.1. Stop System 78
6.1.1. X Axis: 79
6.1.2. R Axis: 80
6.1.3. Z Axis: 80
6.1.4. Specifications 82
7. Operation 83
7.1. Bending Cell Control 84
7.2. Starting the Bending Cell 85
7.3. Selection of the Lightest Operating Mode 86
7.4. Switching the Bending Cell Off 87
8. Faults 89
8.1. Troubleshooting Schematic 90
8.2. Overview of the Check Lamps 92
9. Maintenance 93

Introduction
9.1. General 94
9.2. Maintenance 95
9.2.1. Checking and Adjusting the Top Beam Guide 95
9.2.2. Tool Change 97
9.2.3. Checking Parallelism of the Top Beam Mount 101
9.2.4. Starting the Machine if the Top Beam is Lowered at an Angle 102
9.2.5. Checking and Adjusting the Position of the Backstop. 102
9.3. Lubrication 103
9.3.1. Lubrication Every Month/200 Hours 103
9.3.2. Lubrication Every 3 Months/600 Hours 103
9.3.3. Lubrication Every Two Years/5000 Hours 104
9.3.4. Maintenance and Lubrication Schedule 105
9.4. Electrical Circuit Diagram 107
9.5. Mechanical Overview 108
INDEX 109
INDEX 110
Appendix 113
Separate
Fanuc Instructions
Lenze Instructions
Sick Instructions

Introduction
LIST OF ILLUSTRATIONS
Illustration Page
Illustration 1-1 Main Dimensions and Foundation Dimensions 17
Illustration 1-3 Examples of Eccentric Loading SafanDarley R-Brake
Bending Cells 21
Illustration 1-4 Preparation 22
Illustration 1-5 Panel Clamping 23
Illustration 1-6 Bending 23
Illustration 1-7 Removing the Panel 24
Illustration 1-8 Result 24
Illustration 1-9 The Various Axes on a Press Brake 25
Illustration 2-1 : Combination of Mechanics and Electronics 29
Illustration 2-1 :Main Parts of the Bending Cell 30
Illustration 1: SafanDarley control panel outside the safety area on top
of the Fanuc control box. 31
Illustration 2-2 The Main Parts of the SafanDarley R-Brake Brake Press 33
Illustration 2-3 Examples of “Blanking”. 35
Illustration 2-4 Control Panel with HTR Mechanism. 36
Illustration 2-5 Fanuc switchgear cabinet 37
Illustration 2-6 SafanDarley Robot Switchgear Cabinet Outside the
Safety Zone 38
Illustration 2-7 Signalisation 39
Illustration 2-8 Operating Parts on the Electrical Switchgear Cabinet. 40
Illustration 2-9 Markings on Electrical Switchgear Cabinet 42
Illustration 2-10 Operating Parts on the Electrical Switchgear Cabinet. 45
Illustration 2-11 Fan in the Electrical Switchgear Cabinet 47
Illustration 2-12 Licence Sticker 48
Illustration 2-13, Overview IPC with Cabled Image-Backup USB 49
Illustration 2-14 Control Panel 50
Illustration 2-15 Overview of Terms 53
Illustration 4-1 Trap hazard 68
Illustration 5-1 No Forklift Truck 70
Illustration 5-2 Transport Data 71
Illustration 5-3 Drawing , Required Working and Maintenance Space 74
Illustration 5-4 Resin Anchor with Steel Foundation Plate 75
Illustration 6-1 Stop System 78
Illustration 6-2 Stop Finger 78
Illustration 6-3 Toothed Belt Tensioning 79
Illustration 6-4 Zero Position Between the X1 and X2 Stop Fingers 79
Illustration 6-5 Height Equalisation Setting R Axis 80
Illustration 6-6 Toothed Belt Tensioning Z Axis 81
Illustration 9-1 Cross-Section of the Press Brake Guide 97
Illustration 9-2 Top Tool Mount 97
Illustration 9-3 Bottom Tool Mount (Single Tools) 100
Illustration 9-4 Bottom Tool Mount OB3/EUR-1 101

Introduction
INTRODUCTION
These operating instructions apply to:
Name: SafanDarley E-Brake Mini Cell

Technology Version MPB-RD100/101
EU Mark :
Year of Manufacture: 2023
APPLICATIONS
The Type Designation, the Machine Number and the Year of Manufacture are
quoted in Paragraph 1.2 of these operating instructions.
These operating instructions contain useful and important information for the
proper functioning and maintenance of this product. It also contains important
instructions to prevent possible accidents and severe damage before the
commissioning and during working of the product, and, as far as possible, to
ensure problem-free and safe functioning of the product. Read these operating
instructions carefully before commissioning the product, and familiarise yourself
with the method of functioning and operation of the product. Comply fully with
the instructions provided.
If you have any questions or if you need further explanation of specific aspects
of the product, please do not hesitate to contact one of our staff members.
Depending on the arrangement, there may be other operating instructions

provided by Fanuc, Lenze, Pilz, etc. that are available for qualified maintenance
personnel, in addition to these operating instructions.
Keep these operating instructions, and all the overviews, diagrams, etc., with the
machine as long as it is in operation, and make sure that these user instructions,
with all the overviews, diagrams, etc., are available for qualified maintenance
personnel.

Introduction
THESE OPERATING INSTRUCTIONS

Chapter 1 Introduction
This chapter contains information for the operator of the bending cell, and for
other people who are concerned directly and indirectly with the machine.
Chapter 2 Description
A detailed description of the bending cell, also for information for the operator
and other employees responsible.
Chapter 3 Functionalities
Explanation for the operator and employees responsible concerning the
functionalities of the bending cell.
Chapter 4 Safety
This is important for all people directly or indirectly concerned with the machine;
this concerns safety.
Chapter 5 Transport, Installation, Commissioning

This is provided for people who are involved in the transport, installation and
commissioning of the machine, and in the preparation for these tasks. You need
to be familiar with the content of Chapter 4 “Safety”.
Chapter 6 Accessories
Contains information about all the accessories supplied with the machine;
backstop, tool clamp, crowning device, etc.
Chapter 7 Operation
In the same way as the TS operating instructions, this chapter explains the
operation of the bending cell to the operator. The operator must have a good
knowledge of sheet metal processing.
Chapter 8 Faults
Deals with faults and how to rectify them.
Chapter 9 Maintenance
This is intended for the maintenance personnel.
Bending Cell Section

The additional equipment, such as the zero table, reversing point, etc., is
explained in this section.

Introduction
OVERVIEW OF NOTATION
Function keys on the keyboard are shown in a rectangular

key symbol.
☺ Recommendations in the text are shown with a “Smiley”.
Literal text on the screen or on the product is shown

" " between double quotation marks.
A pointing finger at the edge means that this note is

important.
An exclamation mark indicates danger of damage to

! equipment or the product.
Dangers to people are indicated by a triangle with an

exclamation mark.
Warning of dangerous electrical voltage.
Wear hearing protection.
Wear protective clothing: safety shoes, gloves, etc.

Introduction
SAFETY
Familiarise yourself with the warning symbols. The machine is equipped with
safety and protection equipment. However, it is important to be careful when the
machine is in operation. Warning symbols in the various different chapters
indicate possible dangers. These symbols are positioned in the text where the
dangerous behaviour is discussed. The same symbols are present in the bending
cell in the form of stickers.
Check regularly that all the warning symbols are still in the correct locations. If
warning symbols are missing or are damaged, you should apply new symbols.
Stick them in the correct location. See also Chapter 6 “Maintenance”.
LIABILITY
The data published in these operating instructions is based on the most up-to-
date information. It is issued under the reservation that future changes may be
made.
We reserve the right to change the design and/or the execution of our products
at any time, without the obligation to adapt earlier types to suit.
GUARANTEE
The guarantee stipulations for the product are quoted in our conditions of supply,
which are in your possession.
The guarantee for your machine will expire if

service and maintenance is not carried out precisely as stipulated.
changes have been made to the machine without our prior written consent.
non-genuine parts, or lubricants, other than those prescribed are used.
the machine is used inexpertly, improperly, negligently or not as intended.
MAIN ACTIVITIES
The main activities of SafanDarley B.V. Are the development and manufacture of
machines for the sheet metal processing industry. These machines can be sub-
divided into three main groups:
Press brakes
Guillotine shears
Automated bending solutions
The machines can be supplied either as standard versions or fully automated
versions
MACHINE NOT BEING USED?

Introduction
If the machine is not used for an extended period, or if the device is to be

scrapped, all the environmentally-hazardous and dangerous parts must be
removed.
ALWAYS CONCENTRATE ON SAFETY WHEN WORKING!

SafanDarley has been careful to advise you, as precisely and completely as
possible, of the possible dangers when handling the machine.
You are personally responsible for compliance with these rules of behaviour.
The purchaser/user is obligated to familiarise the operating, cleaning and
maintenance personnel with these instructions.
Check the delivery immediately upon receipt for the following:
1. Possible damage and/or incorrect quantities as a result of the transport. Have

the freight forwarder prepare a damage report of the transport damage on
site.
2. The correctness of the delivery; are any parts missing?
In all cases of damage, you must contact SafanDarley B.V. or the freight
forwarder.

Introduction
1. INTRODUCTION

Introduction
1.1. GENERAL
The E-Brake MiniCell models are machines for bending and punching sheet metal
panels. The sheet metal parts are manipulated using an inbuilt robot.
The bending force in these bending cells is 350 kN (35 t).

The swivel length of the robot remains within the cell.
The working length in these bending cells is 1250 mm.
The bending cells can be equipped with various different control systems, such
as:
EC 10
EC 20
EC 3
Robobend
WLM
Example:
The designation of an E-Brake MiniCell bending cell having a press force of 35 t
and a working length of 1250 mm, with a robot carrying capacity of 25 kg. would
be:
SafanDarley E-Brake MiniCell 35-1250-25
1.1.1. APPLICATIONS
The application possibilities of a bending cell are limited to the folding (bending)
and punching (perforating) of panel materials, such as sheet metal panels,
plastic panels, wire mesh etc.
Bending back of folded profiles (flattening) is not permitted.
Bending back may cause the material to be flattened to tip

over, possibly causing the material to be jammed in the
machine.
The hold-up arms and the bending aids must not be used as
storage areas. Only place one product at a time on these
accessories.

Introduction
1.2. EXECUTION AND DATA
SafanDarley bending cells are supplied in several different versions. This bending
cell is supplied in the following execution:
Machine Type: SafanDarley E-Brake Mini Cell 35-1250

Technology Version: MPB-RD100/101
Machine Number: M7143
Year of Manufacture: 2022.
Control System: EC 20
Safety:
Safety screening as per Machinery Directive. Consisting of a sturdy

aluminium frame with transparent polycarbonate panels. The electrically-
interlocked
access doors ensure that unauthorised people cannot gain access to the rotary
swivel joint
cell.
Top tool mount:

NSCL II with hydraulic tool clamping
Process Check:
SafanDarley E-Bend S Sheet Metal Thickness Measurement on Left-Hand
Backstop Finger
Bottom tool mount:

NSCR II, Crowning Device CNC-controlled, with hydraulic tool clamping
Backstop:
SafanDarley Type G with X Axis, R Axis, Z1/Z2 Axes and DeltaX Axis, fully
programmable
Extra stop finger: Backstop finger with sensors
Support arms:
n.z.s.
Closing press tool:

Selection possibility not used

Introduction
Bending aid:
Selection possibility not used
Robot
Fanuc Robot M20iB25 with R-30iA control.
Various different items:

Extra Hold To Run control panel, linked and/or programmable, zero table,
reversing station, double-panel check, tool magazine, Airco in switchgear
cabinet.
In addition to the common designations, these user instructions often quote

numbers (SafanDarley numbers) that are stored in the computer at SafanDarley
B.V. We would ask you to quote these numbers, as far as possible, when
ordering replacement parts (see Chapter 9 Maintenance).

Introduction
1.2.1. MAIN DIMENSIONS AND FOUNDATION

DIMENSIONS
Illustration 1-1 Main Dimensions and Foundation Dimensions
Type: SafanDarley E-Brake Mini Cell 35-1250

Q: 590 mm
G: 1250 mm
Total area: 5000 x 3000 mm
1.2.2. TECHNICAL DATA

Max. press force: 350 KN
Max. working length: 1250 mm
Q dimensions: 690 mm
Max. top beam stroke: 300 mm
Top beam fall speed: 110 mm/sec
Top beam press speed: 10mm/s
Top beam press speed when
using the light curtain safety device: 10mm/s
Top beam return speed: 110 mm/sec
Backstop area: 600 mm
Mains voltage*: 3 x 400V/50/60Hz/N/PE
Cable diameter*: 10 mm2
Fuse slow-response: 63 A
Connection rating: 22 KW
Weight: 17000 kg
Fanuc Robot M20i-B25 25 Kg

Introduction
*See also Chapter 5.2.2 “Electrical Connections

”.
Compressed air consumption sheet metal thickness measurement: 0.0002 m3n

per Min/6 Bar
This technical data serves only as information and is therefore non-binding.

Introduction
1.3. INFORMATION ABOUT MACHINE NOISE LEVEL
The noise measurement was carried out on the Type E-Brake 100-3100 in
standard equipment level.
The press brake was standing on a concrete floor.
There was a 1.70 m high plastic wall approx. 1 metre behind the press brake.
The measurement was made at an approximate distance of 1 metre from the
front of the press brake.
In the unloaded condition (execution of the bending movement without sheet
metal), the noise level of the press brake was 73 dB(A).
In the loaded condition (when bending sheet metal), the noise level of the press
brake was 73 dB(A).
During the measurement on the back of the machine during the execution of a
traverse movement with the backstop beam (over a greater distance), the noise
level of the press brake was 73 dB(A).

Introduction
1.4. INFORMATION ABOUT LOADING

POSSIBILITIES
The loading possibilities of a SafanDarley bending cell are shown in the following
illustration.
Illustration 1-2 The Loading Possibilities of a SafanDarley R-Brake Bending Cell

As is the case with all bending cells, on the SafanDarley E-Brake Mini Cell, the
permissible loading is not the same over the entire working length. The above
table shows the permissible loading possibilities for the various different machine
types.
The next page shows a few examples:

Introduction
Example 1 Example 2
Machine Type: Machine Type:
SafanDarley E-Brake 80-2550 SafanDarley E-Brake 80-2550
Bending length: 1000 mm Bending length: 750 mm
Bend position: left end Bend position: left end
Maximum bending force: 27 Ton Maximum bending force: 25 Ton
Example 3 Example 4
Machine type: Machine type:
SafanDarley E-Brake 80-2550 SafanDarley E-Brake 80-2550
Bending length : 500 mm Bending length : 250 mm
Bend position : left end Bend position : left end
Maximum bending force : 5 Ton Maximum bending force : 2.5 Ton
Illustration 1-3 Examples of Eccentric Loading SafanDarley R-Brake Bending Cells

Introduction
1.5. REPRESENTATION OF THE BENDING PROCESS
The bending process consists of various different steps as explained below.
Preparation
The following illustration shows a side view of a press brake where the sheet
metal is located between the die and the top tool. The top tool is mounted on
the top beam and can be moved up and down (Y direction). The maximum
tool height is known as the top dead centre. At the start of the bending
process, the tool is in the start position, known as the top dead centre (TDC).
The zero point of the Y axis is the
Illustration 1-4 Preparation
top side of the sheet metal (the so-called clamping point (SPP)).
The backstop holds the sheet metal in the correct position for it to be bent. The
backstop can be moved backwards and forwards horizontally (X direction).
Before introducing the sheet metal, the backstop is moved to the correct X
position.
The sheet metal to be bent is then placed on the die and pushed up against the
backstop.
Sheet metal clamping

When the sheet metal is positioned between the tools, the tool is moved
downwards at fall speed (or fast speed) to the changeover point (USP) after
actuating the two-hand controller or the foot-switch. From this point, the tool
moves at the fastest press speed to the bottom clamping point (KLP). Here
we clamp the sheet metal between the top tool and the die.
The clamping point is used as the zero reference. That means that the
positions above the clamping point have a positive value and those below the
clamping point have a negative value.

Introduction
Illustration 1-5 Panel Clamping
The clamping point itself is also called the zero point.

The panel cannot move any more after it has been clamped in the clamping
point. If the backstop presents an obstacle to the panel to be bent with certain
bends, the clamping point can be used to move the backstop backwards to the
pull-back position (X-POS. + RET.X).
Bending
The panel can be bent from the clamping point onwards. The top tool is now
moved downwards at the programmed pressing speed, thus bending the
panel. The top tool is moved downwards until it reaches the bottom dead
centre (BDC). The distance that the top tool moves from the clamping point
to the bottom dead centre is the penetration depth.
Illustration 1-6 Bending
Removing the panel

When the bottom dead centre is reached, the top tool is moved upwards
after a fixed waiting period (return movement).
The return can be carried out at a limited speed in the first section of the
return movement (decompression distance). This limited speed is used to

Introduction
achieve a controlled spring-back of the machine and the sheet metal.

From the decompression distance, the tool returns at maximum return speed
to the top dead centre.
The panel can then be removed from the machine.
Illustration 1-7 Removing the Panel
Result
The panel removed from the tools can then be measured. If the bending
result deviates from the desired bending result, the various different bending
parameters can be corrected using the press brake control system.
Illustration 1-8 Result

Introduction
1.5.1. THE VARIOUS AXES ON A PRESS BRAKE
Illustration 1-9 The Various Axes on a Press Brake

Description
2. DESCRIPTION

Description
2.1. GENERAL
A sheet metal product can be produced fully automatically with the SafanDarley
Bending Cell M7143. The bending cell consists of
The SafanDarley Press Brake E-Brake MiniCell 35-1250-25 with Fanuc robot
M20iB25, fitted with a vacuum gripper. The R-30iA is the robot control
system,
A reversing station,
A location for pallets for panels with a magnetic separator.
A location for pallets for products
Checking mechanisms are incorporated in many locations to keep the production
process under control.
The panels are supplied on pallets. The robot takes a panel from the stack where
the magnetic panel separator separates the panels. The double panel detector
makes sure that two panels are not picked up at once. The panel will now be
bent. The reversing station is used in the interim. The product is placed in the
container/on the pallet when it is finished.
The positions where pallets need to be placed are indicated by cams.

The bending cell is protected by a mechanical screen guard to prevent people
from being in a dangerous situation when the bending cell is in operation. The
bending cell is stopped immediately as soon as a person goes through the
secured door.
The secured niche for the control panel permits swivelling of the control panel
within the cell so that the press brake can be operated manually.
The bending cell is controlled by the Fanuc robot programme. The safety
protection can be interrupted by a person in the course of the programme. When
the interruption is rectified, the operator must make sure that there is nobody in
the safe area and then actuate the “Reset ” – Reset Button” to start the
programme.
The combination of mechanics and electronics ensures a unique method of

operation that guarantees increased productivity, balanced force distribution in
the top beam, and high levels of accuracy with lower energy consumption.

Description
Illustration 2-1 : Combination of Mechanics and Electronics
The bending cell has been developed to carry out bending work as safely as
possible. In addition, the bending cell is provided with protection measures.
Nevertheless, there is a residual risk; the operator runs the slight risk of
crushing when working with the press brake. There are 3 pictograms on the
front, on the top beam, that warn the operator of these dangers.
Danger of body parts being trapped between the top beam and
the bottom beam
Danger of body parts being trapped between the top beam and
the panel
Danger of trapping caused by the panel moving up or down

Description
2.2. THE MAIN COMPONENTS OF THE BENDING

CELL
Illustration 2-1 :Main Parts of the Bending Cell
1. Electrical switchgear cabinet for the 7 Fanuc control

press brake.
2 Press brake. 8 Secured cell entrance
3 Secured niche for control panel. 9 Robot

Description
4 Contactless panel thickness 10 Pallet change door

measurement
5 Gripper store 11 Chute outlet and small product
6 Pallet change door container
2.2.1. 2.2.1. THE ROBOT CONTROL BOX
The control panel, which is located outside the safety area, is arranged in
such a way that the operator can check, at any time, whether there are any
people/items in the cell.
The Fanuc control box is mounted above the MiniCell control box so that the
functions of the control panel can be controlled outside the safety area.
The SafanDarley bending cell is operated using the buttons on the
SafanDarley control panel. The buttons and signals of the robot on the robot
control panel are shown and explained in detail in the FANUC handbook.
Illustration 1: SafanDarley control panel outside the safety area on top of the Fanuc
control box.

Description
2 Press brake
SafanDarley Press Brake 35-1250 Premium.
3 Secured niche for control panel
Secured niche for control panel to enable manual operation of the press
brake within the cell.
4. Contactless panel thickness measurement
Checking whether multiple panels are suspended from the gripper.
5. Gripper storage
Storage of the grippers that are used with the robot.
6. Pallet change door
The pallet change door can be opened to permit pallet changing. The system
is stopped immediately when the door is opened.
7. Fanuc control panel
The bending cell robot is operated and programmed from here.
Measurement of the thickness of the panel.
8. Secured cell entrance
Secured door providing cell access. The system is stopped immediately when
the door is opened.
9 Robot
Fanuc Robot M20iB25 with R-30iA control.
10. Pallet change door
The pallet change door can be opened to permit the changing of pallets. The
system is stopped immediately when the door is opened.
11 Chute discharge and small product container
The robot uses the chute discharge for small products

Description
2.2.2. THE MAIN COMPONENTS OF THE PRESS BRAKE
Illustration 2-2 The Main Parts of the SafanDarley R-Brake Brake Press
1. Top beam
2. Intermediate section
3. Clamping plates
4. Top tool
5. Bottom tool
6. Press brake table
7. Bottom beam / bottom tool mount
8. Safety curtain
9. Press brake control system on the adjustable swivel arm
10. Electrical switchgear cabinet - main operating elements
11.Control panel
12. Electrical switchgear cabinet
13. USB drive
14. Rear access door
15. Side protection hoods

Description
2.2.3. DESCRIPTION OF THE MAIN COMPONENTS

1. Top beam
The top beam is the moving part of the press brake, on which the top tool
(punch) is mounted.
The intermediate section is mounted directly under the top beam. A so-
called setting wedge can be mounted on the intermediate section. This
wedge allows you to compensate for the deflection of the top and bottom
beams.
3. Clamping plates
The clamping plates are used for clamping the top tool on the top beam or
intermediate section.
4. Top tool
The top tool is mounted in the top tool mount on the top beam (or
intermediate section).
5. Bottom tool
The bottom tool is mounted on or in the bottom beam (Item 2).
Various different tools can be mounted on the bottom beam (see Item 6).
6. Press brake table / bottom tool mount

The bottom tool mount is the section of the press brake on which the
bottom tool is mounted.
The bottom tool mount is available in various different versions:

Standard table
Standard table with tool mounting groove
Standard table with T-slot
Table with Modufix bottom tool
Press-down tool with tool mounting groove
Bottom tool change
Many accessories can be mounted on it, such as:
Angle stop --> for 90 degree bending of steel panels
Support arms ---> for improved support of the panel
Pre-stop cams ---> for bending a panel to a pre-stop
7. Bottom beam
The bottom beam is mounted in a fixed position on the machine frame.

Description
8. Safety light curtain

The light curtain is mounted behind the side protection hoods. The light
curtain secures the operator and other people when the machine is
operated at a closing speed in excess of 10 mm/s.
The light curtain is therefore arranged at a minimum distance from the
tools.
The top beam stops as soon as the light curtain is interrupted so that body
parts cannot be trapped in the machine.
If the light curtain is interrupted at fall speed, the top beam stops
immediately and returns to the TDC.
If the light curtain is interrupted at pressing speed, the operator will need
to push the reset button in order to be able to continue.
If the light curtain is interrupted when the foot switch is depressed, the top
beam lowers at a safe speed (< 10 mm/sec).
The light curtain is equipped with “Blanking”.
Illustration 2-3 Examples of “Blanking”.
In both cases on the right-hand side the top beam stops immediately.
“Blanking” means that the light beams can be interrupted at a specific

distance, up to a maximum of 28.5 mm, irrespective of the position. The
position of this distance, over which the light beams can be interrupted, is
not fixed and can change over the length of the light curtain during the
process. If the light curtain is interrupted outside the 28.5 mm zone at the
same time, the downward movement of the top beam stops immediately.
The light curtain can also be used for operating the machine. The top beam
can be actuated, for example, by interrupting the light curtain once or
twice (single cycle or double cycle mode). This can be an efficient operating
mode for certain products.

Description
The various different processes can be selected manually using the selector
switch (see also Paragraph 2.3 “Electrical Switchgear Cabinet”, 4). The
operator can then choose from 3 different processes on the sensor screen.
The selector switch has 6 positions.
9. Press brake control system on the swivel arm

The height of the press brake control system can be adjusted to suit the
wishes of the operator.
The press brake control system is covered in separate control system
instructions. This control system can be used to control the movements of
the top beam and possibly also the backstop movements etc.
The operating elements of the press brake control system are described in
Paragraph 2.5 “Switching panel”.
10. Electrical switchgear cabinet - main operating elements

These are described in Paragraph 2.3 “Electrical switchgear cabinet”.
11. Control panel

The reset button (2) and the HTR foot switch (3) are located on the control
panel (1). See adjacent illustration.
The foot switch has 3 positions. Everything is switched off in the first
position and, in the second position, the top beam and the backstop are
started.
If the operator presses the foot switch through the resistance to the third
position, the stop function is triggered.
Illustration 2-4 Control Panel with HTR Mechanism.
Before each use, the operator must ensure that this third position is
working perfectly, since the third position is a safety device. For example,
the foot switch may be blocked by material under it.
12. Electrical switchgear cabinet

The electrical switchgear cabinet is mounted on the right-hand side of the
press brake. It can also be mounted on the left-hand side if the customer

Description
requests it.
13. .USB drive

The USB drive is located behind a small door.
14. Access door at the rear (with mesh guard)

The back guard on the press brake is intended to prevent people from
being crushed by the backstop.
The access mesh guard is equipped with a safety switch. The main machine
drive is switched off automatically when the mesh guard is opened.
15. Side protection hoods

The side protection hoods prevent people from being trapped by the press
brake drive system.
They also prevent damage to the measuring equipment.
There is a hatch on both sides of the side guard, through which the tools
can be changed. These hatches are also equipped with a safety device.
2.2.4. ROBOT SWITCHGEAR CABINET

The robot switchgear cabinet is positioned outside the safe zone, so that the
operator can always check whether there are people/items inside the cell.
The Fanuc control system is built into the press brake, whilst the functions of the
system control can be operated outside the safe zone.
The buttons and signalisation of the robot are shown and explained in detail in
the FANUC handbook.
Illustration 2-5 Fanuc switchgear cabinet

Description
Illustration 2-6 SafanDarley Robot Switchgear Cabinet Outside the Safety Zone
The buttons in the upper section of the SafanDarley Control Panel correspond to
the buttons on the Fanuc control system. The buttons in the lower section of the
window are used to operate the bending cell.
Stop
Only in “AUTO MODE”
If this button is actuated, the light will come on and the cycle for starting the
next movement is interrupted.
RESET can be used to restart the cycle
Cycle stop
Only in “AUTOMODE”
If this button is actuated, the light will come on and the cycle is interrupted at
the end of the cycle.
RESET can be used to restart the cycle
Access
If this button is actuated, the light will come on and access to the safe zone is
granted.
Reset
You can press RESET after all the safety measures have been taken, and if there
is nobody within the safe zone. The bending cell is ready for production when the
light goes out.
THERE MUST BE NOBODY WITHIN THE BENDING CELL WHEN

THE BENDING CELL IS OPERATING.

Description
2.2.5. SIGNALISATION
There is a signal light located at the highest point of the bending cell. The signal
light issues the following warnings:
Red Red light on: There is a fault in the bending cell
Yellow Yellow light on: The panel is not located precisely up

against the stop finger.
Green Green light on: The bending cell is working in

AUTOMODE
Illustration 2-7 Signalisation
2.2.6. THE SWIVEL ARM ON THE PRESS BRAKE

The swivel arm on the press is equipped with a protection facility to prevent
collisions between the robot arm and the swivel arm. The complete system can
operate in Auto Mode in the safe position. If the swivel arm enters a position
where the robot arm can come into contact with the swivel arm, the robot arm
can only move in slow mode. The operator must make sure that the swivel arm
and the robot arm do not touch each other.
The press brake must be operated carefully.

Description
2.3. ELECTRICAL SWITCHGEAR CABINET
2.3.1. THE OPERATING PARTS ON THE ELECTRICAL

SWITCHGEAR CABINET
Illustration 2-8 Operating Parts on the Electrical Switchgear Cabinet.
4. Safety Selection Switch

5. Locking the Selection Switch
6. Main Switch

Description
2.3.2. FUNCTIONS OF THE OPERATING PARTS ON THE

ELECTRICAL SWITCHGEAR CABINET
1. Safety Selection Switch
The Safety Selection Switch (4) switches the control mode on.
For the most important parts of the control system, we switch the desired
actuation device on with it.
Each position of the selection switch can be locked using the selection lock
(5). The Safety Selection Switch has a total of 6 positions. Its functions are
described in Chapter 3 “Operating the Press Brake”.
2. Locking the Selection Switch with a Key

The selection lock is used to lock the Safety Selection Switch in a specific
position.
3. Main Switch
This switch is used to switch the mains power to the machine on and off (1
and 0).
If the mains power is switched off, the

switch can be locked in position with a padlock.
Electrical power danger warning

This safety warning indicates potential dangers of
electrical power when opening the switchgear
cabinet door.

Description
2.4. OVERVIEW OF THE INSTRUCTION SYMBOLS

ON THE ELECTRICAL SWITCHGEAR CABINET
Illustration 2-9 Markings on Electrical Switchgear Cabinet

Description
2.4.1. DESCRIPTION OF THE MARKINGS ON THE

Machine Type
The type and size of the machine are indicated in this section.
SafanDarley E-Brake MiniCell 35-1250/25 means:
Machine Type: SafanDarley E-Brake MiniCell
Maximum bending force 35 t
Nominal working length 1250 mm
Robot carrying capacity: 25 Kg
MACHINE NUMBER
The manufacturing number of the machine is indicated in this section.
With the bending cells, this number always starts with “M”.
Always quote the machine number and the type in your

correspondence with SafanDarley.
Year of manufacture
The year of manufacture of the machine is indicated in this section.
Maximum bending force

The maximum bending force of the machine is indicated in this
section.
Maximum working length

The maximum working length of the machine is indicated in this
section.
Top beam maximum stroke

The maximum stroke of the top beam is indicated in this section.
Weight
The total weight of the press brake is indicated in this section.
Maximum connection rating

The maximum connection rating of the machine is indicated in this
section.
Connection voltage
The connection voltage of the machine is indicated in this section.

Description
Top beam stop time

The stop time of the top beam is indicated in this section.
The stop time of the top beam is the time between the point at which
the actuating signal drops out and the point at which the top beam
comes to a standstill.
Minimum safety distance to light curtain

The minimum distance between the light curtain and the bend line is
indicated in this section.

Description
2.5. ELECTRICAL SWITCHGEAR CABINET
2.5.1. THE OPERATING PARTS ON THE ELECTRICAL

SWITCHGEAR CABINET
On the front of the electrical
switchgear cabinet
Tool lighting switch (optional)
USB drive
On the back
Mode selection switch
Main Switch
Locking the Selection Switch
Illustration 2-10 Operating Parts on the Electrical Switchgear Cabinet.
2.5.2. FUNCTIONS OF THE OPERATING PARTS ON THE

Mode Selection Switch
The Mode Selection Switch (4) switches the control mode on.
For the most important parts of the control system, we switch the desired
actuation device on with it.
Each position of the selection switch can be locked using the selection lock
(5). The Mode Selection Switch has a total of 6 positions. Its functions are
described in Chapter 3 “Operating the Press Brake”.
Locking the Selection Switch with a Key

The selection lock is used to lock the Mode Selection Switch in a specific
position.
USB drive
USB drive for data exchange. There must be no memory stick in the drive
when the machine is started.

Description
Main Switch
This switch is used to switch the mains power to the machine on and off (1
and 0).
Tool lighting switch (optional)
Switch for turning the lighting of the tools on the front on and off.
If the mains power is switched off, the

switch can be locked in position with a padlock.
Electrical power danger warning

This safety warning indicates potential dangers of
electrical power when opening the switchgear
cabinet door.
2.5.3. FAN
The switchgear cabinet is equipped with a fan to control the temperature in the
cabinet. There are three openings with filters for inlet and outlet of air.
The filters should be cleaned / replaced at regular intervals. See Chapter 9 Care.
1. Fan
2. Power cable bushing
3. Plug

Description
There is a door switch in the centre at the top of the switchgear cabinet. It
switches the fan off when the door is opened. There is a thermostat on the
BULKHEAD in the switchgear cabinet. This should be set to + 30 ° C.
Illustration 2-11 Fan in the Electrical Switchgear Cabinet
1. Fan door switch

2. Thermostat
3. IPC
2.5.4. IPC
The configuration of the IPC in this machine is as follows:
Component Description
Housing Embedded housing for Mini-ITX, black.
Power supply ACE-A627A-RS 270 W ATX mains section.
Main board Mini-ITX SBC supports 6th generation, HDMI
2.0/HDMI/DP/VGA, SATA 6Gb/s, Dual Gb Ethernet, USB 3.0,
PCle Mini, HD Audio and RoHS
Processor Intel Core i5-6500 (6M Cache, up to 3.60 GHz) 6th
Generation Intel Core i5 Processor
Working 8GB DDR3 RAM (2x4GB)

memory
Hard drive 64 GB industrial SSD 2.5” MLC Flash

Description
I/O 3x RS232 port, 1x PS/2 port

Software W10 Pro 64 Bit
USB memory Sandisk 64 Gb USB 2.0 Key + Image
No use of HDMI connections
Version dated April 2015
Operating system
Windows 10 Iot Enterprise 2019 LTSC Value.
Dongle hardware: USB dongle.
Software
Supplied E-control software: Version 1.1.2.1 or a newer version.
Windows Software Licence

The specific licence sticker is applied to each PC housing.
Illustration 2-12 Licence Sticker

Description
HDD/Flash-LED red
Power-LED green
Illustration 2-13, Overview IPC with Cabled Image-Backup USB

Description
2.6. CONTROL PANEL
Illustration 2-14 Control Panel
1. Pushbutton/check lamp main drive on

2. Reset button/check lamp
3. Mute pushbutton/check lamp
4. Pushbutton/check lamp tool clamping (option)
5. Emergency stop switch
6. Teach button
7 Sensor screen, lower section
8. Sensor screen, upper section
9. Optional
10. Control panel height adjustment

Description
2.6.1. DESCRIPTION OF THE OPERATING PARTS ON THE

CONTROL PANEL
1. Pushbutton/check lamp main drive
The drive is switched on using this pushbutton; the emergency stop device
and the lock are activated and all the axes can be actuated.
2. Reset pushbutton/check lamp

This element is both pushbutton and check lamp. The pushbutton has a
reset function. The lamp indicates the status of the machine. See also
Chapter 8.
3. Switch-off pushbutton/check lamp

safety reset function. This lamp indicates the status of the machine. See
Chapter 8.

These elements are both pushbuttons and check lamps. The tool clamping
can be switched on and off using these buttons.

The entire machine can be switched on and off using this emergency stop
switch. The movements of the backstop and the top beam are stopped
immediately. The tool clamping (option) is switched off
6. Teach button
The top beam or the backstop axis is brought to the correct position when
this button is turned. See the TS operating instructions for a detailed
description.
7. Sensor screen, lower section

Commands are entered into the E control system by touching this screen. A
detailed description can be found in the E control operating instructions.
8. Sensor screen, upper section

This screen shows the graphic files.
9. Optional
This button can be used for possible external devices

Description
10. Height adjustment of the control panel

The height of the control panel can be adjusted to suit the height of the
operator. This increases user-friendliness. The lock button is on the back of
the plate. Support the control panel before actuating the lock button. Pull
the knob and slide the cover to the desired position.

Description
2.7. TERMS
Overview of the terms used
Illustration 2-15 Overview of Terms
X-RET Backstop reverse travel distance

X Axis Backstop position
TDC Top dead centre
USP Changeover point (or MUTE point)
KLP Clamping point
BDC Bottom dead centre
Maximum Maximum stroke distance of top beam
stroke

Description
2.7.1. DESCRIPTION OF THE VARIOUS DIFFERENT TERMS

X-RET Backstop reverse travel distance
The distance between the stop position and the reverse travel
position (backstop not an obstacle for the material to be bent)
X Axis Backstop position

This is the distance from the backstop finger to the centre of the
tool.
TDC Top dead centre

The highest point reached by the tip of the top tool during a
bending process. During the programme sequence, the TDC
represents the programmed top dead centre. The mechanical
top dead centre is reached when the safety selection switch is
placed in the service/tilt position.
USP Changeover point (or MUTE point)

The point at which the top beam changes over from high speed
(= fast movement) to low speed (= pressing movement).
KLP Clamping point

This is the position where the panel to be bent is clamped
correctly between the tools.
BDC Bottom dead centre

The lowest point reached by the tip of the top tool during a
bending process.
Maximum stroke Maximum stroke distance of top beam

This is the maximum vertical movement of the top beam.

Functionalities
3. FUNCTIONALITIES

Functionalities
3.1. GENERAL
The top beam on the SafanDarley press brake is lowered using two belts that are
driven by two electric motors. This generates a maximum bending force of 350
kN to 2000 kN. See also Illustration 2.1 in these operating instructions.
The product can be positioned precisely using several backstop axes to achieve a
perfect result. See also Chapter 6 “Special Accessories”.
The operator can programme the size and procedure on the sensor screen. See
also the E-Control operating instructions.

Functionalities
3.2. SAFETY SELECTION SWITCH
Whether and how the light curtain is used depends on the position of
the selection switch (Position 4, Paragraph 2.3.1) and on the method of
operation programmed on the sensor screen. A comprehensive
explanation is available in the TS operating instructions.
The Safety Selection Switch has 6 positions:
Position 0: UIT - OFF - AUS

Operation switched off
In this position the operation of the machine is switched off.
The machine cannot be started and this prevents use by unauthorised
people.
Position 1: +
Light curtain safety + foot operation, blanking
(Programmable foot operation mode)
In this position we can choose from the following 3 processes:
In this position the light curtain is switched on to provide safety throughout

the entire stroke of the top beam.
All movements of the machine (stops or top beam) are started by pressing
the foot pedal.
The top beam moves downwards at fast speed (fall speed) when the foot
pedal is actuated. It changes over to pressing speed at the changeover
point (mute point).
The light curtain must not be interrupted during the entire top beam
closing movement.
Since the light curtain is switched on as a safety device in this setting, the
maximum top beam closing speed is allowed to exceed 10 mm/s when
using foot control.
In this position the light curtain is switched off, all movements of the
machine (stops or top beam) are started by pressing the foot pedal.
The light curtain can be interrupted during the entire top beam closing
movement.
Since the light curtain is switched off, the maximum top beam closing
speed must not exceed 10 mm/s.

Functionalities
In this position the light curtain is switched on as a safety device only

during the first section of the top beam stroke (up to the changeover point
or mute point). The light curtain is switched off at this point.
All movements of the machine (stops or top beam) are started by pressing
the foot pedal.
The top beam moves downwards at fast speed (fall speed) when the foot
pedal is actuated. Since the light curtain is switched on as a safety device
in this setting, the maximum top beam closing speed is allowed to exceed
10 mm/s when using foot control.
The light curtain must not be interrupted during this section of the
movement. (However, if the light curtain is interrupted, the top beam stops
immediately and returns to the TDC.)
The movement stops at the changeover point (mute point) and the light
curtain is switched off. If the foot pedal is then actuated again, the top
beam closing movement starts again, but this time at slow speed. The light
curtain can be interrupted during this section of the movement.
Since the light curtain is switched off as a safety device during this section
of the stroke, the maximum top beam closing speed must not exceed 10
mm/s.
Position 2:
Single cycle mode
Light curtain operation, no blanking
Programmable single cycle mode
If no interruption has occurred within 30 seconds of the top beam reaching
TDC, the operator must push the reset button to return to the single cycle
mode.

All movements of the machine (stops or top beam) are started by a single
interruption of the light curtain.
(When you change over to single cycle mode, you must first move the X
axis to the correct position by actuating the foot switch.) Even if the light
curtain is interrupted during the return stroke, the system assumes that
this will be the first interruption.
Switch on Auto Return (see TS operating instructions).

Functionalities
If the light curtain is interrupted once, the top beam moves downwards at
fast speed (fall speed). It changes over to pressing speed at the
changeover point (mute point).
The top beam returns to the TDC at the BDC.
closing movement.
maximum top beam closing speed is allowed to exceed 10 mm/s.
movement.
In this position the light curtain is switched on as a safety device only

during the first section of the top beam stroke (up to the changeover point
or mute point). The light curtain is switched off at this point.
this will be the first interruption.
If the light curtain is interrupted once, the top beam moves downwards at
fast speed (fall speed). Since the light curtain is switched on as a safety
device in this setting, the maximum top beam closing speed is allowed to
exceed 10 mm/s.
The light curtain must not be interrupted during this section of the
movement.
The movement of the top beam stops at the changeover point (mute point)
and the light curtain is switched off. If the foot pedal is then actuated, the
top beam closing movement starts again, but this time at slow speed. The
light curtain can be interrupted during this section of the movement.
Position 3:
Double cycle mode

Functionalities
Light curtain operation, no blanking

programmable double cycle mode
If no interruption has occurred within 30 seconds of the top beam reaching
TDC, the operator must push the reset button to return to the double cycle
mode.

this will be the first and/or the second interruption.
If the light curtain is interrupted twice, the top beam moves downwards at
fast speed (fall speed). It changes over to pressing speed at the
changeover point (mute point).
The top beam returns to the TDC at the BDC.
closing movement.
maximum top beam closing speed is allowed to exceed 10 mm/s.
movement.
The light curtain can be interrupted during this section of the movement.

Functionalities
Position 4: +
With closed safety guards; robot mode
The control of the system is taken over by the robot control system. There
must be nobody inside the safe area.
With open safety guards; foot operation mode at safe speed

In this position, all the movements of the backstop and the top beam are
started by pressing the foot pedal. The maximum closing speed of the top
beam is 10 mm/sec.
The robot can be programmed using the handheld programmer.
Position 5: Service position”

The drive is switched off in this position.
The motor shafts can be rotated manually if the reset button is pressed
constantly. For example, if the belts have come loose.
If the top beam is tilted: Jogging the reset button causes the top
beam to move upwards under spring pressure. In this way the
belt does not come loose.
In the service position, the drive is switched on using the reset

button.
If the reset button is not actuated, the drive will be switched off
automatically after 4 seconds.
Wait for 9 seconds before being able to actuate the reset button
again.

Functionalities
3.2.1. THE CONTROL PANEL
1. Pushbutton/check lamp main drive

The drive is switched on using this pushbutton; the emergency stop device
and the lock are activated and all the axes can be actuated.
This lamp comes on when the drive is started.
It takes 9 seconds after actuating this button for switching the drive off
before the drive can be switched on again.
2. Reset pushbutton/check lamp
reset function. The lamp indicates the status of the machine. See also
Chapter 8. When the safety selection switch is set to the service position,
this button acts as a drive button. Switch-off takes place automatically
after 4 seconds.
3. Switch-off lamp -pushbutton/check lamp

safety reset function. This lamp indicates the status of the machine. See
Chapter 8.

These elements are both pushbuttons and check lamps. The tool clamping
can be switched on and off using these buttons.
If the tool clamping is switched off, the operation of the bending cell is
blocked to prevent mechanical damage.

The entire machine can be switched off using this emergency stop switch.
The movements of the backstop and the top beam are stopped
immediately. The tool clamping (option) is switched off
6. Teach button
The top beam or the backstop axis is brought to the correct position when
this button is turned. See the TS operating instructions for a detailed
description.
7. Y Axis
The top beam lowers clockwise.
The top beam rises counter-clockwise.
8. X Axis
The X axis moves away from the tool clockwise.
The X axis moves towards the tool counter-clockwise.
At high speed, the axis rotates in steps of 10 mm, at medium speed it
rotates in steps of 1 mm, and at slow speed it rotates in steps of 0.1 mm.

Functionalities
9. R Axis
The R axis moves in a clockwise direction.
The R axis moves in a counter-clockwise direction. At high speed, the axis
rotates in steps of 10 mm, at medium speed it rotates in steps of 1 mm,
and at slow speed it rotates in steps of 0.1 mm
10. Z1 and Z2 Axis

The X axis moves clockwise to the right.
The X axis moves counter-clockwise to the left.
rotates in steps of 10 mm, and at slow speed it rotates in steps of 1 mm.
11. Delta X Axis (Option)

The X axis moves clockwise away from the tool. The X axis moves counter-
clockwise towards the tool.
rotates in steps of 1 mm, and at slow speed it rotates in steps of 0.1 mm.
12. Keyboard (option)

The control system can be equipped with a keyboard and a graphics control
programme.
! Caution: When using the keyboard, the rules covering the

notation for software must be observed, e.g. do not enter file
names containing full stops. Slashes or similar characters.
13. Sensor screen

Commands are entered into the TS control system by touching this screen.
A detailed description can be found in the TS operating instructions.
14. Optional

Functionalities
3.3. THE BACKSTOP
The method of operation of the backstop is explained in Chapter 6 “Special

Accessories”.

Safety
4. SAFETY

Safety
4.1. WORK SAFE !
SafanDarley has been careful to advise you, as comprehensively and completely

as possible, of the possible dangers when handling the machine. You are,
yourself, responsible for compliance with these rules of behaviour.
The purchaser/user is obligated to the familiarisation of the operating, cleaning
and maintenance personnel with these instructions.
The legal regulations for the field of application of the machine concerning the
installation, use, operation, and maintenance apply. Technicians, maintenance
personnel, users, and operators may only install, use, operate, and maintain the
machine so that they do not contradict the applicable laws and regulations.
Use of the machine for unintended applications that are specifically described,
see Chapter 1.1.1, “Application”, and incorrect or improper use, operation and
maintenance may render null and void the responsibility of the manufacturer or
their authorised representatives, fully or in part, with respect to fault complaints,
damage and accidents.
Wear the correct clothing. The edges of panels may be sharp:

Wear sturdy working gloves and footwear with steel toecaps to
prevent injuries from falling panels.
4.1.1. FOR REPAIRS / MAINTENANCE (LUBRICATION)

Turn off the main power supply at the electrical switchgear cabinet: With the
exception of the connections T1, T2 and T3, the electrical switchgear cabinet
is now no longer live. The sensor screen is also switched off.
Clear away all tools immediately;
If necessary, close off the compressed air connection (close the cock in the
feed line or set the reducer valve to 0 bar)
4.1.2. LIMITATIONS TO USE

The application possibilities of the bending cell are limited to the folding
(bending) and punching (perforating) of panel materials. (such as sheet metal
panels, plastic panels, wire mesh etc.)
Do not use the support arms or bending aids for storage of items.
Always only place one product at a time on these accessories.

Safety
4.1.3. DAILY CHECK

Check the machine daily for:
• parts coming loose;
3. (Before starting work) whether the hold-to-run pedal on the control panel is
working properly. Since the third position is a safety position, the operator
must check the proper functioning of this third position every time before
starting work.
For example, there may be items under the foot switch which would
cause it to be blocked.
4. Leaks (when using hydraulic or pneumatic parts).
4.1.4. SAFETY PARTS AND INSTRUCTIONS

Do not remove any of the operating instructions from the machine.
Do not remove any machine parts that are fitted for safety reasons.
(Side guards, back guard, protection hoods etc.)
4.1.5. TOOL REPLACEMENT

The tools can only be changed from the side or via the front of the bending cell.
Turn the main power supply off using the main switch on the electrical
switchgear cabinet before changing tools.
A tool must never be held in such a way that your hand (or a part thereof) is
located between the bottom of the tool and the top of the die.
4.1.6. REPLACEMENT OF PCBS AND OTHER WORK IN THE

Switch the main power supply off using the main switch on the front of the
electrical switchgear cabinet.
With the exception of the connections T1, T2 and T3, the electrical switchgear
cabinet is now no longer live.
4.1.7. CAUTION
When carrying out installation work on the amplifiers on the
beam drive, you must comply with a waiting time of 5
minutes.
There will be residual electrical voltages on some of the live
parts of the amplifier

Safety
4.1.8. WARNING OF TRAP HAZARD

Some of the trap hazards are listed in the drawings below.
Illustration 4-1 Trap hazard

Transport, Installation, Commissioning
5. TRANSPORT, INSTALLATION,
COMMISSIONING

5.1. TRANSPORT
The SafanDarley E-Brake bending cell is properly packaged for road transport or
overseas transport.
5.1.1. INDOOR TRANSPORT IN YOUR COMPANY

The following rules must be observed for indoor transport:
Handling
Weight: see Technical Data, Paragraph 1.2.1
Dimensions: see Main Dimensions and Foundation Dimensions
Paragraph 1.2.2
5.1.2. LIFTING
! The centre of gravity is located immediately behind the top beam on

the machine. This means that there is a danger of the machine tipping
over to the front during transport.
For this reason, the press brake must never be lifted from below with a
forklift truck.
Illustration 5-1 No Forklift Truck
You must use the lifting eyes provided on the top of the press brake for lifting.
One next to the electrical switchgear cabinet and the third hole from there.

On a machine with a tool cabinet: use the hole next to the electrical switchgear
cabinet and the hole next to the tool cabinet.
The angle between the two parts of the chain or the cable sections that are used
to lift the press brake, should not be greater than 90°.
The reason for this is are the horizontal reaction forces acting on the frame of
the press brake.
Illustration 5-2 Transport Data
5.1.3. DELIVERY
Delivery report
When the delivery is received, check immediately for:
and defects
If necessary, ask the freight forwarder for a transport damage report upon
delivery.
Completeness of the delivery with regard to all the ordered parts and
accessories.
Always contact SafanDarley B.V. Immediately in the event of damage or defects

5.2. INSTALLATION
5.2.1. CLEANING
If the machine has been treated with a preservative it should be removed using
a soft cloth impregnated with alkaline paraffin.
If necessary, the plastic film can be carefully removed. Do not use any other
solvents.
5.2.2. CONNECTIONS
5.2.2.1. ELECTRICAL CONNECTIONS

The power cable bushing is located on the front of the electrical switchgear
cabinet, at floor level
The electrical switchgear cabinet is mounted on the left-hand side of the
machine.
The electrical switchgear cabinet must be connected by

an authorised installer.
The technical data concerning the power, voltage, fuses and cable diameters is
available in Chapter 1.2.2 “Technical Data”.
The connections are: T1, T2, T3, N and Earth.

T1, T2 and T3: see bottom of main switch in the electrical switchgear
cabinet;
Earthing: see M6 earthing of the baseplate;
Null connection: see terminal rail nest to the main switch.
The cable diameter applies only to multi-core insulated copper conductors (3
phases + N + Earth).
The cable is suitable for the maximum current that the main motors can
accommodate.
The fuse quoted (slow-response) is the maximum fuse size for this type of cable.
The length of the cable must not exceed 20 metres.

If a longer cable is required, then please contact our customer services
department.
If local regulations require it, use a Differential

Switch RCCB Type B Idn=300mA.

Field rotation to the right
The voltage at the bending cell must not deviate from the
mains voltage by more than +/- 5 %.
Damage caused by improper electrical connections is not

covered by the guarantee !
5.2.2.2. COMPRESSED AIR CONNECTIONS

The compressed air connection sleeve - R¼ x 10mm - is located above the
electrical switchgear cabinet, behind the protection hood on the side frame.
Check points:
Transformers: Does the input voltage (TRANSFORMER - IN) correspond to the

mains voltage?
5.2.3. REQUIRED WORKING AND MAINTENANCE SPACE

The minimum space required for operation of the machine is shown in the
following illustration (plan view).
The machine must be installed in a location that forms a complete unit.
The surface must be flat and without any obstacles.

Illustration 5-3 Drawing , Required Working and Maintenance Space
The cross-hatched area of the above illustration indicates the working space
required around the bending cell.
You have to leave a space on the left and/or right of the

bending cell, the length of which must be at least approx. 1
metre longer than the working length of the machine.
This space is required to make it possible to slide in an
intermediate section / tool into the machine from the side.
This can be deviated from if only short tools are used.
5.2.4. FLOOR CALCULATION

When calculating the foundations for the bending cell, we must assume that 100
% of the total weight rests on the two front baseplates.
Practice has shown that this value is more than adequate for the sum of the
static and dynamic loading.
The thickness of the foundations is entirely dependent on the

environment (substrate).
Contact the construction consultant in the event of any
confusion.

5.2.5. ERECTION AND ANCHORING

Each bending cell must always be erected on good foundations and must be
anchored to the foundations.
Since the frame of the bending cell is very sturdy, it is not necessary to set the
frame parts parallel (also because of the four-point erection of the frame).
The machine must be anchored down to the floor using four anchor bolts (size
M24x300).
5.2.6. EXAMPLE OF FOUNDATIONS

The SafanDarley R-Brake bending cell needs to have its machine feet anchored
to the floor.
The adjusting screw on the machine foot can be used to level the machine
horizontally in the lateral direction.
Resin anchor with steel foundation plate
Illustration 5-4 Resin Anchor with Steel Foundation Plate

5.3. COMMISSIONING
5.3.1. ERECTION
1. Make sure that the bending cell is erected in the right place straight away to
prevent having to relocate it at a later date.
2. Fix the machine down on the baseplate.
3. Make sure that the tool mount on the top beam is parallel to the tool mount
on the bottom beam.
4. Make sure that the backstop beam is parallel to the tool mount;
5. Mount the control system on the swivel arm on the press brake and note the
swivel arm detection.
6. Adjust the height of the press brake control system so that it is easily
accessible for the operator.
7. Then mount the various different accessories, if necessary.
8. Have the bending cell connected by an approved installer.
9. Switch on the main power supply to the bending cell.
10. Start the bending cell.
11. Make sure that everything functions properly.
12. If necessary, check the proper functioning of the various different
accessories.
5.3.2. COMMISSIONING REPORT

Fill out the commissioning report in full. (see Chapter 4.8).
COMMISSIONING REPORT
SafanDarley B.V. or its representative must fill out this form when carrying out
the commissioning.
The report must be signed both by the commissioning agent and the customer
when the machine is handed over to the customer.
The original will be archived by SafanDarley B.V. and the copies are for the
customer.
The customer confirms that the machine has been installed properly and that he
has fully understood the operating, safety, and maintenance instructions.

Special Accessories
6. SPECIAL ACCESSORIES

Special Accessories
6.1. STOP SYSTEM
The E-Brake MPB-RD100/101 35/100T is equipped with a generously-dimensioned

backstop that is fitted with a backlash-free recirculation ball spindle and backlash-
free linear recirculation ball straight guides on the right and left.
Illustration 6-1 Stop System
In the standard configuration, the backstop is equipped with a CNC-controlled X

axis and a CNC-controlled R axis. The X axis is driven by a toothed belt and is
positioned with backlash-free recirculating ball spindles. The R axis height
adjustment is driven and positioned by a belt structure.
The standard version has stop fingers that fold up and which can be displaced
manually, parallel to the bend line (Z axis). As an option, the stop systems can be
equipped with CNC-controlled Z1/Z2 axes and Delta X axes.
Illustration 6-2 Stop Finger
The frame structure allows use of the stop fingers over the full working length.
The stop fingers are equipped with exchangeable cams. In addition there is an
additio0nal stop facility giving a stop range of 1000 mm.

Special Accessories
6.1.1. X AXIS:
The X axis is driven by a servo motor which is equipped with plugs. The toothed
belt on the drive is tensioned by displacing the tensioning roll set furthest away
from the motor.
Illustration 6-3 Toothed Belt Tensioning
The setting of the mechanical zero position between the X1 and X2 stop finger is
achieved by displacing the tensioning roll set that is located closest to the motor.
Illustration 6-4 Zero Position Between the X1 and X2 Stop Fingers
The displacing of the clamping roll set only affects the position of the X1 stop
finger. If the clamping roll set is moved upwards, the X1 dimension is reduced. A
displacement of 1 mm effects a X1 displacement of 0.1 mm.

Special Accessories
The X axis position is set by stopping at a mechanical limit when starting the
machine by a reduced torque regulation. The initialisation point is then set on the
resolver on the motor.
6.1.2. R AXIS:
The R axis is driven by a servo motor which is equipped with plugs, mounted on a
reducer. The height adjustment of the stop beam is achieved by the unrolling of a
flat belt having the same dimensions as the Y axis drive.
Any play in the components is corrected automatically by the weight of the stop
structure.
Illustration 6-5 Height Equalisation Setting R Axis
If the drive is set completely horizontal, it is possible to set the R axis to the
same height on the left and right. If the drive is displaced to the R1 side by 1
mm, the R1 side also lowers by 1 mm, whilst the R2 side rises by 1 mm.
The height position of the R axis is set at the start, where the highest R axis point
is signalled by a proximity switch via a measuring point on the upcoiling wheel.
The initialisation point is then set on the resolver on the motor.
6.1.3. Z AXIS:

Special Accessories
The Z1/ 2 axis is driven by a servo motor, which is equipped with plugs. The
motors for adjusting the stop fingers are mounted directly in the toothed belt
drive. The toothed belt on the drive is tensioned by adjusting the position of the
tensioning roller that is tensioned on the ends of the stop beam.
Illustration 6-6 Toothed Belt Tensioning Z Axis
The Z axis position is set by stopping at a mechanical limit when starting the
machine through reduced torque control, left and right. The initialisation point is
then set on the resolver on the motor.

Special Accessories
6.1.4. SPECIFICATIONS
X Axis range: 550 mm
X Axis applied: 575 mm
X Axis applied long: 1000 mm
Speed: 350 mm/sec.
X Axis accuracy: +/-0.02 mm
R Axis range: 150 mm
Z Axis range: Working length
Delta X Axis range: 100 mm

Operation
7. OPERATION

Operation
7.1. BENDING CELL CONTROL
The SafanDarley E-Brake MiniCell bending cells are characterised, amongst other
things, by their simple and safe operation.
The operating regulations are described in separate operating instructions.
These operating regulations are based on the special characteristics of the

bending cell control system in this machine.
The operating instructions refer to the following bending cell control system
types:
E-Control EC 10
EC 20
EC 3
All the safety regulations described in Chapter 4 “Safety” must be observed to

the letter.
For this reason, the bending cell must not be operated by unauthorised people,
and must only be operated by operators who are familiar with the operating and
safety regulations.
In addition, the operator must have the requisite knowledge of sheet metal
processing.
THERE MUST BE NOBODY INSIDE THE GUARDS ON THE

BACK OF THE MACHINE WHEN THE MACHINE IS
OPERATING.

Operation
7.2. STARTING THE BENDING CELL
1. Switch the main power on using the main switch on the electrical switchgear
cabinet.
2. Wait until the control system shows the “Y Axis Page” (see TS control system
operating instructions)
(If the control system is configured in a network, you need to enter a password).
3. Push the reset button on the panel (the flashing of the yellow check lamp
stops if the reset button is pushed).
4. Push the “INIT” button on the control screen. The following text appears on
the screen:
“SWITCH THE DRIVE ON FIRST, THEN INITIALISE”
5. Start the machine drive by pushing the Drive On button on the electrical
switchgear cabinet.
6. Push anywhere on the screen.
7. Push the RUN button on the sensor screen.
8. Depress the foot switch

The backstop moves to the programmed position.
9. Select a programme using the selection and programme switch.
10. The bending cell is now ready for operation.
See the E-Control instructions for an explanation of the programming of

the bending programme.
Bending back of folded profiles (flattening) is not permitted.

Bending back may cause the material to be flattened to tip
over, possibly causing the material to be jammed in the
machine.

Operation
7.3. SELECTION OF THE LIGHTEST OPERATING

MODE
The operator can use the Safety Selection Switch to select the quickest and
easiest procedure. The various different selection opportunities are described in
detail in Chapter 3 “Functionalities”

Operation
7.4. SWITCHING THE BENDING CELL OFF
1. Push the Windows button on the Y Axis screen on the sensor screen after the
last production action and close off the control system.
2. Push the red Drive Off button,
3. Switch off the main power with the main switch,
4. Clean the machine and the surroundings.
Do not use the support arms and bending aid for storage
purposes. Only place one product on these accessories.

Faults
8. FAULTS

Faults
8.1. TROUBLESHOOTING SCHEMATIC
FAULT/PR CAUSE RECTIFICATION

OBLEM
Top beam The control system or Switch the mains power off for at least 15
not coming drive is blocked seconds using the main switch.
down
Top beam The press brake Change the press brake control system to
not coming control system is in working mode
down programming mode.
Top beam The hydraulic tool (Option) Check the oil pressure and the
not coming clamping system has booster for internal leaks.
down not yet reached the
required pressure
Top beam Beam drive not Push the drive start button
not coming started
down
Drive does Side or rear guard is Close the side or rear guard. Push the reset
not start open button and then the start button
Drive does Safety Selection Move the selection switch to a position other
not start Switch is at “0” or “S” than “0” or “Service”
Drive does Emergency stop Unlock the emergency stop switch.
not start switch pushed on Push the reset button and then the start
control panel button
Drive does Top beam at an angle Move the selection switch to the service
not start in the machine position. Jog the reset button. The spring
pressure slowly moves the top beam upwards
to the TDC. In this way the belt does not come
loose. Move the selection switch back to the
production position, push the reset button and
then the start button
Drive does Belt protection on top Switch the selection switch to the service
not start beam has responded. position. Hold down the reset button. The
brakes on the main motors are decoupled.
Both belts can now be tensioned using a
hexagon spanner (size 12 or 17 mm).
Both drive axes must be turned (by the motor)
to be able to tension the drive belts. The
correct direction of rotation is indicated on the
sticker adjacent to the two motors.
Return the Safety Selection Switch to the
production position.
Push the reset button and then the start
button.

Faults
Incorrect The backstop position Reset the backstop finger (by repositioning or
product does not correspond by using the micro-adjustment).
dimensions to the value of the
backstop control
system
X axis Many different causes Analyse the problem. Contact SafanDarley
cannot be B.V. or the representative.
positioned

Faults
8.2. OVERVIEW OF THE CHECK LAMPS

Maintenance
9. MAINTENANCE

Maintenance
9.1. GENERAL
The SafanDarley E-Brake Mini Cell bending cells are characterised, amongst
other things, by their maintenance-friendliness.
The nevertheless necessary maintenance must be carried out carefully and in
accordance with the regulations.
Read Chapter 4 "Safety" in these operating instructions, with

regard to the safety regulations, first, before starting
maintenance and lubrication work on the press brake.
The following maintenance regulations state the way in which

the various different maintenance tasks are to be carried out.
For this reason, read the description of the method of working
for the maintenance and lubrication tasks, before starting
them.
IF YOU DISCOVER ANY CONFUSION CONCERNING THE PROCEDURE, PLEASE

CONTACT THE SERVICE DEPARTMENT OF THE REPRESENTATIVE WHO SUPPLIED
THE MACHINE, OR WITH THE SafanDarley B.V. SERVICE DEPARTMENT.
When adjusting the TOOL ALIGNMENT and the BACKSTOP, the setting of the
GUIDES on the TOP BEAM is of great importance.
The guides must thus first be checked and, if necessary, adjusted before
alignment of the tools and the setting of the backstop is carried out.
The main switch must be switched off for all maintenance

work, provided that it is not specifically stated otherwise.
Keep these operating instructions, and all the overviews,

diagrams, etc., with the machine as long as it is in operation, and make sure
that these operating instructions, with all the overviews, diagrams, etc., are
available for qualified maintenance personnel.

Maintenance
9.2. MAINTENANCE
Polished parts must be cleaned regularly and then lightly coated with oil:
Press brake table
Top tool mount
Bottom tool mount
Tools
Backstop beam and backstop fingers
Support arms
Handles and levers
Replace defective parts in good time.
Adjust the correctly before starting the bending work.
Carry out a daily maintenance walkaround of the press brake.
If necessary, take out a maintenance contract with SafanDarley B.V.
9.2.1. CHECKING AND ADJUSTING THE TOP BEAM GUIDE

If you detect a deviation when checking the tool alignment or the backstop
setting, adjustment of the top beam guides may be required.
The power supply needs to be switched on for the following tasks.

Guards are removed or opened; as a result, this may create
dangerous situations for the maintenance technicians and third
parties.
Make sure that there is nobody else in the immediate vicinity of the
machine.
These tasks must be carried out by a maintenance technician trained by

SafanDarley B.V. or by a person trained to carry this out properly.
Proceed as follows when setting or adjusting the top beam guides:
Use the press brake control system to position the top beam so that the guide
components mounted on the machine frame and the parts located on the
top beam overlap (see Illustration 9-1).

Maintenance
Turn the main power supply off using the main switch on the electrical
switchgear cabinet (point 6 in Paragraph 2.5.1)
Remove the side protection and the top beam guard from the press brake.
Check the clearance with a feeler gauge:

between the guide surface on the back of the top beam and the guide
surface on the rear guide strip;
between the guide surface on the front of the top beam and the guide
surface on the front guide strip.
The total clearance on each side of the machine must be between 0.05 mm and
0.10 mm.
A 0.05 mm feeler gauge is a tight fit between one of the
☺ two guide surfaces, and a 0.10 mm feeler gauge does

not fit between one of the two guide surfaces.
The guides need to be adjusted if necessary. This involves

slightly releasing the guide fixing bolts (Item 7) on the front guide strip
(Item 3).
The locking nuts (Item 5) must be released slightly to do so.
You must then tighten the setting screws to set the clearance to the value stated
above. The two setting screws must be locked again with the locking nuts
once the guide is set correctly.
The guide fixing bolts (Item 7) can then be tightened again.
The above checks and adjustments must be carried out on both sides of the
machine.
Replace the side protection and the top beam guard properly and start the press
brake.

Maintenance
1. Top beam
2. Rear guide strip
3. Front guide strip
4. Machine frame
5. Setting screw with locking nut
6. Guide fixing bolts on the rear
7. Guide fixing bolts on the front
Illustration 9-1 Cross-Section of the Press Brake Guide
9.2.2. TOOL CHANGE

The press brake can be fitted with Wila hydraulic tool clamping. In this case you
will find specific information in Chapter 6 “Special Accessories”.
1. Top beam
2. Clamping plate
3. Top beam securing wedge
5. Clamping plate
6. Intermediate section securing
wedge
7. Top tool
Illustration 9-2 Top Tool Mount
9.2.2.1. CHANGING TOP TOOLS

The top beam, intermediate sections and top tools on the SafanDarley R-Brake
are equipped with a top tool mount as standard.
This tool mount is fitted with a so-called securing wedge as standard.
The securing wedge ensures that the top tool cannot fall out of the tool mount
when being removed.
If the top tool needs to be replaced, you need to slightly release the clamping
plates with which the top tool is fixed to the top beam (or intermediate section).

Maintenance
The top tool drops down slightly as a result, until it is resting on the securing
wedge.
The top tool can then be pushed out of the press brake.
Procedure
Dangerous situations can be created for the machine operator and

third parties when carrying out the following work: Make sure that
there is nobody else in the immediate vicinity of the machine.
1. Use the press brake control system to move the top beam to the position
where the top tool can be pushed out of the press brake, through the frame, to
the side.
2. Turn the main power supply off using the main switch on the electrical
switchgear cabinet (point 6 in Paragraph 2.5.1)
3. Open the side protection on the press brake.
4. Turn the clamping bolts on the clamping plates counter-clockwise by approx.

half a turn.
5. Slide the top tool out of the press brake to the left or right side of the top
beam.
Do not place parts of your upper limbs under the top tool as long
as they are in the machine.
The top tool may be sharp:

wear leather working gloves.
! The top tool is fragile: handle with care.
6. During
installation, the top tool must be pushed from the side through the tool opening
in the side frame of the press brake over the securing wedge.
Make sure that the tool mounting surfaces both on the

top beam and on the top tool are clean and undamaged.

Maintenance
7. When the top tool is suspended in the correct position, the clamping plates
that are used to clamp the top tool to the tool mount must be tightened.
The maximum torque value of the clamping plates is

approx. 50 Nm.
8. In a final step, the top tool must be pressed in place so that it engages in the
fold correctly.
This involves switching the press brake control system to single stroking at low
press force.
When the top tool and the bottom tool run into each other (possibly with a strip
of material between them), the top tool is positioned flush with the tool mount in
the top beam or intermediate section.
! Caution, do not exceed the maximum tool loading.
9.2.2.2. CHANGING THE BOTTOM TOOLS

The bottom beams on the press brakes are fitted with a so-called clamping table
as standard.
In these table executions there is a mounting groove into which so-called single
tools can be mounted.
Cube tools (tools with several grooves) cannot be mounted on this bottom tool
mount.
There is only one groove in a single tool.
There is generally a line on the front of a single tool; this line indicates the front
of the single tool.
Changing the single tool:

1. Use the press brake control system to move the top beam to the maximum
top dead centre.
2. Turn the main power supply off using the main switch (Point 6 in Paragraph
2.5.1).
3. Turn the clamping bolts on the clamping plates counter-clockwise by approx.

half a turn.

Maintenance
4. Slide the single tool to the left or right side of the bottom tool mount and lift
the tool out of the machine.
5. During installation, the single tool must be directed into the bottom tool
mount from the side.
Make sure that the tool mounting surfaces both on the

bottom beam and on the single tool are clean and
undamaged.
There is generally a mark that runs the full length of the

front of a single tool;
this mark indicates the front of the single tool.
6. When the single tool has been pushed into the correct position, the clamping
bolts on the clamping plates must be re-tightened.
7. Re-start the press brake.

1. Bottom tool (single tool)
2. Bottom tool clamping bolt
3. Clamping table
4. Bottom beam
5. Marking on the front
Illustration 9-3 Bottom Tool Mount (Single Tools)
Observe the correct installation sequence if the press

brake is equipped with an OB/EUR-1 bottom tool
mounting table. First fix the rear pressing beam,
then mount the bottom tool holder/multi V-tool, and
then fix the bottom pressing beam in place.
This will ensure that the tools are correctly aligned.
If you are using single tools, the front and rear pressing beams must be
removed.
See the illustration below.

Maintenance
front rear
pressing beam pressing beam
Front
Illustration 9-4 Bottom Tool Mount OB3/EUR-1
9.2.3. CHECKING PARALLELISM OF THE TOP BEAM MOUNT

The parallelism of the top tool mount and the bottom tool mount must be
checked by bending a test panel on the left-hand side and by simultaneous
bending of an identical panel on the right-hand side of the machine.
☺ This assumes that:

both tool mounts are undamaged;
the tool mounts are well aligned;
the tools are undamaged;
you are using good quality sheet metal;
the sample panels are bent in the same rolling direction.
The bend angle after bending the two test bends must not be different from each
other.
If there is a difference in angle between the left side of the machine and the
right side of the machine (=difference in depth of penetration), the parallelism of
the top beam to the bottom beam will need to be corrected.
There is a linear recorder on both the left and right sides of the
top beam, rigidly fixed to the machine frame.
☺ The parallelism of the top and bottom tool mounts can be adjusted
in the machine constants in the press brake control system.

Maintenance
The above correction can have an effect on the bending

programme because the position of the top beam has changed
with respect to the bottom beam.
This means that the correction on the right-hand side of the top
beam is minimal, whilst the correction on the left-hand side is the
greater one.
9.2.4. STARTING THE MACHINE IF THE TOP BEAM IS

LOWERED AT AN ANGLE
Under certain circumstances the top beam is lowered in the machine at an angle.
The automatic incline safety device switches the machine off to prevent damage
to the machine.
The inclined positioning of the top beam can have the following causes:
Excessive single-sided loading of the top beam.
Fault in the electronic to[ beam control system.
The machine drive can be restarted as follows:
1. Switch the Safety Selection Switch (Item 4 in Paragraph 2.3.1) to the service
position, and jog the RESET button. The spring pressure moves the top
beam up slowly.
This prevents the belt from coming off.
2. The top beam is re-aligned at the mechanical top dead centre,
3. Switch the Safety Selection Switch (Item 4 in Paragraph 2.3.1) back to the
previous working position and push the reset button,
4. Push the “Drive On” button (Item 1 in Paragraph 2.3.1),
5. The machine is ready for production.
9.2.5. CHECKING AND ADJUSTING THE POSITION OF THE

BACKSTOP.
See Chapter 6 “Special Accessories” for comprehensive information about the
backstop and the opportunities for setting and adjusting.

Maintenance
9.3. LUBRICATION
Wherever possible, we quote Rhenos lubricants for topping up or lubricating

machine parts. It is permitted to replace the quoted lubricants by other brands
of the same or higher quality.
In the stated frequency of lubrication, you need to observe the time interval that
needs to be reached first.
Most of the lubrication points on the press brake have been provided with
adequate grease or oil during assembly of the machine. Under normal usage
conditions, these lubrication points only need to be provided with clean grease
during a general overhaul.
Damage that can be traced back to inadequate

maintenance (including lubrication) is not covered by the
guarantee.
9.3.1. LUBRICATION EVERY MONTH/200 HOURS
Guide carriages of the linear guides on the X axis

The guide carriages of the linear guides that are mounted in the backstop need
to be lubricated at the grease nipples with a grease gun. Inject oil until it comes
out of the strippers on the guide carriage (remove excess oil with cleaning
cloths). (Lubrication with Rhenus-NorlithSTM2, for example).
9.3.2. LUBRICATION EVERY 3 MONTHS/600 HOURS

Recirculating ball spindles
The recirculating ball spindles that are mounted in the backstop carrier need to
be lubricated with low-viscosity lubrication oil.
The spindles need to be lubricated at the lubrication nipples on the spindle nuts
using an oil injector. Inject oil until it comes out of the strippers on the guide
carriage (remove excess oil with cleaning cloths). (Lubrication with Rhenus-
NorlithSTM2, for example).
The top beam guides

Once a month these guides need to be checked for excessive dirt contamination
and cleaned if necessary.
These guides do not require any maintenance.
Spring pack

Maintenance
Clean and check for wear and damage to the spring mounts and socket mount.
Only Teflon products should be used to lubricate the guides, such as plastic bushes
and steel guides.
Do not lubricate with oil or grease, because these products are sticky, attract dust
and dirt and will harden over time.
That applies also to preservatives, and these agents must not be applied to moving
guides.
9.3.3. LUBRICATION EVERY TWO YEARS/5000 HOURS
Reduction gearbox on top beam drive

Drain the oil, preferably hot, from the reduction gearbox by removing the drain
screw.
The drain screw is located on the bottom on the connection flange of the drive
motor.
After the oil has been completely drained, the reduction gearbox should be filled
with new oil on the top of the reduction gearbox.
(Filling with: High-performance gear oil CLPHC 320, for example)
Reduction gearbox type Oil volume

GFL07 around 4 litres

Maintenance
9.3.4. MAINTENANCE AND LUBRICATION SCHEDULE
MACHINE MAINTENANCE OR MAINTENANC MAINTENANCE MAINTENAN

SECTION LUBRICATION E OR OR CE OR
FREQUENCY LUBRICATION LUBRICATION LUBRICATIO
POINT ACTION N MATERIAL
1 x every 2000 Top beam Check for

Top beam
operating hours guides excessive dirt
contamination
and clean if
necessary.
1 x every 5000 Reduction Drain oil, then fill CLP HC 320,
operating hours gearbox on the with for example
or max. 2 years top beam drive oil
1 x every 2000 Spring pack on Check for Teflon
operating hours top beam excessive dirt products.
contamination, Do not use oil
clean and or grease
lubricate the
guides if
necessary.
1 x every 200 Guide carriage Lubricate the e. g. Rhenus-

Backstop
operating hours on linear lubricating NorlithSTM2
guides. nipples with the
oil injector
1 x every 600 Recirculating Lubricate the e. g. S
operating hours ball spindles lubricating nipple Rhenus-
with the oil NorlithSTM2
injector
1 x every Fan Replace filter

Electrical
2000 operating hours
switchgear
cabinet
every week Control panel Cleaning Cleaning cloth

Press brake
and buttons
control
system

Maintenance
9.4. ELECTRICAL CIRCUIT DIAGRAM

Maintenance
9.5. MECHANICAL OVERVIEW
Spare parts overview
Ordering spare parts:

YOUR ORDERS MUST INCLUDE THE FOLLOWING DETAILS:
1. Machine Type.
2. Machine serial number + year of manufacture
3. Page and date in the operating instructions where the spare part is
referred to.
4. Number(s) of the spare parts and, if possible, the name of the
spare part.
5. The desired number of the spare parts

Maintenance
INDEX

Maintenance
INDEX
Subject Page
1 x interrupted and left ........ 59, 61 Recirculating ball spindles ......... 108
closing off .................................91 Light curtain .............................59
Connections ..............................76 Delivery ..................................13
Connection rating ......................20 Linear recorder ........................ 106
Working length ..........................20 Hatches ....................................38
Support arms ............................17 Machine Number ........................17
Mounting groove ...................... 103 Machine Type ............................17
Aligning .................................. 105 Installation sequence ............... 104
Auto Return ........................ 59, 61 Adjusting the top beam guides ....99
Construction consultant ..............78 Mains voltage ............................20
Year of Manufacture .................... 9 Emergency stop device ......... 52, 65
Year of Manufacture ...................17 Emergency stop switch ......... 52, 65
Keep the operating instructions ...98 Top beam guides ..................... 108
Operating regulations .................88 Top tool mount ..........................17
RECTIFICATION .........................94 Parallelism .............................. 106
Loading possibilities ...................22 Press force ................................20
Damage ...................................75 Compressed air consumption ......20
Danger of damage .....................11 PROBLEM ..................................94
Bending aid ...............................17 Process Check ...........................17
Bending force ...................... 16, 44 Q dimensions ............................20
Blanking ............................. 36, 59 reset .................................. 52, 65
Braking ....................................64 Residual risk .............................31
CNC-controlled R axis .................82 Residual voltage ........................71
CNC-controlled X axis .................82 RUN button ...............................89
Pressure ...................................94 quickest and easiest ...................90
Efficient ....................................37 written consent .......................... 2
Single cycle ...............................37 Protection .................................30
Spare parts ............................. 114 Safety switch ............................38
Falling speed .............................20 Service/ tilting ...........................64
Guide carriage ......................... 108 Safety ......................................17
Guide carriage ......................... 108 Fuse .........................................20
Danger of body part trapping ......31 Clearance ............................... 100
applicable laws ..........................70 Start ........................................89
Weight .....................................20 Status ......................................66
Keep these operating instructions . 9 daily ........................................71
Backstop ..................................17 Keyboard ..................................66
Backstop area ...........................20 Touch screen .............................66
HTR foot switch .........................37 interrupted ......................... 59, 60
Stroke ......................................20 Reduction gearbox ................... 109
Commissioning Report ................80 Bottom tool mount .....................17
INIT .........................................89 CAUSE ......................................94
Cable diameter .................... 20, 76 USB .........................................38
Knowledge of sheet metal processing Lock ................................... 52, 65
.............................................88 Warning symbols .......................12
Clothing ....................................70 Tool alignment ..........................98

Maintenance
How do we order spare parts ..... 114 Closing press tool ......................17
Difference in angle ................... 106 Double cycle .............................37

Maintenance
APPENDIX
Release document

Maintenance
RELEASE DOCUMENT
SERVO ELECTRONIC
BENDING CELL
MACHINE TYPE SafanDarley E-Brake Mini Cell 35-1250-25
MACHINE NUMBER M7143
YEAR OF MANUFACTURE 2023
WE HEREBY DECLARE THAT THE ABOVE MACHINE CONFORMS WITH THE

SPECIFICATIONS DESCRIBED IN THE ORDER CONFIRMATION.
This is realised by the application of:

INSTALLATION REGULATIONS.
SETTING PROCEDURE.
CHECK LISTS, INITIALLED BY THE TECHNICIAN.
FURTHER CHECK BY THE QUALITY MASTER.
NAME OF INSPECTOR
INSPECTOR INITIALS
DATE

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SafanDarley E-Brake Mini Cell

APS Bending Cell

SafanDarley E-Brake Mini Cell 35-1250

Technology Version MPB-RD100/101

Operating Instructions M7143 2023 En

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 1

This handbook is the version translated into English.

SafanDarley Lochem B.V.

Tel. +31(0)573 222222

The technical and technological information contained in these operating

© 2022 SafanDarley B.V.

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 2

TITLE AND PREFACE

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 3

Title and Preface 3

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 4

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 5

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 6

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 7

These operating instructions apply to:

Name: SafanDarley E-Brake Mini Cell

Year of Manufacture: 2023

Depending on the arrangement, there may be other operating instructions

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 8

THESE OPERATING INSTRUCTIONS

Chapter 5 Transport, Installation, Commissioning

Bending Cell Section

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 9

Function keys on the keyboard are shown in a rectangular

☺ Recommendations in the text are shown with a “Smiley”.

Literal text on the screen or on the product is shown

A pointing finger at the edge means that this note is

An exclamation mark indicates danger of damage to

Dangers to people are indicated by a triangle with an

Warning of dangerous electrical voltage.

Wear hearing protection.

Wear protective clothing: safety shoes, gloves, etc.

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 10

The guarantee for your machine will expire if

MACHINE NOT BEING USED?

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 11

If the machine is not used for an extended period, or if the device is to be

ALWAYS CONCENTRATE ON SAFETY WHEN WORKING!

Check the delivery immediately upon receipt for the following:

1. Possible damage and/or incorrect quantities as a result of the transport. Have

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 12

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 13

The bending force in these bending cells is 350 kN (35 t).

The working length in these bending cells is 1250 mm.

Bending back may cause the material to be flattened to tip

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 14

1.2. EXECUTION AND DATA

Machine Type: SafanDarley E-Brake Mini Cell 35-1250

Safety screening as per Machinery Directive. Consisting of a sturdy

Top tool mount:

Bottom tool mount:

Closing press tool:

Operating Instructions SafanDarley 35-1250 Premium M7143 2023 15

Various different items: